moldes fabricados con polyjet...6 stratasys / the 3d printing solutions company which plastics? 0...
TRANSCRIPT
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1 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Moldes Fabricados con PolyJet
Pablo Mora
Iñaki Quintana
Irene Díaz
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2
Cuando usar moldes en 3D
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3 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
En qué etapa?
Diseño
CAD software
Prototipo 1
Modelo Conceptual
Prototipo Rápido
Simulación
Prototipo 2 Fabricación
Moldes en 3DFuncional
Material Final
Ultimos tests y verificación
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4 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
En qué etapa?
Diseño
CAD software
Prototipo 1
Modelo Conceptual
Prototipo Rápido
Simulación
FabricaciónSeries cortas
Moldes en 3DFuncional
Material Final
Últimos tests y verificación
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5 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
VIDEO
01:32
Ejemplo de un molde 3D en funcionamiento
http://youtu.be/weiVuCcXbzk
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6 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
WHICH PLASTICS?
0
200
400
600
10040
500
100
300
70
Mínimo Piezas
Mínimo número de piezas
reportadas por el cliente con
un solo molde
Máimo Piezas
Máximo número de piezas
reportadas por el cliente con
un solo molde
.
Media Piezas
Número medio de piezas
reportadas por el cliente con
un solo molde
.
Min. Max. Avg.
Soft / Elastomeric Plastics Standard Plastics
Based on 2014 customer survey (58% response
rate)
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7 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
La duración de los moldes dependerán de las geometrías y tamaño de piezas
Duración media de molde
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• Usar Plásticos con temperaturas de
moldeo de hasta 300° C (570° F).
Como:
PE, PP, PS, ABS, TPE, PA, POM,
PC-ABS and glass-filled resins
• Piezas no muy grandes de 165 cm3.
• Usar máquinas de moldeo de hasta
200-ton.
Condciones Ideales
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9
Como Mejorar el Rendimiento
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10 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Tratamiento Térmico Polyjet
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Materiales de PolyJetrecomendados
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• ABS Digital (RGD 515 plus + RGD 535)
• VeroClear (RGD810)
• RGD525 high temperatura
• Rigur (RGD 450)
Materiales PolyJet Recomendados
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CUSTOMER STORIES
SECTION TWO
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14 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
3D Printer: Objet30 Pro™
Industry: Control switches (lighting, motion, HVAC)
Need:Quick and inexpensive prototypes for functional testing
Berker
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15 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Berker – Part Assembly
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16 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Functional tests include:
• Electrostatic discharge test
• Used to determined whether assembly of electrical parts will produce a charge of electricity.
• Fit tests
• All components of the assembly had to fit properly.
End use materials were necessary to validate tests (PC, ASA, TPU).
Berker - Functional Testing
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17 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Berker- 3D Printed Injection Molding Process
Mold Prep and Assembly
Printing and Cleaning Process
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18 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Berker- 3D Printed Injection Molding Process
Part Assembly
Injection Process
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19
3,800
Berker: Benefits
22,350
3
28
Traditional Tooling
3D Printed Tooling
Traditional Tooling
3D Printed Tooling
Time (Days)
Cost (USD)
“This new flexibility enables us to try out two or three different solutions at the same time to get the best result. The confirmed quality of our products produced using these functional prototypes has accelerated our R&D processes.”
Andreas Krause
Head of Technical Department & Manufacturing at Berker
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20 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
3D Printer: Objet260 Connex™
Industry: Water measurement solutions
Need:Quick and inexpensive prototypes for functional testing
Arad Group
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21 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Part Assembly
Arad Group – Functional Testing
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22 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Functional Tests in end use material GRILAMID TR90 (amorphous Nylon):
• Ultrasonic welding
• Gasket assembly design
• Material physical and mechanical properties
It was necessary for the parts to be in the real end-use material and in the end-manufacturing practice for the tests to be successful.
Press
Holding Fixture
Part
Assembly
Ultrasonic Stack
Arad Group – Functional Testing
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23 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Assembly Cross Section 3D Printed Injection Molds
Use of inserts for undercut feature
Arad Group - 3D Printed Injection Molding Process
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24 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Arad Group - 3D Printed Injection Molding Process
Injection Process
Molded Parts
Machine – 50T Arburg• Injection temperature – 260° C
• Injection pressure – 880 bar
• Shot size – 38 cubic cm
• Switch-over point – 8.5 cubic cm
• Packing pressure – 200 bar
• Cooling time – 140 sec
• Number of injected parts – 25 Parts
Results of Tests
Passed IEC (International Electrotechnical Commission) code IP54 for dust and water infiltration.
Parts passed translucency test.
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25
2,000
Arad Group: Benefits
10,000
2
42Traditional Prototype Tooling
3D Printed Tooling
Traditional Prototype Tooling
3D Printed Tooling
Time (Days)
Cost (USD)
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26 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Grundfos
3D Printer:
Objet500 Connex3™
Industry:
Pump manufacturing
Need:
• Production-ready prototypes
• Complex mold design with best
surface finish
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27 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Functional test in end-use material - 30% GF Noryl (PPE-PS-GR30):
• Assembly of molded part to pump
• Run pump at various flow rates to assess damage to molded part
Grundfos: Pump Test
Injection molded part inside PolyJet mold.
Side view of part with mold and sprue. Final part produced from the PolyJet mold.
Machine: Engel 200T• Clamp force – 500 KN
• Injection temperature – 270° C
• Injection Pressure – 500 bar
• Shot Size – 330 cubic cm
• Switch-over point – 51.1 cubic cm
• Packing pressure – 50 bar
• Cooling time – 110 sec
• Number of injected parts – 20 Parts
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Grundfos - Benefits
Cost Savings
Grundfos saved 50% over traditional aluminum
prototype tooling.
50%Time Savings
Grundfos saved 70% in lead time compared to traditional aluminum
tools.
70%
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29 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Grundfos - Use of Inserts
Parts after injection process.Mold design with inserts.
Inserts were used to mold complex features that would be costly to mold using
traditional molding techniques.
• Inner threads
• Outer threads
• Side holes
• Undercuts
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30 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Considerations When Molding With Inserts
Design Considerations
• Design inserts with a tolerance gap so
they fit in the mold without post-
processing.
• 0.05 mm (0.002 in.) with draft
• 0.1 mm (0.004 in.) without draft
Printing Considerations
• Make sure all surfaces that come in
contact with molten plastic are printed in
glossy mode.
Injection Consideration
• Manual ejection of inserts from molded
part
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31 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Other Uses of Inserts
Reasons for using 3D printed inserts
Venting
• Air traps may cause unfilled parts and inserts can help release air in areas beneath the parting line.
Mold longevity
• Fragile features can be designed as inserts in the mold. These inserts can be replaced with minimal costs to achieve higher yield.
Testing Multiple Designs
• Print multiple designs for a particular feature and insert each in metal mold.
Air Air Air
Air
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Summary
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www.stratasys.com/webinar-injectionmolds
• Download webinar and application documents
• View webinar on-demand
• Contact us
More Information and Resources
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34 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
www.stratasys.com/webinar-injectionmolds
Questions?
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35 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
THANK YOU