I presented the results of a study comparing AM methods to create patterns for investment casting last year at the Investment Casting Institute Fall Technical Conference. The ICI then printed the study in a series of three articles in their InCast magazine. This is the second of three articles.
A Comparison of 3D Printing Technologies Used to Make Investment Casting Patt...Tom Mueller
I presented the results of a study comparing AM methods to create patterns for investment casting last year at the Investment Casting Institute Fall Technical Conference. The ICI then printed the study in a series of three articles in their InCast magazine. This is the first of three articles.
A Comparison of 3D Printing Technologies Used to Make Investment Casting Patt...Tom Mueller
This is the third of three articles published by InCast magazine on the results of a study I did comparing AM methods to make investment casting patterns.
Suggestions on the Methodology of Parameters in Fused Deposition Modeling Pro...IRJESJOURNAL
ABSTRACT: The Manufacturing technology is really moving towards unpredictable change over the century. Nowadays, product cycle life in the evolution stage itself is totally reduced to the minimum most level from years to months. This gives new product development strategies likely to be in sequential development that is each individual component production time to reduce from months to weeks. The research and development team focus only on automation to go in line with the fast phase growth. The current trend in the manufacturing industry is Additive Manufacturing (AM). It’s been evolving in much high rate, the complex products are developed within the days and even this can be improved from one product to other product in the design phase itself instead of product testing phase. This paper focus only on Fused Deposition Modeling (FDM), one of the simplest AM process. Enormous researches envisaged that it has potential growth in the near future. So all the parameters related FDM is being analyzed clearly to give detailed study with some optimization solutions for it.
Estimation of Manufacturing Costs in the Early Stages of Product Development ...IJMER
ABSTRACT : One of the crucial factors in increase of productivity of supply chains is the management of production
costs. Since the number of methods and tools used to estimate the production costs in product development phase is limited,
the designers often estimate the costs based on their experience. The designers can mainly affect the direct costs of a
product, including material, labor and purchased parts. Direct costs vary greatly depending on the number of produced
units. Indirect costs include for example the work in process, storage and internal transportations. The developed software
prototype is based on the Lucas method. It will take a simple and ideal part, whose costs are known and then use factors to
produce the final costs. The application calculates sophisticated estimates about how much it would cost to produce a single
part. The developed software seems to work surprisingly well. It may not tell the final truth about the component costs but
can be used to open the eyes of the designer when the costs of the component under design are growing too high. It can also
be used to find the most suitable manufacturing method and when considering the make or buy decisions.
Keywords: Cost estimation, Manufacturing costs, Product Development
A Comparison of 3D Printing Technologies Used to Make Investment Casting Patt...Tom Mueller
I presented the results of a study comparing AM methods to create patterns for investment casting last year at the Investment Casting Institute Fall Technical Conference. The ICI then printed the study in a series of three articles in their InCast magazine. This is the first of three articles.
A Comparison of 3D Printing Technologies Used to Make Investment Casting Patt...Tom Mueller
This is the third of three articles published by InCast magazine on the results of a study I did comparing AM methods to make investment casting patterns.
Suggestions on the Methodology of Parameters in Fused Deposition Modeling Pro...IRJESJOURNAL
ABSTRACT: The Manufacturing technology is really moving towards unpredictable change over the century. Nowadays, product cycle life in the evolution stage itself is totally reduced to the minimum most level from years to months. This gives new product development strategies likely to be in sequential development that is each individual component production time to reduce from months to weeks. The research and development team focus only on automation to go in line with the fast phase growth. The current trend in the manufacturing industry is Additive Manufacturing (AM). It’s been evolving in much high rate, the complex products are developed within the days and even this can be improved from one product to other product in the design phase itself instead of product testing phase. This paper focus only on Fused Deposition Modeling (FDM), one of the simplest AM process. Enormous researches envisaged that it has potential growth in the near future. So all the parameters related FDM is being analyzed clearly to give detailed study with some optimization solutions for it.
Estimation of Manufacturing Costs in the Early Stages of Product Development ...IJMER
ABSTRACT : One of the crucial factors in increase of productivity of supply chains is the management of production
costs. Since the number of methods and tools used to estimate the production costs in product development phase is limited,
the designers often estimate the costs based on their experience. The designers can mainly affect the direct costs of a
product, including material, labor and purchased parts. Direct costs vary greatly depending on the number of produced
units. Indirect costs include for example the work in process, storage and internal transportations. The developed software
prototype is based on the Lucas method. It will take a simple and ideal part, whose costs are known and then use factors to
produce the final costs. The application calculates sophisticated estimates about how much it would cost to produce a single
part. The developed software seems to work surprisingly well. It may not tell the final truth about the component costs but
can be used to open the eyes of the designer when the costs of the component under design are growing too high. It can also
be used to find the most suitable manufacturing method and when considering the make or buy decisions.
