3d printing 201 - applications · • product design often includes testing of various kinds •...

© 2006 SolidWorks Corp. Confidential.

3D Printing 201 Applications

Tyler Reid

CAMWorks Product Specialist

September 25, 2013


• 3D printing has permeated into every industry

Application Overview

• Automotive

• Aerospace

• Architecture

• Advertising

• Agriculture

• Anatomy

• Archaeology

• Anthropology

• Astronomy

• Acoustics


FDM or Polyjet Technology

Precision…..

• Range of simulated plastics & elastomers

• Design prototyping versatility

• Fine detail accuracy

• Smooth surface finish

• Multi-Material Jetting

• High volume efficiency

Performance….

• Variety of real thermoplastics

• Wide application scope: idea - production

• Strong, tough & durable parts

• Part stability & accuracy over time

• Variable part density control

• Low total cost of ownership

Polyjet Technology FDM Technology

Common / Shared….

• Market Leading Technology

• Pioneering & Innovative Manufacturer

• Facility Friendly

• Ease of Use


Top Applications

FDM Best Fit

Polyjet Best Fit

BOTH

• Inexpensive concept models • High-requirements prototyping • Jigs and Fixtures • Sand Casting • Soluble Cores - Composites • Low-Volume EUP (select) • End-of-arm tools: Inj. Mold. • Paper-pulp molds

• ≤ Moderate duty prototyping • RTV molding masters • Thermoforming patterns

• Aesthetic concept models • Visual models • Clear/transparent models • Rubber-like prototypes • Over molding • Injection Molding inserts • Dental

Polyjet Technology

(precision) FDM Technology

(performance)


Application Groups

# Applications

Group Breakdown

1 Testing Form, Fit & Assembly, Function, Ergonomics, Wind Tunnel

Testing

2 Marketing Focus Group, Exhibitions, Sales & Marketing Models, Graphic

Design & Packaging, Communication Tools

3 Tooling

Silicone Molding, Vacuum Forming, Injection Molding, Rapid

Tooling, Sand Casting, Blow Molding, Fiber Lay-Up, Soluble Core

Molding, Paper Pulp Molding, Sheet Metal Forming

4 Connex

Over Molding, Soft Touch Coating, Dynamic Friction, Gaskets

Plugs & Seals, Impact Resistance, Shock Absorption, Labeling &

Texturing, Living Hinges

5 Manufacturing

Jigs & Fixtures, Molding Validation, Production Line Testing,

Equipment Calibration, Measuring Equipment Guides, Rapid

Manufacturing, End-Use Parts, Surrogate Parts, Inserts

(Threaded, Metal Reinforcement, etc.)

6 Medical Hearing Aids, Dental, Surgical


1. Testing Applications

• Form Testing

• Fit & Assembly Testing

• Functional Testing

• Ergonomics Testing

• Wind Tunnel Testing


Form Testing

• Visual Appreciation

• Concept Modeling

• Most common Application in

3D-Printing

• Also the easiest


User Case: Ducati

Needed time-to-market reduction

– Engine: 28 months to design and build

– Majority of prototypes were outsourced

Fortus for in-house prototypes

– 2 alternative prototype engines built

– Nearly all from polycarbonate

More holistic view of engine design

– Decreased design errors

– Sped up design process

Time-to-market reduced 71%

– Engine designed and built in 8 months

– Prototyping costs also substantially reduced

Process Development

Time

Outsourcing to

Service Bureau

28 months

Fortus system

in-house

8 months

Savings 20 months

(71%)


Fit and Assembly Testing

• Fitting elements together

• Testing components fitting

• Not a trivial application

• Why Stratasys:

• Accurate, Good Tolerance

• Fine Details

• Material Variety (Transparent)

• Thermoplastic Stability


User Case: Polaris

Method Cost Time

Injection

molding

$60,000 70 days

In-house

FDM

prototyping

$1,200 2 days

Savings $58,800

(98%)

68 days

(97%)

Injection molding for prototypes

• Tooling changes common

• Typical cost: $60,000

Installs Fortus system

• Builds FDM prototypes in-house

• PC-ABS provides 70% of production part strength

FDM carrier rack

• Used to perfect the design

• Eliminated 3 mold revisions

Time and cost savings

• FDM cost $1200; saved $60,000 in mold fixes

• Lead time reduced from 70 days to 2 days


Functional Testing

• Validate functionality of designs

• Test a product in its environment

• Identify potential flaws

• Why Stratasys:

• Good mechanical properties

• Large variety of materials

matching end-use requirements

• Accurate, stable materials


Ergonomic Testing

• Ergonomics: designing equipment to fit the worker

• No CAD SW offers proper ergonomic grasping

• Prototyping is critical in this phase

• Also important in manufacturing tools

• Why Stratasys:

• Large variety of materials

• Smooth parts

• Rubber-like (gripping)

