Rosenbauer is the world&rsquo;s leading manufacturer of systems for firefighting and disaster&nbsp;protection. The company develops and produces vehicles, fire extinguishing systems, equipment and digital solutions for professional, industrial, plant and volunteer fire services, and systems for preventive firefighting. All of the main sets of standards are covered by products manufactured in Europe, the US and Asia. The Group has an active service and sales network in over 120 countries.The listed family company is in its sixth generation and has served fire departments for more than 150 years. A strong customer focus, innovative strength and reliability are Rosenbauer&rsquo;s key assets.-rosenbauer.comWhen the firetruck manoeuvred into our office&acute;s driveway everyone wanted to take a look at this massive vehicle. The Team from Rosenbauer Group Karlsruhe coming to pay a visit to SHINING 3D on that day, delivered an elaborate introduction to how firetrucks are tailored on demand adapted to the specific requirements of the customers. The team came to the SHINING 3D EMEA headquarters to explore the capabilities of the&nbsp;<a href="https://www.einscan.com/handheld-3d-scanner/einscan-pro-hd/" target="_blank">EinScan Pro HD</a>.<h3>Goal: 3D Scanning vehicle parts and equipment to enhance the 3D design process</h3>In the process of equipping a truck with the tools requested by the customer, Rosenbauer started to go fully digital for the fitting of all the equipment into the vehicle. The digital models of the requested products to be integrated in the truck are fitted into the virtual vehicle in Keyshot. This allows the Rosenbauer Team to react fast on customer&acute;s comments and requirements of change in the customization journey. It also saved them a great deal of time to go fully digital. So far so good, there is just the issue that sometimes the original drawings and model data of products are too complicated to obtain or simply not available. How can this issue be resolved in order to guarantee a smooth and seamless design of a custom firetruck?Fast, reliable and authentic acquisition of object characteristics is handled at ease by the EinScan Pro HD Multifunctional Handheld 3D Scanner. With the assistance of the latest 3D scanning technology by SHINING 3D, Rosenbauer was able to fill the gap of missing product details. Let&acute;s take a closer look at the workflow in detail:Upon the arrival of the Rosenbauer Team, the EinScan Pro HD has been set up with a dedicated work station. Due to its versatile and flexible handling, creating a perfect setting for 3D scanning of different areas, tools and equipment of the firetruck only took a few minutes.<figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTI3NjQ5LTE2MTMxNTA1Mjc2NDkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>Setting up the EinScan Pro HD for scanning complex objects is fast, easy and convenient<h3>Less limitations while scanning dark objects and surfaces</h3>The light weight of the&nbsp;<a href="https://www.einscan.com/handheld-3d-scanner/einscan-pro-hd/" target="_blank">EinScan Pro HD</a> and the capacities of dark objects capturing enabled a fast and uncomplicated data acquisition of the driver&acute;s cabin with great results.<figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTI4OTIwLTE2MTMxNTA1Mjg5MjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>Convenient and uncomplicated 3D data acquisition with&nbsp;<a href="https://www.einscan.com/handheld-3d-scanner/einscan-pro-hd/" target="_blank">EinScan Pro HD</a>. No matter if from the top&hellip;<figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTI5NTYwLTE2MTMxNTA1Mjk1NjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>&hellip;or from the side. The light weight of the 3D scanner enables a flexible and comfortable handling.<h3>Fast scan speed for high efficiency</h3><figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTI5MDA2LTE2MTMxNTA1MjkwMDYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>Within short time the team has been able to scan the truck&acute;s cabin&hellip;<figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTI4MjM1LTE2MTMxNTA1MjgyMzUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>&hellip;and check on the scanning data immediately.<h3>Processing and evaluation of scan data on site</h3><figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTI5NDc0LTE2MTMxNTA1Mjk0NzQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>By using a high power flexible work station and the SHINING 3D battery, the sighting and&hellip;<figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTMyNzIwLTE2MTMxNTA1MzI3MjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>&hellip;evaluating of the scanning data is fast, simple and efficient.<h3>Rosenbauer uses scan data to tailor products on clients request</h3>By using the EinScan Pro HD to scan various parts of the firetruck, it is possible to obtain authentic and precise 3D data of the objects, which are perfectly suitable for rendering in Keyshot and thus are the perfect match for the application requirements of the Rosenbauer Team.<figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTMxMTkzLTE2MTMxNTA1MzExOTMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure><figure><img alt="" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMTUwNTMxMzA1LTE2MTMxNTA1MzEzMDUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></figure>Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/creating-spare-parts-with-3d-scanning-and-3d-printing" rel="noopener noreferrer" target="_blank">Creating Spare Parts with 3D Scanning and 3D Printing</a>This project proves evidence that the <a href="https://www.einscan.com/handheld-3d-scanner/einscan-pro-hd/" target="_blank">EinScan Pro HD</a> is the ideal companion to capture highly accurate 3D data of a multitude of different objects empowering the users to take the next step on their digital technology journey.

The firetruck needs to be customized according to the firebrigade´s needs

Customization of a Rosenbauer Firetruck with EinScan Pro HD

How 3D Scanning Helps the Firebrigade

In the drive to accelerate new product development and time to market, the pressure to validate a design can be intense. With a prototype of a product or component, designers’ finally move designs from the screen to physical objects that can be handled. Does it fit? Will it function as intended? Can a 3D printed part be manufactured by injection moulding? And—in the case of prototype products, rather than parts—what might potential customers think of it? Increasingly, smart manufacturers—and their design teams—are looking ahead, past the prototyping phase of the product design process, and are thinking in terms of the end product and its required performance characteristics.<a name="first" target="_blank"></a><h2>Right first time</h2><h2><a data-lightbox="/media/1015734/lifecycle-inforgraphic2.png" data-title="" href="https://www.protolabs.co.uk/media/1015734/lifecycle-inforgraphic2.png" target="_blank"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMDMyNDc0OTMyLTE2MTMwMzI0NzQ5MzIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" style="width: 300px;"></a></h2>In product development, parts or products generally move through three phases of evolution: first, prototyping; second, low-volume production; then third—and final—serial production.Prototyping is about crystallising a proven, working design. A prototype can be one of several (or many) such iterations, or just a final one-off physical validation of an on-screen design before design sign-off. On the other hand, low-volume production is less about the product itself, and more about its market or production process: a phase of low-volume production can help to refine a manufacturing process, or alternatively get test products or launch products to market in order to gain and validate customer perceptions. Finally, the precise volumes that are associated with serial production will depend on the product itself, and its market, and will typically range from thousands each year, to millions each year.In each case, the goal at each stage is to move smoothly from each phase of development to the next, refining the product and its manufacturability. Overall, the objective is to minimise the total time and cost of the overall process, bringing a product from initial concept to serial production smoothly and efficiently, and as quickly and cost-effectively as possible.In some industries bringing a product to market involves extensive compliance testing, often involving third-party certification. Aerospace and defence product development, for instance, calls for such compliance, and no manufacturer will want to finalise a product design and get ready for serial production, only to discover that the product in question does not meet its design requirements in terms of durability, usage cycles, or some other testable attribute. Making use of the prototyping stage to carry out such testing—a process known as pre-compliance testing—is therefore prudent. In such circumstances, it makes excellent sense for a designer to seek guidance from the prototyping provider in order to use a prototyping material that will yield meaningful information on attributes such as strength, flexibility and durability.Finally, as well as these development and testing stages of bring a product to market, a manufacturer may wish the prototyping and development process of a product to take into account a number of broader business considerations.Decisions about packaging, for instance, can impact packaging cost, vulnerability to damage during shipment, and the cubic utilisation of both primary and secondary packaging. Ultimately, of course, cubic utilisation will affect vehicle and container requirements, as well as shipping cost. It can be prudent to, wherever possible, use product prototypes in order to inform packaging decisions as early as is practicable.Similarly, a business may have sustainability and branding objectives in addition to those impacted by packaging and shipping utilisation. A decision to use a particular means of packaging, for instance, may again impact damage statistics, or product aesthetics during a long shelf-life. An objective of using high levels of reclaimed plastic may not prove practical when injection moulding a specific part. And sourcing both prototypes and production parts over long distances will impact a business’s carbon footprint, as well as drive costs higher.<a name="prototyping" target="_blank"></a>Quality, reliability, and business resilience are other important considerations. These are generally trade-offs: the cheapest prototyping provider will not usually be the fastest, or produce the highest-quality prototypes, for instance. Maintaining a close business relationship with a prototyping provider is becoming a strategic consideration for many businesses; value is placed on sourcing a recommended manufacturer as an outsource partner with the ability to satisfy prototype needs, plus low- and medium-volume product requirements. These suppliers provide the support that fully understands the need for DFM (design for manufacture) and are key to smoothing the way.In short, successfully bringing a new product to market can call for a multi-faceted approach to design and development, embracing a wide range of issues, priorities, and trade-offs. In this paper we look at how an intelligent approach to prototyping strategy at each phase of the development process can help with this. The objective: an approach to prototyping that shortens overall development time, and brings to market a better product with a better performance, and at a lower overall development cost.<h1><a href="https://get.protolabs.co.uk/prototype-to-production-whitepaper/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-white-paper-0221&utm_content=prototype-to-production-0221" rel="noopener noreferrer" target="_blank">Continue reading -&gt;</a></h1>

