<p id="isPasted">Consider the following details when conducting power profiling:</p><ol start="1" type="1"><li>Hardware and sensor configurations: Analyze the components and sensors used in the device and their power consumption characteristics.&nbsp;Understand how different hardware configurations impact energy usage.</li><li>Firmware settings: Examine the firmware settings and configurations to identify any potential areas where power consumption can be optimized. Adjust settings and parameters to achieve more efficient power usage.</li><li>Communication parameters: Evaluate the communication parameters used by the device, such as transmission frequency and data rate. Analyze how different communication settings affect power consumption and battery life.</li><li>Use cases and corner cases: Consider the different use cases and scenarios in which the device will be deployed. Investigate how the device's behavior and power consumption vary under different conditions. Pay special attention to corner cases that may have unique power consumption patterns.</li></ol><p>Continuous benchmarking is crucial throughout the product development process. Utilize UART clever printouts and correlate them with power consumption to identify specific components or features that may be draining energy. This analysis will provide valuable insights on areas that can be optimized for improved power efficiency. Remember to turn off UART once the analysis is complete to avoid any impact on the final product.</p><p>Additionally, consider network variables that can impact power consumption. Import network log files to understand how factors like distance to the gateway or Node B, weather conditions, and device density within the network influence power consumption. These variables can significantly affect how the battery is drained and should be taken into account when estimating battery life.</p><p>By iteratively calculating battery life based on power consumption profiles throughout the development project, developers gain valuable knowledge and intuition about the factors that affect the power profile. This understanding allows them to maintain the desired power profile despite changes in the development stack, ensuring optimal power usage and battery life.</p><h2><strong>Refined battery selection with battery profiling</strong></h2><p>Understanding the power consumption behavior of an IoT device goes beyond relying solely on data sheet information. It involves conducting a critical analysis to assess the battery's performance in the unique scenario relevant to your project. This process provides insights into the battery's efficiency, stability, and suitability for the deployment.</p><h2 id="isPasted"><strong>Defining a Battery Profile</strong></h2><p>A battery profile is not just a general overview; it is a tailored description of how a battery discharges under specific loads in particular environments. You can find such profiles in the battery's data sheets. To select the ideal battery for your solution, you need to <a href="https://www.qoitech.com/battery-toolbox/" target="_blank">create profiles</a> that align with your device's power requirements. Additionally, it is beneficial to profile several battery alternatives from different brands, batches, and temperatures to gain a thorough understanding of their behavior.</p><p><img border="0" width="605" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713351007606-1713351007606.jpeg" alt="En bild som visar skärmbild, Multimedieprogram, programvara, GrafikprogramvaraAutomatiskt genererad beskrivning" class="fr-fic fr-dii"></p><p>By following these steps, you can gain a deeper understanding of the power consumption behavior of your IoT device and make informed decisions when selecting the most appropriate battery for your project.</p><h2><strong>Accelerated Battery Profile</strong></h2><p>To create a battery discharge profile that aligns with your device's current consumption profile, you may need several months or even years. Thus, it is essential to develop an accelerated discharge profile. Here are some best practices to create an accurate and helpful profile:</p><p><strong>Maintain High Discharge Consistency:</strong> Coin cell batteries are particularly sensitive to high discharge, so it is crucial to match your device's peak current. Lithium-ion rechargeable batteries can withstand higher discharge currents, while alkaline batteries fall in between.</p><p><strong>Shorten Cycle Time</strong>: Determine the low discharge time the battery requires to recover.</p><p><strong>Increase Sleep Current</strong>: Ensure the battery can recover even in high discharge. Consult with Manufacturers: Seek assistance from battery manufacturers to verify your assumptions for the batteries you want to profile.</p><h2><strong>Accuracy Considerations</strong></h2><p>It's worth noting that precisely matching the discharged energy in the accelerated profile to the original profile may not be feasible, which could affect the profile's accuracy. The less acceleration used, the more accurate the results, but this method's level of accuracy is usually adequate for IoT implementations. It ensures a comprehensive real-world understanding of the battery's performance, contributing to successful IoT solutions.</p><h2><strong>Profiling Different Battery Chemistries</strong></h2><p>Here is an example from a customer case with LoRaWAN waste management IoT device. For this specific application, we profiled two distinct electro-chemistries encompassing six brands, including multiple samples from each brand. The profiling was carried out at room temperature, using an accelerated battery profile developed with input from battery manufacturers. Comparing samples from multiple manufacturers allowed us to evaluate how different form factors and chemical compositions influenced the results. Profiling the batteries in various environments could be the next logical step to observe the available capacity deviation from these controlled profiles, given that the profiling occurred at room temperature.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713351055997-otii-arc-battery-profiling.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Battery profiling set-up with Otii Arc Pro</em></span></span></span></p><p id="isPasted"><strong>Battery Profile Analysis</strong></p><p><strong>LM17500</strong>: Three samples of this battery were profiled, yielding an average capacity of approximately 3050 mAh before reaching the cut-off point, slightly higher than the data sheet capacity of 3000 mAh.</p><p><strong>CR123A</strong>: Two batteries were profiled, with an average capacity of about 1600 mAh, consistent with the data sheet for that specific temperature.</p><p>Interestingly, alkaline batteries exhibited significant variations in available capacity based on the manufacturer, which is a crucial consideration if customers will be responsible for battery replacement.</p><p><strong>AAA</strong>: These batteries had capacities ranging from 1080 to 1150 mAh, with an average of around 1100 mAh. The data sheet indicated a capacity of 1200 mAh.</p><p><strong>AA</strong>: The AA batteries showed a wider range of capacities, from 2420 to 2730 mAh, with an average of approximately 2590 mAh. For example, the data sheet for Varta indicated a capacity of 2950 mAh.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713351084975-battery.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Batteries profiled in this study</em></span></span></span></p><p>Our profiling process identified performance nuances across different battery brands, chemistries, and form factors. These insights are crucial for making informed decisions specific to the device and use case, going beyond the data sheet capacities. Conducting profiling in diverse environmental conditions, particularly temperature, could further enhance our understanding and contribute to a more resilient IoT device design. You want to see more details from this study? Download the <a href="https://www.qoitech.com/whitepaper/powering-iot-devices/" target="_blank" id="isPasted">white paper</a>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713351110704-picture6.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Battery profiles graphed for lithium manganese batteries from Saft and GP.&nbsp;</em></span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713351132266-picture7.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Battery profiles graphed for alkaline batteries (AA and AAA) from five different brands.</em></span></span></span></p><h2 id="isPasted"><strong>Replaying the Battery Profiles</strong></h2><p>Accurately measured battery profiles provide a more realistic and tailored understanding of the battery's capacity for a specific application, surpassing the information provided in mere data sheets when estimating battery life. By directly applying the profiled battery discharge to the device instead of using a standard power supply, you can determine the actual usable capacity and further enhance the accuracy of the estimation. The actual usable capacity depends on the behavior of the device itself, and in some cases, we have encountered as low as 20% of the measured capacity. Tools such as <a href="https://www.qoitech.com/otii-ace/" target="_blank">Otii Ace Pro</a> with <a href="https://www.qoitech.com/battery-toolbox/" target="_blank">Battery Toolbox</a> can replicate these battery profiles, effectively serving as profiled batteries for the IoT device. By adjusting the used capacity in the battery emulator of these instrumentsand monitoring when the device either shuts down or reboots, you can uncover the true, realistic usable capacity. This ensures a more precise understanding of the battery's potential in the context of the specific application.</p><p><span class="fr-img-caption fr-fic fr-dii" style="width: 758px;"><span class="fr-img-wrap"><img border="0" width="605" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713351148170-1713351148170.png" alt="Battery emulation with OtiiBattery Toolbox. MEasured and saved battery profile can be replayed to mimic the actual usable capacity and battery behaviour." class="fr-fic fr-dii"><span class="fr-inner"><em id="isPasted">Battery emulation with Otii Battery Toolbox</em></span></span></span></p><h2><strong>Conclusion</strong></h2><p>We propose a technique for selecting the ideal battery: initial selection based on a defined use case and data sheet, power profiling of the IoT device and the battery for the use case, and a refined battery selection using device power behavior to assess the battery's real-world performance for the specific use case and device. This nuanced approach enables developers to make well-informed decisions that boost battery life.</p>

Once the first prototype of your IoT device becomes available, it is essential to start power profiling and estimating battery life. This process involves gaining a comprehensive understanding of the device's configuration and power consumption characteristics within its specific deployment context.

How to pick the right battery for an IoT device: A waste management case study

<h2 id="isPasted">Understanding Rapid Prototyping</h2><p>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.</p><p>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.</p><p>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.</p><h2>The BOEN Difference</h2><p>BOEN distinguishes itself in the rapid prototyping industry through a blend of proprietary techniques and state-of-the-art technology. Their advanced approach combines:</p><p><strong>Innovative Workflows:</strong> 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.</p><p><strong>Advanced Hardware:&nbsp;</strong>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.</p><p>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.</p><h2>Practical Impacts on the Industry</h2><h3>Streamlining the Design to Manufacturing Pipeline</h3><p>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.</p><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><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"><span class="fr-inner">5-axis CNC machines allow BOEN to deliver rapid prototyping at low volume. Credit: BOEN.</span></span></span></p><p>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.</p><p>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.</p><p>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.</p><h3>Opening Doors for Startups and Innovators</h3><p>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.</p><p>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.</p><p>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.</p><p>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.</p><p>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.</p><h2>Beyond Prototyping: The Future with BOEN</h2><h3>From Prototyping to Low-Volume Production</h3><p>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:</p><p><strong>Detailed Planning:</strong> Establishing a clear roadmap from prototype to production, considering timeframes, budget, and resource allocation.</p><p><strong>Material Selection and Sourcing:</strong> Choosing materials that balance cost, performance, and availability for low-volume runs.</p><p><strong>Manufacturing Technique Adjustment:</strong> Shifting from prototyping methods to those more suitable for small-scale production without compromising quality.</p><p><strong>Quality Control Systems:</strong> Implementing stringent quality control measures adapted for low-volume production to ensure each unit meets the high standards set during prototyping.</p><p><strong>Logistics and Supply Chain Management:</strong> Optimizing logistics to handle the distribution of smaller product quantities, managing supply chain relationships to ensure timely delivery of materials.</p><p>BOEN supports businesses through this transition by leveraging its expertise in both rapid prototyping and small-scale manufacturing. Their support encompasses:</p><p><strong>Consultation and Strategy:&nbsp;</strong>Advising on the best pathways for scaling production in a cost-efficient manner while maintaining product quality.</p><p><strong>Custom Manufacturing Solutions:&nbsp;</strong>Offering tailor-made manufacturing solutions that address the unique challenges of low-volume production.</p><p><strong>Quality Assurance:&nbsp;</strong>Ensuring that the quality established during the prototyping phase is maintained or enhanced as production scales.</p><p><strong>Supply Chain Optimization:&nbsp;</strong>Assisting in creating a responsive and efficient supply chain tailored to the needs of small-scale production.</p><p>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.</p><h2>Empowering Innovation Across Industries</h2><p>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.</p><p>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.</p><p>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.</p><p>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.</p><p>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.</p><h2>Conclusion</h2><p>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;</p><p><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;</p>

