Improving Plant Efficiency with 3D Printed Production Aids

Additive manufacturing (or popularly known as 3D printing) has proven itself to rapidly manufacture strong and functional parts. The technology is changing the way products are being manufactured but alternatively it is also improving the efficiency of traditional manufacturing processes.

To put this in
perspective, all manufacturing factories require the help of production aids to
manufacture and assemble the products. A production aid is any device type of
tool, jig, fixture, or a device used to enhance, optimize, and assist or
speedup the manufacturing or assembly process.

More often than not, production aids are customized to suit the product being manufactured but manufacturing such customized tools in limited quantities is always costly.

Considering the importance of production aids and its limited quantities, 3D printing can be a perfect fit in this scenario. Factories can leverage the capabilities of 3D printing to produce them at reduced costs. 3D printing can hand a powerful tool to organizations to improve its overall plant efficiency.

We’ll first look at the benefits of using 3D printing in creating production aids.

VALUE OF 3D PRINTED
PRODUCTION AIDS

  • Faster
    Time-to-Market

With 3D printing,
production aids can be manufactured rapidly. This starts a chain reaction to also
speed up the pace of production and assembly, thus cutting down the
time-to-market to take your product from factory to customer.

  • Improved
    Plant Efficiency

With faster production
and assembly leading to faster output and delivery, plant efficiency can be
considerably improved.

  • Reduced
    Cost of Production

By improving part
repeatability and accuracy, rejections can be reduced, leading to reduced cost
of production. When manufacturing jigs and fixtures, 3D printing can eliminate
the time needed for iterations before finalizing on the desired jig or fixture.

  • Performance
    Improvements

By using the design freedom capability of 3D printing, innovative and complex fixtures can be designed and printed to improve the production and assembly performance with fewer constraints.

  • Better Production
    Aids

Compared to traditionally manufactured production aids, 3D printed production aids can be more efficient. It can be made from lighter materials but still offer comparable strength and durability. Alternatively, the tools can be topology optimized to reduce weight and material usage.

  • Part
    Consolidation

3D printing offers the
capability to consolidate multiple jigs and fixtures into a single production aid
thus operators are able to perform multiple operations at the same work station
using a same fixture, saving costs, storage, and handling.

  • Worker
    Safety

As factories are
getting more advanced there is even more impetus on ensuring workers’ safety.
By 3D printing customized safety aid solutions such as safety latches, casings,
locks, and even obsolete safety parts, the workplace safety can be improved.

TYPES OF 3D PRINTED
PRODUCTION AIDS

Let’s take a look at some of the different types of production aids that
can be 3D printed to improve overall plant efficiency.

Jigs & Fixtures

Jigs and fixtures
are customized tools used to hold, guide and control the movement of a workpiece
while other operations are carried out.

Examples of
customizable jigs and fixtures include guides for burr removal, dimensional
accuracy testing, sticker pasting in packaging operations, etc. All can be
manufactured on demand.

Guides

Drill guides are a
commonplace tool on all shop floors. They ensure that holes are drilled in
their intended center and are not deflecting from this position in either
linear or angular terms and are staying within the prescribed tolerance limits.

Marking Tools

In traditional manufacturing a part travels from one work station to the other as different operators perform cutting operations and it is important that the cutting accuracy and repeatability is maintained in all parts. For this, a tool can be 3D printed to perfectly identify the marks to perform accurate cutting operation.

Safety Latches, Casings
and Locks

Apart from making sure
the production is carried out efficiently, the plant also has to ensure the
safety of its workers. For this a plant employs multiple safety tools like
latches, casings, locks and more. These safety tools help minimize on-site
accidents.

Go / No-Go Gauges

Go / No-Go gauges are
used in a manufacturing plants as a testing tool to test weather a finished part
meets the dimensional standards. A Go/No-Go gauge can easily identify any
deflection of the part in terms of its form, shape and dimension. It can
rapidly conform or reject a part according to the fit in the gauge instead of
using other measurement tools like calipers.