Manufacturing throughout the product life cycle

From Prototype to Production

Our Insight video series will help you master digital manufacturing.Every Friday we’ll post a new video – each one giving you a deeper Insight into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.<a href="https://get.protolabs.co.uk/insight-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-subscription-0221" rel="noopener noreferrer" target="_blank">Never miss an Insight by subscribing here</a>.<hr><h3>Insight: Plastic Injection Moulding - Improving Part Design with Uniform Wall Thickness</h3>TranscriptThis week we’re going to take a closer look at how 3D printing is impacting medicine. &nbsp;Firstly, let’s briefly recap on where the technology is before taking a closer look at some impressive applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1613030673636-1613030673636.png" alt="" class="fr-fic fr-dii" style="width: 300px;">As you know 3D printing is an additive manufacturing process where material is added to the structure layer by layer. &nbsp;This technique allows you to design exactly what you want, there are few, if any constraints, and you can design minute parts with incredibly fine details.Most people think of polymers and plastics when it comes to this technology with the stereolithography process allowing the production of complex geometries as well as very small structures.New materials are being introduced all the time, for example Microfine Green allows us to produce incredibly fine, high resolution structures for things like miniaturised catheters or minimally invasive tools.But 3D printing can use far more materials than this. &nbsp;Another process called direct metal laser sintering is great for printing parts made from metals and other alloys.It’s fair to say that 3D printing opens a whole new world for medical equipment manufacturers, surgeons, doctors, and dentists.Let’s start with implants. The fact that you can achieve any geometry that you require, it makes it a perfect solution for a cost-effective way to produce one off parts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1613030673369-1613030673369.png" alt="" class="fr-fic fr-dii" style="width: 300px;">Modern medical imaging produces data that allows the production of an implant specifically for a patient.Before this, custom-made implants took time to produce and were expensive.Now you can have a 3D printed femur implant, hip bone, finger joints, jawbone, cranial bones and far more all tailored to your body. And if you visit the dentist for a tooth implant, the chances are that 3D printing will produce it.It saves money, is specific to the patient and it is quick to produce. &nbsp; This means the delivery of the implant is there exactly when the surgeon needs it.&nbsp;As well as producing parts for the body, 3D printing is proving a winner for producing individual medical devices and custom-made products.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1613030673722-1613030673722.png" alt="" class="fr-fic fr-dii" style="width: 300px;">Special parts often need precise dimensions and unique geometries. &nbsp;A surgeon often wants aids specifically designed for an individual patient and their operation. &nbsp;A good example is a template for drilling into the skull with millimeter precision. &nbsp;Again, you can use CT scans to create accurate files for a 3D printer to produce precise templates quickly.You can also produce products for special drilling, for incisions and better suturing of surgical wounds. The medical industry is finding new applications all the time. It means that what was once impossible is now possible.Some of these innovations can be tiny, such as a single part in a pacemaker that is only a fraction of a millimeter in size using our Microfine Green material.In fact, when far cleverer minds than mine really start to think about it, whole new possibilities open up. &nbsp; Things that in the past were science fiction are now becoming science fact.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1613030673516-1613030673516.png" alt="" class="fr-fic fr-dii" style="width: 300px;">Prosthetic limbs are one application, another is the development of specialist exoskeletons to improve musculoskeletal function. &nbsp; There are discussions about producing specific body parts in different materials for both medical students and surgeons to practice complex surgery when training. &nbsp;And because flexible materials can be printed, these models will even have the same characteristics as the actual body part.So, 3D printing has revealed a whole new world of possibilities in medicine, some of which are only just being discovered.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1613030673581-1613030673581.png" alt="" class="fr-fic fr-dii" style="width: 300px;">The future is even more exciting. &nbsp;There are already the first prototypes for replacement organs such as a 3D printed heart. &nbsp;Other research is exploring bioprinting to produce human skin and biological prostheses such as ears and to print this organic material straight onto the patient.The development of 3D printed organic material may also limit the need for future animal and human trials of new drugs. &nbsp;When you think about it, the implications are enormous.It is too soon to say when or all of this will become a reality, but the technology is certainly expanding what might be possible. &nbsp;Using 3D printing for medical applications will explore what processes are possible and how they can improve everyday clinical practice.It also means that the links between manufacturers of devices and clinicians will get closer as more “what if” questions are answered.The technology is very much a technology of the present for both clinicians and equipment manufacturers. &nbsp;In this fast-changing industry, the challenge is as much about keeping up to date with today’s advances as thinking about those of tomorrow.<hr>Watch other Protolabs Insight videos <a href="https://www.protolabs.co.uk/resources/insight/insight-video-library/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-library-0221" rel="noopener noreferrer" target="_blank">here</a>, or <a href="https://get.protolabs.co.uk/insight-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-subscription-0221" rel="noopener noreferrer" target="_blank">subscribe here</a> to never miss an Insight.

Find out more about how 3D printing can be used for implants, medical devices and custom-made products, as well as an outlook to what the future could hold for 3D printing in this field.