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

<p dir="ltr" id="isPasted">Designing parts for CNC machining may seem straightforward—raw materials is removed from a solid block to create the desired shape. However, there are many ways your designs can encounter issues may arise from parts that are not designed with manufacturability in mind.</p><p dir="ltr">We conclude some of the most critical issues, that our engineering experts frequently meet in quote requests. Avoiding the issues will help you improve your part design, shorten lead time, and even perhaps save some costs along the way.&nbsp;</p><h2 dir="ltr">Avoid the Sharp Internal Corners</h2><p dir="ltr">Not all features are achievable, a typical example is an internal angle of 90°. See Figure-1. This is because all current CNC milling tools have a cylindrical shape, which creates a rounded edge instead of a straight or sharp angle when cutting along the edges of the machined cavity. If a straight angle must be retained, the usual approach is to use EDM (electrical discharge machining), which is a more expensive manufacturing process than CNC machining.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909572420-1712909572420.png" width="602" height="157" id="isPasted" class="fr-fic fr-dii"></p><h2 dir="ltr" id="isPasted">Avoid Designing Thin, Tall Walls</h2><p dir="ltr">When designing for CNC machining, it is important to avoid designing excessively thin or tall walls. While thin walls may be necessary for certain projects, it is important to note that studies have shown that wall thickness is proportional to the stiffness of the material, which can impact the achievable accuracy due to vibrations during machining. The standard minimum thickness for walls is 0.8 mm for metals and 1.5 mm for plastics. See Figure-2, tall walls may result in issues such as undesirable surfaces, difficulty in meeting part tolerances, and the risk of chipping, bending, or breaking. A good rule of thumb for walls is a width-to-height ratio of 3:1.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909612525-1712909612525.png" width="602" height="179" id="isPasted" class="fr-fic fr-dii"></p><h2 dir="ltr">Avoid Parts with Unnecessary Tight Tolerances</h2><p dir="ltr">Although CNC machining can tolerate some of the tightest tolerances in manufacturing process, it doesn't mean that every part needs to have the strictest tolerances. In fact, using tight tolerances only when absolutely necessary can greatly reduce costs. As precision requirements increase, more precision manufacturing processes are needed, leading to lower production efficiency and higher costs.</p><p dir="ltr">&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909593141-1712909593141.png" width="602" height="212" class="fr-fic fr-dii"></p><p dir="ltr">But sometimes, the flawless assembly can be achieved through creating reasonable gaps, simplifying assembly relationships, and using positioning features. In addition, it is also important to maintain same tolerancing as this would reduce machining time. See an example in Figure-3.</p><h2 dir="ltr">Avoid the Small and Deep Holes, and the Curved Holes</h2><p dir="ltr">The small, deep holes should be avoided as they can cause drill breakage and make chip removal difficult. The ratio of hole depth to diameter should not exceed 3, and one method to avoid deep holes is to use stepped holes. Blind holes require an additional 25% of hole depth for chip storage. Additionally, the curved holes cannot be machined using CNC methods. However, if this feature is required in your design, Electrical Discharge Machining (EDM) can be used to achieve, with the raised production cost along the way.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909593562-1712909593562.png" width="602" height="355" class="fr-fic fr-dii"></p><h2 dir="ltr">Avoid the Deep Cavity</h2><p dir="ltr">There is a certain proportional limit to the machining depth of CNC cutting tools, and the best machining performance is achieved when the cavity depth is 2-3 times the diameter of the tool. Of course, it is possible to machine deeper cavities, up to a maximum of 4 times the tool diameter, but this will increase costs, especially when using multi-axis CNC machine tools. For example, a milling cutter with a diameter of 12mm can safely machine a cavity with a maximum depth of 25mm, not exceeding 48mm. See Figure-5.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909593090-1712909593090.png" width="598" height="361" class="fr-fic fr-dii"></p><h2 dir="ltr">Summing it Up</h2><p>Of course, no one single design tip can address every practical design issues. For additional assistance, feel free to CONTACT US, and you can get the in-depth and customized design analysis. To get your next design project started today, simply Upload a 3D CAD model now.</p>

