DFM Analysis, Injection Molding Help Spring Company Reduce Costs

An Illinois-based steel-spring manufacturer recently called on Proto Labs to help reduce component count and save time and money on a device the company uses to market its services to the aerospace, automotive, oil and gas, and medical industries.

Smalley has long equipped its sales force with a small demo device, a handheld “comparator” that shows the relative size and performance of a wave spring—which Smalley manufactures—compared with a coil spring.

The company turned to Proto Labs for help with solving a cost issue when Smalley considered redesigning the comparator to “use them as ‘giveaways’ to prospective customers,” explained Lane Persky, Smalley marketing manager. “We were looking to go from about 20 of the original comparators, which each cost about $100 to produce, to an initial run of 1,000 redesigned comparators at a target cost of about $15 each.”

Proto Labs’ design for manufacturability (DFM) analysis, and its injection molding service, helped Smalley designers create a new comparator, which would require just seven parts. The original comparators each consisted of 23 parts.

“We chose Proto Labs for the company’s reputation and ability to do both advanced 3D printing for prototyping and affordable, rapid injection molding” for low-volume production, said Persky.

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IMTS Showcases Manufacturing’s Diverse Landscape

Amar Hanspal, attending his first ever International Manufacturing Technology Show (IMTS) at Chicago’s McCormick Place this week, tweeted that the event “is a digital manufacturing Disneyland.”

And really, it’s hard to argue with that assessment, based on the sheer numbers of attendees (more than 100,000 over the week-long event), exhibitors (over 2,000 companies), seminars, and innovative ideas being featured.

Tony Holtz, left, technical specialist for Proto Labs, discusses rapid overmolding at the International Manufacturing Technology Show Thursday in Chicago.

A stunning variety of participants are visiting the show: Company presidents, chief technology officers, engineers, designers, software developers, entrepreneurs, and college and high school students. This variety showed in the diverse wardrobe: Those in jackets and ties walked the same exhibit halls as those in flip-flops and shorts.

Rahm Emanuel, Chicago’s mayor, showed up to tour the Association for Manufacturing Technology’s Emerging Technology Center, which featured research and development projects from the Oak Ridge National Laboratory. Those projects included a 3D-printed SUV and the “additive bionic human,” showing additive manufactured medical implants and body parts.

Various special focus areas showcased 3D printing/additive manufacturing, machining, controls and CAD/CAM, fabricating and lasers, and more.

At the Proto Labs booth, staffers answered an array of questions, including queries about our new rapid overmolding service, the trend of using 3D printing for production parts, and the finer points of five-axis machining, another new Proto Labs service.

THE SHORT LIST: See You at Trade Shows This Fall

Look for the Proto Labs booth at various trade shows this fall. Here’s a brief roundup of where you’ll find us:

SEPTEMBER SHOWS

IMTS-Chicago-Sept. 12-17

The International Manufacturing Technology Show at Chicago’s McCormick Place is the largest manufacturing show in the Americas and will feature more than 2,000 exhibiting companies and over 114,000 registrants. Visit us at booth N-72 throughout the week. Proto Labs staffers are also presenting at the conference:

  • Jonathan Bissmeyer, Senior Quality Engineer: “Designing for the DMLS Process,” 1:15 p.m., Monday, Sept. 12, Room W192-B.
  • Greg Thompson, Global Product Manager: “Designing for Direct Metal Laser Sintering and Selective Laser Sintering,” 3:30 p.m., at the Additive Manufacturing Conference (co-located with IMTS).

    At a recent trade show in New York, Proto Labs staffers found time for a photo. From left, Eric Utley, Jenna Nyman, Abby Christensen, Kory Dirnberger, and Charlie Johnson.

MD&M-Minneapolis-Sept. 21-22

Medical Design & Manufacturing at Minneapolis’ Convention Center is the region’s largest medical technology event, with 5,000 industry professionals expected to attend. See us at booth 525.

As part of the show’s programming, Rich Baker, Proto Labs’ Chief Technology Officer, will present, “More Than Prototyping: Digital Manufacturing’s Role in Industry 4.0,” at 3:15 p.m. Wednesday, Sept. 21. Baker also will participate in a panel discussion on “3D Printing: The Brave New World of Manufacturing” at 11 a.m., Thursday, Sept. 22.

Device Talks-Boston-Sept. 28

Now in its fifth year, this gathering of medical technology professionals will include a day of workshops, panel discussions, and networking at the Boston Marriott Long Wharf.

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Proto Labs Garners Top Workplace Honor for 6th Straight Year

For the sixth consecutive year, Proto Labs has been recognized as a Top Workplace by Workplace Dynamics, a national survey firm that researches participating companies through confidential employee surveys.

The firm looks at individual factors such as employee wages and management, but also aspects that include career potential and a company’s future. The survey is conducted in 50 U.S. markets and local results are compiled by Minneapolis’ Star Tribune.

Welcome to the “Code Cave,” a new collaboration area inside renovated office space at Proto Labs’ Maple Plain, Minn. headquarters.

Our company is one of 110 Minnesota-based employers that scored high enough to qualify as a Top Workplace against Workplace Dynamics’ national benchmark.

On a related note, providing employees with a work environment that supports productivity and nurtures innovation is a key aspect of being a top workplace. Along these lines, the vacated production area on the lower floor of Proto Labs’ headquarters building in Maple Plain was recently renovated and converted into office space. That office area is now home to software engineers, web developers, and other technology-based roles. High-tech conference centers are sprinkled throughout and there’s even a “Code Cave” (see photo). Additionally, we’ve opened a new, larger 3D-printing facility in Cary, N.C.

Though the Workplace Dynamics survey covered only Minnesota employees, Proto Labs globally now includes 1,600 employees in 12 locations in eight countries.

NEW JOURNAL: How Technology is Transforming Injection Molding

The new issue of Proto Labs Journal is out and includes a cover story focusing on the digital transformation of injection molding. A related, second feature story explores the pros and cons of printed plastic molds.

The cover story reports on how automating the front-end of the manufacturing process has reinvented injection molding, and served as a game-changer for the entire industry.

The related feature, “3D-Printed Molds,” advises product designers, engineers and developers to take a careful look at part finish, size, design capabilities, mold longevity considerations and cost when comparing printed plastic molds to aluminum tooling.

Elsewhere in the Journal, look for our Eye on Innovation feature, which highlights cool new products and technology you should know about.

Read the entire Journal here.

We’re always on the hunt for though-provoking content, so send your cool project or article idea to our editor at angelo.gentile@protolabs.com.

Thanks and enjoy the issue!