IGNITE your…. Rapid Manufacture - in the real world.
Presenter – Stuart Offer, Sales Manager for 3T RPD Ltd in Newbury will present
"examples and cases studies from real world applications of rapid manufacturing with world beating clients"
3T RPD are an Additive Manufacturing company specialising in Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). Both technologies are full melting additive layer manufacturing methods used in a vast array of industries.
3. • Started trading
• Installed 2 x P700’s in
• New Building
• DMLS Facility opened
• UK’s first M 280 machine installed
• Currently the UK’s largest commercial Plastic
AM facility, 3rd largest in Europe
• 2nd largest Metal AM (DMLS) facility in UK
About 3T RPD
1999
2003
2006
2007
Nov 2011
5. • The process of creating 3D objects, layer by layer
• As opposed to subtractive manufacturing methods
Definition of Additive Manufacturing (AM)
Overview of Additive Manufacturing
7. Thermal process
Semi crystalline when finished building
During cooling parts will shrink
Scaling factor is applied to CAD to allow for shrinkage
Generating suitable data
9. 200mm x 150mm x 150mm
£250 each
130mm x 120mm x 15mm
£80 each or
£25 each for 15 off
Plastic AM Costing
10. 600mm x 200mm x 500mm
£2,500 each 165mm x 165mm x 180mm
£250 each
Plastic AM Costing
11. Rapid Manufacturing - Benefits
N1 = Break-even point
Costs
• Cost Comparison (Sintering vs Tooling):
Plastic AM has no initial tooling costs
AM Costs
Tool Based
Manufacturing
Costs
AM Cost
effective
Tooling
Cost
12. Rapid Manufacturing - Benefits
N2
Costs
• Cost Comparison (Sintering vs Tooling):
If part complexity increases, the gap favours Sintering
Tooling costs increase to incorporate extra functions
Complex Tool
Manufacturing
Costs
N1
AM Cost
effective
13. AS 9100 Rev. C
ISO 9001:2008
ISO 13485:2003
Plastic AM Process Control
Quality Standards
20. Intake Manifold:
Tested in Climatic Chamber
Fitted to engine and run
Benefits from Plastic AM
Functional testing
21. Designing for Plastic AM
Applications not suited to Plastic AM:-
Clear parts
Very fine detail
High temperature
Multicolour models
Specific materials
26. Project started: 5th May
SULSA Flight: 8th June
Article published in New Scientist
Designing for Plastic AM
Southampton University Laser Sintered Aircraft
Unmanned Aerial Vehicle (SULSA UAV)
27. Designing for Plastic AM
Southampton University Laser Sintered Aircraft
Unmanned Aerial Vehicle (SULSA UAV)
Ailerons built in
Plastic AM weight less than 2.0kg
Internal structures for strength
28. Navtech Radar W500
automatic surveillance system
Navtech Case Study
Designing for Plastic AM
Design change to reduce cost
Currently selling 50 off per annum but ramping up to 200 off
BRIEF
29. Outside changed to more economic production methods
but internals remained complex and expensive
Internal components to be replaced were Rotating Sensor
system, support and guidance for the lens and the mounting
and location of the emitter reel
Designing for Plastic AM
30. Extensive test programme
Placed the parts in extreme versions of a normal operating
environment
Simulated over 15 million cycles of the critical components
during a two month period
Pivot arm became highly polished within a few hours,
improving efficiency
Designing for Plastic AM
31. Durability of the Plastic AM parts lead to Navtech adding new
features into their design
Flexibility of the material led to creation of built-in springs
as a return mechanism for the lens
Designing for Plastic AM
32. Reduced part count by integrating parts into one Plastic AM part
Reduced assembly time
New features incorporated into design
Flexibility of design now increased
Overall benefits
Designing for Plastic AM