manufacturing tooling with fdm technology - hkpcevents.hkpc.org/9743735/20170405_tooling seminar_mr...

1

Fred Fischer

Director – Applications, Products, Technology

Manufacturing Tooling with FDM Technology

Application Benefits, Solution Fitment, Best Practices

2 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

APPLICATIONS

DESIGN – STEADY GROWTH * MANUFACTURING – EXPONETIAL GROWTH

MANUFACTURINGTOOLS

FORM/FIT/FUNCTION PROTOTYPES

PRODUCTION PARTS

3

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

4

FDM & PolyJet – Manufacturing Tooling Applications

- Sand Casting Patterns- Invest. Cast Patterns- Stretch Forming Tools- Hydroforming Tools

- Layup Tools- External Forms- Soluble Core Patterns- Trim Tools

- Injection Mold Tools- Blow Mold Tools- RTV Mold Patterns- Thermoform Patterns

- Engineering- Assembly - Transportation - Inspection

JIGS & FIXTURES

METAL PROCESSING TOOLING

COMPOSITE PROCESSING TOOLING

PLASTIC PROCESSING TOOLING

Direct UsageAM Part Properties ≥ Application Requirements

Indirect UsageAM Part Properties < Application Requirements

* AM = Additive Manufacturing


AM (Additive Manufacturing) Opportunity Assessment

General Manufacturing Floor

AssemblyTooling for the

assembly process,

aiding workers to align

and hold parts during

assembly

EquipmentParts and tools utilized

in the fabrication

process

Health & SafetySpecialty tooling

designed to aid worker

safety and address

ergonomic issues in the

production environment

Quality ControlTooling to aid in the

inspection and QC process,

specialty holding devices or

measurement aids

Packaging & LogisticsTooling designed to allow for

movement of parts within a

facility or during shipment

R&DTooling used in the

development phases of

product development and

manufacturing


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


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

Benefits

• Allows early programming of CMM

• Significant comparative savings

Method(In-house)

Time CostInspect

Time

Aluminum

CNC7 hrs $250 30 Days

FDM3.5

hrs$55 1 Day

Savings

3.5

hrs

(50%)

$195

(78%)

29 Days

(97%)


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

* CNC machining outsourced locally.

** FDM parts produced on in-house equipment.Machined EOAT (steel).Four design iterations of an FDM EOAT.

Waterjet cutter with FDM vacuum gripper.

Method Time Weight

CNC

machining

*

20 days 15.9 kg

FDM ** 3 days 1.4 kg

Savings17 days

(85%)

14.5 kg

(91%)


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


• 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

Tooling – Blow Mold Tooling

* Image of blow molding not from CCI, but representative of application


Injection Molding – with 3D Printed Molds

PolyJet inserts in a mold base

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


Worrell – Injection Molding with 3D Printed Molds


INFINITE-BUILD 3D DEMONSTRATOR

Scale & Endurance for Large Tools & Production Parts

• Large Prototypes - dashboards, interior / exterior door panels, bumpers, ATM & kiosk facades, white goods panels

• Composite Lay Up Tooling – aerospace, performance automotive, performance sporting goods / products

• Production Parts – aerospace/MRO interior panels & ECS ducting, pilot production large facades (ATM, kiosk, MRI)


• Infinitely Large Parts – 1220 x 610 x infinite mm

• High Part-to-Part Consistency – In Situ process control, precision CNC motion control, improved extrusion head

• Ultra-Fast Throughput – up to 10x faster deposition & high acceleration motion system

• Unlimited Unattended Production – auto material replenishment, tool changer with high reliability & multi-materials


INFINITE-BUILD 3D DEMONSTRATOR


• 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)


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

16

• Optimize design for 3DP/AM

• Finish, hide, or celebrate 3DP/AM aesthetics

• Focus on smart application targets

• Engage with application consultants

Advanced Application Best Practices…

Best chances of successMost challenging to reach success

• Original design must work for 3DP/AM

• Require identical aesthetics directly

• Start with the toughest applications

• Attempt alone

17

Common Obstacles….

Common Obstacle Typical Best Practice Examples

Part Cost

• ↓ Run Time / Material Usage• Change Orientation• Optimize Design for AM

Accuracy / Fitment

• Optimize Part Orientation• Utilize Bushings/Fasteners• Machine Critical Surfaces

Aesthetics

• Optimize Part Orientation• Post Process Part• Optimize Design for AM

Part Properties

• Optimize Part Orientation• Utilize Metal Inserts or Plating • Optimize Design for AM

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18

Fred Fischer

Director – Applications, Products, Technology

Manufacturing Tooling with FDM Technology

Application Benefits, Solution Fitment, Best Practices

manufacturing tooling with fdm technology - hkpcevents.hkpc.org/9743735/20170405_tooling seminar_mr...

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