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IGNITE your…. Rapid Manufacture - in the real world. Presenter – Stuart Offer, Sales Manager for 3T RPD Ltd in Newbury will present "examples and cases studies from real world applications of rapid manufacturing with world beating clients" 3T RPD are an Additive Manufacturing company specialising in Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). Both technologies are full melting additive layer manufacturing methods used in a vast array of industries.
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www.3trpd.co.uk
Additive Manufacturing – in the real worldStuart Offer, Sales Manager – Plastic
3T RPD Ltd
About 3T RPD
Principles
• Quality • Service • Delivery
• Started trading
• Installed 2 x P700’s in
• New Building
• DMLS Facility opened
• UK’s first M 280 machine installed
• Currently the UK’s largest commercial Plastic AM facility, 3rd largest in Europe
• 2nd largest Metal AM (DMLS) facility in UK
About 3T RPD
1999
2003
2006
2007
Nov 2011
Markets
• The process of creating 3D objects, layer by layer
• As opposed to subtractive manufacturing methods
Definition of Additive Manufacturing (AM)
Overview of Additive Manufacturing
Additive Manufacturing process
Overview of Additive Manufacturing
Additive Manufacturing Process
Subtractive Manufacturing Process
Thermal process
Semi crystalline when finished building
During cooling parts will shrink
Scaling factor is applied to CAD to allow for shrinkage
Generating suitable data
Layer based
Effect on surface
Effect on mechanical strength
Generating suitable data
200mm x 150mm x 150mm
£250 each
130mm x 120mm x 15mm
£80 each or
£25 each for 15 off
Plastic AM Costing
600mm x 200mm x 500mm
£2,500 each 165mm x 165mm x 180mm
£250 each
Plastic AM Costing
Rapid Manufacturing - Benefits
N1 = Break-even point
Cos
ts• Cost Comparison (Sintering vs Tooling):
Plastic AM has no initial tooling costs
AM Costs
Tool Based Manufacturing
Costs
AM Cost effective
Tooling Cost
Rapid Manufacturing - Benefits
N2
Cos
ts• Cost Comparison (Sintering vs Tooling):
If part complexity increases, the gap favours SinteringTooling costs increase to incorporate extra functions
Complex Tool Manufacturing
Costs
N1
AM Cost effective
AS 9100 Rev. C
ISO 9001:2008
ISO 13485:2003
Plastic AM Process Control
Quality Standards
Speed
Reducing design errors
Reduced Time to Market
Customer ‘buy in’ earlier in design phase
Benefits from Plastic AM
Almost unlimited range of part design
Benefits from Plastic AM
Source - Econolyst
Integrate several parts into one
Benefits from Plastic AM
Benefits from Plastic AM
No Tooling
Benefits from Plastic AM
Allows for product personalisation
Benefits from Plastic AM
Customisation
Intake Manifold:Tested in Climatic ChamberFitted to engine and run
Benefits from Plastic AM
Functional testing
Designing for Plastic AM
Applications not suited to Plastic AM:-
Clear parts
Very fine detail
High temperature
Multicolour models
Specific materials
Complexity is not an issue
Designing for Plastic AM
Minimum wall thickness
Wall thicknesses > 1mm
Accuracy
Typical accuracy to be within:
Dimensions <100mm +/- 0.3mmDimensions >100mm +/- 0.3%
Designing for Plastic AM
Holes undersize
Change CAD
Ream Hole
Small as M3
Tap material
Threaded inserts
Holes
Threads
Designing for Plastic AM
Designing for Plastic AM
Project started: 5th May
SULSA Flight: 8th June
Article published in New Scientist
Designing for Plastic AM
Southampton University Laser Sintered Aircraft
Unmanned Aerial Vehicle (SULSA UAV)
Designing for Plastic AM
Southampton University Laser Sintered Aircraft
Unmanned Aerial Vehicle (SULSA UAV)
Ailerons built in
Plastic AM weight less than 2.0kg
Internal structures for strength
Navtech Radar W500automatic surveillance system
Navtech Case Study
Designing for Plastic AM
Design change to reduce cost
Currently selling 50 off per annum but ramping up to 200 off
BRIEF
Outside changed to more economic production methods
but internals remained complex and expensive
Internal components to be replaced were Rotating Sensor
system, support and guidance for the lens and the mounting
and location of the emitter reel
Designing for Plastic AM
Extensive test programmePlaced the parts in extreme versions of a normal operatingenvironmentSimulated over 15 million cycles of the critical componentsduring a two month periodPivot arm became highly polished within a few hours,improving efficiency
Designing for Plastic AM
Durability of the Plastic AM parts lead to Navtech adding new features into their designFlexibility of the material led to creation of built-in springs as a return mechanism for the lens
Designing for Plastic AM
Reduced part count by integrating parts into one Plastic AM part
Reduced assembly time
New features incorporated into design
Flexibility of design now increased
Overall benefits
Designing for Plastic AM
Questions and Answers
Thank you
www.3trpd.co.uk