E M E X 2 0 1 6 Is metal 3D printing a viable production technology? 40 April 2016 Partnership in precision Since purchasing their first CNC machine, Dynamic Tool & Die and Total CNC Products have forged a close partnership. Dynamic purchased a Kitamura Bridgecenter-8 in 1999 from Total CNC and this machine today is as accurate and precise as it was back then, according to Martyn Neal, director of Dynamic. Since then Dynamic has added another Kitamura 3X and now a new Victor VC-A85 CNC Machining Center also, of course, from reliable partner Total CNC. “These relationships are all about the partnership,” says Rodney Oxford, managing director of Total CNC. “I was involved in unpacking and installing the B-8 in 1999 – Martyn was as meticulous then as he is now and our service team is the same. The partnership works easily and professionally.” The decision to purchase a Victor machine over a new Kitamura was not an easy one and Dynamic worked closely with Rob Bennet, CNC business development manager at Total CNC to come to the decision to buy the new brand. The size is perfect according to Rob, “Dynamic wanted a little more travel over the 3X along with some increased speed and the A85 fitted perfectly with X-axis travel of 850mm and Y-axis of 600mm. It’s a great size for toolmaking.” Offering a little more speed and the same high precision as Dynamic’s well looked after older Kitamuras, the Victor VC-A85 will increase capacity at Dynamic and this third CNC machine from Total CNC will further strengthen a precision partnership. There is no doubt that 3D printing is gaining momentum. But in most cases it is still seen as a technique for prototyping with the majority of this done in plastic. The question is – can metal 3D printing be a viable production technology? The simple answer is yes, however, like all manufacturing there are some guidelines to follow. Metal 3D printing gives good mechanical properties, similar to machined billet; so mechanically it is perfect. The next question is volume. Monthly production of many small parts the size of a pen, a few medium sized parts the size of a cup and a handful of large parts up to 240mm diameter and 280mm high are easily achievable. Parts suitable for printing will vary between fully finished complex parts down to near net shape blanks for further machining. It can get to the stage where printed parts can be cheaper than casting them and the mechanical properties are better. If the parts have solid sections that are not required for their mechanical properties, the ideal is for these to be shelled out and for structural integrity a lattice structure can be put in its place. Not only does this make the parts lighter but it can significantly reduce the cost. This process is undertaken on specialised software with a wide range of lattice structures possible and the wall thickness is user-defined depending on the part requirements. It is also important to note that, when 3D printing metals and plastics, they behave very differently and results may differ. With careful design and programming these effects can be overcome. If the parts are designed for the process then 3D printing becomes a very viable production technology. If you are unsure how you could achieve this, talk to the experts. Rapid Advanced Manufacturing Limited (RAM) info@rapidman.co.nz, ph: +64 7 557 8554 EN030 SLM in Titanium 64, Stainless Steel, Inconel www.rapidman.co.nz Come see us Hall 2, Stand No 3014. EN018
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