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Before We Start

q  This webinar will be available afterwards at

www.designworldonline.com & email

q  Q&A at the end of the presentation

q  Hashtag for this webinar: #DWwebinar

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Meet your Speakers
FEATURED SPEAKER
Derek Roedel
Advanced Tooling Program
MODERATOR Manager
FATHOM
Leslie Langnua
Managing Editor
Design World

FEATURED SPEAKER
Ryan Sybrant
Director, Manufacturing
Channel Enablement
Stratasys

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 CHANGING THE WAY PRODUCTS ARE DESIGNED & MANUFACTURED

Kemeera DBA FATHOM Proprietary and Confidential Information.

studiofathom.com // Oakland 510.281.9000 // Seattle 206.582.1062 All Rights Reserved.
#DWwebinar Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.
3D PRINTED TOOLING
  Overview of Capabilities
•  Very short lead-times
−  Many molds 3D printed in less than a day
•  Quick iterations during development
•  First article inside of a week after kickoff
•  Injection production-grade thermoplastics
•  Ideal for up to 50 parts
  Overview of Limitations
•  Biggest limitations: texture and color
•  Tool action “slides and lifters” are possible—
hand loads
•  Thin walls and undercuts
•  Living hinges are debatable—
stringent on design and location of gate

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DMLS TOOLING INSERTS
  Fits Early Prototyping and Bridge-to-Production Needs
•  Build an insert in 48 hours
•  Post-production is minimal compared to machining
•  20k+ parts (geometry and molding resin dependent)
•  Blend additive with traditional technologies
•  Material Options:
−  Inserts can be made from MS-1 maraging steel
(heat treated mid 50HRC for best results)
−  Aluminum is ideal for very quick turn short-run tooling
−  Can be plated/coated to address abrasion/erosion
•  Inserts can be EDM textured and/or hand polished
after heat treatment (replicate final product texture)
•  Design inserts with features for weight savings,
heat evacuation, and conformal cooling lines

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COMPARISON

ITEM 3D PRINTED TOOLING CONVENTIONAL TOOLING

Mold Base MUD (Master Unit Die) MUD Or Dedicated

Mold Fitting / Build
Hand & Machine Hand & Machine
Up

Cooling Lines None – Done With Cold Air Water Cooling Lines

Minimal – Large Blocks Or None At All – No Sleeves Or

Ejection Standard Pins – Sleeves – Lifters
Lifters

Tool Action - Slides Done With Hand Loads Built Into The Tool

Resin Choices Limited To Low Melt Point – High Melt Flow Index Any Resin

Tool Material Plastic Metal

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VOLUME & TIMEFRAME
3D PRINTED BRIDGE TOOL / PRODUCTION
ITEM 3D PRINTED TOOLS
DMLS INSERTS QUICK TURN TOOLS TOOLS
Lead Time* 2-6 Days *Geometry Dependent 1-2 Weeks 3-5 Weeks 6-10 Weeks
MS-1 Maraging Steel,
Mold Material 3D Printed Resin Aluminum Or P20 Steel Hardened Steel
Aluminum, Or Stainless Steel

Cooling None - Air Complex Cooling Lines Simple Cooling Lines Complex Cooling Lines

Cycle Times
5 Minutes - 10 Minutes 10 Seconds - 2 Minutes 1 Minute - 2 Minutes 10 Seconds - 2 Minutes
Part-to-part

20-100 Parts Some Rework On

Tool Life >20K ~ 20K to 100K ~ 2MM
Later Parts (Flash)

Part Price $$$ $$ $$ $

Changes – 1-2 Days, CAD Time And 1-2 Weeks Or Several Weeks And
1-2 Weeks, $1,500 - $5,000
Time & Cost Print A New Tool ($600 - $1,500) Print Another Tool Thousands Of Dollars

* From Time of Kickoff—DFM finalized, CMF finalized, CAD finalized, material on hand or arranged.

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STEPS & TIMEFRAME

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#DWwebinar Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.
DECISION MAKING PROCESS
  What Tooling Is Best For My Application?
•  3D Printed Tooling (Fast)
−  Feature discovery such as living hinge or snaps
−  Real plastic part prototyping, fastest iteration (new tool)
−  Material performance for available resins (regulatory or drop test)
•  DMLS Insert Tooling
−  Part performance testing
−  Material performance for any resin (regulatory or drop test)
−  SPC data collection: gating/ejection, venting, cycle-time
•  Bridge Tooling
−  Closest to production for short-run applications
−  Production resin choices
−  SPC data collection: gating/ejection, venting, cycle-time

