What is the number one reason to leverage 3D printing?  My new answer.....Innovation.

Having been involved in the 3D print industry for over a decade, many people ask me the reasons for implementing 3D print.  My standard answer is usually it's not just one reason but it's the desire for a company to reduce time to market, produce goods not possible before, reduce costs, and be more innovative.  The last item – innovation – being the one that very rarely people asked me to expand on.  In reading a recent article from Kathleen Gallagher from the BizTimes in Milwaukee – I had an aha moment.  We should all focus on innovation!

She wrote a great article on the recent struggles of Briggs and Stratton and their lack of innovation.  You can read her article here:   BizTime Viewpoints: Lack of innovation explains collapse of Briggs & Stratton

I do realize the challenges Briggs and Stratton faced went well beyond innovation but it put it in perspective when I try to work with clients to help explain how best in class companies are leveraging 3D print.  Most people look to 3D printing for prototypes or to replace existing processes directly but what we need to look at is how to be innovative in leveraging game changing technology – whether 3D print or something else.  With 3D print technologies from HP and Carbon, now is the time to really look at not only your current challenges but future opportunities.  Look to be innovative.  It won't be fast or simple but look to be a game changer to ensure your future success. 

When I look at the typical design process I break it into 4 basic steps.  

1. Sales/Marketing - Develop an idea
2. Design & Engineering - Create the actual design
3. Test & Validation - The process to produce the good is developed
4. Manufacturing & Production - Goods are actually produced
   

This design wheel represents my view.

To me – if you apply “innovative” thinking to each step and how 3D printing can move your company forward – this is the future we desire. Of course we will still have the standard applications where prototypes improve time to market or decrease errors but real innovation will come when you look at additive manufacturing differently. You will need to change old processes, put new standards in place, think differently, etc… This needs to start at a management level so that employees are encouraged to challenge old ways and look at new markets. Often we see the end engineers using 3D print to solve current pains – not develop new applications or markets.

Getting back to Kathleen’s article, it’s tough for any company to survive 100+ years and the only way to do so is evolve and innovate. You can’t be the same company over time. Think of Apple and Microsoft for how they have evolved and innovated. Even MasterGraphics as a smaller company has only been able to survive 70+ years because we have evolved and re-innovated ourselves to be completely different than we were from our origins. Yes, we serve the same industries, but with different solutions.

I encourage you to really step back, to view 3D print anew and how it may be able to move your business forward. At the beginning the end goal is usually a “pipe” dream but as we all have experienced, it does not take long for innovation to deliver on future dreams. Hello self driving cars!

I look forward to any thoughts about what I wrote – even challenges to my thinking. You can take a closer look at the latest 3D print technologies here http://www.mastergraphics.com/3d-printers/ but most importantly if you want to have a discussion around innovation – don’t hesitate to reach out to me.

I wanted to share a great eBook from HP on how educators can lead the way into the industry of tomorrow.  This eBook explores how 3D printing began, how it has evolved, and how it will change the culture of design, as well as the potential of 3D printing for higher education.  The principles outlined mirror many of our other blogs we have posted so make sure to check out the rest of our expert center to learn more.  I truly believe our students are the future for leveraging 3D print and we need to ensure they are learning and applying the technology for the implementing Industry 4.0.  We at MasterGraphics are always looking to support education so don’t hesitate to reach out to me directly with any questions or requests for support.  For now – download this eBook and enjoy.  

Kevin Carr
President
kevin.carr@mastergraphics.com
847-704-4025

As the current situation with COVID-19 (known as coronavirus) continues to evolve, MasterGraphics wants to assure you that we are working to protect our employees, customers and partners. Health and safety remain our highest priority.

We are committed to being responsive to the needs of our customers as this dynamic situation evolves. We are monitoring this situation and want to ensure minimum disruptions, and to make sure we do everything we can to provide you the support you need.  The plans we have in place are designed to ensure our continued service to you.

