CMEDICAL SECTOR A COMPLETE SOLUTION
DMP Factory series (above) is designed for use with a single metal, but DMP Flex 350
(below) allows users to change the metal being printed in only a few hours
printing puzzle. Success also requires a
product design adapted for 3D-printing,
a validated process and the ability to
integrate downstream operations.
GF Machining Solutions and 3D-printing
technology pioneer 3D
Systems provide a full range
of technologies, including
both machines and
automation systems for
downstream processing.
One of the keys to
GF Machining Solutions’
approach is the use of
System 3R pallets as a base
within the DMP Flex 350.
Printed products can be
transferred to secondary
processing (such as milling)
without the need for reclamping
or re-referencing,
and with product manufacturing data
secured via System 3R's radio frequency
identification (RFID) chip.
GF Machining Solutions and 3D Systems
have also introduced a wire-cutting electrical
discharge machining (EDM) system designed
specifically for AM: The AgieCharmilles CUT
AM 500 is unique in that it allows removal of
product from the build plate cleanly and
without cutting forces.
Taking a product from idea to design for
3D-printing requires both experience and the
appropriate software. Three-dimensional
printing is a vertical process: the powder
present in the bed cannot support the weight
of the printed metal, so designs must be
adapted to include support structures, which
can also prevent deformation due to thermal
stresses arising during the melting process.
Build
simulation
software allows
for the verification
of the size and
geometry of
support
structures; at the
same time,
training and
design experience
are also valuable
assets.
The company’s
3DXpert software
offers simulation
tools that consider wall thicknesses, weight
and powder behaviour to ensure that
supports are minimised and not obstructive,
but still of sufficient size and strength to do
their job.
As an advanced software package,
3DXpert also links the printer design, its
laser and its powder characteristics. The
result is a printing process that optimises
the laser path and build strategy to ensure
that the desired mechanical properties of
the product can be achieved. 3DXpert is the
key to both product design and defining the
optimal printing strategy; it is a complete
solution from CAD to the finished product.
In highly regulated, risk-averse sectors
like medical device manufacturing,
qualification and validation can represent big
hurdles for a manufacturer. A validated AM
process includes the entire ecosystem, from
quality control processes for incoming
powder to software, post-processing and
process controls on finished products.
Companies looking to bring AM into their
production portfolio should carefully consider
which supplier/partner has the level of
experience and expertise. As experts in
metal AM, as well as a broad range of other
manufacturing technologies, and with expert
customer training and first-class customer
services and support, GF Machining
Solutions and 3D Systems are uniquely
qualified to help manufacturers integrate
AM into a factory and master every step,
from machine installation to manufacturing
of AM devices.
MAKING THE RIGHT CHOICES
In conclusion, the products a company plans
to make will inform the choice of printing
technology and the make and model of the
printer will increase — or limit — a user’s
flexibility, in terms of materials and the
products that can be made.
The technology used and the 3D-printer
design selected will also drive running costs
— up or down — and influence product
quality. In the final analysis, oxygen
management in the chosen system will likely
be the single biggest driver of running costs
and product quality, and it should be high on
list of priorities choosing a system.
Managing the changes metal AM brings
to product design and understanding
validation of the complete value chain
— including post-processing steps —
are also key. Training staff or hiring people
with relevant experience and adapting
internal processes are also important
starting points.
As 3D-printing continues to cement its
place in the medical device manufacturing
arena, GF Machining Solutions and 3D
Systems bring together the elements
essential to a streamlined integration of the
technology, while delivering not only the
system with the lowest running costs but an
end-to-end solution that includes powder,
software, expert application support,
operator training and customer services. ■
24 November 2020 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets
/www.machinery.co.uk