Prototype Smarter – transitioning to production faster and more effectively
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Early prototyping using 3D printing and CNC machining can increase your speed to market. Learn about key design considerations and benefits of using both processes as well as injection molding during early prototyping stages. Taking prototyping one step further, we will discuss how using low-volume injection molding for engineering-grade parts can help bridge you into large-scale production. You will learn valuable design considerations that are often overlooked in early product development that concern draft, wall thickness, coring, material selection and rib design.
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Prototype Smarter – transitioning to production faster and more effectively
- 2. q This webinar will be available afterwards at www.designworldonline.com & email q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar Before We Start
- 3. Meet your Speakers MODERATOR FEATURED SPEAKER Tony Holtz Technical Specialist Proto Labs Leslie Langnau Managing Editor Design World
- 4. Prototype Smarter Transitioning to production faster and more effectively Tony Holtz | Technical Specialist, Proto Labs
- 5. #DWwebinar
- 6. #DWwebinar § What are you making? § What is its function? § What will be the material? § How many will you need? § What is your expected price? Second First § How do you want the parts manufactured?
- 7. #DWwebinar
- 8. #DWwebinar 3D CAD Form + Fit Testing Functional Testing Low Volume High Volume Design for Production CAD allows us to design with production in mind 3D Printing CNC Machining Injection Molding
- 9. #DWwebinar 3D Printing: Desktop vs. Industrial § Desktop § Hobbyists or concept of design § Fast and easy to use § Poor surface finishes and small build frame § Responsible for maintenance, scheduling and limited material § Industrial § Applications range from prototypes to production parts § Engineering-grade materials available § Thermoplastics, rubbers and metals § High and micro-resolution possible § Good surface finish; multi-colored and secondary finishing available § Service bureau maintains maintenance, scheduling and material to avoid downtime
- 10. #DWwebinar Direct Metal Laser Sintering (DMLS)
- 11. #DWwebinar Design Considerations for DMLS § Support structures § Overhangs § Self-supporting angles § Bridges § Internal stress and warpage § Channels and holes § Internal features
- 12. #DWwebinar § DMLS parts require supports to connect part to platform and hold features in place § Supports prevent part from warping during rapid melting and cooling process Support Requirements Photo courtesy of Concept Laser.
- 13. #DWwebinar Support Removal DESIGN TIP: Design parts that require minimal supports — this also improves part quality § Support Removal: machining, EDM, grinding and sawing Photo courtesy of Concept Laser.
- 14. #DWwebinar § Design large, flat, down-facing surfaces § Work with manufacturer for proper part orientation § If orientation is locked, create features that are “self-supporting” § Reduce hole diameters or create diamond- or tear drop-shaped channels instead of round § Minimize the amount of overhang — use proper angles or decrease the gap between features Minimizing Supports
- 15. #DWwebinar § Unlike other additive processes, DMLS has a small allowance for unsupported overhangs (0.020 in./ 0.5mm) § If left unsupported, large overhangs may lead to build crash or deterioration of part detail Overhangs
- 16. #DWwebinar CAD 50 degrees 45 degrees 40 degrees 35 degrees 30 degrees 25 degrees 20 degrees Self-Supporting Angles
- 17. #DWwebinar § A bridge is any flat down-facing surface that is supported by 2 or more features Bridges § Minimum allowable unsupported bridge distance is small (~0.080 in./2mm)
- 18. #DWwebinar § Changes in cross-sectional areas can lead to warpage between features Internal Stress and Warpage DESIGN TIP: Use solid connections between sharp changes in cross-sectional area, and then remove with secondary operations
- 19. #DWwebinar § Channels and holes are self-supporting features § Great for conformal cooling applications Channels and Holes
- 20. #DWwebinar Channels and Holes § As the hole diameter increases, the overhangs increase near the closing of the hole § Unsupported holes larger than 0.31 in. (8mm) diameter will suffer downfacing distortion or curl, potentially creating other build issues DESIGN TIP: Use diamond or tear drop shapes for larger diameter channels Hole diameters in mm 15 12 10 8 6 5 4 3 2 1 15mm (0.6 in.) 12mm (0.47 in.)
