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CASE STUDIES

ADDIMAT CASE STUDIES

 

With the aim of publicizing additive manufacturing technology and 3D printing and the real possibilities of its industrial application, this section collects success stories from companies associated with ADDIMAT in different sectors.

 


 

Design and manufacture of an AM3DP-based lens manipulator for Continental

LEITAT

Sector: Automotion
Challenge: To develop a light and robust solution for the gripping, handling and placement of the lenses in the hot stamping and assembling process using a cobot.
Solution: Generative design of an integrated lightweight tool and manufactured in polymer with MJF additive technology for use with cobots.

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Reducing process tooling weight
 

ADDIMEN

Sector: Metalworking
Challenge: To reduce the weight of the tool used to tighten a longitudinal steel-cutting shaft. The aim was to reduce the weight by 50%.
Solution: Material was hollowed and removed to improve the ergonomics of a tool that, in this case, is handled manually.

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Recovery of spindles from rubber extruders

IBARMIA

Sector: Automotive
Challenge: Within the framework of the European PARADDISE project, the Michelin company proposed the recovery of damaged rubber extrusion spindles.
Solution: The proposed solution consisted in coating the damaged areas of the extrusion spindle using laser cladding technology.

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Manufacturing trains with additive technology

CAF Digital Manufacturing

Sector: Railway
Challenge: The challenge is to introduce additive manufacturing at a competitive price and with the added value of design.
Solution: Parts capable of being manufactured by AM have been detected in the project phase, as well as their economic feasibility versus traditional manufacturing.
 

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Development of conductive compounds for functional part printing using FDM

AIMPLAS

Sector: Consumer Goods
Challenge: To obtain a plastic with electrical conductivity to replace metal in applications where freedom of design and lightweight properties are essential requirements.
Solution: Selection of materials, load distribution and optimisation of processing conditions are key to obtaining a compound with surface electrical conductivity.

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Improvement of the plastic cap injection process

ADDIMEN

Sector: Moulds & Dies
Challenge: The customer needed to improve productivity of a plastic cap injection mould with 8 cavities.
Solution: A new design was made for the heating/cooling channels inside the insert to improve the injection cycle.
 

 

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KOMET® GROUP innovates cutting tools using metal 3D printing technology

RENISHAW

Sector: Metalwoking
Challenge: Create innovative cutting tools using metal additive manufacturing technology.
Solution: Metal 3D printing technology to produce maraging steel screw-in milling cutters in one build.

 
 

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Serial production of combustor swirler for a Siemens Gas Turbine

SIEMENS

Sector: Energy
Challenge: Combustor parts are complexdesign, high-temperature, performance-critical, long-lead items, critical to increase gas turbine performance and to meet environmental regulations.
Solution: Siemens redesigned a combustor´s swirler assembly by integrating components into a single AM design, and assured reliable serial production.

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Renishaw conformal cooling solutions prove a boost to moulding productivity

RENISHAW

Sector: Moulds & Dies
Challenge: Increase productivity of existing injection moulding equipment.
Solution: Mould designs incorporating conformal cooling with additively manufactured inserts in maraging steel.

 
 

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Optimised active flow control actuators manufactured with SLM for aircraft with UHBR engines

LORTEK

Sector: Aerospace
Challenge: Development of new flow control actuators (FCA) with innovative aeronautical designs to improve fluid flow in future UHBR engines.
Solution:SLM manufacturing of flow control actuators with optimised and complex designs, to be installed in areas with reduced dimensions of aircraft with high-efficiency engines.
 

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Digging deep with Wassara
 
 

RENISHAW

Sector: Heavy industry
Challenge: Reduce cost and increase reliability of the production of the sliding case component of a down-the-hole (DTH) hammer.
Solution: Using additive manufacturing to reduce the number of component parts in maraging steel which is more resistant to pitting corrosion.  
 
 

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LightHinge+: possible thanks to additive manufacturing
 

MSC SOFTWARE

Sector: Automotive
Challenge: Substantial weight reduction, fewer components, fewer assembly steps and integrated pedestrian protection for a cover hinge made using additive metal manufacturing.
Solution: The distortions were simulated to reduce the number of testing steps. Thanks to countermeasures applied to compensate for deformation, part production times were reduced while meeting the quality goals.

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Design and additive manufacture of a metal mould to shape plastic tubes

OPTIMUS 3D

Sector: Moulding
Challenge: Design and manufacture of a mould to shape PA12 tubes, thereby optimising the manufacturing process, facilitating assembly by the worker, reducing costs and delivery times.
Solution:Manufacture of a mould made of AISI 316L stainless steel, printed in parts using SLM technology and welded after manufacture.

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Development of shoe sole prototypes using 3D printing

REDIT

Sector: Consumer goods
Challenge: Additive manufacturing and 3D printing versus traditional milling with CNC to develop industrial prototypes of shoe soles.
Solution: Use of 3D printing as a more efficient alternative to manufacture sole prototypes, thereby reducing costs and time.
 

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DaVINCI painting robot
 

HP

Sector: Consumer goods
Challenge: HP intended to make a new painting robot that is more accurate and sustainable than those that already exist on the market.
Solution: To make a painting machine with the best functionalities and compact systems requires designing parts that are smaller, lighter and with more complex shapes, made possible by additive manufacturing.

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Replacing 5-axis machining of slender parts with additive manufacturing for the science industry

EGILE

Sector: Science
Challenge: Additive versus conventional manufacturing of a kit of 316L steel spacers for superconductor magnets. Technical and economic feasibility analysis.
Solution: The customer found a clear opportunity to improve processes and opted for additive manufacturing of these kits, which were previously manufactured by machining.

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Personalised 3D biosplint for patients with rhizarthrosis
 

OPTIMUS 3D

Sector: Medical
Challenge: To design and manufacture a customised orthesis to improve the ergonomics of the current health product. To prolong its use during treatment and thereby reduce the pain.
Solution: An alternative orthesis adapted to each patient with rhizarthrosis. A customised ergonomic design that is lightweight and manufactured in biocompatible material.

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Development of shoe tree prototypes using 3D printing
 

REDIT

Sector: Consumer goods
Challenge: Using 3D printing techniques to manufacture shoe trees and avoid current subtractive manufacturing techniques.
Solution: Introduction of 3D printing techniques in shoe factories to produce shoe trees for samples, thereby reducing costs and time.
 

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