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FEATURE ADDITIVE MANUFACTURING/3D PRINTING HOW AM CAN MAKE YOU RETH


Additive Manufacturing offers a wide range of advantages to


many industries, from design freedom to on-demand


manufacturing. Here,


Tri-Tech 3D looks into how to reap these


benefits, and examines where AM has proved advantageous in the automotive and


aerospace industries T


here are huge benefits to be reaped by adopting Additive Manufacturing (AM). In fact according to Made Smarter, the benefits


of AM include: Greater design freedom, reduced time to market or production, on-demand manufacturing, reduced inventory holding, and cuts to waste and costs of production. However, for manufacturers that are new to


additive technology, especially sectors that were reliant on machining and injection moulding, it can be tempting to think of 3D printing as a one- size-fits-all solution. There can therefore be an expectation that AM will be a like-for-like solution that delivers instant productivity benefits. However, while 3D printing can produce parts


faster, using less tools, space and workload than traditional methods, productivity and ROI will depend on how users apply this technology. Before installing an AM system, manufacturers


must plan ahead to ensure that the machine will run at optimal performance – considering such factors as the relative humidity (RH) of the air in where the machine and filament sit is critical. In addition, while there are many desktop solutions, this technology may not be able to deliver parts on an industrial scale. Can you fit a larger, industrial-grade system, on the factory floor without compromising on features and benefits? Fully integrating AM to replace injection moulding and other traditional techniques can be counterproductive. In most cases, additive complements subtractive processes, and combining the two can amplify production efficiencies while reducing costs associated with full-scale adoption. Plus, operators need to be using the equipment effectively – a PolyJet system, for example, can produce accurate, smooth, prototypes and tooling. But if the manufacturer needs to produce large quantities of single production part designs with


50 DESIGN SOLUTIONS MAY 2024


industrial-grade quality, selection absorption fusion (SAF) technology would be better suited. Tri-Tech 3D always recommends that


manufacturers create a roadmap that shows where they are now, where they want to be in, say, six months or a year, and how they can get there. This can help them understand if they need to purchase one, two or even three systems, and what AM technologies they’ll need.


AUTOMOTIVE INDUSTRY HPL Prototypes of Coventry specialises in the manufacture of bespoke show cars, with clients including prestigious brands like Bentley, Aston Martin, McLaren and Jaguar Land Rover. The company produces prototypes and concepts with different aesthetics for its clients before they enter full-scale production. While HPL had on-site equipment for CNC machining, it would outsource 3D printing when parts required certain properties that its in-house methods couldn’t provide. For example, CNC machines are incapable of producing functional ultra-clear components, so when producing a new set of ultra-clear headlights, HPL would outsource to a 3D printing bureau that could facilitate its requirement for specialist materials that offer high optical clarity. Outsourcing, however, resulted in delays and added costs. To overcome this, Tri-Tech 3D supplied HPL


Prototypes with a use-friendly Stratasys NEO800 stereolithography (SL) system. Designed to produce large parts with high accuracy and quality, this has a large build area of 800 x 800 x 600mm, and a 2-Watt variable beam laser with dynamic and variable beam size options. It combines high laser power with advanced control to increase print speed and throughput, delivering highly accurate parts with superior surface quality. It is also an open-resin system


and is compatible with all 355 nm SL resins, allowing freedom of material selection. “The NEO800’s print bed provides a competitive


advantage for HPL because it can print large parts like seat backs in one build, rather than in segments,” explained Joe Godfrey, 3D print specialist at Tri-Tech 3D. “Not only does this improve aesthetics by avoiding split lines, but it can also reduce labour because further assembly is not required.” HPL is using the Somos WaterShed XC 11122


low-viscosity material, which produces strong, water-resistant parts with ABS-like properties. The resulting parts are durable, clear and have the look and feel of engineered plastic, with a smooth finish.


NEW BUSINESS In addition to producing parts that can only be 3D printed, HPL is using the NEO800 to supplement its CNC machines. Some automotive components like bevel gears can be both machined and printed, so having the NEO800 readily available means that HPL’s engineers can still produce critical parts while the CNC machine is busy. The NEO800 has also opened HPL to new


business opportunities. HPL recently started working with Cranfield Aerospace Solutions, a Bedford-based company specialising in hydrogen-electric propulsion systems for aircraft. By having the NEO800 in house, HPL can facilitate Cranfield’s requirements and build bespoke powertrain components without having to outsource to a bureau. HPL recently launched Allesley, a coachbuilder offshoot specialising in multi-million pound, highly personalised cars. With the NEO800 now installed, Allesley clients can visit HPL’s site and see how their bespoke motor is coming along. Glyn Horsfield, finance director at HPL, said:


3D printing’s most prominent advantage for aircraft interiors is the ability to quickly customise parts to be lightweight


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