Here are some steps MasterGraphics has taken to address the risk of COVID-19:

• Evaluated travel restrictions for associates to eliminate or reduce travel when possible and reviewed facility access for associates and visitors to minimize the risk of exposure
• Ensured availability of alcohol wipes, sanitizers, tissues, and other needed supplies for use in the workplace
• Developed contingency planning for alternative work arrangements such as working from home

And, here are some vendor replies regarding the steps they’re taking to minimize the impact to our customers:

HP (SYNNEX): (ink & 3D Supplies) We are increasing our warehouse inventory to ensure continued fulfillment on demand and to minimize the impact to our customers. We are managing our supply chain and making every effort to understand and offset the potential impact of production and delivery delays.

OCE' / CANON (media): We are in close contact with our vendor and supply network as they work through potential supply chain issues resulting from the COVID-19 issue.  Our commitment is to take proactive and proportional steps in accordance with the guidance we receive from government and public health authorities.  These actions are designed to minimize the risk of virus spread among our employees and Canon workplaces while ensuring effective business continuity. 

DIETZGEN (media): We do not anticipate any shortages or delays due to the Coronavirus at this time. We will continue to work with our manufacturing partners to monitor any impact to the supply chain that might cause an interruption or delay. While it is more difficult to confirm available logistics and delivery dates at this time, we believe our global manufacturing and logistics capabilities will keep us well positioned to work through these challenges.  We have taken steps to ensure the safety and wellness of our employees and secure our product supply chains.

MasterGraphics appreciates your business and we remain committed to providing the superior service and support that our customers have come to expect of us.  Don’t hesitate to reach out to us with questions or concerns.

Kevin Carr
President
kevin.carr@mastergraphics.com
847-704-4025

MasterGraphics Incorporated, with a corporate office located in Madison, WI, is deemed as an “Essential Critical Infrastructure Workforce” based on the recently released guidelines published by the Cybersecurity & Infrastructure Security Agency (CISA). We are part of the supply chain to various Energy, Government, Communications, Healthcare, and Critical Manufacturing facilities in the United States. Therefore, our continued supply of services, equipment, and other services will continue without interruption.

HP recently announced the expansion of their Multi Jet Fusion (MJF) printer line up to include the new 5200 series.  This has created many questions around the difference between the recently announced 5200 and the existing 4200 since architecturally they look similar.  Let me take a quick step back and provide some background on the 4200 before I get into the differences.  HP launched their ground breaking 3D print technology (MJF) with the 4200 back in 2017.  The 4200 provided revolutionary 3D print technology that moved forward the ability to mass print plastic (PA12 at launch) parts at speeds, cost, and ease of use not seen before in additive manufacturing.  I describe MJF as Selective Laser Sintering (SLS) on steroids.  HP’s MJF technology truly changed the 3D print market and started a further shift from prototyping to manufacturing.  You can see how the 4200 built new service bureaus who grew based on HP’s technologies and how companies now manufacture truly use parts from the 4200 as final parts.  Here are some of those service bureaus who have grown substantially due to HP. 

Personally in my 12 years spent within 3D printing, I have not seen any other technology change the 3D print landscape like the 4200.   The 4200 met its promise to bring Additive Manufacturing to the masses.  Earlier this year, HP started shipping the 500 series that added the ability to print color but lacked the throughput of the 4200.  The differentiation between the 500 series and the 4200 was clear.

Now to the introduction of the 5200, how does this fit in the evolution of HP’s technology? The 5200 does not replace the 4200.  The 4200 will stay as a production unit and still provides manufacturing capability.  The 5200 is the next step forward to increase throughput and most importantly provides tools and processes for manufacturers to replicate the manufacturing standards and processes they currently use in production.  It has more advanced software when compared to the 4200 and provides a feedback loop to allow even better control of output quality.  The 5200 is sold at a premium price so depending on your needs, the 4200 still may be a fit. 

Here is an outline of some of the key advancements now offered with the 5200 versus the 4200.  Keep in mind the goal of the 5200 is to bring true manufacturing predictability and standards to Additive Manufacturing and provide even faster throughput.

