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Project 1
- Title: Combining 3D Printing technologies to reduce price and increase accuracy – Katcon
- Description: Excited to share a recent project collaboration with Katcon, a global leader in Exhaust Systems, Thermal Insulation, and Advanced Materials components. The challenge: crafting a jig that would streamline the verification of finished insulation while optimizing material usage and minimizing deformation risks. Working closely with Katcon engineers, we proposed a solution: combining different 3D Printing technologies to reduce costs and enhance accuracy. Technologies like FDM which has lower costs and lower quality of surface finish but stable and accurate enough for the big base, and MJF technologies using PA12 for better surface finish for other part. As the 2 parts were quite big (780x360x280mm) and massive, we as well suggested to the client to separate the base and the tube into 2 pieces each, and fill up the base with FDM parts, where the surface finish wasn’t important. This jig, consisting of a base bolted to a table, and a tube with handles, would enable them to quickly verify finished insulation by putting it in the base, and pressing the tube against it and checking the fitment. Through strategic hollowing and reinforcement techniques, we not only drove down costs but also ensured the rigidity and longevity of the parts. The assembly process was improved using bolts and heated inserts.
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Project 2
- Title: Satellite mockup - Odysseus Space
- Description: We’ve been working on an incredibly interesting project lately. In 2019, Odysseus Space, based in Luxembourg, was founded with a clear mission: to open the way for a new era in space communication. After having a great conversation with their team, it became evident that there are definitely exciting projects in our future. They required a satellite mockup for the important fair. We received simplified files from Odysseus, which we then modified for 3D printing. Additionally, we incorporated automation, enabling it to rotate and demonstrate its capabilities effectively. We used Fused Deposition Modeling (FDM) for the hidden parts and Multi Jet Fusion (MJF) for the visible components. Additionally at the end we incorporated some laser-cut parts and wrapped all moving sections in MLI foil. 3D printing’s ability to create detailed, cost-effective, and customizable mockups makes it a fantastic tool for product development, design validation, and presentation to stakeholders or potential clients. We’re thrilled to have been involved in this project. If you’d like to explore how 3D printing can benefit your projects, feel free to reach out (here on Earth or in outer space).
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Project 3
- Title: From 3D printing to injection molding
- Description: The goal of this product development project was a serial production for over 10.000 parts. 3D printing was used for getting a proof of concept and prototyping before being able to switch to injection molding. Over 20 different prototypes and iterations have been designed, 3D printed in nylon (MJF PA12) and thoroughly tested. 3D printing made it possible to produce fast and cost-effective prototypes without investing in expensive tooling for injection molding in early phases of the project. During the development phase, 3D printing allowed us to mimic the restrictions for injection molding on the design of the part. The switch to the serial production in injection molding was then fast and straight forward. On the left: the final 3D printed prototype in nylon On the right: the injection molded part
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Project 4
- Title: Improving Quality Control in Foundries with ISO 17025-Certified 3D Scanner
- Description: Massard, a highly respected foundry from Luxembourg, is well-known for its commitment to precision. They chose to partner with us for quality control because we have an ISO 17025 certified 3D scanner, which fits perfectly with their focus on precision. ISO 17025 is a globally recognized standard that sets requirements for the competence of testing and calibration laboratories. When a 3D scanner has this certification, it means it meets strict criteria for accuracy, traceability and reliability. This certification proves that the scanner consistently produces reliable results. This scanner is versatile and has many use cases in foundries: Casting Inspection: 3D scanning is used to thoroughly inspect castings for defects, such as cracks, voids or irregularities in the metal structure. This ensures that only high quality castings are made during production, reducing the risk of costly rework or product failure. Mold and core evaluation: Foundries should use 3D scanning to evaluate the condition and accuracy of molds and cores. By comparing scanned data to CAD models, foundries can identify deviations at an early stage, ensuring that molds and cores meet desired specifications. Pattern Verification: The patterns used in the casting process are essential to creating accurate castings. 3D scanning can verify that models are created accurately and without distortion, thus avoiding problems during casting. Dimensional Verification: 3D scanners are used to check the dimensions of castings against design specifications. This ensures that the final products comply with the required precise measurements, reducing waste and ensuring parts fit tightly into the assemblies. Maintenance of tools and equipment: Foundries rely on a variety of tools and equipment. 3D scanning helps monitor the condition of these assets. By comparing analytics with baseline data, foundries can plan for maintenance or replacement, avoiding unplanned downtime. Reverse engineering: In cases where accurate documentation of existing molded parts is lacking, 3D scanning will enable reverse engineering. Scanned data can be used to recreate detailed CAD models for future reference or reproduction. Process Optimization: 3D scanning helps identify bottlenecks or inefficiencies in the molding process. By analyzing and analyzing each stage of production, foundries can make data-driven improvements, thereby increasing efficiency and reducing production costs. Quality control documents: Detailed 3D scans create comprehensive quality control documentation that can be provided to customers and regulatory agencies as evidence of compliance with quality standards and specifications. Foundries often require custom tools and accessories. 3D scanning enables the precise design and manufacturing of these tools, ensuring they meet the unique requirements of the molding process. In addition to outstanding accuracy, the Creaform Black Elite 3D scanner is also known for its outstanding speed. It swiftly captures intricate details, ensuring that our valuable time is not unnecessarily consumed. Massard greatly appreciates our partnership as they rely on our quick and accurate responses whenever they request our services. Our mobile 3D scanner enables on-site scanning even in remote locations without a power outlet. We prepare mobile batteries well to ensure that scanning can take place wherever needed. Following the scanning process, our customers will receive an official quality report ensuring that their components meet their specific requirements.
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