20240119-Protolabs Insight: 3D Printing in Medicine

Everyone wants to save money on manufactured parts. It sounds simple, but one of the easiest ways to reduce price-per-piece cost in injection moulding is by increasing part quantity. That is because the initial upfront cost to design and machine the mould remunerates over more parts. At Protolabs, for example, up to 25,000 parts or more can be moulded from the same&nbsp;tool.However, maybe your moulding project calls for only a handful of parts. No worries. Protolabs builds cost-effective moulds for production quantities as low as 25 pieces, often within a few days of ordering.<div class="fr-img-space-wrap">In addition to per-unit costs, consider the material. Many plastics overlap in strength and functionality, but some are inherently easier to mould, driving down part costs. You can experiment with different materials in the interactive quote you receive when you upload your design to Protolabs.</div>Here are 11 injection moulding design considerations to stretch your manufacturing&nbsp;dollar:1. Eliminate undercuts 2. Get rid of unnecessary features 3. Use a core cavity approach 4. Reduce cosmetic finishes and appearances 5. Design self-mating parts 6. Modify and reuse moulds 7. Pay attention to DFM analysis 8. Use a multi-cavity or family mould 9. Choose low-volume production option 10. Consider part size 11. Use over mouldingUndercutsUndercut features complicate and, in some cases, prevent part ejection. Get rid of them if you can, but maybe that’s not possible, if, for example, you need a side action, sliding shutoff or pick out. One alternative may be using sliding shutoffs and pass-through cores, or by changing the parting line and draft angles to provide an easier mould build. These reduce tooling costs as you avoid additional pieces to the mould that add to manufacturing costs. In addition to the rise in manufacturing costs of using hand-loaded inserts, this also may have an impact on your piece part price because of longer cycle times and manual mould operation.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEyNTExNTM1Nzg4LTE2MTI1MTE1MzU3ODcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">Undercuts, such as those shown, can complicate and, in some cases, prevent part ejection, so eliminate them if possible. <div class="fr-img-space-wrap">&nbsp;Unnecessary Features</div> Textured surfaces, moulded part numbers, and company logos look good, but be prepared to pay a bit extra for these and other non-mission critical features. That said, permanent part numbers are a requirement for many aerospace and military applications. Use a mill-friendly font such as Century Gothic Bold, Arial, or Verdana (san-serif fonts), keep it above 20 pt., and don’t go much deeper than 0.010 to 0.015 inch. Also, be prepared to increase draft if part ejection is a&nbsp;concern.Core CavityIf you need an electronics housing or similar box-shaped part, you can either sink the wall cavities deep into the mould base, requiring long thin tools to machine ribs into the mould, or machine the aluminium material down around the core and mould the part around it. The latter approach is known as a core cavity, and is a far more cost-effective method of moulding tall walls and ribbed surfaces. Better yet, this makes it easier to provide smooth surface finishes, adequate venting, improved ejection, and can eliminate the need for super-steep draft angles.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEyNTExNTM2MDMzLTE2MTI1MTE1MzYwMzMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Design tip | core cavity" class="fr-fic fr-dii">Using a core cavity, as shown, can be a cost-effective method of moulding tall walls and ribbed surfaces.CosmeticsPretty parts are nice, but they often require bead blasting, EDM, or high mould polish to achieve an elevated level of cosmetic appearance. This drives up tooling costs. Anything greater than a PM-F0 (as machined) finish requires some level of hand work, up to an SPI-A2 mirror finish using Grade #2 diamond buff. Avoid fine finishes such as these unless they’re required for the&nbsp;job. One thing to consider regarding cosmetics is to let Protolabs know if you need the entire half of the mould polished or maybe just one small area. You could save costs by only polishing the area needed versus the entire side of a mould. When requesting a custom finish, just send Protolabs a color-coded image of the critical areas and desired finish level for each area.Self-Mating PartsMaybe you’re designing a snap-together case for some medical components, or two interlocking halves of a portable radio. Why build two mating parts when you can make one? Redesign the snaps so that the halves can be fit together from either direction, thus building a so-called “universal” part. Only one mould is needed, saving production expenses up front. And you can now mould twice as many of one part, instead of half the quantities of two.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEyNTExNTM2MzI5LTE2MTI1MTE1MzYzMjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Self mating part" class="fr-fic fr-dii">This is an example of one half of a self-mating part, which fits together in either direction with its other half, building a “universal” part.Mould ModsIt is relatively easy to remove metal from an existing metal mould. Adding metal, on the other hand, can be difficult or, for all practical purposes, impossible with rapid injection moulding. To look at this from the part perspective, you can add plastic, but you can’t take it away. Designing with this in mind is called “metal&nbsp;safe.”Some injection-moulded parts go through multiple iterations until a final, workable design emerges. Instead of purchasing a new mould for every revision, a little clever planning will allow the same mould to be used multiple times. Starting with the smallest, most basic part design, mould as many pieces as needed, then re-machine the mould to include additional part features, or a larger, taller version of the same part, and mould again. This is not an exact science, but given the right part, this re-use approach can save dollars on tooling development.Mould-ability-DFM AnalysisEvery quote for an injection-moulded part at Protolabs is accompanied by a free design for manufacturability (DFM) analysis. This identifies potential problem areas, or opportunities for design improvement. Insufficient draft angles, “un-machinable” features, impossible geometries—these are just a few examples in which part designs can and should be improved before clicking the “accept” button. Be sure to review these suggestions thoroughly, and contact an applications engineer at Protolabs with any design-related&nbsp;questions.Multi-Cavity and Family MouldsMaybe you are after a higher volume of parts? You can still achieve high volumes using aluminium tooling with two-, four-, or eight-cavity moulds depending on size and part geometry that can reduce your piece part price, although this would impact your tooling costs.Got a family of parts that all fit together? How about multiple moulding projects at one time? There’s no reason to build a mould for each individual part, provided A) everything is made of the same plastic, B) each part is roughly the same size (e.g., have similar processing times), and C) can all be squeezed into the same cavity, while still allowing for proper mould functioning.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEyNTExNTM2Mjk2LTE2MTI1MTE1MzYyOTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="family mould" class="fr-fic fr-dii">Here is an example of a family mould, used to produce the part pictured, which was a component of the SubQ It, a medical tool used to close surgical incisions with bio-absorbable fasteners.In addition, maybe you can join some of those parts with a living hinge? This method is a great way, for example, to mould two halves of a clamshell-style container. These parts would otherwise need a pin-type assembly to open and close. The only caveat here is that a flexible and tough material must be used, such as polypropylene&nbsp;(PP).Low Volume ManufacturingStill another way to reduce moulding costs, depending on your part volumes, is to consider low volume manufacturing. At Protolabs, two injection moulding service options are available&nbsp;(see table below). One is best suited for those who need smaller part quantities, usually associated with prototyping. The other option is a good fit for those who require slightly larger part quantities, typically up to 10,000-plus parts from aluminium moulds. Low volume production can be a great option to manage demand volatility of your parts, reduce total cost of ownership, and leverage cost-efficient bridge tooling. <div class="fr-img-space-wrap">&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEyNTExNTM2NDk4LTE2MTI1MTE1MzY0OTgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" class="fr-fic fr-dii"></div> Part SizeAlways consider part extents. In moulding-speak, that means how big is the part, and will it fit comfortably in the mould while allowing for sprues, runners, ejector pins, and all the other considerations needed to make a mould work. Protolabs’ maximum part size for injection moulding is currently 480mm by 751mm with a maximum depth from the parting line of 101mm deep. However, larger parts like these, in turn, require a larger mould. This may have an impact on your mould and part&nbsp;costs.OvermouldingFinally, consider an overmoulding option. Depending on the part, it might cost you more upfront, but could potentially save you money later. For example, overmoulding a gasket on a part upfront might be an added cost, but it can save costs later from having someone install a gasket manually. <hr>Visit <a href="//protolabs.co" rel="noopener noreferrer noopener noreferrer noopener noreferrer" target="_blank"></a><a href="https://www.protolabs.co.uk/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0221&utm_content=design-tip-reduce-im-costs-0221" rel="noopener noreferrer" target="_blank">protolabs.co.uk</a> to find out more about Injection Moulding. And as always, feel free to contact an applications engineer with any questions, at <a href="mailto:applicationengineers@protolabs.co.uk" target="_blank">applicationengineers@protolabs.co.uk</a> or contact our customer service department at <a href="mailto:customerservice@protolabs.co.uk" rel="noopener noreferrer" target="_blank">customerservice@protolabs.co.uk</a>.

