Additive Manufacturing -3D Printing

Additive Manufacturing (3Additive Manufacturing (3Additive Manufacturing (3Additive Manufacturing (3----D Printers)D Printers)D Printers)D Printers)
ADDITIVE MANUFACTURING
(3-D PRINTERS)
10/5/2015 FDM or PolyJet 3-D Printer?
Tim McDougald
CAD Engineer
tmcdougald@redvalve.com
Comparing Fused Deposition Modeling (FDM)
or PolyJet 3-D Printers is right for Red
Valve/Tideflex® to reduce the overhead cost
and improve productivity.

Tim McDougald | Page 1
Table of Contents
I. Definitions and Terminology 1
II. Purpose of Proposal 3
III. Industry Background Information Related to 3-D Printing 4
IV. Solutions and Cost Scenarios 5
1. Stratasy’s Objet, Fortus, and Dimension series 5-7
2. 3D Systems’ ProJet x60 and ProJet HD 3000/3000 Plus 7-8
V. Conclusion and Wrap-up 9
VI. Sources 10
VII. Quotes 11

Additive Manufacturing (3-D Printers)
F D M O R P O L Y J E T 3F D M O R P O L Y J E T 3F D M O R P O L Y J E T 3F D M O R P O L Y J E T 3 ---- D P R I N T E R ?D P R I N T E R ?D P R I N T E R ?D P R I N T E R ?
I. DEFINITIONS AND TERMINOLOGY
3333----DDDD printingprintingprintingprinting is a process for making a physical object from a three-
dimensional (3-D) digital model, typically by laying down many
successive thin layers of a material called slicing.
Additive manufacturing (orAdditive manufacturing (orAdditive manufacturing (orAdditive manufacturing (or
Rapid prototyping)Rapid prototyping)Rapid prototyping)Rapid prototyping) is the
official industry standard
term (ASTM F2792) for all
applications of the
technology. It is defined as
the process of joining
materials to make an object
from 3-D data (CAD, STL,
etc.), usually layer upon layer, as opposed to subtractive manufacturing
methods.
Compression moldingCompression moldingCompression moldingCompression molding is a method of molding in which the material,
generally preheated, is first placed in an open, heated mold cavity to form
the part.
CNC (Computer Numerical Control)CNC (Computer Numerical Control)CNC (Computer Numerical Control)CNC (Computer Numerical Control) is a computer program that converts
numerical coordinates of a graph and controls the movements of the
cutter shaping the metal material.
FDM technology (Fused Deposition Modeling)FDM technology (Fused Deposition Modeling)FDM technology (Fused Deposition Modeling)FDM technology (Fused Deposition Modeling) is an additive
manufacturing technology commonly used for modeling, prototyping,
and production applications. It is one of the techniques used for 3-D
printing.
Nylon 12Nylon 12Nylon 12Nylon 12 is a polymer made from aminolauric acid or laurolactam
monomers that each has 12 carbons, hence the name ‘Nylon 12’. It is one
of several nylon polymers.
PhotopolymerPhotopolymerPhotopolymerPhotopolymer is a polymer that changes its properties when exposed to
light, often in the ultraviolet or visible region of the electromagnetic

