Several recently commercialized technologies have made the dream of being able to print large, we are talking feet instead of inches, parts a reality. In fact “The age of large format 3D printing is here, and it is going to be huge.”
Waking up at 3 A.M. isn’t something I like to do often. However, for this conference I was about to attend, it was worth the early rise! Caffeine is a must to get through a long day of walking around and being educated by all the different new and old manufacturers of 3D printers. If you have been around 3D printing, you know there are really two conferences that are above the rest; AMUG and RAPID. Here are some of the things that were announced that I believe are the most significant at RAPID.
Stratasys didn’t disappoint this year in introducing a new carbon fiber 3D printer, material, and metal technology that will be coming in a year+. We are very familiar with the Nylon 12 Carbon Fiber reinforced material that Stratasys has. It is THE best Nylon 12 carbon fiber material on the market and there are a few factors as to why that is the case. One is that they are using longer strands of Carbon Fiber than the competitor along with 35% carbon fiber filled parts compared to 15%. Soluble support is huge for this material as well, along with 2 to 5 times faster printer speeds. Check out how One Wheel is using this printer to help with manufacturing their cool skateboard:
ANTERO 800 is the new material that Stratasys released recently. This material is being used in many amazing ways. Lockheed Martin/NASA/Stratasys/PADT collaborated in a very successful task to get flight approved hardware for one of the next missions to space. Below is the full story on this new and exciting ESD version of Antero 800 FDM material. Could your company also benefit from using this type of material? We would like to help!
Vero Magenta V and Vero Yellow V are the new Polyjet materials to help with getting more vibrant colors along with deeper red and brighter yellow. 500,000 color combinations can be achieved now with these 2 materials that have been improved upon. Absolutely beautiful parts can be made with a Stratasys J750 or J735.
Metal We have been asking (and have been asked) for metal for the longest time! When is Stratasys going to jump into the metal game? One of the main reasons why I went to RAPID this year was to see Stratasys Metal parts. They did not disappoint. As far as what density these metal parts are, the process for printing, and when a machine will be available, that is still the big unknown. One thing mentioned at the conference is that they are wanting to make metal 3D printing affordable to all with the ability to 3D print metal 80% cheaper than anything available right now. How this compares to what Desktop Metal, Mark Forged, HP, and others who proclaim to make metal parts cheaper than the Laser or Electron Beam options is yet to be known. Stratasys wants to be able to provide value to the metal market by focusing on areas that are lacking, which is Aluminum. Always good to have competition against the large companies of metal as it makes everyone get better at what they are doing. Read more about this machine and what Phil Reeves (VP of Strategic Consulting from Stratasys) has to say in an exclusive interview with TCT. Also below are a few pictures I took in the Stratasys booth of their metal parts that were on display.
Software was featured big time at RAPID because it unlocks the ability to 3D print amazing parts like this that was featured in the EOS booth. Lattice structures and topology optimized parts!
There were a lot of companies present at RAPID that highlighted where the industry is headed. Materials with vibrant color capabilities was one such area receiving a lot of attention. While competitors have introduced machines that are capable of printing in a wide variety of colors, they still fall short when compared to the Stratasys Polyjet offerings. Machines such as the J750 and J735 both offer a similar range of color compared to other companies on the market, but surpass them when it comes to material options, applications, and overall usability.
I enjoyed talking with all the major 3D printer manufactures at RAPID. One questions I would ask each of them is, what makes your system better than the competitors? I loved hearing the sales pitch about their machines and there was some great insight gained by asking this.At the end of the day, it all comes down to how you are wanting to use the 3D printer. At PADT we have many different 3D printers, and while we see and understand the appeal of the various different offerings on the market today, there is a reason why we continue to resell and support the brands we do. Let us know how we can help you out and any questions that you have with 3D printing.
When it comes to delivering accurate, robust, and feature-rich additive manufacturing, commonly called 3D Printing, to professional users, one brand of systems stands above all the rest: Stratasys. For over a decade PADT has been a reseller of these outstanding machines in the four-corners states of Arizona, Colorado, New Mexico, and Utah. In fact, our leadership position in the Additive Manufacturing space is built on the foundation of our sales and support history with Stratasys.
Stratasys, The World Leader in Additive Manufacturing
There is one simple reason why Stratasys is the world leader in Additive Manufacturing systems and why so many of our customers keep buying Stratasys systems: They Work. The whole point of 3D Printing is that you can go from a computer model to a real part as quickly and easily as possible. Stratasys has created a complete set of hardware, material, and software to make that happen. For hardware, they offer two additive manufacturing technologies: FDM and PolyJet.
