CREAT3D Case Study
FROM DESIGN TO MANUFACTURE OF END USE PART IN UNDER 10 HOURS
WITH 3D PRINTED MOULD TOOLS
"The quality of parts that we can produce in a matter of minutes is incredible. Now using the Nexa3D technology, you don’t have to trade-off between quality, speed or margin. Now it’s possible to benefit from rapid manufacturing, at low cost.”
Peter Kent, Director, PAKT3D
> ABOUT PAKT3D
PAKT3D is a new generation service and engineering bureau, providing ultra high-speed Additive Manufacturing to Automotive, Motorsport, Fitness, Medical, Aerospace and Marine sectors.
PAKT3D specialise in helping businesses improve quality, reduce lead-times and ultimately cut costs for development and production parts. Using advanced Nexa3D NXE400 ultrafast 3D printing technology, PAKT3D offers production volumes of parts, as well as prototypes, and the ability to print composite and injection mould tools.
> SOLUTION
High-speed Additive Manufacturing through
the integration of the Nexa3D NXE400 Ultrafast Industrial 3D Printer.
Through ongoing support and consultation from CREAT3D, PAKT3D have invested in the NXE400 Ultrafast 3D printer installed at their design and manufacturing site in Surrey.
PAKT3D print parts and tools within hours helping their clients to substantially reduce lead times and ultimately costs.
> CHALLENGE
Long lead times, low quality and costly. These are often the problems faced by engineering, design and manufacturing firms in producing components, mould tools, tooling and prototypes. In particular, recent experiences of issues in supply chains have triggered companies to look at new ways to manufacture.
> RESULTS
“Look at the quality of parts we can produce in a matter of minutes or hours.” Peter Kent, Director
PAKT3D have been using Nexa3D’s technology to produce:
> 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.
> THE BENEFITS FROM ADDITIVE
Leading UK specialist manufacturer of handcrafted performance bicycles ARBR Bikes, engaged with PAKT3D to 3D print a mould tool, previously made in Ultem. The Ultem tool was on a two day lead time and the surface finish was poor on the finished carbon fibre part, which required intensive hand-finishing, racking up manual labour hours and costs
> PAKT3D took ARBR’s original mould tool design and made some adjustments to the design, with a focus on achieving excellent surface finish for the finished part
> After just a few hours of redesign, the mould tool was then 3D printed in xCE Black resin on the Nexa3D NXE400. The 340mm long tool took just 6 hours to print
> Once printed, carbon fibre was laminated in the tool and cured at 120⁰C through an autoclave manufacturing process to produce the final component.
The entire process took less than 10 hours from design to end print
“We were amazed at the speed and quality of the parts produced, and will now be working closely with PAKT3D to produce more components for our state-of-the-art bike."
Robert Barr, Founder of ARBR Bikes
INSIDER KNOWLEDGE
The same part, printed on an FFF 3D printer
would take more than 5 days to print.
BOTTOM DOWNTUBE GUARD
COMPONENT & 3D PRINTED MOULD TOOL
COMPONENT USE
Mould tool to produce downtube guide for
use on ARBR bike
TRADITIONAL MANUFACTURE
Tool is traditionally manufactured in Ultem, at high cost, with a 2 day lead time
PROBLEM
Ultem mould tool lacks quality, with poor surface finish and a long lead time. Furthermore, high levels of post processing are required to finish the part to a sufficient quality before use
OUTCOME OF USING ADDITIVE
> Huge step change in part quality resulting in only 10 minutes of trimming required
> Overall time from design to manufacture < 10 hours
> Mould tool 3D printed on the Nexa3D NXE400 in xCE Black in under 6 hours
> Cost saving 30% against traditional Ultem
We asked PAKT3D, what life would be like without Additive?
"Slow!” explains Peter Kent, Director, “With high-speed Additive Manufacturing, we can help companies save costs, and get to production quicker”.
“Our one tip is to talk to us before you turn to old habits!” explains Alun Tribe, Director. “We can help you redesign and manufacture faster and better, but we need to be involved earlier in your design and production processes to truly benefit from this highly effective technology.”
“Fast Additive has become an alternative manufacturing method for one to a few thousand parts and companies are able to exploit the advantages that this technology brings”, concludes Alun.
