Why should you make tooling with 3D printing?

#DWwebinar

#DWwebinar

q  This webinar will be available afterwards at www.designworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar

Before We Start

#DWwebinar

Meet your Speakers

MODERATOR

FEATURED SPEAKER Derek Roedel Advanced Tooling Program Manager FATHOM

Leslie Langnua Managing Editor Design World

Ryan Sybrant Director, Manufacturing Channel Enablement Stratasys

FEATURED SPEAKER

Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved. #DWwebinar

CHANGING THE WAY PRODUCTS ARE DESIGNED & MANUFACTURED

studiofathom.com // Oakland 510.281.9000 // Seattle 206.582.1062 Kemeera DBA FATHOM Proprietary and Confidential Information.

All Rights Reserved.


3D PRINTED TOOLING   Overview of Capabilities

•  Very short lead-times −  Many molds 3D printed in less than a day

•  Quick iterations during development •  First article inside of a week after kickoff •  Injection production-grade thermoplastics •  Ideal for up to 50 parts

  Overview of Limitations •  Biggest limitations: texture and color •  Tool action “slides and lifters” are possible—

hand loads •  Thin walls and undercuts •  Living hinges are debatable—

stringent on design and location of gate


DMLS TOOLING INSERTS   Fits Early Prototyping and Bridge-to-Production Needs

•  Build an insert in 48 hours •  Post-production is minimal compared to machining •  20k+ parts (geometry and molding resin dependent) •  Blend additive with traditional technologies •  Material Options: −  Inserts can be made from MS-1 maraging steel

(heat treated mid 50HRC for best results) −  Aluminum is ideal for very quick turn short-run tooling −  Can be plated/coated to address abrasion/erosion

•  Inserts can be EDM textured and/or hand polished after heat treatment (replicate final product texture)

•  Design inserts with features for weight savings, heat evacuation, and conformal cooling lines


COMPARISON

ITEM 3D PRINTED TOOLING CONVENTIONAL TOOLING

Mold Base MUD (Master Unit Die) MUD Or Dedicated

Mold Fitting / Build Up Hand & Machine Hand & Machine

Cooling Lines None – Done With Cold Air Water Cooling Lines

Ejection Minimal – Large Blocks Or None At All – No Sleeves Or Lifters Standard Pins – Sleeves – Lifters

Tool Action - Slides Done With Hand Loads Built Into The Tool

Resin Choices Limited To Low Melt Point – High Melt Flow Index Any Resin

Tool Material Plastic Metal


VOLUME & TIMEFRAME ITEM 3D PRINTED TOOLS 3D PRINTED

DMLS INSERTS BRIDGE TOOL /

QUICK TURN TOOLS PRODUCTION

TOOLS

Lead Time* 2-6 Days *Geometry Dependent 1-2 Weeks 3-5 Weeks 6-10 Weeks

Mold Material 3D Printed Resin MS-1 Maraging Steel, Aluminum, Or Stainless Steel Aluminum Or P20 Steel Hardened Steel

Cooling None - Air Complex Cooling Lines Simple Cooling Lines Complex Cooling Lines

Cycle Times Part-to-part 5 Minutes - 10 Minutes 10 Seconds - 2 Minutes 1 Minute - 2 Minutes 10 Seconds - 2 Minutes

Tool Life 20-100 Parts Some Rework On Later Parts (Flash) >20K ~ 20K to 100K ~ 2MM

Part Price $$$ $$ $$ $

Changes – Time & Cost

1-2 Days, CAD Time And Print A New Tool ($600 - $1,500)

1-2 Weeks Or Print Another Tool 1-2 Weeks, $1,500 - $5,000 Several Weeks And

Thousands Of Dollars

* From Time of Kickoff—DFM finalized, CMF finalized, CAD finalized, material on hand or arranged.


STEPS & TIMEFRAME



DECISION MAKING PROCESS   What Tooling Is Best For My Application?