Optimize part design to reduce CNC machining time and cost

5 Mistakes to Avoid When Designing Machined Parts

<p id="isPasted">When it comes to finishing options for aluminium parts, the choices can be baffling. Two standout methods, powder coating and anodizing, often find themselves at the centre of the debate. But what exactly sets them apart?</p><p>Whether in the automotive industry, aviation, or just curious, understanding these methods will equip you with the knowledge to choose your specific needs.</p><h2 data-counter-attr="value0"><strong>What is Powder Coating?</strong></h2><p>Powder coating is a finishing technique where a dry, free-flowing powder is applied to a surface, typically aluminium, with a spray gun. The powder adheres to the metal surface through electrostatic application before being cured under heat, forming a tough, uniform layer.</p><h3 data-counter-attr="value1"><strong>Benefits and Key Features</strong></h3><ul><li><strong>Durability</strong>: A powder coat creates a hard finish that’s more resistant to scratching, chipping, and corrosion than traditional paints</li><li><strong>Variety</strong>: Many colours and textures are available, offering great versatility</li><li><strong>Cost-effective</strong>: Though the initial setup may be expensive, the long-term benefits make it cost-efficient</li><li><strong>Environmentally friendly</strong>: This process emits few <a href="https://www.epa.gov/indoor-air-quality-iaq/what-are-volatile-organic-compounds-vocs#:~:text=Volatile%2520organic%2520compounds%2520are%2520compounds,paints%252C%2520pharmaceuticals%252C%2520and%2520refrigerants." target="_blank" rel="noreferrer noopener">volatile organic compounds (VOCs)</a>, making it a greener choice</li></ul><h3 data-counter-attr="value2"><strong>Common Applications</strong></h3><ul><li>Used for coating wheels, bumpers, and other parts for enhanced aesthetics and protection</li><li>Found in appliances and gadgets for a sleek, durable finish</li><li>It is ideal for coating window frames, railings, and other building elements</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909242472-CNC-machined-and-powder-coated-part-768x513.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CNC machined and powder coated part</span></span></span></p><h2 data-counter-attr="value3" id="isPasted"><strong>What is Anodizing?</strong></h2><p>Anodizing is an electrolytic process that forms a protective oxide layer on the surface of aluminium. A robust, corrosion-resistant layer is created by submerging the aluminium in an acid electrolytic bath and passing an electric current through it. This natural oxide layer is not merely a coating but is integrated with the underlying aluminium, providing a strong bond.</p><h3 data-counter-attr="value4"><strong>Benefits and Key Features</strong></h3><ul><li><strong>Strength and durability</strong>: Unlike other coatings, anodized aluminium doesn’t peel or chip, offering lasting protection</li><li><strong>Aesthetic flexibility</strong>: Anodizing allows for colouring and decorative finishes, providing a broad palette of options</li><li><strong>Enhanced adhesion</strong>: The process allows for better adhesion for paints and glues.</li><li><strong>Non-toxic</strong>: The process uses non-hazardous materials and is generally considered more environmentally friendly</li></ul><h3 data-counter-attr="value5"><strong>Common Applications</strong></h3><ul><li>Anodizing is vital in aviation, where weight and durability are key considerations</li><li>Used in surgical instruments and other medical devices due to its resistance to wear and biological contamination</li><li>Kitchen utensils and cookware often utilise anodizing for a smooth, non-reactive surface</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909260643-Sheet-Metal-Aluminium-anodising-768x512.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Sheet metal aluminium anodizing</span></span></span></p><h2 data-counter-attr="value6" id="isPasted"><strong>Powder Coating and Anodizing Comparison</strong></h2><h3 data-counter-attr="value7"><strong>Cost</strong></h3><p>When evaluating cost, several factors come into play. Powder coating often has higher initial equipment and setup costs. Still, it can be more cost-effective in the long run, particularly for large-scale projects.</p><p>On the other hand, anodizing typically has lower entry costs but may be more expensive for custom colours and finishes. Ultimately, the price will depend on the specific requirements and scale of the project.</p><h3 data-counter-attr="value8"><strong>Durability</strong></h3><p>Durability is a vital consideration in choosing a surface treatment. Powder coating provides a robust surface that’s resistant to chipping and scratching. Its uniform coating ensures all-around protection.</p><p>Anodizing, however, takes it further by integrating the protective layer into the aluminium. This results in a finish that doesn’t peel or chip, offering long-term resilience. Both methods are highly durable, but anodizing may provide a slight edge regarding wear resistance.</p><h3 data-counter-attr="value9"><strong>Corrosion Resistance</strong></h3><p>Both powder coating and anodizing offer substantial protection in terms of corrosion resistance. A powder coat forms a sealed, continuous layer that prevents oxidation and corrosion.</p><p>By creating a thick oxide layer, anodizing also offers robust corrosion resistance. While both methods are highly effective, anodizing’s integrated oxide layer might provide more consistent and long-lasting protection against corrosion, especially in aggressive environments.</p><h3 data-counter-attr="value10"><strong>Comparison Table</strong></h3><table id="isPasted"><thead><tr><th>Characteristics</th><th>Anodizing</th><th>Powder Coating</th></tr></thead><tbody><tr><td>Type</td><td>Electrochemical process</td><td>Electrostatic process</td></tr><tr><td>Cost</td><td>High</td><td>Moderate</td></tr><tr><td>Durability</td><td>Excellent</td><td>Good</td></tr><tr><td>Corrosion Resistance</td><td>Excellent</td><td>Good</td></tr><tr><td>Colour Options</td><td>Limited colours</td><td>Wide range of colours</td></tr><tr><td>Surface Finish</td><td>Matte or satin texture</td><td>Glossy, matt, or satin textures</td></tr><tr><td>Colour Fading Resistance</td><td>Poor</td><td>Excellent</td></tr><tr><td>Eco-friendliness</td><td>Good</td><td>Excellent</td></tr></tbody></table><h2 data-counter-attr="value11" id="isPasted"><strong>Application-Specific Considerations</strong></h2><h3 data-counter-attr="value12"><strong>Architectural Applications</strong></h3><p>When it comes to architectural applications, both powder coating and anodizing have their merits. Powder coating’s wide range of colours and textures makes it versatile for adding an aesthetic touch to window frames, railings, and other architectural elements.&nbsp;</p><p>On the other hand, anodizing offers a unique advantage with its corrosion-resistant properties. This makes it particularly suitable for structures in coastal areas where the salty air can accelerate corrosion.&nbsp;</p><p>Anodizing might lead in this context, providing enhanced protection against the elements.</p><h3 data-counter-attr="value13"><strong>Consumer Electronics</strong></h3><p>In the realm of consumer electronics, the coating process shines. Its sleek and attractive finish enhances the aesthetics of gadgets. At the same time, its scratch-resistant nature ensures that everyday wear and tear don’t mar its appearance.</p><p>The versatility in colours and textures allows manufacturers to match the finish with the product’s design. While robust, anodizing might not offer the same array of customisation options as powder coating, making powder coating the preferred choice for consumer electronics.</p><h3 data-counter-attr="value14"><strong>Automotive Industry</strong></h3><p>In the automotive industry, both powder coating and anodizing find their niches. Powder coating’s durability makes it popular for coating wheels, bumpers, and other metal products that withstand harsh road conditions.&nbsp;</p><p>On the other hand, anodizing’s corrosion resistance makes it valuable in areas where vehicles might be exposed to corrosive elements, such as road salt. The choice here might depend on whether durability or corrosion resistance is the higher priority.</p><h3 data-counter-attr="value15"><strong>Aviation and Aerospace Applications</strong></h3><p>For aviation and aerospace applications, the corrosion-resistant properties of anodized aluminium shine. In an industry where weight, durability, and corrosion resistance are paramount, anodizing’s ability to provide all three qualities makes it a top choice.&nbsp;</p><p>The protective oxide layer helps extend the lifespan of crucial components, ensuring the safety and performance of aircraft.&nbsp;</p><p>The unique demands of aviation and aerospace applications often make anodizing the preferred option.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909300406-Powder-coating-vs-anodising-1-768x513.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Powder coating (left) vs anodizing (right)</span></span></span></p><h2 data-counter-attr="value16" id="isPasted"><strong>How to Choose Between Powder Coating and Anodizing?</strong></h2><p>A thoughtful evaluation of multiple factors becomes crucial when deciding whether to opt for powder coating or anodizing for aluminium finishing. In this intricate selection process, aesthetics, environment, and function are pivotal considerations.</p><h3 data-counter-attr="value17"><strong>Aesthetics</strong></h3><p>One must assess the desired visual appeal of the finished product. A powder coat can have various colours and textures, catering to diverse design preferences.&nbsp;</p><p>On the other hand, anodizing’s colour options, though limited, provide a more lasting and integrated appearance. The choice hinges on balancing immediate visual impact and long-term colour retention.</p><h3 data-counter-attr="value18"><strong>Environment</strong></h3><p>The surrounding environment significantly impacts the durability and longevity of the chosen finish. Suppose the aluminium parts are expected to endure corrosive atmospheres or extreme weather conditions. In that case, anodizing’s inherent corrosion resistance offers a distinct advantage.</p><p>Powder coating’s robustness remains undeniable, yet its vulnerability to chipping might necessitate an extra layer of protection in harsh environments.</p><h3 data-counter-attr="value19"><strong>Function</strong></h3><p>The function of the aluminium component must dictate the choice of finish. If the part is exposed to mechanical stresses or potential abrasion, powder coating’s scratch-resistant nature could be instrumental.&nbsp;</p><p>Meanwhile, if corrosion prevention is paramount, anodizing’s integrated oxide layer becomes indispensable.</p><h3 data-counter-attr="value20"><strong>Expert Opinion</strong></h3><p>In this intricate decision-making process, the role of experts cannot be overstated. Engaging with professionals who possess comprehensive knowledge of both finishing methods is essential.&nbsp;</p><p>These experts can evaluate the unique demands of each project, ensuring that the selected finish aligns optimally with its intended application.</p><h2 data-counter-attr="value21"><strong>Conclusion</strong></h2><p>The choice between powder coating and anodizing in aluminium finishes transcends mere aesthetics. It’s a decision that directly impacts durability, corrosion resistance, and overall functionality.</p><p>As we’ve navigated the intricacies of these processes, the significance of informed decision-making has become clear. Powder coatings and anodizing present distinct advantages, each catering to specific requirements.</p><p>Powder coating offers a broad spectrum of colours and robust protection against scratching, making it a strong contender. On the other hand, anodizing embeds corrosion resistance into the very structure of the aluminium, ensuring a longer lifespan.</p><p>In the dynamic landscape of surface treatment, Xometry emerges as a versatile and reliable service provider, offering powder coating and anodizing solutions. With a commitment to precision and excellence, Xometry caters to a diverse range of industries, fulfilling the nuanced requirements of each project.</p>

In a world where quality and durability are paramount, selecting the right finish for an aluminium surface is more than a mere aesthetic choice. This article aims to clear the fog by providing a head-to-head comparison of powder coating and anodising processes.

Powder Coating vs. Anodizing for Aluminium

<p dir="ltr" id="isPasted">Since its founding nearly 25 years ago, welding specialist<a href="https://www.elektrolas.com/en/" target="_blank">&nbsp;Elektrolas</a> has evolved from a company that supplies and maintains welding equipment to one that also offers training and quality management services and, most recently, welding automation services. In parallel to this expansion, the Dutch company has also evolved in terms of the technologies it uses. Notably, it has embraced the use of 3D printing (specifically,<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s5/" target="_blank">&nbsp;UltiMaker’s S5 ProBundle</a>), which has enabled it to improve automated welding setups and streamline operations.</p><h2 dir="ltr">The road to 3D printing adoption</h2><p dir="ltr" id="isPasted">Like many companies familiar with more conventional production techniques, Elektrolas did not immediately recognize the benefits of integrating 3D printing into its processes. It took Thije van Delft, Technical Manager at Elektrolas, to invest in the technology himself and test out how it could be used in a welding context.</p><p dir="ltr">He says: “I had done some tests in school using 3D printers, and I asked the company owner [Joost van den Hooven] if I could buy one. He said it wasn’t possible, so I said ‘I will buy one myself’ and purchased a very simple 3D printer for a couple hundred euros and started with that. We did some tests and after some time, Joost was convinced”. From there, Elektrolas consulted with the engineering students participating in traineeships at the company (who were familiar with 3D printing through their studies) about which 3D printer hardware they should invest in. After much deliberation, UltiMaker’s S5 ProBundle was chosen.</p><h2 dir="ltr">Unlocking new applications</h2><p dir="ltr">The UltiMaker 3D printer has played an important role at the company, particularly as Elektrolas has ramped up its automation department (spearheaded by van Delft), supplying robotic and cobot welding systems to customers in the Netherlands and beyond. To date, the company has sold and installed dozens of cobot welding systems, which empower its customers to accelerate their lead times and achieve consistent quality, all while mitigating labor shortages in the welding sector.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjMzMTE3NjI2LWluc2lkZXdlbGQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Thije van Delft with the UltiMaker S5 ProBundle, and the cobot welding rig in the back.</span></span></span></p><p dir="ltr" id="isPasted">3D printing has come into play in the production of clamps, which are installed on welding cobots to keep things running smoothly and to ensure the freedom of movement of the robotic arm. Van Delft explains: “We have a holder and an arm clamp that attach the torch hose to the robot. This is made up of two parts: one part that clamps to the robot and one part that attaches to the hose. These are fixed with a fixing pin. If you wanted to make that using milling or other conventional processes, it would not be possible.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2NzgwMjQ1LWxvdyBpbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The complex form of the clamp makes it perfect to be 3D printed at a cost and timeframe impossible to replicate in other manufacturing methods. Image credit: Elektrolas.</span></span></span></p><p dir="ltr" id="isPasted">The company has also found it possible to quickly iterate replacement parts for the 3D printed clamps. Made from Tough PLA, it does happen that the clamps break sometimes. “In this case it’s very easy to print a new one and send it the next day to the customer,” van Delft says. “The customer simply sends a picture of what part is broken, we start the printer, and the next day we can send it via DHL to the customer.” This, of course, has the obvious benefit of eliminating the need for large inventories of spare clamps, since they can be printed on demand.</p><p dir="ltr" id="isPasted">Elektrolas has also turned to 3D printing in the production of temporary holders that attach hand welding torches to robotic or cobot systems. In this case, UltiMaker’s solution enabled Elektrolas to meet the needs of one of its customers who wanted to integrate a manual welding torch in an automated system. “We called the supplier of this welding torch, but the automatic version had a delivery time of 10-12 weeks,” van Delft recalls. By designing and 3D printing a holder to attach the welding torch to the robot, Elektrolas was able to offer its customer a stopgap solution while they waited for the final part from the welding torch supplier. This enabled them to keep their automated welding production up and running rather than being setback by system downtimes.</p><h2 dir="ltr">Why the UltiMaker’s S5 ProBundle?</h2><p dir="ltr">While both UltiMaker and Elektrolas are based out of the Netherlands, the local appeal was only part of the equation when the welding company started looking for a 3D printing solution to adopt three years ago. UltiMaker’s S5 ProBundle is a professional-grade solution that combines UltiMaker’s reliable dual-extrusion technology with advanced features like automated material management, superior air filtration, and humidity control for filament. The 3D printer also has a sizable print volume (330 x 240 x 300 mm), which was an important factor for Elektrolas as the company often prints large components.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2ODQ0NTY0LWRlZXAgLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Multiple prints can be completed simultaneously in the S5’s large print bed.&nbsp;</span></span></span></p><p dir="ltr" id="isPasted">Ease of use and print quality were also top of mind for van Delft and his team. The UltiMaker S5 ProBundle delivered on both fronts. Elektrolas has achieved consistency from print to print thanks to the ability to save setup and print settings in Cura. As van Delft explains, he and his team are able to design the parts they need in SolidWorks and print them on demand with the touch of a button. This is also thanks to the work of their trainee students, who have pre-programmed print settings, and UltiMaker’s intuitive user interface, which enables one-button printing. “If, for example, a client wants to weld with some special machine but there is no welding torch on the robot, we can take a normal welding torch and sketch a holder in SolidWorks and then print it.” Using this approach, test parts can be delivered the next day.</p><p dir="ltr">In terms of printing materials, Elektrolas is primarily working with<a href="https://ultimaker.com/materials/s-series-tough-pla/" target="_blank">&nbsp;UltiMaker Tough PLA</a>, a technical PLA filament that offers good toughness (similar to ABS), as well as minimal warping and excellent printability at an affordable cost. While not the most robust material in UltiMaker’s portfolio, Tough PLA does meet the needs of the welding company for the clamps and holders. Even the material’s weaknesses have proven to be a benefit. “I have twice received a request for a new 3D printed clamp because the operator of the robot made a mistake and broke the clamp when the torch hit some corner when the robot was moving,” van Delft elaborates. “Here it is good that the clamp breaks, because it protects the torch from breaking. The clamp is not expensive and easy to replace, the torch is not.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2OTA5Mjg1LWxvdyByZXMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The 3D printed clamps enable the welding hoses to be safely secured. By printing in Tough PLA, the clamps are robust but also quick and affordable to replace when needed.</span></span></span></p><p dir="ltr" id="isPasted">Elektrolas also benefits from other features that come with the S5 ProBundle, including Air Manager, an enclosure that provides closed inside-out airflow and filters up to 95% of ultrafine particles (UFPs) generated in the printing process, and the S5 Material Station. This piece of equipment stores and protects up to six spools of filament and offers end-of-filament detection and automatic spool switching, which facilitates lights-out printing. “If you have a big print, it is maybe 35-45 hours of printing,” van Delft adds. “Since we have big prints, the material station can change the PLA by itself and keep the print going until it’s ready the next day.”</p><p dir="ltr">For 3D printer maintenance and technical support, Elektrolas turns to <a href="https://www.makerpoint.nl/nl-nl/" target="_blank">MakerPoint</a>, a Dutch supplier of 3D printing systems and maintenance provider based in Arnhem, Best, and Harlingen.</p><h2 dir="ltr">Intuitive 3D printing for traditional manufacturing</h2><p dir="ltr">Elektrolas is one of many businesses in the traditional manufacturing sphere that has reaped the benefits of UltiMaker’s professional 3D printing solutions. For example,<a href="https://www.wevolver.com/article/eriks-leveraging-3d-printing-to-improve-manufacturing-processes" target="_blank">&nbsp;industrial supplier ERIKS BV</a> relies on UltiMaker systems for a range of applications, including prototyping, tooling, customized jigs and fixtures, and replacement parts. You can find more<a href="https://www.wevolver.com/profile/team.ultimaker" target="_blank">&nbsp;UltiMaker client stories here</a>.</p>

