<a href="https://www.iss-priorei.de/" target="_blank">I.S.S.</a><a href="https://www.iss-priorei.de/" target="_blank">&nbsp;Tooltec GmbH &amp; Co. KG</a> has been a competent partner to the steel and drop forging industry for wear protection and repair welding work for almost 15 years. This work is carried out on a variety of components such as dies, cutting tools, stretching rollers, forging saddles, rollers and drawing rings. The company also offers comprehensive advice on wear analyses and material selection, which helps extend the service life of valuable tools. Well-known customers from large-scale industry put their trust in the expertise, experience and quality of the work performed by I.S.S. Tooltec.In order to increase work efficiency and minimize costs and complaints, I.S.S. Tooltec GmbH &amp; Co. KG decided to implement 3D measurement technology, to carry out engraving comparisons on a wide variety of forming tools in the forging industry.Before 3D metrology equipment was introduced in the company, it was always difficult to estimate whether the amount of weld metal applied was sufficient to ensure that subsequent tool processing (engraving or milling) would be error-free. In addition, performing these measurements was also intended to help avoid using too much or too little welding material. Too much material means a high cost factor, too little means complaints from the end customer. The <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">3D scanner Go!SCAN SPARK</a> was exactly what they needed: it offers the required accuracy, flexibility, measuring speed, easy-to-use hardware and software, and is user-friendly – and Creaform provided the necessary training and support. Furthermore, it was good value for money. According to I.S.S. Tooltec, implementing the system into their daily business activities was very easy and training took place within a few days, so that they were able to handle the technology confidently in a very short time.<h2>Engraving comparison on a forming tool</h2>Tools are scanned before and after the welding process and compared with CAD data. This ensures that all the required welding quantities can be precisely adhered to.In this example, the 3D scan enables Tooltec to compare the tool they welded with the customer’s design file (CAD). This makes it possible to determine whether or not enough weld metal has been used.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056831929-double_image.webp" style="width: 790px;" class="fr-fic fr-dib">3D scan in the VXinspect software and engraving comparison after welding on a forming tool with color comparison.The&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/vxinspect-dimensional-inspection-software-module" target="_blank">inspection software VXinspect</a>&nbsp;they used – a module of Creaform’s VXelements software suite – allows for dimensional inspections to be carried out and inspection reports to be created based on precise technical requirements. It is intuitive and guides the operator step by step through the inspection process: Scan &gt; Import scan file for CAD comparison &gt; Alignment &gt; Analysis &gt; Inspection report.I.S.S. Tooltec was impressed with the 3D scanner Go!SCAN SPARK and VXinspect: “The 3D measurement solution from Creaform has helped us to work significantly more efficiently and cost-effectively. We have already expanded the use of the scanner in our operations. In addition to the above-mentioned area of application, we now also use 3D scanners to perform scanning services.”

Management and customers demand realistic implementation of individual welding processes at low costs. These costs are often caused by inefficient work processes, such as reworking due to excess or insufficient use of materials, or customer complaints.

Use of 3D scanner increases efficiency and reduces labor and material costs

Zeroing in on which of our six&nbsp;<a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="3D Printing" target="_blank" rel="noopener noreferrer">3D printing technologies</a> you want to use is totally \desired aesthetic. Two of our most popular 3D printing services, stereolithography (SLA) and selective laser sintering (SLS) offer engineering-grade options for parts.Before we dive into the options and benefits, let’s look at how each technology works. <h3 id="isPasted">Process Differences Between SLA and SLS</h3><a href="https://www.protolabs.com/en-gb/services/3d-printing/stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="Stereolithography" target="_blank" rel="noopener noreferrer">Stereolithography (SLA)</a>:&nbsp;With SLA, a laser unit bounces an ultraviolet (UV) beam off of a reflective mirror. The machine’s Galvo Motor System steers the focused beam to the design surface. The laser system first draws support structure layers, followed by actual part geometry. The UV laser solidifies and cures the liquid thermoset resin one layer at a time. After solvent processing to remove any additional resin, the support structures are removed manually.<a href="https://www.protolabs.com/en-gb/services/3d-printing/selective-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="Selective Laser Sintering" target="_blank" rel="noopener noreferrer">Selective Laser Sintering (SLS)</a>: SLS is a powder bed fusion additive process. A laser sinters each layer of part geometry using a bed of material-based powder. After each layer, a roller distributes the next layer of powder, and this process is repeated layer-by-layer until the build is complete. Finally, the part is manually removed from the powder and bead blasted in post-processing.How SLA works:<iframe src="https://fast.wistia.net/embed/iframe/1ye1g3wd0u" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>How SLS Works:&nbsp;<iframe src="https://fast.wistia.net/embed/iframe/ranw97cko8" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>&nbsp;<h3 id="isPasted">Analysing Application Needs</h3>Some common applications for parts made via SLA include cosmetic prototypes with a smooth surface finish, parts requiring high dimensional accuracy and intricate detail, and large parts. However, if durability is a key factor, SLS will likely be the more fitting process.SLS builds accurate prototypes and functional product parts, fast. One consideration to keep in mind: With SLS 3D printing, no support structures are required allowing for the option to include multiple parts into a single build; an economical solution when you need a large volume of 3D-printed parts. <h3 id="isPasted">Material Options for SLA and SLS</h3><a href="https://www.protolabs.com/en-gb/resources/design-tips/a-guide-to-stereolithography-3d-printing-materials/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="A Guide to Stereolithography 3D Printing Materials" target="_blank" rel="noopener noreferrer">SLA materials</a> are considered photopolymers, or thermoset resins that are in liquid form. SLA boasts the broadest selection of 3D-printable plastics with an impressive range of mechanical properties. Some of our thermoplastic-like materials include:<ul type="disc"><li>ABS-like</li><li>Polypropylene-like</li><li>Polycarbonate-like</li></ul>SLS materials originate as thermoplastic powders. In comparison to SLA materials, SLS material can build durable end-use parts. Some options include:<ul type="disc"><li>General purpose nylons (PA 12 Smooth White)</li><li>Filled materials (PA12 Carbon-filled Smooth Black, PA12 40% Glass-filled Smooth White)</li><li>Specialty materials (TPU 88-A Pure Black)</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU4MTcwMjM5LTE3MTM5NTgxNzAyMzkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"><h3 id="isPasted">SLA vs. SLS Surface Finishes</h3>In general, parts made using SLA offer smoother surface finishes compared to SLS- parts. Here are the options we offer for finished SLA parts:<table border="0" cellspacing="0" cellpadding="0" id="isPasted"><tbody><tr><td>Unfinished</td><td>Dots, or standing"nibs," remain evident on the bottom of the part from the support structure remnants.</td></tr><tr><td>Natural</td><td>Supported surfaces are sanded down to eliminate the support nibs.</td></tr><tr><td>Standard</td><td>Supported surfaces are sanded, and the entire part is finely blasted for a consistent look. Note that the layers are still present. &nbsp;For ABS-Like Black, parts will be painted after support removal; if final blasting is wanted, this must be specified while ordering (external surface will become grey)</td></tr></tbody></table>Surface finishes on SLS parts are typically rougher than SLA or other 3D printing technologies, but this service provides parts that are more durable and better suited for heat or chemical resistance. SLS also works well if flexibility or dimensional stability is needed. <h3 id="isPasted">Final Considerations for Choosing Between SLA and SLS</h3>Certain considerations like durability, resolution, or part size may make the decision for you when deciding between SLA or SLS 3D printing. Refer to the table below to see which process tends to win out over the other based on key factors. &nbsp;&nbsp;Durability and Strength: In general SLS builds more durable, higher strength parts due to the engineering-grade materials available and the fact that they are actual thermoplastics being sintered.Surface Finish:&nbsp;SLA will build parts with high quality, smoother surface finishes that more closely resemble an injection-molded parts.Resolution:&nbsp;SLA provides higher resolution compared to SLS. Our SLA 3D printing service offers three resolution options so you can balance detail and surface finish quality with cost.Tolerances:&nbsp;SLA will be capable of achieving tighter tolerances compared to SLS.Part Size: Our SLA printers have a larger build envelope than our SLS machines.Heat and Chemical Resistance: Thermoplastic SLS materials will have better overall heat and chemical resistance than SLA parts.We’ve covered a lot of ground here. Know that you’re not alone when you’re navigating and deciding which 3D printing process best suits your part needs. Our applications engineers are well-versed at helping you through the process, from design to finished part. Be sure to check out our design tips on <a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" target="_blank" title="Designing for Stereolithography" rel="noopener noreferrer">stereolithography</a> and <a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-selective-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" target="_blank" rel="noopener noreferrer">selective laser sintering</a> for more useful tips and tricks. &nbsp;&nbsp;

Learn the key differences between two popular polymer 3D printing processes: Stereolithography(SLA) and Selective Laser Sintering (SLS).

SLA vs. SLS: Comparing Plastic 3D Printing Technologies

<a href="https://www.creaform3d.com/en/applications/quality-control-and-assurance-with-3d-measurement-technologies" target="_blank">Integrating 3D scanning technology into quality control processes</a> can be challenging. It requires balancing the need for cost-effective, scalable solutions with long-term effectiveness.We have compiled a list of our best tips to help you choose a 3D measurement technology that not only meets your current needs but also allows for future growth. This can save you valuable time and resources, and assist you in streamlining your quality control processes to better align with your business goals.<h2 id="isPasted">Step 1: Assess Your Current Needs</h2>To choose the right 3D scanning technology, you need to start by analyzing your current quality control processes and identifying the main challenges you want 3D scanning solutions to help you overcome.After that, you need to determine your specific needs. This includes considering the size and complexity of the objects you want to scan, the level of detail required, how you plan to use the data, the human resources available, and the skills of your quality control team.For instance, industries like aerospace and automotive require extremely high precision for quality control and validation. Meanwhile, other applications like cultural heritage preservation may prioritize the ability to capture colors and textures over geometric precision.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430528437-HandySCAN3D_Helicopter_parts_2.webp" style="width: 100%px;" class="fr-fic fr-dib">If you’re struggling with a labor shortage or bottlenecks with your current metrology team, you will want to ensure that the 3D scanner you choose is user-friendly and intuitive for operators who are not metrology experts.<h2>Step 2: Consider Handheld 3D Scanners</h2>Moving from traditional quality control methods to fully automated systems can be expensive and complicated for most organizations. Installing a complete automated quality control system can cost more than half a million dollars, a significant investment for any business.An effective intermediary solution is to start with portable 3D scanning technology.&nbsp;<a href="https://www.creaform3d.com/en/portable-3d-scanners" target="_blank">Handheld 3D scanners</a> offer numerous advantages, such as:<ul><li>Flexibility: They can be used in various environments and are not limited to objects of a specific size or shape.</li><li>Cost-effectiveness: Handheld 3D scanners are significantly less expensive than their automated counterparts, making them a more accessible entry point for incorporating 3D scanning into your quality control processes.</li><li>Ease of use: Many models are designed with user-friendliness in mind, requiring minimal training and onboarding for quick integration within existing quality control workflows.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430539552-HandySCAN-MAX_Scanner_Van-bumber_Remote-desktop-compatibility-2.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Step 3: Look for 3D Scanners with Integrated 3D Scanning Software</h2>The value of a 3D scanning solution extends beyond the acquisition of hardware. To optimize your investment, ask 3D scanner suppliers whether their solutions come with&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">integrated 3D scanning software</a>. This will help minimize the risk of dealing with multiple hardware/software manufacturers and potential compatibility issues.Also, make sure you have a clear understanding of the integration capabilities of 3D scanning software. If you are currently using&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">CAD software</a> and are &nbsp;, it is crucial to rely on a manufacturer that can provide solutions that can be individually upgraded and adapted based on your specific context.This modular approach ensures that you won’t have to purchase a completely new system to benefit from the latest advancements in metrology when your quality control processes are ready.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430564126-Automotive_Differential-Housing_CAD_on_laptop_220916519-2048x1365.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Step 4: Focus on Ease of Use and Manufacturer Support</h2>As mentioned before, it is crucial not to underestimate the importance of an easy-to-use 3D scanner. Many quality control teams struggle to find and retain skilled metrology professionals. Additionally, conventional CMMs often have capacity limitations that slow down the process. Adding 3D scanners should not worsen this problem.Thankfully, many of the latest 3D scanners are designed to be user-friendly. They are intuitive enough for individuals of all skill levels to pick up quickly, so there is no need to compromise current timelines and quality control KPIs.It’s important to not only consider the price when selecting a 3D scanner for quality control processes. Choosing the&nbsp;<a href="https://www.creaform3d.com/blog/why-using-low-cost-3d-scanners-in-professional-applications-can-be-a-costly-mistake/" target="_blank">cheapest option may lead to inaccuracies and undetected faults, which can negatively impact the quality of your products</a>. Additionally, opting for a 3D scanner that is not manufactured or designed in North America may result in less durable and reliable products.Furthermore, the quality of the 3D scanner and the level of support offered by the manufacturer, including training and after-sales support, are equally essential. To ensure maximum efficiency and productivity, it’s advisable to receive <a href="https://www.creaform3d.com/en/customer-support" target="_blank">good manufacturer training and support</a>. This should ideally be available worldwide to minimize downtimes and ensure that you are getting the most out of your 3D scanners.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713430570437-metrascan3d-scanning-inside-plane-VXelements-software2.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Step 5: Plan for the Future</h2>While choosing technology that meets your current needs is important, it’s equally essential to consider where your industry is headed and how your needs might change. For instance, if you start with a need for occasional quality checks, you may eventually require continuous quality control as your operations scale. Therefore, selecting a scalable solution from the start is essential.When looking for scanners, opt for those designed with the future in mind. This includes&nbsp;<a href="https://www.creaform3d.com/en/corporate/news-room/press-releases" target="_blank">manufacturers that regularly issue software updates and hardware add-ons as well as work with customers in a wide range of industries</a>, allowing for enhanced functionality as new technologies emerge.Market-leading 3D scanner manufacturers typically have a proven track record of innovating, updating, and supporting their metrology solutions over years, if not decades. A company’s commitment to improving its product lifecycle and ensuring long-term research and development indicates how well it will support your evolving needs.<h2>Conclusion: The Lasting Value of Choosing the Right 3D Scanner</h2>The process of improving quality control through 3D scanning should not be just a short-term procurement decision. It’s a strategic choice that will help your business thrive in the future.Choosing the right 3D scanning technology is crucial to balance current needs and future flexibility. It’s a commitment to enhancing quality standards while staying competitive in the market. By adopting portable 3D scanners, supported by solid software and manufacturer support, you can lay a foundation to withstand technological advancements and market fluctuations.Visualize your quality control processes not just as they are, but as they could be. By selecting solutions that promise scalability, you can ensure that your initial investment will turn into a long-term asset that continues to deliver results for years to come.Therefore, choose the option that puts your business at the forefront of quality control, and assures you that when the future of 3D scanning innovations arrives, you will be ready to implement them with confidence.

