SHOP
1 min read

Miss our webinar on Additive Mfg in Education?

By Lynn Milbrath on Jun 15, 2020 1:55:22 PM

Did you miss our webinar on Additive Manufacturing in Education that we did with HP?  Don't worry I did too,  good thing we recorded it.  I just got done watching the webinar and I am excited to share a few new things I learned.

The first thing I am super excited to tell about (even went home and shared it with my family) was the HP 580 Multi Jet Fusion (3D printer) has 140 3D printed parts inside it.  HP used one of its production machines and printed the parts to be used inside.  I found this so cool!  Think of the opportunities this can lead to for a supply parts business.

Another thing I learned was what great opportunities HP and even my own company have to offer institutions educating our future workforce in additive manufacturing. HP has created a curriculum that is easy for institutions to obtain free, simply by filling out a survey.  And MasterGraphics can train new students on systems or help institutions with fund raising.

I encourage you to watch the webinar for yourself to learn more about how HP and MasterGraphics can help support education for the future.

View the webinar on our youtube channel: 

 

Topics: 3D Printing Education
1 min read

New opportunities for higher education to train the workforce for Industry 4.0

By Gene Call on May 18, 2020 8:14:13 AM

Kevin posted an eBook for educators previously and I wanted to follow that up with another great HP e-book on how HP Jet Fusion is opening new opportunities for higher education.   We at MasterGraphics have seen how 3D printing is genuinely transformational for manufacturing and believe higher education institutions will play a central role in driving the Fourth Industrial Revolution.  Together we can change the landscape of design for all manufacturing.  Students with access to innovative technology, such as HP’s Multi Jet Fusion 3D printers, will have the skills demanded by industry when they graduate. 

This e-book outlines the transformative effect 3D printing will continue to have on the way we design and manufacture, and the role higher education will play in the process. It covers the basics of Additive Manufacturing, how 3D printing began, how it has evolved, and how it will change the culture of design.

As Kevin mentioned previously, we believe in the potential of 3D printing and the need for higher education to have the right technology in place.  Enjoy the read and feel free to reach out to me if you think we can assist in anyway with your efforts to build the workforce of the future.   

Download Ebook

Gene Call
gene.call@mastergraphics.com
800-873-7238 x2735

Topics: 3D Printing Education
1 min read

How educators can lead the way with 3D print

By Kevin Carr on May 15, 2020 3:37:09 PM

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

 

 

Topics: 3D Printing
2 min read

How to Minimize Warpage in HP MJF Parts

By Mark Blumreiter on Mar 6, 2020 11:19:36 AM

The HP Multi Jet Fusion (MJF) printing process is similar to injection molding in a few ways. MJF and molding are both heat-based processes that melt raw plastic to form the final part shape. Because of this, there are similarities in how to properly design and prepare a part for each manufacturing process.

Just like injection molding, we want to control the heating and cooling in MJF printing to ensure good part quality. The MJF process uses a combination of lamps and thermal cameras to do this. By monitoring and controlling the heating/fusing and cooling process we can prevent or minimize defects like warpage.

Figure 1: HP MJF Printing Process

MJF Printing Process

Warpage

Warpage is a possible defect in any polymer process that involves heat. Warpage is especially common in long, thin, flat parts. (aspect ratio greater than 10:1) When plastic cools from molten to solid, it contracts to take up less space. When one area of a large flat part cools before another area, it can “pull” the part towards it. With small compact parts (as opposed to long thin parts) it is much easier to control the cooling and prevent warpage.

warpage b

For large, thin, flat parts, we recommend placing the parts parallel to the X-Y plane. This causes the part to melt and cool at a consistent rate. To further prevent warpage, align the length of the part in the Y-axis. The lamp carriage moves in the X-axis, so it will fuse the entire part at once when it move across. Along these same lines, try to avoid fast cooling if warpage is an issue. This allows the parts to naturally cool while they’re “held in place” by the surrounding powder.

