NEW JOURNAL: Pitting Manufacturing Processes Against One Another

In the cover story of our current issue of the Proto Labs Journal, we pit manufacturing processes against one another.

As you know, the manufacturing industry is peppered with prototyping and production processes that share some common attributes, but also some notable differences. Our manufacturing “bouts” explore how several of these processes — big and small — compare. The fight card includes:

  • Magnesium Injection Molding vs. Magnesium Die Casting
  • Stereolithography vs. Fused Deposition Modeling
  • Direct Metal Laser Sintering vs. CNC Machining vs. Metal Injection Molding

Beyond our cover story, read about Sean Doan, a long-time Proto Labs employee who is the go-to person in our R & D division; the latest in innovation and advanced technology we’ve mined from the Internet; and new service offerings at Proto Labs.

Read the full Journal now.

EYE ON INNOVATION: Cool corkscrew arrives in time for holiday parties

File this under having the right tool for the job.

The striking Zig Zag Corkscrew uses the original steel-press molds from the 1920s in France, and is a new, nickel-plated steel replica of those original, iconic, expanding French corkscrews.

Antique Zig Zag-brand corkscrews, which were invented in France and patented in 1919, continue to be sought out in Parisian flea markets and elsewhere by collectors and wine connoisseurs.

This new, updated Zig Zag blends modern functionality and classic design. It features a folding cork remover and a bottle opener, too, and will make opening your holiday vino a pleasure. Price: $39.

‭Design Essentials for Injection Molding

A good rule of thumb is to apply 1 degree of draft per 1 inch of cavity depth.

‭There are multiple paths to injection molding. Some parts are first prototyped through 3D
‭printing where moldability considerations are of limited concern. Others take a more
‭traditional machining route that allows for iterative testing in engineering-grade materials
‭similar to that of molding. And many simply jump right to injection molding.

‭Before production begins, there are important design considerations that will improve the
‭moldability of the parts, and ultimately, reduce the chance of production hiccups,
‭cosmetic defects and other issues.

In this month’s design tip, we walk through these key design elements:

  • ‭Draft and radii
  • ‭Wall thickness
  • ‭Coring out and ribbing
  • Ramps and gussets
  • ‭Undercuts
  • Gating and ejection

Read the full design tip here.

Autodesk University Includes Launch of $100-million Investment Fund

If you didn’t attend Autodesk University this week in Las Vegas, here is one big item you missed. Autodesk announced the launch of Forge, a $100-million investment fund to support the creation of a cloud-based platform that will connect design and manufacturing ecosystems in an effort to help developers bring new ideas to market faster and more often. We at Proto Labs are excited to be one of Forge’s inaugural partners in this effort.

As a result, Autodesk Fusion 360 users now have seamless access to our design for manufacturing analysis and web-based, interactive quoting right from Fusion 360 CAD program. “We are excited to bring this seamless quoting and ordering process to the Fusion 360 users and look forward to continued collaboration with Autodesk on the Forge platform,” said Rob Bodor, Proto Labs’ Vice President and General Manager, Americas.

Meanwhile, in the exhibitors’ area at Autodesk’s annual event, Proto Labs representatives talked with a variety of attendees, including electrical, civil and mechanical engineers and various educators (below).

Read more about the Forge initiative here.

TIPS WITH TONY: Can 3D-Printed Parts Take the Heat?

Here’s a question that’s often asked: How do materials used in 3D printing compare to injection-molded thermoplastics when the temperature rises? To answer that, I’ll briefly dissect the materials used in stereolithography (SL) and selective laser sintering (SLS) processes as these are commonly compared to injection molding.

Stereolithography
SL involves a thermoset resin that is solidified by an ultraviolet laser, followed by a UV post-curing process to completely solidify the resin. As far as material properties, the big takeaway is that SL parts are built from thermoplastic-like resins, so they do break down over time in direct UV light.

SL uses materials that mimic ABS, polypropylene and glass-filled polycarbonate, and they offer an array of material properties still exist. But today we’re concerned with the thermal properties of the materials that are best suited to handle the heat — 3D Systems Acura 5530 and DSM Somos NanoTool. Both are offered in post-cured states and there’s an additional process for thermal post-curing that increases the operating temperatures.

The chart shows optimal heat deflections for SL materials. The other materials offered in SL have a much lower heat deflection ranging from 120˚F to 177˚F.

Material

UV Post-Cure

UV Post-Cure +
Thermal Post-Cure

3D Systems
Accura 5530

85˚C (185˚F)

250˚C (482˚F)

DSM Somos NanoTool

225˚C (437˚F)

263˚C (506˚F)

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