Make Realistic Prototypes in Less Time with Multi-Material 3D Printing
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Stratasys provides advanced 3D printing solutions, focusing on multi-material and multi-color capabilities to produce realistic prototypes in various industries, including automotive and consumer goods. The presentation highlights the benefits of using PolyJet technology for efficient prototyping, functional testing, and end-use parts, allowing for a reduction in design cycle time and improved product realism. Case studies, such as Trek Bicycles, demonstrate the practical applications and advantages of these technologies in enhancing product design and manufacturing processes.
Make Realistic Prototypes in Less Time with Multi-Material 3D Printing
- 1. 1 STRATASYS / COMPANY OVERVIEW Realistic Prototypes in Less Time with Multi-Material 3D Printing Oleg Yermanok
- 2. 2 STRATASYS / COMPANY OVERVIEW THE 3D PRINTING SOLUTIONS COMPANY WE ARE
- 3. 3 STRATASYS / COMPANY OVERVIEW EVERY 3D PRINTING AND ADDITIVE MANUFACTURING TECHNOLOGY AND SOLUTION FROM SYSTEMS TO SERVICE
- 4. 4 STRATASYS / COMPANY OVERVIEW Host Kim Killoran, Marketing Project Manager, Stratasys Presenter Oleg Yermanok, Senior Application Engineer, Stratasys Today’s Event
- 5. 5 STRATASYS / COMPANY OVERVIEW Established / Traditional (Design) Direct Digital Manufacturing (Manufacturing) Additive Manufacturing Concept Models Functional Prototypes Manufacturing Tools Production Parts Applications for Additive Manufacturing
- 6. 6 STRATASYS / COMPANY OVERVIEW One-step production of prototypes with: • Rigid regions • Rubber-like regions • Translucent regions • Varying colors One-step production of multiple prototypes with: • Different properties • Different colors Purpose • Product realism • Eliminate secondary operations • Maximize printer utilization Multi-Material 3D Printing Application Compatibility (0 – N/A, 1 – Low, 5 – High) Idea Design Production PolyJet - 5 5 FDM® - - - Multi-material, multi-color bicycle helmet. Example of color and transparency options available with rubber-like materials.
- 7. 7 STRATASYS / COMPANY OVERVIEW Mutli-Material 3D Printing Video
- 8. 8 STRATASYS / COMPANY OVERVIEW Application Overview Traditional Process PolyJet Process PolyJet Best Fits Benefits Customer Success Story Agenda
- 9. 9 STRATASYS / COMPANY OVERVIEW Digital Materials (DM) • Composite materials • Two or three FullCure® model materials • Specific concentrations and structures • Each combination produces unique properties (physical, mechanical, shades and tones, etc.) • Different from those of the parent materials Two main categories of digital materials: Multi-Material 3D Printing Overview Rigid Digital materials whose primary material is Vero™ Flexible Digital materials whose primary material is Tango™ Illustration of PolyJet triple-jetting process. Multi-material artistic piece (Vero white and TangoBlackPlus™).
- 10. 10 STRATASYS / COMPANY OVERVIEW Most industries • Sporting goods • Consumer electronics • Automotive • Medical • Toys and gaming • Housewares • Entertainment • Arts and fashion Throughout the product development process • Concept modeling • Functional testing Where It’s Used
- 11. 11 STRATASYS / COMPANY OVERVIEW Bicycles Plastic Machining and Fabrication Product Design & Development Consumer Products Plumbing & Sanitary Products Automobiles Special Effects/Character Creation Athletic Goods Companies Benefitting
- 12. 12 STRATASYS / COMPANY OVERVIEW Multi-stage process • Fabrication • Hand work, CNC • Post process • Painting, gluing, machining • Assembly Challenges • Time consuming • Dependent on outsourcing (expertise) • Confidentiality issues Traditional Process CAD Fabrication Post Process First Test Production
- 13. 13 STRATASYS / COMPANY OVERVIEW Design model in CAD Prepare files • Create shells per material • In CAD/STL editing software • Import assembly into Objet Studio™ software • Assign materials Print PolyJet Process CAD Print Test Preparing for multi-material printing in Objet Studio.
- 14. 14 STRATASYS / COMPANY OVERVIEW Applications: • Concept modeling/presentation • Prototyping/light-functional testing • End-use parts • Special effects • Jigs & fixtures • Gaming, figurines Part characteristics: • Approximate/simulate production goods • High detail and complexity • Engage the senses – sight and touch • 1 to 100 needed PolyJet is a Best Fit When: Rigid (orange) digital material with rubber-like overmolding. Rigid and rubber-like combination for living hinge and snap fit simulation.
- 15. 15 STRATASYS / COMPANY OVERVIEW Overmolding • Combines two or more materials in a part • Typically rigid plastic & rubber–like elastomer Uses • Power tools, medical devices • Consumer electronics, kitchenware • Toothbrushes, razors • Jigs & fixtures Characteristics • Simulate • Plastic • Rubber/elastomer (Shore A 27 – 95) PolyJet Best Fit Applications Cross-sections of steering wheel using rigid and rubber-like materials. Screwdriver handle with rubber-like interfaces. Plumbing fixture with rubber-like overmolding.
- 16. 16 STRATASYS / COMPANY OVERVIEW Rubber simulation • Visual and functional prototyping Uses • Seals, gaskets (low pressure) • Door and window seals (home/auto) • Keypads • Grips, cushions, pads Characteristics • Shore A between 27 and 95 • Black, translucent and a variety of colors • Moderate tensile/flexural loads • Moderate duty-cycle testing (<100) PolyJet Best Fit Applications Compression seal. Rubber tracks for a scale model. Wrist rest.