Stretch your budget with these injection moulding design recommendations

Tips to Reduce Injection Moulding Costs

Our Insight video series will help you master digital manufacturing.Every Friday we’ll post a new video – each one giving you a deeper Insight into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.<a href="https://get.protolabs.co.uk/insight-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-subscription-0121" rel="noopener noreferrer" target="_blank">Never miss an Insight by subscribing here</a>.<hr><h3>Insight: Plastic Injection Moulding - Improving Part Design with Uniform Wall Thickness</h3>TranscriptHello and welcome to Proto labs' Insight video series.&nbsp;Today we’re going to be looking at how you can improve the design of your parts by taking advantage of one of the fundamentals of plastic injection moulding – maintaining uniform wall thickness.If you want to see this principle in action, all you need to do is pick up pretty much any mass-produced plastic part, like a toothbrush holder or a washing-up tray. Take a good look at it and you’ll see that while the design might have plenty of curves and angles, the walls are almost certainly a relatively uniform thickness throughout.Why do manufacturers do this?Well, because if they ignore it that can lead to sinking, warping, inaccurate or non-functional parts. As you may have guessed, these are all bad things that we want to avoid wherever possible.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610702649282-1610702649280.png" style="width: 300px;" class="fr-fic fr-dib">However, not every product out there is as simple as a tray or a cup. Sometimes the functional requirements of consumer, medical, aerospace, and industrial products leave you with little room to manoeuvre when it comes to wall thickness.In this case there are two things we need to consider. One: how can we try and keep the walls relatively uniform despite a complex design? And two: what’s the best material for us to work with?Before we start talking this through, let’s try and define what ‘relatively uniform’ really means in a practical sense. As a rough guide, it means making sure that the walls of any plastic-moulded part are no less than 40 to 60 percent as thick as adjacent walls.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610702727757-1610702727757.png" style="width: 300px;" class="fr-fic fr-dib">Basic principles also mean that geometries such as long unsupported spans, sharp internal corners and poorly designed bosses – and we don’t mean senior management – are all bad news, regardless of wall thickness.Instead of using these, we can just make some clever changes to the design. If you need a tall wall, for example, rather than trying to just make it thicker, use ribs to strengthen it.Similarly, while sharp external corners are fine, placing a radius on the inside of them makes them stronger and alleviates the stress that creates warp.It’s also a good idea to make sure you follow recommendations on draft angles – 1 degree of draft per 1 inch of cavity depth is a good rule of thumb – and keep draft consistent throughout the workpiece to prevent internal stresses that lead to warp and curl.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610703122752-1610703122752.png" style="width: 300px;" class="fr-fic fr-dib">However, the design is only ever half the job. All the clever design in the world won’t help save you from a poorly chosen material.Every plastic out there has a minimum and maximum recommended wall thickness, and if your design dips below that you’re in trouble. On top of this you can have a whole list of other things to consider. Does the plastic need to be chemical resistant? Does it need to withstand extreme temperatures? How strong does it need to be? What colour do you want?<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610703135080-1610703135080.png" style="width: 300px;" class="fr-fic fr-dib">But with literally hundreds of materials to choose from, deciding on the right one can be a challenging old task – one that doesn’t come with a single easy answer.I’m sorry to say this is a job you’ll need to puzzle out for yourself. The best advice I can give here is to make sure you talk to your manufacturer, because even if no ideal plastic leaps off the catalogue page, there’s a good chance they’ll be able to help you out, even if this means blending or fine-tuning a material that doesn’t quite fit your requirements.Of course, even if you do get that perfect material and stick to every design principle out there, there’s a chance that a specific part might need to dip below that recommended thickness. Obviously this isn’t ideal, but if you can’t find a way around it you don’t need to start despairing – as there are a few clever edits to part geometry that go a long way to alleviate internal stresses and potential weaknesses produced by less than optimal wall thickness.Parts shaped like dumbbells or sewing bobbins are perfect candidates for coring, which eliminates large cross-sections of material while leaving the strong core in place. This is a great way to avoid sink, reduce material usage and make parts lighter but just as strong – possibly even stronger.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610703149508-1610703149508.png" style="width: 300px;" class="fr-fic fr-dib">If you have parts like box lids with tall, thin walls, they can be reinforced with gussets, as long as the relative wall thickness of the supporting material itself follows the 40 to 60 percent rule. This also eliminates the chance of shadowing, which occurs when one section of the part cools down faster than others.With a bit of luck this should leave you with some idea of how to keep your walls nice and uniform, which I’m sure is a great way to finish off the working week.Right that’s it for this week. I look forward to seeing you again next Friday.<hr>Watch other Protolabs Insight videos <a href="https://www.protolabs.co.uk/resources/insight/insight-video-library/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-library-0121" rel="noopener noreferrer" target="_blank">here</a>, or <a href="https://get.protolabs.co.uk/insight-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-insight-video-0919&utm_content=wevolver-insight-subscription-0121" rel="noopener noreferrer" target="_blank">subscribe here</a> to never miss an Insight.

Gain insight into the importance of ‘uniformity’, in terms of sinking, warping, and essentially non-functioning parts. 

20240119-Protolabs Insight: Plastic Injection Moulding - Improving Part Design with Uniform Wall Thickness

<h3>Medical applications for additive manufacturing</h3>Over the past few years, additive manufacturing - better known as 3D printing - has become established as a driver of innovation in a wide variety of industries. In addition to the many industrial applications - for example for the production of prototypes and spare parts - there are many benefits to using 3D printing for the medical sector. The applications of additive manufacturing since the beginning of their use in the medical field have been just as varied as the production possibilities and materials themselves. The fact that 3D printing is especially suitable for the production of prototypes or one-off individual parts made it possible to use it early on, in the field of implant production amongst other things. The benefits of additive manufacturing in the medical sector, the potential applications that are already commonplace and also the significance of 3D printing for medicine in the future will all be examined in more detail in this whitepaper.&nbsp;<h3>Additive manufacturing - production processes, benefits and materials</h3>To get an overview of the applications of additive manufacturing in medicine, it is first necessary to understand how the 3D printing process works. Basically, additive manufacturing differs from other manufacturing methods in that the particular material being worked on is not cast, such as in the manufacture of injection moulded parts, or cut from a larger block, as is the case for example with CNC machining. As the term "additive" suggests, in additive manufacturing material is applied layer by layer. Even if the individual additive methods differ in the precise process and the materials, the process of layered production of the workpiece is still the same. Unlike other manufacturing processes, with this method there is great freedom in terms of the design of parts and possible geometries. Since the early days and the initial hype about this new production process, 3D printing has seen a great deal of differentiation, so current manufacturing processes differ greatly. The most important manufacturing processes used in the manufacture of medical products today are direct metal laser sintering and stereolithography.Direct metal laser sintering (DMLS)DMLS is particularly suitable for printing parts made of metals and special alloys. In principle, the procedure for printing parts by DMLS hardly differs from the familiar methods of additive manufacturing. To print metals, support structures are required to dissipate the heat generated during the manufacturing process and to ensure the stability of the components. Without support structures there would also be a risk that new material would be simply wiped away during the printing process. In DMLS, the metal is in the form of a powder in a bath and is processed using a laser. The laser melts a cross sectional layer of the final workpiece, which means that the powder becomes a solid shape. In the next step, the baseplate on which this process takes place is lowered by a precise distance and a new layer of metal powder is distributed by the printer on the build platform. This process is repeated layer by layer until finally the finished component, such as an implant, emerges. After the component is completed, it is released from the support structures and the excess metal powder is post-processed depending on its application. A large number of metals are suitable for production using DMLS including titanium alloys, which are important for medicine - in particular the production of bone implants.StereolithographyStereolithography is comparable to other additive manufacturing methods. It is mainly used for the printing of polymers and plastics with complex geometries or very small structures that require a particular rigidity, impact resistance or durability. As with DMLS, this process uses a laser to do the actual printing. Unlike DMLS, however, the material is not in the form of powder in the working area, but in the form of a resin consisting of photopolymers and additives. An ultraviolet laser hardens this resin to a thermosetting plastic. Here, too, the construction platform is lowered at each work stage, ensuring that a new layer of the resin covers the component which is then hardened into the required shape by the laser. After the component has been produced layer by layer, the remnants of the resin are cleaned off in post processing and supporting structures are removed. After an additional treatment to harden off the materials, the component is then ready for its intended purpose. New material MicroFine Green, which can be printed using stereolithography, is ideal for use in medicine. Since it is possible to produce particularly fine, high-resolution structures, medical applications such as miniaturised catheters or minimally invasive tools are potential applications.&nbsp;<h2><a href="https://get.protolabs.co.uk/medical-white-paper/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-medical-hipo-0121&utm_content=3dp-medical-white-paper-0121" rel="noopener noreferrer" target="_blank">CONTINUE READING -&gt;</a></h2>

The new Protolabs whitepaper describes how additive manufacturing has established itself as a driver of innovation in medicine in recent years and what role 3D printing will play in the industry in the future.

