#additive metal 3d printing

[metal3d]

6 MOST POPULAR INDUSTRIES TO USE METAL 3D PRINTING

Metal additive manufacturing has recently developed a lot to bring great benefits to different business sectors. These benefits include reduced material use, lowered costs, and production acceleration. It also enables designers and engineers to create anything from jigs and fixtures to more advanced forms like visualisation aids. The possibilities of using 3D printing for product development and manufacturing in different industries are limitless. The days are not far for you to think of outsourcing metal 3d printing for your industry. The countdown begins!

[materialsscienceandengineering]

North Carolina State University researchers have demonstrated a technique that allows people who manufacture metal machine parts with 3D printing technologies to conduct automated quality control of manufactured parts during the finishing process. The technique allows users to identify potential flaws without having to remove the parts from the manufacturing equipment, making production time more efficient. "One of the reasons people are attracted to 3D printing and other additive manufacturing technologies is that these technologies allow users to quickly replace critical machine components that are otherwise difficult to make outside of a factory," says Brandon McConnell, co-corresponding author of a paper on the work. "And additive manufacturing tools can do this as needed, rather than dealing with supply chains that can have long wait times. That usually means using 3D printing to create small batches of machine parts on demand." McConnell is an assistant research professor in NC State's Edward P. Fitts Department of Industrial and Systems Engineering.

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[3dprinterchat]

Unveiling Aurora Labs' AL250: A Leap Forward in Metal 3D Printing

Australian innovator Aurora Labs steals the spotlight with its groundbreaking AL250 metal 3D printer launch at Formnext 2023. Buckle up for a ride through the realms of aerospace, defence, oil and gas, engineering, and bespoke production runs as we explore the incredible features of this cutting-edge technology. The AL250 Say goodbye to the RMP-1 and welcome the AL250, Aurora Labs‘ latest laser…

[wipro-3d]

Delivering Excellence with Direct Metal Laser Sintering (DMLS) |Additive Manufacturing Solutions| Wipro-3D

Wipro 3D offers additive manufacturing solutions based on direct metal laser sintering(DMLS) technology. Which helps to deliver exceptional accuracy, speed, and quality.

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[innovae3d-pvt-ltd]

Case Study on Aerospace: Cable Routing Mount for The Latest Airbus Model Using Metal Additive Manufacturing

1. About Project – A Cable Routing Mount

A cable routing mount is required for the power supply and data transportation of a camara located in the vertical stabilizer to provide the view of the outside to the passengers and orientation of the ground the pilots. Conventionally manufactured cable routing mount consisted of 30 individual parts combination of sheet metal parts and many rivets and total manufacturing time was 70 days.

This project’s requirement was the production of functionally operational cable mount parts in the lead time of only just two weeks. The project involves analysis of the part, optimization of the design, and final production in that short time frame with compliance with the strict requirements for subsequent aviation industry certification.

2. Metal AM Cable Routing Mount – Solution and Results

Considering the situation – like part’s functionality, complex structure, and time frame – metal Additive manufacturing was the ideal solution. And, Sogeti High Tech followed the tried and tested development process to manufacture this part with metal AM (DMLM technology).

The design freedom offered by metal AM helps in integrating the whole assembly in a single part, hence, weight saving without affecting its functional requirement. Dedicated software used to re-design (topology optimization) the part.

The AlSi10Mg material for the cable mount was considered which ideal for thin-walled and complex structure.

Final part printing was done on EOS M 400 machine with the layer thickness of 90 µm. Final required time to manufacture this cable mount was 19 hours against 70 days for conventional manufacturing methods. Hence, reduction in production time by 90% is achieved with metal AM (DMLM) technology.

New designed cable mount resulted in significant weight reduction, i.e., from 452 gm for original part with conventional manufacturing to 317 gm for additively manufactured cable mount.

In addition to above mentioned results, i.e. lead time and weight reduction, metal AM offers others various other benefits as a consequence of these benefits and those are reduction in post processing cost, no longer need be held in stock, reduced development time, and reduced fuel consumption as a result of weight reduction.

About Us

We are Innovae3D company specialized in producing the parts using metal 3D printing, i.e. Direct Metal Laser Melting (DMLM) technology, for various applications. Innovae3D is AS 9100 and ISO 9001 certified company.

Innovae3D provides the complete solutions (starts from designing, printing, post-processing, to quality control and assurance) for tooling, automotive, aerospace, defense, consumer electronics, medical, oil and gas, and industrial sectors.

[objectify91]

Objectify is the 3D printing and Additive Manufacturing (AM) company in India, providing complete range of Additive manufacturing solutions in Plastics, as well as Metals including Titanium (Ti6Al4V), Aluminum (AlSi10Mg), Maraging Steel 1 (MS1), Stainless Steel 316L (SS-316L), etc.; all in-house through state of the art, manufacturing set-up.

We have successfully delivered various projects to leading Automotive, Aerospace & other companies, including HAL, BorgWarner Inc., TATA Group Companies, Mahindra Group Companies, Wipro, Havells, Philips etc.

