We have gathered together a number of case studies from our Additive Manufacturing Community around the country, these are listed under the various industry headings below.If you would like to list your Case Study please contact John Croft at amhub@amtil.com.au

CSIRO

Jetting off with 3D printing

These 3D-printed jet engines (one has featured at the International Air Show in Avalon) prove that test parts can be produced in days instead of months.

Using Lab22’s Arcam Electron Beam Melting printer in combination with cold spray technology, a range of engine components were made with a new titanium metal powder developed by CSIRO. The powder performs better than previously used products and is also cheaper to use.

Projects like this help put Australia at the forefront of the global aerospace industry and attract the attention of international companies looking to create stronger ties with Australian manufacturing.

Monash University’s Centre for Additive Manufacturing led the project in collaboration with CSIRO’s Lab 22 and Deakin University, with funding support from the Science Industry Endowment Fund (SIEF).

Read more about 3D printed jet engines.

CSIRO

Digitally cloning a 1914 Delage Type S engine block 

CSIRO’s Lab22 was approached by an Australian car enthusiast who was painstakingly restoring a 1914 Delage Type S that also happens to be the only one left in the world. The Delage was a revolutionary racing car for its time, boasting the latest innovations in automotive technology.

Sadly after 103 years the engine block was looking a little worse for wear. The team at Lab22 was asked to help make a new one. But just how do you clone a 1914 engine block without detailed plans or traditional manufacturing methods? With sand of course, and a Voxeljet VX1000 3D sand printer!

Read more about using 3D printing to restore a 1914 Delage


EVOK3D

Triple Eight Race Engineering revs up production thanks to HP Multi Jet technology

A racing car steering wheel is an assembly that typically includes three parts: an armature and grip (rim), or the part that the driver holds to steer the car (this is typically made from a strong metal like a magnesium alloy); the hub and quick-release mechanism, which connects the armature to the steering column; and various switchgear and lights that are mounted to the armature or hub and allow to driver to exert control and receive information about the state of the car.

Read more about Triple Eight Race Engineering

Coming soon

CSIRO

Rapid prototyping for the Hawkei

Albins Performance Transmissions approached CSIRO’s Lab22 to see if they could make a casting mould for Thales Australia’s Hawkei Protected Mobility Vehicle within two days.

Using Lab22’s Voxeljet VX1000 3D sand printer the additive manufacturing researchers were able to deliver a cast prototype part within a week. The delivered part had the same grain structure and material properties as the production design.

Read more about how 3D printing was used to cut a prototype build from weeks to days


Evok3D

Aurea Avionics

The Seeker unmanned aerial system (UAS) is the most advanced intelligence, surveillance, and reconnaissance (ISR) platform designed to meet the critical requirements expected in demanding environments. With virtually no infrastructure needed to deploy the system, its dual EO/IR stabilized payload delivers real-time imagery, making the Seeker a lightweight ISR solution. ISR is essential in all military operations because it provides necessary information to make efficient and timely decisions. Aurea Avionics designs high-precision ISR systems, and its versatile solutions help protect strategic positions during military missions abroad.

Read more about how Aurea Avionics


Evok3D

Aldora UAV

The original idea of manufacturing the prototype was through ribs. Wood and carbon fiber would be used since these materials are light and resistant. For the outer shape we thought about the expanded polystyrene milling, but due to the thickness of the profiles we use, which is too small to make the flight more efficient, it was impossible to mill the material and the only way to achieve the shape we were looking for was making molds which were more expensive. In addition, the number of hours we had to invest were not viable considering that for each iteration we had to create a new mold and because of this we decided to discard this idea.

Read more about how Aldora UAV


GoProto ANZ Pty Ltd

Affordable low volume production of drone camera mounts.

MAPIR has been in the business of supplying drones since 2009. After extensive research and listening to their closest partners, they began the development of modular micro camera mount systems that can be attached securely to a drone without obstructing the original drone camera or functions. MAPIR started using 3D printing technologies several years ago to make prototypes.

Initially, a traditional injection moulding production method was planned, but due to low volumes (500-1000 parts per year) and high tooling costs ($35,000 for a single cavity tool) another path for manufacturing was explored. Having experimented with SLS, fused deposition modelling and stereolithography, MAPIR found these technologies either contained poor surface finish, brittle part materials or slow lead times. Seeking a process more aligned with injection moulding, MAPIR adopted HP MJF technology and benefitted from superior part quality and mechanical properties, as well as quick lead times, low part cost, and high part durability.

With the technology in place, MAPIR was able to create final production parts. One of the biggest benefits MAPIR came to realise, was that the part design can be changed at any time without incurring additional costs. If these parts had been produced with an injection mould tool, this would have required a major engineering change to the injection mould tooling that would have cost over $7,000 and 4 weeks of down time.

Read more about how Affordable low volume production of drone camera mounts.


