Smart Materials 3D – Saving more then 96% of the Cost Compare with Tradition Machining Procedure

Case Study

//Smart Materials 3D – Saving more then 96% of the Cost Compare with Tradition Machining Procedure
Smart Materials 3D – Saving more then 96% of the Cost Compare with Tradition Machining Procedure2018-12-07T15:43:47+00:00

60% savings in a number of tools, due to an improved design, thus making it adaptable to all models of reels.

One of the metal couplings for the plastic filament spooler used by the company Smart Materials 3D for 3D printing breaks. The breakage is caused by the coupling falling to the floor, producing a dent in the conical part, adjusted to fit the rewind reel. At this point, the spooler will not work as it is unable to adjust and the reels are forced against the spooling shaft.

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“3D printing and specific materials design are today’s answer to the future problems and needs. In this case JCR 1000 was the perfect solution.”

Antonio Peláez, Director of Smart Materials 3D

Smart Materials 3D – Introduction

Smart Materials 3D is focused on the analysis, design, manufacture and improvement of materials for FDM 3d Printing process, intended for a big variety of applications. Our company arises from the industrial sector of the polymers transformation, giving a specific answer to problems in the 3D printing sector.

Through our advanced laboratory, our specialized staff and production lines we are able to develop and produce the most demanding materials for FDM applications, being compatible with the widest range of commercial 3D printers.

Through our prior knowledge in the development of polymers, we have specialized in the design of specific materials for several applications in a wide range of activity sectors.

Challenge

The production line cannot start until we have a new conical adjustment since the filament cannot be spooled in the reels. A request for a quote from a machining company to create a similar piece was sent. The price quoted was €575 with 2 weeks of delivery time. Although the order to the machining company was made (assuming 2 weeks of production shutdown), there is still a risk of the piece falling and becoming damaged, as it is a piece that is used in the machine approximately every 5 minutes, each time the reel is changed. The current piece is designed to fit one size, so it can only be used for a single reel size. You need different sized parts to fit the entire range of reels used on the line, so it was not very versatile and efficient for production.

Solution

A design was produced for an improved, universal piece, adaptable to any type of reel used in the production line within Smart Materials, adjustable in terms of both diameter and length. The 3D Sicnova JCR 1000 printer was used to print both sides of the piece, with an exceptional finish, perfectly adapted to the screwing, centering and tightening procedures. Printing material was used that was specifically developed for the piece to withstand impact and shock without becoming damaged or broken.

Results

  • Reduced costs per unit, as this technique is more competitive than machining systems currently used for the manufacture of moulds.

  • Raw materials are cheaper.

  • Waiting time for moulds reduced by more than 50%

  • No financial investment required for the moulds

  • Allows for the manufacture of functional prototypes at a very low cost.

Production Process

  • Foundation with Sand Mold. The realisation of the Model Plate

  • Make a master model to make a sand casting mould (in the cases presented for aluminium casting)

  • Manufacture of a functional coupling for the filament spool as an alternative to ordering a machined part

  • One of the metal couplings for the plastic filament spooler used by the company Smart Materials 3D for 3D printing breaks.

Impact on Customer

  • A saving of more than 96% in costs.€18.3 compared with the€575 of traditional machining procedures.
  • 100% savings in investments, since no replacement parts are needed for future possible breakages.
  • A saving of more than 77% of waiting time. 8 hours of printing in the JCR 1000 compared to 2 weeks of the machining delivery time.
  • 60% savings in the number of tools, due to an improved design, thus making it adaptable to all models of reels.

Cost and Time Saved using 3D Printing

  • A saving of more than 96% in costs €18.30 compared with the €575 of traditional machining procedures.

  • 100% savings in investments, since no replacement parts are needed for future possible breakages.

  • A saving of more than 77% of waiting time, 8 hours of printing in the JCR 1000 compared to 2 weeks of the machining delivery time.

  • 60% savings in the number of tools, due to an improved design, thus making it adaptable to all models of reels.

JRC 1000 3D Printer

LARGE FORMAT 3D PRINTING
MADE THE INDUSTRY

  • Industrial 3D printer from Grupo Sicnova with FFF technology

  • Maximum print volume: 1000 x 600 x 600 mm

  • Enclosed and heated environment with controlled temperature

  • Possibility of printing with two materials in the same piece

  • Manufactures pieces in a large variety of thermoplastic materials with different properties

View the Sicnova 3D JCR Range

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