FDM, or Fused Deposition Modeling, is the most common technology because it is reliable, accurate and builds strong parts. FDM was invented by Stratasys over 25 years ago and still forms the foundation of their product line. It is a layered deposition process that melts a variety of plastics that are then extruded through a nozzle to draw the shape of each layer. From the desktop MakerBot machines to the industry favorite FORTUS 900, there is a machine that works for every need. Recently, we have been selling a large number of F370’s to new an existing customers. FMD systems come in a variety of sizes, speeds, costs, and most importantly, material options. And best of all, the majority of FDM systems come with Stratasys’ patented soluble support material that makes support removal as easy as dropping your part into a cleaning system (many of which are made by PADT).
If you need greater refinement, the ability to change material, or color, then PolyJet technology is your ideal solution. The power of PolyJet is that it uses inkjet print heads to deposit tiny dots of liquid material on a build layr. That material is then hardened with an ultraviolet lamp. What is cool is that you can have multiple inkjet print heads and therefore deposit a mix of material within a given layer. This allows you to make parts with very hard, or very soft material in the same build. Or, to mix clear and colors in the same build. Our customers use Polyjet printers to make everything from accurate medical models of organs to molds for plastic injection molding. No other 3D Printing technology is as versatile as the PolyJet machines from Stratasys.
The PADT Sales Experience
Lots of people sell 3D Printers. We know because we have been doing it for over fifteen years. And as the technology has become more popular, more and more people are getting into the industry. Our experience and technically driven sales approach is why customers keep coming to PADT when they have so many choices. Our sales team is not about this months sales goal. They are about building, and more often than not, growing our relationship with customers new and old. We are all about understanding what you really want to get done, and then finding the right combination of Additive Manufacturing system, accessories, and software that will make it happen.
That expertise comes from the fact that we have been running a 3D Printing service since 1994. We know the real world of Additive Manufacturing. No other reseller can bring our expertise and experience to your aid.
Support that Goes Above and Beyond
Once you purchase a system, your journey with PADT hits full swing. Our engineers will help you install, train your users, and then be there when you need us for maintenance and repair. Or simply to answer your questions. We recently won a series of competitive situations where customers had a choice of who to hire to support their Stratasys systems. They chose PADT over other solutions for one simple reason: we know what we are doing and we really do care. Our team has driven through snow storms, stayed with machines late into the night, and personally shipped replacement parts just so they could get customer’s machines back online and running as quickly as possible.
Talk to PADT about your Additive Manufacturing Needs
Regardless of what systems you currently have, or if you don’t have any 3D Printing capability in-house, now is the time to talk to PADT. We have never had a better offering of solutions in terms of price, performance, and variety of capability. We are helping universities establish labs, Aerospace companies 3D Print hardware for launch vehicles, and consumer products companies shorten their design cycle. It may be time for you to upgrade or add a new material or technology. Or maybe you just need some accessories to get more out of the equipment you have. Regardless of where you are in your Additive Manufacturing journey, PADT is here to help you get more out of your investment.
PADT’s Salt Lake City office has been involved with fulfillment of medical 3d Printing of several cases where customers are exploring the value of multi-color and multi-material medical 3D models by using the Stratasys J750 or the Connex 3. One of those cases was presented at the Mayo Clinic’s Collaborative 3D Printing in Medical Practice 2018 course, which was held in Arizona this year.
An Intermountain Healthcare facility in Salt Lake City needed help with 3D printing a patient-specific anatomy, as they were looking to better their understanding of the value of 3D printing using multi-color printer beyond their existing in-house capabilities. In the picture below, Rami Shorti, PhD., a senior Biomechanical Engineering Scientist at Intermountain Healthcare, wrote:
“A patient with a horseshoe kidney and multiple large symptomatic stones, who had failed Extracorporeal Shock Wave Lithotripsy and Ureteroscopy Treatment, was used to evaluate the benefit of using different imaging modalities intraoperatively.”
Working with us in Salt Lake City, Rami Shorti, PhD, prepared the patient-specific medical imaging segmentation, post-processing of the patient anatomy, and finally generated for us a 3D printable CAD model that we were able to print using a Stratasys Objet 260 Connex 3. Since our office is located just around the corner from the hospital, we were able to work closely with Rami to identify the colors and finish of the final part.
