Advantages and Considerations When using Direct Digital Manufacturing - Stratasys - #3
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DDM PART 2
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PAGE 3
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part quality will be further improved. But presently, there are a few characteristics that may differ from established expectations for high-volume production methods.
The first quality consideration is part accuracy. DDM is currently capable of holding accuracies that are approximately ±0.005 inch for small to mid-sized parts. Contrary to a process like injection molding, DDM is currently not capable of holding ± 0.001 to 0.002 inch tolerances across all features of a part.
Another factor is part-to-part repeatability. With the present state of the technology, as there is with all technologies to some degree, there is dimensional variance from run to run of the DDM machines. Also consider that without secondary finishing, the surface finish of a DDM part may not be suited for external components that demand high aesthetic value. Instead, the finish is more appropriate for internal components. However, surface finish should not be used to arbitrarily disregard DDM. For example, the Fortus 400mc and 900mc systems have external parts that have been produced through DDM.
3. Material Characteristics
A final consideration is the properties of the materials that are available from DDM technologies.
While a technology like FDM offers real production grade plastics such as ABS, polycarbonate and ABS/PC blends, the material selection is much more limited than that for a process like injection molding. Stratasys has one of the broader ranges of materials with distinct formulations, yet it does not come close to the hundreds of engineered plastics or metal alloys that are available for traditional production methods.
For plastics parts, also consider that there may be concessions with mechanical, electrical or thermal properties. Generally speaking, and when considering all DDM technologies, the material properties do not match those of the materials used in traditional manufacturing processes. For example, an FDM ABS material provides approximately 80% of the strength of an injection molded ABS part.
conclusion
DDM is a process that allows companies to innovate product designs, business models and manufacturing processes. It lets engineers optimize designs and maximize performance. DDM can expedite product launches while eliminating tooling costs and tool lead times. And it frees manufacturers from the constraints of conventional processes, which allows the freedom to design complex items and freedom to change the design at any time.
Yet, as with all processes, there are some limitations. For DDM opportunities, look for low-volume production applications that can be adjusted to accommodate the constraints in quality and materials. For the next industrial revolution to occur, improvements and advancements are needed in areas such s technology, equipment, materials and science. Over the coming days, months and years, these advancements will take place. As they do, DDM will become more prevalent throughout more companies and in more products.
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Figure 5: Diebold ATM keypad privacy shield
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For more information about Fortus systems, materials and applications, call 888.480.3548 or visit www.fortus.com
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Fortus 3D Production Systems Stratasys Incorporated 7665 Commerce Way Eden Prairie, MN 55344 +1 888 480 3548 (US Toll Free) +1 952 937 3000
+1 952 937 0070 (Fax)
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Fortus 3D Production Systems Stratasys GmbH Weismùllerstrasse 27 60314 Frankfurt am Main Germany
+49 69 420 9943 0 (Tel)
+49 69 420 9943 33 (Fax)
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FORTUS
3D production systems
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©2009 Stratasys Inc. All rights reserved. Stratasys and FDM are registered trademarks and Fortus, Real Parts, Fortus 200mc, Fortus 360mc, Fortus 400mc, Fortus 900mc, Insight, Control Center and FDM TEAM are trademarks of Stratasys Inc., registered in the United States and other countries. *ULTEM 9085 is a trademark of SABIC Innovative Plastics IP BV All other trademarks are the property of their respective owners. Product specifications subject to change without notice. Printed in the USA. WP-DDM2 03/09
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