Additive manufacturing case studies
Latest additive manufacturing case studies.
The design freedom provided by additive manufacturing (AM) or ‘3D printing' technology is an important enabler in cutting-edge product innovation. As part of the revolution in digital manufacturing, AM can radically simplify the production of complex parts, while simultaneously improving functional performance, reducing part weight and minimising component counts.To take full advantage of AM's unique capabilities, however, complementary software tools need to be optimised to satisfy the new requirements of ‘design for additive manufacturing' (DfAM) rules and guidelines. Dassault Systèmes, a world-leading provider of 3D design software, 3D Digital Mock Up and Product Lifecycle Management (PLM) solutions, collaborated with Renishaw to streamline its 3DEXPERIENCE® platform to deliver a no-compromise end-to-end AM design experience.
KOMET® GROUP is using Renishaw metal additive manufacturing technology to produce new ranges of innovative cutting tools. As well as allowing special cutters to be produced more quickly, the use of additive manufacturing enables more complex shapes to be generated, both for the external shape of the tooling and for the internal cooling channels.
Technology from Renishaw is helping HiETA to move metal additive manufacturing (AM) from prototype manufacture into commercial production of its specialist range of heat exchangers. In particular, the recent addition of Renishaw's RenAM 500M system at the company has enabled manufacturing times and, therefore production costs, to be reduced dramatically.
Additive manufacturing (AM) is highly suited for the design and manufacture of manifolds due to its ability to build internal features and passageways. Renishaw has collaborated with a customer to redesign their current hydraulic block manifold with additive manufacturing in mind. The main goal of the project was to reduce the mass of the component whilst retaining its robustness. Due to the increased design freedom associated with additive manufacturing, an opportunity to increase the efficiency of the flow paths was also identified.
Metal additive manufacturing technology from Renishaw has enabled Robot Bike Co. to produce a novel design of mountain bike that can be customised to match the size and riding style of the rider.
Moto2 team TransFIORmers is using cutting edge metal additive manufacturing (3D printing) technology in an unconventional front suspension system to gain a significant competitive advantage.
Renishaw has collaborated with a leading British bicycle design and manufacturing company to create the world's first 3D printed metal bike frame. The two companies re-designed an existing aluminium mountain bike frame to take advantage of Renishaw's additive manufacturing technology, allowing them to create a titanium frame that would be both strong and light using topological optimisation - the new frame is some 33% lighter than the original.
BLOODHOUND's aim is not only to break the sound barrier but also to be the first land vehicle to exceed 1 000 miles per hour (1609 km/hr) - at this speed it will be travelling the length of 4.5 football pitches every second.
The majority of the cockpit and nose is made from carbon fibre reinforced epoxy. During the record attempt the car will experience more than 20 000 kg of skin drag. However as the nose tip is on the ‘leading edge' it will experience a greater proportion of this load; up to 12 000 kg/m².
The GreenTeam and Renishaw - a premium sponsor - have collaborated to develop and manufacture optimised wheel carriers for a Formula Student racing car, reducing the overall weight of the car by 1.5 kg and making it their lightest vehicle to date.
Formula Student is Europe's most established educational motorsport competition, bringing together industry leaders, high profile engineers, universities and students from around the continent. The aim is to design and build a single-seater car which races on a course normally reserved for Formula 1. Formula Student is also a place where innovation is very much at home, particularly when it comes to new manufacturing methods and design engineering.
Wassara is a Swedish based mining company with a number of innovative products capable of extracting minerals with minimum environmental impact. Wassara's technology uses high pressure water to power the Down-The-Hole (DTH) hammer. The challenge is to reduce cost and increase reliability of the production of the sliding case component of a down-the-hole (DTH) hammer by employing Renishaw's metal additive manufacturing technologies.
The use of cores incorporating conformal cooling in the moulds for its plastic casings has allowed Alfred Kärcher GmbH & Co.KG to reduce the cooling time for each part by 55%, giving a huge boost to the company's moulding productivity. The special cores, which were designed by Renishaw, were produced using metal additive manufacturing technology.
A partnership with Renishaw saw the introduction of additive manufacturing to Swift, fitting seamlessly into a newly implemented digital workflow. Renishaw supplied an AM250 system, which uses a high-powered ytterbium fibre laser to fuse fine metallic powders together to create a final three-dimensional structure.
A seven-year-old Bernese Mountain Dog with a tumour on the left side of his maxilla (upper jaw) had few options other than total excision of the growth followed by reconstruction. A customised 3D printed titanium implant supporting the dog's bone structure was the most appropriate treatment due to the complexity of the region, requiring significant design and manufacturing freedom.
Proslab turned to global engineering company Renishaw to fully digitalise its manufacturing process using additive manufacturing.Before working with Renishaw, Proslab introduced a partially digital workflow, using 3D scanning and design tools to design dentures.
Complex reconstructive surgery can significantly benefit from a digital workflow and pre-planning processes to help optimise operating theatre productivity with excellent surgical results. Read how Renishaw used its additive manufacturing (metal 3D printing) expertise to help the University Hospital of Wales (UHW) treat a patient who suffered cancer of the lower jaw and required removal of the affected region coupled with reconstructive work.
Metal 3D printing's real life applications are ever increasing. Read how a NRIEF's mission to Nepal has taken advantage of this technology by helping a young mother who was a road traffic collision victim.
From complex reconstructive facial surgery to orthopaedic and trauma surgery, advances in additive manufacturing have inspired a growing number of progressive surgeons to commission metal 3D printed patient specific implants (PSIs) and cutting guides for both complex and straightforward procedures.