- 21. #DWwebinar § A huge benefit of DMLS is the ability to create complex internal features § Channels, overhangs, self supporting angles and bridge dimensions must all be taken into consideration when designing areas that may be hard to access § If an internal feature requires supports but allows no access, the supports remain inside, and the geometry may not function as intended § Accessibility for powder removal should also be taken into consideration DESIGN TIP: Lattice structures can be used internally to reduce weight and provide support Internal Features
- 23. #DWwebinar Design Considerations for SL § Horizontal holes § Overhang supports § Sharp points § Build orientation § Support structures § Holes § Microfluidics § Replacing metal with metal-plated SL
- 24. #DWwebinar Holes: § Ø 0.020 in. Normal Res § Ø 0.015 in. High Res § Ø 0.008 in. Micro Res Channels: § 0.025 in. for High Res § 0.013 in. for Micro Res Small Gaps: (negative spaces) § <0.025 in. can seal shut and should be reviewed Feature Recognition
- 27. #DWwebinar Sharp Points Normal Resolution High Resolution
- 28. #DWwebinar Build Orientation X-Direction (on its edge) Y-Direction (flat) Z-Direction (upright)
- 30. #DWwebinar Hollow Parts Hollow Model Section View Drain Hole Vent
- 31. #DWwebinar Microfluidics Sidewall surfaces will be moderately clear, but will have distortion from the layer lines. These surfaces are slightly more clear than downfacing, non-substrative surfaces. Typically upfacing surfaces will be the most clear Downfacing surfaces that are not in contact with the substrate will be moderately cloudy due to the overcure on downfacing surfaces. If built on a substrate, surfaces flush to the substrate will be comparably clear to upfacing.
- 32. #DWwebinar Stereolithography Compared to Injection-Molded PC Accura 5530 Accura 60 Somos NanoTool PC (Molded) Hardness, Shore D 88 86 94 118-120 (R-Scale) Heat Deflection 338-482° F 127° F 185-437° F 250-280° F Tensile Strength 47-61 MPa 58-68 MPa 66-80 MPa 50-72 MPa Flexural Strength 96-108 MPa 87-101 MPa 103-149 MPa 82-93 MPa Stereolithography Compared to Injection-Molded PP Accura Xtreme White Somos 9120 PP (Molded) Hardness, Shore D 78-80 80-82 80-100 (R-Scale) Heat Deflection 117° F 126 - 142°F 124-203° F Tensile Strength 45-50 MPa 30 - 32 MPa 27-40 MPa Flexural Strength 75-79 MPa 44-46 MPa 41 MPa Stereolithography Compared to Injection-Molded ABS RenShape 7820 MicroFine Green Somos Watershed ABS (Molded) Hardness, Shore D 87 85 -- 109 (R-Scale) Heat Deflection 122° F 138° F 115-130°F 185-215° F Tensile Strength 39-51 MPa 45 MPa 47-54 MPa 32-42 MPa Flexural Strength 62-80 MPa 74 MPa 63-74 MPa 60-72 MPa Know the Material Properties
- 33. #DWwebinar Replacing Metal with SLArmor Stereolithography compared to Die-cast Aluminum SLArmor Die-cast Aluminum10% metal volume 20% metal volume 30% metal volume Heat Deflection 122-516° F >500° F Tensile Strength 100 MPa 145 MPa 200 MPa 300 MPa Elongation at Break 0.9% 1.04% 1% 2-5% Mod. Of Elasticity 21,000 MPa 31,000 MPa 42,000 MPa 70,000 MPa
- 34. #DWwebinar CNC Machining § Processes for CNC machining include milling, turning, routing, and lasers and plasma cutting § Wider range of materials versus 3D printing § Material properties comparable to injection molding § More established technology than 3D printing § Higher quantities and surprisingly faster lead time over 3D printing § Challenges can occur with complex geometries, endmill sizes and fixturing
- 35. #DWwebinar Injection Molding § You prototype with 3D printing and CNC machining, so why not with injection molding? § Low-volume injection molding provides actual molded thermoplastics the same way your production parts would be produced § 25 to 10,000+ parts are typically possible from rapid aluminum tooling
