![PolyJet - Best Fit for
Injection Molding When:
•Thermoplastics with:
• Reasonable molding temperatures
• < 300 °C (570 °F)
• Good flowability
• Candidates:
• PE, PP, PS, ABS, TPE, PA,
POM, PC-ABS
• Glass filled resins
•Low quantities (5 to 100)
•Mid-sized parts (< 165 cc [10 cu. in.])
• 50 - 80 ton press
•Confirmation desired
• Before cutting soft/hard tool](https://image.slidesharecdn.com/5obrnyusygkfnwvph3mg-signature-044e541d736359275ceee2a7bb51c521fd1733da366e9d2f44943179ad38c7ca-poli-150226163013-conversion-gate02/85/Tasman-3DPrinters-presentation-Avalon-Airshow-2015-21-320.jpg)
![Sample Part Detail
Material PP
Melt temperature [C] 210
Actual injection pressure
[bar]
200
Clamp force [kN] 300
Cooling time [s] 180
Hold pressure [bar] 200
Hold time [s] 2](https://image.slidesharecdn.com/5obrnyusygkfnwvph3mg-signature-044e541d736359275ceee2a7bb51c521fd1733da366e9d2f44943179ad38c7ca-poli-150226163013-conversion-gate02/85/Tasman-3DPrinters-presentation-Avalon-Airshow-2015-27-320.jpg)
Tasman 3DPrinters presentation - Avalon Airshow 2015
- 2. We're 3D printing's biggest fans. • 40 Years Supplying & servicing the Australian & NZ Manufacturers • Major Supplier of Machinery to Plastics Processing industries. • Sales & Service located across Australia & NZ. • Largest install base of industrial grade 3D Printers in Australia & NZ.
- 3. 1984 SLA 3D Printer 1988 FDM 3D Printer 1999 Polyjet 3D Printer 2007 RepRap 2012 Objet/Stratasys Chuck Hull Scott Crump Adrian Bowyer Development of 3D Printing
- 4. Processes
- 5. • Scanning to CAD • Scanning to Print • CAD Modelling Software Slicing
- 7. FDM
- 8. Polyjet
- 9. Applications How is 3D Printing being implemented?
- 10. Other 2% Visual Aids 9%Presntation Models 9% Fit & Assembly 21% Patterns for prototype tooling 12% Patterns for metal casting 10% Tooling Components 6% Functional Parts 31% Other Visual Aids Presntation Models Fit & Assembly Patterns for prototype tooling Patterns for metal casting Tooling Components Functional Parts
- 11. End-Use Parts: Candidate Profile •Manufacturers needing plastic components for finished goods •Need low-volume production alternative • Pilot, bridge, production or end-of-life •Current methods limit what’s possible (considering time, cost) • Design optimization isn’t practical •Need efficiency, flexibility • With low-volume, high-complexity parts •Open to change • Or seeking innovation
- 12. Camera Housing: EUP – Military Application Digital camera enclosure Low volume – Qty 3,000 PC/ABS High design iteration Complex geometry DDM chosen over injection molding Not moldable PC-ABS 8” x 1/4” x 1/2” 1 undercut per top & bottom
- 13. Unmanned Systems Unmanned Vehicles • FDM viewed as key to “mass customization” • Easier adoption because of limited risks • Overnight production reduces cycle time • Direct build eliminates tooling needs Success Stories • Draganfly: Surveillance UAV • Leptron: Rapid Deployable Aerial Surveillance System (RDASS) • Embry-Riddle: Monocopter • Swiss UAV: Operational UAV Helicopter • Boeing UAV: AFRL Study Picture courtesy of NEO S- 300 VTOL UAV Swiss UAV GmbH Pictures courtesy of Draganfly Pictures courtesy of Leptron Pictures courtesy of Embry-Riddle
- 14. End Use Parts – Light Aircraft
- 15. Injection Molding: Application Overview Thermoplastic parts • Injected into tool/mold • High volume, Best repeatability • Most common method of plastic manufacturing Tooling • Mold cavity • Gates, runners, shut-offs • Cams, sliders, ejection system
- 16. Injection Molding: Where Used High-volume plastic part production • Consumer products • Packaging. • Consumer electronics • Automotive • Aerospace • Electronics • Toys • Household goods • And many more
- 17. Injection Molding: Candidate Profile Company type: • Custom molders • OEMs • Tool/die, model, services shops Industries: • Consumer electronics • Consumer products • Medical device That need: • Early, rapid product confirmation • Design, function, standards (e.g., UL, CE) • Early, rapid assessment of design for manufacturability
- 18. Injection Molding: Process Overview Part design Tool design Tooling making Molding machine setup • Mount tool • Adjust injection settings •Sample (first article) run •Production run • Automated
- 19. Injection Molding: Traditional Processes Tooling Manufacturing • Design • CNC setup • Milling • EDM •Considerations • High skilled labour intensive • Lead times – weeks to months • Costs – $1,000s to $100,000s
- 20. Injection Molding: PolyJet’s Role Alternative to: • Machined soft tooling - Aluminium Process • Design tool or tooling insert • Print • Assemble tool • Fit inserts, add ejection system • Mount on press • Adjust injection parameters Advantages • Quick, cost effective and efficient
- 21. PolyJet - Best Fit for Injection Molding When: •Thermoplastics with: • Reasonable molding temperatures • < 300 °C (570 °F) • Good flowability • Candidates: • PE, PP, PS, ABS, TPE, PA, POM, PC-ABS • Glass filled resins •Low quantities (5 to 100) •Mid-sized parts (< 165 cc [10 cu. in.]) • 50 - 80 ton press •Confirmation desired • Before cutting soft/hard tool
- 22. PolyJet Benefits for Injection Molding: •Spec resins, production process • True functional evaluation •50% to 90% savings • Time & cost •Efficient • Automated with few steps •Early detection • Flaws in part & tool design • Thermoplastic’s performance
- 23. Customer Success Story Robert Seuffer GmbH & Co
- 24. Seuffer video
- 25. Success Story: Robert Seuffer GmbH •PWM housing (automotive control) • Performance verification • Under thermal/mechanical loads •Machined soft tooling (aluminum) • 8 week delivery • $52,725.00 • Inserts for challenging geometry •PolyJet soft tooling • Molded polyethylene housings • Performed well & streamlined process •Results • Saved $51,407 and 7 weeks • Now an element of product development Method Cost Time Machined AL Tool PolyJet Tool $1,400 1 day Savings $ (%) (
- 26. Sample Part Detail System Connex500 Material Digital ABS Print mode DM Print finish glossy Build time 9:00 hr Model material amount RGD515: 860gr; RGD535:515gr Support material amount 96 gr Size Core X:140 Y:100 Z:45 Cavity X:140 Y:100 Z:45 (all in mm) orientation Injection Molding: housing for a PWM (pulse-width modulation)
- 27. Sample Part Detail Material PP Melt temperature [C] 210 Actual injection pressure [bar] 200 Clamp force [kN] 300 Cooling time [s] 180 Hold pressure [bar] 200 Hold time [s] 2