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Wing mirror case study for Omni 3D printing

30.03.2017

Wing mirror case weight reduced by 53% thanks to Omni 3D printing!

Mirror caps, air vents – these are just some of the parts printed by OMNI3D for Arrinera Technology S.A. All models are printed at a full scale, mostly with ABS-42 and are used as functional prototypes as well as final parts. In this particular case, the challenge was to reduce the weight of the mirror case.

TECHNOLOGIES COMPARISON ON THE WEIGHT OF THE MIRROR CASE

DESCRIPTION

In the automotive industry weight is one of the most important aspects. The company was looking for the best solution to produce car parts which are durable and at the same time – as light as possible.

SOLUTION

Parts are printed on a 3D printer – Factory 2.0 Production System using ABS, ASA, PC-ABS, PET-G, HIPS filaments depending on the requirements.

‘Parts printed in 3D on Factory 2.0 Production System meet all of our requirements – both in terms of strength, dimensional accuracy, turnaround time and weight loss. Many elements are installed in the car as the final products,’ – Łukasz Tomkiewicz, Managing Director, Arrinera Automotive S.A.

Omni 3D Printer saving time and money

29.03.2017

Thanks to OMNI additive manufacturing, a new customer saved hundreds of thousands of pounds in just a few weeks! 3D printing using the latest technology can bring hugh potential savings: 90% cost reduction and 80% time savings.

The functional prototype of a train seat was printed using FFF technology on the Factory 2.0 industrial 3D printer from OMNI3D. This project was carried out by METRIS3D for POLGAR KFT, the Hungarian manufacturer of parts for the automotive industry.

Creating a functional prototype has never been so cheap, fast and easy.

 

‘Now, preparing the model cost all together about €40,000, before this was over €400,000 [including the cost of the tooling]. It’s just a fraction of the budget! Regarding the time, now it takes only 3 weeks to prepare first prototype, before it took as long as 4 months…,’ – says Miki Thurzo, Senior Engineer from METRIS 3D.

POLGAR KFT needed the prototype to verify the design of a train seat. There are always some critical points in a design that should be double checked, preferably in real scale.

‘The great thing about having a functional prototype is that we could really test the model. Before, this was impossible due to very long lead time. Now, thanks to 3D printing, we could change the design soon after we made the first 3D prints. It turned out, for example, that some of the movable parts (like trashcans and holders) could not been moved, which was missed in the CAD file,’ adds METRIS 3D.

OMNI3D presents some of the technical specifications of the print performed on the Factory 2.0 Production System:

  • Model: 2 train seats and platform
  • Number of elements: 37
  • Print time: 500 hrs
  • Size of the biggest element: 480 x 210 x 370 mm
  • Size of the smallest element: 70 x 70 x 20 mm
  • Filaments: model ABS-42, support HIPS-20
  • Filaments weight: 10 kg (70% of ABS-42)

Factory 2.0 has one of the largest working platforms with the heated and closed chamber available on the market. Thanks to this, 3D printing specialists from OMNI3D could minimalise the number of the printed parts, which was very important to get the highest strength of the final model.

‘In the case of large models, most challenging is the size of the biggest element, the dimensional accuracy and print time. Factory 2.0 enabled us to print large parts of even 500 mm along each axis with very high accuracy. Thanks to numerous machines available in OMNI3D’s print room, timing is also not a problem. The printing process took us about 2 weeks,’ adds Krzysztof Kardach, Chief of Technologies at OMNI3D – responsible for the printing process.

3D scanning is always the best verification of the 3D printed part.

​​‘We scanned the biggest print (480 x 210 x 370 mm) on our professional 3D scanner – RPS EVO6 – to verify the dimensional accuracy. The results were impressive. The accuracy obtained enabled us to get a perfect fit with the metal seat frame prepared before,’ explains Miki.

New Wax printer for Jewellery & Industrial Investment Casting

22.03.2017

3D Systems announced new products and capabilities to accelerate additive manufacturing in the growing investment casting, jewellery and dental markets, while extending its leadership in precision metal production for healthcare and aerospace.

Among the announcements is expansion of the company’s industry-leading MultiJet Wax family with the new ProJet® MJP 2500W and VisiJet® M2 CAST RealWax™ material, for applications in jewellery and industrial casting. The new wax system combines the precision of the successful MJP 2500 platform with a next-generation 100% real wax material to deliver precise, durable, high-resolution patterns.

CDG are selling the ProJet 2500 Wax printer in the UK.

 

ProJet 2500 Wax 3D Printer

 

 

Supercar with 3D printed parts from OMNI3D

16.02.2017

Poland's first supercar, Arrinera Hussarya, contains 3D printed parts from OMNI3D

Feb 15, 2017 | By Tess

Polish sports car manufacturer Arrinera Technology has teamed up with local industrial 3D printer manufacturer OMNI3D to additively manufacture parts for the Arrinera Hussarya, Poland’s first supercar. OMNI3D, known for its industrial and large-format FFF 3D printing solutions, says it helped to manufacture functional prototypes for the supercar, as well as final parts.

The Arrinera Hussarya supercar, which was first unveiled as a concept back in 2012, has been put into production, and, to a degree, we have 3D printing to thank. Like in other industries, additive manufacturing technologies were leveraged by Arrinera to speed up the prototyping and production process without sacrificing or compromising on quality or optimal design.