• Sparse internal fill


User Case: BMW

Conventional fixture making

– Cost and time requirements were high

– Lack of design freedom reduced productivity

FDM used to produce fixtures

– Have over 400 assembly fixtures

– Several built on Fortus system

FDM enhances ergonomics

– Organic shapes maximize performance

– Sparse fill cut weight 72%

Time and cost savings

– Typical cost reduced from $420 to $176

– Typical lead time reduced from 18 to 1.5 days

Method Cost Time

CNC

Machining

Aluminum

$420 18.0 days

Fortus

system

ABS-M30

$176 1.5 days

Savings $244

(58%)

16.5 days

(92%)


Wind Tunnel Testing

• Testing applications can include:

• Aerospace

• Automotive / Racing

• Architectural

• Why Stratasys:

• Accurate, stable materials

• Parts easy to finish if required

• Easily embed sensors into the part


2. Marketing Applications

• Focus Groups

• Exhibition Models

• Sales & Marketing Models

• Graphic Design & Packaging

• Communication Tools


Focus Groups

• Idea is to have collective understanding

• Help define the product, refine the design

• Purpose: To further ensure product success

• Why Stratasys:

• “Printing Reality”

• “What you see is what you get”

• High quality printing


Exhibition Models

• Place models at shows…

• Get response from customers

• Feedback on design

• Launch / introduce products before production

• Scaled Models for display

• Why Stratasys:

• “What you see is what you get”

• High resolution, thin layer, smooth surfacing,


Sales & Marketing Models

• Prototype given “Look & Feel” of end product

• Marketing images before the product is finished

• Send Marketing Product Managers to the field

• Meet high profile customers and garner feedback

• Provide scaled or cutaway models for the sales

team

• Why Stratasys:

• High quality printing allows for “Printing

Reality”

• Production-Grade Thermoplastics allow for in

the field use


Graphic Design and Packaging

• The idea is to save time in production

• Once product development is complete…..

• Use the prototype as models for packaging

• Rather than wait for pre-series production parts

• This can save a lot of time!

• Why Stratasys?...

• Because with some little finishing you can’t tell!


3. Tooling Applications

• Silicone Molding

• Vacuum Forming

• Injection Molding

• Rapid Tooling

• Sand Casting

• Blow Molding

• Fiber Lay-Up

• Soluble Core Molding

• Paper Pulp Molding

• Sheet Metal Forming


Silicone Molding

• Also known as: RTV Molding, Vacuum Casting, Urethane

Casting, Soft Tooling

• Used for short series production

• Stratasys part is used as a master pattern

• Why Polyjet:

• Smooth surface (critical)

• Fine details

• Good HDT for silicone molding

• Why FDM:

• Large patterns

• Stable materials to create multiple molds

Polyjet ***

FDM **


Vacuum Forming

• Typically used in packaging applications

• Rather than wait for pre-series production, use Stratasys

• Why Polyjet:

• When smooth surface is critical

• Why FDM:

• Sparse fill, reduce cost and weight

• Custom parameters can add porosity to the part

for required vacuum (no need to add holes)

Polyjet **

FDM **


Injection Molding

• Using the 3D Printed mold to inject plastic

• Done using ABS-like material (Connex)

• Successful tests undertaken for small series production


Investment Casting

• FDM is used to create patterns

• The patterns is coated with a ceramic slurry

which hardens and creates a shell in the desired

shape

• The FDM pattern is then burned out, leaving

a cavity into which molten metal is poured

• Replaces traditional injection molding of wax patterns

• FDM patterns have greater strength, toughness and accuracy than wax

• Saves time and cost associated with the production of an injection mold

Polyjet *

FDM ***


Rapid Tooling

• Create a mold used for tooling

• Create the negative of your design

• Typical material injected is silicone or wax

• Why Stratasys:

• Fine details

• Smooth Surfacing (Glossy best)

• Good HDT for silicone

Polyjet ***

FDM ***

http://www.youtube.com/watch?v=iXILJ8U_55s


Sand Casting

• Using the Stratasys model as a master

to generate sand mold

• The sand mold is then held in place

using chemical binder or pressure

• Metal is then cast into the sand mold

• Also a good fit for creating Sand

Core Boxes

• Why Stratasys:

• FDM materials are strong enough to support sand weight

• Make large parts

Polyjet *

FDM ***


Blow Molding

• Manufacturing process using air to

inflate plastic inside a mold cavity

• Stratasys technology can be used to

create molds for blow molding

processes

• Best suited for pre-production,

prototype tooling

• Create entire mold or mold insert

• Niche Application

Polyjet ***

FDM ***


Fiber Lay-Up

• Create tools for composite lay-up (Carbon, Glass, Kevlar)

• Low-Temp Tooling

• Up to 200F (90C) with ABS-M30

• Up to 350F (177C) with

ULTEM & PPSF tools

• Digitally driven process

• Design – Tool – Build – Inspect

• Variety of tools can be created

• Patterns – lay-up tools – Intensifiers –

Trim/drill tools – check gauges

Polyjet **

FDM ***


Fiber Lay-Up

Lay Up, Bag & Cure Trim & Drill Finished Parts

Special Acknowledgements to ACS Winnipeg, CA

Camera Fairing Example


Soluble Core Molding

• Core geometry created in CAD and built with

FDM soluble support material

• Wrap the core with composite

• Cure composite part

• Dissolve away the FDM core!