Breakthrough Economics vs the 4200

Up to a 30% cost per part savings due to multiple machine advancements including:

• One pass printing (versus two on the 4200) resulting in up to 50% less agent consumption
• Shorter routine on print head wipes needed as part of the print process
• 4x longer cleaning roll for better cost efficiency

Improved throughput

Warm up time cut in half versus the 4200

• Faster print times: 5200 in balanced build mode finishes a full build in 11.5 hours compared to 14 hours by the 4200 in balanced mode.
• Enabled via 1 pass printing vs 2 passes- creating the true ability to get two full builds in 24 hours
• Fast build mode reduced to 9 hours from 11.5 hours versus 4200.

Manufacturing standards and controls designed into the printer and software.

• The 5200 has the capability to reach a Cpk of 1.33 on an IT scale of 13. Process capability index (Cpk) is a statistical tool, to measure the ability of a process to produce output within customer’s specification limits. In simple words, it measures producer’s capability to produce a product within customer’s tolerance range. Cpk of 1.33 equals a process yield of 99.99%
• The new Process Control Center software focuses on calibrating Z dimensional accuracy for improved accuracy and repeatability to achieve more accurate output.
• Production software is enabled on the 5200, it uses data feedback from the printer to adjust settings and learn as it prints to improve accuracy and reliability based on the advanced sensor built into the 5200.
• Improved Heating control: the 5200 now has 22 lamps with 14 zones of control (compared to 20 lamps with 12 zones of control on the 4200) – 5X better thermal camera and improved data feedback to measure more minute heating variations, and therefore provide more precise heating adjustments.

Screenshot of the Process Control Center

There are some significant hardware differences to improve manufacturability:

• Better cooling of the print heads to eliminate print failures
• Improved Lamp control: The lamps are now engineered to only use about 50% of their capability which allows improved reliability and the printer can now more easily “throttle up” or “throttle down” the lamp control (in smaller increments) to more precisely control the heat to specific areas of the print bed based on the improved thermal readings from the thermal camera.
• Lamps will now always stay “on” thus allowing for longer lamp life eliminating the cycling of on/off that would reduce lamp life
• Smaller micron layers than the 4200 – now 110 micron layers
• Semi-Automated Printhead alignment: This new process assures X&Y dimensional accuracy
• There have also been improvements in airflow via better seals, fans, and flow-through (via a 2nd “Lung” on top left of machine)
• Machine now has fans & sensors to mitigate against suction/pressure variations created at customer site

New materials support

• Machine designed to support materials up to 225C which enables a larger breadth of material possibilities
• Build unit designed to work with lower flow type materials
• There are redesigned ramps for the material to better flow inside the build unit
• Processing station redesigned to be able to unpack materials at higher temperatures
• Ultrasonic sieve (in processing station) with a wider mesh thus enabling more versatility to supporting new materials
• TPU Material available from BASF: BASF TPU01

• HP has developed specific natural cooling units to allow the cooling of builds without leaving them in the build carts.
• As special Hovmand Forklift allows the moving of the cooling units from the build cart for improved productivity.

These are just some of the highlights.   I encourage you to look closer at the 5200 if you are looking to implement true additive manufacturing.  The 4200 still has a place in the prototype and production space but if you want to have a system designed for manufacturing with specific measurable standards in place, the 5200 is worth investigating. 

Feel free to contact me at Jim.Hill@mastergraphics.com or 847-704-4029

• 20LB Bond – Oce 45-111 series
• Océ 45111 is a 20 lb uncoated bond paper. Ideal for all general purpose copying and printing. The bright white sheet provides strong visual contrast. Océ engineering bond is manufactured to control curl and static. 3" core, untaped, available in 500' or 650' lengths.
• 24LB Coated Bond – Oce' PM24
• Océ 24 lb. Bond matte coated with bright white base. Inkjet receptive coating on front-side and anti-curl treatment on the backside. 

