Lightweight and energy-efficient industrial products thanks to 3D printer – 3Dealise on TV

3Dealise was featured on TV on 9 October 2016

 

Below are the broadcast and the transcript:

 

 

Many people associate 3D printing primarily with small items made of plastic and think that large, serious applications are not yet possible. That is certainly not the case: 3D printing is already being used to manufacture better industrial products. Roland Stapper and Brian Smith from 3Dealise show us what this looks like in practice.

 

Roland Stapper: “It involves products for the automotive industry, for the aerospace industry, for the maritime industry, for machine builders, for pump builders, etc., and for art. Several products are displayed here: some pump parts that can be made more energy-efficient through 3D printing, there is a frame part with 40% weight reduction, and behind me is a large work of art that would have been impossible to produce without 3D printing.

The process consists of three main parts. First, a very accurate 3D design of the product and of the sand mould is made. Subsequently, the sand mould is printed in the printer. Then, metal is cast into the mould, which may be aluminium, or iron, or steel, or bronze, etc.

 

Brian Smith: “The customer starts by providing a design. That can be a 2D file, a sketch with dimensions, a 3D file, or sometimes it is a damaged product. The engineer then prepares a sand mould design, which is sent to the printer. The printer uses three main components: sand, binder and an activator. The printer deposits a thin layer of sand, followed by a print head that injects binder, which cures the sand. Excess sand is removed with an industrial vacuum cleaner, and that sand can be used again for printing the next day.

This technology is sustainable, because products are commonly overdimensioned, and they can be redesigned using simulation software, thereby saving a lot of material. And for pump housings, for instance, the flow pattern can be improved with flow simulations, thereby making that pump more energy-efficient.

 

Roland Stapper: “I think that we will see three important changes. First, companies will increasingly take the possibilities of 3D printing into account already in the design phase, and they will start designing more energy-efficient and lighter products. Second, it is becoming increasingly possible to personalize products first, before they are manufactured. So, instead of manufacturing products in large series at the other side of the world, it is increasingly possible to tailor the design exactly to the client requirements first, and only then to produce them. Linked to that, is that when you are tailoring products, it will become more logical to produce them locally or regionally. And that also means an opportunity for local employment.

 

UNSERE VISION: DIE NÄCHSTE REVOLUTION IM PRODUKTIONSBEREICH

Freiheit des Entwurfs
Direkt vom CAD
In der eigenen Region
Alles aus einer Hand
Keine Verschwen-dung
Wenig CO2
Schnell
Einzelan-fertigungen