spectrum. These changes are often manifested structurally, for example
hardening of the material occurs as a result of cross-linking when
exposed to UV light.
PolycarbonatePolycarbonatePolycarbonatePolycarbonate is a synthetic resin in which the polymer units are linked
through carbonate groups, including many molding materials and films.
PolymerPolymerPolymerPolymer is a large molecule that is made up of repeating subunits
connected to each other by chemical bonds. Polymer, are basically,
anything that has a plastic or rubber material.
* Non-polymers include: elements, metals, ionic compounds, and some organic matter.
PrototypePrototypePrototypePrototype is a first, typical or preliminary model of something, especially
a machine, from which other forms are developed or copied.
Reverse engineeringReverse engineeringReverse engineeringReverse engineering is the reproduction of another manufacturer’s
product following detailed examination of its construction of
composition.
Subtractive manufacturingSubtractive manufacturingSubtractive manufacturingSubtractive manufacturing is achieved by using a block of material
usually metal, and then removing the excess through CNC milling or
turning technology.
Tango familyTango familyTango familyTango family offers a variety of elastomer characteristics including Shore
scale A hardness, elongation at break, tear resistance, and tensile
strength.
Rubber-like material is useful for many applications including:
• Exhibition and communication models
• Rubber surround and over-molding
• Soft-touch coatings/nonslip surfaces
• Knobs, grips, pulls, handles, gaskets, seals, hoses, and footwear.
Rubber-like materials include:
• Rubber-like gray (TangoGray FLX950)
• Rubber-like black (TangoBlack FLX973)
• Rubber-like translucent (TangoPlus FLX930)

• Rubber-like advanced black (TangoBlackPlus FLX980)
Ultem 9085Ultem 9085Ultem 9085Ultem 9085 is a FDM thermoplastic ideal for aerospace, automotive, and
military applications because of its FST rating, high strength-to-weight
ratio, and existing certifications. It empowers design and manufacturing
engineers to 3-D print advanced functional prototype and production
parts.
II. PURPOSE OF PROPOSAL
Does Red Valve/Tideflex® have a competitive edge against our competitors?
For decades, our company has been one of the leading producers of hand-
fabricated parts for valves, gadgets, gussets, and compression molds.
However, it may be time for us to explore the possibilities of reducing the high
volume of waste in order to save the company from financial stress, so the
company has more potential profits from our inventory. Moreover, this positive
momentum to become a sustainable company would allow Red Valve/Tideflex®
to establish an Additive Manufacturing Division to our repertoire.
Being able to utilize this division would allow the Engineering Department to
verify each part’s precision before it is produced and developed by an extremely
exorbitant metal fabricator. The value of adding an additive manufacturing (AM)
system to our engineering
department would pay dividends well
after it was completely paid off in four
to five years. For instance, if one 3-D
printer was purchased today at
$250,000, it would be paid off in as
little as eight (8) business quarters
(two (2) calendar years). Also, AM will
allow us to add presentational
materials before our clients
purchased our products.
Red Valve/Tideflex® could be on the breakthrough of achieving an enormous
amount of productivity while decreasing its overhead and labor costs. This new
proposal will allow Red Valve/Tideflex® to prototyping designs with AM
methods. This proposal covers the definitions, industry background

information, gives valuable solutions, and concludes with information on how
AM is a reliable source for managing time and budgets in the industry.
III. INDUSTRY BACKGROUND INFORMATION RELATED TO 3-D PRINTING
This year Red Valve/Tideflex® has recently purchased an automatic cutting
machine called Autometrix Radium® to help control rubber waste, and shield
overhead costs. This cutting program will be a definite improvement and mark a
cornerstone for the company in the future. However, it should not be the only
scenario to achieve lower cost-saving benefits when dealing with compression
molds. Therefore, one of the best practices is to do ‘test runs’ with lower-priced
materials such as polymers, photopolymers, and other plastics when making 3-
D model of our products. These ‘test runs’ will save engineers, technicians, and
designers lots of time when trying to see if the product will fit in the valve by
having experiments with inexpensive materials like polymers and plastics.
Creating an opportunity to add an AM system to the daily operations will
establish a strong method where we can examine a prototype’s design before
purchasing costly materials. This would prove to be a solid investment for our
company.
Any manufacturing process could be improved with AM to improve efficiency
capacity and unit cost of materials and labor. For instance, companies like Joe
Gibbs Racing in Huntersville, NC utilize 3-D printing to build gadgets for their
race cars at impressive speeds to keep up in the racing industry. Also, they
have used several CNC machines to develop engine parts for their racing
vehicles.
Other companies such as Danko Arlington, Inc. in Baltimore, MD and
Champion Motorsport in Pompano, FL utilize FDM manufacturing in their
businesses. Danko Arlington (Danko) has found a niche for the using AM for
their pattern tooling operation. Using the FDM process, their products have
been successful with rapid prototyping. Danko has earned recognition for its
design with aerospace casting which required 100% radiographic inspection on
its military parts. Similarly, Champion Motorsport (CM) wanted to achieve a
smooth interior and exterior surface finish on its tubular composite

