Additive Manufacturing 3D Printing Process Success Stories

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Case Study:
PBC Linear

Problem:
Needed lower-cost boring magazine and ramp fixtures that would increase shop efficiency

Solution:

PBC Linear used a 3D printer to create fixtures, saving valuable man-hours in their production and implementation on the shop floor.

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Case Study:
Rapid 3D

Problem:
3D printing a large, radio controlled (RC) truck body for a high-profile rugby promotion

Solution:
Rapid 3D utilizes our large format 3D printer to create large parts that are easily fitted together to form the RC Truck.

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Case Study:
3D Printing Tech

Problem:
Help build a 12-foot tall Coca-Cola bottle for College Game Day promotions

Solution:

In only 8 days, 3D Printing Tech was able to print 6 parts and piece them together for the giant bottle mold that would be used for the fiberglass construction.

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Case Study:
FOX Sports Robot

Problem:
Thingergy brings the giant replica of the FOX Sports Robot to life

Solution:
The large format 3D printer was integral in 3D printing many of the 114 big parts that helped to make up the iconic FOX Sports robot and bring Cleatus to life.

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Case Study:
Thermoform

Problem:
Utilizing a small desktop printer can be ineffective and difficult for printing

Solution:
Thermoform fast and effective method to create high quality patterns
and master tooling for vacuum and thermoforming molds to be used for large and small batch production

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Case Study:
Progress Rail

Problem:
Needed to create mock-ups for expensive castings and machining tools.

Solution:
3D-printed quarter-sized mock-ups to develop standards and studies – Saving time and money

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Case Study:
Thingergy

Problem:
Needed a printer that could print with a combination of techniques

Solution:
Quick turn around! Thingergy was able to start printing parts instantaneously. The 3DP Workbench solves these challenges by providing high-quality prints and usable parts.

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Case Study:
Warwick Drone

Problem:
Build a drone with 7-foot wingspan that’s not too heavy

Solution:
3D printed the mold masters in one piece, eliminating the need for heavy fasteners, keeping the craft light

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Case Study:
Titanic Design

Problem:
Needed new, cost effective equipment and tools that could help in product development

Solution:
“Printer directly competes with the best equipment in the market.” Added 2nd machine to meet demand!

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Case Study:
Innovative 3D

Problem:
Required the output of large metal parts with complex shapes

Solution:
Large format print area allows development of support fixtures in one single piece

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Case Study:
Gonzaga University student project

Problem:
Create a simple Ankle Foot Orthosis that meets requirements and is 18” long.

Solution:
Utilized large-format 3D printer to create high-quality, affordable AFOs in an optimized timeframe.

3DP-US-Architectural-Lighting-Case-Study

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Case Study:
U.S. Architectural Lighting

Problem:
Needed a more cost-effective and quicker way to produce lighting prototypes

Solution:
Eliminated the outside source and expense by creating casting masters in-house on 3D Printer.

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Case Study:
Oozing Filament & Poor Print Quality

Problem:
Bulging, oozing, oversized beads of filament

Solution:
Reduce the nozzle temperature and decrease flow rate

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Case Study:
Thin Walls & Damaging Supports

Problem:
Thin walls, steep overhangs and weak parts

Solution:
Increased fill percentage and double support structures

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Case Study:
Common Model Errors

Problem:
Models can exist in the virtual world, but not the physical world

Solution:
Utilize software with file repair features, you can create one solid file that does not have intersecting surfaces

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Case Study:
Blobs and Zits

Problem:
Retraction settings and distance are not setup correctly, as well as bad start points

Solution:
elect a proper retraction distance and a start point closest to specific location

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Case Study:
De-Laminating Layers

Problem:
Poor quality material, print temperature too low

Solution:
Changing to a higher quality material/supplier, raising the active print temperature

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Case Study:
Separation LayersSeparation Layers

Problem:
Separation layers not set correctly, printing directly in contact with solid layers

Solution:
Adjust separation layers and distances allow for easy removal of support material

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Case Study:
Stringing

Problem:
Retraction settings setup incorrectly

Solution:
Adjust retraction distance to proper settings allows the extruder to travel between parts without stringing

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Case Study:
Support Material

Problem:
Support material did not stick to the print surface, minimal surface contact did not allow the material to adhere properly

Solution:
Increasing the number of skirts allows the support to build from a single layer of material as a base

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Case Study:
Underextrusion

Problem:
Extrusion multiplier set too low, under-extrusion occurs when the extruder does not supply enough material as fast as it is needed

Solution:
Increase the extrusion multiplier, raising the print temperature results in better material flow to prevent under-extrusion

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Case Study:
Warping

Problem:
The material creates tension on the thin features of the part as it cools and begins to pull away from the print surface

Solution:
Reduce the infill percentage, the internal tension can be relieved, add a brim to the part to givee the thin features more surface contact

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Case Study:
Sunnyslope High School

Problem:
Creating components for FIRST Robotics Competition

Solution:
Students and faculty use 3D printer to create light-weight and cost-efficient components to take home prize

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