Creaform have compiled a list of their best tips to help you choose a 3D measurement technology that not only meets your current needs but also allows for future growth. 

Smart Steps to Integrating 3D Scanning in Your Quality Control

<h2 id="isPasted">Understanding Rapid Prototyping</h2>Rapid prototyping spearheads a shift in manufacturing, enabling the quick transformation of ideas into tangible products. This approach leverages cutting-edge technologies such as 3D printing, CNC machining, and additive manufacturing to facilitate fast-paced development cycles, crucial for staying competitive in today's market.At the forefront of this transformation is <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN</a>, a company that's integrating advanced rapid prototyping techniques to offer flexible, cost-effective, and time-efficient solutions. Their services cater to a wide range of businesses, from startups dreaming big to global corporations looking for innovative manufacturing strategies. By reducing the time and cost associated with traditional manufacturing methods, BOEN empowers companies to experiment more freely with their designs, iterate faster, and bring products to market more quickly.This shift toward rapid prototyping is not just about speed and efficiency; it's also about the democratization of manufacturing. By lowering the barrier to entry, rapid prototyping enables more creators to bring their visions to life, fostering a new era of innovation in manufacturing.<h2>The BOEN Difference</h2>BOEN distinguishes itself in the rapid prototyping industry through a blend of proprietary techniques and state-of-the-art technology. Their advanced approach combines:Innovative Workflows: Streamlining the design-to-production cycle, BOEN employs agile methodologies that significantly reduce development time. Their seamless integration of client feedback loops ensures that prototypes meet or exceed expectations with minimal iteration.Advanced Hardware:&nbsp;BOEN's investment in cutting-edge hardware, from 3D printers capable of producing complex geometries to sophisticated CNC machines for high-precision machining, sets a new standard for rapid prototyping. This hardware allows for a wide array of materials to be used, each selected through a rigorous materials science approach that matches the right medium to the project's specific requirements.The synergy of these elements positions BOEN as a leader in rapid prototyping, providing unique technical benefits such as reduced lead times, increased precision, and greater flexibility in material selection. Their dedication to pushing the boundaries of what's possible in rapid prototyping not only accelerates product development cycles but also empowers innovation, making them a sought-after partner in the manufacturing sector.<h2>Practical Impacts on the Industry</h2><h3>Streamlining the Design to Manufacturing Pipeline</h3>Rapid prototyping significantly streamlines the journey from design to production, offering a profound impact on manufacturing efficiency and product quality. By enabling quicker iterations and faster validation of designs, organizations can drastically reduce development cycles and associated costs. BOEN plays a pivotal role in this transformation through its advanced prototyping solutions.Leveraging state-of-the-art technologies, BOEN helps industries accelerate their design processes. For instance, the use of 3D printing allows for complex geometries to be created directly from digital models within hours, bypassing the lengthy traditional manufacturing setups. Similarly, CNC machining services offer precision in creating parts from a wide range of materials, further refining the prototype's fidelity to the intended final product.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713185375967-5-Axis-CNC-machining-aluminium-p.jpg" style="width: 100%px;" class="fr-fic fr-dib">5-axis CNC machines allow BOEN to deliver rapid prototyping at low volume. Credit: BOEN.Moreover, BOEN's emphasis on materials science ensures that each prototype not only meets design specifications but also simulates the functional and aesthetic properties of final products. This holistic approach to prototyping encompasses not just the physical creation of parts but also a rigorous assessment of how materials react under real-world conditions, leading to higher quality outcomes.Significantly, BOEN's methodologies foster greater innovation. With reduced time and cost implications, companies are encouraged to explore more ambitious designs, test new concepts, and iterate more frequently. This democratization of high-quality prototyping serves as a catalyst for breakthroughs across numerous sectors, from automotive to medical devices, where the precision and speed of prototyping can mean quicker market entry and competitive advantage.In essence, the services provided by BOEN underscore the practical benefits of rapid prototyping in today's fast-paced industry, emphasizing efficiency, quality, and innovation.<h3>Opening Doors for Startups and Innovators</h3>Rapid prototyping is a game-changer for startups and innovative companies, easing the path from ideation to realization with its cost-efficiency and flexibility. For ambitious projects on tight budgets, this methodology is a beacon, illuminating the route to successful product development without the hefty investment traditionally associated with manufacturing.BOEN, understanding the unique landscape startups navigate, offers specialized services that align with the agile, innovative ethos of these ventures. Their approach demystifies the prototyping process, granting access to high-quality resources and expertise that were once the exclusive domain of industry giants.The technical benefits provided by rapid prototyping, such as improved design accuracy, the possibility of iterative testing, and the capability to quickly adapt to feedback, are crucial for startups. These benefits enable a swift response to market demands or design challenges, enhancing market responsiveness.Furthermore, BOEN’s solutions are not one-size-fits-all but are carefully tailored to meet the distinct needs of innovators. Whether it's selecting the right material for a prototype to test its durability or employing the most suitable prototyping technique to ensure cost-effectiveness, BOEN’s expertise proves invaluable.This support empowers startups to tread boldly in competitive markets, making rapid prototyping not just a manufacturing approach, but a strategic asset for driving innovation and securing a foothold in the industry.<h2>Beyond Prototyping: The Future with BOEN</h2><h3>From Prototyping to Low-Volume Production</h3>The transition from rapid prototyping to low-volume production is a critical phase for any product development process, marking the shift from concept validation to market readiness. This stage involves:Detailed Planning: Establishing a clear roadmap from prototype to production, considering timeframes, budget, and resource allocation.Material Selection and Sourcing: Choosing materials that balance cost, performance, and availability for low-volume runs.Manufacturing Technique Adjustment: Shifting from prototyping methods to those more suitable for small-scale production without compromising quality.Quality Control Systems: Implementing stringent quality control measures adapted for low-volume production to ensure each unit meets the high standards set during prototyping.Logistics and Supply Chain Management: Optimizing logistics to handle the distribution of smaller product quantities, managing supply chain relationships to ensure timely delivery of materials.BOEN supports businesses through this transition by leveraging its expertise in both rapid prototyping and small-scale manufacturing. Their support encompasses:Consultation and Strategy:&nbsp;Advising on the best pathways for scaling production in a cost-efficient manner while maintaining product quality.Custom Manufacturing Solutions:&nbsp;Offering tailor-made manufacturing solutions that address the unique challenges of low-volume production.Quality Assurance:&nbsp;Ensuring that the quality established during the prototyping phase is maintained or enhanced as production scales.Supply Chain Optimization:&nbsp;Assisting in creating a responsive and efficient supply chain tailored to the needs of small-scale production.Through these services, BOEN helps companies navigate the complexities of scaling their products, enabling a smoother transition from concept prototypes to market-ready products. This comprehensive support is invaluable for businesses looking to capitalize on their innovations with minimal delays and optimal product quality.<h2>Empowering Innovation Across Industries</h2>Rapid prototyping, especially when leveraged by BOEN's expertise, catalyzes innovation across various industries by providing tailored solutions that meet each sector's unique demands.In the aerospace sector, precision and reliability are paramount. Rapid prototyping facilitates the production of lightweight, high-strength components, reducing aircraft weight and improving fuel efficiency. BOEN's adept material selection ensures components withstand extreme conditions, from high temperatures to mechanical stress, crucial for aerospace applications.In the medical devices industry, the ability to prototype intricate, biocompatible devices rapidly accelerates the development of lifesaving technologies. BOEN's proficiency in navigating material compatibility and regulatory requirements allows for the swift iteration of designs, from prosthetics to surgical tools, ensuring they meet stringent medical standards. Low-volume manufacturing allows medical device products to be made in small batches, as medical devices, unlike consumer products do not require very large quantities.The automotive industry benefits significantly from rapid prototyping by expediting the design process of both functional and aesthetic automotive parts. BOEN's expertise in durable materials and finishing techniques enables the production of prototypes that closely mimic final products, allowing for comprehensive testing and design optimization.By overcoming technical challenges through innovative solutions and material expertise, BOEN not only advances product development within these sectors but also empowers companies to push the boundaries of what's possible, leading to groundbreaking innovations that reshape industries.<h2>Conclusion</h2>The journey through rapid prototyping's capabilities and its transformative impact on various industries has underscored its indispensable role in modern manufacturing. Through the lens of BOEN's innovative practices, we've seen firsthand how technological advancements in rapid prototyping significantly streamline the design-to-manufacturing pipeline, empower startups, and catalyze innovation across sectors like aerospace, automotive, and medical devices.&nbsp;<a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN</a> stands at the forefront of this revolution, offering expertise and solutions that not only meet the current demands of the market but also pave the way for future advancements. The potential for further innovation in manufacturing, driven by rapid prototyping, is boundless. We invite industry professionals to consider how these advancements could be integrated into their operations, ushering in a new era of efficiency and creativity.&nbsp;

Rapid prototyping is significantly contributing to an innovative manufacturing future by enabling swift conversion from conceptual designs to physical models.

