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.
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.
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 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 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.
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.
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.