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Workflow in Additive Manufacturing

Workflow in Additive Manufacturing

Sep 10, 2023 | Senza categoria

3D Production: Principles, Rules, and Technologies

Industrial 3D printing has evolved from rapid prototyping to mass production, offering significant advantages to companies: reduced production times and costs, improved product quality, and customization possibilities.

This technology enables the creation of complex components in a single phase, simplifying assembly and allowing greater flexibility in responding to market needs.

Workflow

At the core of conceiving productions through additive manufacturing technologies, fundamental aspects remain tied to the employed technologies, materials used, and the skills of designers and operators.

The intricate workflow characterizing a typical production with industrial 3D printers involves delicate phases that can be challenging to manage for less structured companies or those lacking experience and know-how.

A production process using additive manufacturing technologies can be achieved only through some fundamental stages:

  1. Design and optimization/lightweighting of geometries based on technologies and materials.
  2. Nesting and optimization of production parameters.
  3. Utilization of facilities and technologies with high production capacity.
  4. Application of post-processing technologies (aesthetic and functional).
  5. Quality analysis and repeatability.
  6. Certification of processes and materials.

Design for Additive Manufacturing

Design for Additive, or Design for 3D Printing (DFAM), represents an innovative approach in the design of components and products.

New possibilities emerge in the field of design, enabling the creation of complex shapes and intricate geometries that would be difficult or impossible to achieve with conventional methods.

Design for Additive focuses on maximizing the potential offered by 3D printing, optimizing the internal structure of objects to enhance performance, reduce weight, and minimize material consumption.

Moreover, this methodology allows for greater customization of products, adapting them to the specific needs of the user/client.

A profound understanding of the characteristics of 3D printing and the ability to fully exploit its potential are required to create innovative and efficient solutions.

Nesting

Nesting, a specific technique for the orientation and organization of components in the setting phase of production, is crucial in every additive manufacturing project using 3D printers.

Unlike the production of individual parts, the production of medium to large batches with 3D printing requires a complex optimization process before printing.

Aspects such as orientation study and nesting have a significant impact on the times, quality, and costs of production processes, results achievable only through a deep understanding of processes and manufacturing technologies.

Thanks to the use of dedicated software, accumulated experience, and advanced management and control systems, Prosilas has established itself as one of the leading European players in the field of additive manufacturing for the industry

Technology

Prosilas’ machinery fleet, mainly composed of industrial production systems with SLS (Selective Laser Sintering) technology – 13 industrial Selective Laser Sintering printers, including 6 large-sized ones, has allowed the development of a complete and reliable industrial system capable of meeting customer needs from order reception to part realization and post-processing treatments.

The targeted choices made over the years have positioned Prosilas as one of the few entities capable of successfully operating in additive manufacturing for the industry.

Our technologies

Post-Processing

Prosilas has invested significantly in enhancing the finishing department to deliver customized finished products to customers. Our primary commitment is to find flexible and high-quality post-production solutions that fully meet the aesthetic and functional needs of our clients.

We are continually refining our post-production processes to make them replicable and reliable. We have integrated automated finishes, such as vapor smoothing and coloring, along with manual processes to adapt to the unique specifications of each project.

Alla parte stampata in 3D con il materiale PA2200 viene prima applicato il fondo per rendere liscia la superficie e poi colorato secondo le richieste del cliente.

Quality and Certification

To ensure maximum precision and resolution, Prosilas implements stringent control procedures.

Productions undergo a series of detailed checks using specialized software and state-of-the-art 3D acquisition systems. These advanced tools enable our team to identify any non-conformities between CAD geometries and the physical parts produced through additive manufacturing.

Conformity is at the core of our operations, and our codified and certified procedures constitute a fundamental pillar of an integrated system.

This system is designed to ensure a high standard of quality for every stage of additive production, from the initial design to the final realization. Thanks to this commitment to excellence and our established expertise, Prosilas stands out as one of the few companies capable of providing reliable, repeatable, and certified additive manufacturing services

STL File : the most common errors

STL File : the most common errors

Sep 6, 2023 | News Prosilas, Tips & Tricks

Normal lines inverted, holes and multiple shells

In this article, we will discuss the most common errors found in STL files, which usually involve inverted normals, presence of holes, and multiple shells.