- 36. #DWwebinar Design Considerations for Injection Molding § Material selection § Wall thickness § Coring out § Draft § Moldability § Material flow
- 37. #DWwebinar Material Selection Characteristics to consider when selecting a material: § Chemical resistance § UV concerns § Temperature § Flammability § Strength § Stiffness § Impact resistance § Compatibility Characteristics to consider during design process: § Warp § Sink § Porosity § Assembly § Material memory § Appearance § Tolerance § Gate and ejection
- 38. #DWwebinar Material Selection Resin generic name Some brand names Strength Impact resistance High temperature Relative cost Acetal Delrin, Celcon Medium Medium Medium-Low Medium Nylon 6/6 Zytel Medium High Low Medium Nylon 6/6, glass filled Zytel High Medium High Medium Polypropylene Maxxam, Profax Low High Low Low High Density Polyethylene (HDPE) Dow HDPE, Chevron HDPE Low High Low Low Polycarbonate Lexan, Makrolon Medium High Medium High Medium High Acrylonitrile Butadiene Styrene (ABS) Lustran, Cycolac Medium-Low High Low Low Polycarbonate/ABS Alloy Cycoloy, Bayblend Medium High Medium Medium Polybutylene Terephthalate Valox, Crastin Medium High Low Medium High Polybutylene and Polyethylene Terephthalate, glass-filled Valox, Crastin, Rynite High Medium Medium Medium High Polystyrene Styron Medium-Low Low Low Low Thermoplastic Elastomer Isoplast, Santoprene Low High Low Medium-Low Acrylic Plexiglas, Acrylite Medium Low Low Medium
- 39. #DWwebinar Wall Thickness by Resin Type The table shows wall thickness that Proto Labs recommends according to resin. Please note that thin walls only work on small parts and thicker walls are required where the resin has a long way to flow. Proto Labs makes parts with dimensions of about 0.25 in. to 29.6 in. (6.3mm to 752mm). Resin Inches ABS 0.045 – 0.140 Acetal 0.030 – 0.120 Acrylic 0.025 – 0.500 Liquid crystal polymer 0.030 – 0.120 Long-fiber reinforced plastics 0.075 – 1.000 Nylon 0.030 – 0.115 Polycarbonate 0.40 – 0.150 Polyester 0.025 – 0.125 Polyethylene 0.030 – 0.200 Polyethylene sulfide 0.020 – 0.180 Polypropylene 0.025 – 0.150 Polystyrene 0.035 – 0.150 Polyurethane 0.080 – 0.750
- 40. #DWwebinar Uniform Wall Thickness As designed As molded Sink Warp Cored
- 41. #DWwebinar Original Geometry Cored Geometry Core out parts to eliminate thick walls Coring Out Thick Area
- 42. #DWwebinar Core out parts to eliminate thick walls You get the same functionality in a well-molded part. Original Geometry Cored Geometry Coring Out Thick Area
- 43. #DWwebinar Stamping, molding, casting, forming, machining — all benefit from draft Undrafted Drafted Draft
- 44. #DWwebinar Minimizes tool wear and flash with telescoping shutoffs Helps with part ejection Draft
- 45. #DWwebinar Thermoplastic LSR / Elastomeric Metal Die Casting Metal Sand Casting Machining 3D printing 1-3° 1-3° (hand removal) 3-5° minimum 5-7° minimum 0° possible (but not recommended) 0° possible (but not recommended) Recommended Draft
- 50. #DWwebinar Part Design § What is its function? § What are your preferred materials? § How many parts do you need? § What is your budget?
- 51. Questions? MODERATOR FEATURED SPEAKER Tony Holtz Technical Specialist Proto Labs [email protected] @ProtoLabs Leslie Langnau Managing Editor Design World [email protected] @DW_3DPrinting
- 52. q This webinar will be available at designworldonline.com & email q Tweet with hashtag #DWwebinar q Connect with Design World q Discuss this on EngineeringExchange.com Don’t Forget!