SlideShare a Scribd company logo
We're 3D printing's biggest fans.
• 40 Years Supplying & servicing the
Australian & NZ Manufacturers
• Major Supplier of Machinery to Plastics
Processing industries.
• Sales & Service located across Australia
& NZ.
• Largest install base of industrial grade 3D
Printers in Australia & NZ.
1984 SLA 3D
Printer
1988 FDM 3D
Printer
1999 Polyjet 3D
Printer
2007 RepRap
2012
Objet/Stratasys
Chuck Hull
Scott Crump
Adrian Bowyer
Development of 3D Printing
Processes
• Scanning to CAD
• Scanning to Print
• CAD Modelling
Software Slicing
Software Slicing
FDM
Polyjet
Applications
How is 3D Printing being
implemented?
Other
2%
Visual Aids
9%Presntation Models
9%
Fit & Assembly
21%
Patterns for
prototype tooling
12%
Patterns for metal
casting
10%
Tooling Components
6%
Functional Parts
31%
Other Visual Aids Presntation Models
Fit & Assembly Patterns for prototype tooling Patterns for metal casting
Tooling Components Functional Parts
End-Use Parts:
Candidate Profile
•Manufacturers needing plastic
components for finished goods
•Need low-volume production alternative
• Pilot, bridge, production or end-of-life
•Current methods limit what’s possible
(considering time, cost)
• Design optimization isn’t practical
•Need efficiency, flexibility
• With low-volume, high-complexity parts
•Open to change
• Or seeking innovation
Camera Housing: EUP – Military Application
Digital camera enclosure
Low volume – Qty 3,000
PC/ABS
High design iteration
Complex geometry
DDM chosen over injection molding
Not moldable
PC-ABS
8” x 1/4” x 1/2”
1 undercut per top & bottom
Unmanned Systems
Unmanned Vehicles
• FDM viewed as key to “mass customization”
• Easier adoption because of limited risks
• Overnight production reduces cycle time
• Direct build eliminates tooling needs
Success Stories
• Draganfly: Surveillance UAV
• Leptron: Rapid Deployable Aerial Surveillance
System (RDASS)
• Embry-Riddle: Monocopter
• Swiss UAV: Operational UAV Helicopter
• Boeing UAV: AFRL Study
Picture courtesy of NEO S-
300 VTOL UAV Swiss UAV
GmbH
Pictures courtesy of Draganfly
Pictures courtesy of
Leptron
Pictures courtesy of
Embry-Riddle
End Use Parts – Light Aircraft
Injection Molding:
Application Overview
Thermoplastic parts
• Injected into tool/mold
• High volume, Best repeatability
• Most common method of plastic
manufacturing
Tooling
• Mold cavity
• Gates, runners, shut-offs
• Cams, sliders, ejection system
Injection Molding:
Where Used
High-volume plastic part
production
• Consumer products
• Packaging.
• Consumer electronics
• Automotive
• Aerospace
• Electronics
• Toys
• Household goods
• And many more
Injection Molding:
Candidate Profile
Company type:
• Custom molders
• OEMs
• Tool/die, model, services shops
Industries:
• Consumer electronics
• Consumer products
• Medical device
That need:
• Early, rapid product confirmation
• Design, function, standards
(e.g., UL, CE)
• Early, rapid assessment of design
for manufacturability
Injection Molding:
Process Overview
Part design
Tool design
Tooling making
Molding machine setup
• Mount tool
• Adjust injection settings
•Sample (first article) run
•Production run
• Automated
Injection Molding:
Traditional Processes
Tooling Manufacturing
• Design
• CNC setup
• Milling
• EDM
•Considerations
• High skilled labour intensive
• Lead times – weeks to months
• Costs – $1,000s to $100,000s
Injection Molding:
PolyJet’s Role
Alternative to:
• Machined soft tooling -
Aluminium
Process
• Design tool or tooling insert
• Print
• Assemble tool
• Fit inserts, add ejection
system
• Mount on press
• Adjust injection parameters
Advantages
• Quick, cost effective and
efficient
PolyJet - Best Fit for
Injection Molding When:
•Thermoplastics with:
• Reasonable molding temperatures
• < 300 °C (570 °F)
• Good flowability
• Candidates:
• PE, PP, PS, ABS, TPE, PA,
POM, PC-ABS
• Glass filled resins
•Low quantities (5 to 100)
•Mid-sized parts (< 165 cc [10 cu. in.])
