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ProJet Customer Applications. INVESTMENT CASTING. ProJet Case Study: Daimler. ProJet CP 3000. Casting Dept of Daimler Headquarters in Stuttgart, Germany, has purchased the first ProJet CP 3000 delivered in Europe for their high precision casting patterns. Leadership through Innovation.
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ProJet CP 3000 • Casting Dept of Daimler Headquarters in Stuttgart, Germany, has purchased the first ProJet CP 3000 delivered in Europe for their high precision casting patterns
Leadership through Innovation • Daimler has an unsurpassed tradition of innovation and trend-setting in the car industry anticipating most of the common features in nowadays cars like ABS, Airbags and sat nav all done in their in-house research and development department
Leadership through Innovation • At Daimler the ProJet is used on a number of different applications in foundry to create metal parts for small series in a fast and cost effective way without sacrificing accuracy and details
The ProJet CP 3000 Application • Daimler creates models for metal parts like engine parts, manifolds, hinges, components, connectors etc. that easily cast with lost wax process.
The ProJet CP 3000 Advantage • Excellent surface quality • Crisp details • Sharp angles • Easy post processing also for large parts • Perfect castability
Turbine Technologies, LTD. – The Company • Designs & manufactures small gas turbine engines for unmanned aerial vehicles and for use in educational and research settings • In-house capabilities: Analytical software tools, super-alloy vacuum investment foundry, dynamic balancing lab, 5-axis machining and engine test cells with high-speed data acquisition • Client sites on 5 continents that include Fortune 100 firms & Ivy League educational institutions
Turbine Technologies, LTD. - Challenges • Create a seamless in-house RP foundry process to move from CAD model to finished super-alloy component • Eliminate costly and long lead time injection tooling • Improve thin airfoil cross section accuracy
Turbine Technologies, LTD. - Results • Wax patterns are now produced directly from 3D CAD models • In-house foundry now provides prototype gas turbine engine components for less cost at greater accuracy
Mark Two Engineering – The Company • A minority/woman owned company, was founded in 1996 as a manufacturing firm that specialized in creating models, prototypes, and precision machined components. • A leading source for high quality rapid prototypes and advance technology components for companies both large and small. • The high quality supplier of leading surgical instruments and implant companies and aerospace conglomerates.
Mark Two Engineering - Challenges • Provide an affordable alternative to produce high complex components for low to high volume customers • Provide quality investment cast surface finish for medium to very small parts
Mark Two Engineering – Results • Improved surface quality with 16 micron layers • Flexibility of casted metal choices • Elimination of tooling • Improved part accuracy • Reduction of cost and time passed on to end customer • Completed part in the customer’s specified metal from a CAD file in a matter of days.
Jewelry • Watch Designer and Manufacturer • Functional testing & Design verification for one-off customization
Customer Application • A clinic • Medical application for brain surgery • Precision for error reduction & customization
Fresenius Medical Group - Company • World’s largest integrated provider of products and services for individuals undergoing dialysis because of chronic kidney failure. • Provides dialysis treatment to over 175,000 patients around the globe through a network of over 2,000 dialysis clinics. • World’s leading provider of dialysis products such as hemodialysis machines, dailyzers and related disposable products.
Fresenius Medical Group - Challenges • Cost effective in-house solution for producing high quality prototypes of new and revised component designs. • Quickly produce tangible models so all decision makers could gain clear impression of a future design
Fresenius Medical Group - Results • Cost savings for rapid prototyping – A small machine segment cost $37 to produce using in house 3D modeler, while the same part would usually cost $137 if outsourced to a local service provider. • Increased Dependence on Rapid Prototyping – In house rapid prototyping accelerated product and component development and reduced dependency on external service providers. Sensitive data from early development stages remained in house which strengthened the competitiveness of Fresenius Medical Group and helped secure their market-leading position in the field of dialysis.
Medical Modeling Facial masks for radiotherapy and burns treatment
Fonco Fabrication and Design – The Company • Creative design and fabrication agency specializing in custom objects and images for film, videos, displays and presentations. • They develop sculptural and hardedged models, robotic props, prototypes, artwork, molds and castings for a wide range of clients
Fonco Fabrication and Design – Challenges • Increasingly complex design and fabrication projects and tighter deadlines required moving to a new level of rapid fabrication technology. • Produce multiple pieces for assembled structures • Perform advance post processing such as painting and finishing • Meet seemingly impossible time deadlines
Fonco Fabrication and Design – The Results • Fonco was able to print multiple pieces of the assembly in record time and complete challenging projects without sacrificing quality
“Could not create a mold from scanned parts and create a master without ProJet HD 3000 on HD mode
Revolutionary way for character toy development MIC, Japan Masaya Sasano http://www.mic-jpn.com/
Introduction MIC's business consists of model making jobs, mostly for Bandai. Bandai, the biggest Japanese toy company, merchandises TV program characters. When developing character models, the most important factors are“TIME”“QUALITY“and“COST”. Cost is basically the largest concern for everyone. Until now, we have depended on traditional hand-sculpt modeling. TIME QUALITY COST COST
Cost details Vendor price 0 Buying Price Retail Price Development cost Maker has to correspond to “Shift” from accumulated cost concept to restricted cost concept Royalty Management cost Development cost (including MIC’s man cost = time) Product cost Cost-reduction requires “Money (COST)” as the fundamental factor Now “the price to buy (consumer)” is “the price to sell (maker)” Toy makers on the licensee side are currently at the turning point to reconsider traditional thinking and workflow
Cost-reduction requires “Money (COST)” as the fundamental factor “COST” = “Initial Cost (Mold, Master model)” + “Product Development Cost” “Product Development Cost” includes “Labor Cost” ! “Labor Cost” implicitly hides “TIME” The way to exchange “Time” to “Money” By using digital tools to exchange information, confirm & change design, it is indispensable for dramatic cost-saving and to save Licensor approval time The traditional way of sending the physical master model overseas poses the risk & danger of lost or broken pieces multiple times. Cost & Time never change. All depends on Labor, Workflow, Process
design sketch Silicon mold making Paint Clay Modeling Casting to copy master This way, we depend on hand-work to represent taste Analog Process Flow: handwork (traditional way)
MIC Work Flow (Example) Digital Process Flow Final mockup with paint Hand finish Design sketch Hand sculpting Rapid Prototyping FreeForm modeling 3D scan
Traditional Process Final product sizeand spec Analog hand-work based on final product size and spec Final product sizeand spec MIC digital process Can work on bigger size, then output real size Final product sizeand spec Final product sizeand spec Resize later Data can be any size
INPUT Scan Data - New data - Physical model - Imported data - Samples PROCESS Save as STL 3D Paint Simulation Split/PartsSimulation Data Modification & Decide output format OUTPUT RP 3D Printing BASIC WORKFLOW MIC started to build a digital workflow in 2000. First bought ThermoJet in 2001, then InVision in 2005.
Sample Refine by hand RP Output(InVision) ATOS Scanning TV character: design & size change FreeForm Modelingto modify pose
