Rapid Prototyping Machines

Incorporating Screw Threads Into FDM Parts
Screw threads are one of the most common components used for fastening parts in an assembly or attaching pipe tubing together. Here are five ways to incorporate screw threads into Fused Deposition Modeling parts, followed by some useful applications.

Threads directly from the FDM machine
Depending on the pitch and helical profile, it may be possible to design your desired thread right into the CAD file. Typically, large pitched threads on parts used for...

Many years ago I was given the opportunity to design my first product. The terms rapid prototyping, 3D printing, and 3D prototyping were foreign to me. Although I felt confident in my abilities to design a complex piece of equipment, I was ill-prepared when it came to making the parts I needed.

We had a large in-house machine shop and I was assigned a machinist to build my prototypes. I would bring him a drawing of a part I’d worked on all day. He would bring me the part and I would find an error...

This is the first of many posts in a regular series from Stratasys application engineers, who’ll offer technical advice, new ideas and experienced reflections on Fused Deposition Modeling from an engineering perspective.

One thing that’s true of rapid-prototyping machines across the board is that some post-build processes must be done before a 3D printed or rapid-prototyped part is ready to be used. The parts have been built, but support removal and/or some additional post processing is required.

W...

Last week Gardner Publishing, launched “Additive Manufacturing,” a quarterly supplement to Modern Machine Shop and its sister publication, MoldMaking Technology. A surprising move, since these publications are aimed at CNC and mold-making facility leaders.

By recalling hockey legend Wayne Gretsky’s secret to success, Senior Editor, Peter Zelinski explains why Gardner launched the publication. Gretsky said his secret was to skate where the puck is going, not where it’s been. It involves “seeing...

At Evektor  s.r.o, headquartered at the international airport in Kunovice, Czech Republic, size is no longer an issue when it comes to producing prototypes for lightweight aircraft, automotive and consumer components.

When outsourcing proved too time consuming and the costs to produce large components such as airplane dashboard covers started to soar, Evektor turned to Stratasys and its Fortus 900mc system -- a 3D production system which utilizes fused deposition modeling. This in-house solution...

Until our economy turns around, will you hunker down or invest in technology?

When the economy started to tank, Matt Hlavin, CEO of Thogus Products, a 61-year-old manufacturing company rooted in injection molding and heavily dependent on the automotive industry, chose not to await economic recovery, but to invest in Fused Deposition Modeling (FDM) technology and diversify. His decision has paid off in spades.

With FDM in place, Thogus shifted to small-volume molding and now competes with high-cost...

Today Stratasys introduced a new soluble support material for its rapid prototyping and direct digital manufacturing systems. It's called SR-100 and it's for use with the polycarbonate (PC-10) formulation. Without a soluble support material, the prototype's supports must be manually removed. Automating the process speeds up the time to get a finished part in hand. Dissolve time is only about 30-120 minutes.

Prior to this introduction, soluble support material was available only for material...

As additive manufacturing is used more frequently to produce short-run production parts and manufacturing tools, like jigs and fixtures, engineers need to consider how well the parts hold their dimensions over time. The main controlling factor in assessing dimensional stability is the production material.

A Stratasys white paper, entitled "The Accuracy Myth: Don't Make the Mistake of Confusing Resolution with Accuracy" addresses the question of long-term stability of parts produced by additive...

As OTTO, maker of precision controls and communication devices, celebrated its 50th anniversary, it tested a new capability: in-house rapid prototyping on a Fortus 3D Production System. OTTO can design, test and manufacture devices for its demanding military, public safety, medical and commercial clients — all right at home on its Carpentersville, Ill., campus. Machine Shop Manager John Lang, while considering bringing a Fused Deposition Modeling system into the OTTO fold, used a trial...

What could you do in the time it takes to brew and drink a pot of coffee?

Nestlé Nespresso S.A. can pour out a new iteration of its highly-designed single-serve espresso machine with caffeinated speed thanks to its Diminsion 3D rapid prototyping machine.

If you're an espresso afficianado, then you know the care, craftsmanship and attention to detail that goes into each tiny cup. More than 20 years ago Nestlé Nespresso developed a home-brewed option that rivals the pours of trained baristas. The...

When making a business case to purchase an additive manufacturing system the primary focus is usually on the money that can be saved. Another benefit that is more difficult to quantify is the ability to produce prototypes faster, which in turn can result in the ability to get your product to market faster. The problem is that it’s sometimes difficult to quantify additive manufacturing’s ability to make prototypes and production parts faster. A white paper addressing this issue follows, along...

Deploying a robot in space takes preparation. To help astronauts train to use Robonaut 2 (R2), a humanoid helper, aboard the Space Shuttle Discovery on its final flight, engineers used RedEye On Demand's rapid prototyping service to create a full-scale, high-fidelity mockup.

Created by high-tech firm Wyle, R2 works alongside astronauts, taking over repetitive and dangerous tasks. So the mockup had to duplicate the geometry of the actual R2, with poseable limbs and an ability to withstand rough...

Wanting to get new products to market faster, but faced with a bottleneck in first-article inspection, Oreck Corporation found a new use for Fused Deposition Modeling (FDM).

Oreck, which manufactures lightweight cleaning products, uses a coordinate-measuring machine to inspect the dozens of parts that fit snugly into every new product. Inspection happens before the new item can enter production, and requires great precision. Custom fixtures must hold the part perfectly level to avoid...

You know an additive manufacturing system can benefit your operation. But when building a business case for system purchase, be careful not to overstate the benefits or state them in a way that will threaten key players in your organization. A Stratasys white paper addresses how to create a business case that is compelling and believable. It is entitled, "Making the Case: How to Justify the Cost of a Rapid Prototyping System." Below is the second in a series of excerpts from this white paper,...

Fused Deposition Modeling (FDM) technology is helping manufacturers get complex products to market more quickly and at less expense than more traditional manufacturing processes. Following are just a few examples of the advantages offered:

Repeatability. Fused Deposition Modeling uses thermoplastic material, which provides for more consistent, finely finished models and parts, speeding your product to market faster.

Digital technology. With only a change to the CAD data, new variations of products...

Frontline engineers usually have no difficulty seeing the value of an additive manufacturing system, but convincing the executives who must sign off on the capital expense is more difficult. A white paper is available to help designers, engineers and product managers make the business case for a system. The first in a series of excerpts from this white paper entitled “Making the Case: How to Justify the Cost of a Rapid Prototyping System,” provides an overview of the paper and is followed by a...

By Ruth Jacques

FDM speeds design cycle for cycling app

Real-time analysis of performance metrics can be the split-second difference between first and second place for competitive cyclists. Pedal Brain has created an app for that. Its iPhone accessory logs data to an integrated  Web platform for coach and teammate use.

Highly customized cycles, however, require different brackets to hold the application in place, so Pedal Brain created multiple $300 prototypes via a contracted stereolithography...