Parts placed in the center of the build volume towards the bottom will be the least prone to warpage. This is because it will cool the most uniformly (from the outside in)

Figure 2: Avoid warpage by placing parts flat in the center-bottom of the build area

build

Design Changes

If that still doesn’t work, we have a few more options. One, we could print other parts, or even sacrificial parts, surrounding this large one. This, in effect, cages in the bigger part to hold the heat in and also slows down the cooling so it’s nice and uniform. Just like injection molding, we can’t let one area cool faster than another or it will warp. The other option is to add some ribs or supporting geometry to your part to prevent warping. Depending on your application this may or may not be possible. You can design in support bars to keep a part aligned while it cools, then snip the alignment bars off. This is similar to trimming the plastic from the gate in a molding process.

Material Considerations

PA11 will be most susceptible to warpage. If flatness is a major concern, we recommend using PA12 or PA12 with glass beads. If PA11 is necessary, use the Fast print mode. Regardless of which material is used, the HP MJF parts are usually flexible enough to easily be re-shaped or pushed into their final mounting position.

Keep these best practices in mind when designing and preparing your MJF prints, and you should be able to eliminate or at least minimize warpage in your parts.

Topics: 3D Printing
2 min read

Why is additive manufacturing unstoppable?

By Jim Hill on Feb 10, 2020 2:42:14 PM

As additive manufacturing technologies have advanced, 3D printed parts have moved decidedly outside the Research and Development arena and onto the production line. These pivotal processes are developing and producing concepts previously unattainable in the manufacturing world.

Entrepreneurs to Fortune 500 companies and large OEM’s have embraced the advanced enterprise of 3D printing to meet their tough performance standards and requirements. As companies have designed for additive manufacturing and utilized it as a compliment to traditional manufacturing, new applications have come to the scene and changed what’s possible.

There are four industries in particular where the amazing capabilities of additive manufacturing have transformed production:

1. Aerospace
Aerospace companies were some of the first to adopt additive manufacturing. Some of the toughest industry performance standards exist in this realm, requiring parts to hold up in harsh conditions. Engineers designing and manufacturing for commercial and military aerospace platforms need flight-worthy components made from high-performance materials.

Common applications include environmental control systems (ECS) ducting, custom cosmetic aircraft interior components, rocket engines components, combustor liners, tooling for composites, oil and fuel tanks and UAV components.

3D printing delivers complex, consolidated parts with high strength. Less material and consolidated designs result in overall weight reduction – one of the most important factors in manufacturing for aerospace.

2. Medical

The rapidly innovating medical industry is utilizing additive manufacturing solutions to deliver breakthroughs to doctors, patients and research institutions. Medical manufacturers are utilizing the wide range of high-strength and biocompatible 3D printing materials, from rigid to flexible and opaque to transparent, to customize designs like never before.

From functional prototypes and true-to-life anatomical models to surgical grade components, additive manufacturing is opening the door to unforeseen advancements for life-saving devices. Some applications shaking up the medical industry are orthopedic implant devices, dental devices, pre-surgery models from CT scans, custom saw and drill guides, enclosures and specialized instrumentation.

3. Energy

Success in the energy sector hinges on the ability to quickly develop tailored, mission-critical components that can withstand extreme conditions. Additive manufacturing’s advancements in producing efficient, on-demand, lightweight components and environmentally friendly materials provides answers for diverse requirements and field functions.

Some key applications that have emerged from the gas, oil and energy industries include rotors, stators, turbine nozzles, down-hole tool components and models, fluid/water flow analysis, flow meter parts, mud motor models, pressure gauge pieces, control-valve components and pump manifolds.

4. Consumer Products

For designers, graphic artists and marketing teams, the time it takes to form an idea and deliver it to the market is everything. Part of that time is simulating the look and feel of the final product during design reviews to prove ideas to key stakeholders. Consumer product manufacturers have embraced 3D printing to help develop iterations and quickly adjust design.