CSIRO

Putting sleep aponea to bed with a 3D printed mouthguard

CSIRO’s Lab22 worked with dental company Oventus to help over a million Aussies suffering from sleep apnoea breathe easy and stop snoring.

The team of additive manufacturing experts created the first 3D printed mouth piece, which allows air to flow through to the back of the throat, avoiding obstructions from the nose, the back of the mouth and tongue. Is there anything 3D printing can’t do?

Read about how 3D printing is opening new doors for sleep aponea treatment.


Evok3D

NIVELLMEDICAL

Each patient could require between 10 and 15 treatment steps, and each treatment step consists of three dental arch aligners per jaw. The whole treatment requires the use of approximately 30 aligners and 10 molds to produce the aligners. Each aligner is produced with three different thicknesses as different strengths are required for each step. The single aligners are produced by thermoforming them on the 3D printed molds. In the end, an average complex case consists of 60 to 70 aligners and 20 to 30 molds for such an alignment treatment. The cost savings achieved in each alignment treatment is about 450€ to 900€ per treatmentProductivity is increased compared with other 3D Printing technologies. Using HP Multi Jet Fusion technology, output has increased fourfold to more than 100 pairs per day.

Read more about NIVELLMEDICAL


Materialise

OSSTEM IMPLANT Brings Dental Care to the Next Level

Today, human beings live longer than ever before. With a growing elderly population, healthcare, including dental care, has become increasingly important. OSSTEM IMPLANT, a leading dental implant manufacturer, has introduced 3D printing technology into their workflow. Powered by Materialise Magics software, they offer patients the highest quality and most innovative dental implant products.

Read more about OSSTEM IMPLANT Brings Dental Care to the Next Level

Evok3D

Bowman International

Bowman is the 3rd market player for bearing cages. The first two are SKF and SRB. These two competitors have not adopted 3D printing yet, they are bigger companies than Bowman and thus change is more difficult. Moreover, they have a lot of experience producing the aluminum bearing cages and are improving the design, but getting only 5% more productivity while Bowman is getting up to 40% with plastic parts.

Read more about Bowen International


Evok3D

Biesse Group

“We’ve worked with 3D printing since late 1990’s, primarily for rapid prototyping,” says Mr. Mencarini. “HP’s 3D printing solution allows us to do much more, including helping us bridge the leadtime gap of making metal molds and even allowing us to produce final parts, especially in short-runs that would be impossible to profitably manufacture otherwise.”

Biesse produces a premium product and technology innovation plays a key role in their ability to remain competitive. As 3D printing has matured, they have continuously evaluated new opportunities. When HP launched its first Multi Jet Fusion-based 3D printers, Biesse became an early adopter, purchasing an HP Jet Fusion 4200 3D printer.

The company chose HP because Multi Jet Fusion satisfies a variety of needs. Beyond simple models, Biesse wanted a more efficient way to create functional prototypes of it’s machines various mechanical components, including piston rods, pulleys, gear wheels, joints and other parts.

Read more about Biesse Group


Materialise

Supporting Samsonite in Setting New Standards in Luggage

In their mission to create the best travel bags the world has ever seen, Samsonite approached the innovation experts at Materialise to develop a highly detailed prototype for their latest launch. The Samsonite design team is on a mission: to perfect luggage and create the best bags and travel accessories the world has ever seen. To ensure that the prototype would work like the final product, Materialise Engineers used a mixture of Additive Manufacturing technologies, (stereolithography and laser sintering), to produce a complete suitcase. This included the textured case, as well as functional latches, handles, and wheels. In only eight working days, Materialise

Engineers delivered a completely assembled prototype to the Samsonite team

Read more about Supporting Samsonite in Setting New Standards in Luggage


GoProto ANZ Pty Ltd

GoProto’s Digital Warehousing Eliminates Inventory Costs.

Dirk Dorenbros, owner of Ropes Edge, utilises HP Multi Jet Fusion (MJF) 3D Printing for both prototyping and additive manufacturing. Based in America, Dirk wanted to expand globally, without incurring distribution and warehouse expenses. GoProto’s 3D Printing Digital Manufacturing Network (DMN) provided Ropes Edge the freedom to manufacture in American and Australia. Resulting in reduced inventory costs and a lean, agile supply operation with global reach.

On-Demand Manufacturing Boosts Ropes Edges Business Agility For Ropes Edge, additive manufacturing transforms the way they design, manufacture and distribute their products. More than 500 parts for Ropes Edge have been produced by GoProto using MJF technology, with each manufacturing batch undergoing stringent quality control checks. Empowering Customers to Achieve Significant Cost/Time Savings The speed and scope with which GoProto can manage the complexity of low volume manufacturing empowers customers to achieve significant economies of scale and produce functional parts at a fraction of the cost and time required by traditional manufacturing. By applying Design for Additive Manufacturing (DfAM) methods, companies like Ropes Edge can consolidate part/assembly and eliminated dependencies on tooling and fixtures that are part of traditional manufacturing models.