[theankita1996]

The Insight Partners published latest research study on “3D Printing Metal Market Size, Industry Share, Trends and Forecast to 2028- 3D Printing Metal Market Forecast to 2028 – COVID-19 Impact and Global Analysis – by Metal Type (Titanium, Nickel, Stainless Steel, Aluminum, and Others), Form (Powder, Filament, and Others), End-Use Industry (Aerospace & Defense, Automotive, Medical, Construction, and Others), and Geography," the global 3D printing metal market size is expected to grow from USD 4.5 billion in 2021 to more than USD 13 billion by 2028 at a CAGR of 16.5% between 2022 and 2028.

[veerometalsindia]

[otterloreart]

Takara Pony model file (.blender)

Linked is the file for the Takara pony I made (pictured above in pink). As a reminder, this is made from scratch and I don't have my own takara pony but I used as many references as possible. The joints are ball-joints but will require some additional work to use them properly, the joints need a bar across the opening to attach a hook and elastic to.

see below, black bar is a metal rod, blue S is an S-Hook and red is an elastic.

And this would be roughly how to string it, this is inspired by Dollightful's bunny doll but I also advise that the elastic between the legs be pulled upto the hoop as well if possible. The head is not a ball joint, the head + body and head + nose are meant to come together with a peg-in-socket. For the head, the tightness of an elastic should keep it on ideally, but honestly I don't know if the nose will stick in perfectly and might need to be glued, I'm not sure.

In addition to the ball-jointed takara pony, who is 9 separate pieces, I included a simple little sculpt of the "baby pony" takaras. These are just 2-part sculpts and don't need elastics or anything, they have a "peg" and "hole"

Takara baby ponies are already common on the market so I'm not sure if anyone will actually want the babies but I included it anyway. The eyes + nose are just cosmetic, the whole head is just one piece.

Anyways, a reminder that I don't have a 3D printer so I haven't tested it but feel free to download and play with the files and print them yourself if you have a 3D printer! Please credit and also tag me so I can see if someone prints them!

[metal3d]

6 MOST POPULAR INDUSTRIES TO USE METAL 3D PRINTING

Metal additive manufacturing has recently developed a lot to bring great benefits to different business sectors. These benefits include reduced material use, lowered costs, and production acceleration. It also enables designers and engineers to create anything from jigs and fixtures to more advanced forms like visualisation aids. The possibilities of using 3D printing for product development and manufacturing in different industries are limitless. The days are not far for you to think of outsourcing metal 3d printing for your industry. The countdown begins!

[materialsscienceandengineering]

Technique for 3D printing metals at the nanoscale reveals surprise benefit

Late last year, Caltech researchers revealed that they had developed a new fabrication technique for printing microsized metal parts containing features about as thick as three or four sheets of paper. Now, the team has reinvented the technique to allow for printing objects a thousand times smaller: 150 nanometers, which is comparable to the size of a flu virus. In doing so, the team also discovered that the atomic arrangements within these objects are disordered, which would, at large scale, make these materials unusable because they would be considered weak and "low quality." In the case of nanosized metal objects, however, this atomic-level mess has the opposite effect: these parts can be three-to-five-times stronger than similarly sized structures with more orderly atomic arrangements. The work was conducted in the lab of Julia R. Greer, the Ruben F. and Donna Mettler Professor of Materials Science, Mechanics and Medical Engineering; and Fletcher Jones Foundation Director of the Kavli Nanoscience Institute. The paper describing the work, "Suppressed Size Effect in Nanopillars with Hierarchical Microstructures Enabled by Nanoscale Additive Manufacturing," is published in the August issue of Nano Letters.

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[3dprinterchat]

Stratasys is ready to take the lead.

[wipro-3d]

DFAM Expertise| Optimizing Metal 3D Printing for Accurate| Efficient Design| Wipro-3D

Wipro 3D Design for Additive Manufacturing (DFAM) can transform your metal 3D printing process. Our DFAM expertise enables you to optimize product design, reduce production time, and achieve greater accuracy.

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[innovae3d-pvt-ltd]

The Advantages of Conformal Cooling in Reducing Cycle Time

Evaluating the efficiency of injection moulding is dependent on its productivity and quality of component. The proximity of cooling channels decides the cooling efficiency. Even a slight variation in the distance between two cooling channels can cause uneven heat dissipation. This result in increased cycle time, sink marks, part warping, reduced tool life due to heat stress and internal part stresses.

Importance of Reduced Cycle Time

The pace of the injection moulding machine in your factory will decide how much profit your company will make. Cooling takes a significant portion of cycle time, which is why it also has major focus when trying to improve business operations.

Conformal cooling tooling has proven effective in reducing cycle time, by as much as 70% in some cases. Till a few years ago, conventional manufacturing techniques could create cooling channels but this usually limited freedom of design and upped the cost of manufacturing in many applications. However, using additive manufacturing (AM), or 3D printing, as it is popularly known, helps you to experiment with fewer limitations, and reduces cycle time effectively.

Using DMLS, it is possible to design and develop extremely complicated geometric shapes and complex functional components in the most cost-effective manner. In essence, direct metal laser sintering lets you insert cooling channels without drilling, thus making the design more feasible and functional.