Rapid prototyping's transformative role to the future of manufacturing

Do you ever question the accuracy and reliability of your quality control (QC) process? Do you ever doubt the quality of your measurement setup, especially if you are a non-expert in 3D scanning? Have you ever measured large parts that required moving the equipment to expand the measuring volume and questioned if there was a cumulative error that could distort the results?Knowing that decisions can be misguided without a reliable QC process and lead to costly errors, it is crucial to ensure that your measurements are as accurate as possible. If you are unsure about your current QC process, this blog can offer innovative solutions.<h2 id="isPasted">Unreliable QC Process</h2>Doubt can impair decision-making that will directly impact product quality. <a href="https://www.creaform3d.com/blog/how-to-better-detect-manufacturing-defects/" target="_blank">Accepting parts that do not meet requirements</a> while rejecting parts that comply with standards are costly errors that ultimately undermine customer satisfaction and company revenue. Therefore, companies must &nbsp; and understand where this doubt in measurement accuracy and reliability stems from.<h2>Origin of Doubt, Sources of Bad Decisions</h2>Various factors can influence measurement accuracy and reliability in QC processes, leading to bad decision-making. Simply put, errors may arise in QC processes due to three main factors: the measuring equipment, the user conducting the measurements, and the environment or measuring methods around and between the equipment and the user.<h3>Measuring Equipment</h3>Equipment certified according to relevant standards, such as ISO, has been thoroughly tested and qualified to meet specific performance criteria. This ensures its capability to produce accurate, repeatable, and reliable measurements. On the other hand, equipment that has not undergone rigorous testing and meticulous qualification may perform poorly or function inadequately, regardless of who uses it. Opting for <a href="https://www.creaform3d.com/blog/3d-scanning-for-inspection-a-smart-choice/" target="_blank">high-quality equipment</a> engineered by renowned manufacturers typically results in greater accuracy, more reliable measurements, and software features that minimize user error, compared to lower-quality alternatives.<h3>User</h3>Human error is regularly cited as a primary source of error in various processes, including measurement and quality control, despite advances in automation. This is often due to a lack of technical expertise, which has been a significant challenge in recent years. As a result, users without the requisite technical background may not use the equipment correctly, leading to measurement errors and affecting the data quality. This misuse can be caused by a lack of guidance on how to operate the equipment or by not performing the correct setup, which is necessary to ensure accurate measurements.<h3>Environment and Measuring Methods</h3>Equipment performance can also vary depending on the environment and measuring methods used. For instance, quality control of large parts cannot always be carried out in a metrology lab. Inspection must often be conducted directly in the production environment, where vibrations and thermal variations can impact validation jigs, resulting in inaccurate and non-repeatable measurements. Additionally, when dealing with large parts, leapfrogs are often required and can introduce an additional, unspecified error that further contributes to measurement inaccuracy.Therefore, to reject the bad parts and keep only the good ones, QC specialists and metrologists must take all necessary measures to minimize and, ideally, eliminate any uncertainty from all sources. This is an essential step for maximizing overall confidence in the QC process and creating an ideal environment for making confident and informed decisions.<h2>Eliminate Errors in your QC Process</h2>Creaform is introducing three new improvements to the <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">MetraSCAN BLACK+</a><a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">TM</a> to help eliminate errors in your QC process. The new acceptance tests based on ISO 10360 provides better confidence in the measurement equipment, ensuring accurate measurement results. Adding new specifications and easy-to-use 360 magnetic targets further enhances measurement accuracy, especially for large parts that require leapfrogging. Finally, the latest guidance tools make it easier for non-experts to use the measurement tool efficiently and correctly.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712821737338-Large_part_being_scanned_MetraSCAN-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Engineer scanning a massive part with the Creaform MetraSCAN BLACK+<h3 id="isPasted">1. New Acceptance Tests Based on ISO 10360</h3>What is more important than trusting the accuracy specified on a manufacturer’s specification sheet? The best way to generate this trust is to rely on international standards, such as ISO, which has an impeccable reputation in the industry and a proven track record in QC processes. This is why the performance of the MetraSCAN BLACK+ is now also validated based on ISO 10360, in addition to being certified according to the German standard VDI/VDE 2634 part 3.Moreover, Creaform’s acceptance test and performance assessment now include two new specifications: the form error on a sphere and the form error on a flat surface.Concretely, this indicates that our 3D scanners must undergo a more rigorous process and succeed in more performance tests before being shipped to customers, resulting in better-quality products without exceptions. By being fully transparent about our qualification and certification acceptance tests, customers can be confident in the product performance and Creaform’s stated accuracy.<h3>2. QC on Large Parts Simplified with Automatic Volume Extension and 360 Magnetic Targets</h3><a href="https://www.creaform3d.com/blog/do-you-have-trouble-measuring-and-analyzing-large-parts/" target="_blank">Inspecting large parts</a> often requires extending the reach of the measuring device. A measuring arm may have physical limitations that necessitate leapfrogging to expand its volume. Even with equipment having deep measuring volume, line-of-sight issues can occur when measuring hidden areas (like the back of a car), leaving no option but to move the device to have a more direct field of view.Proceeding with leapfrogs has two significant drawbacks in QC processes. The more leapfrogs there are, the more the volumetric accuracy deteriorates, and the longer it takes to complete the QC process, especially with measuring arms that must be repositioned at each step. The problem is that most measuring equipment manufacturers do not specify the impact of leapfrogging in their specifications, leaving users in doubt about the measurement accuracy.Creaform introduces more updates to its MetraSCAN BLACK+. The Automatic Volume Extension (AVE) feature has been enhanced and now includes a specification (0.025mm + 0.015mm/m), indicating that a 5-meter part can be measured with an accuracy of 0.100mm. Additionally, new 360 magnetic targets have been added to improve tracking. These enhancements solve the leapfrog issue, allowing users to move the C-Track and perform real-time photogrammetry with greater accuracy and speed.Automatic Volume Extension (AVE) The AVE feature allows for automatic acquisition volume extension only by moving the C-Track without requiring extra measurements. Creaform’s advanced integrated photogrammetry and scaling algorithms ensure a more precise, repeatable, and human-error-free measurement of large parts.360 Magnetic Targets With their crafty design, the new 360 magnetic targets are automatically detected from any angle by the C-track, making tracking easier and setup quicker. Users, whether they are experts or beginners, can now effectively scan large parts and get accurate and reliable measurements.See how the QC process is simplified for large parts with the AVE feature and new 360 magnetic targets.<iframe width="640" height="360" src="https://www.youtube.com/embed/ZIS3pLxrykU?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h3 id="isPasted">New Setup Assistance Tools</h3>The MetraSCAN BLACK+ now comes equipped with setup assistance tools designed to help new or inexperienced users get up to speed quickly and feel confident using the device, even without extensive prior knowledge.Using live visual feedback, the software helps the user position the targets in the right number and places.The guidance volume display simplifies the setup process and allows users to make swift adjustments. The assistance tools also provide users with advanced setup diagnostics, which help them troubleshoot and validate their setup before starting a new acquisition. Using a target deviation table and vectors, they can determine if there were any deviations since the targets were positioned. This lets them conclude whether the jig has been impacted or thermally deformed.Check out how the Setup Assistance Tools help users troubleshoot their setups.<iframe width="640" height="360" src="https://www.youtube.com/embed/Ejown4IhHOI?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>In short, the setup assistance tools—with their live feedback on positioning targets and advanced troubleshooting assistance—provide guidance for setup preparation, making it easier for non-experts to use their measuring equipment and to be confident in their QC process.<h2>Make the Right Decisions Based on Accurate, Repeatable, and Reliable Data</h2>With these new improvements to the MetraSCAN BLACK+, Creaform is taking a step further to reduce errors that can occur in the QC process. Now, the performance of the measuring equipment is validated based on ISO 10360 for better accuracy. The user, whether expert or beginner, is better guided during setup execution. Measuring methods requiring leapfrogging are now better documented and easier to perform. Users can also troubleshoot their setups to ensure environmental conditions have not created deviations.Therefore, if all sources of error are eliminated from the equation and you no longer doubt the equipment, the user, or the environment and measuring methods, then you make the right decision with confidence, knowing that the default can only come from the part that must be reworked or rejected. This is how you can regain confidence in your QC process.Learn more about the New <a href="https://www.creaform3d.com/en/optical-3d-scanner-metrascan/technical-specifications" target="_blank">MetraSCAN BLACK+</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712821796433-metrascan3d-car-frame-scanning-1-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Engineer scanning a car body with the Creaform MetraSCAN BLACK+

Engineer scanning a massive part with the Creaform MetraSCAN BLACK+

Do you ever question the accuracy and reliability of your quality control (QC) process? Do you ever doubt the quality of your measurement setup, especially if you are a non-expert in 3D scanning?

Do you have confidence in your 3D measurements? Are you certain they are accurate, repeatable, and reliable?

By definition, networking is “the action or process of interacting with others to exchange information and develop professional or social contacts”, but in more recent times, has networking become a buzzword with no action? 

Networking: just a buzzword or pivotal for manufacturing success?

You’re a design firm. You have engineering expertise. You have the know-how. Now, you need access to the technology to bring your part to life. So, how do you choose a manufacturing partner? And how do you ensure you get the most out of that relationship?When choosing a production partner, thankfully, the decision can be narrowed down. Undoubtedly, you will require specific processes, materials, expertise, etc., which not everyone can offer. Once you have narrowed down this list of capabilities, the next question is often, who can give me the best value? Who can deliver my part the quickest? But it is worth looking into your manufacturing partner’s process.&nbsp;Back to the drawing boardPick a partner who allows you to upload your CAD file and amend it as often as you want! Ideally, for free! At Protolabs, our automated <a href="https://www.protolabs.com/en-gb/automated-design-analysis/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-desgin-firms-0224&utm_content=wevolver-design-firms-manufacturing-partners-0324" target="_blank" rel="noopener noreferrer">design for manufacturability</a> software has no cost. You can amend and upload as many times as you like. If you are keen to use us and can’t quite get your part to meet our capability requirements, why not book a meeting with one of our engineers? Our complimentary consultant design service offers up Protolabs engineering expertise. Whilst we are not a design consultancy, our engineers are experts in the services we provide here, and they will work with you to help you achieve your aim of producing a manufacturable part.Rapid PrototypingPick a partner who can produce your <a href="https://www.protolabs.com/en-gb/rapid-prototyping/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-desgin-firms-0224&utm_content=wevolver-design-firms-manufacturing-partners-0324" target="_blank" rel="noopener noreferrer">prototypes</a> quickly! When you’re designing, prototyping is key. Rather than waiting weeks for prototypes to come back so you can test them. Why not work with Protolabs, who can provide parts as fast as a day? While speed depends on complexity and size, we are the quickest in manufacturing, so upload your CAD and find out how soon you could be holding your first test part.Aluminium Tooling?You may read that heading and think; I&nbsp;do not want aluminium tooling –&nbsp;we would ask you why. At Protolabs, we often use aluminium tooling due to its speed and cost efficiency. If you eventually move to production with us and are concerned that your tool won’t last, don’t worry. At Protolabs, when you move to our on-demand production service, your tool comes with a lifetime guarantee! That means if that aluminium tool you are worried about needs replacing, we will do it at no extra cost.No minimum order quantities (MoQs)Chances are, when you are starting out, you will be keen to find a supplier who doesn’t have a minimum order quantity to make the process more expensive and less efficient. At Protolabs, we have no MoQs, so order away as little as 1 part and as many as 25,000+. &nbsp;On-Demand ProductionFind someone who can support you with scaling up. Whilst a small prototyping house might seem like the perfect solution at the start, if you do decide to move on to production, you then have to start again with someone who can offer production capabilities. At Protolabs, we offer both!So you’ve prototyped with us, and now you want to start considering production runs? We are not just a prototyping service (as our name might imply) our extensive on-demand manufacturing service is here to support you with your low-volume production needs. We offer bridge tooling to help support you with the transition. &nbsp;We also pride ourselves on the size and scale of our shopfloors and on our infinite capacity. How can we say infinite capacity? Easy, we scale up as the business need requires. Not convinced? Feel free to come and <a href="https://explore.protolabs.com/book-a-visit/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-desgin-firms-0224&utm_content=wevolver-design-firms-manufacturing-partners-0324" target="_blank" rel="noopener noreferrer">book a tour</a> with us and see what we’re about.&nbsp;<img border="0" width="432" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMzIxOTQ3MTA0LTE3MTAzMjE5NDcxMDQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="A large room with several machinesDescription automatically generated" class="fr-fic fr-dii">&nbsp;Quality is keySelect a supplier who doesn’t cut corners. You want speed, you want low cost, but you also don’t want to cut down on quality. Here at Protolabs, we adhere to ISO 9001 standards in regard to the quality of our production parts, but we also adhere to other quality standards. Some are process-specific, for example, we offer ISO 13485 in our Direct Metal Laser Sintering service, which is important for parts required in the medical industry.We also offer various inspection reports, measurement reports, manufacturing analyses, etc. to read more on these, please visit our process pages.Finally, find a partner with global reach. Many manufacturing partners have a global presence, which can help design firms access international markets and customers. Here at Protolabs, we have production facilities across the globe, but it doesn’t stop there. Have a part that doesn’t fit our capabilities? We also have our <a href="https://www.protolabs.com/en-gb/about-us/what-is-the-digital-network/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-desgin-firms-0224&utm_content=wevolver-design-firms-manufacturing-partners-0324" target="_blank" rel="noopener noreferrer">Digital Network</a> and kind find the capabilities you require at one of our network facilities across the globe.<img border="0" width="566" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMzIxOTQ3MTE5LTE3MTAzMjE5NDcxMTkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">Most design firms won’t have onsite production facilities and will require a partner to support this provision, bridging the gap between the design concept and the actual product. These partnerships should offer manufacturing expertise, cost-effectiveness, time efficiency, quality assurance, scalability, access to technology and risk mitigation.A partnership with Protolabs can help bring your ideas to life quickly and efficiently whilst maintaining high-quality standards. Check out our dedicated <a href="https://www.protolabs.com/en-gb/industries/design-firms/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-desgin-firms-0224&utm_content=wevolver-design-firms-manufacturing-partners-0324" target="_blank" title="Design Firms" rel="noopener noreferrer">Design Firms industry page</a> to give you the insight you need to choose Protolabs as your manufacturing partner.

