Why should you make tooling with 3D printing?
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This webinar discussed how 3D printing can be used to create jigs, fixtures and tools to streamline manufacturing processes. It highlighted challenges with traditional manufacturing aids like long setup times and presented how 3D printing enables complex geometries, design flexibility, and part consolidation. Customer examples were provided where 3D printing reduced costs and lead times for tooling components at Triumph Composite Systems and optimized robotic end-of-arm tooling at Genesis Systems Group. The webinar recommended connecting cross-functional teams to identify opportunities for 3D printed tools and focusing first on implementing them in one department.
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Why should you make tooling with 3D printing?
- 1. #DWwebinar
- 2. #DWwebinar q This webinar will be available afterwards at www.designworldonline.com & email q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar Before We Start
- 3. #DWwebinar Meet your Speakers MODERATOR FEATURED SPEAKER Derek Roedel Advanced Tooling Program Manager FATHOM Leslie Langnua Managing Editor Design World Ryan Sybrant Director, Manufacturing Channel Enablement Stratasys FEATURED SPEAKER
- 4. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar CHANGING THE WAY PRODUCTS ARE DESIGNED & MANUFACTURED studiofathom.com // Oakland 510.281.9000 // Seattle 206.582.1062 Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.
- 5. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar 3D PRINTED TOOLING Overview of Capabilities • Very short lead-times − Many molds 3D printed in less than a day • Quick iterations during development • First article inside of a week after kickoff • Injection production-grade thermoplastics • Ideal for up to 50 parts Overview of Limitations • Biggest limitations: texture and color • Tool action “slides and lifters” are possible— hand loads • Thin walls and undercuts • Living hinges are debatable— stringent on design and location of gate
- 6. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar DMLS TOOLING INSERTS Fits Early Prototyping and Bridge-to-Production Needs • Build an insert in 48 hours • Post-production is minimal compared to machining • 20k+ parts (geometry and molding resin dependent) • Blend additive with traditional technologies • Material Options: − Inserts can be made from MS-1 maraging steel (heat treated mid 50HRC for best results) − Aluminum is ideal for very quick turn short-run tooling − Can be plated/coated to address abrasion/erosion • Inserts can be EDM textured and/or hand polished after heat treatment (replicate final product texture) • Design inserts with features for weight savings, heat evacuation, and conformal cooling lines
- 7. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar COMPARISON ITEM 3D PRINTED TOOLING CONVENTIONAL TOOLING Mold Base MUD (Master Unit Die) MUD Or Dedicated Mold Fitting / Build Up Hand & Machine Hand & Machine Cooling Lines None – Done With Cold Air Water Cooling Lines Ejection Minimal – Large Blocks Or None At All – No Sleeves Or Lifters Standard Pins – Sleeves – Lifters Tool Action - Slides Done With Hand Loads Built Into The Tool Resin Choices Limited To Low Melt Point – High Melt Flow Index Any Resin Tool Material Plastic Metal
- 8. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar VOLUME & TIMEFRAME ITEM 3D PRINTED TOOLS 3D PRINTED DMLS INSERTS BRIDGE TOOL / QUICK TURN TOOLS PRODUCTION TOOLS Lead Time* 2-6 Days *Geometry Dependent 1-2 Weeks 3-5 Weeks 6-10 Weeks Mold Material 3D Printed Resin MS-1 Maraging Steel, Aluminum, Or Stainless Steel Aluminum Or P20 Steel Hardened Steel Cooling None - Air Complex Cooling Lines Simple Cooling Lines Complex Cooling Lines Cycle Times Part-to-part 5 Minutes - 10 Minutes 10 Seconds - 2 Minutes 1 Minute - 2 Minutes 10 Seconds - 2 Minutes Tool Life 20-100 Parts Some Rework On Later Parts (Flash) >20K ~ 20K to 100K ~ 2MM Part Price $$$ $$ $$ $ Changes – Time & Cost 1-2 Days, CAD Time And Print A New Tool ($600 - $1,500) 1-2 Weeks Or Print Another Tool 1-2 Weeks, $1,500 - $5,000 Several Weeks And Thousands Of Dollars * From Time of Kickoff—DFM finalized, CMF finalized, CAD finalized, material on hand or arranged.