Allowing start-up companies to reduce their bill of material (BOM) costs and deliver lighter and more cost-effective parts. GoProto is demonstrating how additive manufacturing is optimising volume production of functional parts, and showing how traditional supply chains can be reinvented for digital manufacturing.

Read more about GoProto’s Digital Warehousing Eliminates Inventory Costs. 


human radiography scan with bones

CSIRO

Cancer patient receives 3D printed rib cage

Suffering from a chest wall sarcoma (a type of cancerous tumour that grows, in this instance, around the rib cage), a 54-year-old Spanish man needed his sternum and a portion of his rib cage replaced. This part of the chest is notoriously tricky to recreate with prosthetics, due to the complex geometry and design required for each patient. So the patient’s surgical team determined that a fully customisable 3D printed sternum and rib cage was the best option.

Melbourne-based medical device company Anatomics, designed and manufactured the world’s first rib and sternum implant using CSIRO’s 3D printing facility, Lab22.

Read more about the world’s first 3D printed rib cage.


Evok3D

iOrthotics

iOrthotics needed to triple production capacity within a six-month period, and they were unable to use current manufacturing methods to scale quickly. iOrthotics engaged University of Queensland’s Advanced Manufacturing and Engineering departments to test and benchmark all materials and to innovate and implement new technologies such as 3D printing. Using subtractive methods during the material removal process results in nearly zero waste in an industry known for producing significant waste.

Productivity is increased compared with other 3D Printing technologies. Using HP Multi Jet Fusion technology, output has increased fourfold to more than 100 pairs per day.

Read more about iOrthotics


GoProto ANZ Pty Ltd

Alternative COVID-19 treatment using HP’s 3D Printing technology.

GoProto ANZ has been working together with Erebus Medical and Cobalt Design to tackle a number of challenges hospitals face in dealing with COVID-19.

The project was initiated in mid-March, as the pandemic was escalating in Italy and Spain, and concerns that our hospitals could be overwhelmed with a predicted peek in Coronavirus patients in our emergency departments and ICU’s.

Working as a consortium, nicknamed project ‘Farnsy’, the group took some initial work that Italian and UK doctors had done in modifying snorkel masks to produce simplified pressurised oxygen masks. Cobalt spearheaded the design of several custom-made adapters to fit both the snorkels and CPAP masks. Allowing patients to receive pressurised oxygen, while their exhaled air is filtered to protect medical staff.

The converted CPAP masks can be used by hospital teams to treat sub-acute COVID-19 patients prior to them needing ICU ventilator treatment. This solution frees up ICU beds, limited ventilators and requires fewer medical staff to monitor them.

The converted CPAP masks with the 3D printed adapters’ features an oxygen feed line, so the patient receives pressurised oxygen-enriched air to their lungs whilst their exhaled air (that may contain aerosolized virus) is filtered out to protect medical staff. This type of system when applied to a sub-acute patient helps prevent the collapse of alveoli (lung air sacs needed for the intake of oxygen into the body) and aids recovery, improving the chances of avoiding incubation.

The HP Multi Jet Fusion 3D printing process at GoProto’s Melbourne facility, enables the components to be made at low cost and delivered quickly for immediate use in hospitals. Long-term applications for these kits can be for use as patient transfer masks or by aged care facilities here in Australia. The data has been made available on Cobalt’s website so that other countries whose hospitals are still under enormous strain or face a second wave and may need alternative recovery and treatment plans.

GoProto would like to thank AMTIL and the Advance Manufacturing Hub for their support. We are also grateful for the liaison and knowledge sharing of Dr Carl Le from Supercars headquarters and Barry Ryan from Erebus Medical who are also refining a number of medical products to help fill the void of PPE to protect medical staff from the virus

Read more about Alternative COVID-19 treatment using HP’s 3D Printing technology.


Coming soon

Evok3D

CAF Rail and Transport

CAF identified a group of metallic parts currently applied and used in train systems, suitable to be changed to plastic parts by digital transformations using HP Multi Jet Fusion technology. One of those parts is the support of the train’s doors cover structure. First, the parts are virtually tested and simulated the FEA (Finite Element Analysis) under their current mechanical requirements applying HP 3D High Reusability PA 12 material properties. As the parts were designed to be produced with metal, the part should be redesigned to adapt to the HP 3D High Reusability PA 12 material. However, a first FEA structural static analysis of the part was done in order to identify the areas that should be reinforced in this new design. CAF engineers started an iterative process of redesign and digital simulation, reinforcing or stiffening weak areas with fillers or other geometries in order to improve its robustness. Finally, the validated design was printed and produced to substitute of the metallic model in new train system assemblies.

Read more about CAF Rail and Transport

Coming Soon

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