Protolabs Global Digital Manufacturing Locations

As a design firm, how do you choose a manufacturing partner? And how do you ensure you get the most out of that partnership?

How can design firms get the best from their manufacturing partnership?

<h2 id="isPasted">Insights into the Inspection Challenges Arising during Sheet Metal Manufacturing.</h2>Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry. No doubt, a combination of advanced technology and skilled labor must be involved to ensure that the sheet metal components are cut and shaped to precise dimensions. This includes checking for correct length, width, surface profile, and overall shape. Quality inspection is vital because automotive sheet metal must withstand stress and fatigue over the vehicle’s lifetime.Apart from ensuring safety, quality inspection also ensures that the visual standards of consumers are met. This is achieved by guaranteeing that parts are assembled with the best possible flush (height on either side of a gap) and the smallest gap (width of a strip between two car components, e.g. door and chassis).This blog post addresses the inspection challenges involved in sheet metal manufacturing. If you are looking to enhance the quality of your sheet metal parts, balance the thoroughness of inspections with cost and time efficiency, and gain some tips that could give you an edge over your competitors, this article might pique your interest.<h2>The Most Popular Manufacturing Techniques for Sheet Metal</h2>Stamping and laser cutting are among the most commonly used methods for manufacturing sheet metal components in the automotive industry. Both techniques require some level of dimensional inspection, ensuring that parts meet specified dimensions and tolerances. However, the extent and nature of the inspection vary depending on the process used.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817909876-Industrial-press-for-sheet-metal-stamping-and-CNC-laser-machine-cutting-sheet-metal-1536x507.webp" style="width: 100%px;" class="fr-fic fr-dib">CNC laser machine cutting sheet metal with light spark. Technology plasma industrial, Blue steel color.<h3 id="isPasted">Stamping</h3>Stamping involves using a stamping press to transform flat sheet metal (in either blank or coil form) into a net shape. This method is used to manufacture high-volume parts like frames, hoods, doors, and panels. Dimensional inspection is crucial in this process due to the high volume and precision required for these automotive parts. Inspections typically focus on checking the dimensions of features like holes, flanges, and bends, as well as overall part geometry.<h3>Laser Cutting</h3>Laser cutting, on the other hand, is used for cutting precise shapes in metal. It is typically used to produce intricate components or those that require a high degree of accuracy. Precision is key in laser cutting, so inspection typically focuses on the accuracy of cut dimensions, edge quality, and the position of features like holes or cutouts.In each of these techniques, various tools and instruments can be used for dimensional inspection, such as traditional calipers and micrometers, coordinate measuring machines (CMMs), or laser scanning and 3D metrology tools. The choice of measuring equipment depends on the complexity of the parts, the precision required, and the production volume.Laser 3D scanning is particularly advantageous for inspecting parts with complex shapes and detailed features or when high precision is required. Its ability to quickly capture a part’s entire geometry in high detail makes it a valuable tool, particularly for sheet metal manufacturing.<h2>What to Inspect on a Sheet Metal Part</h2>On sheet metal, certain features and dimensions are particularly critical to inspect due to their importance in the structural integrity and functionality of the part. Moreover, some bends or curved areas are often challenging to form and are prone to issues like spring back or deformation. Hence, manufacturers must control the quality of their parts, particularly the overall shape and edges.<h2>Keys Points for Controlling the Overall Shape</h2>Objective: Detecting any warping or distortion that might have occurred during manufacturing.While common, regular shape control involves a flatness tolerance, the inspection of complex 3D geometries involves a profile of a surface (or surface profile) tolerance.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817936809-GDT-in-VXinspect_Sheet-Metal-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Mockup image of a businesswoman using laptop with blank white desktop screen with coffee cup on wooden table in cafe<h3 id="isPasted">Flatness</h3>Symbolized by a parallelogram in GD&amp;T, a flatness tolerance specifies a tolerance zone defined by two parallel planes within which the surface or derived median plane must lie.<h3>Profile of a surface</h3>Represented by a half-circle in GD&amp;T, the tolerance zone established by the profile of a surface tolerance is 3D (a volume), extending along the length and width (or circumference) of the considered features.The profile of a surface tolerance is similar to the flatness tolerance. However, it uses the geometry of the part to create a tolerance envelope that conforms to the shape of the part, rather than a flat plane. Tolerances for sheet metal parts can be applied to the entire part or specific areas. Local tolerances are indicated on the 2D drawing and are necessary for tighter assemblies in specific locations.Moreover, tolerances (both flatness and profile of a surface) can be free in space, orientation, and position (no datum) or constrained to a specific alignment. This will affect the results, as a fully constrained profile of a surface tolerance will create an envelope that perfectly follows the geometry of the part, without any allowance for movement in space to fit all the points inside the envelope.<h2>Key Points to Inspecting Edges and Corners</h2>Objective: Detecting deformities and irregularities that might have appeared during the cutting and shaping processes.On common sheet metal parts, two types of edges are mostly present: sharp edges and hemmed edges.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817960526-HandySCAN3D_Sheet-Metal-Car-Part-Inspection-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Sharp Edges</h3>Sharp edges are mostly found on sheet metal parts that are laser-cut or stamped with a punch tool or die.<h3>Hemmed Edges</h3>Rather than sharp edges coming from stamping or laser cutting, hemmed edges present a rounded shape found in places prone to injuries, such as the contour of a car door.In the process of stamping and laser cutting sheet metal, certain edges of circles, oblongs, or part sides can become very sharp, which can be dangerous and cause injury or damage if left untreated. Therefore, it is necessary to deburr these edges to break their sharpness and straightness.To ensure that the edges, both hemmed and sharp, are safe and of high quality, manufacturers must accurately inspect their position, angle, and straightness. To achieve this, special algorithms have been developed and contribute to improving sheet metal manufacturing processes.Learn more about VXinspect’s Edge method, designed specifically for sheet metal edges<h2>More Areas to Control on Sheet Metal</h2>Holes, Oblongs, and Cut-Outs: Precision is key for holes, oblongs, and cut-outs in sheet metal parts, as they often need to align with other components. Inspecting these features ensures they are the correct size and properly positioned.Flanges and Tabs: Flanges and tabs are critical for the assembly process. Their dimensions and angles must be precise for proper fitment with other automotive parts.In short, when inspecting these key areas, you can ensure that sheet metal parts are manufactured to the correct dimensions and tolerance. You also confirm that they are the closest to the nominal design, and interference risks are mitigated. With no physical or functional interference, all parts fit together seamlessly and function as intended in the final assembly. As a result, quality, safety, and comfort are optimized.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817982143-Sheet-metal_Quality-Control_MetraSCAN-3D_Geely-1536x1151.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Which Sheet Metal Parts Are More Challenging to Inspect</h2>Certain parts pose more inspection challenges than others. Here are a few examples.<h3>Roof</h3>The roof of a car plays a vital role in ensuring passenger safety, which is why inspecting it is of utmost importance. However, due to its large size, measuring specific points directly on the assembly line can pose accessibility problems, requiring adapted tools. Therefore, when choosing the right inspection method, it’s not only the part itself that must be considered, but also the condition in which the part is inspected. This is particularly important in an automated quality control (AQC) context or for troubleshooting purposes.<h3>Doors and Fenders</h3>Parts that have structural rigidity once assembled, such as doors, do not need to be physically conformed before inspection. However, other parts, like front and rear fenders, that do not have structural rigidity, must be conformed. Conforming a part can be easy if the appropriate checking fixture is available. (Checking fixtures are typically designed for a specific part.) However, in today’s manufacturing world, production is shifting from Low Mix-High Volume to High Mix-Low Volume. This shift demands more checking fixtures, which in turn adds extra costs to the manufacturing and inspection processes.Holding fixtures are, however, more versatile than checking fixtures. They can be used on multiple parts, which reduces costs and saves storage space. Therefore, holding fixtures to which we add a fast measuring tool can significantly accelerate the conformation process.<h3>Car Body</h3>During the body in white (BIW) stage in which the car body’s frame is joined together, quality control is critical because it involves ensuring the quality of the vehicle’s metal framework before other components like the engine, chassis subassemblies, electronics, and interior trim are integrated into the structure. When inspecting large parts like the car body, pay close attention to the volumetric accuracy of the measuring tool used.Since the measurement deviation increases by a few microns per meter, the cumulative error of scanning a larger part is higher. Such deviations cannot be ignored, and scanning methods have been developed to reduce errors, such as using markers like passive or active targets and photogrammetry.<h2>Next Step: Understand the Technologies for Inspecting Sheet Metal</h2>Sheet metal parts must meet the high standards of quality and safety required by the automotive industry. Inspection is crucial to ensure that the manufactured parts are accurately dimensioned, thereby minimizing waste and reducing the need for rework, ultimately reducing production costs. This efficiency level is critical for any part manufacturer operating in the highly competitive automotive market.However, the manufacturing of sheet metal parts poses certain inspection challenges. To address these challenges, it is essential to select a suitable measuring technology among the different measurement solutions available by analyzing their respective advantages and disadvantages.

Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry.

