Tag: Pattern

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.


07
Sep

Titan Robotics Bringing Large-Format 3D Printing to Foundry in West Africa

One of the largest foundries in West Africa is driving innovation and economic growth in the region by utilizing Titan Robotics’ large-format 3D printer, the Atlas. The application is using 3D printing to create patterns for metal casting. This past summer, Titan Robotics Founder and CEO Clay Guillory traveled to Lagos, Nigeria, to install the largest known 3D printer in West Africa at Nigerian Foundries Limited (NFL).

NFL first contacted Titan Robotics in the Fall of 2016 with the desire to improve their processes and expand their capabilities as a foundry. Encouraged by Titan’s video on 3D printing and pattern making, NFL owner Vassily Barberopoulos and his colleagues were ready to take the leap into additive manufacturing.

Atlas Nigerian Foundries Africa

Staff at Nigerian Foundries Limited print patterns on the Atlas 3D printer.

“It is the future of manufacturing worldwide,” Vassily says of 3D printing.

And the future, says Vassily, is full of opportunity for not just his business but also his country. It has been his life’s mission to build the family business and bring economic growth to Nigeria. The Barberopoulos family started NFL in 1969 as a small grey iron foundry, making municipal castings and water pipeline fittings. Now NFL has grown to become the largest ferrous foundry in Sub-Saharan Africa (excluding South Africa). Currently two NFL plants serve multiple industries such as oil and gas, construction, marine shipping, mines and mineral processing and much more.

“This is a big thing for us, because right now in Nigeria we’re at the stage where local content is very important,” said Vassily.

Using 3D printing to create higher quality and more cost effective patterns means NFL will be able to continue to expand its offerings to industries in Nigeria and globally. Traditionally, foundries like NFL carve patterns and tooling out of wood by hand. Vassily explained that this method takes them over a month, from the design to creating the wooden pattern and then casting it. But with 3D printing on the Atlas, that time is reduced by more than half.

Nigerian Foundries 3D printed pattern Africa

NFL employee prepares the 3D printed pattern for sand casting.

Vassily said, “For us, it’s an important aspect because it means for most castings that we can print, we could actually make a pattern within 48 hours and be in production and have a product within a week out, something that would normally take us a month and a half.”

NFL’s work with 3D printing is also part of a nationwide initiative to foster economic growth and innovation in Nigeria, called the Nigerian Local Content Act. Vassily explained that 3D printing patterns on the Atlas enables the foundry to fabricate better and more complex patterns, making NFL a more competitive company internationally.

Vassily says the goal is to create local goods that meet international standards and are ready for market in a timely manner, something most foundries in West Africa have not been able to do yet.

3D Printed pattern Nigerian Foundries Africa

NFL staff mount first 3D printed pattern for casting.

“So we are looking at going with 3D printing at a much higher level of castings and producing castings for the oil and gas industry, in particular like valves and pump housings and impellers and such things which before would be very difficult for us to actually make the patterns and be able to go through the trouble shooting,” he said. “Now it is within reach.”

And Titan Robotics is proud to be a part of that progress through its work with NFL.

“I think it has a lot of potential here, this country is very hungry for learning and very hungry for opportunity,” said Titan CEO Clay Guillory. “People are ready to compete on a global scale here, that’s one thing I took away from Nigeria is this place has a lot offer and it’s an up and coming country.”

Titan Robotics Nigerian Foundries Africa

Titan CEO Clay Guillory with NFL engineers and staff.

Watch the video here:

Bringing Large-Format 3D Printing to West Africa