Medical Applications for Additive Manufacturing

London based firm Entryphone has been designing, manufacturing and installing door entry systems since 1958. Now, over 60 years on, son Oliver Ashbee heads this family business. Oliver is passionate about using his decades of experience to develop innovative products that meet the demands of the 21st Century.Oliver’s latest concept is an entry phone for the smart phone generation. His aim is to create a product that is simple in functionality with an aesthetic that will appeal to architects and developers who are looking for something sleek and stylish for their high-end city-centre dwellings.Entryphone manufacture many of their own products, utilising a large warehouse at their premises in Wandsworth. However, the company called on <a href="https://www.protolabs.co.uk/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-case-study-0121&utm_content=entryphone-0121" rel="noopener noreferrer" target="_blank">Protolabs</a>’ expertise for support in producing the casing for the new entry phone. As Oliver explains:“The 516v has been a couple of years in the making. After initially getting in touch with Protolabs to produce the 3D printed prototype using their stereolithography (SLA) technology, I was keen to utilise Protolabs again to quickly ramp up production with tooling and moulding for the casing.<blockquote><blockquote>“Protolabs’ quoting system, where you can upload CAD models onto their website, really is brilliant. The interface is really easy to use and then it takes a good look at your design and gives you feedback for production. It’s an invaluable tool.” - Oliver Ashbee, Director, Entryphone</blockquote></blockquote>Oliver uploaded his CAD file to Protolabs’ online quoting platform and, whilst the part was manufacturable, the design for manufacture (DFM) analysis software identified a couple of areas where manufacturability improvements could be made.&nbsp;In response, Protolabs Application Engineer, Charlotte-Anne Smith arranged a call with Oliver and they discussed the advisories that had been flagged up. These included a thickness on one part of the geometry that may have resulted in sink marks as well as thin and zero draft areas. Once identified, Oliver was able to quickly address and eliminate these areas on the final CAD design and thus enhance the part’s mouldability.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610525794540-1610525794540.png" style="width: 300px;" class="fr-fic fr-dib">After going through the technical elements, Charlotte-Anne advised Oliver on <a href="https://www.protolabs.co.uk/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-case-study-0121&utm_content=entryphone-0121" rel="noopener noreferrer" target="_blank">injection moulding</a> tolerances that Protolabs work to. Oliver was clear from the start that he wanted an ABS white as his material, which just left the surface finish to choose. To assist with this, Charlotte-Anne arranged for a sample plaque of the different finishes that can be achieved on Protolabs’ stocked materials. Oliver subsequently chose SPI-A2, the highest polish finish.Protolabs’ quote included a gate and ejector layout. Charlotte-Anne and Oliver had a few discussions about the gate layout because of the high polish finish on the outside of the part. The original gate layout was located on the area of high polish finish, which would leave a gate scar Charlotte-Anne was able to compose a gating option in a different location that would not affect the cosmetic appearance of the part.“It was good working with Oliver as although his design was manufacturable from the outset, he had the flexibility to tweak and refine his design for the injection moulding process. It’s satisfying to have those conversations upfront with a client about the draft, the gate and the ejector layout, and see how the suggested changes are implemented into a design that makes for an even better part – one that the client is really happy with. It gives me great job satisfaction,” explained Application Engineer Charlotte-Anne Smith.A third and final iteration was uploaded and a simple, single cavity, standard open shut mould – with just a core and the cavity – was swiftly made. From this tool, Protolabs was able to rapidly produce a sample production batch of 50 cases. All this within just 15 days.<blockquote><blockquote>“The turnaround that Protolabs offers – on the quotation, the tooling and the moulding – is really appealing. Protolabs are great because not only can you get a sample or production run turned around quickly, you get their expertise and support as well. The DFM report comes back swiftly and the Application Engineers are excellent. Protolabs do this so much better than anyone else out there.”</blockquote></blockquote>“The speed of the tooling was pretty key to all this because when you’re ready to go, you’re ready to go,” explained Oliver. “We had challenges our end with the circuit boards and getting the audio right on this product, so once we nailed that, we just wanted to get going. We didn’t want to be sat around for weeks twiddling our thumbs, so getting samples back in 15 days is a wonderful thing. We are raring to go and keen to get this product out into the market place.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1610525831146-1610525831146.png" style="width: 300px;" class="fr-fic fr-dib">The finished 516v entry phone measures approximately 20cm tall and 8cm wide and will be wall mounted. The white ABS case produced by Protolabs supports a glass screen. When answering the door, a colour image of the person at the door can be seen and the user has 6 touchscreen icons to choose from, including unlock door, mute, switch views between cameras and to ring the porter for those living in apartments with a concierge service.&nbsp;<blockquote><blockquote>“I’m really pleased with the product and Protolabs have been great as far as I’m concerned. Their service has made my life easy, and that’s very important. I will certainly be using them again. Very few people do what they do as well as they do. They occupy that space in the market very well. When it comes to tool making, there are very few people that are very good at it, but they make it easy.”</blockquote></blockquote>Oliver will be soft launching the new 516v entry phone soon, with a full production run from Protolabs in the new year. And always looking to innovate, he’s already working on a new product that will be revealed next year. &nbsp;&nbsp;About EntryphoneEntryphone is a family business formed in the late 1950s as a designer, manufacturer and installer of door entry systems. The last 60 years has seen a great deal of innovation in this area and Entryphone has been at the forefront of this advancement.

Entryphone have developed an entry phone product that perfectly meets the demands of the 21st century. Keen to get their exciting new product to market as quickly as possible, Protolabs' high-speed low-volume production model provided the support needed.

Protolabs supports the development of an entry phone for the smart phone generation

