PRIM. PRinted Injection Molding. Rik Knoppers Pascal Willems CREATING POLYMER SOLUTIONS Promolding BV 2017

Transcription

1 Rik Knoppers Pascal Willems PRIM PRinted Injection Molding CREATING POLYMER SOLUTIONS Promolding BV

2 Content Promolding Introduction PRIM technology PRIM examples Boundary conditions Summary 2

3 Promolding Mission: Transforming high-performance polymer technology into sustainable industrialized applications Some of our customers 3

4 History of 3D printing Rapid Prototyping (1988) SLA (Stereo Lithography), LOM (paper), FDM (Fused deposition modeling), etc. Rapid Tooling (additive tooling) Starting with Stereo Lithography molds Later additive technologies with metal Rapid manufacturing (additive manufacturing) Very promising Small range of materials 4

5 Ability to influence costs Why prototyping Expenditures Major influence Decreasing influence Low influence Cost influence Cost expenditure Validation of the design at an early stage is critical for success Concept phase Detailing phase Time Realization phase Operate 5

6 Current options Additive manufacturing: Successful in manufacturing small series of parts New way of engineering products (has yet to be discovered) Scaling up to large series is economically often not justified Limited amount of materials Ironbridge UK Additive metal tooling: Still expensive Needs finishing Hinges of the airbrake of the bloodhound supersonic car 6

7 Promolding PRIM Focus: To bridge the gap from single prototypes in prototyping materials to injection molded production series in final material Goal: Better validation of the design before critical investments Using: 3D printing of molds and injection molding knowhow A process called PRIM PRinted Injection Molding 7

8 3D Printing Stratasys Objet Connex 350 Layer thickness 0,016mm 600x600 dpi Max dimensions 350x350x200mm 1 support and 2 model materials at the same time 2 components resin ABS-like (RGD515+RGD535) Promolding is a Stratasys VIP customer 8

9 Injection moulding Engel, Arburg and Haitian injection molding machines ton clamping force Mechanical, hydraulic and electric machines Vertical and horizontal machines 60 different material groups 570 different products Production batches 500-1,000,000 9

10 Rubber parts Number of Products: 50 Lead time PRIM: 4 days Material: TPE 10

11 Functional parts Number of products: 200 Lead time PRIM: 4 days Material: PP 11

12 Sensor housing Number of sensor housings: 22 Lead time PRIM: 3 days Material: PBT 12

13 Mold composed of multiple inserts Number of products: 70 Lead time PRIM: 4 days Material: PP 13

14 Materials Q Materials Easy Doable Difficult PP PMMA PC-ABS TPE ABS PC PS PBT PA GF PA PPE POM PVDF PP-GF Series Shrinkage comparable to regular injection molding. Continuously testing new materials 14

15 Boundary conditions Mold buildup No ejector pins No specific mold cooling No slides Product complexity Mold can be composed of multiple inserts (undercut possible) Manual operation Part geometry Draft angles 3 degrees or more No sharp corners minimum radius 0,5 15

16 Advantages of PRIM High level validation of design in early development stage Large range of functional materials available Short lead-time (approximately 5 days) Low costs (depending on design ) 16

17 General information Information on In 2017: A new company (P3D) specialized in PRIM will be started. PRIM will have a full automated website to estimate mold and product costs. New materials new injection molding strategies. 17

18 Thank you! Hope we can help you in the near future Questions? Rik Knoppers Pascal Willems Promolding b.v. Laan van Ypenburg GB Den Haag The Netherlands 18