CREAT3D CASE STUDIES

CHALLENGE

Delivering accurate products and finding effective solutions, in a fast moving, time pressured environment where every decision has a direct impact on race performance

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SOLUTION

Using the Formlabs Fuse SLS 3D printing system.

 

RESULTS

• Same-day turnaround for end-use parts

• No minimum production quantity

• Exact part performance and accuracy

• Batch production of parts to meet short motorsport deadlines

• Enables continuous innovation

CHALLENGE

Ability to deliver bespoke sub-sea solutions that are high in value and low in unit volume. 

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SOLUTION

Incorporating the Markforged Composite 3D printer into R&D and production.

 

RESULTS

• Cost saving 96%

• No minimum production quantity

• Enhanced product with versatility in design and better performance

• Fast turnaround times, from 2-3 weeks to next day

• Generation of new revenue streams through bespoke part manufacture

CHALLENGE

Optimise faster manufacturing of the highest quality fasteners for the Aerospace industry, whilst maintaining stringent standards and produce at a lower cost across multiple variants.

 

SOLUTION

Introducing Markforged Composite 3D printers into LISI AEROSPACE’s Additive Manufacturing capabilities.

 

RESULTS

• Direct ROI in just 6 months

• Zero scrappage costs through using 3D printed components

• Set up of Supply Point Systems with approved 3D printed tooling and components

• Better performing, cross-functional teams with an ability to identify and fix issues earlier in the production process

• Fast problem solving for productive and agile production lines, reducing down time and scrappage

CHALLENGE

End-use parts produced in PLA and ABS materials were pone to warping, discolouration and snapping.

 

SOLUTION

Expanding 3D printing capabilities by investing in the Formlabs Fuse 1 and Sift SLS system (Selective Laser Sintering).

 

RESULTS

• Stronger parts

• Cost savings

• Number of cmponents per part reduced

 

Using PA12 (Nylon), the affordable SLS system has enabled the production of low cost, high-quality parts that are manufactured in small batch runs.

CHALLENGE

Long lead times, low quality, high cost, and recent issues in global supply chains.

 

SOLUTION

Introducing High-speed Additive Manufacturing through the integration of the Nexa3D NXE400 Ultrafast Industrial 3D Printer.

 

RESULTS

• Fast turnaround prototypes

• Mould tooling

• End components

 

The speed of PAKT3D’s Additive Manufacturing capabilities means that parts can be produced in a matter of hours, essential for where immediate design feedback is required, or the product needs to get to market fast.

CHALLENGE

In automation, light-weight end effectors increase robot productivity, increasing efficiency. Challenge is how to achieve bespoke, light-weight, cost-effective solutions, and quickly.

 

SOLUTION

Integrating Additive Manufacturing into all engineering processes with an expansive range of technologies. FFF and SLA for prototyping and Markforged CFF for end-use components and manufacturing on demand

 

RESULTS

• Produce lighter weight end of arm tooling and end effectors

• Reduce production lead times from 3-4 weeks to <12 hours

• Generate new business, by producing end-use components with the Markforged 3D printers that were previously too difficult and costly to achieve using traditional manufacturing methods

CHALLENGE

Increasing productivity in producing large and complex prototypes quickly for internal evaluation,  without sacrificing quality.

 

SOLUTION

Integrating the industrial SLA, Nexa3D NXE400, into their 3D printer equipment range of FDM and other SLA 3D printers.

 

RESULTS

​"The speed and quality of parts still blows my mind every time I run it. I am extremely pleased with the NXE 400, and it is a great addition to our in-house capabilities.  We have been working with the Nexa3D team for almost a year now, and they have taken a lot of feedback and implemented lots of very positive changes to the machine and software in a really short period of time"  Peter Edwards, Lead AM Technology Manager, Motorola Solutions

CHALLENGE

Deliver highly bespoke security entrance solutions to clients, featuring rapidly evolving technologies

 

SOLUTION

Embedding the Markforged Mark Two composite 3D printer into the Engineering Design Team

 

RESULTS

• ​Re-defined business process resulting in bespoke products in 8-10 weeks

• Ability to produce previously cost & time prohibitive end-use parts

• Up to 95.5% cost reduction for production aids and tools

• Achieve right-first-time applications with bespoke jigs

CHALLENGE

Ensuring that products are robustly designed for manufacture, in short turn-around times.

 

SOLUTION

Multiple Markforged desktop 3D printers, 1x Mark Two fully composite 3D printer, 2x Onyx Series printers for increased production capacity.

 

RESULTS

• Return on investment on initial equipment in less than 3 months, adding 2nd and 3rd machines within 9 months

• Clients receive 3D printed solutions to their design and manufacturing problems within days

• Competitive advantage through ability and agility to respond quickly 

• New revenue streams through offering 3D printed end-use components at lower cost, with enhanced functionality and reduced weight

CHALLENGE

Embedding the right type of 3D printing technology into Matter's design, prototype and development workflows to deliver high quality design concepts with minimal finishing, all at a low cost

 

SOLUTION

Deploying multiple Formlabs Form 3 (SLA) 3D printers

 

RESULTS

• Control over full design process, with faster response to design iterations

• Reduced design costs, saving £hundreds on outsourced prototypes per project 

• Enhanced product development, being able to print models that withstand repeat testing

CHALLENGE

To reduce costs & create bespoke solutions

 

SOLUTION

Deploying range of 3D Printers (SLA, CFF & FFF technologies)

 

RESULTS

• ​Freedom with design for bespoke solutions

• Up to 96% lower costs, which feed to the end customer

• Up to 98.8% shorter lead times, from weeks to days

3D PRINTED APPLICATION

Assembly jig

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TRADITIONAL FABRICATION METHOD

3 axis CNC machine

 

ADDITIVE MANUFACTURING SOLUTION

Markforged Mark Two Composite (CFF) 3D Printer

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RESULTS

• 96% cost saving, from £300 to £10.07

• 98% lead time reduction, from 3 weeks to 10 hours

3D PRINTED APPLICATION

Functional prototype for CFD analysis and simulation​

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TRADITIONAL FABRICATION METHOD

Outsourced to 3rd party

 

ADDITIVE MANUFACTURING SOLUTION

Formlabs Form 2 (Stereolithography)

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RESULTS

• Enablement of faster part re-engineering, functionality & performance testing prior to making mould tool

• 93% cost saving, down to just £40 per part

• 97% lead time reduction, from 2-4 weeks to >24 hours

3D PRINTED APPLICATION

Working prototype​

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TRADITIONAL FABRICATION METHOD

CNC Milling

 

ADDITIVE MANUFACTURING SOLUTION

Formlabs Form 2 (Stereolithography)

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RESULTS

• Faster product to market (shortened development cycle)

• ​97% cost saving, from £800 to £25

• 93% lead time reduction, from 2 weeks to 22 hours

CHALLENGE

Product a better performing track car by enabling continuous design improvement, and light-weighting end components

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SOLUTION

Incorporate Markforged Composite 3D printers into design and production workflows to produce end-use components and functional prototypes

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RESULTS

• Overall 60kg weight reduction on the race car

• Design team changed workflow by enabling 3D printing to produce better designs at lower cost and lower risk

• Faster speed of improvement to generate competitive advantages