Tag: Case Study

11
May

A Solution for Foundry: Customer Highlight & CastExpo

In Morelia, Mexico, one pattern shop is revolutionizing its business and the foundries it serves by utilizing Pellet Extrusion and Filament Extrusion 3D Printing on the Atlas. Proveedora de Servicios y Suministros Industriales (PSSI) is a leading pattern shop owned by the same group as Fundidora Morelia. PSSI specializes in manufacturing patterns for pumps, turbines, high-pressure valves and industrial parts.

The Challenge

PSSI’s traditional method of making large patterns required cutting the pattern out of wood. This process was time consuming, taking up to 8 weeks in some cases. Using wood feedstock was also costly, sourcing expensive mahogany that was often not a uniform size that required extensive machining.

The Solution

By utilizing 3D Printing on the Titan Atlas with both pellet and filament extrusion capabilities, PSSI was able to achieve shorter production times of the patterns, in some cases cutting the time in half. Affordable Pellet and filament feedstocks also eliminates the need to source expensive raw wood materials.

3D Printed Pattern
3D Printed Pattern by PSSI. Dimensions 22″x17″x14″

Case Study

3D Printed Pattern

3D Printed Pump Body

Print Method: Pellet Extrusion on the Atlas

Print Setting: 2mm nozzle

Feedstock: ABS Pellets

Print Time: 10 Hrs (3 parts)

Material Weight: 31Lbs

Material Cost: $89

3D Printed Pattern

3D Printed Pump Core Box

Print Method: Pellet (red) and Filament (orange) Extrusion on the Atlas

Print Setting: 2mm nozzle (pellet) and 0.8mm nozzle (filament)

Feedstock: ABS Pellets, ABS Filament

Print Time: 20 Hrs (6 parts)

Material Weight: 25Lbs

Material Cost: $72

3D Printed Body and Core Box Post Processing

Sanding parts to reduce layer lines and apply for high-fill primer can take one to two weeks depending on size and number of parts. Once a smooth surface is achieved, a primer and mold release paint is applied. Patterns are ready for no-bake sand casting with total manufacture time at 3-4 weeks.

Sanding and Painting of 3D Printed Pump Body
Sanding and Painting of 3D Printed Core
Final 3D Printed Pattern ready for casting. Dimension 22″x17″x14″

Customer Conclusions and Value

Production time to manufacture this Pump Body and Core Box Pattern was cut in half, reducing the process from 8 weeks using traditional methods down to 3-4 weeks using 3D printing on the Atlas. 3D printing also reduced raw material costs, with an estimated 15% – 20% Savings.

“Working with Titan has been the best decision we have made. We have improved in so many ways because of the flexibility (referring to pellet and filament extruders) and the speed the machine works with. We have won a lot of projects because of the efficiency of the machine. We can offer better delivery times with the same quality,” said Alonso Alvarez of PSSI.

CastExpo 2019

Titan Robotics shared this case study from PSSI and brought large-format industrial polymer 3D printing to CastExpo for the first time this year, held in Atlanta from April 27 – 30, 2019. Occurring every three years, CastExpo is the largest North American gathering of the metalcasting supply chain companies. Exhibiting at CastExpo 2019 was a great opportunity to share how 3D printing and Titan’s line of Atlas 3D printers can improve pattern making processes with lower cost patterns, faster turn around time and increasing return o investment.