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Archive for 2017

Carbon: The Ultimate Tool in the Additive Manufacturing Tool Belt

Posted on: December 12th, 2017 by Owen Timlin

Material Properties. Part Design. Part Finish. Economics. Lead Time. Pick Two.

That is how most projects go in Additive Manufacturing. It is very rare in the AM world where you can have your cake and eat it too. That is why the University of Adelaide Project is so special.

First Approach

Dr. Tommaso Watson’s Airlock started out as two CNC machined stainless steel parts soldered together. The stainless steel material allowed the part to be autoclavable which was a requirement. However this was expensive, time consuming and compromised the design.

Second Approach

Looking to improve upon the design, Dr. Tommaso Watson’s Airlock moved to Additive Manufacturing with Fused Deposition Modeling. The FDM ABS Airlock allowed for an optimized design and cut down the lead time. However it still was not cost effective at scale, the layer printing created porosity and the ABS material was not autoclavable.

Carbon Approach

Utilizing our Carbon technology, we were able to recommend a material that met all his criteria. Carbon prints isotropic parts which eliminated the porosity. Carbon’s CE 220 material is autoclavable. The lead time was cut down from one month to a week. The Carbon process produced parts at 67% the cost of the first two options.

Find out if CLIP is right for your project.

Check out below for the whole story.

Carbon parts make wine research 60% more economical and 67% faster

TTH Sponsoring Partner For R3D@ Tri-C- Regional 3D Printing and Additive Manufacturing Conference

Posted on: September 19th, 2017 by The Technology House

Come visit TTH this Thursday & Friday at the annual R3D@TRI-C Cleveland 3D Printing Conference at the Huntington Convention Center on September 21-22, 2017.

We recommend coming for the opportunity to see and hear Jason Lopes from Carbon speak about his work in 3D printing and how Carbon is driving the future of additive manufacturing.

To purchase tickets to attend, click HERE.

 

R3D Conference

R3D @ Tri-C

Tri-C’s Workforce Community, Economic and Development Division is excited to host the third annual R3D @ Tri-C Conference at the Huntington Convention Center located in downtown Cleveland, Ohio. Beginning Thursday, September 21, 2017 with a networking event featuring a variety of hands-on workshops for everyone.  Friday, September 22, 2017 will be a day of informative sessions about the latest advances in additive manufacturing technologies, product innovation and case studies.  Along with a keynote presentation by Jason Lopes, 3D Printing Evangelist.

Date:

  • September 21-22, 2017

Who should attend?

  • Companies using additive manufacturing technology and those interested in getting started
  • Entrepreneurs interested in using additive manufacturing technologies
  • Educators who have a vested interest in current and future trends in additive manufacturing, including 7-12 grade educators and higher education faculty/staff

Location:

  • Huntington Convention Center, 1 St Clair Ave NE, Cleveland, OH 44114

Cost:

  • Individual registration $125
  • Educator discount and CEU’s available, please email R3D@tri-c.edu for more information

Keynote Address 2017

 

Jason Lopes

3D Printing Evangelist

Production Development Engineer, CARBON

Jason Lopes is the former lead systems engineer with Legacy Effect who helped create some of the biggest Hollywood blockbusters of all time utilizing Additive Manufacturing. Jason’s credits include Avatar, Terminator Genisys & Salvation, 2012, Thor, Iron Man 1,2, & 3, Cowboys & Aliens, Real Steel, Life of Pi, Captain America 2, Robocop and Pacific Rim; amongst other successful TV and film productions.  After leaving Legacy Effects Jason now helps companies, leverage Additive Manufacturing and educates all spaces of 3D Printing.

Jason is a strong advocate of 3D printing, which has proven to be an invaluable tool in his production workflow, along with 3D scanning, 3D design and 3D modeling. He has been operating numerous 3D printing technologies for a number of years to assist in the production of stunning visual effects and products and was awarded 3D Printing Industry’s Maker Of The Year 2017 the DINO (Distinguished Innovative Operators Award) in 2012 by the Additive Manufacturing Users Group.

Keynote Address Thursday

Thursday’s Keynote

Michael Block, Application Engineer, Stratasys

Mike has been with Stratasys for over 9 years and his roles included: project coordinator, technical support specialist and applications engineer. He is currently supporting the education sector for the Americas and assists with the application support emails for the Americas as well. Mike also lead a team of application engineers on the Comic Con Creature project that appeared on Jimmy Kimmel.