Even a perfectly designed injection-moulded part can fail if manufactured from the wrong material, and with literally <a data-udi="umb://document/4d9db293978f46109e63376d0b1adcad" href="https://www.protolabs.co.uk/materials/comparison-guide/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-comparison-guide-link-0121" rel="noopener noreferrer" target="_blank" title="Comparison Guide">hundreds of thermoplastics and elastomers</a> to choose from, it’s often difficult to know which ones will meet the application’s requirements. This is why a host of factors such as mechanical strength, chemical and ultraviolet light resistance, lubricity, wear resistance, and more must be carefully considered when selecting materials for injection moulding. &nbsp;This situation becomes even more challenging with overmoulded parts, where designers must not only adhere more closely to established moulding principles, but also make certain that the chemical and physical bonds between their chosen materials are both strong and permanent. This tip discusses three key areas—material compatibility, adhesion, and tribology—that designers should be knowledgeable about when designing moulded parts.<h3>Friction and Wear</h3>Let’s start with a term not often heard on the manufacturing floor. Tribology is the study of friction and wear that occurs between two surfaces moving relative to one another. It concerns the interaction between the interlocking clips and tabs of a snap-fit container, for example. An engineer looking at the tribology of parts would probably care less about the chemical and mechanical bonds needed to overmould a handle for a power tool (because they don’t slide against one another, assuming the design is sound), and more about the feel and grippability of the overmoulding material itself. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA5OTIwMzYyNzQwLW1vbGRlZC1wbGFzdGljLWdlYXJzLWlsbHVzdHJhdGlvbi1vZi1mcmljdGlvbi1hbmQtd2Vhci01NzB4MzA4LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=">These plastic gears moving together show how a part design can be influenced by the friction and wear that occurs between surfaces interacting with one another, an important element to consider when selecting materials for your moulded parts.&nbsp;In the snap fit clip example, a wear-resistant polymer such as HDPE might be a good choice, although a relatively lubricious material like acetal could also be a candidate. Both materials have their own unique virtues that should be carefully weighed early in the development process. Yet the product design itself can also play a huge tribological factor. Surfaces that interact with one another should be smooth, lest the miniature peaks and valleys found on rougher surfaces catch and break away with repeated use.The method used to manufacture the part also plays a role. In the clip example, which can easily extend to any number of plastic parts with mating or interlocking surfaces, a machined finish is different than a 3D-printed one, as is an injection-moulded surface (and is likely to be smoother than either). The message here is that these and other part characteristics should be carefully analysed and tested before traveling too far down the design road when part interaction is a design concern.Here’s another example. Metal inserts are a popular option at Protolabs. Whether you need a bronze bushing in an injection-moulded fan blade, a stainless steel sleeve in a plastic pulley, or a threaded brass nut in an equipment knob, placing these and other inserts in injection-moulded parts is no big deal. There’s little concern over material compatibility, and the biggest obstacle the designer will face is making sure that a good mechanical bond is created when the plastic is injected over and around the insert. That said, bronze and brass make for good, low-cost bearing surfaces, but are more prone to wear than an actual ball-bearing. Ask yourself this: Does your design meet the product’s long-term requirements? A good understanding of tribology will help resolve this and other important questions.<h3>Material Compatibility</h3>Few would argue that overmoulding is one of the coolest things to happen to plastic parts since quick-turn injection moulds. It’s a great option anywhere a soft or user-friendly material is needed atop a structural core—an instrument handle, perhaps, or handheld electronics housing—or where multiple colours are desired for aesthetic reasons. There’s plenty of information online about <a data-udi="umb://document/e81ee81b340348ceafdcaf74cdeec327" href="https://www.protolabs.co.uk/resources/design-tips/designing-for-overmoulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-overmoulding-dt-link-0121" rel="noopener noreferrer" target="_blank" title="Designing for Overmoulding">designing for the overmolding process</a>, discussing the need for a sound mechanical bond as well as chemical compatibility between the two adjoining materials.The good news is that a host of chemically compatible materials are available. For instance, Protolabs offers TPV Sarlink 3170 a thermoplastic elastomer that forms a strong chemical bond with polypropylene. There’s TPC Hytrel 4068 a thermoplastic elastomer that mates up just fine with ABS, polycarbonate, and more. Nylon, on the other hand, is among the more difficult substrates for overmolding due to its moisture-absorbing tendencies, though it remains a popular material across a range of applications. <img data-fr-image-pasted="true" src="https://www.protolabs.co.uk/media/1014954/chemical-adhesion-illustration-on-overmolded-parts-570x308.jpg?anchor=center&amp;mode=crop&amp;width=570&amp;height=308&amp;rnd=131780237290000000" alt="chemical adhesion illustration on overmolded parts 570x308" style="width: 300px;">Chemical adhesion of overmolded parts is tricky. The transition between substrate and overlay should be abrupt to avoid feathering/thinning. Use a groove or shoulder to create a cutoff point. Curling and tear points can be eliminated by placing the shutoff in a location that creates a hard stop for soft, flowable TPE. Figure at left shows the substrate in gray and the TPE and potential curling in blue. At right, substrate is gray and TPE is yellow, with the shutoff shown stopping the TPE. <h3>Adhesion</h3>There’s more to it than that, however. Part design can have a significant effect on the adhesion level of overmoulded parts. The transition between substrate and overlay should be abrupt to avoid feathering or thinning—consider using a groove or shoulder to create a clear cut off point. Curling and potential tear points can be eliminated by <a data-udi="umb://document/4375432824d145b0a6c2cae570e12da4" href="https://www.protolabs.co.uk/resources/design-tips/incorporating-shut-offs-in-injection-moulding-design/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-shutoffs-dt-link-0121" rel="noopener noreferrer" target="_blank" title="Incorporating Shut-offs in Injection Moulding Design">placing the shutoff</a> in a location that creates a hard stop for soft, squishy, and very flowable TPE. Use too thin of an overlay—say anything less than 1/16-inch thick—and the material may cool too quickly for proper adhesion. Long length-to-thickness ratios can cause similar problems.Also, be aware of the two materials’ unique thermal characteristics when overmoulding. You might select <a data-udi="umb://document/ac1f833b7ac644b4909bec4957ab4507" href="https://www.protolabs.co.uk/services/injection-moulding/liquid-silicone-rubber/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-service-lsr-link-0121" rel="noopener noreferrer" target="_blank" title="Liquid Silicone Rubber">liquid silicone rubber</a> (LSR) for its excellent heat and chemical resistance, low-temperature flexibility, and inherent lubricity, but keep in mind that LSR cures at 150 to 200 degrees centigrade, a temperature too high for ABS, polyethylene, polypropylene, and a number of other thermoplastics to survive. Venting is also important, as burning, insufficient adhesion, and incomplete cavity filling—short shots—can occur in an improperly vented mould.It’s easy enough to check the <a data-udi="umb://document/d4d023b2d18d4d4e821bf00d0d6f17b0" href="https://www.protolabs.co.uk/services/injection-moulding/overmoulding-and-insert-moulding/design-guidelines/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0121&utm_content=material-science-overmoulding-insertmoulding-design-guidelines-link-0121" rel="noopener noreferrer" target="_blank" title="Design Guidelines: Overmoulding & Insert Moulding">compatibility chart</a> online, but if you prefer to supply your own material, it might be best to check with your plastics supplier for moulding and application advice. This is especially true if you’re using a custom polymer mix, which an increasing number of Protolabs’ customers do. Be aware that colourants can create adhesion problems, as can high amounts of additives such as metal and glass. Our advice is to always run a few sample parts and test thoroughly before pulling the trigger on higher volumes.&nbsp;<h3>Adhere to Design Guidelines</h3>The list of examples is long, the possible polymer combinations nearly endless. That’s why it’s important to check with someone knowledgeable on the vagaries of polymer adhesion and chemical compatibility early in the design process, to verify that A) your chosen materials will play nice together, B) the part or overmoulded assembly is moldable given your current design, and C) that the materials are tribologically sound—that is, they are slippery enough, wear-resistant enough, or sticky enough for the product’s purposes.This is one time when sticking to Protolabs’ guidelines is especially important. Using a plastic that’s high in additives might help you achieve your product requirements, but it might also mean spending more time on the product design; the “sweet spot” of mouldability becomes smaller and smaller as plastic additives increase, and only gets more challenging with high complexity parts.Scared? Don’t be. All of these situations are quite manageable, it just takes a little more attention during the design process and possibly a second look at your material selection. And when in doubt, give Protolabs a call, even if you’re just kicking the tires at this point. Between our knowledgeable staff, automated quoting process, and free <a data-udi="umb://document/430a06346a804eb892f3bb24e7b74bd0" href="https://tryit.protolabs.com/samplequote/moulding-uk/?lang=en-GB" rel="noopener noreferrer" target="_blank" title="Injection Moulding Sample Quote">mouldability analysis</a>, even the most chemically challenging materials are easy to master.As always, if you have questions or concerns, feel free to contact one of Protolabs’ applications engineers at +44 (0) 1952 683047 or <a href="mailto:customerservice@protolabs.co.uk" target="_blank">customerservice@protolabs.co.uk</a> to discuss options.

The role that material compatibility, adhesion, friction, and wear play in design of moulded parts

Why Material Science is Key to Part Interaction

Israeli researchers create the first 3D printed heart. Source: Israel 21

In the near future, 3D bioprinting will allow medical professionals to engineer and 3D print patient-specific organs for organ transplants in a few hours.

3D Bioprinting Gives Researchers the Power To Create Artificial Organs

The Relativity Space Offices - a manufacturer of 3D printed launch rockets. Source: Relativity Space   

There is a small 3D printing revolution happening within astronautics and aeronautics.

Additive Manufacturing Is Slowly Disrupting Aerospace Engineering

Our Insight podcast series is aimed to help you design better parts for digital manufacturing.We will regularly share with you podcasts packed with useful tips that will hopefully save you time and money, from Q&amp;A sessions to design tips.<a href="https://get.protolabs.co.uk/insight-podcast-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-insight-podcast-subscription-1220" rel="noopener noreferrer" target="_blank">Never miss an Insight Podcast by subscribing here</a>.The above Insight Podcast is CPD accredited, once you have viewed the video simply <a href="https://get.protolabs.co.uk/insight/cpd/choosing-a-manufacturing-source/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-choosing-a-manufacturing-source-1220" rel="noopener noreferrer" target="_blank">answer a few questions to gain your CPD certificate</a>.&nbsp;Topics covered in this episode are:<ul><li>Choosing a 3D CAD program for moulding design</li><li>Mastering ProtoQuote to create better parts</li><li>Proper resin flow</li><li>Application Engineers</li><li>Selecting the right plastic for your parts</li></ul><hr><a href="https://get.protolabs.co.uk/insight/cpd/choosing-a-manufacturing-source/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-choosing-a-manufacturing-source-1220" rel="noopener noreferrer" target="_blank">Download your CPD certificate here</a>

Gain Insight into how to design better parts and receive a CPD certificate.