3D printing is great for producing detailed consumer electronics early in the product development life cycle with realistic aesthetics and functionality. Sporting goods have benefited from early iterations delivered quickly and with fine details. Other successful applications include entertainment props and costumes, lightweight models and sets, and finely detailed architectural models.

As 3D printing technology advances in speed and build volume, more consumer products may turn to additive manufacturing for their large volume demands.

Topics: 3D Printing

How the HP Multi Jet Fusion 4200 Works

By Mark Blumreiter on Nov 13, 2019 11:55:38 AM

MasterGraphics Additive Manufacturing Engineer, Mark Blumreiter explains how the MJF works and how this technology is different from other similar 3D Printer technologies.

Topics: 3D Printing
1 min read

3D Printed Robotic Arm Grippers

By Mark Blumreiter on Nov 12, 2019 1:16:43 PM

 

The final application we’ll look at for fiber reinforced 3d printed parts is robotic arm grippers. Any tool at the end of a robotic arm benefits from being lightweight because it requires less energy to move the arm. The grippers also need to be strong and stiff enough to handle the stresses involved with lifting, assembling, or machining the component. Depending on the part that’s being gripped, the grippers sometimes require unique geometry. For these reasons, 3D printed fiber reinforced are the perfect solution.

A U.S. based fittings and valves manufacturer fully embraced the Markforged 3D print technology in their shop. Their engineers used to spend days or weeks tooling up a robotic work cell with custom machined grippers and fittings. Now they can re-tool the robot grippers in less than 24 hours.

End of Arm Gripper

robotic end of arm gripper

 

Topics: 3D Printing
1 min read

3D Printed End-of-Arm Vacuum Tooling

By Mark Blumreiter on Nov 12, 2019 1:04:57 PM

 

Another great example of reinforced 3D printed parts on the shop floor is end-of-arm vacuum tooling. When lightweight, flat parts need to be moved around and assembled, it’s common to use vacuum tooling to use air and suction parts to hold and move them. The image below shows a blue tube that is pulling air through the black tool. This creates the suction necessary to lift and move these lightweight parts.

3D printed end of arm tooling

There are a handful of properties these vacuum tools can require that 3D printing excels at. First, the tool should be lightweight because it is attached to the end of a robotic arm. Second the air suction needs to be routed through internal channels to provide suction at multiple locations. Finally, the tool needs to fit a unique contour of the part it’s picking up. Fiber reinforced 3D printed parts are the perfect solution for strong, stiff, lightweight, custom geometry vacuum tooling.

Keep in mind, these vacuum tools are typically only needed in very low quantities (1-10 parts) which is perfect for additive manufacturing. There’s no need to book time on a CNC mill and fixture an aluminum block for machining. This makes it much quicker to iterate new designs as well.

Using data from another Markforged case study, these numbers show the difference between aluminum and fiber reinforced vacuum tooling.

Part Comparison

vacuum tooling

 

Topics: 3D Printing
1 min read

CMM Fixtures

By Mark Blumreiter on Nov 12, 2019 12:53:55 PM

 

CMM fixtures are used to hold parts in place as they are being measured by a CMM. These measurements help ensure the manufacturing process is working as planned, and parts are meeting their dimensional specs. The traditional way parts are held in place for measurement is a combination of clamps, posts, and stops. But with composite reinforced 3D printed fixtures, we can create a lightweight, sturdy, more functional fixture suited precisely for your part.

The below graphic shows real data is from a Markforged case study regarding a US aerospace company.

CMM-1

The reason these time and cost savings could be realized in the first place was because the 3D printed CMM fixture actually worked. This can’t be said for all 3D printed parts. In fact, many other 3DP materials would not meet the strength and stiffness requirements while still providing the cost savings. The Markforged fiber reinforced Onyx parts also provided a non-marring surface for the aerospace components to sit in. This helped prevent the occasional scratched part.

Engineers at this aerospace company had been looking for ways to avoid bottlenecks like CMM fixtures. Once they discovered the fiber reinforced 3D printed parts as a functional, cost effective alternative, they haven’t looked back.

 

Topics: 3D Printing