Keywords: Cost estimation, Manufacturing costs, Product Development
This above data is related with Sheet Metal fabricated product line.I have elaborated basic difference between Estimation & Costing with strategy for getting best pricing & calculations involved in Actual Spending.
A Merchandiser plays very important role in the apparel industry.
The objective of the merchandising management team is to get the correct balance between the expectations of the customer and the objectives of the company’s financial strategy.
Sampling department is known as the heart of an apparel industry. Company profit or loss depends on this department. Therefore the responsibility of this department is very high.
Careful study & understanding of Tech Pack/files will reduce errors in production, reduce issues with communication, and ultimately can save lots of money and frustration.
By applying their knowledge about fabric and clothing construction, the supplier will study the T/F and find the best way to manufacture the item while taking things like price and buyer’s requirements into consideration.
Design and Engineering Module 3: Prototype to ProductNaseel Ibnu Azeez
As per KTU Syllabus Design and Engineering
Prototyping- rapid prototyping; testing and evaluation of design; Design modifications; Freezing the design; Cost analysis. Engineering the design – From prototype to product.
Planning; Scheduling; Supply chains; inventory; handling; manufacturing/construction operations; storage; packaging; shipping; marketing; feed-back on design.
Epson PrecisionCore Printhead with MicroTFP Inkjet Diessystem_plus
For the first time, Epson integrates thin film PZT MEMS into its office inkjet printer.
More information on that report at: http://www.systemplus.fr/reverse-costing-reports/epson-precisioncore-printhead-with-microtfp-inkjet-dies/
Customizing job shop scheduling using microsoft dynamics ax part2 3Julien Lecadou,MSc.
The Part II and III of this discussion will be focused on:
The presentation of the blown film manufacturing process
The description of the Manufacturing Planning and Control System
Study on the Fused Deposition Modelling In Additive ManufacturingIJERD Editor
Additive manufacturing process, also popularly known as 3-D printing, is a process where a product
is created in a succession of layers. It is based on a novel materials incremental manufacturing philosophy.
Unlike conventional manufacturing processes where material is removed from a given work price to derive the
final shape of a product, 3-D printing develops the product from scratch thus obviating the necessity to cut away
materials. This prevents wastage of raw materials. Commonly used raw materials for the process are ABS
plastic, PLA and nylon. Recently the use of gold, bronze and wood has also been implemented. The complexity
factor of this process is 0% as in any object of any shape and size can be manufactured.
Lesson 26. Optimization of 64-bit programsPVS-Studio
When a program is compiled in the 64-bit mode, it starts consuming more memory than its 32-bit version. This increase often stays unnoticed, but sometimes memory consumption may grow twice. The growth of memory consumption is determined by the following factors:
• larger memory amounts to store some objects, for example pointers;
• changes of the rules of data alignment in structures;
• growth of stack memory consumption.
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
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Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
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Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
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This above data is related with Sheet Metal fabricated product line.I have elaborated basic difference between Estimation & Costing with strategy for getting best pricing & calculations involved in Actual Spending.
A Merchandiser plays very important role in the apparel industry.
The objective of the merchandising management team is to get the correct balance between the expectations of the customer and the objectives of the company’s financial strategy.
Sampling department is known as the heart of an apparel industry. Company profit or loss depends on this department. Therefore the responsibility of this department is very high.
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By applying their knowledge about fabric and clothing construction, the supplier will study the T/F and find the best way to manufacture the item while taking things like price and buyer’s requirements into consideration.
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A Comparison of 3D Printing Technologies Used to Make Investment Casting Patterns - Part 2
1. ®
14 ❘ April 2017
A Comparison of 3D Printing Technologies
Used to Make Investment Casting Patterns –
Part 2: Operating Cost
by Tom Mueller, Mueller Additive Manufacturing Solutions
T
his is the second of three sections
of a detailed comparison of the
four leading methods to print
investment casting patterns. The four
methods are QuickCast, CastForm, Projet
Wax, and Voxeljet Any comparison
must compare the performance in three
separate areas; printer performance,
pattern performance and operating
cost. In the first section, the printer
performance of the four methods was
compared. In this section, operating
cost will be compared.