As one can imagine, designing a car, especially a supercar, is a rigorous process that involves continuous changes and adjustments to designs, so having the ability to make changes to prototypes on the fly, test them, and tweak them some more, is invaluable. OMNI3D provided Arrinera Technology with this capacity, with the added bonus of manufacturing large-scale, complexly structured parts for the car. The companies have been working together for over a year.

3D printed parts for Arrinera Technology

“Detail production on a 3D printer significantly accelerates the work of our R&D team and reduces production time and costs,” commented Łukasz Tomkiewicz, president of Arrinera Technology S.A. “Frequent changes to a model’s shape–the diameter or length–are not as problematic as they used to be. A new model can be printed in just over twelve hours.”

OMNI3D, perhaps best known for its Factory Production System 2.0, a large-scale (500 x 500 x 500 mm) FFF 3D printer, has been offering on-demand 3D printing services for the past year through its Printroom. The service came about through a necessity to demonstrate OMNI3D’s manufacturing technology to potential clients, as well as to provide an option to companies that aren’t prepared to invest in their own 3D printer.

As Krzysztof Kardach, Chief Technologist at OMNI3D, explains, “We opened the Printroom as a result of observing market needs. Many of our customers before making a final purchase decision about Factory 2.0, ask us for test prints. Others, like Arrinera don’t want to invest in their own machine, but still need professional 3D prints. There are also companies that have big needs for 3D printing, but prefer to trust experienced 3D printing technologists from our company.”

OMNI3D Factory 2.0 3D printer

Not only does OMNI3D’s Printroom offer relatively large-scale 3D printing, its FFF technology can also accommodate high-quality and durable thermoplastics such as ABS-42, ASA-39, PC-ABS- 47, PET-G- 32, and HIPS-20. For the Arrinera Hussarya supercar, mirror caps, air vents, and other important components were 3D printed primarily using ABS-42.

Evidently very happy with the supercar’s 3D printed parts, Tomkiewicz added, “Parts printed in 3D on Factory 2.0 Production System meet all of our requirements...in terms of strength, dimensional accuracy, and turnaround time. Some elements, such as air vents, are even installed in the car as the final product.”

 

 

 

Posted in 3D Printing Application

ZMorph case study for product design

13.02.2017

Designer & biomedical engineer Eliza Wróbel has created a multifunctional walker using the company’s 2.0 SX multitool 3D printer. The walker prototype is made of over 100 parts and is realised in Silver ABS for the frame; durable yellow and black PLA support parts; and rubbery Flex filament for the wheels, brakes, and arm pads.

zmorph casestudy

Wróbel’s design also gives the walker an interchangeable basket and seat so it can be used for walking or to aid in shopping.

BT Invests in ProJet 2500 from CDG

01.02.2017

Telecommunications company BT has invested in a new 3D printer for its distribution center in Leicestershire, England. The 3D Systems MJP ProJet 2500 Plus 3D printer is being used for prototyping and creating spare parts. [Article By Benedict, reproduced from at www.3ders.org]

BT (British Telecommunications) is a British multinational company that provides telephone, internet, and television services in roughly 180 countries around the world. Last year it acquired cellphone network EE for £12.5 billion, and currently has assets worth more than £38 billion. As in many industries, telecommunications can benefit from new and advanced manufacturing techniques, whether for installing new phone lines, producing internet routers, or simply fixing up existing equipment. Because of this, BT has recently installed a 3D System 3D printer at its distribution center in Leicestershire, where it will use the additive manufacturing machine for a number of purposes.

Since purchasing its new 3D printer in December, BT has wasted no time in setting it up, with the ProJet MJP 2500 Plus reportedly fired up for the first time in mid-January. BT says it is using the printer for various purposes, including fabrication of spare and replacement parts that are no longer available from suppliers, fast production of urgently needed parts, and rapid prototyping of new items during the research and development stage of product development. The telecommunications company believes the 3D printer will help improve many aspects of life at the distribution center.

Speaking to V3, BT’s Andy Fielden, CIO Supply Chain and Cables, explained how the 3D printer has allowed BT to “provide the stock items at the point of use without having to order, store, and distribute the item—thus significantly reducing cost and time to market.” He added that the 3D Systems machine has enabled BT to “print low volume items for our internal engineers” and “easily prototype and test new ideas.”

The idea of investing big money into a high-quality 3D printer came about after one engineer suggesting that 3D printed plastic needles (below) could be used to thread fibers. The idea was eventually turned into actuality on a MarkerBot Replicator 2X, a much more affordable desktop 3D printer, and the 3D printed pieces helped save the research lab a small amount of money. Before this, an engineer at Openreach (the BT subsidiary that deals with the UK’s telephone cable network) had built her own 3D printer to show others how the technology could benefit BT.

BT staff have said that, as 3D printing technology improves, they will consider adding to their additive manufacturing equipment, with the main focus of the technology being small-batch production of various parts. BT Lead Consultant Iain Monteath told V3 that BT was particularly attracted to 3D printers “that let you print flexible and solid parts in one,” since they could enable the company to print entire objects in one go.

The 3D Systems ProJet MJP 2500 Plus has a build volume of 295 x 211 x 142 mm, a resolution of 800 x 900 x 790 DPI with 32 μ layers, and a typical accuracy of ±0.1016 mm per 25.4 mm.

CDG supply of 3D Systems professional and production printers in the UK.

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