Modern Machine Shop and MoldMaking Technology present ADDITIVE MANUFACTURING, a quarterly supplement reporting on the use of additive processes to manufacture functional parts. More at additivemanufacturinginsight.com.
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16 — AM Supplement F E A T U R E This cap-closing automation component (lead- in shoe) became damaged and needed to be replaced. 3D plastics printing allowed Currier to keep the line running while a metal replacement part was being manufactured off site. evacuation, power requirements, noise levels, and usage and maintenance requirements. A machine's material capacity also should be considered, as some builds may require more material than a machine's capacity, requiring that material be replenished mid-job. "You also need to monitor certain conditions within the printer that are critical to performance, such as head alignment, head cleaning, waste material containment, and maintenance intervals to keep the head cleaned and calibrated for ac- curacy," Kieffer says. "The resolution is important, so keeping the area clean is important." Maintenance also is critical to maximizing any signifcant equipment investment, and a 3D print- and dirt, which can impact performance. Adding 3D printing capabilities requires a signifcant investment from a shop like Currier, so continually managing and controlling printer costs are essential. One way to help minimize these costs is to think beyond using the printer only for creating parts. Many other components can be produced from additive manufacturing. "For example, production components that don't require a lot of stress, molds for casting, parts for robotics, prototypes, fxturing for quality labs, etc." Sieber says. "The cost of a printer can be justifed much faster than people think." Lastly, Currier views 3D printing as an ongo- ing educational process, much like implementing any new technology or strategy. It produces a learning curve for the entire company to under- stand the potential capability at its disposal. Currier recommends that users experiment with the technology, especially with pro- ducing value-added parts. Steve Faes, a Currier CAD designer, recalls an incident on the production foor that shows how a learn-as-you-go ap- proach to 3D printing can pay off. "The bottle capping station of our flling and closing ma- chine had a damaged lead-in shoe with a complex surface curve," he says. "A lead-in shoe is the frst component on the rotary turret closer that comes in contact with the closure or cap when it is in the open state and begins to push the lid down, forcing the pintel into the orifce. We 3D-printed a temporary plastic replacement part on site that kept things running for three weeks while we waited for the damaged metal replace- ment part to come back from repair at an outside machine shop." Without the option of in-house 3D printing, Currier would have been out of production for three weeks on that one product. Now, when similar situations arise, the company has learned it can consider using its printer for more than just prototyping. er is no exception. "The last thing you want to do is take an expensive machine and cause an issue that costs you time and money," Kieffer says. "We have an annual service call from the printer sup- plier. They calibrate the machine, change all the fans and flters, and perform various maintenance items. It is critical to have the annual service per- formed by a qualifed technician who can keep it in calibration." Location of equipment can help minimize maintenance needs. Currier conducts 3D printing in an offce area rather than on the shop foor. Ac- cording to Sieber, a manufacturing foor may not be suitable for a precision instrument. Machines that operate in a factory are exposed to more dust