Carbonmide drone chassis and 3D printing

Carbonmide drone chassis and 3D printing

Jul 2, 2021 | Case History, News Prosilas

Case Study: Topological Optimization and 3D Printing for a Lightweight and Durable Drone Frame

 

Drones that are increasingly high-performing and lightweight demand cutting-edge components.

Prosilas presents a case study showcasing the utilization of topological optimization and SLS 3D printing for the production of a drone frame using carbon fiber-reinforced polyamide.

The challenges:

  • Reduce the weight of the frame to enhance the efficiency and autonomy of the drone.
  • Ensure the frame’s strength against stresses and vibrations during flight.
  • Create a complex and optimized geometry that is unattainable with traditional manufacturing methods.

Design and Optimization

The drone frame was designed using topological optimization software.

This software analyzed the stresses and constraints to which the frame would be subjected during flight and generated an optimal geometry that utilizes only the necessary amount of material to meet strength requirements.

Production

The frame was manufactured using Selective Laser Sintering (SLS) 3D printing technology with carbon fiber-reinforced polyamide.

This material was chosen for its high mechanical strength, lightweight properties, and resistance to high temperatures.

PA603CF materiale caricato con fibra di carbonio per la stampa 3D
Data Sheet

Results

The drone frame produced with carbon fiber-reinforced polyamide was found to be 50% lighter than a frame made with a traditional material such as aluminum.

Furthermore, the frame in this material demonstrated superior mechanical strength and better vibration absorption capabilities.

Benefits

The utilization of topological optimization and SLS 3D printing led to a series of benefits for the drone frame:

 

  • Weight Reduction: The frame is 50% lighter than an aluminum frame, improving the efficiency and autonomy of the drone.
  • Increased Strength: The carbon fiber-reinforced polyamide frame exhibits superior mechanical strength and better vibration absorption, enhancing the drone’s durability and reliability.
  • Design Freedom: The use of 3D printing allowed for the creation of a complex and optimized geometry that would not be achievable with traditional manufacturing methods.
  • Cost Reduction: 3D printing helped reduce frame production costs, making it more accessible for a wide range of applications.
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Hyper-Light Carbon: 20% Less Weight

In addition to carbon fiber-reinforced polyamide, Prosilas introduces Hyper-Light Carbon, one of the lightest materials in the world of 3D printing.

The new formulation of PA 12 with carbon fiber provides lightness, strength, and ease of processing. The material features a uniform surface finish, high precision, and an excellent strength-to-weight ratio.

It represents a further evolution for the production of drone frames and components where lightweight is a fundamental characteristic.

Hyper-Light Carbon stands out for its even lower density (0.82 g/cm³), enabling the creation of even lighter and more high-performance frames. This material also offers high mechanical strength, excellent surface finish, and ease of processing.

With Hyper-Light Carbon, you can:

  • Achieve a new level of lightness and performance.
  • Further enhance the efficiency and autonomy of the drone.
  • Attain complex and optimized geometries for improved aerodynamics.
Data Sheet
PA12 ALU jigs with SLS printer

PA12 ALU jigs with SLS printer

Mar 1, 2021 | News Prosilas, PA12 ALU-SLS Material

Innovative Applications in Industrial Tooling:

Custom Mounting Fixtures with PA12 ALU 3D printed

The tooling sector is undergoing a revolutionary transformation thanks to 3D printing technologies and SLS (Selective Laser Sintering) additive manufacturing.

In particular, the combination of freeform design and advanced materials such as PA12 ALU loaded aluminum is enabling the efficient and innovative production of tailor-made equipment for the industrial sector

Freeform Design:

Freeform design represents a crucial step forward, allowing the production of custom parts on demand without the need to maintain a warehouse.

This flexibility is particularly advantageous for the production of dedicated tools for special processes or for complex assemblies.

SLS additive technologies enable the creation of strong and lightweight geometries in a short period, revolutionizing the way industrial tools are conceived and produced.

Practical Application – Assembly Guides:

A concrete example of this innovation can be found in the Prosilas facilities, where assembly guides have been produced using SLS technology.

These guides are crucial for centering and drilling on mechanical parts, enabling more precise and efficient production processes.

dime sls alumide pa12 stampa 3d

Companies can benefit from exceptionally strong and lightweight geometries, contributing to the improvement of efficiency and precision in production processes.

Prosilas remains at the forefront in this continually evolving sector, providing customized solutions through its expertise in the use of advanced materials and industrial 3D printing technologies.

PA12 ALU

PA12 ALU  loaded with aluminum, has established itself as one of the most utilized materials in the manufacturing industry for 3D printing.

Parts produced with SLS technology and PA12 ALU exhibit excellent mechanical performance, high rigidity, abrasion resistance, and good thermal dissipation.