The Connex 3 printer was introduced in 2014 as the only printer in the world that could combine three different model materials in a single print pass. Most 3D printers can only print with one material at a time, which is one of the main reasons why this technology is preferred for medical use cases along with its added precision. In 2017, Stratasys introduced the J750, which again is an industry first, becoming the only printer in the world that can print 6 different materials at the same time. Combinations of hard plastics and rubber materials allow for a range of shore hardness values along with the ability to mix three primary colors to print 500,000 different colors.
With a quick turnaround needed, we decided to use the Connex 3 and were amazed that we were able to print the parts in two batches. Within 48 hours of receiving the STL files from Dr. Shorti, we were able to 3D print, post-process, and deliver the parts in time for the surgeon to review the time-sensitive surgical planning guides using the mockup. To enhance the transparency of the parts, we simply applied a few coats of Rust-Oleum Clear Gloss to the 3D printed part. Now we were able to relax and wait for it to dry. Below is a picture of the finished products displayed at the Mayo Clinic event.
“3D printing added a level of benefit because of its ability to showcase the stones, renal pelvis, and renal arteries and veins simultaneously through the image fusion step done in Mimics software and with the use of specific materials and contrasting colors. In addition, its ability to be held and manipulated in space was observed to be beneficial especially for patient education.”
– Rami Shorti, PhD., senior Biomechanical Engineering Scientist, Intermountain Healthcare
PADT is excited to continue our work with Intermountain Healthcare, and grow this relationship as new opportunities arise to leverage multi-material printing.
In November of last year we did a press release on new Additive Manufacturing Laboratory at Metropolitan State University in Denver. Since then all of the partners have been hard at work getting the lab up and running. Last week MSUD released an interview with the University President about the lab as well as a tour of the lab. It is a great look at how academia and industry are working together to push advanced manufacturing forward. Not just on equipment, but also with internships and value added engineering at the university.
Take a look:
PADT is proud to have been a key member of the team and a continued partner for the lab along with Stratasys.
If you want to learn more about how PADT can help your company or university create partnerships like this or leverage 3D Printing in other ways, please contact PADT. We love this stuff!
My first time to Miami was a success! Last year, Stratasys held the partner kickoff in New Orleans and that was when they launched the F1, 2, and 3 series. Since then they have sold over 800 units of these types of FDM 3D printers in the USA. This year in Miami, they did announce something new but it still has a few quarters to go until there is an official release. To say I am excited about what is coming is an understatement! In fact, Stratasys is going to be releasing one new printer here in a few weeks. I am excited for the direction they are going. During this partner kickoff, they mentioned a huge price drop on all of their Polyjet printers! Send us a message for the latest pricing at firstname.lastname@example.org.
As for PADT employees that were in attendance, we had quite the representation this year. Rey Chu (Co-Owner of PADT), Mario Vargas (Manager of Hardware Sales), Norman Stucker (Colorado Territory Manager), Anthony Wagoner (Utah Territory Manager), Kathryn Pesta (Sales Operations Manager), and me (James Barker, Sr. Application Engineer).
Pictured above from left to right is Mario Vargas, Kathryn Pesta, James Barker, and Anthony Wagoner.
Above is a picture of the Stratasys Panel that was open to some Q&A. 2nd from the right is S. Scott Crump who is the inventor of FDM (fused deposition modeling) printers 30 years ago. Below is a picture of the anniversary info for Stratasys along with Objet (Polyjet technology 20 years) and the merger between the two companies is now 5 years old!
My introduction to 3D printers started 8 years ago with an Objet Eden 500 printer at L-3 Communications where I ran their 3D print lab. 6 months later we got an additional Polyjet printer which was a Connex 500. Amazing that we were able to justify purchasing another high quality machine after a few months of operating the Objet Eden 500! A few years later we got our first Uprint FDM printer from a sister company that no longer had a need for it. After using the Uprint for a few months, I was made aware of some of these thermoplastic materials that could only be printed on the production grade FDM machines. I created a business case to get the Fortus 450 and had every material option available at that time to print with (ABS family of materials, ASA, PC, Nylon 12, Ultem 9085, and Ultem 1010). I love both of these technologies and am confident that they provide the best solution for either rapid prototyping or tooling applications. We even have many customers that are printing production parts with these very precise 3D printers.
