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back and forth to a workstation two or three times a day,” says Wild.
Fixture Examples Abound
In one case, relays Wild, Solaxis Ingen- ious Manufacturing in Bromont, Canada, using Fortus 3D printers from Stratasys, designed and manufactured a jig for an automotive supplier, which uses it to assemble high-volume door compo- nents. After developing several iterations of the jig, Solaxis not only was able to produce a 3D-printed jig that is more than 100 lb. lighter than a typical jig for this application (the 3D-printed jig weighs 28 lb.), but it also slashed design and manufacturing time by at least two- thirds as compared with traditional methods, according to Solaxis officials.
“No longer is a crane operation needed nor another person needed to spot the jig,” says Wild, “so the burden rate of that tool is reduced.”
Another example: TS Tech, in sup- porting its stamping operations, switched to 3D printing to produce a
seat-bracket check tool. Stratasys Direct Manufacturing redesigned and pro- duced the tool, which featured a weight reduction from 40 to 4 lb. with a pro- duction-time reduction from six to two weeks. The new tool not only had a smaller profile, but it provided better part alignment and was easier to trans- port than the inspection tool it replaced. And, report TS Tech officials, it was tough enough to withstand the needed 42,000-inspections lifetime.
Oreck Manufacturing, according to Wild, is another convert to 3D printing, using the process to create custom assembly fixtures for its high-end com- mercial vacuum cleaners. According to Oreck’s senior model maker, the company has reduced fixture-produc- tion costs by 65 percent by using its inhouse FDM 3D printers. Oreck has used AM to make hundreds of inspec- tion fixtures for its CMMs. On average, it saves $200 and 6.5 days versus having them machined.
Before employing AM, Oreck took
30 days to complete its first-article inspections of 20 to 30 components for a new product. After receiving the first samples from production tooling, the QA department would start making fixtures and programming the coordi- nate measuring machine (CMM). On the 30th day, it would complete the CMM inspection and release the pro- gram to the production floor. With inhouse 3D printing, the company can quickly begin producing fixtures via its 3D printers and begin CMM pro- gramming when a tooling order is released, not after samples are received. As a result, the Quality Assurance department is ready and waiting for the arrival of the first samples. The company estimates that it can save $100,000 to $500,000 annually in such wait-time reductions.
Rapid Tool-Up for Metalforming
Nonmetal AM has proven successful not only as a method to manufacture
October 3-4, 2017 | Cleveland, OH
A two-day technical conference powered by the
Precision Metalforming Association and MetalForming magazine
PMA and MetalForming magazine are proud to bring you the Servo Technology Experience, focused on state- of-the-art servo technology used in presses, transfer systems, coil-feed lines and more. Aimed at engineers and technicians working in metalforming plants, the event will provide technical presentations and case studies describing how modern servo-based equipment can help stampers improve productivity and quality.
Day one of the conference will focus on servo-press technology, and include scheduled breakout sessions with leading suppliers of servo presses. Here, attendees will have the opportunity to network with industry thought leaders and gain unique insights into how this technology is leading the evolution in the metal-stamping industry, and where the technology is headed.
Day two of the conference turns attention to transfer systems, coil-feed lines and other servo- based technology prevalent in pressrooms today. Attendees will learn how these systems work in unison to lead stampers to increased productivity and profitability.
Sponsors:
www.MetalFormingmagazine.com/servo
6363 Oak Tree Blvd. Independence, OH 44131 216/901-8800 www.metalformingmagazine.com www.pma.org
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