These errors often result from mistakes during part modeling or during the export and conversion process to the STL file format using CAD software. These defects need to be corrected in order for the part to be suitable for printing.

As highlighted in the previous post, the STL file, necessary for 3D printing a part, represents a three-dimensional geometry composed of triangles oriented in space.

Watch the full video

Normal line inverted

Each triangle is described not only by the coordinates of its vertices, but also by the normal, which is a vector perpendicular to the plane on which the triangle is positioned, and its orientation defines the outer side. In some cases, the normal of these triangles can be inverted, mistakenly identifying an outer side as the inner side and vice versa. Such a situation can lead to errors during the printing process.

Example of a normal line inverted 

Example of a normal line corrected

Hole in the STL file

The second most common error encountered is the presence of holes, which can be caused by missing surfaces or misalignment between triangle vertices.

These holes need to be manually corrected if they are of considerable size, or automatically using specialized software if they are smaller. The presence of holes can compromise the quality and functionality of the printed part.

The presence of holes can compromise the quality and the realization of the part printing.

Holes in a STL file

STL file corrected

Shell Multiple

Lastly, we encounter the issue of multiple shells. A shell refers to a group of connected triangles. The presence of multiple shells in a part indicates the presence of separate groups of triangles. In this case, the inner shell overlaps with the outer shell.

Resolving this type of error is necessary to avoid anomalies during the slicing of the model into layers or incorrect surface generation, as well as to prevent printer jams. It is important that all shells are properly joined to achieve a coherent and functional printed part.

This situation can also occur when, in the design phase, the shapes that make up the CAD model are not properly integrated into the rest of the shell, but remain separate.

It is crucial to ensure that all components of the model are correctly integrated into the main shell to avoid printing issues and ensure the quality of the final product.

Example of Multiple shells

Example of Multiple shells

Multple shells fixed 

When we receive the files. stl from our customers, it frequently occurs the need to make changes and corrections before proceeding with the production.

STL correction requires specific skills and the use of dedicated software to repair imperfections and ensure that the part is ready for printing.

Our team is fully committed to making such corrections with the utmost precision and timeliness, in order to ensure that the printed parts reach high quality standards and fully meet customer expectations.

Additive manufacturing: from prototyping to 3D printing production

Additive manufacturing: from prototyping to 3D printing production

Aug 10, 2023 | News Prosilas

From Rapid Prototyping to Industrial Production: The Advantages of 3D Printing

3D printing, initially developed as a rapid prototyping technology, has now evolved into an established solution for serial production as well.

Thanks to its numerous benefits, industrial 3D printing can provide companies with a significant competitive advantage, allowing them to reduce development and production times, cut costs, and enhance product quality.

Prototyping

The term “production” is often not associated with 3D printing technologies, as the very nature of additive manufacturing systems, at least in their initial conception, was intended for the creation of individual pieces: models or prototypes.

In the early development phase, additive technologies facilitated the rapid creation of prototypes and aesthetic models, useful in expediting all testing phases, as well as research and development for new applications.

Production

Today, thanks to advanced additive manufacturing systems, it is possible to produce functional prototypes, small to medium batch productions, or even mass productions.

Advantages

Unlike the creation of individual parts or prototypes, additive manufacturing opens up highly advantageous scenarios that can improve and expedite aspects related to the development of new applications designed for mass production.

The main advantages of production with 3D printing can be summarized in five points:

1. Reduction of Development and Production Times:

3D printing allows for the rapid creation of functional prototypes, thereby accelerating the process of developing new products.

Moreover, even pre-series production with 3D printing can be carried out in much shorter times compared to traditional production technologies.

It is possible to introduce batches of components or objects into the market for collecting data from tests or feedback from end-users, facilitating the optimization of shapes or functions.

Prosilas si può stampare in 3d anche parti in metallo per la prototipazione rapida per il settore aerospace

For example, a company manufacturing components for the aerospace industry can use 3D printing to create functional prototypes within a few days, instead of the months or even years required by traditional prototyping technologies.

In this way, the company can expedite the development process of new aircraft and reduce development costs.