Design Essentials Podcast: Design to Prototype

Our Insight video series will help you master digital manufacturing.Every Friday we’ll post a new video – each one giving you a deeper Insight into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.<a href="https://get.protolabs.co.uk/insight-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-insight-subscription-1220" rel="noopener noreferrer" target="_blank">Never miss an Insight by subscribing here</a>.The following Insight video is CPD accredited, once you have viewed this video <a href="https://get.protolabs.co.uk/insight/cpd/choosing-a-manufacturing-source/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-choosing-manufacturing-source-1220" rel="noopener noreferrer" target="_blank">answer a few questions to gain your CPD certificate</a>.<h3>Insight: Choosing a Manufacturing Source</h3>TranscriptHi, it’s Friday, which means it’s time for another Insight video.We have a particularly interesting topic on the cards this week, or at least I think it is. That’s because today we’re going to be having a quick chat about how to choose the right manufacturing source.This can be one of the most important decisions you make on a project, and can easily make the difference between glowing success and not-so-glowing failure. You’ll need to be certain the option you pick fits your needs exactly, whether you want someone to handle your project as a one-off or plan to develop a long-term production relationship with them.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1607329368724-WB-1.png" style="width: 300px;" class="fr-fic fr-dib">Just to be up-front, we don’t think there’s an objectively best option to choose every single time. Rather, they all come with their own strengths and weaknesses, some of which will suit certain projects and products better than others.For that reason we’re going to run through a handful of the most common options out there, and point out a few pros and cons to each.First up is a service broker. The idea is that they’ll meet with you, find out what you need and match you up with an appropriate manufacturer with minimal work on your end.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1607329497366-WB-2.png" style="width: 300px;" class="fr-fic fr-dib">The big pro here is that brokers use a bidding process to see who gets the job, and this can sometimes generate savings as manufacturers compete for your business. This is great; reduced costs are always welcome.Cons? Consistency can be a problem, as the different orders you place through them can end up being handled by different shops across the country. There’s also a real risk that things don’t go as fast as you would like, partially because you need to leave time for the broker to gather bids, and partially because the capacity of their suppliers might be a bit variable. You’re leaving a lot on trust, here.If that’s an issue you might want to go the complete opposite direction and get in touch with an independent machine shop.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1607329556377-WB-3.png" style="width: 300px;" class="fr-fic fr-dib">These types of supplier are usually quite small and highly specialised. If you have a fairly conventional project planned out this isn’t a huge benefit, but if you’re going to work with a difficult or unusual material, finding the right shop with the right expertise can be a godsend. Another pro is that if they have the spare capacity, small shops can have great turnaround time.Of course, one of the cons of working with such a small business can be limited capacity if other clients are calling too. Shops with an industry specialism, or those working with unusual materials, can also be more expensive due to the high-end machines required.Continuing along the theme of contracts, we have high-volume production houses.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1607329656692-WB-4.png" style="width: 300px;" class="fr-fic fr-dib">These tend to focus on injection moulding and CNC machining, and keep unit prices down by manufacturing thousands or millions of parts. They excel at saving seconds and pennies through high-speed repetition, but upfront engineering expenses can be high.In the pros column, we have the fact that – despite what you might initially think – the quality control tends to be very good. Response times are also good, as are the costs.Of course, those last two points come with the caveat “for high-volume orders.”If you need small quantities of parts, these suppliers are going to struggle to be competitive, and prototyping probably isn’t going to be cost effective. You can also face some upfront delays if the supplier has to source equipment to produce your part.Next on our list is in-house production. That is to say, doing it yourself.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1607329720662-WB-5.png" style="width: 300px;" class="fr-fic fr-dib">This option offers great convenience, great quality control and favourable cost structures.However, you’re going to require a decent amount of capital investment, somewhere to store materials and skilled staff to operate the machines. On top of this you can run into long lead times, as in-house shops often operate at capacity, and you may find that you still need to outsource during periods of high demand.Speaking of, we finally turn to on-demand manufacturing services.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1607329811107-WB-6.png" style="width: 300px;" class="fr-fic fr-dib">These usually offer a wide range of different technologies, such as injection moulding, CNC machining and 3D printing. You can also expect benefits like automated online quoting and design-for-manufacturability analysis.Among the big pros are consistent quality control and great turnaround speed – we can be talking as little as a single day in some cases. You also get a wide range of services and plenty of flexibility, which isn’t to be undervalued.In the cons column we have some questions over capacity for smaller services, as well as some higher initial set-up costs.Right, that was a lot of information right there, but hopefully it cleared up some questions. Or, at the very least, gave you an idea of which questions you should be asking.Until next time.<hr><h3>&nbsp;<a href="https://get.protolabs.co.uk/insight/cpd/choosing-a-manufacturing-source/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-choosing-manufacturing-source-1220" rel="noopener noreferrer" target="_blank">Download your CPD certificate here</a></h3>

20240119-Choosing a Manufacturing Source

Our Insight video series will help you master digital manufacturing.Every Friday we&rsquo;ll post a new video &ndash; each one giving you a deeper Insight into how to design better parts. We&rsquo;ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.<a href="https://get.protolabs.co.uk/insight-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-insight-subscription-1120" rel="noopener noreferrer" target="_blank">Never miss an Insight by subscribing here</a>.The following Insight video is CPD accredited, once you have viewed this video <a href="https://get.protolabs.co.uk/insight/cpd/bridging-the-gap-between-prototyping-and-production/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-bridging-the-gap-1120" rel="noopener noreferrer" target="_blank">answer a few questions to gain your CPD certificate</a>.<hr><h3>Insight: Bridging The Gap Between Prototyping And Production</h3>TranscriptHello and welcome to Proto labs&#39; Insight video series.&nbsp;What are these Insight videos about? Well, we want to help you design better parts for digital manufacturing. This is the first in a series of videos packed with useful tips that will help save you time and money.We are going to post a new video every Friday lunchtime. Folks, if you are leaving to start your weekend early then don&rsquo;t worry &ndash; you can catch up, because the videos are going to be hosted right here.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA2NDg3NDk2Njc1LXNjcmVlbnNob3QtMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 331px;" class="fr-fic fr-dib">So let&rsquo;s get into the first topic.We are going to talk about how bridge tooling can get your new product to market weeks earlier than conventional tooling. &nbsp;Not only that, but it allows you to test your product in real life with real customers and quickly refine it at minimal cost.Just like software developers you can quickly and cost effectively tweak a product in response to thousands of customers&rsquo; feedback. &nbsp;Never mind focus groups and VOC, how does it perform in real life?&nbsp;I hope you agree that that&rsquo;s a powerful weapon to add to your armoury.But let&rsquo;s step back and explore how you can make this a reality.Let&rsquo;s go right back to the beginning. Product development often begins with that lightbulb moment, you may hastily sketch out your idea on whatever is handy before you forget.You can&rsquo;t wait to get in front of your CAD to design it properly and talk it through with your colleagues.After what seems an age you are ready to prototype it and get focus groups together to get voice of customer feedback.You are burning to get this product into the market before the competition. You feel each delay because you know that this could be the next big thing in your market.What happens after this successful prototyping and perhaps one or two design tweaks?You have to wait weeks or even months for the steel moulds to come back before you can start <a data-udi="umb://document/21c8e01f681a499ea96b5f08d5930ed7" href="https://www.protolabs.co.uk/services/injection-moulding/plastic-injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-bridging-the-gap-1120" rel="noopener noreferrer" target="_blank" title="Plastic Injection Moulding">injection moulding</a> and production.In the meantime, one of your design team, let&rsquo;s call him Jim, has just left your company and joined your major competitor. Now the pressure is really on.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA2NDg3NTMzMzI3LXNjcmVlbnNob3QtMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">How do you cut back on this lead time, to make sure that you are first to market?I suppose you could have development and manufacturing running in parallel and start the production moulds early. &nbsp;But what happens if customer feedback results in changes to your design? &nbsp;You might have to start the tool design again costing you even more money and delaying the process anyway.It&rsquo;s a tough choice, because today&rsquo;s market rewards speed.The answer is staring you in the face.You already know that rapid injection moulding for prototyping will reduce cost and delay in the design of plastic parts. &nbsp;If moulds are milled from aluminium and not steel, then the process is quicker and cheaper.Why not extend this process and bridge this gap between development and manufacturing?True, rapid injection moulding is not identical to traditional production tooling, but it is close enough to solve a number of your problems. It will reduce your time to market until your steel moulds arrive weeks or months later.Let&rsquo;s run through the benefits.First. As I have said it reduces your time to market from weeks or even months to days.Second. It confirms that the part can actually be moulded.Third. While it is true that production tooling can incorporate capabilities that rapid injection moulding can&rsquo;t, such as internal cooling lines or sophisticated venting, you might actually find that this is a benefit.&nbsp;Let me explain. By adapting a part to the demands of rapid injection moulding through equalising wall thicknesses and maintaining draft, you can simplify and speed up the manufacture of your production moulds. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjA2NDg3NTU4MzgxLXNjcmVlbnNob3QtMy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">In other words, rapid injection moulding doesn&rsquo;t just prototype your parts. &nbsp;It also prototypes the production method that will produce those parts. You can highlight potential issues in advance and eliminate them.Wow. &nbsp;Why wouldn&rsquo;t you do this? It gives you an edge over the competition.And another thing. &nbsp;You can test that new product with thousands of customers in the market before you invest in expensive steel production tooling.We are talking about more than 10,000 parts or products in the market in just days.Does it need tweaking? &nbsp;Not a problem, your supplier should be able to redesign your aluminium tooling in just a few days.Not only are you in the market in just days, rather than weeks or months, but when you are 100 percent ready to commit to production tooling, you can be sure that your product is spot on.The customer expects new products quickly. &nbsp;If you are too slow, you will be left behind. For your next product development think what bridge tooling could do to your lead times.Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/protolabs-insight-customisation" rel="noopener noreferrer" target="_blank">Protolabs Insight: Customisation</a>Well that&rsquo;s it for this week. I hope you found this video helpful.<hr><h3>&nbsp;<a href="https://get.protolabs.co.uk/insight/cpd/bridging-the-gap-between-prototyping-and-production/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-cpd-1120&utm_content=wevolver-cpd-bridging-the-gap-1120" rel="noopener noreferrer" target="_blank">Download your CPD certificate here</a></h3>