One customer that is printing production quality parts is Laika Studios, who has produced these movies: Kubo and the Two Strings, The Boxtrolls, ParaNorman, and Coraline. The presentation they made for us on their stop motion animation was so much fun! 10 years ago for Nightmare before Christmas there were 800+ hand sculpted faces made. For Kubo and the Two Strings, there were 64,000 facial expressions that were all 3d printed with a Stratasys J750. Another fun fact about the movie is that it took 60 hours of 3D printing for one second of film time to be created which is why it takes 2-3 years to complete a film. Moonbeast is a 3ft long puppet that is entirely comprised of 3d printed parts which is the largest character they have done to date. If you have watched Kubo and the Two Strings, it appears to be computer animated but in reality it is stop animation with 3D printed parts! Here is a fun short video (13 seconds) of what the Stratasys printer looks like as it is printing and then support material being removed from the head with different facial expressions.
Matt Gimble, who works for Penske as a Production Manager, shared with us many of the different applications that have helped them save a lot of money since they’ve incorporated 3D printing. Racing is rapidly evolving and is very technical nowadays with a huge emphasis on engineering. 3D printing gives them the tools to meet the new challenges. There are many different great uses they’ve had for 3D printing – from a redesigned rear gear pump design, to a new exhaust tailpipe. Even production parts are made with Stratasys’ newest material, Nylon 12CF. This is a high strength chopped carbon fiber filled Nylon 12. Many that use this material are awe-inspired with its performance! The Superspeedway side view mirror is made out of this material and saved Team Penske 4-6 weeks – which is how long it takes for the mold to be made. Then what if the mold needs altering? Crew Helmet Light/Camera mount is also made in this great thermoplastic/composite material called Nylon 12CF.
The above Fuel Probe was re-engineered and is lighter than its predecessor, plus more ergonomical to help with delivering fuel in a timely manner. Pre-preg carbon fiber sleeves when wrapped around a soluble support material and after the autoclave heating process, the soluble core is dissolved in a sodium hydroxide cleaning tank leaving only the carbon fiber. PADT is a manufacturer for the cleaning tanks that are sold with any Stratasys FDM 3d printer. The core is made out of ST-130 material which is perfect for this application or sacrificial tooling. Ultem 1010 was used as well to create carbon fiber layup tools in a fraction of the time it would have taken for the steel molds to be made. Typical turnaround is 1-3 days, as compared to 4-6 weeks. These are all great applications by Team Penske! Well done!!
We learned a lot at the partner kickoff. Luckily I was able to get this great picture with S. Scott Crump and Mario Vargas! To this day Scott is still inventing and is a major contributor to innovating at Stratasys. While talking with him and Mario, he started talking about these many adventures that he goes on. Scuba diving off the island of Tortuga and having many sharks swimming above isn’t for the faint of heart, yet it is where Scott seems to find his happy place.
My wife flew out Thursday night to come see Miami with me. It was my first time visiting Florida and we had a phenomenal time there. We put 800 miles on the rental car driving all around. Driving down the Florida Keys all the way to Key West was a blast and if you ever go to Key West, make sure to get a Cuban sandwich from the restaurant Bien! It is MUY MUY BIEN! The islands are so beautiful! We also went to the Everglades where we got an airboat tour and where I even held a 4 year old Alligator and gave it a kiss on the back of its head. My little girls shriek every time they see the picture!
We had a great time in Florida! As we now look to the future, watch out for some exciting updates about new products that are coming! Stratasys, in my opinion, is going to continue being a leader in the Additive Manufacturing realm and I can’t wait to help announce some of the new equipment once it is available!
Any questions you have, you can direct them to me at James.email@example.com. Thanks!
|Published on:||December 19, 2017|
|With:||Ted Harris, Joe Woodward, Alex Grishin, Jim Peters, Tom Chadwick, Ahmed Fayed, Eric Miller|
|Description:||In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Alex Grishin, Jim Peters, Joe Woodword, Tom Chadwick, Ahmed Fayed, and Ted Harris, for a discussion on predictions of what the future holds for ANSYS and simulation in general, covering topics such as 3D Printing, Acquisitions, The Cloud, IOT, and Artificial Intelligence.|
|Published on:||December 4, 2017|
|With:||Ted Harris, Joe Woodward, Eric Miller|
|Description:||In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Senior Mechanical Engineer Joe Woodward, and Simulation Support Manager Ted Harris for a look into recent announcements regarding simulating 3D Printing with ANSYS and 3DSIM as well as a discussion about what users can do when their models are taking too long to solve.|
If there is one service that most people connect PADT with it is our 3D Printing Services. We have been making prototypes for companies using this ever-advancing technology since we started the company in 1994. As 3D Printing has become more popular and entered the mainstream even beyond engineering, what 3D Printing means to people has changed as well. Along with that, people’s understanding of exactly what it is we do in this area has drifted a little from what goes on. In this month’s installment of our “Getting to Know PADT” series, we will work to provide insight into what 3D Printing Services are and how they can benefit your company.
