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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.

Cambridge DT partners for reverse engineering

30.01.2017

Our friends at Cambridge Design Technology have published the following article on reverse engineering.

Link to orginal article:- Cambridge Design Technology

 

What is reverse engineering?

Reverse engineering is the process of analysing an existing product’s constituent components to allow a fully replicated design – or design knowledge – to be created from the information extracted.

Products and concepts as wide-ranging in structure and function as mechanical devices, electronic components, computer software, chemical formulas or organic matter are all suitable for analysis using RE techniques.

In practical terms, a typical reverse engineering project will involve working backwards from a chosen product to determine the design and technology used by the product’s creator. This accrued data then allows those applying RE to reproduce or refine the product – or simply to put the information to use in the concept development of a companion or related product.

Why would you need reverse engineering?

In today’s fast-paced business environment, existing mature life cycle products may require reverse engineering for:

2017-01-exploded-model-thumbnail

  • Compliance or revalidation processes
  • Converting design drawings into 3D digital data.
  • Recovering data and designs lost during company transition, data corruption or IT failures
  • Product Improvement

Whatever the need, reverse engineering can shine a light on the processes involved in the creation of the product in question – whether this is to establish details of an existing technologies or an unusual device, or simply to determine technical aspects of an established product that may not have been manufactured for some time.

Product Improvement

Product improvement can be a significant driver in wanting to RE a product.

  • Reducing manufacturing cost
  • Refining product performance
  • Replacement of a product

Designers and engineers are always looking for ways to improve both novel concepts and existing products. RE can provide the data and knowledge required to refine and improve a product’s assembly process and working capabilities.

By simplifying a product’s manufacture, its cost can potentially be reduced and its performance improved. The information provided by reverse engineering can even give designers and engineers the necessary spark to create an alternate version of a product.

How do you reverse engineer?

The basic goal of reverse engineering is to develop an understanding of a product and its parts by applying in de01pth analysis. Once these factors are understood, the engineer can begin to crystallise the original design intent of the working parts, their critical tolerances, materials used and key functions within the assembly.

Design intent capture

The design team will start by measuring components using digital, traditional and sometimes non-contact methods to define the parts. These parts are then modelled up using 3D CAD.

Once the parts have been made and the 3D assembly is created, the models may be proofed and tested. Although in some instances absolute accuracy in the RE process is crucial, some RE projects will require the design to be improved at the same time. Detailed understanding of a design can sometimes lead to the reducing of accuracy, in less critical areas, allowing potential cost savings in manufacture.

There is a technical risk to every design exercise. In RE, a seemingly minor measurement error involving as little as a fraction of a millimetre can potentially have a major and negative effect on the assembly process, so checking and proof reading of specifications and prototyping can be essential.

There are several tools within the CAD environment to achieve accurate design capture:

  • Interference checking to ensure the parts can operate with sufficient clearance or are purposely interfering (such as self-tapping screws etc)
  • Wall thickness analyses to ensure that (for example) a moulding has not been modelled with excess wall thickness which would potentially cause problems in moulding further down the line
  • Draft analyses, again with moulded components to ensure that all surfaces have been correctly drafted in the right direction. This also helps to validate the split lines of the product.
  • Surface analysis methods such as “Zebra Striping” can be employed to visualize curvature on smooth surfaces and evaluate the quality of surfaces created.
  • Other CAD tools that aid the process look at part volume, mass properties and undercut checking to help ensure the products parts are robust.

These various methods can all be employed to develop and streamline modern manufacturing techniques, processes and material usage. With design excellence being a for
emost principle of the exercise, the elimination of parts due to their redundancy or obsolescence are as important as the introduction of new parts and features that will enhance the product.

How do you reverse engineer a very complex shape?

CDT’s design team had their reverse engineering skills challenged when Hornby Hobbies asked us to reverse engineer various shapes of their classic Grand Prix racing cars. This involved detailed research and recreation of car body shapes using various measurement methods, photographs, artistic licence- as well as assessing design features by eye.

Reverse engineering projects like this can be costly and time-consuming – but the results can be spectacular. Even the smallest detail, such as the beautiful lines of a full-scale racing car are reduced to exquisite, 1/32nd scale replica slot cars. A stunning showcase of reverse engineering’s versatility and almost unlimited scope.

There is an alternative – 3D scanning

2017-01-3d-scanning-courtesy-of-cdg-and-shining-3d

Images supplied courtesy of CDG & Shining 3D

The accuracy of modern scanning is down to fractions of a millimetre even on large scale dimensions. And when large, organic shapes require ultimate accuracy to be taken from the original, then the extraordinary precision of 3D scanning can be harnessed to great effect.

By taking multiple scans of an object from all possible directions and viewpoints, the 3D scanner collects geometric data that is combined using a common reference system. From the extrapolated data, a digital 3D model can then be constructed.

3D scanning is a diverse technique, used broadly across many industries. Objects as large as ships, aeroplanes and even entire buildings have been successfully scanned. At the opposite end of the scale, minute, intricately-detailed objects such as dental devices, coins and skin textures have been succesfully captured.

It’s a technique that excels in scanning tangibles, yet can also be used to create intangible designs such as 3D animations and special effects.

3D Scanning applications include:

  • reverse engineering into CAD
  • data input for digital modelling or editing
  • measuring and inspecting parts
  • data achiving
  • virtual reality


3D Scanning partnership: working with Concurrent Design Group

We have been working with 3D scanning experts Concurrent Design Group (CDG) for many years now. In fact, we bought our first 3D printer from CDG. They have been at the cutting edge of 3D engineering design technology since 1993 and, given their vast experience and knowledge in this field, they are Cambridge Design Technology’s preferred supplier of 3D scanning.

Realise your vision

If your company has ideas that require cutting-edge design, technology and engineering input, Cambridge Design Technology have the knowledge, experience and creative energy to help you realise your vision – including a full Reverse Engineering and 3D Scanning service.

For more information about Cambridge Design Technology and how we can work with you on your next product design project, please call Jon Plumb now on 01787 377106 or email info@cambridge-dt.com

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