APPLICATION BRIEF: FDM FOR JIGS AND...

2
OVERVIEW Manufacturing relies on tools including jigs, fixtures, templates and gauges to maintain quality and production efficiency. They are used to position, hold, protect and organize components and sub- assemblies at all stages of the manufacturing process. And although these tools are virtually invisible when production is running smoothly, their importance becomes evident when problems arise. To avoid production halts or product defects, new jigs and fixtures must be rapidly designed, manufactured and deployed. APPLICATION OUTLINE Jigs and fixtures are most commonly fabricated from metal, wood or plastic in quantities of 1 – 100+ using a manual or semi-automated process. On average, each tool takes between one and four weeks to design and build, however elaborate or intricate tools may require several cycles of design, prototyping and evaluation to attain the required performance. Fused Deposition Modeling™(FDM ® ) provides a fast and accurate method of producing jigs and fixtures. FDM is an additive manufacturing process that builds plastic parts layer-by-layer using data from computer-aided design (CAD) files. By using FDM, the traditional fabrication process is substantially simplified; tool- making becomes less expensive and time consuming. As a result, manufacturers realize immediate improvements in productivity, efficiency and quality. Additionally, these tools can be designed for optimal performance and ergonomics because FDM places few constraints on tool configuration. What’s more, adding complexity does not increase build time and cost. The efficiency of FDM makes it practical to optimize jig and fixture designs and increase the number in service. Engineers can easily evaluate the performance of the tool and make quick, cost-efficient adjustments to the design as needed. FDM also makes it practical to produce jigs and fixtures for operations where they have not been previously cost or design feasible when produced with traditional manufacturing methods. Finally, FDM jigs and fixtures are made from tough and durable thermoplastics that can withstand the rugged manufacturing environment. With several bio-compatible options, they are also ideal for use in medical applications. CUSTOMER STORY The Oreck Corporation is a well-respected manufacturer of vacuum cleaners, sweepers, and other household cleaning appliances. Within the vacuum cleaning category alone, Oreck offers nearly 20 unique models which are valued for being lightweight, exceptionally durable and easy-to-use. Every new Oreck vacuum incorporates 20 - 30 complex injection molded parts that must meet specific dimensional tolerance requirements to ensure proper assembly and performance. Before production of a new product can begin, samples of each part are produced for testing. These are called First Articles. Each First Article is inspected by a coordinate measuring machine (CMM) prior to shipment of the mold to the manufacturing facility, and once again before the mold is placed into production. During each inspection, the First Articles must be held rigidly in place. Should a First Article shift during the inspection process, the CMM will register a false failure. Oreck First Articles mounted in FDM fixtures (white ABS-M30) on CMM granite base. Part numbers and hardware pocket integrated in a fixture made from ABS- ESD7, commonly used for electrical component assembly fixtures. CAD model of Oreck vacuum cleaner yoke to be inspected on a CMM. APPLICATION BRIEF: FDM FOR JIGS AND FIXTURES BENEFITS OF FDM Average lead time savings: 40% - 90% Average cost savings: 70% - 95% Greater efficiency: Streamline and improve process - Eliminate detailed drawings - Minimize paperwork Greater design freedom: Integrate / consolidate / improve - Eliminate assembly - Improve performance, accuracy and ergonomics FDM IS A BEST FIT Quantity: Low - volume (1-100+) Properties: Thermoplastic is acceptable. Size (XYZ): < 300 mm (12 inches) per side Environment: < 200° C (390° F) Deployment: Limited due to time and cost. Fabrication: In-house is not feasible. Revisions: Frequent replacements, alterations and revisions must be made. Tolerance: > +/- 0.13 mm (0.005 in) FDM (black ABS-M30) assembly line nest mounted on an aluminum blank.

Transcript of APPLICATION BRIEF: FDM FOR JIGS AND...

OVERVIEWManufacturing relies on tools including jigs, fixtures, templates and gauges to maintain quality and production efficiency. They are used to position, hold, protect and organize components and sub-assemblies at all stages of the manufacturing process. And although these tools are virtually invisible when production is running smoothly, their importance becomes evident when problems arise. To avoid production halts or product defects, new jigs and fixtures must be rapidly designed, manufactured and deployed.

APPLICATION OUTLINEJigs and fixtures are most commonly fabricated from metal, wood or plastic in quantities of 1 – 100+ using a manual or semi-automated process. On average, each tool takes between one and four weeks to design and build, however elaborate or intricate tools may require several cycles of design, prototyping and evaluation to attain the required performance.

Fused Deposition Modeling™(FDM®) provides a fast and accurate method of producing jigs and fixtures. FDM is an additive manufacturing process that builds plastic parts layer-by-layer using data from computer-aided design (CAD) files. By using FDM, the traditional fabrication process is substantially simplified; tool-making becomes less expensive and time consuming. As a result, manufacturers realize immediate improvements in productivity, efficiency and quality. Additionally, these tools can be designed for optimal performance and ergonomics because FDM places few constraints on tool configuration. What’s more, adding complexity does not increase build time and cost.

The efficiency of FDM makes it practical to optimize jig and fixture designs and increase the number in service. Engineers can easily evaluate the performance of the tool and make quick, cost-efficient adjustments to the design as needed. FDM also makes it practical to produce jigs and fixtures for operations where they have not been previously cost or design feasible when produced with traditional manufacturing methods.

Finally, FDM jigs and fixtures are made from tough and durable thermoplastics that can withstand the rugged manufacturing environment. With several bio-compatible options, they are also ideal for use in medical applications.

