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ADDITIVE MANUFACTURING/3D PRINTING
directly correlates to the cost, as a bigger part requires more material and an increased print time. If you are manufacturing a design for proof of concept, you could consider scaling down the model size to reduce cost and lead time. This will allow you to get through the prototyping phase faster and cheaper than a full-scale design. “Another option is to replace solid features
in your design with an internal lattice. Lattices are ideal as they can reduce the amount of material used without compromising the structural strength of your part substantially.” While the capabilities of 3D printing technology
are now beginning to be realised by engineers and manufacturers, only its full potential will become apparent over the next few years to provide even more benefits to multiple sectors, through both the materials and the process itself.
RIDING THE WAVE In 2020, Get It Made was approached by C-Monsta to manufacture, via its 3D printing capabilities, a working prototype to dry wet suits, fittingly named ‘The Wetsuit Hanger’. As a keen surfer in Scotland, C-Monsta’s
founder and director Mark Yeadon, found that in winter, the only time of year which saw significant waves, his wetsuit and accessories would often get neglected in the back of a van for days when removed, often a habit of surfers. When neoprene (the wetsuit material) isn’t properly dried, it smells, and can lead to the fabric and seams rotting, ultimately
limiting the lifespan of the wetsuit. Yeadon wanted to create a design solution which would not only dry surfing gear faster to prevent bad smells and rot but also extend its lifespan in order to reduce landfill waste, as neoprene isn’t recyclable. It was the first time he had taken a project from the prototype stage to being mass-manufactured on a large scale. “Before the design of the product could be
approved for mass production, our team of project managers undertook the process of curating a working prototype of the component, creating a convenient drying tool for those who are bold enough to brave cold waters. Describing the process of creating a prototype
for his company’s product, Yeadon said: “Although I love problem-solving, this was the first time I had worked on designing and manufacturing a product. I had gotten to a point where I had designed and proved the concept but could not find a way to manufacture it economically. I was
FEATURE
given a grant to work with a designer at the Glasgow School of Art, where my idea was refined and modelled for injection moulding. We ran out of time on the project before completing the design, and I couldn't afford to pay for the design to be completed, so I rolled up my sleeves, and worked out how to use Fusion 360 to finish the modelling process on my own. I then required a 3D printed model, which is where Get It Made stepped in. “When the model arrived, I was amazed by the quality of the finish. The approach they have is very straightforward, proactive, pragmatic and professional. They helped me choose the best materials to simulate my final product, were quick to price with good communication, delivery was fast, and the product was exactly what we were after.” He is already seeing the tangible benefits
brought by 3D printing: “Using my prototype, my wetsuit lifespan lasted two winters instead of one, saving me £350 every two years. It is a low-tech solution with a relatively high impact on kit maintenance and lifespan. As well as being manufactured in the UK, the entirety of the wetsuit hanger is made from recycled plastics, as C-Monsta bids to leave behind the smallest carbon footprint possible, underlining the importance we place upon sustainability within the business.”
The wetsuit hanger is made from recycled plastics
Get it Made
https://get-it-made.co.uk
AM SOLUTIONS ARE CATALYSING INNOVATION ACROSS A RANGE OF INDUSTRIES
3D Systems offers a range of additive manufacturing (AM) solutions which, the company states, are catalysing innovation across industries including motorsports, semiconductor equipment, aerospace, and medical device manufacturing. The company’s solutions – comprising 3D printing technology, materials,
software, and applications expertise – are changing the landscape of design, engineering, and manufacturing. Its new SLS Material Delivery Module, DMP Build Changeover Station, GRCop-42, CuCr1Zr, for example, will enable customers to expand the breadth of applications they can address with AM and enhance productivity. The SLS Material Delivery Module is a new accessory for the SLS 380
platform that more easily allows customers to use multiple materials on a single platform. The SLS 380 is a high-throughput SLS additive manufacturing solution with high levels of throughput, consistency, performance and yield to address cost-effective batch production. The ability to quickly change materials with minimum labor using the new Material Delivery Module helps increase the efficiency of the machine and thus improve productivity. Furthermore, the ability to utilise a broader range of materials with the printer maximises the value of the platform for end users to expand the applications they can address. In addition to being compatible with SLS 380, the SLS Material Delivery Module also enables multiple material functionality on 3D Systems’ ProX SLS 6100 and ProX SLS 500. This product is planned to be available for ordering in the second half of 2023. 3D Systems’ DMP Build Changeover Station is a standalone module that
facilitates quick turnover of a DMP Factory 500 removable print module with a finished build to prepare it for a new build. The DMP Build Changeover Station allows the user to de-powder a finished build, remove the base plate with a printed part, add fresh powder, install a new base plate, and prepare a removable print module to launch the next job. Changing materials on the DMP Build Changeover Station proper can be achieved in a matter of minutes, and thus it can serve multiple printers running different materials in parallel. The Build Changeover Station is a lower-cost accessory when compared to 3D Systems’ full peripheral chain, thus making metal AM more accessible to a broader range of customers. As production demands increase in an organisation, customers are able to move to the full peripheral chain.
The DMP Build Changeover Station is currently available for ordering. The company has also announced the addition of two copper alloys to its portfolio: Certified GRCop-42 and Certified Copper-Chrome-Zirconium (CuCr1Zr). Certified GRCop-42 is specifically designed for high-temperature, high-thermal transfer applications found in rocket engines, where high strength is also required. Parts produced in GRCop-42 maintain their mechanical properties at highly elevated temperatures (typical service temperature range of 400˚C to 600˚C, depending upon the strength and creep requirements for the sustained duration of the load). The addition of this material to 3D Systems’ portfolio expands the range of applications customers can address with the DMP platform to include high-performance combustion applications in aerospace and space. Certified CuCr1Zr (A) is a common copper
alloy offering high strength, and high thermal and electrical conductivity. Heat treatment can be used as a post-processing method to enhance the strength and conductivity of parts produced with this material. Customers using this material can collaborate with 3D Systems’ Application Innovation Group (AIG) which has deep expertise in tuning heat treatment parameters to meet specific application requirements. Marrying strength and electrical conductivity renders CuCr1Zr an ideal solution for complex heat management systems as well as electrical applications that also serve a structural function – such as heat exchangers, cooling systems, induction coils, and electrical contacts.
3D Systems
www.3dsystems.com
MAY 2023 DESIGN SOLUTIONS 49
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