Unveiling the Hidden Hurdles of Automotive Part Manufacturers

It’s no secret that digital manufacturing is revolutionising the agriculture industry – In fact, we delved into the <a href="https://www.protolabs.com/en-gb/resources/blog/turning-over-a-new-leaf-digital-manufacturing-in-agriculture/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-agriculture-0124&utm_content=wevolver-digital-manufacturing-agriculture-blog-0224" target="_blank" title="Turning Over a New Leaf: Digital Manufacturing in Agriculture">transformative potential of digital manufacturing</a> in agriculture in an earlier blog. But the demand for more is unprecedented, which begs the question: what is driving the growth?Let’s look at the five root causes of the insatiable appetite for digital manufacturing in agriculture to understand how it is making such an impact. Green Consumers on the RiseDemand Driver: As environmental awareness grows, consumers increasingly seek products produced through sustainable and environmentally friendly practices. This shift in consumer preferences pressures the agriculture industry to adopt sustainable methods throughout the supply chain, from farming practices to food processing.Digital Manufacturing Impact: Digital manufacturing enables the agriculture industry to embrace sustainable practices by incorporating precision farming, reducing waste, and optimising resource usage. The demand for digital manufacturing rises as it becomes a key enabler for meeting consumer expectations for environmentally conscious products.&nbsp;<img border="0" width="431" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4NDMxMzgwNTk1LTE3MDg0MzEzODA1OTUuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="arrow lake - technology for agriculture" class="fr-fic fr-dii">&nbsp;When designing their ozone purification system, The FLO3W®,&nbsp;Arrow Lake, was able to make a rapid decision about the feasibility of their part by using Protolabs’ automated solution to get an immediate initial analysis of manufacturability and cost-effectiveness.&nbsp;<a href="https://www.protolabs.com/en-gb/resources/case-studies/arrow-lake/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-agriculture-0124&utm_content=wevolver-digital-manufacturing-agriculture-blog-0224" target="_blank" title="Arrow Lake">Read the case study to find out how they did it.</a>&nbsp;&nbsp;Regulatory PressuresDemand Driver: Governments and regulatory bodies worldwide are implementing stricter environmental regulations and standards. Compliance with these regulations is not just a legal requirement but also a necessity for businesses to operate sustainably and maintain their Social License to Operate.Digital Manufacturing Impact: Digital manufacturing provides the tools and processes necessary for the agriculture industry to meet and exceed regulatory requirements. From precision farming practices to energy-efficient manufacturing techniques, the demand for digital manufacturing is fuelled by the need to align with and surpass regulatory standards.&nbsp;Small Portions of ResourceDemand Driver: The agriculture industry faces challenges related to resource scarcity, including water, arable land, and energy. Volatile prices for these resources make it imperative for businesses to optimise resource usage and reduce waste to maintain profitability.Digital Manufacturing Impact: Digital manufacturing technologies, such as precision farming and automated processes, help optimise the use of resources. By reducing waste, improving efficiency, and minimising the environmental impact of agriculture and food processing, digital manufacturing has become a sought-after solution to address resource scarcity and volatile prices.&nbsp;<img border="0" width="399" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4NDMxMzgwNjA1LTE3MDg0MzEzODA2MDQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="fambot - automation in horticulture" class="fr-fic fr-dii">&nbsp;FarmBot, the&nbsp;world’s first open-source, CNC small-scale farming machine, allows individuals to create and manage a garden using a laptop, tablet, or phone to oversee the automated planting, watering, and monitoring of crops. Protolabs’ product development experts helped FarmBot transition from 3D-printed components to more&nbsp;<a href="https://www.protolabs.com/en-gb/resources/case-studies/farmbot/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-agriculture-0124&utm_content=wevolver-digital-manufacturing-agriculture-blog-0224" target="_blank" title="FarmBot">repeatable and cost-effective injection-moulded parts.</a>&nbsp;&nbsp;Technological AdvancementsDemand Driver: Advances in technology, including renewable energy technologies, efficient manufacturing techniques, and smart systems, are driving the demand for more sustainable products and processes across industries. Businesses that adopt these technologies gain a competitive edge in efficiency, cost-effectiveness, and environmental stewardship.Digital Manufacturing Impact: Digital manufacturing plays a crucial role in implementing these technological advancements in agriculture. Whether using smart sensors in precision farming or adopting sustainable manufacturing practices, digital manufacturing is at the forefront of technological innovation, driving demand in the agriculture industry.&nbsp;<img border="0" width="491" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4NDMxMzgwNjEzLTE3MDg0MzEzODA2MTMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="small robot company - robotic agriculture innovation" class="fr-fic fr-dii">&nbsp;Small Robot Company&nbsp;developed the 21st-century answer to the 21st-century problem in agriculture, producing more food from less land. Their Tom V4 Per Plant farming makes autonomous robotic farming a reality, meaning more food and less waste at a cheaper cost than ever before. With sustainability as the driving force of their product, they needed to minimise the entire system weight so that ground pressure was reduced, so they partnered with Protolabs to&nbsp;<a href="https://www.protolabs.com/en-gb/resources/case-studies/small-robot-company/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-agriculture-0124&utm_content=wevolver-digital-manufacturing-agriculture-blog-0224" target="_blank">3D Print two different parts&nbsp;for their latest agri-robot.</a>&nbsp;&nbsp;Squaring the Circular EconomyDemand Driver: The circular economy approach, emphasising waste reduction, reuse, and recycling, is gaining traction as a sustainable business model. Life Cycle Assessment (LCA) is a key element in assessing the environmental impact of products from creation to disposal.Digital Manufacturing Impact: Digital manufacturing supports the circular economy by enabling more efficient use of materials, reducing waste in production processes, and promoting developing products with a longer lifespan. The demand for digital manufacturing rises as businesses seek to align with circular economy principles and implement sustainable practices throughout their operations.&nbsp;The agriculture industry is quickly realising the importance of sustainability and the need to address environmental awareness, regulatory pressures, resource scarcity, technological advancements, and the rise of the circular economy. That's where digital manufacturing comes in as a critical solution to support more eco-friendly and efficient practices in agriculture and food production. It's exciting to see businesses recognising the potential impact of this technology and embracing it to meet these challenges.

It's no secret that digital manufacturing is revolutionising the agriculture industry. In this blog, we explore the five root causes of the insatiable appetite for digital manufacturing adoption in agriculture to understand how is making such an impact.

Digital Manufacturing: The Growing Appetite in Food and Agriculture

<a href="https://xometry.eu/en/compression-moulding/" target="_blank">Compression moulding</a> is a manufacturing process used to create various products and components, primarily from thermosetting materials such as composites, rubber or resin material. It offers a variety of unique options for manufacturing functional prototypes as well as for low-volume products.<h2>What is compression moulding?</h2>Compression moulding has become an essential technology in many industries, contributing to the development of modern products that we use every day. The technique involves compressing the raw material within a heated mould tool, usually under heat and pressure, until it takes the desired shape. The moulded parts are durable, economical and suitable for many applications.<h2>How does compression moulding work?</h2>This moulding process uses heat and pressure to form the part’s final desired shape. It involves a measured amount of moulding material (preheated) called “charge” which is compressed into the desired form using two heated moulds. These moulds usually have a pre-heated cavity and a vertical press mechanism to effectively construct and maintain the required tooling.The excess material seeps out of the mould in the form of a flash (the excess plastic that is usually forced out of the mould cavity at the parting line between the two parts of the mould).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708326811338-Compression_molding.svg-768x442.png" style="width: 766px;" class="fr-fic fr-dib">Scheme of a moulding machine and its mains components (Source: Wikipedia)This moulding process works as follows:<ul><li>Step 1 – Create moulds: Produce tooling using methods such as machining, die casting, or 3D printing.</li><li>Step 2 – Set up the machine: Clean the mould, turn on the heat, and complete other necessary set-up procedures based on the machine or device in use.</li><li>Step 3 – Prepare charge: Choose the material and determine the appropriate amount of material. Avoid using too much charge, as this can cause excess material to seep out of the mould, leading to flash that requires manual cutting.</li><li>Step 4 – Insert charge:&nbsp;Position the charge in the centre of the bottom mould.</li><li>Step 5 – Compress part: Close the top mould, apply pressure, and allow time for the piece to form. Some manufacturers use heat during compression, which can quicken production by softening raw materials.</li><li>Step 6 – Release part: Remove the finished piece from the mould.</li><li>Step 7 – Clean part:&nbsp;Remove any resin flash along the edges manually, and clean the part as needed before final assembly.</li></ul><h2>Types of compression moulding</h2>There are several types of moulding techniques, and each method differs in terms of its application and the materials used.<h3>Industrial hydraulic compression moulding</h3>Large industrial compression moulding machines are ideal for commercial large-batch part production. They employ hydraulic lift systems that make it possible to attain a high level of pressure to manufacture and produce large, uniform parts. Workers have full control and monitoring over the process from a separate control panel.<h3>Benchtop presses</h3>Smaller benchtop compression machines are best to manufacture small to midsize parts. Benchtop presses usually take up less space compared to large industrial compression machines but is best for large runs. They have multiple access points that give engineers and operators the flexibility to easily remove finished parts and the produced flash. Also, the smaller size and footprint make it ideal to employ these machines in smaller production facilities or warehouses.<h3>Cold (heatless) compression moulding</h3>This technology is usually done by using heat but on the other hand, there is also cold (heatless) compression where the charge or raw materials are generally preheated before being put into the mould. For softer plastics, even heating is not needed. The engineers and manufacturers can control the procedure and curing and also shorten the production cycles by the timely introduction of heat.<h3>Wet compression moulding</h3>The technique of wet compression moulding is used to combine epoxies, resins and many other liquids with solid fabrics. Wet compression machines are very common in the production lines of car manufacturers like <a href="https://www.youtube.com/watch?v=Ftbf_gf8AjQ" target="_blank">BMW</a> where they produce strong and durable products in less time and low cost.<h2>Suitable materials for compression moulding</h2>Plastics, thermoplastics and thermosets are compatible with the compression moulding process. Thermoplastic materials are plastics that on heating become soft and flexible and harden when cooled. They show no changes in the chemical and mechanical properties even after hardening and hence they can be heated and cooled (or reshaped) numerous times.Whereas for thermoset materials, the characteristics are different. They become irreversibly cured on exposure to heat and all their inherent properties are changed and permanently cured to stay in the given shape. Hence, they can only be moulded once and cannot be repeated or undone.&nbsp;Materials used commonly in compression moulding include:<ul><li>Epoxy</li><li>High-density polyethylene (HDPE)</li><li>Polyether ether ketone (PEEK)</li><li>Polyphenylene sulphide (PPS)</li><li>Polytetrafluoroethylene (PTFE)</li><li>Silicone</li><li>Urethane</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708326844582-Compression-Molding-Non-Conductive-mob.jpg" style="width: 766px;" class="fr-fic fr-dib">Compression moulded parts (Source: Nolato)<h2 id="isPasted">Advantages of the compression moulding process</h2>Let’s take a deep dive into the compression moulding advantages.<h3>Cost-effectiveness&nbsp;</h3>Compression moulding can be termed the most cost-effective manufacturing method for the production of simple, flat and large parts. Small design complications like pockets and curves are acceptable whereas much more complicated designs are often not possible with compression moulding.&nbsp;Since it employs low pressures, tool costs are cheaper and the moulds last long without any defects like warping eliminating the need to be replaced. The main problem of low cycle times can be countered by producing moulds with multiple cavities to produce more parts during the same cycle.<h3>Produces strong parts</h3>The process works by placing the charge into the mould as opposed to injection moulding where the charge is injected into the mould, which theoretically eliminates the flow and knit lines and defects like short shots. The structural stability of the compression moulded parts is also higher compared to injection moulding.Manufacturing with composite materials is easily possible with compression moulding. Composite parts offer unique properties along with being strong and durable.<h3>Flexibility in design</h3>One of the chief advantages of compression moulding is its ability to offer cheap prototyping. For example, cheap moulds can be easily designed on CAD software and 3D printed. Later, this cheap mould can be used to perform compression moulding for research and prototyping before the actual mould is built. This way, it can be more advantageous to tool designers and engineers. This manufacturing process is also a good solution to produce consistently coloured rubber parts.<h2>Limitations of compression moulding</h2>Although this technology has many benefits, it also has a few limitations:<ul><li>Not suitable for complex parts. When the design is complex, for example, the design has intricate details or slant angles, it’s advised not to use compression moulding as it cannot achieve those.&nbsp;</li><li>Slow cycle time. It lasts for minutes compared to injection moulding which is usually seconds. The associated labour time is also increased because of the slow cycle time and hence the cost of labour.</li><li>Creation of flash and burrs. They need to be removed manually which results in extra time and material wastage.</li></ul><h2>Applications of compression moulding manufacturing process</h2>Compression moulded parts offer a plethora of applications in every commercial industry:<ul><li>Automotive parts: Many interior parts of cars and bikes can be produced using compression moulding. Big parts like tractor bumpers and engine components using plastic are produced cheaply with the help of compression moulding.&nbsp;</li><li>Computer, gaming devices and consoles: The keyboards for computers, monitor frames and controllers for video games and buttons can be compression moulded.&nbsp;</li><li>Kitchenware: Plastic dishes like plates, cups and cutlery can be compression moulded. Especially the parts that are produced using melamine are usually compression moulded. &nbsp;</li><li>Electrical components: Electrical sockets, switches, faceplates, and metering devices are usually manufactured with this technology.</li><li>Medical and dental device parts: Many plastic and silicon medical and dental equipment used in daily life, like syringe stoppers, equipment handles, and respirator masks are manufactured using this process.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708326885611-compression-moulded-bottle-caps-768x512.jpeg" style="width: 766px;" class="fr-fic fr-dib">Compression moulded blue plastic caps<h2 id="isPasted">What is the difference between injection moulding and compression moulding?</h2>The main difference in operation relies on the fact that, in&nbsp;<a href="https://xometry.eu/en/injection-moulding/" target="_blank">injection moulding</a>, the charge is introduced as pellets into the injection mould and on the other hand, in&nbsp;<a href="https://xometry.eu/en/compression-moulding/" target="_blank">compression moulding</a>, the mould is closed or pressed against the charge to get its shape.&nbsp;Manufacturers use both technologies these days but for different types of parts and have different applications. Sometimes there are big and ultra-large parts for which an injection mould cannot be produced. That is when a compression mould is ideal. On the contrary, for complex moulds, injection moulding is an ideal option. If the design is simpler, compression moulded solutions remain cheaper.Because the material is loaded into the mould cavity directly, there is no limitation on the weight of the part that can be made other than the size of press and tonnage required, whereas injection moulding presses are limited in the weight of part they can produce by the volume of the injection barrel that fills the mould.In terms of speed of manufacturing, injection moulding has a shorter cycle time and is hence faster and more cost-effective for large batch production compared to slow compression moulding. On the other hand, the compression moulding technique uses low pressure and is also cheap for the same reason. The wastage is also reduced and can be advantageous when working with costly materials.&nbsp;In conclusion, for&nbsp;<a href="https://xometry.eu/en/high-volume-manufacturing/" target="_blank">high-volume production</a> and complex parts, injection moulded parts are ideal whereas, for medium to small batches and simple designs, compression moulding is recommended.<h2>Conclusion</h2>Compression moulding is a manufacturing process that wastes less material and has a lower cost tooling than injection moulding since no runners, sprue, or gates are required to form the part. Consequently, this technique produces an aesthetically and functionally superior surface finish. This makes it the go-to technique for large flat and curved components.The simplicity of compression moulding machines makes the process an attractive option for functional prototyping and low-volume manufacturing. In addition, compression moulding is the best option when the part material used is impossible to produce using other moulding techniques and custom composites are fabricated.