• 50 - 80 ton press
•Confirmation desired
• Before cutting soft/hard tool
PolyJet Benefits for
Injection Molding:
•Spec resins, production process
• True functional evaluation
•50% to 90% savings
• Time & cost
•Efficient
• Automated with few steps
•Early detection
• Flaws in part & tool design
• Thermoplastic’s performance
Customer Success Story
Robert Seuffer GmbH & Co
Seuffer video
Success Story:
Robert Seuffer GmbH
•PWM housing (automotive control)
• Performance verification
• Under thermal/mechanical loads
•Machined soft tooling (aluminum)
• 8 week delivery
• $52,725.00
• Inserts for challenging geometry
•PolyJet soft tooling
• Molded polyethylene housings
• Performed well & streamlined process
•Results
• Saved $51,407 and 7 weeks
• Now an element of product development
Method Cost Time
Machined AL
Tool
PolyJet Tool $1,400 1 day
Savings $ (%) (
Sample Part Detail
System Connex500
Material Digital ABS
Print mode DM
Print finish glossy
Build time 9:00 hr
Model material
amount
RGD515: 860gr; RGD535:515gr
Support material
amount
96 gr
Size Core
X:140 Y:100 Z:45
Cavity
X:140 Y:100 Z:45 (all in mm)
orientation
Injection Molding: housing for a PWM (pulse-width modulation)
Sample Part Detail
Material PP
Melt temperature [C] 210
Actual injection pressure
[bar]
200
Clamp force [kN] 300
Cooling time [s] 180
Hold pressure [bar] 200
Hold time [s] 2

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Tasman 3DPrinters presentation - Avalon Airshow 2015

  • 1.
  • 2. We're 3D printing's biggest fans. • 40 Years Supplying & servicing the Australian & NZ Manufacturers • Major Supplier of Machinery to Plastics Processing industries. • Sales & Service located across Australia & NZ. • Largest install base of industrial grade 3D Printers in Australia & NZ.
  • 3. 1984 SLA 3D Printer 1988 FDM 3D Printer 1999 Polyjet 3D Printer 2007 RepRap 2012 Objet/Stratasys Chuck Hull Scott Crump Adrian Bowyer Development of 3D Printing
  • 5. • Scanning to CAD • Scanning to Print • CAD Modelling Software Slicing
  • 7. FDM
  • 9. Applications How is 3D Printing being implemented?