Points to Consider when using Conformal Cooling Technique

There are four main principles that guide the functioning of conformal cooling method.

1. Wall Thickness

Cooling time exponentially increases with increase in thickness of walls of the component being manufactured using DMLS conformal cooling method. For instance, a component with a 1-mm thick wall takes around 5 seconds to cool down while a component with walls 5-mm thick may take as much as 40 to 75 seconds.

2. Thermal diffusion

Thermal diffusion is the ratio of thermal conductivity to heat capacity. This factor is vital because when thermal diffusion of a material is low, the longer it takes to dissipate heat.

3. Mould temperature

High mould temperatures allow lowering of pressure during the filling phase. This helps to get a better surface finish on components and can also increase cooling time multi-fold.

4. Pitch and Depth

The depth, size and spacing of cooling channels should cause the temperature to change across the mould surface by 5 to 10 degree Celsius. Increasing the number of cooling channels placed close together near the surface accelerates cooling and also maintains temperature uniformity.

Benefits of Conformal Cooling in Reducing Cycle Time

Conventional cooling methods often cause shrinkage on core side, creates gaps in the part with limited space and the channels in the core are likely to experience higher temperature exchange.

To remedy this, the best way is to use two thermal controllers, choosing a lower-conducting material for cavity and changing the distances between channels and cavity. This method works incredible well for numerous applications.

Here are the distinct benefits of using conformal cooling tooling for prototyping and manufacturing:

1. Less cycle time

Various studies have shown that conformal cooling can cut cycle time by as much as 70% as compared to traditional cooling channels.

2. Freedom of design

This technique helps designers to create smooth transitions and smaller diameter channels with elliptical or circular cross-sections. Conformal cooling helps to reach spaces not allowed with conventional cooling channels.

3. Better quality

With uniform temperature distribution through conformal cooling, it is possible to reduce risk of stress that can cause visual defects and deformation of design. This helps improve product quality noticeably.

Conclusion

Using conformal cooling technique, it is possible to not only reduce cycle time, but also improve product quality, create incredibly complex designs and control the functionality of components more effectively. Last, but not the least, conformal cooling eventually helps to improve your company’s profits.

[richerlandtv]

So last year when the 15th Doctor's Sonic Screwdriver was revealed...

A lot of people were going on about how it doesn't look enough like a screwdriver. It made me think "well, what does a Sonic Screwdriver look like?" And the more I thought about it, the more I thought, ultimately, you can get away with a lot with the Sonic Screwdriver so long as it's at least cylindrical.

So I opened up Maya and made a bunch of pieces and swapped them in and out until...

I had designed my own Sonic Scriver. Quite proud of it, too!

But to fabricate it, all I could really do was 3D print it, and while it's lovely for a hunk of plastic it just doesn't do anything.

So I asked a wizard.

Custom Sonics are absolutely amazing at making Sonic Screwdrivers. I sent them 3D turnarounds, photographs, and design documents and good (time) lord did they knock it out of the park.

Look at this!

It's absolutely beautiful!

Machined in real metal, with brass accents and durable resin grips, and fitted with lights and sound. Its weighty but light, feeling good in the hand.

I feel like it certainly measures up to other Sonic Screwdrivers!

I am so happy and so proud to have this in my collection.

If you want your own Sonic Screwdriver, definitely consider Custom Sonics for replicas, original designs, or to get a quote on your own custom design! (I'm not being paid to advertise, I promise lmao)

About the design:

I wanted this to look like the original Sonic Screwdriver had been built upon over the years, rather than simply being replaced. So there are elements of the Sonic Screwdriver seen in the Classic series acting as a base for the design, with everything else added on over the top.

Thinking of how the Doctor might improve on that original design in-universe, I thought about its weaknesses as an item. The Doctor could easily drop it and it might roll away, so I added a flat-edged grip. It also gets used a lot, so I thought it should have a ventilation system to prevent overheating. There are two sets of vents: the round ones near the top, and more subtle square ones near the grip.

The War Doctor uses the original Sonic Screwdriver but with the emitter head removed. We're never told why, but I like to think this, along with the additional piece added to the base, was done to give it more power. With that in mind, I thought perhaps an even more powerful Sonic Screwdriver - without an emitter ring - would need something to focus and stabilize the sonic waves. The Eleventh Doctor's and Fourteenth Doctor's Sonic Screwdrivers have "petals" which may or may not serve that function. This design has two additional emitters mounted on antennae to focus and stabilize the beam. The emitter head has a screw thread so a new emitter ring can be screwed on. I did design an emitter head, but with the stabilizers, the shape wasn't very satisfying, so that went unfabricated.

The base was left with an opening, which I imagined would allow it to plug into the TARDIS. This worked out well as it left room for Custom Sonics to install a charging port.

The brass rings were inspired by the Dalek Time Controller and The Rani's TARDIS console.

The silvery metallic blue colour was inspired by K-9.

The emerald and brass colours were chosen simply because it's my favourite colour combination. The use of brass was also inspired by clockwork, with its obvious relation to time travel and my own personal enjoyment of clockwork.

So that's my custom Sonic Screwdriver!