•  3D Printed Tooling (Fast) − Feature discovery such as living hinge or snaps − Real plastic part prototyping, fastest iteration (new tool) − Material performance for available resins (regulatory or drop test)

•  DMLS Insert Tooling − Part performance testing − Material performance for any resin (regulatory or drop test) − SPC data collection: gating/ejection, venting, cycle-time

•  Bridge Tooling − Closest to production for short-run applications − Production resin choices − SPC data collection: gating/ejection, venting, cycle-time


WHEN TO USE 3DP IM   When Prototype In Final Material Is Needed For Design Decision

•  Durometer of a TPE—Is it 30 or 90 Shore A? •  Impact testing •  A crucial snap •  Fluid / air flow •  A flexure •  Sonic weld testing, or adhesive bonding

  When You Need 50 Parts For Functional Testing With Clients •  Fastest / cheapest way to 50 parts of production material •  Regulatory test units

  Fast Part Design Iteration •  If parts don’t work as anticipated, we can adjust CAD in the afternoon,

3D print new tool parts overnight, and mold new parts the next day


MATERIAL OPTIONS   FATHOM Stocks Several Materials

•  Polypropylene (PP), Polyethylene (PE), Thermoplastic Elastomer (TPE) Shore A 60, ABS, ABS/PC, Nylon (PA – Polyamide)

  Always Consider Lead-time In Selecting Your Materials •  Some materials can take months to get, especially in small

quantities •  Just because it is listed on a website, doesn’t mean that small

quantity orders are available   Lower melt points are better

•  Heat degrades the tool   Higher Melt Flows Are Better

•  Thinner when molten


IDEAL SITUATION   Part Was Designed For Injection Molding From The Beginning

•  Drafted to 2-3+ degrees •  Parting line defined •  Gate was considered •  Consistent wall thickness •  Tool action is defined (slides, no lifters, etc.) •  No thin standing steel (think in the inverse of part design)

  Open And Shut Tool Design •  Minimum amount of tool action (hand loads)

  Simple Resins   Minimal Part Finish Requirements   Natural Colored Resin


FATHOM’S BEST PRACTICES   Well Designed Parts Get Made Much Faster

•  New ideas are great, but new methods of manufacturing take longer to see the light of day—FATHOM can help, but invention on a timeline is a dangerous game

  Decide On What It Is That This Model Needs To Answer •  What are the objectives of the build?

  Do Design Reviews Early and Often •  Like voting in Chicago •  Don’t hesitate to give FATHOM a call to review your design

  Design With The End In Mind •  If you are going to injection molding in the end, start your design that way •  Don’t fall in love with a bad design

  Think Of How The Tool Will Be Built To Make The Part •  Where will the gates be? And the knit lines? •  Where are parting lines? And the draft? •  How will tool action be implemented?

−  If you have a hole in the side of your part, consider the size of the hand load to make it


FUTURE OF 3DPT   New & Better Mold Materials •  Better finishes •  Longer part runs •  Higher mold pressures

  Shorter Lead-times   Influence Future Machine Design



EXAMPLE   Phone Case (PolyJet)

•  3D printed tool in 7 hours and molded parts within 24 hours

•  Tool Material: ABS-Like (PolyJet) •  Part Material: TPE Shore 60A − Grade offers soft/tactile feel, adhesion

to Polypropylene, good weatherability •  Up to 50 Parts •  Dimensions: − A-Side: 4.75” x 4.75” x 1.5” − B-Side: 4.75” x 4.75” x 1”

•  Shot Size: 27cm³


EXAMPLE   Infrared Transmitting (DMLS)

•  Inserts printed with MS-1 Steel in 2 days •  CNC machine surfacing and polish in 1 day •  Tool Material: MS-1 Steel −  SPC data collection for production specification

•  Part Material: Acrylite IR specific resin −  Grade offers infrared transmitting capabilities

•  Up to 50k Parts (heat treated insert) •  Dimensions: −  Insert: 3” x 4” −  Shot size: 2cm³

#DWwebinar

CONTACT INFORMATION

OAKLAND OFFICE (510) 281-9000

329 Jefferson Street Oakland, CA 94607

OAKLAND PRODUCTION CENTER

315 Jefferson Street Oakland, CA 94607

www.studiofathom.com [email protected]

SEATTLE OFFICE + PRODUCTION CENTER

(206) 582-1062 4302 Stone Way North

Seattle, WA 98103

21 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY #DWwebinar

Efficiency and Productivity with 3D Printed Manufacturing Aids

March 24th, 2016

#DWwebinar

Transforming the Manufacturing Floor

#DWwebinar

Jigs, Fixtures and Tools Streamline production floor workflows

A means to optimize manufacturing by reducing cost and cycle time, while increasing product quality and repeatability