Maintenance Parts

Custom quality check and maintenance parts a can be rapidly manufactured.
Simple customizable tools such as stopper tools used to tighten nuts and bolts
can be kept in the individual machine’s toolbox, thus increasing maintenance
efficiency while saving time.

3D PRINTING OF
PRODUCTION AIDS

Production aids can be 3D printed through
various 3D printing technologies. For industrial printing, the commonly used
technologies include Selective Laser Sintering (SLS), Selective Laser Melting (SLM),
Direct Metal Laser Sintering (DMLS) and Binder Jetting.

SLS 3D Printing

Selective Laser Sintering (SLS) is a
powder-bed fusion technology. It uses a powdered material that is sintered via
a laser to form the object. This technology offers greater design freedom than
some of the other 3D printing technologies. For parts involving complex
designs, SLS can be effectively used.

SLM & DMLS 3D Printing

FDM printing can offer cheaper production
aids, SLA can offer aids with smoother surface finishes while SLS can provide
greater design freedom but all these technologies print only with polymers. For
industrial parts requiring heavy-duty jigs, metal 3D printing is recommended.
Metal 3D printing technologies suitable for production aids include SLM, DMLS and
Binder Jetting.

Selective Laser Melting (SLM), Direct Metal
Laser Sintering (DMLS) are both powder-bed fusion technologies but for metals.
Both of these technologies can be used for small-size precision production
aids.

Binder Jetting

Binder Jetting technology can be used in
case of large parts. This technology also uses powdered metal material but uses
a binder material to fuse the metal particles together. The greatest advantage
of binder jetting is that it can manufacture parts at a fraction of the cost
compared to DMLS/SLM and Material Jetting. Moreover it is suitable for low-to-medium
batch production when multiple tools need to be mass produced for the entire
factory.

CONCLUSION

Factories can leverage 3D printing to create high-quality production tools to improve their plant efficiency. With 3D printing’s wide applicability, range of materials, design freedom and manufacturing flexibility, this technology provides many benefits that should not be overlooked.

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The post Improving Plant Efficiency with 3D Printed Production Aids appeared first on Shapeways Blog.

3D Printed Jigs and Fixtures Can Help Boost your Productivity

Liuzhou JingDa Automotive Brake Tube Manufacturing Co., is a leading supplier for SAIC Motor for break tubes for both Micro and Passenger cars. Mr. Bian, the technical director of JingDa, says that 3D printing is certainly having a tangible impact on how break tube engineers create solutions that improve the effectiveness of production lines while enhancing the effectiveness of the tubes.

Everything JingDa does with 3D printing revolves around aiding in one or more of three benefits: quality, productivity, and increased effectiveness. In fact, those pillars are arguably at the core of any factory around the world.

Here’s a look at JingDa Automotive’s brake tubes. There are 6 sorts of brake tubes, at least, required on every single vehicle, some require 8 kinds or more. Each and every tube needs test fixtures to measure them to see if they’re in spec.

Traditional brake tube fixture

 Traditional fixtures can’t test these tubes quickly enough. They also can’t test them accurately according to the key position and the tortuosity of the brake tubes. The quality and the precision that FDM 3D printing brings to the table can satisfy the conditions required.

Traditional brake tube fixture

In order to complete a whole project in one week, the company will need 2 sets of 3 meter long fixtures to inspect a fixture line. To complete this task Jingda reached out to Deed 3d printing company. With more than 40 Stratasys Fortus printers, Deed3D have very short turnover time. Indeed the delivery of the fixtures was completed within 5 days.

ABS-M30 material printed on Stratasys 900MC printers, 500mm to 800mm length model.

Comparison between CNC and 3d printing fixtures

mode of production

Original CNC Production

Stratasys FDM 3D Printing

Production Method

After each independent inspection fixture is completed, all inspection fixtures are fixed on the substrate by means of bonding.

Print in one piece, or print in sections, and then fix it on the substrate.