Communication/Posters

Type of Image: Company announcements, Signage, Information Boards

Recommended Media:

• 48LB Heavy Weight Matte Presentation Paper – HW48 – A 48lb (180 gsm), is an economical, bright white matte coated paper. This heavyweight coated paper is durable for short-term outdoor applications. It delivers water-resistant prints with no need for lamination when using pigment inks. This coating produces crisp lines, dense blacks and vivid colors with a fast dry-time.
• 24LB Coated Bond with Removable backing – Oce' ABBND; a bright white stock with an acrylic repositionable microspehere adhesive on the back that will mount to a variety of surfaces. This product is an excellent choice for indoor signage. The thin silicone release liner removes easily for quick mounting. Physical properties: 90gsm, 5mil, Opacity 91, Whiteness 94, Brightness 84, 3" core.
• 7mil Satin Resin Coated Photo Paper – Oce' PHPR7 is a 7mil satin resin coated photo paper. Main Applications are indoor display graphics, POP, posters and presentations.

Presentation/Charts/Infographics

Type of Image: Project Management Organizations, Construction Site Information,

Recommended Media:

• 48LB Heavy Weight Matte Presentation Paper – HW48 – Described above
• 24LB Coated Bond with Remove bale backing – Oce' ABBND – Described above
• 7mil Satin Photo – Oce' PHP7 is a satin resin coated photo paper. Main applications include indoor display graphics/POP, posters and presentations
• 8mil water resistant Polypropylene banner – Oce' 6008 is a polypropylene film designed to be used for short term outdoor graphics. Oce' 6008 is weather resistant and virtually waterproof. It can be used outdoors without lamination.

GIS Maps

Type of Image: GIS Images

Recommended Media

• 24lb Coated Bond Oce' PM24

Point of Purchase (POP) Signs

Type of Image: Retail Signs, Sales Signs

Recommended Media:

• 24LB Coated Bond with removable backing – Oce' ABBND – Explained Above
• 7mil Satin Photo – Oce' PHPR7 – 8mil water resistant Polypropylene banner – Oce' 6008 is designed to be used for short term outdoor graphics and is weather resistant and virtually waterproof. 

Banners
Type of Image: Various large format signs

Recommended Media:

• 5mil Water-resistant Matte Vinyl with PSA– Oce' OPVYNLPS – A 3.5 mil water-resistant, matte calendered vinyl with PSA. Whether you are creating a short term outdoor sign, or a long term indoor banner, Oce' OPVYNLPS is the perfect choice.   Specially designed for use with dye and pigment inks, Oce' OPVYNLPS can be used with or without lamination.
• 15mil Universil Economy Scrim Vinyl – Dietzgen 90042040 is a bright white scrim vinyl banner. It has scratch and waterproof matte coating and is tear resistant polyester fabric that is sandwiched between two layers of white vinyl.
• Oce' 10 mil Tyvek banner is a matte inkjet coated, tear resistant Tyvek. Inkjet coating compatible with many wide-format thermal and piezo inkjet printers. Durable and water resistant inkjet-receptive topcoat. Dye and pigment based printing capability for indoor and outdoor banner material. Very high tear strength and easy for grommeting and sewing. 
• 6 mil Polypropylene film with permanent pressure sensitive adhesive – Oce' OPPOLYPS is a 6.6 mil economical, water resistant polypropylene film with permanent pressure sensitive adhesive. Whether you are printing on thermal or piezo waterbased inkjet printers, the result will be brilliant color every time. The backside PSA will simplify the mounting and installation process and the water resistant coating means you do not have to laminate when using pigment inks.

Gift Wrap – Can you believe this one?

Type of image: Anything you want

Recommended Media:

• Satin wrapping paper – HP Z6G71A can produce high-quality wrapping paper and posters that provide excellent image quality. The paper dries quickly and stays intact with handling-avoiding smudges and smears.

Keep in mind if you have other large format inkjet printers we may have similar media to the above but specific to your advice.  Don’t hesitate to contact us for more information. 

Check out more media options at https://estore.masterg.com/

In this episode Kevin Carr, President of MasterGraphics shares his view on the Evolution of 3D Print & Additive manufacturing over the past 30 years.

MasterGraphics installs one of the first HP Multi Jet Fusion 5210 3D Printing Production  Solutions at Illinois based Service Provider RE3DTech.