Dutch welding solutions specialist Elektrolas uses the UltiMaker 
S5 ProBundle to minimize machine downtimes and facilitate cobot welding for its customers.


How UltiMaker 3D Printing Supports Automated Welding

<p id="isPasted">Black anodizing refers to the process of anodizing an aluminium part and then dying it black using a suitable dye. This must not be confused with black oxide coating which is unsuitable for aluminium parts. Anodized aluminium has improved wear and corrosion resistance, while black anodized parts have the additional benefits of being light absorbent as well as being able to effectively radiate heat. This article will describe what black anodizing is, how it works, as well as the various pros and cons.</p><h2 data-counter-attr="value0"><strong>What is Black Anodizing?</strong></h2><p>Black anodizing refers to the electrochemical process of blackening an aluminium part by first performing standard anodizing to create a semi-porous aluminium oxide layer. The oxide layer is then dyed black using one of three dyeing techniques: organic dyes, inorganic dye, or electrolytic dyeing using metal salts.&nbsp;</p><p>The metals that can be black anodized are aluminium, magnesium, and titanium. Aluminium, however, is the most common material used for black anodizing. It must be noted that not all grades of aluminium can be black anodized. Only aluminium series 5, 6, and 7 can be anodized.</p><h2 data-counter-attr="value1"><strong>How Does Black Anodizing Work?</strong></h2><p>Black anodizing works by first anodizing the part using the standard anodizing process with either a type II or type III anodizing process. A minimum anodized coating thickness of 25 microns or more is recommended for optimal colourfastness. Once anodized, the part will have a semi-porous surface structure. These pores are utilised to hold the black dye.&nbsp;</p><p>There are three types of dyeing techniques, as described below:</p><ol><li><strong>Organic pigments</strong>: These dyes are dissolved in warm water and then placed into the dye bath. The part is placed into the dye bath and the dye fills in the semi-porous surface of the anodic layer. Typically, black dyeing requires additional dyeing time compared to lighter colours. Organic-dyed parts are not recommended for outdoor usage.</li><li><strong>Inorganic pigments</strong>: These pigments are not soluble in water. Inorganic pigments produce coatings with excellent light fastness. For black anodizing, parts can be produced with inorganic salts of cobalt sulfide.</li><li><strong>Electrolytic dyeing</strong>: After normal anodizing, parts are placed in another electrolysis bath with a solution containing heavy metal salts. The anodic layer acts as the cathode, and a stainless steel electrode is placed in the acid electrolyte bath. The metal salts are then deposited into the bottom of the pores. Nickel, cobalt, and tin salts are used to produce different colours, a proprietary process that produces parts with exceptional colourfastness.</li></ol><p>After dyeing, the pores on the anodic layer must be sealed to prevent colour leaching. Sealing is typically done via hydration of the coating, which closes the pores off by reaction with the anodic layer. Wherever there is a pore, AI2O3H2O is formed; this is less abrasion-resistant than the normal aluminium oxide surface. Alternatively, chemical sealing can be put into effect, for example by using nickel acetate or dichromate sealing.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/LBLV1CPBRRk?&amp;wmode=opaque&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></span></p><p id="isPasted">The time required to black anodize a part depends on the desired anodic layer thickness, the dyeing method, and the post-dye sealing technique. In general, it takes five minutes to anodize 2.5 microns. So to anodize the minimum recommended black anodized thickness of 25 microns will take around an hour. The dyeing process can take up to 20 minutes. However, these time frames also depend on the cleaning and rinsing processes.</p><h2 data-counter-attr="value2"><strong>Applications of Black Anodizing</strong></h2><p>Black anodized aluminium has all the benefits of standard anodized aluminium with the additional benefits afforded by the black colouring. The black anodized aluminium is used in applications where the black coating is beneficial. Here are some applications examples:&nbsp;</p><ul><li>Satellite components that rely on the black anodic coating to&nbsp;</li><li>efficiently radiate heat back into space</li><li>Optical equipment that relies on the ability of black coatings to absorb any stray reflective light</li><li>Architectural trimmings in which the deep black colours are aesthetically pleasing while also having excellent colourfastness, and the surface finish provides improved abrasion resistance.</li></ul><p>An anodized coating can last between 10 and 20 years depending on the application, the thickness of the coating, and whether or not the relevant sealing steps were performed after anodizing. When metal salts are used for dyeing, the colour will not fade. However organic dyes will fade over time.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711444501200-Stack-of-black-anodised-aluminium-extrusion-bars.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Stack of black anodized aluminium extrusion bars</span></span></span></p><h2 data-counter-attr="value3" id="isPasted"><strong>Benefits of Black Anodizing Finish</strong></h2><p>The benefits of black anodizing include increased wear resistance and corrosion resistance. This finish ensures that anodized aluminium parts will not be prone to rust. Rust is typically used to describe the formation of a destructive flaking oxide layer on ferrous metals. When an oxide layer forms on aluminium, it adheres to the metal surface and prevents further oxidation of the base material.</p><p>However, black anodizing has a few additional specific benefits described below:</p><ul><li><strong>Heat emissivity</strong>: Aluminium components are often dyed black to increase their emissivity; applications can include heat sinks as well as satellite components.</li><li><strong>No outgassing</strong>: Black anodized parts, if properly sealed after dyeing, do not undergo outgassing when exposed to a vacuum. This lack of outgassing helps protect sensitive equipment, especially sensitive space-based equipment.&nbsp;</li><li><strong>Colour fastness</strong>: Black anodized parts, especially if dyed with inorganic or metal salts, have excellent colourfastness, which means they will typically maintain their colour when exposed to UV (ultraviolet) light.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711444547421-A-black-anodised-flashlight.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">A black anodized flashlight</span></span></span></p><h2 data-counter-attr="value4" id="isPasted"><strong>Limitations of Black Anodizing</strong></h2><p>While black anodizing stands as a robust finishing process with notable advantages, it is important to acknowledge its inherent limitations. Navigating beyond its sleek black aesthetic and corrosion-resistant properties, certain constraints shape the boundaries of its applicability.</p><ul><li><strong>Surface cracking</strong>: When exposed to thermal cycling, black anodized parts will form cracks in the anodic coating. These cracks are mainly due to the difference in thermal expansion rates of the substrate and the coating.&nbsp;</li><li><strong>Limited materials</strong>: Not all aluminium series can be black anodized. In general, the most commonly anodized aluminium series are 5, 6, and 7, with series 6 being the most commonly anodized.</li><li><strong>Colour fading</strong>: If organic dyes are used, black anodized parts will lose their colour as these dyes are unsuitable for UV light exposure.</li></ul><h2 data-counter-attr="value5"><strong>Summary</strong></h2><p>In conclusion, black anodizing emerges as a versatile and essential process in the manufacturing landscape. Its dual advantages of enhanced corrosion resistance and an appealing black finish make it a preferred choice in industries ranging from aerospace to robotics.</p><p>Xometry provides a wide range of manufacturing capabilities and other value-added services for all of your prototyping and production needs.</p>

Explore black anodising, a key finish in manufacturing, and gain insights into the detailed process from pre-treatment to sealing. Understand its practical applications in industries such as aerospace and robotics, known for its durability and corrosion resistance in components.

