Additive manufacturing. Fused deposition modeling. Rapid prototyping. 3D printing.
Whatever you call the process, additive manufacturing has undergone a perception change.
While prototyping remains a key functionality served by additive manufacturing equipment,
3D printing is gaining acceptance as a method of short-run production.
Plastics Business interviewed Joe Hiemenz, technical communications and public
relations manager for Stratasys, Inc., and Patrick Gannon, engineering manager for rp+m,
to discuss their perceptions of the ways additive manufacturing is changing the face of
the injection molding industry. Stratasys is a producer of additive manufacturing
equipment and inventor of fused deposition modeling, and rp+m uses the technology to
create prototypes, while also exploring additional uses, including short-run
production.
How is additive manufacturing used today?
Both Hiemenz and Gannon agree that additive manufacturing is used in two primary ways:
rapid prototyping and direct digital manufacturing in low volume. “For prototyping,”
Hiemenz explained, “there are two areas in which additive manufacturing is used: concept
modeling and functional prototype testing. For direct digital manufacturing, there also
are two areas: fabricating manufacturing tools (like jigs and fixtures) and for the low
volume production of finished goods.”
Stratasys has noted the use of additive manufacturing for prototyping in almost every
industry by design engineers who want to prove out the design before going to production.
These industries include aerospace, automotive, defense, education, medical, consumer
product industries and business and industrial machinery.
At rp+m, the company operates as a service bureau, supporting the production and
engineering sides of sister company Thogus Products Company, an injection molder, with
assembly fixtures, design builds and prototyping. rp+m also has customers for which it
prototypes and produces short manufacturing runs.
“I wouldn’t say prototyping and manufacturing are an equal mix,” said Gannon. “Volume
leans more to the prototype side, and it’s still the use people are most familiar with,
but I’ve seen an uptick in quoting for manufacturing for final product.” Gannon stated
that rp+m is making an effort to spread the word about its manufacturing capabilities,
particularly for customers who need a smaller production run.
What are the limits of additive manufacturing?
While gaining in popularity due to its ability to manipulate materials in ways not
possible with traditional injection molding, additive manufacturing isn’t the answer for
every situation. As Gannon mentioned, the costs associated with additive manufacturing
often eliminate certain types of production runs. “It’s tough, because you’re not going
to compete on piece price with an injection molded part on larger runs,” Gannon
explained. “There’s a moving line for where it makes more sense to do additive
manufacturing or when injection molding is the best choice, and it often depends on the
type of part and the type of resin needed.”
Resin remains a severe limit for the additive manufacturing process. The equipment
manufacturers often limit the types of resins approved for use, which subsequently limits
the type of products that can be produced. “Thogus has 200 active materials for injection
molding,” Gannon said. “At rp+m, we have ten active resins. We’re doing some research,
along with our polymer representatives, to run different resins through the machines, and
we’ve been somewhat successful, but we’ll never have the material range that is available
in injection molding.”
How is additive manufacturing impacting plastics processing right now?
Stratasys has seen an increase in the number of plastics processors adopting additive
manufacturing, putting it to use in strategic ways. “Molders are using the equipment to
make a model of the part during the quoting process,” Hiemenz stated. “They can deliver
the model, along with the tooling and production quote, to the customer, and at the same
time make recommendations for a design change if it could improve product performance or
reduce the tooling or production cost.”
Gannon seconded the value of having an actual model in hand when discussing production
with customers. “You can always do something on the screen,” he said, “but for most
people, holding it in their hand and pointing to things is how they actually get it.”
Gannon went on to say that he has seen a number of processors starting to catch on to the
possibilities of additive manufacturing. “They see that they can provide this value to
their customers very easily, and in some cases, very cheaply,” explained Gannon. “That’s
what happened to us. Our first machine was bought specifically for injection molding, so
that we could print the customer’s part and send it back to them.” Then, Gannon said,
innovation took over. “Once the equipment was in-house, and we had a bunch of engineers
standing around it, there was no more ‘water cooler’ conversation,” he laughed. “Now it’s
3D printer conversations! You put two engineers in a room with a 3D printer, and they’re
going to think of 10 things to do with it.”
What trends have been identified by Stratasys?
One of the trends Stratasys has seen is that molders aren’t limiting additive
manufacturing to prototyping. “Of this group of users, some use it for 5S operations,
creating tool boards that aid organization by having a designated home for each tool,”
said Hiemenz. “Still another way we’re seeing molders using additive manufacturing is to
build custom robotic end effectors to pick and place injection molded parts. When users
get their hands on additive manufacturing equipment, innovation naturally occurs.”
Hiemenz sees the pace of additive manufacturing adoption increasing in 2012. “When these
manufacturers see how additive manufacturing can lead to more business or reduce costs,
the purchase becomes easy to justify,” he explained. “The word is getting out and
awareness is going up. It’s not just the forward-looking companies adopting additive
manufacturing; more and more, it’s becoming a mainstream tool.”
How will rp+m push the limits of additive manufacturing in 2012?
rp+m has a full range of Stratasys 3D printing equipment, including two Fortus 400mcs,
two Dimensions, a uPrint desktop 3D printer, a Fortus Finishing Touch Smoothing Station
(to vapor-smooth and seal the parts) and a Fortus 900mc, which can make parts up to 3
feet by 2 feet by 3 feet. With this variety of additive manufacturing equipment and two
engineers dedicated to the process, rp+m is stretching the limits of the technology.
“We have a great process that makes strong parts, but one of the limitations is the
durometer of the material,” Gannon said. “Some of the other presses can make soft parts,
so we’re working on end of arm tools that have soft touch materials on the contact
points. We’re trying to place in-mold labels with a 3D printed, soft touch part with a
vacuum line in it.”
rp+m also continues to build the resin variety available for its additive manufacturing
equipment, which would expand the production possibilities. “Once you start thinking of
new ways to use the equipment, you never have enough capacity,” Gannon explained.
“Additive manufacturing gives us a limitless ability to design.”
For more information, visit www.rpplusm.com and www.stratasys.com. |