leaders in additive manufacturing - fdm digital solutions€¦ · fdm digital solutions —...

FDM Digital Solutions — [email protected] — +0044(0)1282 872 370

leaders in additive manufacturing


about us Founded in 2012, FDM Digital Solutions has grown to be one the largest Additive Manufacturers (3D printing) in the UK.

With the largest commercially available FDM (Fused Deposition Modelling) build envelopes and capacity in the UK, FDM Digital Solutions offer a wide range of engineering solutions in

sectors as diverse as Aerospace, Motorsport and Healthcare.

Managed by experienced engineers, our promise is to offer the best possible service and solutions regardless of whether the customer requires a straightforward build using an

existing 3D model, or if the design requires reverse engineering and our expert input in design optimisation for additive manufacturing. Either way we aim to provide the best

possible solution to the end client.

At FDM Digital Solutions we utilise the benefits of additive

manufacturing across many different applications in many different

sectors. Particular areas of focus include:

• Carbon forming soluble/lay-up tools

• Jigs and fixtures for fabrications and assemblies

• Flight ready components for aircraft interiors

• Metal-plated components

• Design for additive manufacturing consultancy

• Reverse engineering

• Short run production components


forming tools carbon-fibre

Top-left - ULTEM Lay-up tool Above - Soluble pipe mandrel Left - Tool and finished part

FDM Digital Solutions has great experience in the design and manufacture of carbon-fibre forming

tools.

Having helped develop soluble tooling solutions for several Formula 1 teams, we are capable in the

design of complex ducting and panels, using soluble core technology to build a 3D-printed mandrel

upon which carbon-fibre can be laid. Once the core is extracted, the carbon-fibre component

remains.

Our ULTEM-9085 high temperature FDM material also allows us to design and manufacture com-

plex lay-up tools that can withstand high temperatures and pressures. The inclusion of scribe lines

and other features adds little to the cost using additive manufacturing.


Additive manufacturing allows complex patterns, jigs and tools to be built without the need for hours of

machining with the added benefit of turn-around times of days rather than weeks. Produced straight

from CAD these solutions are a quick and simple alternative to traditional methods.

jigs and fixtures

Above: Anchor nut marking templates and be-

spoke packaging

Right: Drill template for accurately drilling on a

complex surface

Below: Jig to ensure pipe components are glued

together accurately


ULTEM flight ready components

Utilising ULTEM 9085 material, FDM Digital Solutions produces many flight ready

components that are manufactured to AS9100.

Taking advantage of the flexibility that additive manufacturing can provide, BE Aerospace

have utilised FDM Digital Solution’s ability to build non-load bearing components in a

flame retardant material with full material traceability.

With greater design freedom than traditional methods, complex shapes can be created

without needing to consider tooling design limitations.

The systems managing the production facility at FDM Digital Solutions allow our team to

keep track of orders providing parts on-time and in labelled, job specific bespoke

packaging.

Above: A selection of ULTEM 9085 components in bespoke laser-cut

packaging

Left: Completed 9085 flight ready components


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Above: FARO scanner in action Right: Reverse engineered custom steering wheel

FDM Digital Solutions has full reverse engineering and design capabilities. With a FARO

blue laser scan arm, we are able to capture complex data and convert it to a point cloud

then an stl mesh.

From this we can reverse engineer using a variety of software including SpaceClaim,

PolyWorks, Catia, SolidWorks and Cimatron.


other applications Above: 3D Printed last Above Right: Nickel plated panel Right: Nickel plated engine parts

Keen to provide alternative solutions for our customers, at FDM Digital Solutions we have explored

the use of different technologies and conducted research into new applications for additive

manufacturing.

With the East-Lancashire NHS we are producing 3D printed rubber insoles using our Polyjet process in

order to reduce pressure on lesions that develop on diabetic patients. This rapid intervention is

intended to reduce the number of amputations carried out by the trust.

Again using our Polyjet process we are able to finish components with metal plating, which increases

rigidity, strength and thermal dissipation.

