Tag Archives: Additive Manufacturing

A manufacturers guide to… Additive Manufacturing

Additive Manufacturing (AM) – or 3D printing as it is often referred to – is a method of creating a three-dimensional object, layer-by-layer, using a computer created design.

AM moves very quickly. Over the past few years, we have seen metal 3D printing go from something that is highly specialised and very high cost, to something that is achievable on desktop machines.

Material R&D has played a huge roll in the uptake of additive as materials are easier to work with and have far better properties. The software has also developed with some pace and we are now seeing topology optimisation and bespoke objects that could have only been produced via 3D printing.

My interest in 3D design began with design and modelling for 3D animation. The switch to making functional parts, especially those which are 3D printed, came about as I needed some parts for a research degree that I was working on at the time at the University of Sunderland.

I joined the team at the university’s FabLab when that opened and supported a number of companies who were looking for 3D prototype parts and when the SAM Project began, it offered a fantastic opportunity to work with more advanced technologies.

Although I had worked with 3D printing prior to the SAM Project, it has been during my time here that I have really focussed on design for additive and how to get the most out of all the different technologies that are available.

I have worked on numerous AM projects at SAM, they include those that I have led on that focus on all aspects of additive, as well as supporting the work of my colleagues who frequently require parts and prototypes produced for their projects.

Additive is hugely impactful as it is one of the easiest ways to produce a part, simple or complex. This is allowing us to rapidly prototype and evolve designs.

In the North East, we are still seeing additive being used mainly for prototyping, but I think there is huge potential for it to have an impactful roll within traditional precision engineering firms for work-holding and jig production that could significantly increase productivity.

The two areas that we are seeing the most development in are materials and speed. Machines are now working with a broader range of materials than ever before, sometimes combining multiple materials in the same part. Machines are becoming faster and faster and in shorter runs can be more competitive than injection moulding. They also enable the mass customisation of parts in each build and allow complex assemblies to be printed as one piece.

For those interested in learning more about the uses and benefits of 3D printing, it has never been easier thanks to the support available through the SAM Project. To find out more about the support and how your business could benefit, contact the team today.

Desktop Metal – Metal 3D Printing from Desktop to Production

Join Desktop Metal and the SAM Project to discover how metal 3D printing can help you take designs from your desktop and put into production.

Paul Gately (Strategic Accounts Director, Desktop Metal) will explore the exciting range of metal additive solutions which they offer. Paul will look at their systems that are suitable for desktop fabrication for small numbers of items as well as their Shop and Studio systems that can produce quantities suitable for a production run of parts.

Date and time

Tue, 7 June 2022 09:00 – 12:00 BST

Location

The Industry Center, Sunderland SR5 3XB

Book your place here.

Meet the Experts: Carl Gregg, Product and Process Design Specialist

Carl Gregg, product and process design specialist, has helped open the eyes of hundreds of SME manufacturers to the potential of additive manufacturing.

In its earliest form, Additive Manufacturing (AM) – or 3D printing as it is often referred to – has been with us since the early 80s and it should be no surprise that the technology has evolved significantly since then.

We are now at a stage where functional parts can be produced that can potentially outperform those which are conventionally manufactured. Prototyping remains a major use for additive manufacturing, however the days that 3D printing’s sole use was to produce non-functional prototype parts is over and increasingly, there is a trend emerging within the industry where additive manufacturing is being used for far more impactful means.

Our Prototype and Innovation Factory is home to a range of 3D printers that range from very basic (but still very useful) to advanced industrial machines. We even have a large format 3D printer that has a print area of 1mx1mx0.7m that can rapidly produce large parts that would usually need to be split apart to print on numerous printers.

In terms of advanced materials, we also boast two printers from market-leading 3D Printer manufacturer MarkForged (Metal X and Mark Two). The Metal X is able to print metal parts in a range of materials such as stainless steel, tools steels, Inconel and copper. This same printer was recently utilised for a project to produce an alternative to a cast part that was needed for testing. The lead time to produce the initial casting was six weeks compared to the production time on the Metal X which was just a few days.

We have had similar successes with the Mark Two system, which allows us to produce composite reinforced parts. The printer is fantastic for producing components that require highly functional parts such as machining fixtures or end of arm tools. The printer achieves this in two ways. Firstly, the material that is used to produce the parts is a blend of nylon and chopped carbon fibre, however the feature that sets this printer apart is its ability to inlay continuous fibre reinforcement such as carbon fibre or Kevlar. This fibre reinforcement allows us to produce plastic parts that have a similar functional strength to 6061 aluminium.