2.Cost Reduction:

3D printing can decrease production costs through the use of advanced materials and the reduction of material waste. Materials employed in 3D printing are often lighter and more durable than traditional materials, potentially reducing product weight and, consequently, transportation and energy consumption costs.

Additionally, 3D printing allows for minimizing material waste since the material is used only to create the necessary parts of the product.

Prosilas - Member of Prototal - PA 603 CF - nylon caricato carbonio - Racing - Motorsport - F1 - Moto GP

For instance, a company manufacturing components for the automotive industry can leverage 3D printing to produce lighter and more durable components.

This can contribute to enhancing vehicle efficiency, reducing fuel consumption, and promoting the metal-replacement process.

Our Materials

3. Quality Improvement:

3D printing can ensure greater precision and repeatability of products, enabling the creation of complex geometries and shapes impossible to achieve with traditional production technologies.

3D printing allows for the production of products with very tight tolerances, meeting the most stringent requirements.

Moreover, it can be used to manufacture products with intricate geometries that would be impossible to achieve with traditional production technologies.

Prosilas - Member of Prototal - PA 603 CF - nylon caricato carbonio - Racing - Motorsport - F1 - Moto GP

For example, a company specializing in medical prosthetics can utilize 3D printing to create customized prosthetics that perfectly fit the patient.

By employing 3D scanning technologies and reverse engineering, an exact model of the part can be created to tailor the prosthetic precisely to the individual’s needs.

More on toleraces

4. Product Customization:

3D printing enables the customization of products based on specific customer needs, creating unique and distinctive items.

With 3D printing, products can be crafted with personalized features such as dimensions, shape, color, or material. This can be a competitive advantage for companies aiming to provide their customers with unique and customized products.

For instance, a company manufacturing eyewear could use 3D printing to create personalized jewelry with unique shapes and colors.

Prosilas - Member of Prototal - PA 603 CF - nylon caricato carbonio - Racing - Motorsport - F1 - Moto GP

5. Production Flexibility:

3D printing is a flexible technology that can be adapted to various production needs, enabling the creation of products of any size and complexity.

3D printing can be employed to manufacture products of various sizes, ranging from small components to large objects.

With our industrial SLS printers, we can produce objects of considerable dimensions (680x370x540mm).

Furthermore, 3D printing can be used to create products of any complexity, including those with intricate geometries or shapes impossible to achieve with traditional production technologies.

Entrusting production to 3D printing offers significant advantages to companies in terms of reducing development times, controlling costs, improving quality, enabling customization, and providing production flexibility.

This technology is emerging as a versatile and innovative solution, allowing businesses to successfully tackle competitive challenges and respond effectively to market needs.

With proper workflow and optimized design, 3D printing continues to prove itself as a key catalyst for the evolution of the manufacturing industry.

More on Workflow
What is an STL file?

What is an STL file?

Jul 21, 2023 | News Prosilas, Tips & Tricks

An Overview of the Three-Dimensional Representation for 3D Printing

Today, we delve into the analysis of the STL file extension and its crucial role in the realm of additive manufacturing. If you are interested in the world of 3D printing, you are likely already familiar with this extension and its unique characteristics.

 

Watch the full video

STL file

Essentially, the STL file represents a three-dimensional geometry through a combination of triangles arranged in three-dimensional space. This representation simplifies more or less complex surfaces, modeled using CAD software, into a series of planar triangles described by the Cartesian coordinates of their vertices.

 

The primary reason for the widespread use of the STL fileformat in the field of additive manufacturing lies in its ability to translate the language of CAD software, which is based on mathematical functions, into a format understandable by all 3D printing technologies on the market (SLS, SLA, FDM, etc.). This simplified format is based on a three-dimensional coordinate system, which represents a more accessible and immediate language for different printing technologies.

Export of  STL file

We often encounter the receipt of files with different extensions, such as .iges or .step, or even proprietary files from modeling software, each with specific characteristics. However, in order to materialize them through 3D printing, they need to be transformed into the STL file format. This conversion process simplifies the 3D models but may involve some modifications, such as approximating cylindrical or spherical parts and the presence of facets that do not accurately reflect the originally designed surfaces.

Example of 3D modelled file

Example of correctly exported file in STL with good resolution

Example of file exported in STL with incorrect resolution. Note the inside of the hole that has lost its initial sphericity.