20240119-Bridging The Gap Between Prototyping And Production

Small manufacturers play a critical role in keeping the world’s supply chain moving, yet adoption of Industrial IoT solutions by the group is lagging. What can be done?Industrial IoT is already bringing huge benefits to multinational manufacturers who have made the investment. But how can small-and-medium sized enterprises (SMEs) with fewer resources start to benefit?<h2>IoT adoption rate lags in small businesses</h2>If you look at any of the surveys done on Industrial IoT adoption, they all tell a similar story. Deployment of operational IoT solutions in large companies is around 20%, and in some industries as high as 80%. But in small to medium enterprises (SMEs), adoption is closer to 10% with low levels of general awareness reported.In 2016, 94% of US manufactured exports came from SMEs at an export value of approximately USD $180 billion. 98% of US-based manufacturing firms have less than 500 employees, while three-in-four employ less than 20.This matters, because the health of some of the world’s biggest manufacturing companies depends on the health of this complex network of SME suppliers. While an aircraft manufacturer may implement the latest IoT technology throughout its assembly plant, they are still reliant on many smaller suppliers across the world.Unplanned downtime can cripple a small manufacturer who may not have adequate backup equipment or spare capacity to make up for the loss of production. In industries that embrace a lean approach to manufacturing, such failures can quickly propagate throughout the supply chain.Given the cost pressures faced by many SME’s, Industrial IoT solutions with a proven ROI should be an easy sell. So why aren’t they?<h2>A lack of resources to focus on IoT</h2>Building up Industrial IoT expertise in a small company from scratch is at best an extremely difficult task. SMEs don’t possess the same financial or human resource options as multinationals. With little background in the connected world, such SMEs don’t know what they don’t know.With this in mind, there is a risk of a growing divide opening up between the haves and the have-nots when it comes to Industrial IoT.<h2>The problem with solution providers</h2>Some full service providers market themselves toward the SME market. And the benefits are compelling: Access to expertise, ready-to-use solutions and so on. But there are significant downsides, in particular the high cost of convenience.Full service providers are not necessarily independent. SMEs run the risk of unwittingly tying themselves into a system or platform that may not last the course.A quick web search is all you need to see the rapid rise of solution providers peddling IoT solutions to smaller enterprises. But many of these are merely simple web shops, with little or no expertise behind them.This compounds the problem. Even an SME with basic knowledge of IoT doesn’t have the time or skills to distinguish the good from the not-so-good. For someone without IoT knowledge, the task quickly becomes impossible.<h2>Are company builders the solution?</h2>Outsourcing Industrial IoT development to a specialist ‘company builder’ is an intriguing new alternative. The concept involves a collaborative approach to innovation and value creation. Both the risks and the benefits are shared between the existing company and a group of entrepreneurs.The person (or more likely, team) has the core competencies required, including:<ul><li>Overview of current technology standards and trends</li><li>Overview of current methodologies</li><li>Knowledge of current implementation best practices</li><li>Overview of current products, and those in the pipeline</li><li>Experience with entrepreneurship and launching new ventures</li><li>Marketing and sales expertise from other projects</li></ul>That said, the company builder should also have knowledge of the unique challenges of SMEs and preferably the specific market.<h2>Tackling the big problems of small business</h2>There’s a real need for Industrial IoT solution providers that work for SMEs. The market potential is there. While the revenues are likely to be lower, SME’s tend to operate on a much leaner model. This means quicker decision-making, faster time to deployment, and improved cash flow.Industrial IoT solutions need to be made easier to understand and easier to access for SMEs because of their crucial role in the world’s supply chain.What such companies need most are monitoring systems that can identify issues early, and/or cost-cutting systems such as a smart lighting system. This can become the backbone for a mesh network that eases their path to a more connected facility in the future.While large multinationals can afford the big consulting companies, they are not feasible for the typical SME. A consultant, solution provider or company builder that can offer these kind of services with a business model that works for small business could see massive returns.&nbsp;<hr>This article was first published on Nordic's&nbsp;<a href="https://blog.nordicsemi.com/getconnected" rel="nofollow" target="_blank"></a><a href="https://blog.nordicsemi.com/getconnected?utm_campaign=2021%20wevolver" rel="noopener noreferrer" target="_blank">Get Connected Blog</a>.

Small manufacturers play a critical role in keeping the world’s supply chain moving, yet adoption of Industrial IoT solutions by the group is lagging. What can be done?

How SMEs Can Get Started With Industrial IoT

<section><h2>The Business</h2>Alicat Scientific is a pioneer in the manufacturing of mass flow meters, mass flow controllers, and pressure controllers, for gases and liquids. Alicat is part of Halma, a global group of life-saving technology companies.<h2>Task</h2>Tending a Takisawa LA 250 YS Lathe<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1606321122678-shutterstock-video.jpg" style="width: 788px;" class="fr-fic fr-dib"><h2>The Challenge</h2>Alicat Scientific sought an automation solution that would allow them to meet their steadily growing demand. Despite increasing their workforce, they’d hit a wall in overall throughput. With cycle times exceeding 45 minutes, machining components on their lathe had become a chokepoint for the rest of their operations. In order to meet demand, they needed to be able to run overnight, when skilled labor is most difficult to come by.Although they were already looking to automate, COVID-19 related demand increased the urgency at which they needed a solution in production. They couldn’t afford to wait for weeks or months to get a solution designed. And they also couldn’t risk implementing a solution they would be unable to manage in-house and risk downtime. Alicat also needed a solution that could be implemented rapidly by their own people to limit exposure.</section><section><blockquote>From unboxing to training and setup, this was one of the easiest operations I’ve ever experienced in the world of machining. More than that, our machinists actually found it fun!</blockquote></section><section><blockquote>Greg Camron, Machine Shop ManagerAlicat Scientific</blockquote></section><section>The SolutionAfter extensive research into the available options, including industrial and collaborative robot manufacturers and custom integrators, Alicat Scientific selected a Forge-powered automation solution from READY. Rapid deployment and ease-of-use were critical decision factors for them. It was also important that their chosen solution was one that they could maintain and troubleshoot themselves - in order to minimize downtime and dependency on third-parties.The solution consists of a complete hardware package, including robot arm, shipped to Alicat in a crate. What differentiates the READY solution is that everything from the robot arm to the pneumatics is controlled by Forge/OS and programmed with READY’s Task Canvas visual programming application. Alicat got an automation solution they could quickly program and easily maintain with their existing team. Although their machinists hadn't previously programmed an industrial robot, they were able to program their lathe automation task without so much as a training class. In addition, they were able to uncrate and fully deploy their automation task in just three days - with no outside support.</section><section><blockquote>This (automation bundle from READY) solved a critical chokepoint in our ventilator component manufacturing, allowing us to meet COVID-19-related demand that would have been impossible before.</blockquote></section><section><blockquote>Greg Camron, Machine Shop ManagerAlicat Scientific</blockquote></section><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1606321341018-alicat-2-image-collage.png" style="width: 788px;" class="fr-fic fr-dib"><h2>The Results</h2>Alicat Scientific received, trained, programmed, deployed, and achieved full ROI in 30 days. Within 8 hours they were comfortable programming automation with Task Canvas. Within three days they had their lathe fully automated. After 10 days they were running lights out. Within 30 days their READY automated solution had already paid for itself.Automating with READY allowed Alicat to boost output by 74% by adding a “lights out” third shift on weekdays, and another two “lights out” shifts on the weekend. This solution allowed them to achieve constant production on a critical production task. Without automation, machining bobbins for ventilators would have been the bottleneck in their operation, but automating with READY enabled them to expand throughput. Automation enabled them to aggressively scale up production in support of the COVID-19 response.<h2>Highlights</h2>74% boost in output - on a task that would have been a chokepoint<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1606321204012-1606321204012.png" style="width: 788px;" class="fr-fic fr-dib"><blockquote>This solution has performed beyond our expectations. From programming it ourselves in three days, to running lights out in 10 days, to paying for itself in the first month - we couldn’t be more pumped. We’re looking for the next task to automate!</blockquote><blockquote>Greg Camron, Machine Shop ManagerAlicat Scientific&nbsp;</blockquote>

The fastest flow controller manufacturer in the world doubles production to support skyrocketing COVID-19 ventilator demand for mass flow meters, mass flow controllers, and pressure controllers.

digital manufacturing

Latest Posts