What is “3D Printing” and “3D Printing Services?”
To start, it should be called “Additive and Advanced Manufacturing and Prototyping Services, ” but people search for “3D Printing” so that is what we call it. 3D Printing is the common name for what is technically referred to as Additive Manufacturing, or AM. Most physical parts are made (manufactured) by casting or shaping material into a shape you want, removing material from stock to get the shapes you want, and/or combining physical parts you get by the other two methods. Instead of these well-proven methods, AM creates a part by building up material one layer at a time. That is why it is called additive – it adds layers of material to get a shape. Here is an older blog article showing the most common technologies used in AM.
The advantage of this approach is that you just need one machine to make a part, you can go straight from a computer model to that part, and you are not held back by the physical constraints of traditional processes. These features allow anyone to make a part and to make shapes we just could not create before. At first, we only used it for prototypes before parts were made. Then we started to make tools to make final products, and now 3D Printing is employed to manufacturing end-use parts.
In the world of mechanical engineering, where 3D Printing is heavily used, we call companies that use additive manufacturing to make parts for others 3D Printing Service Bureaus or 3D Printing Service Providers. Therefore, the full process of doing manufacturing using the technology is called: 3D Printing Services.
The critical word in that last sentence is “full.” Sending a computer model to a 3D Printer is just one of many steps involved in Additive Manufacturing. When the service is employed correctly, it includes identifying the right type of additive manufacturing to use, preparing the geometry, setting parameters on the machine, printing the parts, removing supports, cleaning the parts, sanding, applying a surface finish treatment, and then inspection and shipping. Anyone can send a part to a printer; the other steps are what make the difference between simply printing a part, and producing a great part.
What Services does PADT Offer?
Additive Manufacturing covers a wide range of technologies that create parts one layer at a time, using a variety of approaches. Some extrude, some harden, some use an inkjet print head, and still others melt material. What they have in common is creating solid geometry one layer at a time. Each technology has its own unique set of advantages, and that is why PADT offers so many different 3D Printing technologies for our customers. Each of these approaches has unique part preparations, machine parameters, and post-printing processes. Each with a unique set of advantages. The key to success is knowing which technology is best for each part and then executing it correctly.
Currently, PADT’s 3D Printing Services Group makes parts for customers using the following technologies. Each one listed has a brief description of its advantages. See our website for more details.
Reliability of systems
Broad material choice
Water soluble supports
Multiple materials in a single build
Broad material choices
Custom material choices
Multiple colors in single build
Water soluble supports
Fully dense metal parts
As a proud reseller for Stratasys systems, we feel strongly that the two primary technologies from Stratasys, FDM and Polyjet, are the best for customers who want to do Additive Manufacturing in-house or as a service provider. When customers need something different, they can come to PADT to take advantage of the unique capabilities found in each technology.
How is 3D Printing with PADT Better?
The difference is in what we know and how to execute the complete process. As a provider of 3D Printing services for over 23 years, very few people in the industry even come close to the amount of experience that we bring to the table. We also know product development and traditional manufacturing, so when a customer comes to us with a need, we understand what they are asking to do and why. That helps us make the right recommendation on process, material, and post-processing.
A few differentiators are:
- We know our machines
- We know our materials
- We offer a wide range of plastic and metal materials
- We understand post-processing
- We understand support removal (we manufacture the leading support removal system)
- We understand design and manufacturing
- In-house machining, painting, and part finishing
- In-house inspection and quality
- Employees who are enthusiastic and dedicated to providing the right solution.
In addition to all of these things, PADT also offers On-Demand Manufacturing as a Carbon Production Partner. We combine Carbon’s DLS technology with our existing and proven manufacturing processes to provide low volume manufacturing solutions for plastic components.
We are also always looking at the latest technologies and adding what our customers need. You can see this with the recent addition of systems from ConceptLaser, Carbon and Desktop Metal systems.
Next Steps and Where to Learn More
The very best way to learn more about PADT’s 3D Printing services is to have us print a part. The full experience and the final product will explain why, with so many choices, so many companies large and small count on us for their Additive Manufacturing. If you need to learn more, you can also contact us at 480.813.4884 or firstname.lastname@example.org.