components. They used the Fortus 3-D Production System to make conceptual
and functional model prototypes that were soluble cores for their high
performance turbo inlet ducts. Now, its ducts are made in a single piece by
laying up carbon fibers on the FDM printed soluble core.
IV. SOLUTIONS AND COST SCENARIOS
This proposal includes price quotes from two very reputable 3-D printing
companies: Stratasys and 3-D Systems. Stratasys has an established
reputation in the 3-D community by
building its AM systems to help
engineering deparments make realistic
prototype designs. Also, 3-D Systems
has transformed its classic printing
company to become a 3-D printing
industry giant. Both, however, have
quite unique products that would
enable Red Valve/Tideflex® to choose
which system is more valuable and
well-balance to meet our needs.
StratasysStratasysStratasysStratasys:::: Objet, Fortus, and Dimension SeriesObjet, Fortus, and Dimension SeriesObjet, Fortus, and Dimension SeriesObjet, Fortus, and Dimension Series
Stratasys has three potential choices in their additive manufacturer line:
Objet, Fortus, and Dimension series. All three are capable of serving our
company but come with different speeds, abilities, and costs.
Objet Series (24, 30 Pro, and 30 Prime)
This series builds prototypes in a photopolymer material and cures it with a
UV (ultraviolent) light. The size of the build chamber or build plate where the
model is prepared varies among series types. All of these Objet series use a
process called PolyJet 3-D printing and is much like an inkjet printer. The
material is jetted out onto layers of a curable liquid photopolymer where the
build preparation software has calculated each placement of photopolymer and
support constituents used. Basically, this process accumulates fine layers to

make a 3-D part and any support material can be removed by hand or with
water-based solutions. A prototype can be used immediately without any
chemicals or powder added at the end.
F
o
r
F
o
Fortus (250mc, 350mc, and 450mc)
The Fortus machines use FDM plastic and have the capabilities of using
multiple materials if you choose the 350mc and 450mc models. The build
plates on these models are rather larger than the Objet series. They are more
expensive with price tags above $150,000. The 350mc and 450mc additive
machines have the ability to run real ABS, Nylon 12, Ultem 9085, and
polycarbonate. All of these products use FDM technology which enable
production grade builds while having extremely durable characteristics. Fortus
3-D printers use thermoplastics that have advanced mechanical properties such
as high heat, caustic chemicals, sterilization, and high-impact applications.
These properties make finished products have fine details, and smooth
surfaces, accurate strengths. Also, no special venting is required with the Fortus
production systems.
Dimension (1200es and Elite)
Other FDM technologies, the Dimension 1200es and Elite, are special in their
own distinctive ways. The build plates are roughly 10”x10”x12” and only ABS
plastics are available with limited colors. These products print from the bottom