For higher volumes of production, we have an HP Multi Jet machine that can produce accurate, highly detailed parts in batches in an overnight run. Increasingly, companies are seeing this as a viable alternative to injection moulding for shorter runs of under 10k. The printed parts from the HP machine are air and watertight and some interesting case uses have been found to exploit this, such as, incorporating vacuum lines into end of arm tooling to produce a part that cuts out numerous assembly steps.

A common trait that we do see is that the 3D printing can increase the band width of conventional machines. For example, the printers need very little oversight when compared to CNC machining and they’re very easy and quick set up. Typically, a machine could be set up with a “digital warehouse” of jigs, fixtures, end of arm tooling, etc. and they can be called off with only a button press. This can reduce lead time and cost for any production change over and to ensure your machines keep running.

SAM Features in The Journal

The SAM Project featured in The Journal, published in Newcastle in a special feature in March 2022.

The article covers all of the areas of expertise offered by the the project with an introduction to the Technical Team, alongside case-studies featuring companies who have received support. There is also information about the grant funding the project offers.

The full supplement can be downloaded here.

Capital investment leaves manufacturer beaming

A County Durham business is hoping to establish itself as a leading light in the world of manufacturing, as it continues to invest in the region and increase its global footprint.

Artech Lighting, based on the outskirts of Durham city, has invested in a Ultimaker S5 Pro 3D printer as it looks to bring the production of many of its lighting components back to the region, creating a number of new jobs in the process.

Additive manufacturing, a term for industrial 3D printing, is the process where a three dimensional CAD model is turned into a physical object. For Artech, this will bring several benefits, the most significant will be to reduce costs and lead times for parts as well as making in-house prototyping more efficient, making the company more competitive on the global stage.

Since its launch in 2017, Artech Lighting has made a commitment to support UK manufacturing, producing 100% of its product range at its facility in Durham and securing contracts to supply some of the world’s most high-profile developments, from the Dubai World Trade Centre to The University of Edinburgh and cinemas across Saudi Arabia.

Stuart Hylton, managing director, said: “As one of the very few lighting manufacturers left in the UK that produces 100% of its products within our borders, we are incredibly proud to stamp our products with the Made in Britain marque and to fly the flag for UK manufacturing.

“While many businesses were hit by supply issues during the pandemic, we saw our business grow three-fold, as developers across the globe began to seek out products that not only offered sustainable delivery and lead times, but were also environmentally sustainable, and we would never have been able to achieve this had it not been for the fantastic work of our team over the last few years.

“Looking forward, the investment into our new 3D printing system will allow us to bring the production of even more components in-house, creating more highly skilled jobs, further driving down our carbon footprint and massively improving productivity, and we’re excited to see what the future holds.”

The purchase of the 3D printer was supported by matched-grant funding from the ERDF-backed £10.9 million Sustainable Advanced Manufacturing (SAM) Project led by the University of Sunderland.

The project is a collaboration between the European Regional Development Fund (ERDF), the University of Sunderland and the Northern Powerhouse Initiative and Industry, supporting the implementation of product and process development and the introduction of technology within the SME manufacturing base in the North-East Local Enterprise Partnership (NE LEP) area.

“The support from SAM has really been fantastic,” Stuart added. “Not only did they provide the funding required to invest in the machinery, but their guys also guided our design team through the entire process of identifying the right kit and ensuring we saw the maximum possible return on our investment.

“Prior to engaging with the programme, we always knew that embracing additive manufacturing would be key to sustaining the future of our business over the coming years, however the support from Carl and the team at SAM has helped us to achieve what we thought we would in three years, in just three months. I can’t recommend them enough.”

Artech Lighting is also making significant investment of its own into a series of factory upgrades, purchasing a second paint plant, press brake, profile roller and punch tool, as well as making substantial upgrades to its IT network.

Stuart said: “The Artech brand continues to be a major industry disruptor. We are willing to compete with the more recognised brands and offer equal or better quality, output, delivery and efficiency, but with significantly less cost with the added peace of mind that you are buying a UK manufactured product. It is a strategy that is working, as recognition of the Artech brand continues to grow.”