Everything You Need to Know About Black Anodizing

<p><a href="https://www.ifam.fraunhofer.de/en.html" target="_blank" id="isPasted">Fraunhofer IFAM</a> – an institute in the renowned Fraunhofer Society – is a recognized leader in the field of Metal Injection Molding (MIM), and is serving companies in the aerospace, energy, maritime and other demanding industries. To support research into new applications while lowering lead-times and costs, Fraunhofer recently decided to implement the Freeform Injection Molding (FIM) process powered by Nexa3D’s <a href="https://nexa3d.com/3d-printers/xip/" target="_blank">XiP Desktop 3D printer</a> and LSPc® technology. This platform enables manufacturers to quickly and cost-effectively prototype complex injection-molded parts before making investments in conventional metal tooling.</p><h2 id="isPasted">The challenge</h2><h3><em>Tooling for metal injection molding is costly and time-consuming to produce</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1MzUyNzcwLUZyYXVuaG9mZXItRklNLXRvb2wtMTgwMHgxMDEzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>In metal injection molding (MIM), metal powder is mixed with a plastic binder to create a feedstock that is then injected into a metal mold. The abrasive nature of the feedstock places high demand on the quality of the tooling, and the complexity of the MIM process typically results in the need for multiple iterations. Fraunhofer wanted to offer companies a path to quickly and cost-effectively test new concepts and turned to Nexa3D and Freeform Injection Molding to provide a solution.</p><blockquote id="isPasted"><p>“Freeform Injection Molding provides us with the perfect tools to support innovative companies as they test out new concepts and materials.”<strong>– Sebastian Hein, Fraunhofer IFAM</strong></p></blockquote><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1Mzk5NjAzLTE3MTEwMTUzOTk2MDMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"></p><h2 id="isPasted">The solution</h2><h3><em>3D printed injection mold tooling using xMOLD resin and Freeform Injection Molding</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDE0OTY3LUdFLUVuZ2luZS1CcmFja2V0LTE4MDB4MTIwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>Fraunhofer was inspired by other companies using <a href="https://nexa3d.com/digital-tooling/" target="_blank">Freeform Injection Molding</a> and decided to introduce the XiP desktop 3D Printer and the xMOLD resin. This compact platform is the ideal solution for printing molds in the product size range typically encountered in MIM, and the xMOLD tooling resin has a strong track record for the molding of high-performance materials.</p><h2 id="isPasted">The benefits</h2><h3><em>2-week design cycle enabled for complex metal parts</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDM4MDI1LUdFLU1ldGFsLUVuZ2luZS1CcmFja2V0LXYyLTE4MDB4MTIwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>By adopting the FIM process using Nexa3D’s XiP 3D printer and xMOLD material, the Fraunhofer IFAM team enables a host of benefits to their clients.</p><p><strong>Rapid Prototyping:</strong> FIM enables Fraunhofer to quickly prototype MIM parts for customer demonstration and validation testing. The material properties of FIM parts have been shown to closely match those produced with conventional steel tools, ensuring accurate performance evaluation.</p><p><strong>Time and Cost Savings:</strong> FIM allows Fraunhofer IFAM to dramatically reduce the time and cost required for pilot tooling production. The XiP printer’s exceptional speed allows for same-day printing and injecting while at the same time enabling cost and time savings exceeding 75% compared with conventional pilot tooling.</p><p><strong>De-risking Development and Innovation:</strong> Fraunhofer IFAM has already demonstrated that FIM is compatible with the gold-standard Catamold feedstocks from BASF, enabling customers to use well-characterized materials for their development and innovation.</p><h2 id="isPasted">Customer Impact</h2><h3><em>Prototype MIM for complex designs demonstrated</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDY5NDU4LUlNR18xNzk5LTc2OHg1MTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>Metal injection molding has suffered from a scarcity of prototyping options. Conventional AM-based approaches, whether powder – or binder-based, cannot be used to evaluate flow paths, in-mold stress patterns or warpage of molded parts during debinding and sintering. As a consequence, injection molders have had to invest in high-cost pilot tools when wanting to validate part designs and process parameters. Already with the first project – modeled around the GE Jet Engine Bracket – Fraunhofer IFAM demonstrated the simplicity, speed and design freedom unlocked with Freeform Injection Molding.</p><p>The Fraunhofer team decided on a bracket design that would be suited for injection molding, and to use a well-known off-the-shelf Catamold 17-4PH feedstock from BASF as the material. A XiP printer cell was used to print the soluble injection mold tooling, and an Arburg 320 injection molding machine was employed to complete the molding.</p><p>The project confirmed several important aspects of Freeform Injection Molding:</p><ul><li>Mold design time shrinks from days to hours, as molds do not have to incorporate split lines, ejector pins or sliding features.</li><li>The manufacturing of test molds can be done in days instead of weeks.</li><li>Injection Molding can be carried out using standard injection molding machines and feedstocks, and delivering a material quality that rivals that of conventional metal injection molding.</li></ul><p>To learn more about Freeform Injection Molding, download the&nbsp;<a href="https://nexa3d.com/case-studies/fraunhofer-case-study/#3d-printed-tooling" target="_blank">3D Printed Tooling Design Guide</a> or&nbsp;<a href="https://nexa3d.com/contact/" target="_blank">reach out</a> for more information.</p>

Research institute adopts Freeform Injection Molding to provide rapid prototyping of complex metal parts

Fraunhofer Speeds Up Metal Injection Molding with 3D-Printed Tooling

<p id="isPasted">SPT Vilecon is a fully integrated provider of development and manufacturing services to the medical device industry, working at the intersection of design, development, and manufacturing to allow customers to move a new product from concept to commercialization, and with inhouse tool building in place to ensure shortest possible lead-times. Certified according to ISO 13485, the European standard governing medical device manufacturing, they provide product development support as well as injection molding and other manufacturing services to a large number of companies in northern Europe.</p><p>Recognizing that speed is always of the essence, SPT decided to implement Nexa3D Freeform Injection Molding. The goal was to help customers shorten times-to-market on complex medical devices in demanding medical-grade materials and to expand on the range of materials that can be quickly and reliably used in prototyping and early device test manufacturing.</p><h2 id="isPasted">The challenge</h2><h3><em>Medical device development requires production-grade prototypes</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5MTgzNDEyLW1lZGljYWwtZGV2aWNlLXByb2R1Y3Rpb24tZ3JhZGUtcHJvdG90eXBpbmctMTgwMHgxMzM5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>Medical device manufacturers face rigorous regulatory requirements when introducing new devices into the market. A medical device needs to be safe and efficient to use for the intended purpose, and it is the job of the manufacturer to demonstrate that a given device meets these essential requirements. To do so, manufacturers must develop elaborate test protocols that evaluate every aspect of device manufacturing and usage, and they must ensure that tests are carried out in a way that accurately represents the conditions that apply for the manufacturing and usage of the finished medical device. The later these tests are carried out, the more severe the consequences are if a test fails. Medical device companies are constantly on the lookout for tools and methods that help them improve early-stage device testing to reduce development risks and costs of rework.</p><p>SPT Vilecon often works with Silicones, a group of materials that are heavily used in the medical device industry due to their excellent chemical resistance, mechanical performance and biocompatibility. However, silicone parts are notoriously difficult to prototype and test, since most grades need to be injection-molded to achieve their full performance.</p><blockquote id="isPasted"><p>“Freeform Injection Molding has enabled us to dramatically accelerate the delivery of production-grade prototypes and low-volume productions in challenging materials and designs.”<strong>– Bjarne Andersen, CEO, STP Vilecon</strong></p></blockquote><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5Mjk4NTI5LTE3MTAxMjkyOTg1MjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"></p><h2 id="isPasted">The solution</h2><h3><em>3D printed injection mold tooling allows early verification, new applications</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5MzQwMDQzLXhpcC1kZXNrb3AtM2QtcHJpbnRlci1maW0tbWVkaWNhbC0xODAweDE2NTUuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>To meet customer demands for rapid prototyping of silicones, and other complex medical-grade materials, SPT Vilecon wanted a prototyping platform that would integrate seamlessly with their existing tool-building and injection molding capabilities. Other key requirements included biocompatibility, compatibility with the wide range of thermoplastics and silicones already in use, as well as design freedom for complex part prototyping. In the end, they decided to implement Nexa3D’s XiP desktop system and Freeform Injection Molding with xMOLD resin. This compact and highly versatile platform was the only alternative that met all the key requirements, while at the same time enabling SPT Vilecon to expand into new domains based on metal and ceramic injection molding.</p><h2 id="isPasted">The benefits</h2><h3><em>2-day development and verification of complex silicone parts</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5MzU1MjczLXNwdC12aWxlY29uLTNkLXByaW50ZWQtdG9vbHMtMTgwMHgxMjAwLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>With Freeform Injection Molding, SPT Vilecon was able to offer a customer developing an intravenous silicone product, early design and material verification by utilization of 3D printed tools.</p><p><strong>Early Verification:</strong> The use of 3D-printed xMOLD tooling enabled the customer to obtain injection-molded silicone parts in a medical-grade silicone within two days, and to verify key design and performance aspects.</p><p><strong>Rapid iterations:</strong> At the same time, important design input was collected from the first tests, which could be integrated in a second iteration that took only a couple of hours to complete. In comparison, the conventional metal tooling that would normally be needed for this kind of verification would have taken more than six weeks to design and procure, and the adjustments needed for the second iteration would have taken the inhouse tool-shop a week to complete.</p><p><strong>Cost and time savings:</strong> The costs of the 3D-printed silicone molds for the first and second iterations were less than EUR 2.000 combined. And the two-day design cycle was more than 90% faster than the speed achievable with conventional metal tooling.</p><p><strong>Seamless scalability:</strong> Based on the design input collected from the first two iterations, the design of the silicone part was approved and the manufacturing of a metal tool could be initiated with full confidence of part moldability and performance. The collected design input and learnings enabled the inhouse tool-shop to produce the metal tooling within 4 weeks, with no iterations needed in the final tool.</p><h2 id="isPasted">Customer Impact</h2><h3><em>Compliance with project timeline, budget ensured through early verification</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5Mzc3Mzk2LW1lZGljYWwtZGV2aWNlLW1hbnVmYWN0dXJlZC0zZC1wcmludGVkLTEyMDB4MTgwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>Medical device manufacturers face strong pressures to bring new and innovative products to market. Robust and valid prototyping and verification is key to minimize costs, time and risks associated with the development. By implementing Freeform Injection Molding, SPT Vilecon has created a new toolbox for medical device companies seeking to accelerate their innovation and obtain early verification of part performance and moldability.</p><p>Using the XiP with Freeform Injection Molding, a medical device manufacturer was able to save 6 weeks, and 87% of prototyping investments, while at the same time removing a challenging silicone component from the critical path of product development.</p><p>SPT Vilecon has been able to start expanding the range of injection mold prototyping into the domains of silicone, metal and ceramic injection molding, to provide medical device manufacturers with an even wider selection of product development and verification services.</p>