Cost

The cost of the two methods of production is not very different

Time

The production time is long, it is difficult to control the delivery period, and it will affect the project progress.

The turnaround time is short and controllable. It can be controlled according to its own production schedule without affecting the project schedule.

Production difficulty

The more curved detection parts will make the production of the inspection fixture difficult and the accuracy difficult to control.

The degree of bending of the product has nothing to do with manufacturing difficulty, and the accuracy is easy to control.

Accuracy

Low accuracy caused by splicing fixture

Accuracy is much higher than the customer requirement

Data requirements

2D projection + height marking

3D data, need to redraw

Convenience

Heavyweight solid material, inconvenient to use

Sparse printing, lightweight, easy to use

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How 3D Printing Jigs and Fixtures Transforms Manufacturing Part II – All About Fixtures

Fixtures are essential for custom manufacturers. Fixtures hold the workpiece in place so it does not move during a step in manufacturing. Some shapes are easy to hold such as a rectangular block. For example, the part can be simply held in a vice. For shapes with various curves and angles, it can be difficult to hold them sturdy using standard tools. Fixtures solve this problem by clamping onto parts while matching the part’s geometry like a glove.

Jig or Fixture?

Fixtures may sometimes be called jigs, but they are not the same thing. Jigs guide the motion of tools and they are usually used in manual operations such as drilling holes. Fixtures are very sturdy and will accurately hold the workpiece at the correct angle, but fixtures do not guide tools. Fixtures are more often used with automated manufacturing methods. For more information on Jigs, check out our article about jigs.

All about Fixtures

Fixtures make inserting and removing parts much easier. They are typically designed in an intuitive way that reduces the risk of human error. Fixtures can be re-used for large production runs, or created specifically for a small number of custom parts.

Fixtures must be mounted to a sturdy surface before they can be used effectively. Some fixtures are designed to fit onto a standard bench vice, others attach to standard mounting boards like  T-slot tables or hole grids. Fixtures are rigidly bolted or mounted onto shop equipment.

Traditionally, custom fixtures are made manually. The design is planned out, then work material is cut, milled, and drilled into shape. This process requires costly materials, expensive equipment, skilled machinists, and a considerable amount of labor. It may also require purchasing new tooling for unique shapes.

Benefits of 3D Printed Fixtures

3D printing is a viable alternative when it comes to creating custom fixtures. It is more cost-effective to 3D print a custom fixture than it is to machine one in-house. With 3D printing, a fixture only needs to be designed using CAD software and sent out to a 3D printing service such as www.shapeways.com After a few days, it’ll get printed, shipped and delivered, ready to use.

3D printed fixtures are made from strong and lightweight plastics such as nylon. Nylon is tough and durable. Fixtures made from nylon will last for many production cycles. As a plastic, it is not as dense as metal, so large fixtures will be lightweight in comparison. Nylon is softer than most rigid materials, and this is good because the fixture will not scratch or damage the part’s surface. The softer material aids in providing a more uniform clamping pressure. Under high clamping loads, the nylon can deform to the shape of the part, saving both from being damaged.

Here are a few examples of innovative fixtures that have been designed specifically for 3D printing.

1”x1” Board Fixture

This fixture is mounted onto a 1”x1” mounting grid board or mounting table. It can be used to hold your working piece in place to either be cut, drilled or assembled. The working piece is clamped by the fixture as screws are tightened, holding it securely. This fixture can also be used as a cylinder holder for cutting pipes and tubes.

Material: Multi Jet Fusion Plastic – Gray PA12 (nylon 12)

Bench Vice Jaw Adapter Fixture

This fixture is an accessory for a bench vice that when attached, can hold a wide arrangement of objects. This is done by inserting magnets (not included) into the provided spots on the back of the fixture and then placing the fixture onto the jaws of a bench vice.

