Appliance Design - October 2007 - (Page 39)

PROTOTYPING ing may represent the next great advancement in manufacturing. In addition to shortening the development cycle, the concept will lead to the mass production of customized parts. Met-L-Flo is a plastics prototyping and secondary tooling service center that offers SLA, SLS, FDM, silicone molding and urethane casting services. It can also do metal casting and injection molding. When more than a few parts are needed, but still a relatively low volume, RP machines can also produce temporary tooling for short-run production. The plastic-based additive technologies, such as SLA, SLS or FDM, are being used to generate soft tooling that allow for cast replicates to be produced in urethane or a variety of other materials. These soft tools cannot yet be used in conventional injection-molding machines, but research is underway to try to develop a process that will allow this to occur. Various laser-melting RP technologies such as directmetal, laser-sintering (DMLS) and SLS have an advantage over other additive methods in that they can be used to fuse metal powders, permitting the fabrication of temporary metal tooling. These laser technologies are already being used to produce high-quality, rapid tooling made from aluminum that can be used on injection molding machines, according to Dekker. In addition, research is ongoing on a number of other processes including tooling made via spraytype additive technologies. There have been some successes with these new techniques, but many are still cutting their teeth and many require a machining stage to clean them up before going into the molder, says Dekker. This is an example of problem identification and resolution that could happen on any prototype. This could be the point where solutions can be implemented allowing a program to move forward successfully. Photo: Met-L-Flo. those that can be made in a conventional injection-molding machine. For small parts, one additive fabrication technology often used is a three-dimensional printer. These smaller-sized prototyping machines typically produce parts faster than their larger cousins, often able to “print” out a part within hours. Their size and clean operation typically allows them to be used in offices, instead of being relegated to the plant floor. Build envelopes for parts made on these concept modelers are typically in the 8in. cube range As parts grow in size, or as additional testing properties are required, parts are more likely to be made on larger, rapid prototyping machines using processes such as stereolithography (SLA), 3D Systems’ selective laser sintering (SLS), and fused-deposition modeling (FDM), a patented technology from Stratasys. These prototype machines use materials that are closer in composition to the thermoplastics used in an injection molder. As a result, physical properties such as strength, durability, chemical resistance, and heat tolerance often can be tested. Build www.applianceDESIGN.com envelopes for SLA machines are typically 20 in. by 20 in. and SLS machines are about 13 in. x 15 in. Accuracy can vary depending on the technology used and the materials, but, in general, tolerances for SLA are +/-0.005 in. and tolerances for SLS are +/-0.3 in. with a minimum of +/-0.005 in. on features and parts 1 in. or less in size. While the relatively slow RP technologies were originally intended for prototyping, for extremely low volume or customized part applications, the RP machines are used to produce the actual part for the end product. Known as either rapid manufacturing or direct digital manufacturing, the concept is a growing phenomenon that many expect to expand greatly in the years ahead. In fact, some consider the concept to be the future of manufacturing. Terry Wohlers, an RP consultant, calls rapid manufacturing the “next frontier” and believes that it will eventually grow to become the largest application of additive fabrication technology. Carl Dekker, president and owner of Met-L-Flo, Sugar Grove, Ill., says that rapid manufactur- In the innovative appliance design industry Knowledge is Power. In the dynamic appliance design industry knowledge is a key component of continued success for your business. Market research provides the information needed for a powerful competitive advantage. Clear Seas Research pairs its market research expertise with appliance design industry professionals to ensure a superior information gathering process. Clear Seas Research Approach to Market Research • Customized research: benchmarking, industry trends, brand awareness, positioning, etc. • Advanced statistical analysis • Quantitative and qualitative research • Business-to-business analysis • Global capabilities and reach • Actionable results • Access to industry experts via proprietary databases and industry speciﬁc online communities Partner with us for a competitive advantage deserving of your brand and maximize your company’s future success. Research to Gain Market Intelligence For more information on our market research services please contact: Phone: 248-362-3700 Email: info@clearseasresearch.com www.clearseasresearch.com applianceDESIGN October 2007 39 http://www.clearseasresearch.com http://www.clearseasresearch.com http://www.appliancedesign.com

Table of Contents Feed for the Digital Edition of Appliance Design - October 2007

Contents Editorial Shipments/Forecasts News Watch Applying Powder Coatings to Plastic Parts is No Longer a Pipe Dream New Technology Platform Provides the Ability for a single IC to Control Two- Motors in a Single Appliance, Simplifying Motor Control Design Advanced Motor-Control Techniques have Become More Accessible to a Wider Array of Appliances, Helping to Improve Efficiency and Reduce Noise Adding USB Host Capability to Appliances Permits In-Field Programming and Acquisition of Test Data ZigBee Modules Make it Easier to Design Wireless Connectivity into Applications New Concepts such as Rapid Tooling and Rapid Injection Molding Provide Stepping Stones Between Prototyping and Full Scale Production A Number of Factors and New Developments Affect the Decision on Whether to Build Prototypes In-House or Outsource to a Service Bureau DesignMart Advertiser’s Index Association Report: CEA

Appliance Design - October 2007

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