Manufacturing Tooling with FDM Technology Application Benefits, Solution Fitment, Best Practices Fred Fischer Director Applications, Products, Technology 1
APPLICATIONS DESIGN STEADY GROWTH * MANUFACTURING EXPONETIAL GROWTH FORM/FIT/FUNCTION PROTOTYPES MANUFACTURING TOOLS PRODUCTION PARTS 2 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Benefits of Direct Manufacturing (DDM) Reduced cost & time Enabling low-volume production Generally 40-80% savings Increased geometric freedom Reduced constraints vs. traditional Enable personalization & mass customization Enhanced part functionality Optimize for part utilization Combine multiple AM or traditional & AM Reduced hassle & bureaucracy Eliminate numerous non-value added steps Focus teams on meaningful tasks 3
FDM & PolyJet Manufacturing Tooling Applications JIGS & FIXTURES PLASTIC PROCESSING TOOLING METAL PROCESSING TOOLING COMPOSITE PROCESSING TOOLING - Engineering - Assembly - Transportation - Inspection - Injection Mold Tools - Blow Mold Tools - RTV Mold Patterns - Thermoform Patterns - Sand Casting Patterns - Invest. Cast Patterns - Stretch Forming Tools - Hydroforming Tools - Layup Tools - External Forms - Soluble Core Patterns - Trim Tools Direct Usage AM Part Properties Application Requirements Indirect Usage AM Part Properties < Application Requirements 4 * AM = Additive Manufacturing
AM (Additive Manufacturing) Opportunity Assessment R&D Tooling used in the development phases of product development and manufacturing Assembly Tooling for the assembly process, aiding workers to align and hold parts during assembly Quality Control Tooling to aid in the inspection and QC process, specialty holding devices or measurement aids Packaging & Logistics Tooling designed to allow for movement of parts within a facility or during shipment Health & Safety Specialty tooling designed to aid worker safety and address ergonomic issues in the production environment General Manufacturing Floor Equipment Parts and tools utilized in the fabrication process 5 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Jigs & Fixtures Role FDM/PJ Tool Fulfills: Categories inspection, transportation, manufacturing Direct production of tools that.hold, organize, protect, check, measure, move, etc AM is a best fit for Jigs & Fixtures when: Thermoplastic - meets application requirements 1-100s quantity 25-500mm tool size ± 0.13 mm accuracy Any shape - simple, complex, organic 6 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Oreck Vacuum CMM Inspection Fixture 20-30 Injection molded parts / product All require first article inspection Adjustable fixtures not valid for complex parts Utilize FDM to produce prototypes Validate design & communicate with suppliers Utilize in CMM program set up Utilize FDM to produce CMM fixtures Designed & built immediately No penalty for complex shapes Method (In-house) Aluminum CNC Time Cost Inspect Time 7 hrs $250 30 Days Benefits Allows early programming of CMM Significant comparative savings FDM Savings 3.5 hrs 3.5 hrs (50%) $55 1 Day $195 (78%) 29 Days (97%) 7 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Genesis End of Arm Tools (End Effectors) Waterjet Cutter Required specialized tooling Robot moves composite part Mechanical Gripper (Traditional) Traditional CNC machined $8,000 & 4 weeks FDM Vacuum Gripper Internal vacuum channels Optimized for FDM Benefits 85% faster 94% less expensive 91% lighter Waterjet cutter with FDM vacuum gripper. Method Time Weight CNC machining * 20 days 15.9 kg FDM ** 3 days 1.4 kg Savings 17 days (85%) 14.5 kg (91%) 8 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY * CNC machining outsourced locally. ** FDM parts produced on in-house equipment. Four Machined design EOAT iterations (steel). of an FDM EOAT.
Thogus Streamlining Manufacturing Required cost effective short run & fast turn over tools Customization - storage & specialty tooling Ability to automate creating inexpensive end of arm tools 5S shop floor (customized) tooling organizers Results: 70-90% - weight savings 50-85% - cost & time savings On demand tooling 9 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Tooling Blow Mold Tooling CCI - Japan Bottle design & manufacturing company Purchased Eden for design verification models Unhappy as they cannot use PJ models for functional testing Executed Application Validation program in 2016 Identified PolyJet Blow Molding as an indirect solution Customer warm to the concept Created benchmarks at SSYS-JP to Leverage PolyJet to create mold Blow mold (functional) bottle for rigorous testing Utilizing process when rigorous functional testing required Usage of consumables and customer satisfaction up 10 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY * Image of blow molding not from CCI, but representative of application
Injection Molding with 3D Printed Molds Role PJ Injection Molding Tool Fulfills: Mold insert for injection molding process Ejector pins, injection port, etc can be added Compliance testing & prototype IM parts AM is a best fit when: Molding temp <500 C (PE, PP, PS, ABS, TPE, PC-ABS) 1-100 quantity of parts molded < 165 cc (10 cu in) part size 50-80 ton molding machines PolyJet inserts in a mold base 11 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Worrell Injection Molding with 3D Printed Molds 12 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
INFINITE-BUILD 3D DEMONSTRATOR Scale & Endurance for Large Tools & Production Parts Scale & Endurance for Large Tools & Production Parts Infinitely Large Parts 1220 x 610 x infinite mm Large Prototypes - dashboards, interior / exterior door panels, bumpers, ATM & kiosk facades, white goods panels High Part-to-Part Consistency In Situ process control, precision CNC motion control, improved extrusion head Composite Lay Up Tooling aerospace, performance automotive, performance sporting goods / products Ultra-Fast Throughput up to 10x faster deposition & high acceleration motion system Production Parts aerospace/mro interior panels & ECS ducting, pilot production large facades (ATM, kiosk, MRI) Unlimited Unattended Production auto material replenishment, tool changer with high reliability & multi-materials 13 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
INFINITE-BUILD 3D DEMONSTRATOR Scale & Endurance for Large Tools & Production Parts Boeing development partner for IB3D (for composite lay up tool & large prototypes - expand application usage) Ford early adopter of IC3D (large prototypes, tooling, and pilot production components) 3D Demonstrator product currently publically announced, but not widely available (available to exclusive partners) 14 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
ROBOTIC CONTROLLED 3D DEMONSTRATOR Enabling Composite Parts With Strength In Any Direction Ultra Strong Parts utilizing 8 axes motion control of directional composites Swift Throughput up to 10x faster deposition, elimination of Z layer limitation, no support material cost or removal Simple / Single Workflow up to 10x faster deposition & high acceleration motion system Factory Integration motion control & factory management powered by 15 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Advanced Application Best Practices Most challenging to reach success Best chances of success Original design must work for 3DP/AM Require identical aesthetics directly Start with the toughest applications Attempt alone Optimize design for 3DP/AM Finish, hide, or celebrate 3DP/AM aesthetics Focus on smart application targets Engage with application consultants 16
Common Obstacles. Common Obstacle Typical Best Practice Examples Part Cost Run Time / Material Usage Change Orientation Optimize Design for AM Part Properties Optimize Part Orientation Utilize Metal Inserts or Plating Optimize Design for AM Aesthetics Optimize Part Orientation Post Process Part Optimize Design for AM Accuracy / Fitment Optimize Part Orientation Utilize Bushings/Fasteners Machine Critical Surfaces 17
Manufacturing Tooling with FDM Technology Application Benefits, Solution Fitment, Best Practices Fred Fischer Director Applications, Products, Technology 18