Here are some links that you may find useful:
- PADT’s 3D Printing Services Pages on our website.
- Our 3D Printing Services Brochure
- The On-Demand Manufacturing Brochure
- More Information on Scanning & Reverse Engineering
- Details on our Product Development Services
- Blog posts on 3D Printing
The addition of a new UnionTech RSPro 450 further establishes PADT as the leader in Additive Manufacturing technology in the Southwestern US. With a build volume of 17.7 x 17.7 x 15.75 inches, this state of the art Stereolithography(SLA) machine will triple the company’s capacity to 3D Print with SLA technology at this Las Vegas print shop. It not only allows the printing of larger parts, it can also create multiple smaller parts in less time. It will join PADT’s two existing SLA machines along with the Fused Deposition Modeling (FDM), PolyJet, and Selective Laser Sintering (SLS) solutions currently producing parts daily for their customers across the country.
“When we started the company in 1994, one of our first purchases was an SLA machine. It started our 3D Printing services business, and the technology is still heavily used today.” Said Rey Chu, a co-owner of PADT and the leader for PADT’s Advanced Manufacturing efforts. “This new system gives us added capacity in size, speed, and material choices. We looked at a wide range of SLA systems and felt that UnionTech provided the quality and robustness we need to keep our customers happy.”
The new system was delivered the second week of October and will be calibrated and producing customer parts by the end of the month. One of the advantages of the machine is the easy setup and strong calibration capabilities. The team will be able to produce parts that are about 75% larger than they can currently. The additional volume and speed will allow for three times as many parts to be printed in a given week than is possible with the current two smaller and older machines. Initially, a new rigid ABS-like material will be used that produces very strong and precise parts with white plastic. PADT’s existing pre- and post-processing tools will be applied to this process with little change.
The UnionTech RSPRO 450 SLA System
UnionTech systems are the most popular machines for SLA Additive Manufacturing outside of the United States. They have proven to be reliable, easy-to-use, accurate, and fast. They are also an open system, allowing users to use any SLA compatible resin that can usually be acquired at a more affordable price than proprietary material solutions.
Stereolithography is the oldest commercial 3D Printing process. It uses photo-curable liquid resins to build parts one layer at a time. A vat in the machine is filled with liquid material, and a plate is placed just under the surface. Then an ultraviolet laser draws on the very top layer of the liquid, and all of wherever the laser traces, the liquid turns to a solid. The plate is lowered, a new layer of liquid is spread on top, and the laser creates a new layer. The process repeats until the part or parts are made.
The UnionTech machine is a refined and proven application of this technology that was a perfect match for PADT’s current needs. Also, the company itself was great to work with, and the local sales and support team have been outstanding. As the team learns the system, they are finding it to be easy to use as well as simple to maintain and calibrate. The initial quality of parts has been outstanding.
PADT’s 3D Printing Services
PADT has been the Southwest’s leading provider of 3D Printing services since the company was started over 23 years ago. The company has survived industry consolidation and a vastly changing landscape by focusing on providing high-quality 3D Printed parts to customers using Fused Deposition Modeling, Polyjet Printing, Selective Laser Sintering, and Stereolithography systems combined with one of the most experienced and knowledgeable teams in the Additive Manufacturing space.
Located in the ASU Research Park in Tempe, Arizona, PADT’s advanced manufacturing facility currently features ten machines dedicated to printing parts for customers. The lab includes a full machine shop, part finishing facilities, and an advanced scanning and inspection capability.
This added capability is yet another reason why so many companies large and small count on PADT for their 3D Printing needs.
Contact us today to learn more about our 3D Printing Services or:
The long-term promise of 3D Printing has always been using the technology to replace traditional manufacturing as a way to make production parts. The various technologies that are considered Additive Manufacturing have been fantastic for prototyping and making tools that are used to manufacturing end-use parts, but rarely work well for production. Carbon is literally turning the 3D printing world upside down by introducing real production capabilities with their systems. And now that PADT has joined Carbon’s Production Partner Program, on-demand manufacturing using 3D Printing is now a reality in the Southwestern US.
The Production Partner program establishes vetted service providers with 3D Printing and manufacturing experience as manufacturing centers. This allows customers who are early adopters of CARBON’s exciting technology, to find a trusted source for their production parts. PADT was chosen to participate because of our twenty-plus years of experience as a 3D Printing service provider and more than $5,000,000 in injection molding projects, along with in-house product development, scanning, simulation, and inspection.
