www.3trpd.co.uk

Additive Manufacturing – in the real worldStuart Offer, Sales Manager – Plastic

3T RPD Ltd

About 3T RPD

Principles

• Quality • Service • Delivery

• Started trading

• Installed 2 x P700’s in

• New Building

• DMLS Facility opened

• UK’s first M 280 machine installed

• Currently the UK’s largest commercial Plastic AM facility, 3rd largest in Europe

• 2nd largest Metal AM (DMLS) facility in UK

About 3T RPD

1999

2003

2006

2007

Nov 2011

Markets

• The process of creating 3D objects, layer by layer

• As opposed to subtractive manufacturing methods

Definition of Additive Manufacturing (AM)

Overview of Additive Manufacturing

Additive Manufacturing process

Overview of Additive Manufacturing

Additive Manufacturing Process

Subtractive Manufacturing Process

Thermal process

Semi crystalline when finished building

During cooling parts will shrink

Scaling factor is applied to CAD to allow for shrinkage

Generating suitable data

Layer based

Effect on surface

Effect on mechanical strength

Generating suitable data

200mm x 150mm x 150mm

£250 each

130mm x 120mm x 15mm

£80 each or

£25 each for 15 off

Plastic AM Costing

600mm x 200mm x 500mm

£2,500 each 165mm x 165mm x 180mm

£250 each

Plastic AM Costing

Rapid Manufacturing - Benefits

N1 = Break-even point

Cos

ts• Cost Comparison (Sintering vs Tooling):

Plastic AM has no initial tooling costs

AM Costs

Tool Based Manufacturing

Costs

AM Cost effective

Tooling Cost

Rapid Manufacturing - Benefits

N2

Cos

ts• Cost Comparison (Sintering vs Tooling):

If part complexity increases, the gap favours SinteringTooling costs increase to incorporate extra functions

Complex Tool Manufacturing

Costs

N1

AM Cost effective

AS 9100 Rev. C

ISO 9001:2008

ISO 13485:2003

Plastic AM Process Control

Quality Standards

Speed

Reducing design errors

Reduced Time to Market

Customer ‘buy in’ earlier in design phase

Benefits from Plastic AM

Almost unlimited range of part design

Benefits from Plastic AM

Source - Econolyst

Integrate several parts into one

Benefits from Plastic AM

Benefits from Plastic AM

No Tooling

Benefits from Plastic AM

Allows for product personalisation

Benefits from Plastic AM

Customisation

Intake Manifold:Tested in Climatic ChamberFitted to engine and run

Benefits from Plastic AM

Functional testing

Designing for Plastic AM

Applications not suited to Plastic AM:-

Clear parts

Very fine detail

High temperature

Multicolour models

Specific materials

Complexity is not an issue

Designing for Plastic AM

Minimum wall thickness

Wall thicknesses > 1mm

Accuracy

Typical accuracy to be within:

Dimensions <100mm +/- 0.3mmDimensions >100mm +/- 0.3%

Designing for Plastic AM

Holes undersize

Change CAD

Ream Hole

Small as M3

Tap material

Threaded inserts

Holes

Threads

Designing for Plastic AM

Designing for Plastic AM

Project started: 5th May

SULSA Flight: 8th June

Article published in New Scientist

Designing for Plastic AM

Southampton University Laser Sintered Aircraft

Unmanned Aerial Vehicle (SULSA UAV)

Designing for Plastic AM

Southampton University Laser Sintered Aircraft

Unmanned Aerial Vehicle (SULSA UAV)

Ailerons built in

Plastic AM weight less than 2.0kg

Internal structures for strength

Navtech Radar W500automatic surveillance system

Navtech Case Study

Designing for Plastic AM

Design change to reduce cost

Currently selling 50 off per annum but ramping up to 200 off

BRIEF

Outside changed to more economic production methods

but internals remained complex and expensive

Internal components to be replaced were Rotating Sensor

system, support and guidance for the lens and the mounting

and location of the emitter reel

Designing for Plastic AM

Extensive test programmePlaced the parts in extreme versions of a normal operatingenvironmentSimulated over 15 million cycles of the critical componentsduring a two month periodPivot arm became highly polished within a few hours,improving efficiency

Designing for Plastic AM

Durability of the Plastic AM parts lead to Navtech adding new features into their designFlexibility of the material led to creation of built-in springs as a return mechanism for the lens

Designing for Plastic AM

Reduced part count by integrating parts into one Plastic AM part

Reduced assembly time

New features incorporated into design

Flexibility of design now increased

Overall benefits

Designing for Plastic AM

Questions and Answers

Thank you

www.3trpd.co.uk