Medical device manufacturer adopts Nexa3D’s FIM process to shorten times-to-market on complex medical devices

SPT Vilecon Accelerates Medical Device Development with Freeform Injection Molding

<p>Is the 3D printing not enough for your prototyping applications for functional testing? Are your iterations for the traditional injection mold making too costly and time consuming for a new part you are developing? You are also not 100% sure if this part design is your final design. With Freeform Injection Molding (FIM), you can cut the cost and time significantly and make multiple iterations until you find your sweet spot. Then you can make the metal mold as your final step before the production with 100% confidence.&nbsp;<br id="isPasted"><br>The APSX-PIM desktop injection molding machine can speed up the process with reduced costs and faster turnarounds. Simply design the mold, 3D print it, inject the plastic in it then demold or directly use the part.&nbsp;<br><br>First off, what exactly is Freeform Injection Molding? With FIM, complex geometries can be achieved without the constraints of traditional tooling, thanks to the high-speed, high-resolution capabilities of Nexa3D printers. You can even dissolve the mold made by xMOLD material to test the plastic part functionality until it is perfect. Nexa3D utilizes its groundbreaking LSPc (Lubricant Sublayer Photo-curing) technology, enabling blazing fast print speeds without compromising on detail.&nbsp;<br><br>But what if you need larger quantities of your parts? That's where the APSX-PIM desktop injection molding machine comes in. This compact yet powerful machine allows you to quickly and affordably produce small to medium-sized batches of parts using traditional injection molding techniques.<br><br>By combining the precision 3D printing with the scalability of injection molding, you have a winning combination for accelerating your product development process. Not only does this save time, but it also significantly reduces costs compared to traditional manufacturing methods.<br><br>Whether you're a startup looking to iterate quickly on your designs or an established company aiming to streamline your production line, Freeform Injection Molding with Nexa3D and the APSX-PIM machine offers unparalleled flexibility and efficiency.<br><br>Freeform Injection Molding is changing the game, and with Nexa3D and APSX-PIM, you're well-equipped to stay ahead of the curve. Please visit the <a target="_self" href="http://www.apsx.com/" data-test-app-aware-link="">www.apsx.com</a> website to get more details.&nbsp;</p><p><br></p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/3fdu_OptGN4?&amp;wmode=opaque&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></span><br></p><p><a href="https://youtu.be/3fdu_OptGN4?si=z1-sMfi1PvNg3u6b" target="_blank" rel="noopener noreferrer">YOUTUBE VIDEO.</a></p><p><a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=prototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#prototyping</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=manufacturing&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#manufacturing</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=engineering&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#engineering</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxpim&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#apsxpim</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=nexa3d&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#nexa3D</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=xmold&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#xMOLD</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=plasticparts&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#plasticparts</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=partdesign&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#partdesign</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=moldingmachine&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#moldingmachine</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=3dprinting&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7168001489381117953" data-test-app-aware-link="" target="_blank">#3dprinting</a></p><p><br></p>

Are your iterations for the traditional injection mold making too costly and time consuming for a new part you are developing? You are also not 100% sure if this part design is your final design. 

Is the 3D printing not enough for your prototyping applications for functional testing?

<p>Makers and innovators wanted! Welcome to the world of injection molding, cnc machining and Swiss lathe using the APSX Machines.<br id="isPasted"><br>We'll be showcasing the APSX-NANO for creating ejector pins and a reamer tool, the Spyder CNC for machining the mold and reaming ejector pin holes, and finally, the APSX-PIM for producing plastic parts using the mold we create. It's the perfect success trio!<br>Let's kick things off with the APSX-NANO, a compact and versatile machine that's perfect for creating precision components. Today, we'll be using it to craft ejector pins and a reamer tool for our injection mold.<br>With its user-friendly interface, the APSX-NANO allows us to easily manufacture our ejector pins. These pins play a crucial role in the injection molding process, ensuring smooth ejection of the finished parts from the mold.<br>And don't forget the reamer tool! The APSX-NANO makes the custom designed reamer tool as well.<br>Now that we have our ejector pins and reamer tool, it's time to move on to the Spyder CNC for machining the mold itself. The SPYDER CNC ensures accurate and clean holes in our mold for the ejector pins. This small but powerful CNC machine allows us to take our design from the digital realm to the physical world with accuracy.<br>With the Spyder CNC, we can carve out our mold design with incredible detail. The machine's robust capabilities ensure a smooth and precise finish, providing the foundation for a high-quality injection mold.<br>Now that our mold is ready, it's time for the grand finale - producing plastic parts using the APSX-PIM, the heart of our success trio!<br>The APSX-PIM is an injection molding machine that brings our creations to life. By injecting molten plastic into the mold we've crafted, we can replicate our design with ease and efficiency.<br>And there you have it, the Success Trio in action! From crafting ejector pins and reamer tools with the APSX-NANO, precision machining the mold with the Spyder CNC, to bringing our ideas to life with the APSX-PIM – it's a seamless process that opens up endless possibilities for creators like you.</p><p><a href="https://youtu.be/fF-tIKxt43s?si=f3w2Y6bHR-2B9Eda" target="_blank" rel="noopener noreferrer">YOUTUBE VIDEO</a>.</p><p>More details: <a href="https://www.apsx.com/" data-attribute-index="0" target="_self">https://www.apsx.com/</a></p><p><br><a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxllc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="1" target="_blank">#apsxllc</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxnano&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="2" target="_blank">#apsxnano</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=swisscnc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="3" target="_blank">#swisscnc</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=spydercnc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="4" target="_blank">#spydercnc</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxpim&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="5" target="_blank">#apsxpim</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=cncmachining&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="6" target="_blank">#cncmachining</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="7" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=molddesign&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="8" target="_blank">#molddesign</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=moldmaking&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="9" target="_blank">#moldmaking</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidprototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7163648087201181696" data-attribute-index="10" target="_blank">#rapidprototyping</a></p>

Are you a manufacturer looking to streamline your production process while saving costs?

Desktop Machines for Injection Mold Making

<p>Traditionally, this process has been reserved for large-scale production in industrial settings. However, with the development of desktop injection molding machines, global companies, small businesses and hobbyists can now take advantage of this technology to speed up their product development and small batch production.&nbsp;<br id="isPasted"><br>Cost-Effective<br>One of the main benefits of desktop injection molding machines is their cost-effectiveness. Traditional injection molding machines can cost hundreds of thousands of dollars, making them inaccessible for small businesses and individuals.&nbsp;<br><br>Compact and Portable<br>Another advantage of desktop injection molding machines is their compact size and portability. Traditional injection molding machines are large and require a dedicated space in an industrial setting. Desktop machines, on the other hand, are much smaller and can easily fit on a desk or workbench.&nbsp;<br><br>Easy to Use<br>Desktop injection molding machines are designed to be user-friendly and easy to operate. They come with intuitive controls and can be set up and ready to use in a matter of minutes. This makes them accessible to individuals with little to no experience in plastic manufacturing.&nbsp;<br><br>Versatile<br>Desktop injection molding machines are also highly versatile. They can be used to produce a wide range of plastic parts, from small and intricate pieces to larger and more complex ones. This versatility makes them suitable for a variety of industries, including automotive, medical, and consumer goods.&nbsp;<br><br>High-Quality Results<br>Despite their smaller size and lower cost, desktop injection molding machines are capable of producing high-quality plastic parts. They use the same technology and materials as traditional machines, ensuring precision and accuracy in the production process. This means that businesses and individuals can produce professional-grade plastic parts without the need for expensive equipment.<br><br>In conclusion, desktop injection molding machines offer a range of benefits that make them a game-changer in the plastic manufacturing industry. From cost-effectiveness and compact size to versatility and high-quality results, these machines are revolutionizing the way plastic parts are produced. As technology continues to advance, we can expect to see even more advancements in desktop injection molding machines, making them an essential tool for businesses and individuals alike. Visit <a target="_self" href="http://www.apsx.com/" data-test-app-aware-link="">www.apsx.com</a> for more information about the APSX Machines by&nbsp;<a target="_self" href="https://www.linkedin.com/company/apsx-llc./" data-test-app-aware-link="">APSX, LLC.</a>.&nbsp;<br><br><a href="https://www.linkedin.com/feed/hashtag/?keywords=injectionmolding&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#injectionmolding</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidprototyping&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#rapidprototyping</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=rapidtooling&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#rapidtooling</a> <a href="https://www.linkedin.com/feed/hashtag/?keywords=apsxllc&highlightedUpdateUrns=urn%3Ali%3Aactivity%3A7170461148239126529" data-test-app-aware-link="" target="_blank">#apsxllc</a></p><p><a href="https://youtu.be/SZ35BVJ-yvE?si=Vc1URbHcgTbsHHgs" target="_blank" rel="noopener noreferrer">APSX-PIM Short Video</a></p><p><br></p><p><br></p>

In the world of plastic manufacturing, injection molding is a widely used process for creating high-quality, precise plastic parts. 