STL file resolution

It is directly related to the number and size of the triangles that make up the model. A large number of triangles implies a higher resolution.

However, it is important to emphasise that a large file size does not necessarily mean significant advantages. Rather, it is preferable to adapt the size of the triangles to the printing resolution of the machine used. For example, our SLS machines operate with a resolution of about 5 hundredths of a millimetre. Therefore, it is vital to have a correctly adapted .STL file in order to guarantee optimum surface resolution.

 

Lube Volley and Prosilas together to win, with the support of 3D printing

Lube Volley and Prosilas together to win, with the support of 3D printing

Jul 4, 2023 | Case History, News Prosilas, TPU - SLS Material

Lube Volley + Prosilas Case History

What Prosilas and Lube Volley have in common is not only their city of origin, Civitanova Marche, but also their shared pursuit of challenges and desire to succeed. For the esteemed Marche team, this translates into winning trophies and championships. Meanwhile, for Prosilas, it means constantly seeking innovative solutions to support the development of an increasingly demanding industrial market. The collaboration between the two companies was recently solidified through a sponsorship agreement, which prominently displays Prosilas’ name on the volleyball team’s uniforms. Additionally, they engage in a strong joint effort that connects sports achievements with the utilization of additive manufacturing.

 

watch the full video

Lube Volley, Prosilas-supported club is the  most successful in the 21st century

 

Champion of Italy 2022, Lube Volleyball is an acclaimed team, boasting  in its list of victories a World Club title, seven league titles (the last three won consecutively), two Champions Leagues, seven Italian Cups and four Italian Super Cups, three CEV Cups and one Challenge Cup. The team expresses a very high technical level of play, capable of always competing at the top: and when playing at high levels even small details can make a difference.

Lube Volley, the team

A tangible collaboration, thanks to 3D printing

 

When Enrico Diamantini and Ivan Zaytsev, two prominent athletes from the club, expressed their need for new hand protection devices during games, the relationship between Lube Volley and Prosilas evolved beyond a simple sponsorship. Prosilas immediately utilized its expertise in 3D printing to develop an innovative, customized, and tailored solution for both players.

‘We took the opportunity to get even closer to the world of medicine and sport, trying to develop a truly useful and professional application,’ says Vanna Menco, CEO Prosilas

Diamantini required an alternative to the temporary brace he had been using to support his injured right little finger, while Zaytsev needed a replacement for the medical tape he typically used to stabilize his fingers during high-impact phases of the game.

Ivan Zaytsev and Enrico Diamantini

The previous solutions had limitations in terms of materials, lacking of technical performance, reusability, and customization, which resulted in a sub-optimal playing experience. However, with the advent of 3D printing, Prosilas believed that they could overcome these limitations and produce custom-made and reusable devices with exceptional speed and precision.

For Diamantini, the old brace was rigid, bulky, and therefore uncomfortable. The negative impact on his ball touch led him to use it sporadically and only for the minimum required time. Similarly, Zaytsev sought a custom-made, reusable alternative that provided better sensitivity compared to traditional medical tape.

Through their collaboration with Prosilas, both athletes found the solution they were looking for, addressing their specific needs and improving their playing experience on the court.

Fast and successful product development

 The initial phase of the project focused on acquiring the 3D models of Diamantini and Zaytsev’s hands using the Gom Atos 5 3D scanner, which involved scanning plaster casts. Subsequently, the design phase commenced, incorporating reverse engineering techniques to accurately model customized designs. These designs were tailored to protect and immobilize the injured joint in one case, and provide comfortable support in the other. The devices underwent testing and, with valuable feedback from the athletes, were progressively refined to achieve the best possible results.

“The responsiveness of additive technology is truly remarkable. The initial contact with the players took place in October 2022, and after just five rounds of improvements, we were able to arrive at the final version of the devices for both players within a very short timeframe,” states the CEO of Prosilas.

3D scan of Ivan Zaystsev’s right hand

3D design through reverse engineering of protective devices

TPU protective devices being tested on the cast of Ivan Zaystsev’s right hand

TPU: a strategic choice

 

To create these customized and highly comfortable devices, Prosilas opted for BASF’s TPU Ultrasint 88a due to its flexibility and mechanical impact resistance. Thermoplastic polyurethane (TPU) is an elastic polymer known for its versatility and resilience. It can withstand shocks, abrasions, tears, chemical and weathering agents, and is impermeable to water and gases.

