POWER October 2015 - 20

3-D Printing Offers a Solution
In certain situations, such as when a
bearing fails, resulting in slight damage
to a shaft or collar, a unique replacement
may need to be constructed using
dimensions developed in the field (Figure
3). The process can take some time
and will often keep a piece of equipment
out of service for the duration.
Recently, Stafford Manufacturing Corp.
developed a rapid prototype and repair
collar system, which lets users create
their own working prototypes of specialpurposed
shaft collars within a few hours.
Called the SPARC (Stafford Prototype and
Repair Collar) system, it features precision-machined
shaft collar masters, which
are available from stock and accept 3-D
printed inserts.
" We have great hopes for the system, "
said Arthur Stafford, president and founder
of Stafford Manufacturing. " It's a very interesting
technology. What we're trying to
do is develop a large database of designs
that will work with these products-that
have utility. "
Combining the clamping strength of
a conventionally machined shaft collar
with the flexibility of unlimited insert
configurations, users can create
custom-designed inserts with bores to
fit virtually any type of shaft, while accommodating
for features such as holes,
bosses, slots, tabs, hubs, pulleys, and
other items.
" The insert is pretty basic as is, but
it can do a lot of different things just
limited by the imagination and what
the user wants to do with it, " Stafford
said.
Getting Started
Supplied in steel, stainless steel, or
aluminum, masters currently come in
three sizes to accommodate shaft diameters
from one-eighth inch to three
inches. The 3-D printed inserts in the
SPARC system can be either user-defined
or selected from a library of computeraided
design drawings offered free by
Stafford.
Printing can be done onsite with a
3-D printer, which saves time, and the
inserts are designed to mate securely
with the master to create a unified
working part. Although 3-D printers
are not commonplace at many facilities,
the equipment is readily available
in a wide range of capabilities and
build-area sizes. Entry-level models can
be purchased for under $1,000, while
some third-generation models with excellent
user ratings can be obtained in
the $1,500 to $3,500 range. High-end
models can get pricey, costing up to
$40,000 or more.
Materials used in the printing process
vary, but Stafford has created inserts
using a material commonly called ABS
(acrylonitrile butadiene styrene). It is a
thermoplastic polymer material that is
strong, flexible, durable, and offers good
resistance to heat and chemicals. These
characteristics, along with the material's
machinability, make it a preferred
plastic for many engineering and professional
applications.
When using ABS, it is important for
the 3-D printer to have a heated bed
to minimize upward curling of the surface
in direct contact with the print
bed. The cost for ABS is roughly $4.50
to $5.00 per cubic inch of printed
product. ■
-Jim Swiezynski (jswiezynski@
staffordmfg.com) is technical director for
Stafford Manufacturing Corp.
New challenges - we are
very eager & excited
We talk to our customers. We work closely with
them to design and install custom wear and corrosion
solutions. Our 3-D modeling software along with
customer comments help us determine if we
suggest replacement or re-line existing pipe and/or
components, total re-routes, weld overlays, coatings
and much much more. This process may take weeks
or months.
We are the design & drafting team. We work with
our customers and field service to solve your wear
and corrosion problems.
(center) Chris Waggoner - C.A.D. Manager,
(right) Trevis Nall - Draftsman,
(left) Jason Schumacher - Draftsman
New company name. New products.
Same mission in Urbana, Indiana.
www.abresist.com
CIRCLE 13 ON READER SERVICE CARD
20
www.powermag.com
POWER | October 2015
Kalenborn Abresist
5541 North State Road 13, Urbana, IN 46990
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POWER October 2015

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