PROTOTYPES with help of printing 3d (HI-TECH craft)
3d printing is a clear example of prior art in which advances in processes are ahead of the uses and applications. Although the machines are becoming more accurate and able to print in new materials, is in the field of their applications where the real revolution is taking place.
When we approach to 3d printing the obvious question is can be valid parts for Assembly and functional testing? But every day is showing us that the proper use of a good tool opens us fans of possibilities that we had never before thought.
As an example we will present a manufacture of functional prototypes in drawn sheet.
MODEL CAD 3d
We received a file compatible with our software (SolidWorks) 3d client. In this model we do a first feasibility study taking into account the material which is to be manufactured (yield strength, toughness..), as well as feasibility of drawing (desmoldeable) form. In this case it's veneer DC01 in 2.5 mm of thickness.
It is produce three pieces of sample, and then a batch of 150 pieces for Assembly testing.
MODEL 3d printing
First, we print in 3d a model of the piece that will help us during the process of thinking the position needed to stuff, as well as serve as a template for verification in the setting of the tool
For the printing of the model we use two materials. For part PLA and PVA for support. During printing, we need supports which will fill the areas on which presents overhangs the piece, since the printer "deposited" the melted material and need a supporting surface. This support should be designed in such a way that allows their removal without damaging the target piece.
PRELIMINARY DESIGN DRAWING
The piece that we have, in the case of manufacturing in series, would be to stuff in several stages, in useful with walked on and a process of final cut to remove excess material.
This process requires several tools that would entail an excessive cost, both in money and in time.
The proposal we are presenting is to make a unique drawing tool, without crushing and cut the final piece by LASER3d.
As we can not dispose of stepped on, we have to modify the model to make the same excess of veneer which perform the functions of braking. Model extended as well as the comparison with the target model, where you can appreciate the large amount of excess material that acts as a brake for the drawing appears in illustrations.
Based on this design we define the two surfaces (male and matrix) tool, located with the necessary guidance for the drawing.
These surfaces are machined on CAM and we verify form with help of 3d printed model (on the left in grey)
After defining the model for mortise, we estimate the development on the starting sheet plane and cutting laser.
Part, is stuffed obtaining an acceptable result that gives start to the adjustment process, eliminating friction, polishing drawing radii and correcting possible misalignments.
The process intended for 150 parts of the lot is final cut in LASER3d, but our customer shows us the urgency in having three prototypes as soon as possible to carry out checks and adjustments in their Assembly tools.
To cut these pieces we design and print in 3d a "template" that allows us to draw on the drawn sheet outline and position of the holes.
Subsequently to the path we proceed to cut the silhouette using a saw, jig, manually, and to tap and drill the holes.
3d LASER COURT
The method chosen to cut 150 pieces of the batch of prototypes will be LASER 3d, because of its flexibility and speed. So we start from the 3d file (designed in SOLIDWORKS) that we have used for the machining of tool and 3d printing
. First you designed and manufactured tools of positioning that firmly hold the piece still in a position allowing all its silhouette, including holes cut.
Located once the piece proceeds to check the court giving a "path" pass
Once verified by the printed template 3D that we use for the layout of the samples, is cut.