CUSTOMER STORYThe Oreck Corporation is a well-respected manufacturer of vacuum cleaners, sweepers, and other household cleaning appliances. Within the vacuum cleaning category alone, Oreck offers nearly 20 unique models which are valued for being lightweight, exceptionally durable and easy-to-use.

Every new Oreck vacuum incorporates 20 - 30 complex injection molded parts that must meet specific dimensional tolerance requirements to ensure proper assembly and performance. Before production of a new product can begin, samples of each part are produced for testing. These are called First Articles.

Each First Article is inspected by a coordinate measuring machine (CMM) prior to shipment of the mold to the manufacturing facility, and once again before the mold is placed into production. During each inspection, the First Articles must be held rigidly in place. Should a First Article shift during the inspection process, the CMM will register a false failure.

Oreck First Articles mounted in FDM fixtures (white ABS-M30) on CMM granite base.

Part numbers and hardware pocket integrated in a fixture made from ABS-ESD7, commonly used for electrical component assembly fixtures.

CAD model of Oreck vacuum cleaner yoke to be inspected on a CMM.

APPLICATION BRIEF:

FDM FOR JIGS AND FIXTURES

BENEFITS OF FDM

Average lead time savings:

• 40% - 90%

Average cost savings:

• 70% - 95%

Greater efficiency:

• Streamline and improve process

- Eliminate detailed drawings - Minimize paperwork

Greater design freedom:

• Integrate / consolidate / improve

- Eliminate assembly

- Improve performance, accuracy and ergonomics

FDM IS A BEST FIT

Quantity:

• Low - volume (1-100+)

Properties:

• Thermoplastic is acceptable.

Size (XYZ):

• < 300 mm (12 inches) per side

Environment:

• < 200° C (390° F)

Deployment:

• Limited due to time and cost.

Fabrication:

• In-house is not feasible.

Revisions:

• Frequent replacements, alterations and revisions must be made.

Tolerance:

• > +/- 0.13 mm (0.005 in)FDM (black ABS-M30) assembly line nest mounted on an aluminum blank.

©2014 Stratasys Inc. All rights reserved. Stratasys, FDM and Fortus are registered trademarks and Fused Deposition Modeling, FDM Technology, Fortus 250mc, Fortus 360mc, Fortus 400mc, Fortus 900mc, Insight and Control Center are trademarks of Stratasys Inc., registered in the United States and other countries. ULTEM™ is a registered trademark of SABIC or affiliates. All other trademarks are the property of their respective owners. Product specifications subject to change without notice. SSYS-AB-JigsFixtures-02-14

For more information about Stratasys systems, materials and applications, contact Stratasys Application Engineering at 1-855-693-0073 (toll free), +1 952-294-3888 (local/international) or [email protected].

7665 Commerce WayEden Prairie, MN 55344+1 888 480 3548 (US Toll Free)+1 952 937 3000 (Intl)+1 952 937 0070 (Fax)

2 Holtzman St. Science Park, PO Box 2496 Rehovot 76124, Israel +972 74 745-4000 +972 74 745-5000 (Fax)

ISO 9001:2008 Certified

Stratasys | www.stratasys.com | [email protected]

During inspection, Oreck’s quality control team would manually attach a variety of modular aluminum clamps to hold the First Article in place. This pain-staking process generally took 30 minutes to complete and was then followed-up by two to four hours of CMM programming time.

Consequently the total time needed to test all of the First Articles required for production of a new vacuum model was approximately 30 days. If a defect was found - which happened at the rate of once a month – the timeline was further delayed while the QC team investigated the problem.

Oreck now uses FDM to make fixtures that are specifically designed to quickly and perfectly position each First Article for testing, thereby eliminating the need for manual placement. Furthermore they are able to create an FDM prototype of the First Article, which when used in conjunction with the complementary fixture, allowed the QC department to preprogram the CMM while the actual First Article was in production.

Now, the opportunity for testing error has been virtually eliminated, and the quality control process that previously took a month to complete can be done in one day — a 2,900% improvement.

“The accuracy and consistency of FDM allows us to move the programming stage up in the process, and essentially remove the First Article inspection process from the critical path in the new product development schedule. This makes it possible to start production faster,” said Craig Ulmer, Senior QA Labs Technician for Oreck.

FDM First Article (gray ABS-M30) on FDM fixture (ivory ABS-M30) used by Oreck for CMM programming.

REFERENCE COMPANIES

Companion and reference materials:• Technical application guide

- Document• Application brief

- Document• Video

- Commercial- Success story- How it’s used

• Referenced processes- Metal inserts- Color change- Building assembly parts- Integrated structures- Insight custom groups

Application compatibility: (0 – N/A, 1 – Low, 5 – High)

• FDM: Idea (3), Design (3), Production (5) • PolyJet™: Design (2)

CUSTOMER PROFILE

Forward-thinking manufacturers, engineers and designers that use jigs and fixtures for:

Departments:

• Manufacturing

• Inspection

• Engineering

• Inventory

Applications:

• Positioning / Holding• Transportation • Protection• Organization

Traditional technology obstacles:

• Creation time and expense outweigh value.

• Bottlenecks / delays in fixture making are present.

• Jigs and fixtures are used infrequently or have short lives.

• Jigs and fixtures are nice to have but low priority.

How does FDM compare to traditional methods for Oreck?

Method Production Time

Cost

CNC 7 hours $250

FDM 3.5 hours $55

SAVINGS 3.5 hours (50%)

$195 (78%)

Total Inspection Time

30 days

1 day

29 days — 2,900% improvement