PADT will be adding three Carbon M2 printers to our existing 3D Printing facility at our main office in the ASU Research Park in Tempe, Arizona. The first two machines will be available for production in early 2018, and the third machine will be online by early summer. Customers will then be able to order production quality parts in volume and receive them within a week. PADT’s investment and this partnership make the dream of On Demand manufacturing of complex plastic components a reality.
“We have been looking for a low volume plastic manufacturing solution that uses 3D Printing for some time.” Said Rey Chu, co-owner of PADT “Since we started the company we have been providing soft tooling and rapid injection molding. Once we saw the Carbon DLS technology in action, we knew we found our solution. The part quality and material properties are as close to injection molded as we have ever seen.”
About Carbon’s Disruptive Technology
Carbon has introduced a revolutionary way to 3D Print plastic components called Digital Light Synthesis, or DLS. It combines their proprietary continuous printing technology with programmable liquid resins to create parts with the same strength and surface finish of injection molded parts. The part creation is fast because it is a continuous process, whereas most 3D Printing machines build up one layer at a time with pauses in-between. This continuous process is not only fast, but it also avoids the stair-steps created with layered methods. This results in textured surfaces and a surface finish that no other process can approach.
Programmable materials are the other technology that enables production quality parts. This unique approach joins two liquid resins as the build material; one that hardens with light and the other with heat. The 3D Printer creates the desired geometry of the part by using light to shape the first material. Then a second step uses an oven to harden the heat activated resin, resulting in engineering-grade mechanical properties. Moreover, since the strength comes from a heat cured resin, the properties are the same in every direction. Most 3D Printed parts that use a layered approach are weaker in the build direction. The other significant advantage of including heat activated resins is that they offer a much broader material selection than light activated resins.
PADT’s On-Demand Manufacturing Service
In the past, when PADT’s customers needed parts manufactured with production quality, surface finish, and strength we had to use soft tooling or low-volume injection molding. Both are expensive and take time to make tools. 3D printing is leveraged to make those tools faster, but it still takes time and labor. Production manufacturing could benefit from going directly from a computer model to a finished part, as we do with prototyping. When we first saw an early Carbon sample part we knew that this was a technology we needed to watch. As the technology matured further, it became obvious that this was the process PADT was looking for – this was the type of end-use part our customers were requesting. Then, when the Production Partner program was introduced, we knew we needed to take part.
Our On-Demand Manufacturing service will be built around the Carbon Digital Light Synthesis process. Initially, we will use three Carbon M2 systems, a cleaning station, and a curing oven. This will be placed in the middle of our existing advanced manufacturing facility, allowing us to add machining, hand finishing, painting, and other post-processing steps into each production process as needed.
What sets PADT’s offering apart from other providers of production manufacturing with 3D Printing is that we also provide full product development, simulation, and part scanning services to help customers make sure their designs are correct. Before parts are made, we can use our simulation and design knowledge to make sure everything is correct before production begins. And when the parts are completed, we can use our advanced scanning to inspect and our product development testing to verify performance. By adapting our proven quality to this new technology, we can ensure that every step is done correctly and traceability exists.
You do not have to wait till our production line is up and running. We can start working with customers now on getting their parts ready for manufacturing with Carbon’s breakthrough Digital Light Synthesis. Our experienced staff can evaluate your components and find the best fit, recommend design changes, and work with Carbon to produce samples. And when our line is up, you can hit the ground running and obtain your parts on-demand, when you need them.
- Download the On-Demand Manufacturing brochure
- View the official press release announcing the partnership
- Visit the Carbon website
Take part in the transition of manufacturing to faster, better, and on demand by contacting PADT today to learn more.
It is no mystery that I love my Subaru. I bought it with the intention of using it and I have continually made modifications with a focus on functionality.
When I bought my roof crossbars in order to mount ski and/or bike racks, I quickly realized I needed to get a fairing in order to reduce drag and wind noise. The fairing functions as designed, and looks great as well. However, when I went to install my bike rack, I noticed that the fairing mount was in the way of mounting at the tower. As a result, I had to mount the rack inboard of the tower by a few inches. This mounting position had a few negative results:
- The bike was slightly harder to load/unload
- The additional distance from the tower resulted in additional crossbar flex and bike movement
- Additional interference between bikes when two racks are installed
These issues could all be solved if the fairing mount was simply inboard a few more inches. If only I had access to the resources to make such a concept a reality…. oh wait, PADT has all the capabilities needed to take this from concept to reality, what a happy coincidence!