up on deposited layers with supports material. No curing is required with these
models; simply wash them with water-based solutions. Also, the models can be
drilled, tapped, sanded, and painted to match the designer’s requirements.
This model is a good match for modeling compression molds, patterns, and
customized tools and fixtures. Overall, the Dimension 1200es includes many
beneficial aspects of what Red Valve/Tideflex® would be looking to accomplish
with an AM system.
3D Systems: ProJet x60 and ProJet HD 3000/3000 Plus3D Systems: ProJet x60 and ProJet HD 3000/3000 Plus3D Systems: ProJet x60 and ProJet HD 3000/3000 Plus3D Systems: ProJet x60 and ProJet HD 3000/3000 Plus
3D Systems of Rock Hill, SC, has several powdered and plastic filament 3D
printers which can generate models of about 12” by 7.7” with the height of 8”.
All of these printers have a different build volume. The powdered 3D printers
utilize monochrome or color printer and start from the top of the machine
working its way to the bottom. The printing machine fills the microscopic holes
or gaps in the model, seals the surface, enhance the
color saturations, and thus, improve mechanical
properties of the part. Essentially, this process
solidifies the materials use to create the component
model leaving the rest of the powder for to be recycle
for the next part to be printed.
3D Systems has different approaches to achieving
AM. The first 3-D Printer model is called the ProJet
x60 (160, 260C, 360, 460 Plus, 660 Pro, and 860 Pro)
utilizes a powder-print format. The second models
are called ProJet HD 3000 and HD 3000 Plus, which use an ABS filament plastic
for its tasks.
ProJet x60 Series

The ProJet x60 series has the ability to use either mono or color depending
on the model. They can be print 3-D models which provide extremely good
tensile and flexible strengths for the finish prototypes. However, they do have
one setback being the parts are formed using a powder substance that has to
be air-brush, cleaned, and soaked in cleaning solution after printing is
complete. Moreover, the ProJet x60 requires a toxic solution, not water-based,
to help remove any debris or powder particles. This process is very time-
consuming and the chemicals used are not safe for everyday use.
P
P
r
ProJet HD 3000/3000 Plus
ProJet HD 3000 and HD 3000 Plus are professional 3-D printers with high-
definition and high-volume. These do not use a powder for their builds, but
rather an ABS material plastic. These parts still need to get cleaned with a toxic
chemical solution once they are printed. Basically, this AM system needs to
remove the bulk wax by soaking the prototype in a wax bath. In 2010, the
machine cost about $16,000 per unit.

V. CONCLUSION AND WRAP-UP
Engineers, designers, and shop builders at Red Valve/Tideflex® could be
able to manage their waste content, add productivity to the workload, and
produce scaled graphical prototypes with either of these AM systems in this
article. Many questions remain to be unanswered still about 3-D printing, but
this report should clarify several topics. One problem is which product is the
right choice for our capacity? Do we want a powdered or ABS 3-D modeling
systems? Several enquiries such as these are all very reasonable to ask if we
want to manage our materials better to become more financially stable and
improve our profit margins.
All of these models in this article have different abilities, characteristics, and
processes that they use to create a 3-D prototype. Some use ABS filaments,
while other types of 3-D printer may use a recycled powder component. Other
types of filaments such as Nylon 12, ABS, HDPE, polycarbonate, and Tango
(rubber-like properties) can be utilized to make a design. Stratasy’s supports a
blending formula for filaments to create unique color, but only their Connex 2
and Connex 3 models which range from $120,000 to $250,000. Thus, the
Connex models have be excluded from this report.
Whether we choose Stratasy or 3D Systems to select from, however, we will
begin a thorough transformation of improving our company’s reputation and
output performance to our customers. Our clients will be able to see if the parts
fit before detailed and costly metal fabrications begin. This is literally what we
are after with pursuing our requirement for a quality 3-D printer. Simply having
an AM system produce flexible and extremely robust sample parts would make
Red Valve/Tideflex® a choice that perspective clients will trust for years to
come.
VI. SOURCES

Mishek, Dan. “How and When to Choose Between Additive and Subtractive
Prototyping?” Moldmaking Technology. 2009. 1-2. Internet. 24 Aug
2015
http://www.3dsystems.com/3d-printers/professional/overview
http://www.stratasys.com/3d-printers/design-series
“D3VU 2015: Digitial Manufacturing and Prototyping.” D3 Technologies.
Webinar. 01 September 2015.
VII. QUOTES
See next pages for three (3) price quotes for Stratasys’ Objet 24, Objet 30 Pro,
and Objet 30 Prime from Prototyping Solutions.

Additive Manufacturing -3D Printing

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