custom prototyping for lighting applications tony holtz | technical specialist, proto labs how to...
TRANSCRIPT
Custom Prototyping for Lighting Applications
Tony Holtz | Technical Specialist, Proto Labs
How to use rapid injection molding and 3D printing for housings, fixtures and optical parts
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Do you currently use rapid manufacturing during product development of custom optical and lighting
prototypes?
2
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Additive manufacturing (3D printing) and injection molding
provide quick-turn parts for several industries.
Learn how you can leverage these services during development, and bring products to market faster and
more cost effectively.
3
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Low-volume Injection Molding
25 to 10,000+ parts in 1 to 15 days SPI-A2 quality clear parts Great for lens, light pipe, housings and all injection-molded
prototypes and low-volume production parts
Hundreds of clear, transparent and opaque thermoplastic materials available
Thermally conductive materials available for lighting housings to dissipate heat
4
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Thermoplastic Materials
PC Lexan and Makrolon Improved impact resistance over PMMA Up to 89% transmittance
PMMA (Acrylic) Can improve part quality in thick parts over PC Up to 92% transmittance
K-Resin Improved flexibility over PC and ABS; can be used in a living hinge part
design Fills well in thin parts Up to 93% transmittance
Styron Medical and packaging industries High tensile strength Up to 90% transmittance
5
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Thermally Conductive Plastic
Do you need heat dissipation? Plastics can: Reduce weight up to 50% over other materials Lower cost of manufacturing over die casting and machining Improve features with traditional
injection molding techniques Reduce assembly costs with part consolidation Improve thermal conductivity by 50-500 times over conventional plastics
Can reach 35+W/(m.k) compared to 167+W/(m.k) for aluminum, so please do your homework
Used extensively in LED luminaire, electronics and aerospace industries
Applications like automotive cooling systems, battery/motor housings and sensors
Materials like CoolPoly and Therma-Tech are just two examples of advanced materials that are making an impact in the
industries.
6
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Design Considerations: Plastics
Ejection Will ejector pins be on a cosmetic surface or are alternative ejection
possible?Gating
Is your gate on a cosmetic surface and how will the knit lines effect your cosmetics?
Part thickness Will your part have sink or voids in thick areas?
Undercuts Undercuts can be achieved, but some may not be possible
Surface finish Does your part need to be clear, textured a combination?
Draft Surfaces that are highly cosmetic may require more draft for
improved mold release
7
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Liquid Silicone Rubber (LSR) Molding
25 to 5,000+ parts in 1 to 15 days Up to 94% light transmission Extreme thin and thick parts Improved light pipes, LED and outdoor lighting designs Lightweight, flexible, non-yellowing, vibration control, scratch, crack, UV and heat resistant
Up to 400% flexibility -49 to 392°F (-45 to 200°C)
Easily cleaned and chemical resistant No ejection required and minimal gate vestige
8
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Material Selection: LSR
Clear Elastosil 3003 (30,50 and 70 durometer) Most commonly used
Water Clear Dow Corning QP1-250 (50 durometer) Medical devices or components, USP class VI
Optically Clear Dow Corning MS-1002 (70 durometer) Primary or secondary lenses, light pipes and light guides
9
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Design Considerations: LSR
Are you able to combine parts to minimize assembly? Does your part require a gasket? An LSR lens can eliminate multiple
componentsYou don’t have the typical molding constraints that you do for PC or acrylic
Mold your part with thick and thin walls Mold your part using negative draft Mold your part using no ejection or concern of where the gate would be located Mold your part with minimized knit lines, sink and voids
Surface finish Does your part need to be clear,
textured or a combination?
10
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Design Considerations: LSR
11
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Design Considerations: LSR
12
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Side-by-Side Comparison
13
Silicone PC PMMA Glass
Light Transmission 94% 88-90% 93% 95%
Refractive Index 1.42 1.58 1.49 1.52
UV Resistance High Low Medium High
Chemical Resistance High Medium Low High
Temperature >150°C 120°C 90°C >200°C
Yellowing No Yes Yes No
Micro Detail Yes No No No
Thick Part Yes >1 in. No >PC Yes
Minimum Part Thickness <0.020 in. 0.040 in. 0.040 in. -
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
3D Printing: Stereolithography (SL)
1 to 50+ parts in 1 to 7 days Nearly any geometry possible Small complex parts Thick cross-sectioned parts Post processing for optically finished part
Hand polish and sprayed with clear coat Near distortion-free appearance similar to molding
High clarity and transparent materials or finishes available Not truly optical — some level of distortion is possible and should be
considered Produce multiple parts together
Custom finishes allow multiple colors or finishes on each part
14
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Material Selection: Clear SL
Somos WaterShed XC 11122 (ABS) Ideal for lens applications in high-humidity applications
3D Systems Accura 60 (10% GF PC) Clear with blue tint and high stiffness
Accura 5530
15
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Design Considerations: SL
Avoid thin ribs or internal cavities that would be difficult to polish Part orientation for build — where would support structures be
located? Is your surface completely flat? If so, can a substrate such as an
acrylic sheet be used? This helps on flat surfaces, but internal surfaces may still be hazy
16
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Design Considerations: SL
17
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Manufacturing Processes at Proto Labs
18
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Benefits of using Proto Labs
19
Reduced up-front investment Increased speed to market Design for manufacturability (DFM) analysis is built into quote Talk with on-hand experts regarding design and process Quick return time on quotes
Instantaneous for additive manufacturing Within hours for machining and molding
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Interactive Quote for Molding
20
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING21
Complete DFM Analysis for Molding
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING22
Mold Flow Analysis for Molding
ADDIT IVE MANUFACTURING | CNC MACHIN ING | IN JECT ION MOLDING
Do you think a custom prototype manufacturer can help during product development?
Upload a 3D CAD model online at protolabs.com for an interactive quote with free design and cost analysis.
23
