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Omni 3D Printer saving time and money

29.03.2017

Thanks to OMNI additive manufacturing, a new customer saved hundreds of thousands of pounds in just a few weeks! 3D printing using the latest technology can bring hugh potential savings: 90% cost reduction and 80% time savings.

The functional prototype of a train seat was printed using FFF technology on the Factory 2.0 industrial 3D printer from OMNI3D. This project was carried out by METRIS3D for POLGAR KFT, the Hungarian manufacturer of parts for the automotive industry.

Creating a functional prototype has never been so cheap, fast and easy.

 

‘Now, preparing the model cost all together about €40,000, before this was over €400,000 [including the cost of the tooling]. It’s just a fraction of the budget! Regarding the time, now it takes only 3 weeks to prepare first prototype, before it took as long as 4 months…,’ – says Miki Thurzo, Senior Engineer from METRIS 3D.

POLGAR KFT needed the prototype to verify the design of a train seat. There are always some critical points in a design that should be double checked, preferably in real scale.

‘The great thing about having a functional prototype is that we could really test the model. Before, this was impossible due to very long lead time. Now, thanks to 3D printing, we could change the design soon after we made the first 3D prints. It turned out, for example, that some of the movable parts (like trashcans and holders) could not been moved, which was missed in the CAD file,’ adds METRIS 3D.

OMNI3D presents some of the technical specifications of the print performed on the Factory 2.0 Production System:

  • Model: 2 train seats and platform
  • Number of elements: 37
  • Print time: 500 hrs
  • Size of the biggest element: 480 x 210 x 370 mm
  • Size of the smallest element: 70 x 70 x 20 mm
  • Filaments: model ABS-42, support HIPS-20
  • Filaments weight: 10 kg (70% of ABS-42)

Factory 2.0 has one of the largest working platforms with the heated and closed chamber available on the market. Thanks to this, 3D printing specialists from OMNI3D could minimalise the number of the printed parts, which was very important to get the highest strength of the final model.

‘In the case of large models, most challenging is the size of the biggest element, the dimensional accuracy and print time. Factory 2.0 enabled us to print large parts of even 500 mm along each axis with very high accuracy. Thanks to numerous machines available in OMNI3D’s print room, timing is also not a problem. The printing process took us about 2 weeks,’ adds Krzysztof Kardach, Chief of Technologies at OMNI3D – responsible for the printing process.

3D scanning is always the best verification of the 3D printed part.

​​‘We scanned the biggest print (480 x 210 x 370 mm) on our professional 3D scanner – RPS EVO6 – to verify the dimensional accuracy. The results were impressive. The accuracy obtained enabled us to get a perfect fit with the metal seat frame prepared before,’ explains Miki.

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