• Best fit for:

• Low- volume production (10’s-100’s)

• Complex internal geometries

Polyjet

FDM ***


Paper Pulp Molding

• Molded paper pulp is used for a

variety of packaging applications

• Environmentally “Green” packaging

• Traditional tooling is machined, with a

fine screen mesh used as tool surface

• Why FDM?

• Custom porous tool surface is ideal

for pulp molding

• Prototype and low volume

production tooling

Polyjet *

FDM ***


Sheet Metal Forming

• Metal forming with FDM Tools

• Hydroforming and rubber pad press processes

• Form a variety of materials

• Aluminum (Al)

• Stainless Steel (SS)

• Titanium (Ti)

• Detailed documentation available

• Why FDM?

• Durable Materials

• Additive process reduces lead time,reduces tool costs

FDM Material

Forming Pressure

ABS 3,000 psi (21 MPa)

PC 6,000 psi (41 MPa)

ULTEM 10,000 psi (69 MPa)

Polyjet *

FDM ***


5. Manufacturing Applications

• Jigs & Fixtures

• Assembly / Manufacturing Tools

• Testing / Inspection

• Transportation

• Production Line Testing

• Equipment Calibration

• Molding Validation

• End-Use Parts (Rapid Manufacturing)

• Surrogate Parts

• Inserts


Jigs and Fixtures

Assembly /

Manufacturing Transportation Testing /Inspection

• One of the fastest growing applications for FDM technology

• Often starts out as something thought of after machine purchase, or as a secondary

application, but today customers are buying machines solely for this purpose!!

• There is a HUGE variety of different jig / fixture applications in industry…

• So we’ve broken it down into 3 categories


Jigs & Fixtures: Assembly/Manufacturing

• Common example is assembly tools

• Enable a worker to perform a reproducible tasks

• Optimize efficiency by reducing tool weight and optimizing ergonomics

• These tools help to achieve uniformity in operation across sites and individual workers

• Examples include: holding fixtures, assembly jigs, trim and drill guides, etc.


Jigs & Fixtures: Test/Inspection

• Product design often includes testing of various kinds

• These tests often require jigs and fixtures to be customized for the part in question

• Inspections also need to be made both during and after production

• Creating these jigs and fixtures in the traditional manner (CNC) is lengthy and expensive

• With Stratasys we can just print them: fast, accurate and in-house availability


Jigs & Fixtures: Transportation

• Custom tools to move parts and partially assembled products

• Part carriers, assembly line pallets, & end of arm tooling

• Design freedom and efficiency, Stratasys materials are up to the task!

• Familiar with 5S organizational efforts? Stratasys can help here as well!!!


Jigs & Fixtures


Production Line Testing

• Example: A manufacturing plant producing medical pills

• Verify that the production line is well calibrated & tuned

• When the product is launched, the production line is all set

• Systems need to be tuned & calibrated:

• Counting unit measurements

• Sorting and packaging units

• Single file line systems

• You can use Polyjet printed models

• Highly accurate parts & uniform weight density


Mold Validation

• Imagine you are a small design firm

• And like most of the rest of the world…

• Your product is manufactured in China

• Cultural barriers, communication barriers, and distance is challenging

• Why not send the prototype together with your drawings and CAD data

• Make sure the mold is aligned with prototype – reduce Risk of Error!


End-Use Parts

• Production of finished goods & sub-assemblies

• FDM is a great fit thanks to production-grade thermoplastics

• Pilot production, bridge to production, and even full production

• FDM is a best fit when…

• Low-volume production (1’s, 10’s, 100’s, 1000’s)

• High cost parts (complex, custom, etc.)

• Batch production (Just-in-time)


Surrogate Parts

• Simple Concept – components used to occupy space during design and production activities

• Helps engineers make decisions about: assembly, serviceability, clearance, layout, routing, etc.