Each of the manufacturers sells
multiple models of printers with
different build envelopes and build
speeds. To limit the scope of the
analysis, we selected the model most
commonly used to print investment
casting pattern. Table 1 shows the
printer models used in this study and the
materials printed.A printer with great
performance that builds patterns that are
easily and reliably cast is of little value if
the cost of creating patterns makes them
economically unfeasible. In this section
of the comparison, the purchase price
of printers as well as operating cost will
be examined. Some of the prices have
changed since this information was first
presented at the 2016 ICI Fall Technical
Conference. As a result, some of the
operating costs have changed.
Printer Price
The four printers in this comparison have
a wide range of prices, from $100,000
to more than $700,000. Table 2 lists the
price of each of the four printers. The
price of the Voxeljet printer is based on
currency exchange rates at the time of
publication.
In reality, few buyers of these printers
pay the list price for the machine.
Prices are often discounted, sometimes
heavily. Determining average actual
purchase prices, however, would be
extremely difficult.
In addition, all of the printers offer
several pieces of auxiliary equipment
in addition to the printer. Some of
the auxiliary equipment is necessary
to the operation of the printer and
some is optional. For simplicity, this
analysis uses only the list price of the
printer without auxiliary equipment for
comparison.
Capacity Cost
Comparing printer simply on the basis
of price can be very misleading. As
shown in the previous article in the
series, the four printers have widely
varying build rates. Expensive printers
build much faster. Might it be better to
buy several low cost printers? To answer
that question, we need to compare the
printers on the bases of equivalent build
rates.
We can calculate Capacity cost,
which is the cost of one cubic inch per
hour of build capacity. Capacity Cost
is easily determined by dividing the
printer cost by the average build rate
as determined in the previous article.
Figure 1 compares the capacity cost of
Technical Article
Table 1: Printer models used for comparison.
Technology Printer Model Material
QuickCast ProX 800 Accura® CastPro
CastForm S-Pro 60 CastForm™ PS
Projet Wax 3510 CPX VisiJet® M3 Hi-Cast
Voxeljet VX1000 PMMA/Polypor B
Figure 1: Capacity Cost of the Printers
2. ®
April 2017 ❘ 15
the four printers.
Surprisingly, the least expensive
printer has the highest capacity cost. The
Voxeljet printer has the lowest capacity
cost followed by the QuickCast printer.
Elements of Pattern Cost
Capacity cost only measures the cost of
obtaining build capacity. Operating cost
is how much it costs to run the printer
after acquisition. Other than labor, there
are three major elements of pattern cost;
the cost of materials, depreciation and
the cost of maintenance.
• Material Cost - For purposes of this
analysis, list prices of the materials
supplied by the manufacturer of the
printer were used. Manufacturers
often sell at a discount and
aftermarket material suppliers
often supply less expensive
materials. Given the difficulty of
determining actual average prices,
manufacturers’ list prices are used.
Material cost for QuickCast patterns
varies widely with the geometry of the
pattern and has four components:
1. Resin used to build the internal
support structure – the volume
of resin used for internal support
structure is approximately 13% of
the pattern volume.
2. Resin used to build the skin – the
volume of resin used to build the
skin of the pattern is the surface area
times the skin thickness
3. Resin used to build supports – the
stereolithography process builds
supports which attach the part to the
build platform and act as a fixture.
The amount of supports required
varies dramatically from pattern to
pattern and can vary significantly
depending on how the part to be
built is oriented in the build.
4. Resin undrained from the interior of
the pattern – In the build process,
liquid resin is trapped within the
pattern. Drain and vent holes
allow that liquid resin to be drained
out after the build is complete.
Draining is further encouraged by
placing in the pattern in a centrifuge
for several minutes. Nonetheless, it
is virtually impossible to completely
drain the pattern and some liquid
resin will remain inside. It will
be cured in place in the post cure
process. It could easily be a percent
or two of the pattern volume and for
patterns with thin walls, it could be
significantly higher
For this analysis, it was assumed that
resin volume consumed averaged 40%
of pattern volume, although the actual
percentage is likely higher.
