The design and manufacturing of inspection and assembly jigs are often costly and complex processes, especially when traditional materials like aluminum and steel are used, which are machined through subtractive methods.
Aluminum is widely preferred for its excellent combination of lightness, stiffness, and corrosion resistance, making it ideal for applications requiring precision and durability. However, it also has significant limitations in this context: machining costs are high, production processes are time-consuming, and material waste is substantial. Thanks to the unique capabilities of Fabbrix® ELEMENTO TC, it has become possible to redefine the design and production of such equipment, achieving significant advantages in terms of cost, time, and performance.
From Traditional Design to Design for Additive Manufacturing (DfAM)
The inspection jig, initially produced through traditional machining processes, was assembled from multiple interconnecting parts. While this approach ensured rigidity and precision, it entailed high costs and significant production and assembly times. Additionally, the final artifact's overall weight and size posed challenges for ergonomics and ease of use.
The transition to Design for Additive Manufacturing (DfAM) was enabled by using the advanced modeling software nTopology (nTop), a revolutionary tool for 3D printing-oriented design. This software excels in optimizing the topology of geometries, reducing unnecessary material while ensuring the rigidity required for demanding industrial applications.
Thanks to a dedicated workflow, nTop allows for the creation of high-performance tools for additive manufacturing:
Through parametric computation algorithms, material can be removed from low-stress areas while maintaining strength in critical zones to ensure high performance.
This combination of capabilities makes nTopology an essential tool for those looking to push the boundaries of mechanical design toward more efficient and innovative solutions.
Design Choices and Materials
The jig was designed with particular attention to overall rigidity and durability by selecting advanced materials for 3D printing. Specifically, PET-CF, a carbon-fiber-reinforced polymer, was chosen for its:
- High Rigidity and Mechanical Strength: Ideal for applications requiring tight tolerances and dimensional stability.
- Lightweight Properties: The integration of carbon fiber ensures exceptional lightness, significantly improving ergonomics.
- Chemical Durability: Resistant to chemicals commonly found in industrial environments, extending the component's lifespan.
The combination of optimized design and material properties enabled the creation of a jig that fully meets functional and production requirements, providing a highly performant solution. Compared to the traditional aluminum solution, the improvements are evident not only in weight and cost but also in structural performance. Specific rigidity, calculated using load simulations in nTopology, showed a 15% increase, while overall weight was reduced by more than 70%. These results demonstrate how adopting PET-CF in 3D printing has led to a lighter, stronger solution, ideal for industrial applications.
Production Workflow
The production of the jig was divided into three main phases, each optimized to make the most of large-format 3D printing capabilities:
1. Digital Design: Using nTopology, the jig's design was completely revamped to ensure structural optimization, reducing weight while maintaining necessary rigidity. The software enabled the creation of a highly customized model, integrating specific functionalities for the intended application.
2. Print Preparation: The 3D model was processed with UltiMaker Cura for slicing and gCode generation. This step ensured optimal preparation for printing, leveraging the advanced capabilities of the ELEMENTO TC.
- Material: PET-CF (carbon-fiber-reinforced polymer)
- Layer Resolution: 0.3 mm
- Extruder Temperature: 250°C
- Heated Bed Temperature: 70°C
- Print Speed: 120 mm/s
- Infill: 30% triangular structure for lightweight rigidity
- Print Time: 1 day, 14 hours, and 13 minutes
- Material Weight: 1965 g
3. 3D Printing with ELEMENTO TC: The jig was printed as a single piece, reducing assembly times and ensuring perfect integration with commercial components. The precision of the Fabbrix® ELEMENTO TC ensured flawless results, minimizing tolerances and optimizing the final product's quality.
Achieved Advantages
The transition to 3D printing with Fabbrix® ELEMENTO TC brought numerous benefits, including:
Improved Ergonomics: The jig's overall lightness, achieved through intelligent mass distribution, significantly reduces operator fatigue, enhancing usability.
Extreme Customization: The design flexibility provided by nTop enables the integration of specific functionalities, such as dedicated housings, positioning guides, and details that improve production efficiency, all of which are impossible with traditional methods.
Cost Reduction: By eliminating traditional machining methods and producing the jig in a single piece, it was possible to save up to 80% in costs compared to the previous method.
Faster Production and Assembly Times: Lead time was reduced by 92% by producing the jig in-house without waiting for lengthy machining and assembly processes.
Enhanced Performance: The new jig offers superior rigidity, significantly lower weight, and better ergonomics, ensuring more efficient and comfortable operator use.
Sustainability: On-demand production reduces waste and minimizes environmental impact, a growing priority in modern industry.
Conclusions
The new inspection jig, created with the ELEMENTO TC, is a tangible example of how 3D printing is revolutionizing the industrial tooling sector. Looking ahead, this technology offers myriad potential applications beyond the production of inspection jigs. With the ongoing evolution of materials and design software, we can imagine greater integration of 3D printing in complex processes such as industrial automation, customized production, and the development of highly specialized components.
For young engineers, these innovations represent a unique opportunity to redefine manufacturing itself, embracing a more sustainable, agile, and technologically advanced approach.
By integrating advanced technologies, it has been possible to achieve a solution that combines high performance, reduced costs, and significantly shorter production times.
If you want to optimize your production processes with innovative solutions, contact an expert and discover how Fabbrix® technology can make a difference for your business.
