Normal is a company in New York City that is using 3D printing to develop a gadget that many of us rely on every day - earphones. Earphones are a cherished component of smartphones, mp3 players, tablets, and computers. In the earphones industry, there are a wide variety of options available, ranging in size, shape, material, and sound quality. But even with this abundance of choices, it can be difficult to find a comfortable pair that fits perfectly in your ear and remains tight in place through basic activities. At Normal, CEO Nikki Kaufman’s frustration with ill-fitting headphones fueled her desire to find a design solution. She discovered that the only application currently used for customization was silicone molding, a process which can cost up to several thousand dollars per unit. But her knowledge of additive manufacturing lead her to come up with the idea to use 3D printing as a primary method of production. By using Normal’s mobile app, or visiting Normal’s retail headquarters in Chelsea New York, consumers simply get photos taken of their ears. Normal processes the photos, and then 3D prints the lobe attachment with ABS thermoplastic, using a Fortus 250. The earphones can be printed in a variety of [...]

Let’s explore investment casting and how FDM tooling can be employed in this distinctive process. Investment casting, also known as lost wax casting, is a centuries old process used to produce metal components with intricate geometries and precise details. In this process, molten metal is poured into a ceramic cavity, which is formed by a wax pattern. The wax pattern is dipped into a ceramic slurry, and then melted out once the ceramic shell hardens. Metal is poured into the shell and after cooling, the shell is broken and removed, revealing a finished end-use part. The advantages to this process are great surface finish, high dimensional accuracy, endless shape potential, and the ability to fill very thin sections. It is generally used in applications that have relatively low production quantities and changing product designs. Injection molds are typically used to form the wax patterns. However, since investment casting is used for intricate designs, these molds require complex core assemblies and can cause parting line flash. In addition, lead times to produce these molds are approximately two months, with high costs ranging between $5,000 to $25,000. A big problem for foundries is they cannot produce any castings until the wax mold is complete, so [...]