TTH is sponsoring the event along with the following:

Case Western Reserve University Engineering
MAGNET
America Makes

 

 
 
 

5 Things Engineers Need to Know About Digital Light Synthesis (DLS)

Posted on: July 20th, 2017 by The Technology House

As an engineer, you’re always looking for new and better solutions for your design projects. You’ve likely experimented with traditional additive or 3D printing to produce models and prototypes. Besides being slow, the surface finish and mechanical properties are often suspect. But have you tried the newest innovation in 3D printing? Digital Light Synthesis (DLS)!

Carbon 3D Prototyping and Production DLS Process

Enabled by Carbon’s proprietary CLIP Technology, DLS uses digital light projection, oxygen permeable optics and programmable liquid resins to produce products with much improved durability, resolution and surface finish.

Here’s how it works:

  1. The printer projects UV images through an oxygen-permeable window that sits below a reservoir of liquid resin.
  2. Controlling the oxygen flow forms a “dead zone” layer of uncured resin above the window. Light passes through the “dead zone,” curing the resin above to form a solid part. The object forms as it the build platform lifts it from the resin puddle below.
  3. The finished part is baked in a forced-circulation oven strengthening the materials.

If you’re not familiar with digital light synthesis, here are key items you need to know.

1. Increased Smoothness and Durability

DLS greatly improves upon the surface and mechanical property issues of traditional 3D printed objects. Because this process doesn’t print layers, the surface of the object is much smoother. The higher quality finish combined with the second chemical reaction from the heat of the forced-circulation oven makes for high resolution parts with engineering-grade mechanical properties.

2. Speed to Market

With the Digital Light Synthesis process, you can create prototypes, test them and run your production all in the same process and with the same material. This saves you time and cost while getting your products to your customers faster.

3. Available Materials

3D printing with the DLS process is available with the materials below:

  • RPU Rigid Polyurethane: Tough and abrasion resistant, stiff. Similar to ABS.
  • FPU Flexible Polyurethane: Tough, impact and abrasion resistant with moderate stiffness. Similar to polypropylene.
  • EPU Elastomeric Polyurethane: Highly elastic, resilient. Similar to TPE. 68A durometer.
  • CE Cyanate Ester: High-temperature resistance, strength and stiffness. Similar to glass-filled nylon.
  • EPX Epoxy: Temperature resistant, strong and accurate. Similar to glass-filled PBT or PC/ABS.
  • UMA Urethane Methacrylate: Rigid resins for manufacturing jigs, fixtures and general purpose prototypes. Tough SLA material available in all colors. Similar to SLA resin.
  • DPR Dental Production (NEW!): Fast and accurate. Designed for dental and orthodontic. Similar to UMA or SLA resin.

4. adidas Partnership with Carbon for Futurecraft 4D

adidas is utilizing DLS with Carbon’s CLIP technology to open up new possibilities in shoe design. Carbon developed a revolutionary elastic material for the midsole of adidas’s new product, Futurecraft 4D. Traditional 3D printing was too slow for production, created wasteful part supports and used materials that were brittle.

Carbon’s DLS sped up the process and removed the need for prototyping. They were able to test performance in the design phase. It also created products with no support material, eliminating waste. With the results of DLS, adidas will be able to customize its shoes for optimal performance by sport and by customer.

This is a huge step for the additive manufacturing. These improvements for large volume production can be applied across all industries.

5. Digital Light Synthesis Is Available with The Technology House

The Technology House (TTH) was one of a select few Beta-sites selected for the Carbon M1 Printer in 2015. Currently, TTH is running six Carbon DLS Machines, including the latest M2 model which offers a larger build platform and double the build volume than the M1 model.

Customers can create prototypes, models, parts, etc. for medical, automotive and other industries. We can create what you need to your specifications. Experience the speed and new design capabilities TTH can offer with CLIP Technology.