This article sums up everything you need to know about compression moulding: how it works as a manufacturing process, the suitable materials, its benefits, limitations and applications.

Compression Moulding: Technology Overview

<div data-id="9908f31" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Modern window systems from Switzerland</h2></div><div data-id="69b735e" data-element_type="widget" data-widget_type="text-editor.default">A warm fall day in Winterthur, Switzerland. The wooden building of <a href="https://www.eschbal.ch/" target="_blank">Eschbal</a>, clad with tall glass windows, already gives an idea of what this company specializes in. We are greeted by Michael Ebnöther and are guided through a production hall. Here and at two other locations, the Eschbal group develops and produces its own wood and wood/metal window systems. 'Our diverse customer base particularly appreciates our innovation, proximity and flexibility', emphasizes Ebnöther. The employee in the technology department is currently focusing on sustainability and material cycles.</div><div data-id="69b735e" data-element_type="widget" data-widget_type="text-editor.default"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0MjUwMzkwLTE3MDgzMjQyNTAzOTAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">The “Sirius” window system is Eschbal’s main product. Image source: Eschbal AG<div data-id="371df47" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Innovation and product optimization</h2></div><div data-id="a4a60e8" data-element_type="widget" data-widget_type="text-editor.default">Technical drawings of components appear on the screen in Ebnöther’s office. In addition to its core business, the fabrication of aluminum frames and sashes, Eschbal’s daily agenda includes the continuous optimization and development of its products. For its flagship product, the <a href="https://www.sirius-fenster.ch/" target="_blank" rel="noopener">“Sirius” window system</a>, the team succeeded in maximizing the glass surface to let in as much light as possible. But innovative ideas alone are not enough. 'To strengthen our market position, we need to respond quickly to individual customer requirements', says Ebnöther. This is where additive technologies come into play.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0Mjg5MzI2LTNfRWJub2V0aGVyRnJhbWUuanBnLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Since 2018, Michael Ebnöther is part of the technology department at Eschbal.<div data-id="66f7fc8" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Incorporating 3D printing processes</h2></div><div data-id="bc27b16" data-element_type="widget" data-widget_type="text-editor.default">'In terms of design, 3D printing gives us much more creativity – we can now develop things that we hadn’t even thought of before', explains Ebnöther. Until a year ago, Eschbal had commissioned 3D printed parts from external service providers. However, as internal demand continued to grow, the company decided to acquire its own printer. '<iframe width="640" height="360" src="https://www.youtube.com/embed/cRdVdqEZ0Vc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> Sintratec was the ideal solution for us. As we are a company that manufactures exclusively in and for Switzerland, it was essential for us to find a Swiss 3D printer', emphasizes Ebnöther. Since fall 2022, a <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank">Sintratec S2</a> has been successfully in use at Eschbals’ production facility.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0MzIzMTUxLTRfM0RwcmludFBhcnRzLmpwZy53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">3D printing has become an integral part of product development.<div data-id="af667bd" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>High-quality parts in a short time</h2></div><div data-id="5c13cdf" data-element_type="widget" data-widget_type="text-editor.default">The team uses the modular SLS system to realize prototype parts, production tools and small series of window components with robust <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank">PA12 nylon</a>. Why did Eschbal choose selective laser sintering (SLS) in particular? «With the SLS process, we were especially impressed by the tolerances of up to 0.1 millimeters and the surface quality», explains Ebnöther. 'In addition, other technologies such as FDM cannot deliver the quantities we need – with the S2 we can print up to 100 parts within 24 hours', the technician continues.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0MzU3NDU4LTE3MDgzMjQzNTc0NTgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Profiles and window components are laser sintered with PA12.<div data-id="aab5b28" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Comparable material properties</h2></div><div data-id="c6edfcb" data-element_type="widget" data-widget_type="text-editor.default">3D parts have become indispensable for Eschbal, especially for prototyping. «Before we invest in an expensive injection molding tool, we need something in our hands that we can test and verify,» says Ebnöther. It is crucial that the SLS parts have very similar properties to the injection molded products. Equally important is the shorter development time: 'Compared to the previous process with external suppliers, the S2 saves us several days.' For small quantities, Eschbal also manufactures series parts. For example, a reinforcing element that is only required for special profile combinations. An injection molding tool would not be profitable here, so the component is produced on demand on the S2 instead.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0Mzg3MDIxLTE1X0N1dHRpbmdNYWNoaW5lLmpwZy53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">At Eschbal, SLS is used for prototypes, series parts or production aids such as cutting bases.<div data-id="2d57e47" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Less weight – more flexibility</h2></div><div data-id="a9737b0" data-element_type="widget" data-widget_type="text-editor.default">Ebnöther presents another application example. A connector was previously heavy and bulky. To optimize it, the design was revised, quickly printed with PA12, iterated and verified. 'As a result, we were able to reduce the weight of the new connector by 33%', says Ebnöther. Eschbal’s production department is also grateful for the SLS printer. Tools and auxiliary materials, such as the cutting bases for the cutting machine, which previously had to be commissioned, are now 3D printed in-house to precisely fit the corresponding profile. This is cheaper, faster, and allows the company to react much more effectively to potential adjustments.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0NDE2MTM5LTEwX1BhcnRzU2NyZWVuLmpwZy53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">A connecting element was optimized using an SLS prototype.<div data-id="738f8b9" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Pushing design boundaries</h2></div><div data-id="8731b84" data-element_type="widget" data-widget_type="text-editor.default">By implementing SLS 3D printing, the technicians at Eschbal have gained valuable design freedom. «It is simply easier, faster and cheaper to push the boundaries», says Ebnöther. For Eschbal’s development department, the Sintratec S2 has fulfilled the team’s expectations and hopes. 'From the first contact until today, we are completely satisfied – the team and the support from Sintratec are a clear recommendation', concludes Michael Ebnöther.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4MzI0NTI4OTI1LTE3MDgzMjQ1Mjg5MjUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></div></div></div></div></div></div></div>

At Eschbal, a Swiss manufacturer of window systems, prototypes, small series and production tools are additively manufactured. To this end, the technical department around Michael Ebnöther successfully uses a Sintratec S2.

Innovative window systems with SLS components

Our non-destructive surface evaluation solution for the pipeline industry has received valuable feedback since its launch last year. The suggestions for improvement include increasing the scanning capacity of our scanners and making our analysis algorithms more versatile for the geometries that our software supports.Creaform has been attentively listening to the feedback and requests for improvement from its valued customers. We also have noticed a persistent trend in the requests. It has become clear that the limited alternatives available in the market for this type of assessment, particularly for large components and curved surfaces, have been the primary reason for these demands.<h2 id="isPasted">Pit Gauge Challenges for Large and Corroded Structures</h2>The pit gauge is the preferred method for evaluating corrosion on large components due to its affordability and widespread availability in most industries. However, this technique has significant limitations.Operators using the pit gauge may struggle to measure irregularly shaped pits or those with complex geometries accurately. The tool is typically designed for relatively simple, cylindrical pits and may not provide accurate readings for more intricate corrosion patterns. Additionally, the reliability of measurements is contingent on the skill and experience of the operator. Interpreting pit gauge readings requires a certain level of expertise, and variations in technique among different operators may lead to measurement inconsistency. Finally, while pit gauges are effective for localized measurements, they may not be suitable for assessing overall corrosion across large surfaces. Indeed, on a large structure, it can be challenging and time-consuming for operators to probe all surfaces and report all indications using the pit gauge.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708009286416-area-with-severe-corrosion-pitting-1536x1024.jpeg" style="width: 766px;" class="fr-fic fr-dib">Zoom on an area with severe corrosion and pitting that is usually very challenging to inspect and for which asset owners have difficulties trusting the results.<h2 id="isPasted">Long-Range 3D Scanner Challenges for Large and Corroded Structures</h2>Long-range 3D scanners are gaining popularity with the democratization of Industry 4.0 and the widespread use of digital twins. Their use has increased over the past decade in various industrial applications, including the digitization of factories and critical infrastructures. These scanners are sometimes used to assess mechanical damages, such as dents in storage tanks or other large assets.However, they are not typically used for corrosion assessment due to their limited resolution. This lack of precision makes detecting minor irregularities or mild corrosion challenging, as long-range scanners may not capture fine details with sufficient resolution.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708009308397-handyscan-black-ndt-solutions-refinery-Valve.webp" style="width: 766px;" class="fr-fic fr-dib">NDT technician holding a metrology-grade 3D scanner and inspecting the corrosion on a corroded valve.<h2 id="isPasted">Why Are Metrology-grade 3D Scanners a Good Alternative to Those Solutions?</h2>Ten years ago, Creaform revolutionized the pipeline industry by introducing 3D scanning technology. Nowadays, any specialized pipeline inspection service company must possess Creaform’s 3D scanner pipeline inspection solution to secure a service contract.Compared to traditional techniques, the benefits of 3D scanning for corrosion inspection are significant. Metrology-grade 3D scanners are not only faster and more precise, but they also eliminate acquisition and reporting errors. With 3D scanning technology, generating reports on-site is now possible, which helps to make the right maintenance decision as quickly as possible with the most accurate data.Moreover, this type of inspection creates a digital clone of the inspected asset, allowing the inspection to be revisited with the highest degree of precision and even track the progression of damages over time.<h2>3D Scanning vs Manuel Techniques on Curved Surfaces</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/YwqbxKIiaaE?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2 id="isPasted">New 3D Scanner Designed for Large Parts</h2>Creaform, continually recognized as a leading provider of 3D damage assessment solutions in the pipeline industry, is proud to announce the launch of a new metrology-grade 3D scanner for large parts. The HandySCAN 3D|MAX Series, combined with VXintegrity software, will transform the process of conducting damage assessments on large parts.With the new 3D scanner, mechanical damage assessments of large-dimension assets, such as those with API 650, API 570, and API 510, now take only a fraction of the expected inspection time.The MAX Series can digitize entire structures with a precision of 75µm, ensuring that the maximum thickness loss is captured. Once the surface is digitized, specialized software analyzes mechanical damages, such as corrosion or dents, without the need for CAD. The dimensions of all damaged areas are then automatically exported and documented.Furthermore, if a more precise corrosion rate is required for the next inspection, it is possible to compare two damaged areas very precisely and observe any changes compared to the previous inspection.<a href="https://www.creaform3d.com/blog/pun5th75ef_wp/wp-content/uploads/handyscan-max-ndt-solutions-refinery-Storage-tank-3-LR.jpg" target="_blank"> </a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1708009348106-handyscan-max-ndt-solutions-refinery-Storage-tank-3-LR-1536x1024.webp" style="width: 766px;" class="fr-fic fr-dib">NDT technician holding the HandySCAN MAX and inspecting corrosion under insulation at the bottom of a reservoir.<h2 id="isPasted">Right Equipment for Better Decisions Based on Accurate Data</h2>Evaluating corrosion on large surfaces can be time-consuming and error-prone, and reporting these big areas can get messy and inaccurate. Therefore, service companies may benefit from better equipment to counter these challenges. The new HandySCAN 3D|MAX Series makes it easier to communicate the indications while ensuring 100% inspection coverage and eliminating human error on the data. As a result, service companies can increase their productivity by making better decisions based on accurate data they can now fully trust.