Material: SLS – PA11 (nylon 11)

Door Lock Installation Fixture

This is a fixture used to assist in the installation of a doorknob or lever. It provides accurate alignment between the working parts of a doorknob or lever. This is done by finding the centerline of your door edge, aligning the two smaller holes with the centerline and securing the fixture to the door with screws temporarily at those points. Once that is done, you can now use the recommended hole saw and the fixture as a guide to drill the remaining holes out where you would be left with perfectly aligned holes to install a doorknob or lever.

Material: Versatile Plastic – White Processed

Cut Down Your Production Costs

If you would like to learn more about how 3D printing can help your business save money and reduce manufacturing costs, get in contact with Shapeways using our Sign up form.

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How 3D Printing Jigs and Fixtures Transforms Manufacturing 

In the industrial world, 3D printed jigs and fixtures are truly unsung heroes. Both jigs and fixtures are types of tools that are used to control the operation of another instrument. However, a fixture sets itself apart in that it’s mainly used to hold another tool or device in place during the manufacturing process.

As a manufacturer, in any industry, you rely on essential components like jigs and fixtures to get the job done. The difference is that these days, more and more manufacturers are realizing massive productivity increases and lowered costs by 3D printing these essential manufacturing aids.

In this series of articles, we will layout the benefits of using additive manufacturing to produce Jigs & Fixtures. The first part will focus on Jigs. To find out more about how you can harness the potential of 3D printing jigs and fixtures to increase productivity and reduce costs, read on.

Jigs 101

Jigs are custom-made tools that hold in place and control the motion of other devices or parts in the manufacturing process. Unlike a fixture, a jig lets manufacturers expedite the assembly or construction of a product by allowing for greater interchangeability and repeatability.

It should come as no surprise, then, that jigs are a staple in virtually all mass-production systems in the developed world. However, small and medium-sized firms traditionally haven’t been able to create custom-made jigs until the arrival of 3D printing technologies.

Why 3D Print Jigs and Fixtures?

Most companies cannot afford to splurge on traditionally manufactured jigs and fixtures to add to their assembly lines or build processes. Thanks to the advent of additive manufacturing, productivity-enhancing tools such as jigs, fixtures, and grips can now be produced at a fraction of the cost of their traditionally made counterparts.

Producing jigs and fixtures via 3D printing is a highly cost-effective means of speeding up your assembly times and reducing labor costs. Plus, on-demand jig and fixture production eliminates upfront inventory requirements. Instead, digital inventory allows for seamless updates and revisions to keep your equipment working the way it should.

Other benefits of 3D printed jigs and fixtures include weight reduction (via high-strength plastic construction), ergonomic superiority (via customizable item contouring and shaping) and reducing overall complexity during the manufacturing process.

Here are examples of jigs that you can 3D print today:

Router Corner Jig

Built with black versatile plastic, a SLS nylon 12, this woodworking tool is designed to create precise cuts around angular corners during woodworking. A workshop essential, this 3D-printed tool allows users to make consistent cuts around edges when using a Router tool.

Cutting corners has never been easier thanks to this corner jig, which holds to the corner of your working piece to guide cuts at an exact and consistent radius.

Rotary Tool Drill Bit Sharpener Jig

Constructed with multi-jet fusion plastic, smooth black nylon 12, this rotary drill bit sharpener tool is the DIYers dream. This jig sharpens dull drill bits to their original condition by crafting a new cutting edge on the side of the tool. The process is simple: the jig attaches to a rotary tool and a grinding disc.
Then, the drill bit is inserted into the jig at the correct angle. The jig, in conjunction with the abrasive disc, proceeds to grind the drill bit to the user’s preferred degree of sharpness in seconds.

Center Point Finder Jig

This time-saving jig tool streamlines your assembly processes by allowing you to locate the midpoint of objects with varying levels of thickness. Made of durable red versatile plastic, a SLS nylon 12, the Center Point Finder Jig works according to a simple process: the jig is placed on top of an object that the user wants to measure, then the jig is twisted until the pegs cannot move any further. Then, the indicator in the center of the jig signifies where the midpoint of the object is.