- 9. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar STEPS & TIMEFRAME
- 10. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar
- 11. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar DECISION MAKING PROCESS What Tooling Is Best For My Application? • 3D Printed Tooling (Fast) − Feature discovery such as living hinge or snaps − Real plastic part prototyping, fastest iteration (new tool) − Material performance for available resins (regulatory or drop test) • DMLS Insert Tooling − Part performance testing − Material performance for any resin (regulatory or drop test) − SPC data collection: gating/ejection, venting, cycle-time • Bridge Tooling − Closest to production for short-run applications − Production resin choices − SPC data collection: gating/ejection, venting, cycle-time
- 12. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar WHEN TO USE 3DP IM When Prototype In Final Material Is Needed For Design Decision • Durometer of a TPE—Is it 30 or 90 Shore A? • Impact testing • A crucial snap • Fluid / air flow • A flexure • Sonic weld testing, or adhesive bonding When You Need 50 Parts For Functional Testing With Clients • Fastest / cheapest way to 50 parts of production material • Regulatory test units Fast Part Design Iteration • If parts don’t work as anticipated, we can adjust CAD in the afternoon, 3D print new tool parts overnight, and mold new parts the next day
- 13. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar MATERIAL OPTIONS FATHOM Stocks Several Materials • Polypropylene (PP), Polyethylene (PE), Thermoplastic Elastomer (TPE) Shore A 60, ABS, ABS/PC, Nylon (PA – Polyamide) Always Consider Lead-time In Selecting Your Materials • Some materials can take months to get, especially in small quantities • Just because it is listed on a website, doesn’t mean that small quantity orders are available Lower melt points are better • Heat degrades the tool Higher Melt Flows Are Better • Thinner when molten
- 14. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar IDEAL SITUATION Part Was Designed For Injection Molding From The Beginning • Drafted to 2-3+ degrees • Parting line defined • Gate was considered • Consistent wall thickness • Tool action is defined (slides, no lifters, etc.) • No thin standing steel (think in the inverse of part design) Open And Shut Tool Design • Minimum amount of tool action (hand loads) Simple Resins Minimal Part Finish Requirements Natural Colored Resin
- 15. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar FATHOM’S BEST PRACTICES Well Designed Parts Get Made Much Faster • New ideas are great, but new methods of manufacturing take longer to see the light of day— FATHOM can help, but invention on a timeline is a dangerous game Decide On What It Is That This Model Needs To Answer • What are the objectives of the build? Do Design Reviews Early and Often • Like voting in Chicago • Don’t hesitate to give FATHOM a call to review your design Design With The End In Mind • If you are going to injection molding in the end, start your design that way • Don’t fall in love with a bad design Think Of How The Tool Will Be Built To Make The Part • Where will the gates be? And the knit lines? • Where are parting lines? And the draft? • How will tool action be implemented? − If you have a hole in the side of your part, consider the size of the hand load to make it
- 16. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar FUTURE OF 3DPT New & Better Mold Materials • Better finishes • Longer part runs • Higher mold pressures Shorter Lead-times Influence Future Machine Design
- 17. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar
- 18. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar EXAMPLE Phone Case (PolyJet) • 3D printed tool in 7 hours and molded parts within 24 hours • Tool Material: ABS-Like (PolyJet) • Part Material: TPE Shore 60A − Grade offers soft/tactile feel, adhesion to Polypropylene, good weatherability • Up to 50 Parts • Dimensions: − A-Side: 4.75” x 4.75” x 1.5” − B-Side: 4.75” x 4.75” x 1” • Shot Size: 27cm³
- 19. Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.#DWwebinar EXAMPLE Infrared Transmitting (DMLS) • Inserts printed with MS-1 Steel in 2 days • CNC machine surfacing and polish in 1 day • Tool Material: MS-1 Steel − SPC data collection for production specification • Part Material: Acrylite IR specific resin − Grade offers infrared transmitting capabilities • Up to 50k Parts (heat treated insert) • Dimensions: − Insert: 3” x 4” − Shot size: 2cm³
- 20. #DWwebinar CONTACT INFORMATION OAKLAND OFFICE (510) 281-9000 329 Jefferson Street Oakland, CA 94607 OAKLAND PRODUCTION CENTER 315 Jefferson Street Oakland, CA 94607 www.studiofathom.com info@studiofathom.com SEATTLE OFFICE + PRODUCTION CENTER (206) 582-1062 4302 Stone Way North Seattle, WA 98103