Madison, Wis., August 13, 2019 – Last week, Re3DTech solidified its commitment to HP’s 3D print technology by adding the new HP Multi Jet Fusion (MJF) 5210 to its growing portfolio of HP 3D Printers. The Illinois based service provider has been a proponent of HP’s 3D print technology since its introduction three years ago. The 5210 installation compliments the multiple HP MJF 4210 and HP MJF 580 printing solutions already in place at Re3DTech.   Re3DTech has seen increased market demand in the mid to low volume production space since the inception of their business, which is built on HP’s MJF technology. The 5210 system builds off the core 4210 technology and adds software and print technology that brings traditional manufacturing practices and standards to additive manufacturing. These enhancements ensure repeatable and predictable results.  

Kevin Carr, President of MasterGraphics, explains “the capabilities of the HP MJF 5210 are game-changing. This new technology creates more scenarios where it is cost-effective to utilize additive manufacturing versus traditional manufacturing processes such as injection molding. As the market is changing and adapting to new 3D print technologies, digital manufacturing is a term we continue to hear more and more. Manufacturers want to be more innovative, cost-effective, and quicker to market. The HP MJF 5210 helps enable achieving these goals. We have seen a more flexible manufacturing process and reduction in overall inventory to produce specifically what you need.”

“We see clients such as Re3DTech not as a service bureau but as a manufacturing hub. We are at a true tipping point where innovators such as HP are providing technologies that production houses like Re3DTech are building businesses on by providing unique and cost effective manufactured goods”, says Carr.

Learn more about Re3dTech.

HP recently announced their new, sub-$100k, 500 series of 3D printers utilizing their innovative MJF (Multi Jet Fusion) 3D print technology. This is the same technology being used in HP’s revolutionary 4200 production-level 3D printers that were released in 2017. I should also note that HP MJF uses HP PageWide print head technology, which is also used in their 2D line of printers.

The 500 series of HP’s first expansion of their portfolio, at a lower acquisition price, and in the case of the 580, the ability to print true color. These are all-in-one systems, that produce nylon plastic white parts (HP 540), or full color (HP 580). For those familiar with traditional SLS, let me just repeat, these are all-in-one systems. Both printing and processing are contained in a single unit.

HP is positioning these units to not only produce traditional prototypes, but also short run production parts. While the HP 4200 is slotted for full production, the 500 series is intended to provide ramp-up capability for 3D print production.

The color technology integrated in the 580 is attracting most of the attention and, yes, although certainly industry changing, I believe the market is missing what the non-color version actually provides. Let me explain…

The base 540 systems starts below $90k and, although it does not offer color output, it prints utilizing HP’s Multi-Jet Technology. MJF melts PA12 nylon material, which on the 540, results in a smooth, white finish for outstanding visual appeal. More importantly, these are truly functional parts. In fact, I often refer to HP’s MJF technology as SLS (Selective Laser Sintering) on steroids. SLS has been the standard for high quality, durable parts and HP has created a process to increase productivity – up to 15 times faster – with less waste. Historically, SLS systems were north of $250k. In addition, you had to set up special environments and have highly trained operators. The HP 540 system is completely self-contained, office-friendly and easy to use.

In the past, our clients have spent more than $100k on 3D printers to produce prototypes; 3DS Projet 3500 for example; that were slow and expensive to run. Now, with the HP 540, you can make a similar investment and get the returns that, in the past, were only possible on systems costing well over $350k.

Our client’s previous investments around 3D printing clearly offered business advantages and financial returns but, with this new 500 series, offers a return on investment – also steriod size.

As a manufacturer, product designer, etc., this new printer truly offers a new way to be more innovative and get to market even faster. How fast? Within 24 hours you now have the ability to produce an end-use part – not just a prototype. Our smaller clients can compete with larger ones – in fact in most cases they are able to implement the process changes faster – this is the world we are living in.

In the past 18 months – we have helped two startup companies leverage HP Technology to create brand new businesses that are thriving.

I encourage you to look at the new HP 500 series 3D printers – look past the cool factor – and at the true design/manufacturing capabilities possible. we are in a Manufacturing revolution and HP has now provided a unique tool to help you be more competitive. Let’s build the future of manufacturing in the U.S. We are excited to have one of the first 500 series units installed at our facility and invite all to come visit.