Ready to Save Money for Your Company?

There has never been a better time to invest in jigs, fixtures, grips, and other tools that can save your company time and money when manufacturing. Typically, a jig or fixture would be sent away to be produced by a trained machinist for days at a time.

Today, 3D printing has cut down production times and created a more affordable alternative for manufacturers in need of custom-made assembly tools.

Interested in learning more about how 3D printing can impact your business by increasing productivity and lowering production costs? Get in touch today to learn how Shapeways, the leading end-to-end 3D printing fulfillment platform, is helping millions of companies leverage 3D printing to scale their businesses.

The post How 3D Printing Jigs and Fixtures Transforms Manufacturing  appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

INTAMSYS Launches Jigs and Fixtures-Themed Industrial 3D Printing Global Competition

Shanghai-based 3D printer manufacturer INTAMSYS, which stands for Intelligent Additive Manufacturing Systems, often makes the headlines for its reliable, industrial-grade FUNMAT 3D printers‘ capabilities in providing 3D printing solutions with tough, functional, high-performance, and high-temperature materials, such as PEEK and PEKK, ULTEM 1010 and ULTEM 9085, PSU, and PPSU, thanks to heated build plates, high-temperature nozzles, and breakthrough thermal technologies on active heated chambers.

INTAMSYS, which partners with many well-known companies around the world, operates several manufacturing and research facilities, and runs its own 3D printing service, provides solutions for many applications, ranging from medical, as in the case of this innovative PEEK knee brace, to industrial, such as making end-use parts, tools, jigs, and fixtures. The company is focusing on the latter for an exciting new event – INTAMSYS is hosting its very first competition this summer.

The Industrial 3D Printing Global Competition for Industry 4.0, focusing on a theme of Jigs and Fixtures, has officially launched, with entries being accepted up until August 31st, 2018. Over $10,000 in cash and prizes are at stake, so you should start preparing your entry soon.

Chun Pin Lim, the Marketing Director of INTAMSYS, said, “During our business visits in the USA, Europe and China, we’ve learned first-hand from our customers and partners that 3D printed jigs and fixtures in polycarbonate, nylon and PEEK have significantly improved lead time, worker safety and costs on their production floors.”

The aim of INTAMSYS’ new Industrial 3D Printing Global Competition is to identify and reward participants who can, as the company puts it, “best exemplify” the use of 3D printing solutions in terms of manufacturing jigs and fixtures, in order to achieve the best possible manufacturing lead time and cost savings.

This competition is open to any and all organizations, companies, and research and educational institutions around the world that currently use 3D printing to manufacture jigs and fixtures. When entering, participants must submit the following:

  • Full name of entity
  • First and last name(s) of team’s main contact person
  • Email and phone number, for award notification purposes only
  • Full address
  • Main purposes of the 3D printed jig or fixture and its dimensions in millimeters
  • Types of material used to 3D print fig or fixture

Competition entries must also include details regarding the cost, durability, lead time, and any other benefits of 3D printing the jig or fixture when compared to previously used fabrication methods. Additionally, entrants must include three photos – one of the jig or fixture being 3D printed, a photo of the fully printed object, and one of it while being used; check out this link to see sample photos.

The three competition winners will be announced on this site, and informed via either email or phone, on September 14th, 2018. The second runner-up will receive US$1,000, while the first runner-up will be awarded a prize of $2,000.

The winner of the competition will receive the grand prize: $2,000, a FUNMAT HT 3D printer, and 2 kg each of INTAMSYS nylon, PEEK, and polycarbonate filaments – all together, this prize is worth a total of $10,000, including global shipping costs for the 3D printer and filaments, which INTAMSYS will provide. Prizes are not exchangeable.

What do you think of this news? Discuss advanced manufacturing competitions, challenges, and contests, and other 3D printing topics, at 3DPrintBoard.com or share your thoughts in the Facebook comments below.