Philmac Adopts 3D Printing for Prototype Tooling to Enable More Complex Design

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 testing

  Improving 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
  validation

  As 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 solution

  After 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 properties

  Philmac 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 180ÀöC, as the final selection would need to withstand
  the 220ÀöC 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 demand

  Many 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 results

  For 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.