Unlock Possibilities with Metal Printing

Learn how metal printing can bring your business to the next frontier.

Case Study 1:

75% cost-savings with metal printed replacement parts

Case-Study-Challenge

Client Challenge

  • Client is a global FMCG company where were are supporting the Asia pacific team
  • A critical cutting part of the packaging equipment suffered from consistent failures due to lateral pressure putting stress on a metal “jaw” holding a rubber “blade” in position – The part typically failed every few weeks
  • Client was constantly re-ordering the part due to failure but the OEM required long lead time (3-4 months), high minimum order causing high stock keeping
Case-Study-How-3DMF-Helped

How we helped

  • We visited the factory and redesigned the part to improve performance. After which we printed in a much shorter lead time with reduced volume
  • Design: we changed the shape of the metal jaw to strengthen it and thickened the critical part to increase the lateral strength
  • Production: we were able to print 36 pieces on a single print bed and were able to ship within 2 weeks of order
  • Reprint: we stand ready to re-print at one week’s notice
  • Price: we met the OEM price
Case-Study-Impact

Impact

  • 3 months faster supply of replacement parts reducing downtime risk
  • Improvement in design to extend lifespan of part (first piece was still working will after 4 months)
  • Reduction in through-cycle cost of 75% at last count

Case Study 2:

Saving more than $30,000 by printing obsolete parts for vehicle braking system

Case-Study-Challenge

Client Challenge

  • Client runs a fleet of old vehicles that it is under contract to maintain and keep in operation
  • A key part of the braking was failing and the OEM could not supply without significant cost
  • Options for the client included replacing the entire braking system or the engine completely
Case-Study-How-3DMF-Helped

How we helped

  • We scanned the original part and, working with the part drawing, we created a digital model of the part
  • Then we worked with the client to select a suitable material based on the original part
  • The part was then printed in a metal printing machine
  • Part was installed in the client vehicle fleet
Case-Study-Impact

Impact

  • Client was able to save the braking system and successfully extended use of fleet at minimal cost
  • Value to the client was $30,000 to $40,000 based on replacement of 15 sets of hydraulic brake system

Case Study 3:

Improving part design for retrofit, leading to increase in production uptime

Case-Study-Challenge

Client Challenge

  • Client runs a number of packaging plants in SE Asia
  • During production, significant amount of dust typically escapes and enters vital parts of the production machinery – causing increased cleaning time
  • Cleaning time was up to 7 minutes per machine per shift (3 shifts per day)
  • Previous suction and partition solutions had been tried unsuccessfully
Case-Study-How-3DMF-Helped

How we helped

  • We visited the factory and developed a range of solutions including:
    • Nozzles to place at various points across the production machine
    • Re-design 2 key parts of the equipment by hollowing it out and adding a vacuum pump system
  • Instead of dust being removed by blowers, it was now sucked back through the parts themselves
Case-Study-Impact

Impact

  • Significant reduction in dust entering critical machinery
  • 75% reduction in cleaning time per shift from 7 min to 2 min
  • Millions of savings to client per factory, per year upon full roll-out

Case Study 4:

Replacing custom fit metal impeller for marine company and saving more than a month’s lead time

Case-Study-Challenge

Client Challenge

  • Client runs a small fleet of highly specialist ships, in which many parts are old and obsolete with limited design and drawings available
  • Designing and production of an impeller typically takes 6-10 weeks by traditional manufacturer
  • We were asked to produce in a shorter time to test 3D printed parts
Case-Study-How-3DMF-Helped

How we helped

  • We reverse engineered the outgoing failed part and created a digital file
  • After experimentation we found a unique way to align the part on the print bed with minimal supports so it could be printed in 1 piece
  • We printed a set of test coupons in parallel to allow for a complete set of tests, including UT, dye penetrant, tensile strength etc.
Case-Study-Impact

Impact

  • We were able to deliver a completed impeller in less than 3 weeks
  • The part passed all required testing to show it met minimum standards for ASTM cast part
  • Value to client was pump working at least 4 weeks ahead of traditional timeframe
  • Balancing achieved with 50% less machine adjustment compared to traditional design

Do you have anything in mind that you would like printed in metal?