- 17. 17 STRATASYS / COMPANY OVERVIEW Labeling • Print text and graphics Uses • Production-like markings • Product identifiers (part #) • Instructions and usage guides • Branding Characteristics • Fine lines and small fonts • Lines: ≥ 0.2 mm (0.008 in) • Text: ≥ 0.8 mm (0.03 in) • Rigid or rubber-like • All available colors PolyJet Best Fit Applications Clear syringe printed with dosage markings. 3D printed calculator has printed keypad symbols and numbers.
- 18. 18 STRATASYS / COMPANY OVERVIEW Transparent / translucent + opaque Uses • Medical models (education, pre-surgical planning) • Engineering models (fluid flow, demonstration) • Marketing models (visualization, product realism) • Art and entertainment (special visual effects) Characteristics • Tinted translucent items (requires Connex3™) • Clear & opaque combinations • Full transparency (with post processing*) • Not suited for optics *For better translucency, the transparent models must be polished. PolyJet Best Fit Applications Shower head with clear body for visualization. Eyeglass printed with opaque frame and clear lenses. Medical model illustrating bone structure.
- 19. 19 STRATASYS / COMPANY OVERVIEW Multi-color • Final product realism Uses • Sales/marketing samples • Industrial design concepts • Product development • Heat/color maps (FEA analysis) • Component identification Characteristics • Palette-based • Light hues/dark hues • Monochrome (color+black+white) • Translucent color • Flexible color • > 2 mm (0.8 in) thickness (for true colors) PolyJet Best Fit Applications Multi-colors used for product realism. Example of color bleed for 0.5 – 2.5 mm (0.02 – 0.10 in).
- 20. 20 STRATASYS / COMPANY OVERVIEW Mixed tray • Simultaneous printing • Multiple parts • Multiple materials Composite Material • Digital ABS™ and Digital ABS2™ PolyJet Benefits Parts printed with different materials in a single job. Digital ABS materials with TangoBlackPlus simulating overmolding.
- 21. 21 STRATASYS / COMPANY OVERVIEW Shortening the design cycle • More iterations in less time • Identify errors early Simple and efficient • One process vs. multiple operations • One part vs. assembly of multiple parts Final product realism • Color and properties • Freedom of design Time & cost reductions • 50% - 90% • Increased productivity (fewer material swaps) PolyJet Benefits Typical time and cost savings derived from numerous end-user analysis, testimonials and feedback. Actual savings may vary based upon numerous factors, including traditional time/cost, part geometry and utilized technology. Eyewear printed with tinted lenses and multi- color frames. Rubber keypad printed in multiple colors.
- 22. 22 STRATASYS / COMPANY OVERVIEW Trek Bicycles CASE STUDY
- 23. 23 STRATASYS / COMPANY OVERVIEW Bicycle components and accessories • Design evaluation & trial rides • Communication, visualization Need: Look & feel like production parts • Helmet and grip • Saddles and chain guard Used multi-material, multi-color 3D printing • Saddle – pressure mapping • Others - Digital ABS & rubber-like Benefits • Improved durability & visualization • Improved productivity • Eliminated bonding • More printer uptime Case Study: Trek Bicycles Functional handlebar grip prototype produced using rubber-like TangoBlackPlus. Prototype helmets.
- 24. 24 STRATASYS / COMPANY OVERVIEW Bicycle components and accessories • Design evaluation & trial rides • Communication, visualization Need: Look & feel like production parts • Helmet and grip • Saddles and chain guard Used multi-material, multi-color 3D printing • Saddle – pressure mapping • Others - Digital ABS & rubber-like Benefits • Improved durability & visualization • Improved productivity • Eliminated bonding • More printer uptime Case Study: Trek Bicycles Saddles with rigid and rubber-like regions (Vero + TangoBlackPlus). Chain protector and sound guard produced using Digital ABS and rubber-like TangoBlackPlus.
- 25. 25 STRATASYS / COMPANY OVERVIEW Bicycle components and accessories • Design evaluation & trial rides • Communication, visualization Need: Look & feel like production parts • Helmet and grip • Saddles and chain guard Used multi-material, multi-color 3D printing • Saddle – pressure mapping • Others - Digital ABS & rubber-like Benefits • Improved durability & visualization • Improved productivity • Eliminated bonding • More printer uptime Case Study: Trek Bicycles Rider putting a Trek bike to the test. Saddles with rigid and rubber-like regions (Vero + TangoBlackPlus). Functional handlebar grip prototype produced using rubber-like TangoBlackPlus. Prototype helmets. Chain protector and sound guard produced using Digital ABS and rubber-like TangoBlackPlus. Multiple colors representing a pressure map (Vero).
- 26. 26 STRATASYS / COMPANY OVERVIEW Case Study – Trek Bicycles
- 27. 27 STRATASYS / COMPANY OVERVIEW Who • Manufacturers • Design firms • Service bureaus What • One-step, multi-material prototypes When • Communications à evaluations Why • Look and feel of final products • Breadth of materials & colors • More uptime & utilization Summary: Multi-Material 3D Printing Multi-material, multi-color razor handle. Multi-color bicycle helmet.
- 28. 28 STRATASYS / COMPANY OVERVIEW www.stratasys.com/webinar-multi-material • Download webinar slides & documents • View webinar on-demand • Request a benchmark • Submit technical questions to engineer More Information and Resources