Why would you need a desktop injection molding machine?

<p dir="ltr" id="isPasted">According to the Global EV Outlook from IEA, the EV stock reaches 145 million in 2030, accounting for 7% of the road vehicle fleet. However, one of the main challenges facing EVs is the battery, which determines the performance, range, safety, and cost of the vehicle. The battery enclosure is the protective structure that houses the battery cells and modules. The article explores different materials and design considerations for enclosures to optimize and supercharge EV performance. &nbsp;</p><h2 dir="ltr">Steel vs. Aluminium vs. Carbon Fiber</h2><p dir="ltr">Steel is a traditional material that offers high strength and durability. However, steel is heavy and prone to corrosion, which can reduce the energy efficiency and lifespan of the battery. In addition, steel has high thermal conductivity, which affects the battery performance and safety. Aluminum, in contrast, is preferred due to its lightweight and high strength-to-weight ratio. It is also more resistant to corrosion than steel.</p><p dir="ltr">Sounds like aluminum wins in every way, no material is without its challenges, however. There is also the poor impact performance of metal materials. Carbon fiber reinforced polymer (CFRP), a newer and more innovative composite material, offers lightweight, anti-impact, durable and flexible performance. However, it is also more expansive. Moreover,<a href="https://www.sae.org/news/2021/01/novel-materials-approach-to-ev-battery-box-design" target="_blank">&nbsp;its thermal expansion mismatch with the battery cells</a>, which makes it still a cautious choice.</p><h2 dir="ltr">Design to Improve Cooling Efficiency</h2><p dir="ltr">Other than material selection, the factors such as structure optimization, thermal management system, etc., are also crucial. The modular design with multiple cooling channels and the use of cooling fins and heat sinks can enhance the cooling efficiency of the battery pack. Therefore, the surface area for heat transfer increased, allowing air or liquid to flow through the channels. If the heat, generated by battery cells during operation, is not dissipated properly, can reduce the lifespan of the battery, and even cause safety hazards.</p><h2 dir="ltr">Multi-layered Housing Structure</h2><p dir="ltr">Another important aspect of the battery pack housing design is the protection against mechanical and thermal shocks. A multi-layered housing structure consisting of an outer layer of aluminum or steel, a middle layer of insulation material, and an inner layer of polymer film can balance the pros and cons of different materials.</p><p dir="ltr">This structure protects against physical damage to the battery cells from external impacts or vibrations, and protects against thermal runaway, which can occur when the battery overheats and triggers a chain reaction leading to a fire or explosion. The insulation layer prevents heat from spreading to adjacent cells and absorbs impact energy, while the polymer film acts as a barrier to prevent oxygen from entering the battery and fueling the combustion.</p><h2 dir="ltr">On-demand Manufacturing Accelerates Your Enclosure Development</h2><p dir="ltr">Before launching battery packs to the market, you need to conduct many prototyping verifications. RPWORLD is happy to support alongside your auto part development with 20-years’ experience and expertise. Choose RPWORLD, you will get:</p><ul><li dir="ltr">Fast delivery in as little as 7 days to help you ahead of competitions.</li><li dir="ltr">One-stop manufacturing including CNC machining, injection molding and more to bring your design to life under one roof.</li><li dir="ltr">Design optimization and manufacturability advice to mitigate production risks.</li><li>00+ high-performance engineering materials to suite your different needs.</li></ul>

According to the Global EV Outlook from IEA, the EV stock reaches 145 million in 2030, accounting for 7% of the road vehicle fleet. However, one of the main challenges facing EVs is the battery, which determines the performance, range, safety, and cost of the vehicle.

Supercharge EV's Performance with Optimized Battery Enclosures

<p id="isPasted"><a href="https://xometry.eu/en/injection-moulding/" target="_blank">Injection moulding</a> is a plastics manufacturing technology that is capable of very high production volumes. The process works by injecting liquid plastic into a mould at very high pressure. <a href="https://xometry.eu/en/compression-moulding/" target="_blank">Compression moulding</a>, on the other hand, is better suited to medium-volume production and is typically used with rubbers and silicones.</p><p>Injection moulding is better suited to creating complex parts, whereas compression moulding is better suited to simple geometries and large panels. Injection moulding is highly automated and does not need constant human supervision, while compression moulding often requires human intervention to load a charge and remove completed products. Tooling is also cheaper for compression moulding.&nbsp;</p><h2><strong>Injection moulding definition and comparison to compression moulding</strong></h2><p>Injection moulding works by injecting molten thermoplastic into a mould cavity. During the <a href="https://xometry.eu/en/injection-moulding-technology-overview/" target="_blank">plastic injection process</a>, the plastic resin pellets are melting inside a barrel. The barrel contains a screw with a shaft whose diameter increases along its length. As the screw rotates, plastic is forced into an incrementally smaller volume. This compression is the primary mechanism responsible for melting the plastic. The barrel is also heated to supply additional heat. Once enough plastic to fill the mould has melted, the screw retracts and then is pushed forward to force the plastic resins into the mould at very high pressures.&nbsp;</p><p>Moulds are made from at least two components and are held together with hydraulic rams so that the high-pressure plastic injected into the mould cannot escape from the parting line. The mould has cooling channels that cool the part enough so that it can be ejected from the mould without damaging it. Injection moulding can achieve high production volumes unmatched by any other plastic processing technique. Compression moulding, on the other hand, is better suited to medium-volume production.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637518953-ezgif-7-34a4753f4f.gif" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Injection moulding process animation</em></span></span></span></p><h3 id="isPasted"><strong>Advantages of injection moulding compared to compression moulding</strong></h3><p>Listed below are some advantages and disadvantages of injection moulding compared with compression moulding:</p><ul><li>Injection moulding is a method for large production runs that can produce millions of parts per machine annually.&nbsp;</li><li>Due to the high levels of automation and rapid manufacturing speed, injection moulded parts are cheaper than compression moulded parts.</li></ul><h3><strong>Disadvantages of injection moulding compared to compression moulding</strong></h3><p>Listed below are some disadvantages of injection moulding compared with compression moulding:</p><ul><li>Injection moulding requires very high plastic injection pressures. The mould must therefore be built to withstand these high pressures. This adds cost to the tooling.&nbsp;</li><li>Injection moulding is not well suited to manufacture large, thin parts like vehicle panels.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637547696-injection-moulding-setup-768x588.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Injection moulding setup</em></span></span></span></p><h2 id="isPasted"><strong>Compression moulding definition and comparison to injection moulding</strong></h2><p>Compression moulding is a process most often used to manufacture parts from pliable materials. <a href="https://xometry.eu/en/compression-moulding-technology-overview/" target="_blank">This moulding technique</a> typically employs a two-part mould, with one part fixed to the base of the compression moulding tool while the top half is free to move up and down. The moulds are usually heated to help cure the final product while also heating the charge before compression. A precisely weighed-out charge is heated until it is pliable. It is then placed into the bottom half of the mould.&nbsp;</p><p>The top half then moves down and forces the charge to conform to the desired shape of the mould. The heated mould stays closed while the material is allowed to cure. This typically takes a few minutes. Once cured, the part is removed from the mould. Post-processing is required to cut off any flash. Flash (or excess material at the parting line of the mould) is a common occurrence for compression-moulded parts.</p><p>Compression moulding is used for creating reinforced panels. The process involves laying out fibre-filled plastic sheets in the bottom half of the mould. Thereafter, the top half of the mould compresses and heats the material to force the plastic throughout the mould, creating a composite part. This is how large plastic car bumpers are made.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637616083-ezgif-7-1b2e488406.gif" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Compression moulding process animation</em></span></span></span></p><h3 id="isPasted"><strong>Advantages of compression moulding compared to injection moulding?</strong></h3><p>Listed below are some advantages of compression moulding compared to injection moulding:</p><ul><li>Compression moulding can make use of SMC (Sheet Moulding Compound) and BMC (Bulk Moulding Compound) to create composite panels. These panels do not have continuous fibre-impregnated sheets, but rather chopped fibre strands that are distributed throughout the bulk material. The injection moulding method cannot make composite material parts.&nbsp;</li><li>Compression moulds do not need to withstand high internal pressures as do injection moulds. Instead, the only load they experience is a compression force from above. This means that compression moulds tend to be less expensive.</li></ul><h3><strong>Disadvantages of compression moulding compared to injection moulding</strong></h3><p>Listed below are some disadvantages of compression moulding compared to injection moulding:</p><ul><li>Compression moulding is a very manual and slow process. Even if a robot arm is used to add the charge and remove the product, the cycle time between parts is still much slower than injection moulding due to the need for the parts to be set before being removed.</li><li>Compression moulding cannot create plastic parts with high levels of complexity. The materials used are typically very viscous and as a result, they don’t flow well into small, complicated features.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637640110-rubber-compression-machine-768x512.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">A rubber compression machine</em></span></span></span></p><h2 id="isPasted"><strong>Comparison table between injection moulding and compression moulding</strong></h2><p>Attributes of compression moulding and injection moulding are shown in the table below:</p><figure><table><tbody><tr><td><strong>Attribute</strong></td><td><strong>Injection Moulding</strong></td><td><strong>Compression Moulding</strong></td></tr><tr><td><strong>High-volume production process</strong></td><td>Yes</td><td>No</td></tr><tr><td><strong>Materials</strong></td><td>Thermosets, thermoplastics (including fibre and metal-filled), thermoplastic elastomers, metal-filled polymers, fibre-filled thermoplastics</td><td>Thermosets, thermoplastics, silicone, unvulcanized rubber, BMC, SMC</td></tr><tr><td><strong>High tooling cost</strong></td><td>Yes</td><td>No</td></tr><tr><td><strong>Can produce large, thin-walled panels</strong></td><td>No</td><td>Yes</td></tr><tr><td><strong>Post-processing required</strong></td><td>Yes</td><td>Yes</td></tr></tbody></table></figure><p><br></p><p>Injection moulding is better suited to high-volume production whereas compression moulding is better suited to pliable and flexible materials. Compression moulding also has cheaper tooling costs.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637659491-capabilities-injectionmolding-xometry-768x511.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Blue injection moulded bottle nozzles in high-volume</em></span></span></span></p><h3 id="isPasted"><strong>Injection moulding vs. compression moulding: Lead cost comparison</strong></h3><p>When it comes to individual part cost, injection moulding can produce inexpensive, complex parts. However, this manufacturing process is only cost-competitive if production run volumes are large enough to spread the high cost of injection moulding tooling over a sufficient number of pieces. At lower volumes, compression moulding is cheaper than injection moulding due to the lower initial mould costs.</p><h3><strong>Injection moulding vs. compression moulding: Speed comparison</strong></h3><p>Injection moulding is significantly faster than compression moulding. The cycle time for injection moulded parts can be a few seconds, whereas compression moulding cycle times can easily reach a few minutes. This is because compression moulded components often need to cure thanks to the heating process before they are removed from the mould.</p><h3><strong>Injection moulding vs. compression moulding: Volume comparison</strong></h3><p>Injection moulding is a high-volume production method that is unmatched by any other manufacturing technology. Injection moulding processes can be fully automated, while compression moulding often requires a person to place the raw materials into the mould, remove it, and post-process it.</p><h3><strong>Injection moulding vs. compression moulding: Materials comparison</strong></h3><p>Injection moulding can make use of&nbsp;<a href="https://xometry.eu/en/injection-moulding-materials-selection-guide/" target="_blank">rigid thermoplastics as well as thermoplastic elastomers</a>. Compression moulding more often makes use of flexible elastomers like rubber and silicone, but can also produce rigid composite components by making use of SMC and BMC.</p><h2><strong>Summary</strong></h2><p>This article presented the comparison of injection moulding to compression moulding, explained what they are, and discussed the different attributes of each.</p><p>Xometry provides a&nbsp;<a href="https://xometry.eu/en/capabilities/" target="_blank">wide range of manufacturing capabilities</a>, including&nbsp;<a href="https://xometry.eu/en/injection-moulding/" target="_blank">plastic injection moulding</a>,&nbsp;<a href="https://xometry.eu/en/compression-moulding/" target="_blank">compression moulding</a> and other value-added services for all of your prototyping and production needs.</p>