At FDM Digital Solutions we are always happy to develop new processes and ideas with customers, if

we don’t have the answers we are happy to work with our clients until we are confident to go to

production.


FDM Digital Solutions has a suite of 9 Stratasys and HP machines — the largest commercially

available capacity in the UK with the largest build envelopes for the following processes.

The FDM process uses common engineering thermoplastics, enabling high quality engineering

components to be produced. Unlike many other processes these aren’t simulants and so they

represent typical material qualities of parts made in similar materials using different processes.

The Polyjet process enables greater design freedom, allowing us to mix materials of different

properties (i.e. ABS simulant and Rubber simulant) at any stage of the build process whilst printing

in fine 0.03mm build layers. This process produces great aesthetic models and allows us to develop

components for unique applications

The MJF process uses the latest technology available to the market, allowing tough, flexible parts to

be produced at very attractive prices for small runs where conventional mould tooling could be cost

prohibitive.

machine capacity

Fortus 400mc Fortus 450mc Fortus 900mc Connex 500 HP MJF

Build Envelope (XYZ) mm

406 x 355 x 406 406 x 455 x 406 914.4 x 609.6 x 914.4 490 x 390 x 200 380 x 284 x 380

Our Capacity 4 2 1 1 1


FDM 900 specification


FDM 400/450 specification


HP MJF specification

Build envelope 384x280x384mm


case study airbus a330 neo demo box

Creation of a life size replica of a complex wing-box section from existing CATIA CAD data. This project helped prove

the design change from CEO to NEO by ensuring all engineering tolerances were workable.

This is the largest 3D-printed model used by Airbus and the Launch Team concluded that ‘this was an excellent

application for 3D modelling to de-risk the design solution before production commences later in 2016’.

Prior to this model being created, there were doubts as to whether pipes and cabling could be assembled through the

wing. Once the model had been created, the design was quickly proven, however if there had been any tolerance

issues the consequences could have been extremely expensive.

Above Left: Completed demo box Above: A330 Neo Below Left: Demo box in testing

Business Case:

• Design Improvements - Helped prove the design change from CEO to NEO

• Greater Accuracy - Ensured all engineering tolerances were workable

• Clive Devey - Head of Industrial Launch ‘The project assists with the overall objectives of

weight reduction, reduced parts count and savings on installation time‘


FDM Digital Solutions have been fully ISO-9001 approved since March 2016 across

all operations including purchasing, order processing and design.

We currently supply BE Aerospace with non-structural flight ready components

built to AS9100 standards. We are aiming to gain full AS9100 approval in early

2017

Direct digital manufacture alongside our Sage Manufacturing business system

allows full traceability of materials within our component builds and ensures that

the progress of orders through our production cells is optimised.

quality systems


Airbus Tier 1 Supplier — FDM Digital Solutions have been

awarded tier 1 status as an Airbus supplier since June 2016

BE Aerospace Approved Supplier — Approved supplier of

non-structural flight ready components.

Formula 1 team supplier — Supplier of several leading Formula

1 teams particularly specialising in the production of Carbon-

Fibre forming soluble and lay-up tools.

Approved supplier to several aerospace OEMs including Safran

Nacelles, Kaman, Sonaca and EDM

quality approvals


Address: FDM Digital Solutions

Suite 17, Lancashire Digital Technology Centre

Bancroft Road

Burnley

BB10 2TP

Contact Us At FDM Digital Solutions we are always happy to discuss ways that we can help engineer solutions for you and your business. Feel free to contact any of our

team listed above.

To e-mail us for a quotation or enquiry, please e-mail [email protected] . For a quotation all we require is a 3D model, preferred formats be-

ing .stl, .stp or .iges files, although we can convert from most other file formats.

To speak to one of the team call +0044 (0)1282 872 370. Our team will be more than happy to discuss and advise on your needs.

leaders in additive manufacturing - fdm digital solutions€¦ · fdm digital solutions —...

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