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WHEN TO USE 3DP IM
  When Prototype In Final Material Is Needed For Design Decision
•  Durometer of a TPE—Is it 30 or 90 Shore A?
•  Impact testing
•  A crucial snap
•  Fluid / air flow
•  A flexure
•  Sonic weld testing, or adhesive bonding
  When You Need 50 Parts For Functional Testing With Clients
•  Fastest / cheapest way to 50 parts of production material
•  Regulatory test units
  Fast Part Design Iteration
•  If parts don’t work as anticipated, we can adjust CAD in the afternoon,
3D print new tool parts overnight, and mold new parts the next day

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MATERIAL OPTIONS
  FATHOM Stocks Several Materials
•  Polypropylene (PP), Polyethylene (PE), Thermoplastic Elastomer
(TPE) Shore A 60, ABS, ABS/PC, Nylon (PA – Polyamide)
  Always Consider Lead-time In Selecting Your Materials
•  Some materials can take months to get, especially in small
quantities
•  Just because it is listed on a website, doesn’t mean that small
quantity orders are available
  Lower melt points are better
•  Heat degrades the tool
  Higher Melt Flows Are Better
•  Thinner when molten

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IDEAL SITUATION
  Part Was Designed For Injection Molding From The Beginning
•  Drafted to 2-3+ degrees
•  Parting line defined
•  Gate was considered
•  Consistent wall thickness
•  Tool action is defined (slides, no lifters, etc.)
•  No thin standing steel (think in the inverse of part design)
  Open And Shut Tool Design
•  Minimum amount of tool action (hand loads)
  Simple Resins
  Minimal Part Finish Requirements
  Natural Colored Resin
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FATHOM’S BEST PRACTICES
  Well Designed Parts Get Made Much Faster
•  New ideas are great, but new methods of manufacturing take longer to see the light of day—
FATHOM can help, but invention on a timeline is a dangerous game
  Decide On What It Is That This Model Needs To Answer
•  What are the objectives of the build?
  Do Design Reviews Early and Often
•  Like voting in Chicago
•  Don’t hesitate to give FATHOM a call to review your design
  Design With The End In Mind
•  If you are going to injection molding in the end, start your design that way
•  Don’t fall in love with a bad design
  Think Of How The Tool Will Be Built To Make The Part
•  Where will the gates be? And the knit lines?
•  Where are parting lines? And the draft?
•  How will tool action be implemented?
−  If you have a hole in the side of your part, consider the size of the hand load to make it

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FUTURE OF 3DPT
  New & Better
Mold Materials
•  Better finishes
•  Longer part runs
•  Higher mold pressures
  Shorter Lead-times
  Influence Future
Machine Design

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#DWwebinar Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.
EXAMPLE
  Phone Case (PolyJet)
•  3D printed tool in 7 hours and molded
parts within 24 hours
•  Tool Material: ABS-Like (PolyJet)
•  Part Material: TPE Shore 60A
−  Grade offers soft/tactile feel, adhesion
to Polypropylene, good weatherability
•  Up to 50 Parts
•  Dimensions:
−  A-Side: 4.75” x 4.75” x 1.5”
−  B-Side: 4.75” x 4.75” x 1”
•  Shot Size: 27cm³
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EXAMPLE
  Infrared Transmitting (DMLS)
•  Inserts printed with MS-1 Steel in 2 days
•  CNC machine surfacing and polish in 1 day
•  Tool Material: MS-1 Steel
−  SPC data collection for production specification
•  Part Material: Acrylite IR specific resin
−  Grade offers infrared transmitting capabilities
•  Up to 50k Parts (heat treated insert)
•  Dimensions:
−  Insert: 3” x 4”
−  Shot size: 2cm³

#DWwebinar Kemeera DBA FATHOM Proprietary and Confidential Information. All Rights Reserved.
 CONTACT INFORMATION

OAKLAND OFFICE OAKLAND SEATTLE OFFICE

(510) 281-9000 PRODUCTION CENTER + PRODUCTION CENTER
329 Jefferson Street 315 Jefferson Street (206) 582-1062
Oakland, CA 94607 Oakland, CA 94607 4302 Stone Way North
Seattle, WA 98103
www.studiofathom.com
info@studiofathom.com

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Efficiency and Productivity with 3D Printed
Manufacturing Aids

March 24th, 2016

#DWwebinar 21 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

Transforming the
Manufacturing Floor

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Jigs, Fixtures and Tools
Streamline production floor workflows

A means to optimize manufacturing by reducing

cost and cycle time, while increasing product
quality and repeatability

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 Jigs, Fixtures and Tools
Most important considerations

