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Formero company powerpoint


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Quick slideshow demonstrating some of the production, tooling and manufacturing services available at Formero. For more information visit our webstie at

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Formero company powerpoint

  2. 2. CAD Requirements <ul><li>Convert to STL: </li></ul><ul><ul><li>defacto format for all RP machines </li></ul></ul><ul><li>Binary format </li></ul><ul><li>Conversion Tolerance Setting 0.02 </li></ul><ul><li>Recommend thickness for parts is 0.5mm </li></ul><ul><li>Iges for Production </li></ul>
  3. 3. Stereolithography (SLA) <ul><li>Utilises a UV frequency laser </li></ul><ul><li>Vat full of resin, light cured material </li></ul><ul><li>3 levels of finishes: Concept, Engineering, Premium </li></ul>
  4. 4. Mammoth SLA CAD design validation Fitment validation <ul><li>Build platform of 2050 x 780 x 700mm </li></ul>
  5. 5. Selective Laser Sintering (SLS) <ul><li>Laser driven machine </li></ul><ul><li>heat process </li></ul><ul><li>typically uses nylon or GF nylon </li></ul>
  6. 6. 3D Printing – Objet Geometries <ul><li>Light cured materials </li></ul><ul><li>operates like inkjet printer </li></ul><ul><li>cures resin via VU lights </li></ul><ul><li>multi-material machine </li></ul>
  7. 7. OBJET FullCure720 – Transparent Gold Resin Tango – Black Shore A61 + Grey Shore A75 Vero White – Opaque White Resin Vero Blue – Opaque Blue Resin
  8. 8. New Material - Digital
  9. 9. Z-Corp <ul><li>Starch based process </li></ul><ul><li>Colours </li></ul><ul><li>Concept validation </li></ul><ul><li>Ideal for thick wall components </li></ul>
  10. 10. FDM <ul><li>Fused Deposition Modeling (FDM) extrudes material, layer-by-layer, to build a model. </li></ul><ul><li>ABS Material </li></ul>
  11. 11. RP model
  12. 12. Surgical planning
  13. 13. Craniostenosis -Surgery
  14. 22. Rapid Manufacture <ul><li>DDM – Direct Digital Manufacture </li></ul><ul><li>Benefits: </li></ul><ul><ul><li>Complex designs </li></ul></ul><ul><ul><li>Speed </li></ul></ul><ul><ul><li>Low volume </li></ul></ul><ul><ul><li>Ideal for small parts </li></ul></ul><ul><ul><li>Not the same quality as injection mouldings. </li></ul></ul>
  15. 23. CNC machining <ul><li>Start with plastic or metal stock </li></ul><ul><li>subtractive process </li></ul>
  16. 24. Rapid Plastic is a combination of vacuum casting with advanced silicone tooling to produce low volume prototype plastic parts. Silicone Tooling & Vacuum Casting
  17. 25. Example <ul><li>Ford Rocker cover for BA Falcon: </li></ul><ul><ul><li>Redesigned from metal to plastic component </li></ul></ul><ul><ul><li>Aim: </li></ul></ul><ul><ul><ul><li>Reduce production costs </li></ul></ul></ul><ul><ul><ul><li>Reduce engine noise </li></ul></ul></ul><ul><ul><ul><li>Increase performance </li></ul></ul></ul>CAD Design/Engineering Prototyping to validate design Findings: Over-engineered. Redesigned to reduce internal ribs. Consequently reduced tooling + materials costs + increased production cycle time. Pre-production to validate materials Production Process Prototype Injection Mould Tooling
  18. 26. Production <ul><li>Injection Moulding & Diecasting </li></ul>
  19. 27. <ul><li>Product Simplification EXAMPLE </li></ul><ul><li>Complex assembly </li></ul><ul><li>Part proliferation </li></ul><ul><li>40 separate tools </li></ul><ul><li>Reduced tool count to 33 </li></ul><ul><li>Reduced assembly complexity </li></ul><ul><li>Total product cost saving </li></ul><ul><li>30% reduction in capital cost </li></ul><ul><li>Six figure $$$ saving in tooling </li></ul><ul><li>Nominated for 2009 Australian Design Award </li></ul>