• No need to purchase and possibly damage expensive components for design evaluations

• Preserve critical details in the 3D printed parts

• Can also be used as training aids or manufacturing tools after designs have been finalized


User Case: Bell Helicopter

Conduit prototypes normally cast aluminum

– 6 weeks; very expensive

– Epoxy rapid prototypes attacked by fuel and fluids

Fortus produced functioning prototypes

– Polycarbonate and PPSF resist fuel and fluids

– Work well in functional testing

FDM saved time in post-processing

– Other process: extensive labor

– FDM: remove supports and ready for use

FDM reduced cost and development time

– Allowed more iterations than other processes

– Resulted in better-designed components


Inserts

• FDM has the unique ability to be programmed to pause mid-build

• A variety of components can be inserted before resuming

• Bolts, nuts, washers, bearings, electrical connectors,

metal reinforcement, RFID tags, etc. can all be embedded

• A little creativity can yield some very cool parts!

• The thermoplastic material also works well

with post-build threaded inserts, bearings, etc.


Mass Finishing

• Centrifugal barrel or vibratory tub

• Typically used for higher volumes (> 25 pieces)

• Benefits

• Hands-free surface smoothing and polishing

• Consistent quality

• No harsh chemicals or solvents

• Compatible with all FDM materials & platforms


Finishing Touch Smoothing Station

• Low volume (typically less than 100 pieces)

• Seal surfaces at ambient pressures

• Fast, simple process

• Minimize labor

• Retains part accuracy +/- .0009in (.023mm)

• Applicable to ABS family of materials

(ABS, ABSi, ABSplus,ABS-M30, and ABS-M30i)

• Best for parts at or below 176 ºF (80 ºC)


Finishing Touch Smoothing Station

• Paint ready parts

• Allow 12-18 hours fully cure before priming and

painting

• Master pattern prep

• Investment casting

• Sand casting

• RTV/silicone molding

• Sealing

• Seal and smooth surfaces exposed to vapor

• Electroplating

• Smooth and seal the parts


FDM and Polyjet: Common Apps

Both FDM and Polyjet are proven technologies that enable wide Applications:

• Testing: Form, Fit & Assembly, Function, Ergonomics, Wind Tunnel Testing

• Marketing: Focus Group, Exhibitions, Sales & Marketing Models, Graphic Design & Packaging, Communication Tools

• Finishing: Bonding, Painting, Polishing, Metal Coating, Chrome Plating, Mass Finishing

There’s no one clear cut answer…..

FDM Plated Part Polyjet Plated Part FDM Part Polyjet Part


FDM and Polyjet: Common Apps

More common applications also exist in:

• Tooling: Silicone Molding, Vacuum Forming, Injection Molding, Rapid Tooling, Sand Casting, Blow Molding, Fiber Lay-Up, Spin Casting

• Manufacturing: Jigs & Fixtures, Molding Validation, Production Line Testing, Equipment Calibration, Measuring Equipment Guides, End-Use Parts

Polyjet FDM

Spin Casting

Polyjet FDM

Blow Molding


Unique Polyjet Apps

Some solutions are more suitable for Polyjet:

• Clear and Translucent models:

• Polyjet technology enables the user to print VeroClear /FullCure720 models

• These materials allow for clear/ translucent properties

• FDM models can be translucent – but not transparent

• Rubber like flexible materials


Unique Polyjet Apps

• Connex Capabilities: Over Molding, Soft Touch Coating, Dynamic Friction, Gaskets

Plugs & Seals, Impact Resistance, Shock Absorption, Labeling & Texturing, Living Hinges

• Tango family of materials and Connex abilities makes Polyjet unique

• These include seals, gaskets, shock absorbance and dynamic friction


Unique FDM Apps

Some solutions are more suitable on FDM:

• Soluble Cores:

• FDM Technology offers SR20, SR30, & SR100 (Soluble release)

• Enables user to form composite materials on soluble structures easily and

efficiently


Unique FDM Apps

• Unique FDM Applications include: Soluble Core Molding, Paper Pulp Molding, Sheet Metal Forming, Inserts (Threaded, Metal Reinforcement, etc.)

• Strong FDM Applications: End-Use Parts, Jigs & Fixtures

• Unique FDM finishing applications: Mass Finishing, Finishing Touch Smoothing Station

• Thermoplastics used in FDM process provide a wide range of mechanical properties

• This offers mechanical and chemical resistance superior to other technologies


Applications: FDM and Polyjet

Both Technologies have some inherent strengths to consider…

• Many applications we discussed are possible using either technology

• Critical to match the needs of the prospect with the strengths of the technology

FDM Technology

Production-Grade Thermoplastics

Accuracy & Repeatability

Durable Materials

Material Stability over Time

Sparse Internal Fill Capability

Soluble Materials

Polyjet Technology

Excellent Surface Finish

Fine Feature Detail

Variety of Material Options

Multi-Material Build Capability

Rubber-Like Materials

Transparent Materials


Questions/Comments?

Technical:

Tyler Reid [email protected]

Sales:

Daren Warnick [email protected]

mailto:[email protected]

mailto:[email protected]

3d printing 201 - applications · • product design often includes testing of various kinds •...

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