Markforged video Lean production

Markforged video Lean production

Learn how Saskatoon-based metal fabrication company Lean Machine has used 3D printing for production. Lean Machine specializes in custom machining primarily for the commercial transportation and mining sector. The company had previously used heavy duty steel tooling, which they would usually make in-house.

This was not a scalable option for the company, as they found they were spending a large amount of time on internal tooling instead of on customer parts.

To keep costs down and reduce the wear and tear on parts, the team turned to Markforged 3D printing technology for lean production. “We found Markforged by researching for the best printers out there for commercial and industrial quality printing,” says Josh Grasby, R&D Engineer at Lean Machine.

Lean Machine has since created 3D printed sheet metal bending dies using Markforged carbon fiber material, and found the 3D printed parts haven’t experienced any marring when coming in contact with metal parts.

The team also has 3D printed metal grippers for their robotic arms, saying “the metal printed parts look nicer than most machined parts.” The company has also seen a lot of success in 3D printed fixtures, tools, and several other parts to keep things efficient while keeping costs down. Learn more about how Lean Machine has used 3D printing to improve its production cycle.

Guhring UK Case Study

Guhring UK Case Study

 

Guhring UK

Guhring UK 3D printed a milling cutter body, brazed industrial-grade diamond tips to the top of it, and qualified the tool by successfully reaming aluminum — and it worked.

Opening Up New Revenue Streams with Additive Manufacturing

The Challenge

Founded in 1973, Guhring UK — the Birmingham-based subsidiary of the Guhring Group — manufactures precision cutting tools. The company began as a stockholder of the more standardized cutting and milling tools. Today Guhring UK manufactures bespoke cutting and milling tools for some of the world’s largest companies, including BMW, Jaguar Land Rover, Airbus, and BAE Systems. Guhring’s expertise in manufacturing carbide and polycrystalline diamond (PCD) cutting tools is world-renowned. Their range of PCD tools are made-to-order to suit customer requirements, and are manufactured by brazing ultra high-hardness industrial-grade diamond cutting tips onto bespoke hardened tool steel bodies.

Each piece of special tooling Guhring UK makes needs to first be designed and approved by the customer. Depending on the size and complexity of the component, special tooling can take up to eight weeks to design, test, and manufacture in-house — and the work can’t even start on the tool until the design is approved. Smaller manufacturers with less volume can’t justify the costs or lead time for special tools. “As we started looking at supplying smaller volume customers, it became an issue,” says Alan Pearce, PCD Production Supervisor at Guhring UK. This led the company to look into additive manufacturing as an option to open up new revenue streams, reduce lead times for existing ones, and manage timelines for smaller customers.

The engineers at Guhring UK have been able to rapidly prototype cutting tools in composite materials before printing them in metal.

“We certainly like to think that we’re well on the road to being a factory of the future.”

— Alan Pearce, PCD Production Supervisor, Guhring UK

The Solution

The team looked into 3D printing to make their products and services accessible to a wider variety of businesses — especially the smaller ones. “The idea was to make the prototype cost and iterative cycle time come right down,” says Pearce. They teamed up with local Markforged partner Mark3D UK to find the best 3D printer for their needs, and decided upon a Markforged  Metal X system as well as a Markforged continuous fiber 3D printer for customer samples and plant maintenance. The company then started to use its carbon fiber 3D printer to manufacture low-volume special tool prototypes, and quickly turned to metal 3D printing to produce functional tooling. “We can now make a one-off production part and supply it to a customer in less than one-third of the time and at a lower cost,” says Pearce.

metal 3D printed tool
Guhring UK has sent metal 3D printed tools to customers to test new concepts.

The first 3D printed tool Guhring UK made was a basic milling cutter using H13 Tool Steel. “Within one day, we had designed and printed a tool in Onyx [nylon mixed with chopped carbon fiber], and we could immediately see if we were going to come up against any problems in manufacturing it. Within five days, we had printed and sintered a fully functional metal cutter body. Using Markforged 3D printers just speeds up everything.” After adding the cutting tips, Guhring qualified the milling cutter by testing it initially as an aluminum reamer, and found that it performed extremely well. The engineers then changed the configuration of the tool-tip geometry and ran the 3D printed tool as a milling cutter to test its capabilities, with an off-centre loading. This too worked exactly as planned. The 3D printed tool is 60% lighter than its traditional predecessor, which allows for faster tool changes in cycles and a reduction in cycle times. This application discovery has allowed the company to produce more versatile, lightweight tools for its customers at a far lower price.

“From verifying the tool’s design to printing the tool, we can vastly reduce the lead time with 3D printing, as opposed to manually machining the parts.”

— Alan Pearce, PCD Production Supervisor, Guhring UK

Tool tips were fixed to the 3D printed body before being ground to the required shape.

