Additive manufacturing as a (low volume) production solution- TOM CASTERMANS -

Pillars of PLASTIC 3D Printing …

3D printing is ecologic

3D printed parts are cheap

3D printing will replace injection moulding

A 3D printed part is ready-to-use

Everybody will own a 3D printer and will be able to produce parts at home or in the company

Pillars of PLASTIC 3D Printing … No Evidence

3D Printing is ecologic because …

- ZERO waste Cleaner + Supports on SLA/DLP prints

Refresh rate SLS powders (upto 100%)

Pillars of PLASTIC 3D Printing …

3D Printed parts are cheap because …

- Industrial 3D print materials are 20x to 50x more expensive then rawmaterials

- High power consumption of 3D printing machines versus output (compared to injection moulding)

- 3D Printed parts require almost always post processing

Pillars of PLASTIC 3D Printing …

3D Printing will replace injection moulding because …

- 3D Printed parts require almost always post processing

- Material properties are different (sometimes an advantage)

- Surface quality is different in most cases

- Machine output is too low, raw materials too expensive

Pillars of PLASTIC 3D Printing …

A 3D printed part is ready-to-use …

Pillars of PLASTIC 3D Printing …

Everybody will own a 3D printer and will be able to produce parts at home or in the company

CNC machining

Additive manufacturing

Injection moulding

Pillars of PLASTIC 3D Printing …

… and yet …

3D Printing is shifting from niche market of prototyping towards industrialapplications

Prototyping Small batch production Production ramp up

- Technological possibilities

- Part quality- Process stability- Cost per part

- Quality control- Total cost- Automation- Technological

Integration

Actions (to be) taken

When is AM a succesfull production technique?

Complexgeometry

Integration of

functionalities

'Customization’

(numbers)

InnovativeAM solution

How to use 3D Printing as production technique?

Founded in 2008 → grown into ‘One stop shop SOLUTION provider’

Services Design services / Production consulting Serial production and prototyping Development and assembly

Machines 4 DLP machines 2 large format SLA machines 1 large format SLS machines 1 UV printer (artwork) 1 CNC Milling machine + lathe Ultrasonic cleaning equipment Sandblasting Tumble polishing In-house painting facility Vacuum casting Different mechanical techniques

(reaming, tapping, drilling, turning, …) Injection moulding services (low to large volumes)

General Case studies

1 10 pieces

Automotive tooling – SLS technology

Hollow tool

Stiff design

Ergonomical

1 10 pieces

Automotive tooling

Lightweight design (CF integration)

Optimal stiffness (Lower reject rate)

Cost reduction

+ 500 Pieces

Industry: Lightguide for access control (outdoor use, UV stable, …)

+ 200 Pieces

3D printing + finishing

Injection moulding

CNC Turning

Assembly + testing

Industry: Dispensing unit for shower use

Case studyDesign for AM manufacturing

Electronics module for Simrace steering wheel

Electronics module for Simrace steering wheel

Design for AM requires:

Technology knowledgePart orientationTechnology specific details (e.g. bridging, slope angle, …)

Awareness of limitations as ‘everything’ is possibleMaterial limitations (Layer thickness vs. Resolution)Mounting limitations (e.g. magnet in blind hole)

Different approach

AM specific design features

AM specific design features

Overhang

AM specific design features

Strain Relief

AM specific design features

Cable Hole

AM specific design features

Magnet Holder

AM specific design features

Positioning Slot

AM specific design features

Flipper Axle Hole

AM specific design features

M4 Thread

AM specific design features

45° Slope Angle

AM advantage features

+

CONCLUSION

3D printing

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Additive Manufacturing

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Additional ManufacturingAM is part of your ‘toolbox’ besides other technologies

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