Staying relevant is essential for CNC machine shops in a highly competitive market. To stay ahead of the competition and meet the increased expectations of their clients, CNC shops must employ the most modern machine shop tools and machinery in their operations. One such piece of equipment that is becoming more and more well-liked and significant is the 3D printer for composite polymer.
The ability to investigate 3D printing as a prospective business strategy is now possible for CNC service organizations thanks to developments in additive manufacturing technology. Before mass production, prototypes are crucial for testing and fine-tuning designs, and they can be made rapidly and economically with 3D printing. When compared to conventional production methods, CNC service providers might be more adaptable and provide quicker turnaround times. The numerous uses of composite polymer 3D printing in machine shops are covered in this article.
Jigs and fixtures
Jigs and fixtures play a crucial role in CNC machining operations. During machining, they hold and position workpieces, speeding up setup time and ensuring accuracy and reproducibility. Composite polymer 3D printers have changed the way custom jigs and fixtures are made in machine tool shops because to developments in 3D printing technology.
A real-life example of this application is demonstrated by Siemens AG in their Motion Control division. They used a Markforged composite 3D printer to print an alignment jig for their cast-and-machined aluminum component manufacturing process. The jig was reinforced with Kevlar using Onyx material, providing robustness and durability that exceeded the PLA-printed prototype they had previously used. The printed jig was then used to position the aluminum parts in the lathe, with a lightweight UR10 robot precisely fixture them in place, providing accuracy and repeatability throughout the production process. The result was a more accurate part that has held up through over 600 cycles with minimal wear.
Custom Alignment Jig for CNC Lathe
Parts Repairs
Parts replacement is just one of many uses for composite polymer 3D printing in production machining. One real-life example of this application can be seen in the case of Brooke and Mackenzie, who needed a replacement change gear arm for a lathe. The original part had failed, and no spare parts were available anywhere.
They could have made a new one by casting the old one and then machining it, but it would have been expensive and time-consuming. Alternately, they might have spent hundreds of dollars and waited in line at a CNC machining facility to have it made. Instead, they used cloud-based software called Eiger to design the component, and a Markforged machine to print it out of fiberglass-reinforced Onyx, a tough composite material.
Lathe Change Gear Arm
The time and money required to refine and print the new part were negligible (only a few days) compared to other available choices. In addition to being more cost- and time-efficient, this method also allowed Brooke and Mackenzie to evaluate the mechanical strength and longevity of the replacement part in actual use.
Complex custom parts
Customizing parts is one particular use for composite polymer 3D printing in CNC machining services. This is especially helpful when creating parts with distinctive geometries, sizes, and shapes that are difficult to create using conventional subtractive manufacturing methods. The versatility of composite polymer 3D printing allows for the creation of complicated shapes that may be difficult or impossible to machine conventionally.
Making a unique robotic gripper in a CNC machine shop is one practical illustration of CP3DP in action. The component was produced by a firm called Carbon using EPU 41 material and their Carbon DLS technology.
The gripper was made to be light and flexible while still being able to grasp and move items. Assembling the gripper was unnecessary because it was printed in a single piece, which also helped to lighten the part’s overall weight. The gripper’s intricate internal structures could only be made possible because to the exact geometry control made possible by Carbon DLS technology.
The design of the gripper in CAD software was the first step in the CP3DP manufacturing process. The design was later integrated into the Carbon software as an STL file after being exported. The part’s orientation and support structures were optimized for printing using the software. The EPU 41 material was then deposited and light-cured before being used to print the part layer by layer using the Carbon printer. The support structures were taken away when the printing was finished, and the part was cleaned and finished as required.
Prototyping
In a manufacturing setting, composite polymer 3D printers can be quite helpful for rapid prototyping. With the aid of these printers, engineers can swiftly create working prototypes that can be tested and approved before going into production. Since the composite materials used in these printers are frequently robust and long-lasting, they are perfect for testing the shape, fit, and functionality of parts that may eventually be constructed of metal or other materials.
A practical illustration of this application can be found in Shukla Medical’s usage of a Markforged carbon fiber 3D printer to produce functioning prototypes for orthopedic surgery equipment. To precisely portray the performance of the finished product, the carbon fiber material offered the required rigidity and strength. The team decided to purchase a Markforged Metal X system to create metal prototypes since they were so pleased with the quality of the carbon fiber printer. The team was able to evaluate the part’s shape and fit while also confirming and validating the design thanks to the 17-4PH Stainless Steel material.
Helicopter sockets
The prototyping process at Shukla Medical was considerably altered by the usage of the 3D printer. The team frequently experienced lengthy lead times and high expenditures to iterate on prototypes while using the CNC machining technique. The team used 3D printing to swiftly create functioning prototypes that were very similar to the finished result, allowing surgeons to test and evaluate the instrument’s performance before using it in surgery. The team’s ability to manufacture more intricate pieces that matched implant geometry, which would have been prohibitively expensive to fabricate, was made possible by the Metal X 3D printer.
Conclusion
The role of composite polymer 3D printing in today’s CNC machine shop is expanding rapidly. All stages of manufacturing can benefit from the technology’s precision and consistency because to its adaptability. You can use it to make sophisticated custom parts, repair existing ones, or even just make quick prototypes. In today’s cutthroat business climate, these services are necessities.