Looking Ahead

Guhring UK now has the ability to service smaller businesses, making their product and services  more accessible. Engineers at the company have even started experimenting with 3D printed coolant pathways — one of the first Markforged customers to do so. The extra money Guhring UK has saved by adding Markforged 3D printers won’t be going to waste, with Pearce saying that any savings made will be “reinvested back into the company so we can continue growing and supplying bigger and better products to our customers.” As for the extra time saved, Pearce says it will be redeployed into the fabrication of production parts. The addition of the Markforged 3D printers has already allowed engineers to free up their 5-axis mills and conventional technology to produce other revenue-generating parts, boosting the company’s earnings.[/et_pb_text][/et_pb_column][/et_pb_row][/et_pb_section]

Running a smarter factory with 3DEXPERIENCE

Running a smarter factory with 3DEXPERIENCE

Running a smarter factory with 3DEXPERIENCE

 

When Kobelco Construction Machinery invented its first electric excavator in 1930, it facilitated construction work. For 90 years, the company has continuously supplied new and optimized products, such as hydraulic excavators and crawler cranes, to their customers around the globe.

 

The machinery industry is a fast-moving and changing business, so adaption and flexibility are key. To remain competitive and to better adapt to technological changes and customer requests, Kobelco Construction Machinery implemented a Smart Factory initiative, based on three fundamental areas:

  1. Engineering Process Transformation – to be more efficient in the production process
  2. Unified Plant Management Information – to centrally manage all data
  3. Automation ahead of standardization – to improve the work environment

Dassault Systèmes’ 3DEXPERIENCE platform helps the company to support this initiative and therefore transform their business processes. The integrated production system on the platform enables sustainable management of global manufacturing operations while the whole product development becomes more efficient through the use of 3D modeling and digital simulation. All information related to the production process can be shared in real-time with all stakeholders, leading to better collaboration and improved traceability.

 

Watch the video to find out more how Kobelco Construction Machinery keeps up with the ever-changing machinery industry by leveraging the 3DEXPERIENCE platform.

Source: “This post original appeared on Navigate the Future blog from Dassault Systèmes”

Client Specific Dashboard Customization on the 3DEXPERIENCE platform by Mecanica Solutions

Client Specific Dashboard Customization on the 3DEXPERIENCE platform by Mecanica Solutions

The 3DEXPERIENCE Platform is a powerful suite of tools designed to provide tightly integrated solutions for every organization in your company.

As such it comes pre-packaged with a series of applications. With built in best practices baseline behaviors. In some cases however, our clients ask us for specific add-ons tailored to their business needs. In the accompanying video we highlight a small development made by our intrepid team of Mecanica PLM Application Specialists.A dynamic reporting tool showing (over a span of 2 years) the monthly number of parts released by the individual members of the work teams.

 

 

Got a request for a specific 3DEXPERIENCE development your organization desires?

Drop us a line @ info@mecanicasolutions.com or give us a call at 1 800 567 4223 & let’s talk.

We are your one stop shop for all your 3DEXPERIENCE-Enovia/Catia/Delmia/Simulia needs.Licensing Installation, Performance Tuning, Remote Sites Deployment, Training Best Practices, Methodologies,Customization & Development

 

CATIA Systems Architecture Requirements Webinar

CATIA Systems Architecture Requirements Webinar

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Learn how an integrated automotive systems architecture and requirements engineering process can save time and money!

Designing the architecture of automotive systems has never been more challenging. This short recorded seminar will show how you can improve productivity using :

  • A unified system engineering process that fosters innovation and integrates with existing processes and tools.
  • A single source of truth shared across all disciplines provides a common understanding, eliminate errors, enhances collaboration and reduce revisions.
  • Seamless integration across the total process that allows engineers to develop the architecture of complex systems, using a structured role & model based systems engineering methodology.

With the 3DEXPERIENCE Systems Architecture and Requirements engineering solution you can:

  • Model, simulate and analyze all vehicle systems starting from systems operational, functional and component views through to their detailed definition and implementation.
    Quickly and easily map systems requirements to architectural models.
  • Automatically generate documentation that describes the technical specification of the system, sub system or single component for sharing with suppliers and partners.
  • Accelerate and optimize the overall automotive systems architecture design process by leveraging powerful configuration and lifecycle management capabilities to drive asset reuse.
  • Our 10 minute video shows how you can achieve these and additional benefits in defining, decomposing and implementing the architecture of vehicle systems.

Watch now[:fr]Learn how an integrated automotive systems architecture and requirements engineering process can save time and money!

Designing the architecture of automotive systems has never been more challenging. This short recorded seminar will show how you can improve productivity using :

  • A unified system engineering process that fosters innovation and integrates with existing processes and tools.
  • A single source of truth shared across all disciplines provides a common understanding, eliminate errors, enhances collaboration and reduce revisions.
  • Seamless integration across the total process that allows engineers to develop the architecture of complex systems, using a structured role & model based systems engineering methodology.

With the 3DEXPERIENCE Systems Architecture and Requirements engineering solution you can:

  • Model, simulate and analyze all vehicle systems starting from systems operational, functional and component views through to their detailed definition and implementation.
    Quickly and easily map systems requirements to architectural models.
  • Automatically generate documentation that describes the technical specification of the system, sub system or single component for sharing with suppliers and partners.
  • Accelerate and optimize the overall automotive systems architecture design process by leveraging powerful configuration and lifecycle management capabilities to drive asset reuse.
  • Our 10 minute video shows how you can achieve these and additional benefits in defining, decomposing and implementing the architecture of vehicle systems.

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