Validated Injection Molding : Meeting Design Specs, Every Time

Posted on: April 19th, 2017 by The Technology House

When it comes to manufacturing parts, there are many methods to choose from. For example, injection molding is used to make everything from bottle caps to MRI coils. The process produces end-use ready results for applications in many industries. There are applications, such as medical devices or aerospace that require an even higher degree of accuracy and trust for a consistent, molded part. For these situations, Sea Air Space Machining and Molding (SAS) offers validated injection molding. Validation involves making sure that the machines used, materials employed, and manufacturing processes followed meet stringent accuracy and repeatability standards. While SAS offers a complimentary design review on all orders, validated injection molding involves far deeper design verification and customer collaboration. It starts with working closely with the customer to make a plan. SAS has a standard process and then tailors these steps to the customer’s unique needs. This collaborative process ensures that the standards SAS follows meet the customers’ expectations and requirements.

Communication is vital when making validated parts. Not only does SAS have regular contact with customers during the validation process for updates and progress, but they are also sure to immediately halt production and call the customer whenever SAS finds something that is not up to specifications.

Due to the cost and time overheads associated with validation, many manufacturers do not offer validated injection mold services, especially not on low volume orders. But, with the way SAS is setup, they are able to apply their skills and time to validate injection molding no matter the size of the order.

The Steps of Validated Injection Molding

Validation is a multi-step, detailed process. While there may be unique customer requirements, there are some steps that occur whenever a client requests validation.

Installation Qualification: Making Sure Everything Works

One of the ways validated injection molding differs from traditional processes is that it involves using IQ, or Installation Qualification. During IQ, the injection mold press equipment that will be used to manufacture a part is verified that it is installed correctly, working properly, and that the machine is receiving the proper power. This involves inspections from the manufacturer to make sure the equipment is set up correctly. The machines must be capable of repeatability and accuracy to meet all specifications.

Operational Qualification: Test, Test, and Test Again

After the IQ demonstrates that the equipment is correctly installed per manufacturer’s requirements, the next step of validation is to make sure the equipment is capable of performing over a specified range. This range is based on the material processing range and the processing parameters of the tooling and parts. This is called the Operational Qualification, or OQ phase. Here, data becomes especially important. An operator performs test runs, in which the operator records the machine’s operating settings by adjusting all manner of controls, including speed, pressure, temperature and more. Testers log, compile and store all data. This helps ensure the machines can operate over the processing range and notifies the operator if it falls out of the certain tolerances within that range.

Performance Qualification: The Real Thing This Time

Once OQ is complete, operators or technicians use the real manufacturing materials, while running the equipment through full cycles of parts. Basically, operators run the planned process for the part and verify that the process fits within the OQ range and the molded part meets all customer requirements. This is known as PQ, or Performance Qualification. During PQ, operators:

  • Record process parameters.
  • Ensure measurement accuracy for dimensional requirements.
  • Verify that materials behave as expected regarding durability and strength under various conditions.
  • Get customer approval that parts meet their specifications.

If PQ fails, it is back to OQ.

Lessons Learned

Formulating the validation process was a learning experience for SAS. Going through the validation process helped SAS to better plan out processes based on customer requirements and communicate the needs and importance to all levels of the organization. SAS now finds that it has less scrap when making any order, validated or not. Communication improved among all levels of employees. Learning that changing and updating processes is a good thing was something that became apparent to everyone. The importance of collecting and analyzing data, verifying processes and materials, and making sure everyone is clear on all steps became even more focused than it already had been.

Do you have an injection molding project that requires validation? Submit your design for review and a quote.

ADM – Cleveland 2017

Posted on: March 22nd, 2017 by The Technology House

2017 Advanced Design and Manufacturing Cleveland

What is Advanced Design and Manufacturing (ADM) Cleveland?

ADM Cleveland will deliver the full spectrum of advanced design and manufacturing technology. Engineers and executives will get access to the latest solutions in the product development process with cutting-edge technologies, networking events, and educational opportunities.

Who Should Attend?

Engineers and executives who use or are interested in 3D printing and additive manufacturing in key industries such as automotive, medtech, aerospace, robotics, automation, plastics, packaging, and design technology. The conference will have interactive events and exhibits for people of all skill levels.

Will I See TTH There?

Of course!  We will be exhibiting at the conference at booth #523.  Be sure to stop by to see firsthand the innovation and benefits of 3D printing and additive manufacturing.  Also, we will have plenty of free giveaways.

Sign Me Up!

Individual registration is $75, which includes all speakers, presentations, exhibits, and meals.

Registration 2017 Advanced Design and Manufacturing Cleveland