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3D Printing for Foundries President and Future-壓鑄展-鑄造展-2015第十六屆廣州國際壓鑄、鑄造及工業爐展覽會-中國最受關注的壓鑄鑄造展會-巨浪展覽-The 16th Guangzhou Die-casting, Foundry & Industry Furnace Exhibition
12/4/2014 壓鑄展-鑄造展- Die-casting expo-foundry expo |
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Branch President Adrian Aspley welcomed members and visitors to this his final meeting of his presidential year. The Branch AGM preceded the lecture during which John Small was handed the chain of office as the President for the year 2015-2015. John Patterson gave the vote of thanks to the Branch Council for the work done on behalf of the Branch and Institute.
Following the AGM branch members with 30 and 50 years membership of the Institute were given pins to recognise this by outgoing President Adrian.
Dave Yair began by explaining that although the presentation had been prepared by Kevin Smith he was presenting because Kevin was away on business.
Voxeljet has its main office and works in Germany but also operates from 3 offices around the world. It employs 110 people and turns over �12m. Whilst it will sell printers it can also offer sand moulds and cores, patterns and models or carry out research and development for clients.
In 2002 Kevin Smith developed a rapid casting process using 3D printing technology. The printer at that time was a 2010VX500 printer but now the range has been significantly extended and includes the only continuous printer available to industry plus also the largest available at 4m x 2m x 1m. This process is another tool in the foundrymans tool box, not a panacea for all problems, and used as such offers solutions not available by other methods.
The first patent for the process was filed in Germany in 1997. Building in layers enables what would be impossible geometry by other methods. Gates and feeders can be placed where needed not constricted by joint lines for example. With well thought out techniques improvements in yield and better use of energy improved profits are possible.
Voxeljet’s customers rarely start by buying a printer first and developing the need after but would initially purchase product whether that be moulds, cores, patterns, or any other of the many parts available from the process and would continue to do so until economics suggested it was the right time to buy a machine and produce in house. Development does not stop there and when a customer has reached capacity with his machine would go back to purchasing the extra requirements until again the point has been reached where purchase of a second machine is viable and so on.
Modern equipment will enable a full 1m x 1m x 1m build to be completed in 30 hours and with reducing operating costs and 24/7 operation the number of parts necessary to produce before the process becomes viable is falling. The range of machines available also ensures that there is a machine available to suit most needs and pockets.
Techniques available also have developed with printing, sintering, fused deposition modelling and direct laser sintering providing wide choice covering vast industry sectors. The materials now available to industry is also vast and growing. Voxeljet Services however concentrate on two materials, PMMA and sand.
With PMMA as the build medium the sectors serviced include patternmaking, art, entertainment, modelling, design and development. The film industry is a major user of products produced by the process and Pinewood Studios has two machines for the production of models and special effects.
Sand printing is primarily for the foundry industry producing moulds and cores the resultant products used in a multitude of industries from automotive to art to any number of other areas. The process opens up opportunities for exploitation, new markets for example, or reduced development time and if the foundryman makes the most of the process by designing for 3D printing the opportunities are vast. He is not constrained by joint lines and other limitations of more traditional processes giving more freedom to engineer the ideal solution. Cores and moulds can be made hollow reducing cost and weight and providing ideal venting of moulds and cores.
Since its introduction development has continued at a pace and materials and markets have expanded as a result. For the future the process could move into ceramics, concrete, nylon and special sands. Even materials specially created for the process could be developed.
The challenge to the foundryman was to visit the Voxeljet manufacturing facility in Augsburg, take part in a design workshop together with the end user and or design engineer and see what is possible. Choose a project to case study and see what advantages may be gained. Become aware of opportunities that 3D printing technology may bring to the business as others are doing thereby keeping abreast of latest technology which just may provide an answer to a problem if not now but in the future.
壓鑄展-鑄造展-2015第十六屆廣州國際壓鑄、鑄造及工業爐展覽會-中國最受關注的壓鑄鑄造展會-巨浪展覽-The 16th
Guangzhou Die-casting, Foundry & Industry Furnace Exhibition
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