1. Case Study: Volvo Additive Manufacturing Solution
SCHIVO.....engineering Partnerships

2. The Problem
Volvo engineers recently designed a new water pump housing for the company’s A25G and A30G articulated haulers.
Engineers used simulation to optimize the design of internal flow passages in the housing, but needed to build a prototype to perform functional testing to validate the new design
The tooling cost for this project would have been approximately $9,090, with the part cost around $909. The lead time for producing the prototype would have been 20 weeks minimum.

3. The Solution
VCE management tasked the engineering team with cutting development costs and reducing the lead time on large engine projects from 36 to 24 months.
Engineers felt 3D printing would be a good benchmark to determine if printed parts could withstand functional testing.
Water pump housing prototypes must be able to survive the heat and high pressure of the engine compartment.

4. The Solution
3D printed the housing in Transparent material, also called FullCure 720.
They mounted nine threaded inserts into the part and sealed the housing with epoxy resin and hardener to prevent leakage. They fastened the jacket to a water pump and then mounted the pump to an A30G.
Engineers took water flow and pressure measurements from both the existing water pump and the water pump with the new housing. The newly designed housing passed the tests.

5. 3D printed this water pump housing in Transparent material for quick functional testing

6. Water pump installed in an A30G for functional testing

7. Success
This project demonstrated the feasibility of integrating 3D printing into Volvo’s engine development process. Each new generation of engines typically requires 15 to 20 new cast metal parts and 12 to 15 profile molded hoses for each engine.
3D printed prototypes can be produced in about 1/10th of the time required to produce prototypes using traditional manufacturing methods, which adds up to a hefty time savings.

8. Case Study: Medronic Additive Manufacturing Solution
SCHIVO.....engineering Partnerships

9. The Problem
Engineers recently designed a ratcheting counter-torque instrument that surgeons use to fasten set-screws to a corrective implant on a patient’s vertebrae.
After the screws are fixed in place, the tool shears off the screw heads at a pre-set torque level. The existing method required surgeons to use separate tools, working them in opposing directions, using both hands.
The result was often a violent impulse that occurred at the moment the screw head sheared off, and the surgeons wanted to eliminate that.

10. The Solution
The engineers produced a working polycarbonate ratchet strong enough to withstand testing on stainless steel set-screws and durable enough to survive an autoclave.
Surgeons are really rough on these prototypes while trying them out, so we have got to have tough material. FDM gave the prototypes the strength and durability needed.
After sending the counter-torque ratchet out to three hospitals, Engineers learned that the tool design could be improved by rotating its handle 90 degrees — information it might not have learned without working prototypes.

11. The Solution
A working prototype printed in fully serializable material

12. Success
The financial advantages of including FDM Technology in the prototype lab are evident. Now designs are defined more before you start cutting metal, which is where the costs start going up exponentially.

13. Case Study: J750 Polyjet Solution
SCHIVO.....engineering Partnerships

14. Case Study: FDM Oreck Jig/Fixture Solution
SCHIVO.....engineering Partnerships

15. Case Study: FDM EOAT Solution
SCHIVO.....engineering Partnerships

16. Case Study: Architecture Solution
SCHIVO.....engineering Partnerships