Maximizing Production Efficiency with 3D Printed Tools
Volkswagen Autoeuropa: Maximizing production efficiency with 3D printed tools, jigs, and fixtures Volkswagen Autoeuropa, who is responsible for manufacturing iconic Volkswagen models such as the Scirocco and Sharan, and has yearly output levels of 100,000 cars, now uses 3D printing to revolutionize its workflow. The facility 3D prints manufacturing aids that are used daily on the assembly line. No longer having to rely on external suppliers for its tools, jigs, and fixtures greatly reduces the costs and shrinks lead times from several weeks to just a few days. 3D printed manufacturing aids The case of Volkswagen Autoeuropa illustrates how 3D printing can be of great value to the automotive industry. While - traditionally - 3D printing used to be associated with creating prototypes, it has great potential for manufacturing businesses in creating custom tools, jigs, fixtures, and other manufacturing aids. With 3D printing, it's possible to create highly complex designs and make rapid revisions and amendments, without cost penalties or long lead times. The tools can be tailored to match exact requirements, making function and performance the main drivers of design - not cost or time. This 3D printed wheel protection jig was previously sourced for $950, but can now be printed at [...]
Desktop Metal Releases Pure Copper 3D Printing Material
Now Commercially Available to Studio System Customers Worldwide, Copper Enables High-Performance, Highly Optimized Parts for Oil & Gas, Auto and Consumer Products Industries Desktop Metal recently announced the launch of copper for the Studio System. With its excellent thermal and electrical conductivity, copper is considered an ideal material for transferring heat or electricity and is used in virtually every electronic device made, as well as in many of the heat exchangers used across a variety of industries, including oil and gas, automotive, and consumer products. A key benefit for Desktop Metal customers is that the copper material used with the Studio System is pure copper. Unlike laser-based processes, which often print chromium zirconium copper, the Studio System’s proprietary Bound Metal Deposition process is able to print pure copper, unlocking the full benefits of the material. “Known for its excellent thermal and electrical conductivity, copper is a highly desired material for a variety of industries and applications, such as heat exchangers and electrical components for heavy industries to consumer products,” said Jonah Myerberg, CTO and co-founder of Desktop Metal. “Whether for heat sinks, electrical motor and power grid components, or resistance welding electrodes, 3D printed copper on the Studio System is an ideal choice [...]
3D Lathe Tool Enhancements in Mastercam 2021
Mastercam 2021 offers some great enhancements for 3D lathe tools. 3D tools now support interchangeable inserts defined for the same holder, multiple cutting definitions for each insert, as well as supporting multi-station toolholders. Let’s take a look at how this all works. In the tool designer, there is now an insert list for each holder. This allows you to simply add an insert definition for all the different inserts that fit this specific holder. This is a great time and space saver when building your tool library. To use it, start by selecting the Add Insert button, give it a name, and then select the insert from the graphics screen. Then, just like any other 3D tool, you need to define the corner radius, rotation angle, and compensation point. From this page, you can also add cutting definitions to each insert. This allows you to define different cutting conditions to select from your insert list. If you often use the same insert to cut various material types, this will allow you to quickly change your speeds, feeds, and coolant options. It also allows you to change any other cutting condition required to machine each material type without needing to create a new tool [...]
Success with Mastercam Swiss Solutions
Two of our Mastercam experts (Rick Bair and Yolexis Lima) recently joined a corporate Mastercam meeting to discuss the success they were having with Mastercam Swiss Solutions. Here is what our experts shared about their confidence in the product, and how it is not only opening the doors to new customers but strengthening relationships with customers already using Mastercam. The following are excerpts from the presentation. Top left to right: Mastercam Swiss Product Specialist Chris Leclerc, Cimquest Director of Mastercam Sales Rick Bair. Bottom left to right: Cimquest Senior Account Executive Yolexis Lima, Mastercam Chief Technology Officer TJ Boberek Rick: I’ve been selling Mastercam for thirty years, and this is the first time that I’ve had a Swiss solution that I feel comfortable with. The Swiss market has been growing tremendously in our territory, so it’s something we definitely need to have. Chris’s knowledge of the Swiss world and machines allows him to be extremely helpful when explaining the Swiss solution to customers and potential customers. Having this Swiss solution keeps us in the conversation with potential customers that have Swiss machines, as well as keeping our existing Mastercam customers from looking at other products for a solution. It’s very easy to [...]
Measuring Features on a Mesh Without a CAD Model
While most inspection software will use a nominal CAD model during the inspection process for comparison of manufactured features to exact CAD features, Control X can perform a feature-by-feature analysis without utilizing a CAD model. This can come in very handy when a CAD model doesn’t exist for inspection and just a 2D drawing is used. The first step is to import just the mesh file or point cloud into Control X. As a reminder, mesh files go into the MEA (Measured) node and CAD or nominal models end up in the REF (Reference) node. Since the system will assume the mesh or point cloud should be the MEA for the upcoming inspection, that is the node where the polygonal file ends up. We need to use the Model Manager and transfer the mesh to the REF node, indicating that no CAD model will be used and just the mesh will be inspected. Next, we need to create Regions on the model so the software can identify features. Once Regions are created, you can measure any of the Region Features as if they come from a solid model and not a mesh or point cloud. Regions are identified by color, as depicted below. [...]
Using Surfaces to Create Stock Models Mastercam 2021
This blog post will cover how to use the Surface Stock Model feature in Mastercam 2021 when remachining a finished part. In this example, we will walk through remachining the orange pocket shown below in the mold core. We will use Stock Model to create machineable stock only on the walls of the pocket. To get started, we can create some surfaces from the solid model. First, create a new level and name it surfaces. Now launch the From Solid Surface tool and select the pocket walls to create your surfaces. Now you are ready to create your stock model. Start by selecting the stock model tool from the Toolpath tab. Then give it a name. Next, you can set your initial stock shape to model and hit the selection arrow to pick your surfaces from the graphics screen. Finally, you can add .03” of additional offset to represent the stock to be removed from your pocket and select a color so your stock model stands out from the part. Add the additional offset here. Use this icon to bring up the color palette window. And select your color. One of the benefits of using Stock Model [...]