•  Accuracy
•  Rigidity
•  Ease of Use
•  Economy in production
•  Workforce safety

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 Jigs, Fixtures and Tools
Objective

•  Ensure interchangeability and accuracy of parts

manufactured,
•  Minimize the possibility of human error
•  Permit the use of medium skilled labor
•  Reduce the manufacturing time
•  Allow production of repeat orders without
retooling

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Moving up the Value Chain

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Moving up the Value Chain

Product Development Efficiency Tools Final Components

•  Prototype •  Work holders •  Covers
•  Review •  Gauges •  Brackets
•  Refine •  Guides •  Ducts

Func.onal Jigs and Produc.on

Prototyping Tooling
Tes.ng Fixtures Parts

Application Verification Process Facilitators

•  Performance testing •  Molds
•  Integration validation •  Patterns
•  Acceptance testing •  Mandrels

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Challenges & Opportunities

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Today’s Challenges

•  Long machine set-ups

•  Variation during assembly and fitting
•  Complicated part holding requirements
•  Ease of handling and transportation
•  Defects caught too far down production line
•  Employee safety and ergonomics
•  Cost, time, wait and storage prevents manufacturers from
producing needed efficiency tools

#DWwebinar 29 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

 Addressing Today’s Challenges

•  Complex geometries no longer a barrier

•  Design flexibility
•  Shorten set-up times
•  Part consolidation
•  Integrated features
•  Ergonomics
•  Simple duplication

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 Justification for AM

Key Success Factors

•  Efficient; path of least resistance
•  Allows for more on the floor
•  Translates to operational savings
•  Reduced burdened rate
•  Change in design and manufacturing mindset
•  Will impact multiple departments

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Customer Success Stories

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 Triumph Composite Systems

Why Triumph adopted Additive Manufacturing:

To lower tooling component costs, decrease schedule (lead-
time) and reduce dependence on external tool suppliers

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 BMW

Creating worker friendly factories

•  Focus on ergonomics
•  Light-weighting tools
•  Increasing tools performance
•  Customizing tools to the assembler
•  Reduced automobile rework

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 Wair Products

Rethinking traditional processes

•  Transforming test fixtures
•  Reduced part count
•  Reduce cost and lead-time
•  User friendly

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 Opel

Changing the Approach to Process Tooling

•  Brings the line worker into the design process
•  Allows them to adapt tools much better to the
worker and automobile
•  Makes it possible to find and implement the most
appropriate solution

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 Genesis Systems Group

Investment in Innovation
•  Optimized robotic end-of-arm tooling
•  Reduced part count
•  Reduce cost and lead-time

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 Solaxis

Reducing tool footprint and weight while increasing accuracy

•  Removed 100lbs from previous tool
•  Agility increased flexibility of design
•  Solved compliance issues for supplier

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Taking the First Steps

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 Successful Implementation

•  Connect cross-functional teams to seek out opportunities

where 3D printed tools can make an impact
•  Interview the workforce that is involved in day to day
production
•  Don’t forget about operational efficiency programs such as
5S
•  Focus on one area or department and duplicate success to
others

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Re-Engineer your Vision

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 Initiate for results

Reduce Production Time and Cost

Maximize Efficiency
Maintain Consistent Quality
Improve Functionality
Enhance Safety

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 Thank You

Ryan Sybrant
Director, Manufacturing

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Questions?
FEATURED SPEAKER
Derek Roedel
Advanced Tooling Program
MODERATOR Manager
FATHOM
Leslie Langnua
Managing Editor
Design World

FEATURED SPEAKER
Ryan Sybrant
Director, Manufacturing
Channel Enablement
Stratasys

#DWwebinar
Don’t Forget!

q  This webinar will be available at

designworldonline.com & email
q  Tweet with hashtag #DWwebinar

q  Connect with Design World

q  Discuss this on EngineeringExchange.com

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THIS DOCUMENT IS PROPRIETARY TO STRATASYS, INC. AND/OR STRATASYS LTD.,
AND SHALL NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED
FOR ANY DESIGN OR MANUFACTURE EXCEPT WHEN SUCH USER POSSESSES
DIRECT WRITTEN AUTHORIZATION BY STRATASYS, INC. AND/OR STRATASYS LTD.
STRATASYS, INC MAKES NO CLAIM, PROMISE, OR GUARENTEE OF ANY KIND ABOUT
THE ACCURACY, COMPLETENESS, OR ADEQUACY OF THE CONTENT OF THIS
PRESENTATION AND EXPRESSLY DISCLAIMS LIABILITY FOR ERRORS AND OMISSIONS
IN SUCH CONTENT.

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