This article will describe the similarities and differences between injection moulding and compression moulding to help you determine which process is best for your project in terms of the manufacturing process, materials used, and production rates.

Injection Moulding vs. Compression Moulding: Differences and Comparison

<div data-id="9908f31" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>A global automotive supplier</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524209040-ti_fluid_systems_IMG_0032.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">TI Fluid Systems is one of the biggest suppliers for automotive fluid solutions. Source: TI Fluid Systems</span></span></span></p></div><div data-id="69b735e" data-element_type="widget" data-widget_type="text-editor.default"><p><a href="https://tifluidsystems.com/" target="_blank"><strong>TI Fluid Systems</strong></a> is a manufacturer for automotive fluid technology headquartered in Oxford, England. With more than 100 years of experience and 28’000 employees across 29 countries, the company has established itself as a major supplier to the automotive industry. Primarily, TI Fluid Systems specializes in the development and production of industry-leading fluid carrying systems, as well as fuel tank and delivery systems that are found in two-thirds of all vehicles worldwide.</p><div data-id="371df47" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Innovation from Poland</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524232497-IMG_8402.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Under the lead of Paweł Pułtorak, the Sintratec S2 has been in regular use for over two years at TI Fluid Systems.</span></span></span></p></div><div data-id="a4a60e8" data-element_type="widget" data-widget_type="text-editor.default"><p>One of TI Fluid Systems 114 branches is located in Bielsko-Biała, Poland, where Paweł Pułtorak has been the head of the design department for the last 18 years. Under his guidance, the team has gradually incorporated additive technologies into their research and development. «3D printing is a very important tool for supporting the work of engineers in the design department», states Pułtorak. With these advanced manufacturing methods, the team is able to reduce production costs and time-to-market.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524259047-1709524259047.png" class="fr-fic fr-dib"><span class="fr-inner">The design department uses selective laser sintering to rapidly advance their product development.</span></span></span></p><div data-id="66f7fc8" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>SLS for precise prototypes</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524288377-cleaningpart_TIFLUID_3-1.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">SLS parts being depowdered inside the Sintratec Material Handling Station.&nbsp;</span></span></span></p></div><div data-id="bc27b16" data-element_type="widget" data-widget_type="text-editor.default"><p>«The main use of the 3D prints is to verify the shape and geometry of the designed elements before making the injection mold and going into series production», Pułtorak explains. Due to the high requirements for prototypes in the automotive sector, the company decided to invest in a <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank"><strong>Sintratec S2</strong></a> – a selective laser sintering (SLS) system. «Other technologies did not allow us to print as precise components as SLS does», says Pułtorak. With the robust <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank"><strong>Sintratec PA12</strong></a> material in particular, the engineers can cover the majority of the company’s prototyping needs.</p><div data-id="af667bd" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>A wide range of applications</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524305009-compositesls_web.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3D printed with PA12 nylon: Automotive components similar to these are laser sintered by TI Fluid Systems.</span></span></span></p></div><div data-id="5c13cdf" data-element_type="widget" data-widget_type="text-editor.default"><p>According to Paweł Pułtorak, the Sintratec S2 is used practically every day. «The SLS parts allow us to assess whether there are collisions in our assemblies», explains the department head. «We also use them during our project group meetings and in functional tests.» Apart from the previously mentioned prototypes, the main pieces printed at TI Fluid Systems are housings, construction and tooling elements, jaws and work pieces to assist with assembly, as well as spare parts for the maintenance department.</p><div data-id="738f8b9" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Accuracy and strength combined</h2></div><div data-id="8731b84" data-element_type="widget" data-widget_type="text-editor.default"><p>«What we like the most about the Sintratec S2 system is the accuracy of 3D printed elements», emphasizes Pułtorak. For the TI Fluid Systems design department, the precision and strength of these components plays a crucial role in their development efforts. After over two years in use, the economic benefits of the Sintratec S2 have become apparent as well. «The machine is definitely a good investment», summarizes Paweł Pułtorak.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524343019-1709524343019.png" class="fr-fic fr-dib"></p></div></div></div></div></div>

At a Polish branch of TI Fluid Systems, functional prototypes and spare parts for the automotive industry are selectively laser sintered. Using a Sintratec S2, Paweł Pułtorak’s team prints precise and complex parts to validate their designs.

Shifting into high gear with SLS

<p dir="ltr" id="isPasted">Finding the right supplier for product development and manufacturing can be a challenging and time-consuming task. Some suppliers offer batch production, but this applies to products with a frozen design that cannot be modified. But jumping straight from part design to batch production can be a risky move. Another type of supplier provide single or limited manufacturing services. And product developers have to find more manufacturing suppliers to support along the product development life cycle. At RPWORLD, we offer one-stop shop solution for product development, prototyping, and production, whether it is for low or high volumes.</p><p dir="ltr">With over 20 years of experience and expertise in manufacturing, RPWORLD has served industries, such as: automotive OEM, Tier I, and Tier II suppliers, biotech &amp; medical device and more. Our four manufacturing solutions provide customers with flexibility and rapidity for all their manufacturing needs.</p><h2 dir="ltr">CNC Machining with High Precision and Complex Structures (10-1,000pcs)</h2><p dir="ltr">RPWORLD CNC machining is designed for customers who require precision machined parts with complex structures in medium-to-small volume production runs. With tons of 3-, 4- and 5-axis CNC machines, RPWORLD is capable of producing parts that meets DIN ISO 2768 M (F) standards. Ranging from 10 to 1,000 pieces, RPWORLD CNC machining delivers your accurate and consistent parts in as fast as 3 dasys</p><h2 dir="ltr">CNC Turning for High-Volume Production (Diameter up to 44mm)</h2><p dir="ltr">RPWORLD CNC turning, a cost-effective manufacturing process for cylindrical parts that are structurally simple. With expertise in high-volume production of machined parts up to 44mm in diameter, we ensure consistent quality and fast turnaround times using advanced equipment and techniques. This service is perfect for customers who require a high volume of small CNC machined parts for their products.</p><h2 dir="ltr">High-Volume Injection Molded Parts</h2><p dir="ltr">With advanced injection molding equipment and our engineering experts dedicated to finding ways to increase production, such as using multi-cavity molds, our injection molding is designed for customers who require large quantities of small injection moled part. And you can also expect the consistent quality from the fast delivery in as fast 7 days.</p><h2 dir="ltr">Prototyping with Multiple Manufacturing Processes</h2><p dir="ltr">For prototyping needs, RPWORLD uses a range of manufacturing services, including CNC machining, injection molding, vacuum casting, sheet metal fabrication, finishing options, and more. We are committed to producing complex-geometry prototypes with most fitted process, for industries such as medical devices and automotive components, and can meet your exact specifications.</p><p dir="ltr">In addition to multiple manfuactuirng processes, RPWORLD also provides Free and Comprehensive DFM analysis for every order. The DFM report includes suggestions for the process, material, surface treatment selection and design optimization from the perspective of manufacturability and assembly. The in-depth analysis helps reduce manufacturing risks before any actual production begins, avoid the costly reworks, and is one of the core benefits for customer to work with RPWORLD.</p><p dir="ltr">When it comes to finding a reliable partner for your product development and manufacturing needs, RPWORLD offers the turnkey manufacturing solutions. With specialized services in prototyping projects, low- to high-volume CNC machining, and large quantities of injection-molded parts, we can provide a one-stop solution for specific for your manufacturing needs.</p><p>None of your projects match these requirements? We have engineering experts tailored for your product development.</p>

RPWORLD offers one-stop shop solution for product development, prototyping, and production, whether it is for low or high volumes.

Streamline Your Product Development with RPWORLD Turnkey Manufacturing

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Nexa3D

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MacroFab

prototyping