NDT technician holding a metrology-grade 3D scanner and inspecting the corrosion on a corroded valve.

Creaform's non-destructive surface evaluation solution for the pipeline industry has received valuable feedback since its launch last year.

3D Scanning vs Manual Techniques: A Comparison of Their Effectiveness in Evaluating Large and Curved Surfaces

<a href="https://www.zeppelin-cat.de/en/" target="_blank">Zeppelin Baumaschinen GmbH</a> has been a German based sales and service partner of Caterpillar Inc., the world’s largest manufacturer of construction machinery, since 1954. Zeppelin Baumaschinen GmbH has in the interim developed into the largest business unit in the Zeppelin Group, and today it is Europe’s leading sales and service organization in the industry.The company has been using conventional metrology equipment for years, but for some tasks, this approach has now become obsolete. For example, there are no blueprints or geometry data available for many machines and components, especially older ones, and it is not possible to verify the dimensional accuracy of components with complex geometries using their traditional metrology equipment. The company therefore decided in June 2022 to expand its metrology equipment with a <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank">HandySCAN 3D|Black Elite</a> and the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms" target="_blank">data capture software VXelements</a> with its <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">VXmodel scan-to-CAD module</a>.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3Mzk5Mzk5NjA3LTE3MDczOTkzOTk2MDYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"><h2 id="isPasted"><h2>3D scan of engine blocks including connection poin</h2></h2>In order to refurbish an existing engine test bench at the Cologne site, several engines had to be measured to create customized trolley mounts. With the help of these mounts, attaching the engines on the engine test bench becomes a quick and smooth operation.The current engine test bench is now 59 years old (it was built in 1962) and has reached the limits of its performance when some Caterpillar diesel engine series have to be tested. Assembling the engines on the test bench, as well as the set-up and dismantling for the test bench run, is very time-consuming and limits the engine throughput on the test bench.The new engine test bench will be used to test engines with an output of up to 1000 kW. In the future, the test objects will be assembled using so-called trolleys. The advantage is that the engines are pre-assembled on the trolleys, and the trolley with its test object is then quickly mounted in the test bench room.In order to accommodate, to the greatest extent possible, the widest range of engine types on the trolleys, it was decided to scan the majority of the engines with the <a href="https://www.creaform3d.com/en/portable-3d-scanner-handyscan-3d" target="_blank">HandySCAN 3D</a>. This has the advantage that the connection points of the media supply, such as fresh air and exhaust gas, as well as the dimensions of the flywheel for the individual engine types can also be captured.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3Mzk5NTM0ODQ5LVplcHBlbGluX0ltYWdlLTQtMTUzNng4NjQud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Engine block on the trolley mount. This makes it possible for the engine block, including connection points, to be digitized from all sides.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA3Mzk5NTY5NDQ4LVplcHBlbGluX0ltYWdlLTUtMTUzNng4ODQud2VicCIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Scan of the engine block in the VXelements data capturing software. The areas highlighted in green show the connection points for the test bench.<h3 id="isPasted">Advantages of the Creaform HandySCAN 3D and the VXelements software</h3>This project would have been difficult or even impossible to realize using traditional measurement equipment. Given the complex geometries of the engines, it would not have been possible to record the missing dimensions. It would also have been virtually impossible to reconstruct hidden elements.The scanning process itself has been optimized to such an extent that the engine measurement can now be carried out quickly:<ul><li>Preparation time approx. 1 hour</li><li>Measurement time approx. 0.5 hours instead of 2 hours</li><li>Post-processing/creation of the auxiliary construction varies from approx. 4-8 hours, depending on requirements</li></ul>In addition, thanks to the VXmodel software, preparation of the model for further development in CAD is considerably simplified.According to Zeppelin Baumaschinen, the&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">3D measurement software VXelements</a> offers clear advantages:<ul><li>Simple and reliable operations</li><li>Clear interface and functions</li><li>Direct interface to CAD software systems</li></ul><h3>Areas of application of the HandySCAN 3D|BLACK at Zeppelin</h3>Zeppelin Baumaschinen GmbH now uses 3D metrology equipment for a whole range of applications. These include:<ul><li>Damage analysis of assemblies and individual parts</li><li>Reverse engineering of existing machine components for individual modifications according to customer requirements (e.g. new development of individual components, customizing, and much more)</li><li>Creation of 3D models for training and education purposes</li><li>Creation of 3D models for adaptive component development / installations &amp; conversions on existing machines</li><li>Scan-to-print solutions for supply bottlenecks</li></ul>There are also plans to use the measurement solution in the future for other projects, such as adapting operating elements for people with disabilities, e.g., modifying a joystick.

Given the complex geometries of the engines, it would not have been possible to record the missing dimensions. It would also have been virtually impossible to reconstruct hidden elements.

