1. THE USE OF 3D PRINTING IN MANUFACTURING WESTERN WASHINGTON UNIVERSITY JACOB GREEN 2-17-16

2. 3D Printing in Manufacturing3D Printed Injection Mold ToolingStratasys Design Guide LinesQuestion and Answer 2 LECTURE OVERVIEW:

3. Tooling Thermoforming Injection Molding Blow Molding End of Arm Robotic Tooling (EOAT) Fixtures Part Prototypes 3 3D Printing in Manufacturing 3D PRINTING IN MANUFACTURING OVERVIEW:

4. THERMOFORMING TOOLING 4 3D Printing in Manufacturing [Cit.1]

5. THERMOFORMING TOOLING 5 3D Printing in Manufacturing [Cit.2]

6. 6 [Cit.3] [Cit.4] 3D Printing in Manufacturing INJECTION MOLD TOOLING [Cit.3]

7. 7 BLOW MOLD TOOLING [Cit.5] 3D Printing in Manufacturing

8. END OF ARM TOOLING (EOAT) 8 3D Printing in Manufacturing

9. FIXTURES 9 3D Printing in Manufacturing [Cit.6] Assembly Secondary (Heat Stake) Inspection

10. PART PROTOTYPES 10 3D Printing in Manufacturing Industries Automotive Medical Sporting Goods Materials TPE’s Commodity Engineering Grade

11. PROBLEM DEFINITION 11 Idea to Production (Injection Molding)

12. 12 3D Printed Injection Mold Tooling Design Approval / Payment FabricationTestEvaluation PRE-PRODUCTION ITERATIVE PROCESS

13. 13 3D Printed Injection Mold Tooling Design Approval / Cost Fabrication Test Evaluation PRE-PRODUCTION ITERATIVE PROCESS

14. WHY? 14

15. 15 CHOOSING THE RIGHT PATH 3D Printed Injection Mold Tooling

16. 16 COMMON WAYS TO ADAPT 3D PRINTED MOLDS TO THE IMM. 3D Printed Injection Mold Tooling MUD Housing Steel Plate With EjectionSteel Plate No Ejection

17. 17 1. Design Idea 2. Part to Mold Insert 3. Fit Check 4. Mold Fabrication 5. Test / Evaluation 3D Printed Injection Mold Tooling

18. 18 FURTHER PRODUCT/MOLD DEVELOPMENT Rev. 1Rev. 2 Rev. 3 3D Printed Injection Mold Tooling

19. 19 COST/LEAD TIME ANALYSIS 3D Printed Injection Mold Tooling $1,800 / 1.5 Days$8,000 / 21 Days

20. Recommended Sprue Gate Tab Gate Recommended Sprue Gate Tab Gate 20 DESIGN CONSIDERATIONS GATE Not Recommended Cashew Gate Sub Gate Not Recommended Cashew Gate Sub Gate Stratasys Design Guide [Cit.7]

21. 21 DESIGN CONSIDERATIONS EJECTION / COOLING SYSTEMS Recommended Ejection System Cooling Through the Mold Not Recommended Cooling Through the 3D Printed Medium Recommended Ejection System Cooling Through the Mold Not Recommended Cooling Through the 3D Printed Medium Stratasys Design Guide [Cit.7]

22. 22 DESIGN CONSIDERATIONS PRINT ORIENTATION Recommended Orient Mold Such That the Print Lines are in the Direction of Flow. Recommended Orient Mold Such That the Print Lines are in the Direction of Flow. Stratasys Design Guide [Cit.7]

23. 23 DESIGN CONSIDERATIONS DRAFT Recommended 3 degrees to 5 degrees The more the better! Recommended 3 degrees to 5 degrees The more the better! Stratasys Design Guide [Cit.7]

24. 24 Stratasys Design Guide [Cit.7] MOLD FINISHING Size ejector pin holes such that they can be reamed to size post printing. Sand rough features or residual layer lines on the mold face. Fit mold to housing (if applicable) so that it is fully supported and ‘snug’ in the housing. Tap holes for cooling lines (if applicable).

25. 25

26. CITATIONS (IN ORDER OF APPERANCE) [1]http://usglobalimages.stratasys.com/Case%20Studies/Commerical%20Products/ SSYS-CS-XeroxThermo-06-13.pdf?v=635174384366627817 [2]http://studiofathom.com/wp-content/uploads/Vacuum-Forming-White-Paper- F001-5-1-2014.pdf [3]http://www.plasticstoday.com/sites/default/files/images/2.%203D- Printed%20Mold%20Components%20(Stratasys).jpeg [4]http://www.i3dmfg.com/industries/tooling/ [5]http://www.etmm- online.com/index.cfm?pid=10890&pk=404667&fk=580928&type=article [6]http://www.dalsinind.com/dfm-and-design-engineering.htmlhttp://www.dalsinind.com/dfm-and-design-engineering.html [7]Objets Recommendations for 3D Printing. (White Paper) www.stratasys.com 26