moldes fabricados con polyjet...6 stratasys / the 3d printing solutions company which plastics? 0...

1 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

Moldes Fabricados con PolyJet

Pablo Mora

Iñaki Quintana

Irene Díaz

2

Cuando usar moldes en 3D


En qué etapa?

Diseño

CAD software

Prototipo 1

Modelo Conceptual

Prototipo Rápido

Simulación

Prototipo 2 Fabricación

Moldes en 3DFuncional

Material Final

Ultimos tests y verificación


En qué etapa?

Diseño

CAD software

Prototipo 1

Modelo Conceptual

Prototipo Rápido

Simulación

FabricaciónSeries cortas

Moldes en 3DFuncional

Material Final

Últimos tests y verificación


VIDEO

01:32

Ejemplo de un molde 3D en funcionamiento

http://youtu.be/weiVuCcXbzk

http://youtu.be/weiVuCcXbzk


WHICH PLASTICS?

0

200

400

600

10040

500

100

300

70

Mínimo Piezas

Mínimo número de piezas

reportadas por el cliente con

un solo molde

Máimo Piezas

Máximo número de piezas


un solo molde

.

Media Piezas

Número medio de piezas


un solo molde

.

Min. Max. Avg.

Soft / Elastomeric Plastics Standard Plastics

Based on 2014 customer survey (58% response

rate)


La duración de los moldes dependerán de las geometrías y tamaño de piezas

Duración media de molde

8

• Usar Plásticos con temperaturas de

moldeo de hasta 300° C (570° F).

Como:

PE, PP, PS, ABS, TPE, PA, POM,

PC-ABS and glass-filled resins

• Piezas no muy grandes de 165 cm3.

• Usar máquinas de moldeo de hasta

200-ton.

Condciones Ideales

9

Como Mejorar el Rendimiento


Tratamiento Térmico Polyjet

11

Materiales de PolyJetrecomendados

12

• ABS Digital (RGD 515 plus + RGD 535)

• VeroClear (RGD810)

• RGD525 high temperatura

• Rigur (RGD 450)

Materiales PolyJet Recomendados

13

CUSTOMER STORIES

SECTION TWO


3D Printer: Objet30 Pro™

Industry: Control switches (lighting, motion, HVAC)

Need:Quick and inexpensive prototypes for functional testing

Berker


Berker – Part Assembly


Functional tests include:

• Electrostatic discharge test

• Used to determined whether assembly of electrical parts will produce a charge of electricity.

• Fit tests

• All components of the assembly had to fit properly.

End use materials were necessary to validate tests (PC, ASA, TPU).

Berker - Functional Testing


Berker- 3D Printed Injection Molding Process

Mold Prep and Assembly

Printing and Cleaning Process


Berker- 3D Printed Injection Molding Process

Part Assembly

Injection Process

19

3,800

Berker: Benefits

22,350

3

28

Traditional Tooling

3D Printed Tooling

Traditional Tooling

3D Printed Tooling

Time (Days)

Cost (USD)

“This new flexibility enables us to try out two or three different solutions at the same time to get the best result. The confirmed quality of our products produced using these functional prototypes has accelerated our R&D processes.”

Andreas Krause

Head of Technical Department & Manufacturing at Berker


3D Printer: Objet260 Connex™

Industry: Water measurement solutions

Need:Quick and inexpensive prototypes for functional testing

Arad Group


Part Assembly

Arad Group – Functional Testing


Functional Tests in end use material GRILAMID TR90 (amorphous Nylon):

• Ultrasonic welding

• Gasket assembly design

• Material physical and mechanical properties

It was necessary for the parts to be in the real end-use material and in the end-manufacturing practice for the tests to be successful.

Press

Holding Fixture

Part

Assembly

Ultrasonic Stack

Arad Group – Functional Testing


Assembly Cross Section 3D Printed Injection Molds

Use of inserts for undercut feature

Arad Group - 3D Printed Injection Molding Process


Arad Group - 3D Printed Injection Molding Process

Injection Process

Molded Parts

Machine – 50T Arburg• Injection temperature – 260° C

• Injection pressure – 880 bar

• Shot size – 38 cubic cm

• Switch-over point – 8.5 cubic cm

• Packing pressure – 200 bar

• Cooling time – 140 sec

• Number of injected parts – 25 Parts

Results of Tests

Passed IEC (International Electrotechnical Commission) code IP54 for dust and water infiltration.

Parts passed translucency test.

25

2,000

Arad Group: Benefits

10,000

2

42Traditional Prototype Tooling

3D Printed Tooling

Traditional Prototype Tooling

3D Printed Tooling

Time (Days)

Cost (USD)


Grundfos

3D Printer:

Objet500 Connex3™

Industry:

Pump manufacturing

Need:

• Production-ready prototypes

• Complex mold design with best

surface finish


Functional test in end-use material - 30% GF Noryl (PPE-PS-GR30):

• Assembly of molded part to pump

• Run pump at various flow rates to assess damage to molded part

Grundfos: Pump Test

Injection molded part inside PolyJet mold.

Side view of part with mold and sprue. Final part produced from the PolyJet mold.

Machine: Engel 200T• Clamp force – 500 KN

• Injection temperature – 270° C

• Injection Pressure – 500 bar

• Shot Size – 330 cubic cm

• Switch-over point – 51.1 cubic cm

• Packing pressure – 50 bar

• Cooling time – 110 sec

• Number of injected parts – 20 Parts

28

Grundfos - Benefits

Cost Savings

Grundfos saved 50% over traditional aluminum

prototype tooling.

50%Time Savings

Grundfos saved 70% in lead time compared to traditional aluminum

tools.

70%


Grundfos - Use of Inserts

Parts after injection process.Mold design with inserts.

Inserts were used to mold complex features that would be costly to mold using

traditional molding techniques.

• Inner threads

• Outer threads

• Side holes

• Undercuts


Considerations When Molding With Inserts

Design Considerations

• Design inserts with a tolerance gap so

they fit in the mold without post-

processing.

• 0.05 mm (0.002 in.) with draft

• 0.1 mm (0.004 in.) without draft

Printing Considerations

• Make sure all surfaces that come in

contact with molten plastic are printed in

glossy mode.

Injection Consideration

• Manual ejection of inserts from molded

part


Other Uses of Inserts

Reasons for using 3D printed inserts

Venting

• Air traps may cause unfilled parts and inserts can help release air in areas beneath the parting line.

Mold longevity

• Fragile features can be designed as inserts in the mold. These inserts can be replaced with minimal costs to achieve higher yield.

Testing Multiple Designs

• Print multiple designs for a particular feature and insert each in metal mold.

Air Air Air

Air

32

Summary

33

www.stratasys.com/webinar-injectionmolds

• Download webinar and application documents

• View webinar on-demand

• Contact us

More Information and Resources


www.stratasys.com/webinar-injectionmolds

Questions?


THANK YOU

moldes fabricados con polyjet...6 stratasys / the 3d printing solutions company which plastics? 0...

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