tasman 3dprinters presentation - avalon airshow 2015

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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?

Other2%

Visual Aids9%Presntation Models

9%

Fit & Assembly21%

Patterns for prototype tooling

12%

Patterns for metal casting

10%

Tooling Components6%

Functional Parts31%

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 moldablePC-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

LeptronPictures 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