TPU is often considered the intersection between rubber and plastic, thanks to its physical characteristics, wide range of hardness options, and flexibility without the need for plasticizers.

For the initial test with Diamantini, three different TPU models were created using SLS (Selective Laser Sintering) technology, each with varying thicknesses of 1, 1.5, and 2 mm. TPU allows for slight variations in thickness, enabling flexibility in the final product.

For Zaytsev, an initial set of devices was produced with a consistent thickness of 2 mm to provide greater rigidity. Additionally, a lateral cut was made to improve the fit of the devices for him.

3D design through reverse engineering of protective devices

TPU protective devices for Enrico Diamantini in three different thicknesses: 1, 1.5 and 2 mm

Testing phase and results

“The results achieved through the utilization of additive technology are undeniably positive,” remarks Vanna Menco. “This is further corroborated by the outcomes of resistance tests conducted on the material by our supplier, BASF 3D Printing Solutions.”

 The testing phase was a critical step in the process. Collaborating with BASF, an effort was made to replicate a volleyball game in a laboratory setting. This involved evaluating the material’s chemical resistance, short and long-term durability, as well as color stability.

To assess the material’s mechanical stability, strength tests were conducted after 30 minutes, 7 days, and 14 days, with the parts immersed in synthetic sweat.

Tensile strength and elongation at break were measured at these intervals. Furthermore, a sudden impact test was performed to simulate crushing, and no significant changes were observed. The color measurement, which determined its stability over time, confirmed that there was no yellowing or noticeable alteration after 14 days. These results provide evidence of the material’s reliability and longevity.

TPU testing samples

Sudden impact test results

The remarkable durability and strength of the custom 3D-printed devices can be deduced from the absence of significant degradation observed during testing. This ensures the longevity of the product even under repeated stress and in special chemical conditions. Apart from the scientific findings, the enthusiastic feedback from the athletes themselves confirmed the positive results and the significant improvement in playability and game feel.

“I recommend the protection systems made by Prosilas to everyone. Because they are customized, they give maximum comfort in every technical gesture. It’s like not having them!”

says Enrico Diamantini, who used the device during his recovery from a dislocation.

Ivan Zaytsev, on the other hand, continues to use the customised devices on his hands. He says:

“Thanks to Prosilas, I immediately felt comfortable with hitting the ball, the four braces were  efficient and above all eco-friendly given the amount of tape they save me!

 

The combination of improved performance, stable feel, durable material, and complete customization results in an overall increase in comfort for athletes during competition, leading to an enhancement in playing performance.

Customization has become an essential trend in the world of ultra-competitive champions, and additive solutions go above and beyond by offering specific shapes and characteristics tailored to each individual athlete’s needs.

 

Working with BASF 3D Printing Solutions

 

BASF 3D Printing Solutions, operating under the Forward AM brand, is a division of BASF New Business GmbH that is specialized in advanced materials, system solutions, components, and services in the field of 3D printing. With a lean structure and an agile mindset akin to a start-up, BASF 3D Printing Solutions is well-equipped to cater to the diverse needs of various industries by offering innovative and customized services. The company works closely with other departments within BASF, research institutes, universities, start-ups, and industrial partners to serve customers in automotive, aerospace, consumer goods, and other product categories.

The partnership with BASF 3D Printing Solutions holds significant strategic importance for Prosilas, further solidified by the mutual respect between the two companies.

 “Prosilas brings extensive experience in printing our flexible TPU materials, ensuring the consistent delivery of superior quality parts,” explains Tobias Haefele, Product Manager Powder Bed Fusion. “We greatly appreciate their exceptional creativity,” he continues, “and their attitude to push the limits of the 3D printing market, paving the way for new applications, which align with our vision. With their specialist knowledge and established presence in sectors such as fashion, they have earned our trust as a reliable partner in consistently delivering exceptional products over the years. At BASF 3DPS, we are excited to continue our journey with Prosilas, forging a promising future for additive manufacturing.”