- 21. 21 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY#DWwebinar Efficiency and Productivity with 3D Printed Manufacturing Aids March 24th, 2016
- 23. #DWwebinar Jigs, Fixtures and Tools Streamline production floor workflows A means to optimize manufacturing by reducing cost and cycle time, while increasing product quality and repeatability
- 24. #DWwebinar Jigs, Fixtures and Tools Most important considerations • Accuracy • Rigidity • Ease of Use • Economy in production • Workforce safety
- 25. #DWwebinar Jigs, Fixtures and Tools Objective • Ensure interchangeability and accuracy of parts manufactured, • Minimize the possibility of human error • Permit the use of medium skilled labor • Reduce the manufacturing time • Allow production of repeat orders without retooling
- 26. #DWwebinar Moving up the Value Chain
- 27. #DWwebinar Moving up the Value Chain Prototyping Func.onal Tes.ng Jigs and Fixtures Tooling Produc.on Parts Product Development • Prototype • Review • Refine Application Verification • Performance testing • Integration validation • Acceptance testing Process Facilitators • Molds • Patterns • Mandrels Efficiency Tools • Work holders • Gauges • Guides Final Components • Covers • Brackets • Ducts
- 29. #DWwebinar 29 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY Today’s Challenges • Long machine set-ups • Variation during assembly and fitting • Complicated part holding requirements • Ease of handling and transportation • Defects caught too far down production line • Employee safety and ergonomics • Cost, time, wait and storage prevents manufacturers from producing needed efficiency tools
- 30. #DWwebinar Addressing Today’s Challenges • Complex geometries no longer a barrier • Design flexibility • Shorten set-up times • Part consolidation • Integrated features • Ergonomics • Simple duplication
- 31. #DWwebinar Justification for AM Key Success Factors • Efficient; path of least resistance • Allows for more on the floor • Translates to operational savings • Reduced burdened rate • Change in design and manufacturing mindset • Will impact multiple departments
- 33. #DWwebinar Triumph Composite Systems Why Triumph adopted Additive Manufacturing: To lower tooling component costs, decrease schedule (lead- time) and reduce dependence on external tool suppliers
- 34. #DWwebinar Creating worker friendly factories • Focus on ergonomics • Light-weighting tools • Increasing tools performance • Customizing tools to the assembler • Reduced automobile rework BMW
- 35. #DWwebinar Rethinking traditional processes • Transforming test fixtures • Reduced part count • Reduce cost and lead-time • User friendly Wair Products
- 36. #DWwebinar Opel Changing the Approach to Process Tooling • Brings the line worker into the design process • Allows them to adapt tools much better to the worker and automobile • Makes it possible to find and implement the most appropriate solution
- 37. #DWwebinar Genesis Systems Group Investment in Innovation • Optimized robotic end-of-arm tooling • Reduced part count • Reduce cost and lead-time
- 38. #DWwebinar Solaxis Reducing tool footprint and weight while increasing accuracy • Removed 100lbs from previous tool • Agility increased flexibility of design • Solved compliance issues for supplier
- 39. #DWwebinar Taking the First Steps
- 40. #DWwebinar Successful Implementation • Connect cross-functional teams to seek out opportunities where 3D printed tools can make an impact • Interview the workforce that is involved in day to day production • Don’t forget about operational efficiency programs such as 5S • Focus on one area or department and duplicate success to others
- 42. #DWwebinar Initiate for results Reduce Production Time and Cost Maximize Efficiency Maintain Consistent Quality Improve Functionality Enhance Safety
- 43. #DWwebinar Thank You Ryan Sybrant Director, Manufacturing
- 44. #DWwebinar Questions? MODERATOR Leslie Langnua Managing Editor Design World Ryan Sybrant Director, Manufacturing Channel Enablement Stratasys FEATURED SPEAKER FEATURED SPEAKER Derek Roedel Advanced Tooling Program Manager FATHOM
- 45. #DWwebinar q This webinar will be available at designworldonline.com & email q Tweet with hashtag #DWwebinar q Connect with Design World q Discuss this on EngineeringExchange.com Don’t Forget!
- 46. #DWwebinar
- 47. #DWwebinar THIS DOCUMENT IS PROPRIETARY TO STRATASYS, INC. AND/OR STRATASYS LTD., AND SHALL NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY DESIGN OR MANUFACTURE EXCEPT WHEN SUCH USER POSSESSES DIRECT WRITTEN AUTHORIZATION BY STRATASYS, INC. AND/OR STRATASYS LTD. STRATASYS, INC MAKES NO CLAIM, PROMISE, OR GUARENTEE OF ANY KIND ABOUT THE ACCURACY, COMPLETENESS, OR ADEQUACY OF THE CONTENT OF THIS PRESENTATION AND EXPRESSLY DISCLAIMS LIABILITY FOR ERRORS AND OMISSIONS IN SUCH CONTENT.