  • 10. Other 2% Visual Aids 9%Presntation Models 9% Fit & Assembly 21% Patterns for prototype tooling 12% Patterns for metal casting 10% Tooling Components 6% Functional Parts 31% Other Visual Aids Presntation Models Fit & Assembly Patterns for prototype tooling Patterns for metal casting Tooling Components Functional Parts
  • 11. End-Use Parts: Candidate Profile •Manufacturers needing plastic components for finished goods •Need low-volume production alternative • Pilot, bridge, production or end-of-life •Current methods limit what’s possible (considering time, cost) • Design optimization isn’t practical •Need efficiency, flexibility • With low-volume, high-complexity parts •Open to change • Or seeking innovation
  • 12. Camera Housing: EUP – Military Application Digital camera enclosure Low volume – Qty 3,000 PC/ABS High design iteration Complex geometry DDM chosen over injection molding Not moldable PC-ABS 8” x 1/4” x 1/2” 1 undercut per top & bottom
  • 13. Unmanned Systems Unmanned Vehicles • FDM viewed as key to “mass customization” • Easier adoption because of limited risks • Overnight production reduces cycle time • Direct build eliminates tooling needs Success Stories • Draganfly: Surveillance UAV • Leptron: Rapid Deployable Aerial Surveillance System (RDASS) • Embry-Riddle: Monocopter • Swiss UAV: Operational UAV Helicopter • Boeing UAV: AFRL Study Picture courtesy of NEO S- 300 VTOL UAV Swiss UAV GmbH Pictures courtesy of Draganfly Pictures courtesy of Leptron Pictures courtesy of Embry-Riddle
  • 14. End Use Parts – Light Aircraft
  • 15. Injection Molding: Application Overview Thermoplastic parts • Injected into tool/mold • High volume, Best repeatability • Most common method of plastic manufacturing Tooling • Mold cavity • Gates, runners, shut-offs • Cams, sliders, ejection system
  • 16. Injection Molding: Where Used High-volume plastic part production • Consumer products • Packaging. • Consumer electronics • Automotive • Aerospace • Electronics • Toys • Household goods • And many more
  • 17. Injection Molding: Candidate Profile Company type: • Custom molders • OEMs • Tool/die, model, services shops Industries: • Consumer electronics • Consumer products • Medical device That need: • Early, rapid product confirmation • Design, function, standards (e.g., UL, CE) • Early, rapid assessment of design for manufacturability
  • 18. Injection Molding: Process Overview Part design Tool design Tooling making Molding machine setup • Mount tool • Adjust injection settings •Sample (first article) run •Production run • Automated
  • 19. Injection Molding: Traditional Processes Tooling Manufacturing • Design • CNC setup • Milling • EDM •Considerations • High skilled labour intensive • Lead times – weeks to months • Costs – $1,000s to $100,000s
  • 20. Injection Molding: PolyJet’s Role Alternative to: • Machined soft tooling - Aluminium Process • Design tool or tooling insert • Print • Assemble tool • Fit inserts, add ejection system • Mount on press • Adjust injection parameters Advantages • Quick, cost effective and efficient
  • 21. PolyJet - Best Fit for Injection Molding When: •Thermoplastics with: • Reasonable molding temperatures • < 300 °C (570 °F) • Good flowability • Candidates: • PE, PP, PS, ABS, TPE, PA, POM, PC-ABS • Glass filled resins •Low quantities (5 to 100) •Mid-sized parts (< 165 cc [10 cu. in.]) • 50 - 80 ton press •Confirmation desired • Before cutting soft/hard tool
  • 22. PolyJet Benefits for Injection Molding: •Spec resins, production process • True functional evaluation •50% to 90% savings • Time & cost •Efficient • Automated with few steps •Early detection • Flaws in part & tool design • Thermoplastic’s performance
  • 23. Customer Success Story Robert Seuffer GmbH & Co
  • 25. Success Story: Robert Seuffer GmbH •PWM housing (automotive control) • Performance verification • Under thermal/mechanical loads •Machined soft tooling (aluminum) • 8 week delivery • $52,725.00 • Inserts for challenging geometry •PolyJet soft tooling • Molded polyethylene housings • Performed well & streamlined process •Results • Saved $51,407 and 7 weeks • Now an element of product development Method Cost Time Machined AL Tool PolyJet Tool $1,400 1 day Savings $ (%) (
  • 26. Sample Part Detail System Connex500 Material Digital ABS Print mode DM Print finish glossy Build time 9:00 hr Model material amount RGD515: 860gr; RGD535:515gr Support material amount 96 gr Size Core X:140 Y:100 Z:45 Cavity X:140 Y:100 Z:45 (all in mm) orientation Injection Molding: housing for a PWM (pulse-width modulation)
  • 27. Sample Part Detail Material PP Melt temperature [C] 210 Actual injection pressure [bar] 200 Clamp force [kN] 300 Cooling time [s] 180 Hold pressure [bar] 200 Hold time [s] 2