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Additive manufacturing as a (low volume) production solution- TOM CASTERMANS -
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Pillars of PLASTIC 3D Printing …
3D printing is ecologic
3D printed parts are cheap
3D printing will replace injection moulding
A 3D printed part is ready-to-use
Everybody will own a 3D printer and will be able to produce parts at home or in the company
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Pillars of PLASTIC 3D Printing … No Evidence
3D Printing is ecologic because …
- ZERO waste Cleaner + Supports on SLA/DLP prints
Refresh rate SLS powders (upto 100%)
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Pillars of PLASTIC 3D Printing …
3D Printed parts are cheap because …
- Industrial 3D print materials are 20x to 50x more expensive then rawmaterials
- High power consumption of 3D printing machines versus output (compared to injection moulding)
- 3D Printed parts require almost always post processing
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Pillars of PLASTIC 3D Printing …
3D Printing will replace injection moulding because …
- 3D Printed parts require almost always post processing
- Material properties are different (sometimes an advantage)
- Surface quality is different in most cases
- Machine output is too low, raw materials too expensive
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Pillars of PLASTIC 3D Printing …
A 3D printed part is ready-to-use …
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Pillars of PLASTIC 3D Printing …
Everybody will own a 3D printer and will be able to produce parts at home or in the company
CNC machining
Additive manufacturing
Injection moulding
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Pillars of PLASTIC 3D Printing …
… and yet …
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3D Printing is shifting from niche market of prototyping towards industrialapplications
Prototyping Small batch production Production ramp up
- Technological possibilities
- Part quality- Process stability- Cost per part
- Quality control- Total cost- Automation- Technological
Integration
Actions (to be) taken
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When is AM a succesfull production technique?
Complexgeometry
Integration of
functionalities
'Customization’
(numbers)
InnovativeAM solution
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How to use 3D Printing as production technique?
Founded in 2008 → grown into ‘One stop shop SOLUTION provider’
Services Design services / Production consulting Serial production and prototyping Development and assembly
Machines 4 DLP machines 2 large format SLA machines 1 large format SLS machines 1 UV printer (artwork) 1 CNC Milling machine + lathe Ultrasonic cleaning equipment Sandblasting Tumble polishing In-house painting facility Vacuum casting Different mechanical techniques
(reaming, tapping, drilling, turning, …) Injection moulding services (low to large volumes)
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General Case studies
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1 10 pieces
Automotive tooling – SLS technology
Hollow tool
Stiff design
Ergonomical
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1 10 pieces
Automotive tooling
Lightweight design (CF integration)
Optimal stiffness (Lower reject rate)
Cost reduction
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+ 500 Pieces
Industry: Lightguide for access control (outdoor use, UV stable, …)
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+ 200 Pieces
3D printing + finishing
Injection moulding
CNC Turning
Assembly + testing
Industry: Dispensing unit for shower use
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Case studyDesign for AM manufacturing
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Electronics module for Simrace steering wheel
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Electronics module for Simrace steering wheel
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Design for AM requires:
Technology knowledgePart orientationTechnology specific details (e.g. bridging, slope angle, …)
Awareness of limitations as ‘everything’ is possibleMaterial limitations (Layer thickness vs. Resolution)Mounting limitations (e.g. magnet in blind hole)
Different approach
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AM specific design features
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AM specific design features
Overhang
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AM specific design features
Strain Relief
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AM specific design features
Cable Hole
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AM specific design features
Magnet Holder
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AM specific design features
Positioning Slot
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AM specific design features
Flipper Axle Hole
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AM specific design features
M4 Thread
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AM specific design features
45° Slope Angle
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AM advantage features
+
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CONCLUSION
3D printing
=
Additive Manufacturing
=
Additional ManufacturingAM is part of your ‘toolbox’ besides other technologies
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QUESTIONS ???COME VISIT US AT BOOTH 7C022