The possibility of surface finishing treatments and post-processing CNC machining provides additional customization options.

Material Characteristics:

  • Good mechanical strength
  • Abrasion resistance
  • Good thermal dissipation
  • Possibility of surface finishing treatments and post-processing CNC machining
L'Alumide, risultato della combinazione di alluminio e nylon nella stampa 3D mediante sinterizzazione laser, trova ampio impiego nella prototipazione industriale e nella produzione di componenti finali. Le sue proprietà uniche, quali resistenza, rigidità e buona conduttività termica, lo rendono adatto a una vasta gamma di settori, tra cui l'industria manifatturiera, l'aerospaziale e l'automotive.
Data Sheet

Scanning, reverse engineering and analysis for 3D printing

Jan 29, 2021 | News Prosilas

Scanning & Analysis: Fundamental Stage in Additive Manufacturing and 3D Printing

Additive manufacturing and 3D printing are cutting-edge processes revolutionizing how we conceive and produce industrial components. One of the crucial stages in this innovative process is 3D scanning, a key element in ensuring the quality and compliance of the produced parts.

The Importance of Scanning and Analysis

3D scanning and analysis through specialized software are not merely tools for dimensional verification; they play a crucial role in identifying potential non-conformities. These may arise from behavioral variations in printing technologies or the characteristics of the materials used.

High-Resolution 3D Scanners

The 3D acquisition systems at Prosilas stand out for their exceptionally high resolution, capable of reconstructing details that escape the human eye.

This advanced technology, combined with the expertise of our professionals, allows us to ensure high-quality standards in all our productions

Reverse Engineering and Structured Light 3D Scanning

The use of structured light 3D scanning technology allows us to precisely capture geometries of both small and large dimensions with remarkable resolutions. These systems also empower us in the field of reverse engineering, enabling the acquisition of data from existing components and generating new designs.

Thanks to our qualified personnel, we can perform 3D scans on physical geometries, creating new mathematical foundations useful for advanced design or production through our Selective Laser Sintering (SLS) additive technologies.

Scanner Gom per scansione 3d e reverse engineering per stampa 3d

Dimensional Control and Quality Certifications

At Prosilas, all processes of acquisition, analysis, and 3D printing are conducted internally following certified procedures. This ensures the highest quality standards in our productions.

Dimensional control is an integral part of this approach, ensuring the accuracy and consistency of the produced components.

scansione 3D
Production equipment ( molds ) in PA2200 with 3d printing

Production equipment ( molds ) in PA2200 with 3d printing

Jan 8, 2021 | Case History, Pa2200 - SLS Material

Prosilas and DUEPì join forces to revolutionize the production of silicone components.

The present article outlines a successful case study arising from the collaboration between Prosilas, a leading 3D printing company, and DUEPì Automazioni Srl, a company specializing in the design and manufacturing of industrial automation.

The shared objective? Harnessing the capabilities of 3D printing in PA2200 to create molds in short timeframes and at affordable costs, revolutionizing the production process of silicone components.

Silicone Components through 3D Printed Molds

The two companies collaborated on the production of molds in PA2200 using Selective Laser Sintering (SLS) technology.

The choice of PA2200 as the printing material was based on its excellent mechanical and chemical properties, combined with biocompatibility (certified according to EN ISO 10993-1 and USP/level VI/121°C).

Stampo in silicone 3d

Creation of the PA2200 Mold

DUEPì handled the design of the mold geometries, while Prosilas took care of their 3D printing using SLS technology.

The synergy between the two companies allowed for the optimization of the mold geometries, significantly reducing production times and costs.

Production Technologies

Prosilas’ industrial 3D printers, based on SLS technology, ensure the production of individual parts and batches of ready-to-use products.

Laser sintering on polymeric powders currently stands as the most efficient solution for the production of industrial applications.

stampa 3d silicone stampi

Materials for 3D Printing: PA2200 and Its Exceptional Properties

PA2200, or polyamide 12, stands out as an excellent choice among 3D printing materials. Its characteristics make it a versatile and high-performance material, suitable for a wide range of applications.

  • A resilient and versatile material

PA2200 boasts high mechanical and chemical resistance, making it ideal for the production of robust components resistant to impacts, wear, and tension. Its rigidity and toughness make it suitable for bearing heavy loads and for use in various industrial environments.

  • Biocompatibility and safety

The biocompatibility of PA2200, certified according to EN ISO 10993-1 and USP/level VI/121°C regulations, makes it safe for contact with the human body. This makes it an ideal material for the production of medical and food components, where safety and hygiene are fundamental requirements.