First, we used our in-house ZEISS Comet L3D scanner to get a digital version of the standard left fairing mount bracket. The original bracket is coated with Talcum powder to aid in the scanning process.
The output from the scanning software is a faceted model in *.STL format. I imported this faceted CAD into ANSYS SpaceClaim in order to use it as a template to create editable CAD geometry to use as a basis to create my revised design. The standard mounting bracket is an injection molded part and is hollow with the exception of a couple of ribs. I made sure to capture all this geometry to carry forward into my redesigned parts, which would make the move to scaled manufacturing of this design easy.
Continuing in ANSYS SpaceClaim, as it is a direct modeling software instead of traditional feature-based modeling, I was able to split the bracket’s two function ends, the crossbar end and fairing end, and offset them by 4.5 inches, in order to allow the bike rack to mount right at the crossbar tower. I used the geometry from the center section CAD to create my offset structure. A mirrored version allows both the driver and passenger side fairing mount to be moved inboard to enable mounting of two bike racks in optimal positions. The next step is to turn my CAD geometry back into faceted *.STL format for printing, which can be done directly within ANSYS SpaceClaim.
After the design has been completed, I spoke with our 3D printing group to discuss what technology and material would be good for these brackets, as the parts will be installed on the car during the Colorado summer and winter. For this application, we decided on our in-house Selective Laser Sintering (SLS) SINTERSTATION 2500 PLUS and glass filled nylon material. As this process uses a powder bed when building the parts, no support is needed for overhanging geometry, so the part can be built fully featured. Find out more about the 3D printing technologies available at PADT here.
Finally, it was time to see the results. The new fairing mount offset brackets installed just like the factory pieces, but allowed the installation of the bike rack right at the tower, reducing the movement that was present when mounted inboard, as well as making it easier to load and unload bikes!!
I am very happy with the end result. The new parts assembled perfectly, just as the factory pieces did, and I have increased the functionality of my vehicle yet again. Stay tuned for some additional work featuring these brackets, and I’m sure the next thing I find that can be engineered better! You can find the files on GrabCAD here.
As the world of manufacturing continues to grow and change, engineers are being challenged to design, test, and evaluate products in increasingly complex environments. In such a time it is necessary to rely on an all-encompassing simulation platform that can handle a variety of physics efficiently, operating as a one stop shop for complete virtual prototyping. ANSYS is that platform!
Join us for this informative seminar including presentations from customers and ANSYS technical experts, focusing on how to effectively implement the ANSYS platform and productivity enhancement tools into your work-flow.
Through this free event we hope to inform you on how a single consolidated platform for complete virtual prototyping can help to drive efficiency across your company!
Date: October 4, 2017
Time: 9:00 AM – 4:30 PM MST AZ
Location: ASU SkySong – Building 3
1365 N. Scottsdale Rd.
Scottsdale, AZ 85257
Check out the full agenda, with presentations covering a plethora of topics including:
- ANSYS Solutions for Additive Manufacturing
- Wireless Connectivity with RF Engineering
- Commercial Antenna Array Work Flow Using ANSYS Electromagnetic Tools
This event will include presentations from customers and ANSYS technical experts alike, focusing on how to effectively implement the ANSYS platform and productivity enhancement tools into your work-flow.
The aerospace industry’s adoption of additive manufacturing is growing and predicted to revolutionize the manufacturing process. However, to meet stringent FAA and EASA requirements, AM-developed aerospace products must be certified that they can achieve the robust performance levels provided by traditional manufacturing methods. Current certification processes are complex and variable, and thus obstruct AM adoption in aerospace.
Thanks to a newly released aerospace package released by Stratasys for their Fortus 900mc printer and ULTEM 9085 resin, Aerospace Organizations are now able to simplify the aviation certification process for their manufactured parts.
Join PADT’s 3D Printing General Manager, Norman Stucker for a live webinar that will introduce you to the new Stratasys aerospace package that removes the complexity from FAA and EASA certification.
By attending this webinar, you will learn:
- How Stratasys can help get more parts certified for flight quicker and easier.
- The benefits of Aerospace Organizations using the Fortus 900mc and ULTEM 9085 resin
- And much more!
Don’t miss your chance to attend this upcoming event,
click below to secure your spot today!
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