Philmac Adopts 3D Printing for Prototype Tooling to Enable More
Complex Design
3D Systems’ On Demand Manufacturing experts help Philmac find
the right process and materials for 3D printed production tooling
CHALLENGE:
Create a 3D printed
tool for complex component manufacture.
SOLUTION:
Partnering with 3D
Systems to validate a methodology and material for 3D printed production
tooling.
RESULTS:
- DuraForm¨
HST proves capable of withstanding temperature and pressure of injection
tooling - Philmac
unlocks new technique for complex injection parts - Materials
and expertise from 3D Systems facilitate successful process testingImproving the design of a part within a system is rarely
straightforward. From the simplest enhancement to the most complex, a cycle of
iterations can be expected to verify the design during prototyping and
implement it in production. During a recent test for a new valve product
design, this experience played out for Philmac, a global leader in designing
and manufacturing specialist fittings and valves for the transfer, control and
application of water.Accustomed to accelerating its design cycle with 3D printing for
prototyping, Philmac expanded its use of 3D printing to prototype tooling in
order to enable a more complex geometry. Teaming with 3D Systems On Demand
Manufacturing experts in Australia, Philmac conducted a successful trial of
this new methodology to bring its new concept to life.3D Systems On Demand Manufacturing delivers
the technologies, materials and expertise to support the entire product
development lifecycle from fast turn and advanced prototypes to appearance
models and low volume production.Fast design
validationAs one of Philmac’s new valve product designs was undergoing
testing, an opportunity to improve its function in silty water applications was
identified. Comprised of a body, piston, cap and spring, the valve design was
revised accordingly and a prototype was 3D printed for testing. After refining
the designs based on prototype test feedback, they were reprinted for another
test cycle and confirmed. Bringing the design revision into production meant
two of the components would need a tool adjustment before samples could be
manufactured. Whereas one of the tools could be adjusted by remaking a core,
the other tool was far more complex and could not be achieved easily with the
existing equipment. With a range of options available for component
manufacture, Philmac had a decision to make. It could use aluminium prototype
tooling, machine parts directly from Acetal rod, or seize the opportunity to
trial a 3D printed tool. After discussions around cost and timing, Philmac
decided to explore a 3D printing solution.Partnering
for the right solutionAfter contacting 3D Systems’ local Australian office, Philmac and
3D Systems met to discuss the solutions available. Though the project would be
the first of its kind for each local office, the initial design review left
both companies feeling confident about their choice in partner. With 3D printed
tooling design guidelines provided by an overseas sister company in the Aliaxis
group, Philmac began researching desirable material properties to begin
benchmark testing. In parallel, 3D Systems produced a series of material plaques
for evaluation and provided Philmac’s team with background technical
information to bolster its research.Testing
material propertiesPhilmac conducted comparative testing on the material plaques to
determine the suitability of the various materials. Testing included heating the plaques to
analyze material behavior at elevated temperatures, after which several plaques
were ruled out. Following temperature testing, Philmac switched gears to
measure pressure performance.The four remaining plaques were subjected to compressive loads of
85kN and 100kN. Pressure performance results reduced the contending plaques to
two. To determine the final material, Philmac repeated heat testing, this time
heating each material to 180ÃöC, as the final selection would need to withstand
the 220ÃöC melt-temperature of Acetal. On the basis of retaining both it shape
and lettering, Philmac’s testing pointed to DuraForm¨ HST, a fiberreinforced
SLS material with high temperature resistance. Philmac’s final evaluation
involved comparing the properties of DuraForm HST with other 3D printing
materials that had been identified in previous research on successful 3D
printed production tools. 3D Systems provided additional plaques in DuraForm
HST enabling Philmac to evaluate the material for machining and polishing
suitability. Philmac was especially pleased with machining results.Fully
finished test parts on demandMany of Philmac’s injection mold tools are family based and use
change over cores and cavities. To test the 3D printed tooling, Philmac
selected an existing tool that suited the 3D printed cavities based on the
insert size required. For installation, the test team designed a steel ejector
sleeve and nozzle inserts into the initial tool concept. With its design
finalized and material determined, Philmac placed an order for the cavity set
with 3D Systems On Demand Manufacturing and received finished parts within the
week. From there, the inserts were machined to fit the ejector, nozzle and gate
inserts and sized for fit into the tool.Trial day
and resultsFor the initial trial, Philmac loaded the tool to the injection
machine to test the ejector function. Cooling circuits had been designed into
the inserts, and air was connected to the tool for cooling, along with manual
air directed onto the insert surfaces in between shots. As part of Philmac’s
testing precautions, the tooling team first applied mold release to assist with
the release of the part. Beginning with 75% of the calculated weight and lower
pressures for the initial shot,Philmac started the molding process and incrementally increased
the shot and pressure until a full part was produced. At each stage, Philmac’s
team checked the 3D printed blocks with an infrared thermometer to ensure
recommended temperature ranges were reached at the surface and target before
commencing the next cycle. In the next phase, Philmac increased hold pressure
to achieve a packed part. To mitigate the risk of material sticking to a thin
rib on the core side of the tool, Philmac’s team reapplied mold release and
hand polished the rib with sandpaper between shots to help keep the surface
smooth. The settings were then increased until a stable part weight was
achieved. According to Philmac’s tooling team, the 3D printed tool was a
success and should be capable of making an additional 50 parts without
incident.Could 3D Systems’ experts and On
Demand Manufacturing services help you succeed in your next project? Whether
you need fast turn 3D printed parts, advanced prototyping with assembly and
finishing services or low volume manufacturing including CNC, urethane casting
and injection tooling, 3D Systems’ On Demand Manufacturing services can help.Contact 3D Systems for more information on its complete On Demand Manufacturing
services.