Carl Gregg, product and process design specialist at the SAM Project, said: “It’s been a real pleasure working with Stuart and the design team at Artech on this project.

“The SAM Project was set up to help the region’s SME manufacturers innovate and grow by breaking down the barriers to embracing new technology and to see Artech not only increasing its global presence, but also creating highly skilled jobs in the region following this investment, shows just how much of an impact the programme can have on those that engage with it.”

Tech investment leaves Heliguy flying high

A North East drone specialist is scaling new heights after investing heavily in its own manufacturing facility.

heliguy™, based in North Shields, has established itself as a go-to drone supplier for clients across the globe since its launch in 2006.

The company started life as a retailer of remote-controlled helicopters but has since grown into a full-service drone specialist, providing drones, bespoke accessories, servicing, repairs, custom integrations, product development, drone pilot training and end-to-end workflow support.

Over the past two years, this diversification has seen the company secure contracts with 38 police forces across the country, as well as the London Fire Brigade, Port of Tyne and a host of personal and commercial clients.

One recent project, for a police force in the South East of England, saw the company’s design experts produce a bespoke drone mount, allowing officers to test mobile phone and radio signal strength in hard-to-reach areas such as farms and rural roads.

Another design and manufacture project, working with a commercial client – Aerial Ashes – resulted in the team developing a safe, sensitive way of scattering ashes at beautiful and memorable locations, such as out at sea or on mountain peaks.

This expansion of its services – and the establishing of a dedicated manufacturing hub at its Orion Business Park base – has not only led to the company onboarding more clients, but also more staff, with its headcount in North Shields now at 28.

Ross Embleton, custom integration specialist at heliguy™, said: “We identified a gap in the market – quite early on – when the drone market was just maturing and swiftly established ourselves as one of the UK’s leading independent providers of drones and accessories.

“Since then, we’ve continued to invest in the business year-on-year, ensuring we continue to service our clients to the highest possible standard and continuing to create job opportunities for local people.”

Central to bringing product development and manufacturing in-house and growing the business has been a suite of state-of-the-art 3D printers that has allowed heliguy™ to design and produce parts at its North Shields facility, helping to slash lead and prototype times while reducing costs.

*Ross Embleton from Heliguy based in North Shields has purchased equipment with support from SAM project. Photo with Carl Gregg (SAM Project)*

The company purchased the printers after receiving technical support and a grant from the £10.9 million Sustainable Advanced Manufacturing (SAM) Project, which is a collaboration between European Regional Development Fund (ERDF), University of Sunderland, the Northern Powerhouse Initiative and Industry, set up to support North East (LEP) SME manufacturers to explore and introduce new technology to improve their products or processes.

The funding supported the purchase of a market leading Markforged X7 3D printer, which allows the company to print parts in reinforced carbon fibre and Kevlar and will work alongside its selective laser sintering (SLS) machine and a Formlabs Fuse 1 3D printer.

The firm also purchased a Form 3L SLA 3D printer in November and aims to acquire a number of surface finishing machines over the coming months as it continues to invest in its design and manufacturing capabilities.

Ross added: “Bringing the production of our components in-house was key to us broadening our horizons and expanding into new markets and the support we received from SAM has been key to helping us do that.

“Carl [Gregg] was fantastic as he really bought into the concept. After working with him to identify which areas of our business could benefit from additive manufacturing and which 3D printers would be best suited to our needs, we went on to buy a state-of-the-art Markforged composite printer that has helped us significantly slash costs and lead times.

“It has massively reduced design times too. Now, if the managing director or a client has an idea, we can create a physical, working prototype within a week as there’s no waiting around for third party suppliers.

“Aviation parts also need to be strong and light, therefore being able to print parts in carbon fibre and kevlar on the Markforged printer is a huge benefit to us. It’s really helped us to step our business up a gear and we can’t thank Carl and the team enough for all of their support.”

Carl Gregg, product and process design specialist at the SAM Project, said: “As a team of engineers who thrive upon helping businesses overcome challenges to growth, it was fantastic to work with heliguy™ and to become so involved in helping them plan for the future as they continue to innovate and grow and create jobs here in the North East.

“The SAM Project was set up to help the region’s SME manufacturing base improve products and processes by adopting new technologies such as additive manufacturing and heliguy™ is a prime example of just how much of a positive impact the project can have.”