#DWwebinar

Jigs, Fixtures and Tools Most important considerations

•  Accuracy

•  Rigidity

•  Ease of Use

•  Economy in production

•  Workforce safety

#DWwebinar

Jigs, Fixtures and Tools Objective

•  Ensure interchangeability and accuracy of parts manufactured,

•  Minimize the possibility of human error

•  Permit the use of medium skilled labor

•  Reduce the manufacturing time

•  Allow production of repeat orders without retooling

#DWwebinar

Moving up the Value Chain

#DWwebinar

Moving up the Value Chain

Prototyping Func.onalTes.ng

JigsandFixtures Tooling Produc.on

Parts

Product Development •  Prototype •  Review •  Refine

Application Verification •  Performance testing •  Integration validation •  Acceptance testing

Process Facilitators •  Molds •  Patterns •  Mandrels

Efficiency Tools •  Work holders •  Gauges •  Guides

Final Components •  Covers •  Brackets •  Ducts

#DWwebinar

Challenges & Opportunities

#DWwebinar 29 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

Today’s Challenges

•  Long machine set-ups •  Variation during assembly and fitting •  Complicated part holding requirements •  Ease of handling and transportation •  Defects caught too far down production line •  Employee safety and ergonomics •  Cost, time, wait and storage prevents manufacturers from

producing needed efficiency tools

#DWwebinar

Addressing Today’s Challenges

•  Complex geometries no longer a barrier

•  Design flexibility

•  Shorten set-up times

•  Part consolidation

•  Integrated features

•  Ergonomics

•  Simple duplication

#DWwebinar

Justification for AM

Key Success Factors •  Efficient; path of least resistance •  Allows for more on the floor •  Translates to operational savings •  Reduced burdened rate •  Change in design and manufacturing mindset •  Will impact multiple departments

#DWwebinar

Customer Success Stories

#DWwebinar

Triumph Composite Systems

Why Triumph adopted Additive Manufacturing: To lower tooling component costs, decrease schedule (lead-time) and reduce dependence on external tool suppliers

#DWwebinar

Creating worker friendly factories •  Focus on ergonomics •  Light-weighting tools •  Increasing tools performance •  Customizing tools to the assembler •  Reduced automobile rework

BMW

#DWwebinar

Rethinking traditional processes •  Transforming test fixtures •  Reduced part count •  Reduce cost and lead-time •  User friendly

Wair Products

#DWwebinar

Opel

Changing the Approach to Process Tooling •  Brings the line worker into the design process •  Allows them to adapt tools much better to the

worker and automobile •  Makes it possible to find and implement the most

appropriate solution

#DWwebinar

Genesis Systems Group

Investment in Innovation •  Optimized robotic end-of-arm tooling •  Reduced part count •  Reduce cost and lead-time

#DWwebinar

Solaxis

Reducing tool footprint and weight while increasing accuracy •  Removed 100lbs from previous tool •  Agility increased flexibility of design •  Solved compliance issues for supplier

#DWwebinar

Taking the First Steps

#DWwebinar

Successful Implementation

•  Connect cross-functional teams to seek out opportunities where 3D printed tools can make an impact

•  Interview the workforce that is involved in day to day production

•  Don’t forget about operational efficiency programs such as 5S

•  Focus on one area or department and duplicate success to others

#DWwebinar

Re-Engineer your Vision

#DWwebinar

Initiate for results

Reduce Production Time and Cost

Maximize Efficiency

Maintain Consistent Quality

Improve Functionality

Enhance Safety

#DWwebinar

Thank You

Ryan Sybrant Director, Manufacturing

#DWwebinar

Questions?

MODERATOR

Leslie Langnua Managing Editor Design World

Ryan Sybrant Director, Manufacturing Channel Enablement Stratasys

FEATURED SPEAKER

FEATURED SPEAKER Derek Roedel Advanced Tooling Program Manager FATHOM

#DWwebinar

q  This webinar will be available at designworldonline.com & email

q  Tweet with hashtag #DWwebinar

q  Connect with Design World

q  Discuss this on EngineeringExchange.com

Don’t Forget!

#DWwebinar

#DWwebinar

THIS DOCUMENT IS PROPRIETARY TO STRATASYS, INC. AND/OR STRATASYS LTD., AND SHALL NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY DESIGN OR MANUFACTURE EXCEPT WHEN SUCH USER POSSESSES DIRECT WRITTEN AUTHORIZATION BY STRATASYS, INC. AND/OR STRATASYS LTD. STRATASYS, INC MAKES NO CLAIM, PROMISE, OR GUARENTEE OF ANY KIND ABOUT THE ACCURACY, COMPLETENESS, OR ADEQUACY OF THE CONTENT OF THIS PRESENTATION AND EXPRESSLY DISCLAIMS LIABILITY FOR ERRORS AND OMISSIONS IN SUCH CONTENT.