3D Scanning Helps with the Design of Engine Block Mounts

3D printing, also known as additive manufacturing, is a revolutionary technology that has transformed the way we design and manufacture objects. It works by creating a three-dimensional object from a digital model, typically by laying down many thin layers of a material in succession. This technology has found applications in a wide range of industries, from aerospace and automotive to healthcare and fashion.In the consumer-focused desktop 3D printer market, the two main types of 3D printing technologies that have gained significant popularity due to their unique capabilities are Fused Deposition Modeling (FDM) — otherwise known as Fused Filament Fabrication (FFF) — and various types of vat photopolymerization technology, perhaps the most famous of which is Stereolithography (SLA). Both of these technologies have their own set of advantages and disadvantages, and their suitability varies depending on the specific requirements of the project at hand.Understanding the working principles, capabilities, and limitations of these two different technologies is crucial for anyone looking to leverage 3D printing for their prototyping and manufacturing needs. This article therefore looks at FDM vs SLA in terms of cost, benefits, materials, and applications.<h1 dir="ltr">Understanding FDM</h1><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2ODYyNTczNjY4LTNkX3ByaW50ZXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib" alt="FDM">An FDM 3D printer printing yellow filamentFused Deposition Modeling (FDM) is the most widely used 3D printing technology in terms of machines sold, being used by industrial manufacturers and hobbyists alike. It works by extruding a thermoplastic filament, which is heated to its melting point and then deposited layer by layer to create a three-dimensional object.[1] The filament is fed from a spool through a moving, heated printer extruder head and onto the build area below.The materials used in FDM 3D printing are thermoplastic polymers that come in a filament form. These FDM materials include Acrylonitrile Butadiene Styrene (ABS), Polylactic Acid (PLA), and Polyethylene terephthalate glycol-modified (PETG) at the lower end of the scale and high-performance engineering materials like PEEK at the higher end (though most ordinary printers don’t have the power to print such materials). Common printing materials have their own unique properties and are suitable for different applications. For instance, ABS is known for its high strength and durability, making it ideal for functional prototypes and end-use parts, while PLA is notably easy to print thanks to its low melting point.FDM has several advantages that make it a popular choice for 3D printing. It is known for its ease of use, cost-effectiveness, and the ability to use a variety of materials. However, it also has its limitations. Print quality on consumer-level machines is limited, and the parts may have visible layer lines. Additionally, unlike certain 3D printing technologies such as selective laser sintering (SLS), FDM requires the use of support structures for overhanging areas, and these need to be manually removed post-printing.Recommended reading: <a href="https://www.wevolver.com/article/fff-vs-fdm-is-there-any-difference" target="_blank">FFF vs FDM: Is There Any Difference?</a><h2 dir="ltr">The FDM Printing Process</h2>The FDM printing process begins with a <a href="https://www.wevolver.com/article/how-to-make-a-3d-model-for-printing" target="_blank" rel="noopener noreferrer">3D model</a> that is sliced into layers using specialized software. This software converts the 3D model into a series of thin layers and produces a G-code file that contains instructions for the FDM 3D printer. The <a href="https://www.wevolver.com/article/your-guide-to-3d-printing-g-code" target="_blank" rel="noopener noreferrer">G-code file</a> guides the movements of the printer head to deposit the material in the correct locations.The printer heats the thermoplastic filament to a temperature just beyond its glass transition temperature. The heated filament is then extruded through a nozzle onto the build platform. The nozzle moves in the X and Y directions, depositing the material layer by layer according to the instructions in the G-code file. After a layer is completed, the build platform moves down (or in some printers, the extruder head moves up), and the next layer is deposited. This process continues until the entire object is printed.The final product created by FDM printing is a solid object that has been built up from successive layers of material. The object may require some post-processing, such as the removal of support structures and smoothing of the surface to reduce the appearance of layer lines. The quality and characteristics of the final product can be influenced by various factors, including the type of material used, the layer thickness, the printing speed, and the temperature settings.<h2 dir="ltr">Applications of FDM</h2>Fused Deposition Modeling (FDM) has found widespread use across a variety of industries due to its versatility, cost-effectiveness, and the ability to work with a range of materials. It is primarily used for prototyping across these industries, but it can also be useful for spare parts, repairs, and even production parts.In the automotive industry, FDM is used to create functional prototypes, end-use parts, and custom jigs and fixtures — Volkswagen being one major company deploying FDM for this purpose. For instance, the ability to print with high-strength materials like ABS and Nylon makes FDM a suitable choice for producing durable components that can withstand the rigors of automotive testing.The medical field also benefits from FDM technology. Custom surgical guides, anatomical models for surgical planning, and even patient-specific prosthetics can be created using FDM. Materials like PLA are often used in these applications due to their biocompatibility.In the realm of consumer goods, FDM is used to rapidly prototype new product designs, create custom parts, and even manufacture end-use products. In footwear, for example, sportswear brand Adidas has used 3D printing to create midsoles for sneakers. In general, the wide range of available FDM materials, each with different properties, allows for a high degree of customization based on the specific needs of the product.In education, FDM printers serve as an invaluable tool for teaching students about design, engineering, and manufacturing. The relatively low cost and ease of use of FDM printers make them an accessible technology for schools and universities.<h1 dir="ltr">Understanding SLA</h1><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2ODYyNTg0NzkwLTNkX3ByaW50aW5nLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="SLA">An SLA 3D printer printing a transparent resin partStereolithography (SLA) is another prominent 3D printing technology that operates on a completely different principle compared to FDM. SLA is part of the category of vat photopolymerization resin 3D printing methods, which use a light source to cure and solidify a liquid resin, layer by layer, to form a solid object.[2] With SLA specifically, the light source is usually a UV laser, which is directed by a set of galvanometers that rapidly deflect the laser beam across the build platform. Digital light processing (DLP), a similar process, uses a projector instead of a laser.The materials used in SLA are photosensitive thermoset polymers that come in a liquid resin form. These SLA resins are transformed from a liquid to a solid state when exposed to a specific wavelength of light. The properties of the final product can vary greatly depending on the type of resin used. There are a wide variety of resins available, each with different properties, such as flexibility, strength, temperature resistance, and optical clarity.Advantages of SLA include its high resolution and accuracy, which allows for the creation of high-quality parts with fine details and smooth surfaces. However, SLA also has its limitations. The materials used in SLA are generally more expensive than FDM filaments, and the post-processing can be more labor-intensive. Furthermore, build volumes tend to be small, making the process limited to small printed parts.Recommended reading: <a href="https://www.wevolver.com/article/how-do-resin-printers-work-sla-dlp-more" target="_blank">How Do Resin Printers Work? SLA, DLP &amp; More</a><h2 dir="ltr">The SLA Printing Process</h2>The SLA printing process begins with a vat of liquid resin. A build platform is lowered into the vat, and a UV laser traces the first layer of the object onto the surface of the liquid resin, causing it to harden. Once the first layer is complete, the build platform moves up, and the process is repeated for the next layer. As with FDM, printer control comes from a sliced part design which is converted into printer instructions.The final product created by the SLA printer is a solid object that has been built up from successive layers of cured resin. The object is typically attached to a support structure during printing to prevent deformation or displacement. After printing, the object requires post-processing, which includes removing the support structures, washing the object to remove excess resin, and <a href="https://www.wevolver.com/article/knowing-how-long-to-cure-resin-prints" target="_blank" rel="noopener noreferrer">curing the object under UV light to ensure complete solidification</a>.The quality and characteristics of the final product can be influenced by various factors, including the type of resin used, the layer thickness, the laser power, and the exposure time. By adjusting these parameters, it is possible to control the mechanical properties, dimensional accuracy, and surface finish of the printed object.<h2 dir="ltr">Applications of SLA</h2>Stereolithography (SLA) has a wide range of applications across various industries, primarily due to its high precision and ability to produce parts with smooth finishes and intricate details.In the medical and dental industries, SLA is extensively used due to its high precision and the availability of biocompatible resins. It is used to create dental models, surgical guides, and hearing aids. Detailed anatomical models can be created for pre-surgical planning, helping surgeons visualize complex procedures beforehand. A well-known user of SLA in this space is Align Technologies, the company behind Invisalign dental braces.In the jewelry industry, SLA is used to create highly detailed and intricate designs. The high resolution of SLA allows for the creation of complex geometries and intricate patterns that would be difficult to achieve with traditional manufacturing methods. These models can then be used to create molds for casting precious metals.In product design and manufacturing, SLA is used for rapid prototyping. Designers can quickly create a physical model of their design, allowing them to test the form, fit, and function of the product before moving to mass production. The smooth surface finish achieved with SLA also makes it ideal for creating prototypes for aesthetic and ergonomic evaluations.In the field of education and research, SLA is used for creating accurate 3D models for study and demonstration. The high resolution and accuracy of SLA make it ideal for creating detailed models that accurately represent complex structures and systems.<h1 dir="ltr">FDM vs SLA: A Side-by-Side Comparison</h1><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2ODYyNTk1NzgzLTNkLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="SLA parts">SLA parts can provide better detail and surface finishWhen comparing FDM vs SLA, it's essential to consider various factors such as cost, speed, precision, material options, and post-processing requirements. Each technology has its strengths and weaknesses.<div dir="ltr" align="left"><table><tbody><tr><td> </td><td>FDM</td><td>SLA</td></tr><tr><td>Cost</td><td>Generally more affordable</td><td>Typically more expensive</td></tr><tr><td>Speed</td><td>Faster for larger, less detailed parts</td><td>Slower, but better for intricate details</td></tr><tr><td>Precision</td><td>Lower resolution, visible layer lines</td><td>Higher resolution, smooth surfaces</td></tr><tr><td>Material Options</td><td>Wide range of thermoplastic filaments plus composites (reinforced with glass, carbon fiber, etc.)</td><td>Variety of photosensitive resins</td></tr><tr><td>Post-Processing</td><td>Support removal, surface smoothing</td><td>Support removal, washing, curing</td></tr><tr><td>Trusted Printer Models</td><td><ul><li dir="ltr">Creality Ender 3 ($169), hobbyist level</li><li dir="ltr">Original Prusa MK4 ($1,099), intermediate level</li><li dir="ltr">Ultimaker S5 ($6,950), professional level</li></ul></td><td><ul><li dir="ltr">Formlabs Form 3 ($3,499), professional level</li><li dir="ltr">3D Systems SLA 750 ($400,000), industrial level</li></ul></td></tr></tbody></table></div>FDM is often the preferred choice for projects that require a lower cost, faster printing times, and the ability to use a wide range of thermoplastic materials. (Printers with hard nozzles can also process composite materials containing non-plastic additives like chopped carbon fibers.) It is well-suited for producing functional prototypes, large parts, and objects that do not require a high level of detail or surface finish. FDM is also a good choice when the printed object needs to withstand higher temperatures or mechanical stress, as there are a variety of high-strength and high-temperature resistant filaments available.On the other hand, SLA is ideal for projects that demand high precision, intricate details, and smooth surface finishes. In fact, researchers have found that the surface of roughness of SLA parts can be even lower than injection molded equivalents.[3] SLA is particularly useful for creating small, complex parts, such as jewelry, dental models, and highly detailed prototypes. However, it tends to be more expensive and slower than FDM, and the materials used are generally more costly. SLA is also a good choice when the printed object requires a level of transparency.The choice between FDM and SLA also depends on the post-processing capabilities and requirements. FDM parts often require some amount of post-processing to improve the surface finish, while SLA parts require washing and curing after printing, which can be time-consuming and require additional equipment.Recommended reading: <a href="https://www.wevolver.com/article/what-is-3d-printing-a-comprehensive-guide-to-its-engineering-principles-and-applications" target="_blank">What is 3D Printing: A Comprehensive Guide to its Engineering Principles and Applications</a><h1 dir="ltr">Conclusion</h1>Understanding the differences between FDM and SLA 3D printing technologies is crucial for making informed decisions when selecting the most appropriate method for a specific project. Each technology has its unique strengths and limitations, making each one suitable for certain applications. By considering factors such as cost, time, precision, material properties, and post-processing requirements, users can choose the most suitable 3D printing technology for their specific needs and ensure the success of their projects.<h1 dir="ltr">Frequently Asked Questions (FAQs)</h1>What is the main difference between FDM and SLA?FDM uses a thermoplastic filament that is heated and extruded layer by layer to create a 3D object, while SLA uses a UV laser to cure and solidify a liquid resin, also layer by layer.Which technology is more cost-effective, FDM or SLA?Generally, FDM is more cost-effective due to the lower cost of materials and equipment. However, the specific cost-effectiveness depends on the project requirements and the materials used.Which technology is better for creating highly detailed parts?SLA is better suited for creating highly detailed parts due to its higher resolution and ability to produce smooth surface finishes.Can both FDM and SLA print with a wide range of materials?FDM can print with a wide range of thermoplastic filaments and composites, while SLA uses specially formulated photosensitive resins. FDM offers a slightly wider range of material possibilities.What are the post-processing requirements for FDM and SLA?FDM parts often require support removal and surface smoothing, while SLA parts require support removal, washing, and curing under UV light.<h1 dir="ltr">References</h1>[1] Solomon IJ, Sevvel P, Gunasekaran J. <a href="https://www.sciencedirect.com/science/article/abs/pii/S2214785320340645" target="_blank">A review on the various processing parameters in FDM</a>. Materials Today: Proceedings. 2021 Jan 1;37:509-14.[2] Yang Y, Li L, Zhao J. <a href="https://www.sciencedirect.com/science/article/pii/S0264127518308803" target="_blank">Mechanical property modeling of photosensitive liquid resin in stereolithography additive manufacturing: Bridging degree of cure with tensile strength and hardness</a>. Materials &amp; Design. 2019 Jan 15;162:418-28.[3] Özdilli Ö. <a href="https://dergipark.org.tr/en/pub/umagd/issue/60118/762942" target="_blank">Comparison of the Surface Quality of the Products Manufactured by the Plastic Injection Molding and SLA and FDM Method</a>. International Journal of Engineering Research and Development. 2021 Jun 6;13(2):428-37.

Resin and extrusion 3D printers from Prusa Research

FDM vs SLA is one of the most common questions asked by desktop 3D printer buyers. The two technologies have their respective strengths and weaknesses.

FDM vs SLA: Comparing Extrusion and Photopolymerization 3D Printers

The SAE Racing Team of the Munich University of Applied Sciences designs and builds its own racing car from scratch every year as part of the Formula Student racing series and participates in events all over Europe. The high demands on individually manufactured components and the material properties make 3D printing indispensable for the development of motorsport. We were able to accompany Niklas Rösler and his team at the largest Formula Student event at the Hockenheimring.<iframe width="640" height="360" src="https://www.youtube.com/embed/mJ_uzANMilk?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</iframe><div data-id="c66a2bb" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Picking up speed in your studies</h2></div><div data-id="a063078" data-element_type="widget" data-widget_type="text-editor.default">The interdisciplinary team of <a href="https://munichmotorsport.de/" target="_blank">munichmotorsport</a> is made up of about &nbsp;40 students from different faculties and disciplines of the <a href="https://www.hm.edu/en/index.en.html" target="_blank">Munich University of Applied Sciences</a>. From automotive, electrical and mechanical engineering to business administration, design, and marketing, the team bundles its competencies to fulfill all disciplines of the <a href="https://www.formulastudent.de/fsg/" target="_blank">Formula Student</a> racing series. In one of the biggest engineering competitions of the world, approximately 100 teams not only compete against each other on the race track but also have to prove their skills in static disciplines such as business planning and cost calculation.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MDg3NTY3LTE3MDY2ODUwODc1NjcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 768px;" class="fr-fic fr-dib">Every year, around 100 teams take part in the largest Forumula Student Event at the Hockenheimring in Germany.<h2>Unique rapid prototypes thanks to SLS 3D printing</h2><div data-id="fbef267" data-element_type="widget" data-widget_type="text-editor.default">Almost all the parts needed for the interior of the fully electric race car are one-offs that have to be manufactured over a short period of time. '3D printing offers the best prototyping platform for us to manufacture, our housings and brackets built into the car', explains Niklas Rösler. The engineering student was in charge of the car’s high-voltage system this year.&nbsp;Due to their complex geometry, many of the required components are usually impossible or very cost-intensive to realize using conventional manufacturing technologies. 'SLS 3D printing is the most suitable prototyping technology for us. We can use it in almost every situation around the car', Rösler notes.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MTUxNTI1LUZTVF9NdW5pY2gtRmVhdHVyZUltYWdlLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 302px;" class="fr-fic fr-dib">The Munich motorsport team busy in the pits preparing the car for the dynamic disciplines.“SLS 3D printing is the most suitable prototyping technology for our racing team. We can use it in almost every situation around the car.” - Niklas Rösler, Prototyping Technician, munichmotorsport. <h2>Stable and safe with PA12</h2><div data-id="2c67180" data-element_type="widget" data-widget_type="text-editor.default">SLS 3D printing meets the requirement for almost all applications in the car. &nbsp;One of Rösler’s tasks was to make sure that the battery cells are well stored and that the cooling of the system is also guaranteed. To that end he developed housings which were subsequently 3D printed with <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank">PA12</a> and on the <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s3/" target="_blank">Sintratec S3</a>. This component stabilizes the individual battery cells in the vehicle’s rear and ensures a firm hold during rapid load changes and three-dimensional force application.&nbsp;For use in electric vehicles, dielectric strength plays a very important and safety-relevant role. For cooling the entire system, spacers, also made of PA12, are used to regulate the airflow. 'The PA12 material from Sintratec covers most areas of application in the race car. It offers the best mechanical properties for our purposes and high dielectric strength', Rösler says.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MTg4NzA4LUN1c3RvbWVyU3RvcnlQaWN0dXJlX0ZTR19NdW5pY2hfSW5zZXJ0VGhlQmF0dGVyeV93ZWIuanBnLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 302px;" class="fr-fic fr-dib">3D printed components for the high-voltage system made with PA12.<h2>Constant potential for improvement</h2><div data-id="fc3658e" data-element_type="widget" data-widget_type="text-editor.default">The race weekend of the Formula Student main event was visibly exhausting for Niklas Rösler and his team, but successful. After initial technical problems, the team achieved a good run in the autocross and also scored plenty of points in the static disciplines. In the overall standings, the team secured 20th place out of 71 participating teams in the electric class.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MjE5NTc5LTE3MDY2ODUyMTk1NzkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">'We are very proud of the performance and the design of the car, and above all, of what we have achieved and accomplished as a team in the past year,' Rösler sums up. He and his team are sure to rely on 3D printing again next year</div></div></div></div>