Agenda of needs
• Reduce time-to-market
• Increased team productivity
• Reduce design & manufacturing costs
• Improved solution for manufacturing tools
• Convenient & confidential in-house solution
Why Companies Choose FDM
• Variety of durable thermoplastics
• Large capacity & envelope
• Versatile & expandable
Thermoplastics Family
Material
Characteristic
ABS-M30
Versatile material
ABS-M30i
Biocompatible (ISO-10993)
ABSi
Translucent
PC-ABS
High Impact Strength
Polycarbonate
High Tensile Strength
PC-ISO
Biocompatible (ISO-10993)
ULTEM 9085
FST Certification, High Mechanical
PPSF/PPU
Thermal and Chemical Resistance
Soluble Supports*
*Not a thermoplastic, alternate usage
Performance
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•
•
Envelope size
Materials
Accuracy
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•
•
Resolution
Flexibility
Supports
Summary
• Reduce time-to-market
• Increased team productivity
• Reduce design & manufacturing costs
• Improved solution for manufacturing tools
• Convenient & confidential in-house solution
Thermoplastic
Materials
Materials: ABS-M30
Unique Properties
• Up to 70% stronger than ABS material
• High tensile, impact, and flexural strength
• More durable part than standard ABS
• Versatile, good for form, fit and function
• Variety of colors
Materials: ABS-M30
Success Story
• Simple fixture to aid in assembly process
• Consistent height of post above plate
• Integrated part number & description
• Single vs. multiple piece construction
• Time & cost savings
Materials: ABS-M30i
Unique Properties
• Biocompatible (ISO 10993 certified)
• Medical, pharmaceutical and food packaging
• Sterilize using gamma radiation EtO
• Best fit for good strength and sterilization
Materials: ABS-M30i
Success Story
• Custom dental drill guide in hours
• Contact with flesh - ISO-10933
• Designed from dental impression scan
• Locks in and accurately positions drill
• Tungsten bushing on wear surfaces
• Fast, accurate, inexpensive tools
Materials: ABSi
Unique Properties
• Translucent material
• Amber
• Clear
• Red
• Ideal for automotive tail lens applications
• Blend of mechanical and aesthetic properties
Materials: ABSi
Success Story
• Bidding process for after-market supplier
•Desired new design concept model
• Set apart from others with concept model
• Chose their design over others
• Attributed to lighted concept model
Materials: PC-ABS
Unique Properties
• Best properties of PC and ABS
• Mechanical props heat resistance of PC
• Feature definition surface appeal of ABS
• High impact strength
Materials: PC-ABS
Success Story: New Stapler Design
• Design objectives
• Ergonomic & modern design
• Reduce manufacturing cost
• Consumer focus group
•8 design concepts evaluated
• 3 month field testing
• PC-ABS functional prototype
• Good fit with high-impact strength
• Improved design & profitability
Materials: Polycarbonate (PC)
Unique Properties
• Most widely used industrial thermoplastic
• Superior mechanical properties
• Accurate, durable, and stable
• High heat resistant
Materials: Polycarbonate (PC)
Success Story
• Small scanner for research subjects
• PC does not show up in imaging
•Reduced time & cost
•14 days vs.
5 days (64% savings)
•£1800
£680 (62% savings)
vs.
Materials: PC-ISO
Unique Properties
• Biocompatible (ISO 10993 certified)
• Sterilize using gamma radiation or EtO
• Medical, pharmaceutical and food packaging
• Applications requiring strength and sterilization
Materials: PC-ISO
Success Story
• Patient custom cutting & drilling guide
• Designed from 3D MRI data
• ISO 10993 Certification
• Increased surgical accuracy
• Reduced surgery and recovery time
Materials: ULTEM 9085
Unique Properties
• FST (flame, smoke, toxicity) certified
• High heat and chemical resistant
• Ideal for commercial transportation
• Highest tensile and flexural strength
Demonstration of mechanical strength
Materials: ULTEM 9085
Success Story
• New “eye-ball” air vent design required
• Required for commercial aircraft approval
• Initially to test fitment and validate design
• Certifications allowed commercial flight
• Also use for low-volume manufacturing
Materials: PPSF/PPSU
Unique Properties
• Highest heat and chemical resistance
• Mechanically superior, greatest strength
• Sterilize using gamma radiation or EtO
• Applications in caustic and high heat
Materials: PPSF/PPSU
Unique Properties
• Diesel vapor coalescer filter
• Captures & re-burns oil, fuel, soot
• Required by new emissions standard
• Robust & functional prototype required
• Testing +70hrs part survived
• Validated design to OEM
Materials: Soluble Supports
Unique Properties
• Soluble material
• Dissolves in detergent/water
• Quick and hands free
• Flush down drain
• Easy to sand and polish
• Soluble supports & cores
BMW Reduces Time and
Cost to Build Fixtures
Conventional fixture making


Cost and time requirements were high
Lack of design freedom reduced productivity
FDM used to produce fixtures


Have over 400 assembly fixtures
Several built on Fortus system
Method
FDM enhances ergonomics


Organic shapes maximize performance
Sparse fill cut weight 72%
Conventional
CNC

Typical cost reduced from £420 to £176
Typical lead-time reduced from 18 to 1.5 days
Time
£420
18.0 days
Fortus system
ABS-M30
£176
1.5 days
Savings
£244
(58%)
16.5 days
(92%)
Time and cost savings

Cost