FEATURE MATERIALS IN DESIGN & PROTOTYPING REPRODUCING OBSOLETE PARTS WITH REVERSE ENGINEERING, 3D PRINTING AND COMPOSITE MATERIALS
Reverse engineering is being used more often these days for such tasks as the reproduction of broken or worn components where spare parts are difficult to obtain or are no longer available. The reverse engineering process, combined with professional 3D printing and high-performance composite materials, allows broken or worn production tool components to be quickly reconstructed and replaced. One example of this was where a T-shaped
attachment bracket was fixed to a linear actuator for some large electro-mechanical blinds. Due to wear
and prolonged use, the part broke into three parts, making it impossible to open and close the blinds. This turned into an occasion for field-testing by 3D printing company, CRP Technology, to demonstrate
that the most advanced technologies are vital when, for example, spare parts are obsolete. Advanced technologies can, in fact, be used to quickly rebuild components. For such tasks, the company starts by evaluating the 3D file of the component to be built, however in
this case the file was unavailable. So, reverse engineering was used instead. This replicates a design by laser scanning, to create 3D data that allows for modifications, adaptations or reconstruction of the part. The bracket was bonded to restore its original shape, then the reverse engineering process was carried out:
• Digitisation – Data captured from the surface of the T-shaped attachment bracket by scanning, to obtain its initial geometry.
• Reconstruction – Data processing. From the mesh, through the use of special engineering CAD software, the solid geometry is reconstructed and fitted to the original shape.
• Production. Once the 3D .STL file was produced after reverse engineering, the CRP Technology team proceeded with the creation of the T-shaped attachment bracket using Windform (
www.windform.it) TOP-LINE composite materials and selective laser sintering technology. Windform SP, a polyamide-based carbon composite material from CRP Technology’s TOP-LINE range of high-performance composite materials, was used. The material has excellent mechanical properties, with a high level of impact strength and elongation at break, as well as excellent resistance to high temperatures. The entire process – from the reverse
engineering phase to the construction via 3D printing – took place in just a few days. The new T-shaped attachment bracket was then scanned again to check for dimensional accuracy and then mounted in place of the original.
CRP Technology
www.crptechnology.com
ASA FOR HARSH
ENVIRONMENTS MakerBot has introduced ASA (acrylonitrile styrene acrylate). Part of the company’s line of Precision Materials, this is an engineering-grade material with high weather-resistant properties, suiting it to outdoor applications such as in the automotive, power and utilities, agriculture, oil & gas, and mass transit industries. ASA has mechanical properties
similar to ABS but with stronger ultra- violet (UV) long-term heat resistance and chemical resistance, enabling it to retain its gloss, colour and properties in outdoor exposure better than ABS, the company claims. ASA is available for METHOD X, a
powerful manufacturing workstation with an up to 100˚C Circulating Heated Chamber capable of providing a superior print environment for industrial-level materials. Powered by Stratasys, the MakerBot METHOD X is designed to help engineers achieve dimensionally-accurate production- grade parts at a lower cost than traditional manufacturing. According to the company, engineers
can print unrestricted geometries when printing ASA with Stratasys SR-30 industrial support material.
MakerBot
www.makerbot.com
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