CastForm is the easiest material cost
Table 2: Printer List Price
System List Price
3D Systems ProX 800 $550,000
3D Systems S Pro 230 $475,000
3D Systems ProJet 3510 CPX $100,000
Voxeljet VX1000 PPB $735,625
Figure 2: Material Cost for the Printers
Figure 3: Depreciation Cost per Cubic Inch of Patterns
3. ®
16 ❘ April 2017
Technical Article
to calculate. It is simply the volume of
the pattern times the cost per cubic inch
of polystyrene powder. Any unused
powder in the build is recycled.
The Voxeljet analysis considered
the price of PMMA powder, binder,
and cleaner used to clean the print
head during the build. The amount of
wax required for infiltration depends
on the surface area of the pattern. For
this analysis, it was assumed that wax
volume was 5% of the pattern volume.
The Projet Wax system uses two
different waxes, one for the pattern
and one for the supports. The ratio of
support wax to pattern wax varies with
the geometry of the pattern and the
build orientation. For this analysis, it
was assumed that the amount of support
wax used was 50% of the volume of
pattern wax. Users have stated that this
number is conservative.
Figure 2 shows the cost per cubic
inch of pattern volume for each of the
four technologies.
At $6.70 per cubic inch, the
Projet Wax printer had by far the most
expensive material cost, more than triple
the cost of the next highest cost material,
QuickCast. The least expensive material
cost was PMMA from Voxeljet with a
cost of $0.81 per cubic inch.
• Depreciation – Depreciation is
a significant expense in building
patterns. More expensive printers
will have a higher total depreciation
cost, but they also will print more
patterns. To get a true comparison,
the depreciation cost per cubic
inch built was calculated. For this
analysis we will assume a straight
line seven year depreciation. The
monthly depreciation cost is then
the printer cost divided by 84
(number of months in seven years).
To compare from printer to printer,
it is necessary to compensate for the
volume of patterns built. For this
analysis, it was assumed that each
printer would be operated 16 hours
per day for five days a week, or
320 hours per month. Multiplying
the 320 hours by the average build
rate will yield the total volume of
parts built per month. The monthly
depreciation is then divided by the
volume of parts per month to get a
depreciation cost per cubic inch.
Figure 3 shows the depreciation
cost per cubic inch of pattern for
each of the four printers. Note that
the cost depends on the number
of hours per month the printer is
used. As printing hours increase,
cost per cubic inch decreases. The
Project Wax printer has the highest
depreciation per cubic inch of
pattern built.
• Maintenance Cost – A significant
cost of running a pattern printing
operation is the cost of maintenance.
Determining actual maintenance
costs would be extremely
difficult. However, a reasonable
approximation can be obtained by
looking at the cost of the highest
level maintenance contract offered
by each manufacturer. For those
customers who purchase the
contract, it covers most if not all of
their maintenance cost. To calculate
Figure 4: Maintenance Cost per cubic inch of Pattern
Figure 5: Total Non-labor operating cost per cubic inch of pattern.
4. ®
April 2017 ❘ 17
the cost of maintenance per cubic inch, the monthly
cost of the maintenance contract is divided by the
total volume of patterns built per month (320 hours
per month as calculated above). The result of those
calculations is shown in Figure 4. Like depreciation
cost, the more hours per month the printer is used,
the lower the maintenance cost per cubic inch will
be. CastForm has the highest maintenance costs.
• Total Non-Labor Pattern Cost – To obtain total non-
labor pattern cost, we can simply add the three
previous costs together and is shown in Figure 5.
The Projet has the highest cost per cubic inch of
part volume followed by Castform, QuickCast, and
Voxeljet. Note that the highest cost is more than 7
times the lowest cost.
Observations
Several observations can be made
1. The least expensive printer, the ProJet 3510 CPX has
both the highest capacity cost and operating cost.
2. The most expensive printer, Voxeljet VX1000 has
both the lowest capacity cost and operating cost.
3. Capacity cost, depreciation cost, and maintenance
cost (but not material cost) are all dependent on the
build rate. An increase in build rate will lower both
capacity cost and operating cost.
Build rate varies significantly depending on the
number of parts being built, build orientation and the
geometry of the parts being built. As was explained in the
first article, average build rates is determined from actual
data gathered on a number of machine runs. As more
data is gathered, better estimates of average build rates
will be determined. As a result, cost data may change.
A great printer with low costs will be of no value if
the patterns it creates cannot reliably be converted into
acceptable castings. The ability to convert the patterns
into acceptable castings is dependent on characteristics
of the patterns. In the next issue, those characteristics
will be examined.