  • Flexibility and printing performance

The versatility of PA2200 extends to 3D printing. The material can be used for printing complex and intricate geometries, offering high resolution and a premium surface finish. The ability to print in a variety of colors further expands creative and applicative possibilities.

PA2200 (nylon) utilizzata come materiale di produzione nella stampa 3D, in particolare nella tecnica di stampa SLS (Selective Laser Sintering).

Advantages for Mold Production

3D printing of molds in PA2200 offers a series of significant advantages compared to traditional technologies. Firstly, it allows for a drastic reduction in production costs, up to -180% compared to CNC machining or vacuum casting. This is achieved through the optimization of mold geometries and the reduction of material waste.

Secondly, 3D printing enables the production of molds in significantly shorter timeframes compared to traditional technologies. The speed of production allows for the creation of prototypes and finished products in a short time, ensuring greater flexibility and responsiveness to market needs.

Design flexibility and sustainability

3D printing in PA2200 provides extensive design freedom, allowing for the creation of complex and customized geometries. This results in molds optimized for specific applications, with the possibility of integrating various functionalities into a single mold.

Furthermore, 3D printing in PA2200 aligns with sustainability goals, thanks to the reduction of material waste and the production of lightweight and durable components.

From CNC to 3D SLS: advantages

From CNC to 3D SLS: advantages

Dec 15, 2020 | Case History, Pa2200 - SLS Material

Industrial Revolution: Performance and Design Optimization with SLS 3D Printing

 

3D printing as a viable alternative to CNC

Additive manufacturing and 3D printing technologies are emerging as effective alternatives to traditional CNC industrial systems.

In the following case study, we will explore how the use of our Selective Laser Sintering (SLS) 3D printing systems has allowed for the redesign and improvement of the performance of an industrial application.

New Industrial Application:

The goal was to design a new gripping and handling component based on the principle of the suction pad with differentiated vacuum chambers, intended for the automatic machinery sector.

Project Objectives:

During the development process, we set several objectives, including improving the production performance of the automated line, reducing the weight of the component, addressing assembly challenges, and shortening the time to market.

  • Improve the production performance (revolutions per minute) of the automated line on which the component is installed.
  • Reduce the weight of the component.
  • Address assembly challenges – monolithic part.
  • Shorten the time to market.

 

Design for Additive Manufacturing:

We have embraced the principles of design for additive manufacturing and 3D printing, focusing on optimizing conventional geometry. This approach has allowed us to fully leverage the capabilities of 3D SLS systems, achieving innovative solutions that would be impossible with traditional techniques.

Throughout the redesign process of the application, we achieved significant results, including the optimization of integrated channel flows for air depression, weight reduction of the component while preserving its mechanical properties, elimination of two air depression grip points, and the integration of threaded metal inserts.

3D SLS Manufacturing Technologies and Materials:

The printing of the application was entrusted to Prosilas’ Selective Laser Sintering machines.

During the process, advanced materials such as polyamide PA2200 (biocompatible according to EN ISO 10993-1 and USP/level VI/121°C regulations, approved for food contact) and reinforced polyamides (e.g., alumide, PA12GF, PA2210 FR…) were employed.

It is possible to choose the optimal printing material for each specific need.

our materials

Advantages of SLS 3D Printing over CNC Systems:

1.Significant Weight Reduction of the Component:

Through a meticulous redesign and optimization process, SLS 3D printing has allowed for a drastic reduction in the weight of the component while maintaining structural integrity and required performance. This lightweight characteristic opens up new possibilities in terms of energy efficiency and dynamic performance.

2.Realization of Complex Geometries for Excellent Fluidodynamic Performance:

The design freedom offered by SLS 3D printing has enabled the realization of complex geometries optimized to enhance the fluidodynamic performance of the component. This ability to create intricate and functional shapes has revolutionized how we conceive and implement engineering solutions.

 

4. Part Consolidation for Simplified Management:

One distinctive feature of SLS 3D printing is the ability to consolidate multiple complex parts into a single monolithic structure. This not only reduces the total number of components in the system, simplifying assembly but also contributes to greater overall efficiency and durability.

5. Elimination of Seals and Simplification of the Connection Interface:

SLS 3D printing has allowed for the elimination of the need for complex seals, simplifying the component’s architecture and improving overall reliability. The machinery connection interface has been optimized, reducing grip points and enhancing overall integration into the automated line.

6. Overall Performance Enhancement and Delivery Time Improvement:

With the adoption of SLS 3D printing, there has been a significant improvement in the overall performance of the automated line.

Additionally, delivery times are considerably reduced compared to traditional machining, allowing for greater flexibility and responsiveness in the industrial context.

The evolution towards SLS 3D printing has proven to be a strategic choice, redefining the paradigms of engineering and industrial production through continuous innovation and unprecedented optimization.