How 3D printing is being used for Direct manufacturing

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1 How 3D printing is being used for Direct manufacturing Martin Forth V.P. Sales Envisiontec

2 Agenda EnvisionTEC overview Customised Eyewear manufacture Injection Moulding developments Hearing Aid production Casting overview (indirect)

3 Founded in Offices Worldwide: US, Germany, UK & Canada 150+ Partners Worldwide and Increasing Over 6000 Machines Installed Number 1 in Jewelry, Dental, and Hearing Aids Over 170 Employees

4 Portfolio Perfactory Desktop Range Perfactory Range 3D-Bioplotter Range Ultra Range Perfactory-Xede & Xtreme

5 Why do our clients use Envisiontec for Direct manufacturing First choice in Rapid Prototyping 1 Functionality ~40 proprietary materials supported by 6 product platforms Stable and durable end-use products Exclusive bioprinting platform Poised to rapidly grow in markets where material performance and versatility in the key (i.e. highly filled materials, castable materials and high temperature materials etc.) Vision Surface Quality 2 100% Razor-Razorblade model (1) Focused on end-markets requiring mass-customization Target applications and industries consuming large quantities of consumables No layering No side-stepping Accuracy of up to 16 microns Ready to use production parts Minimal post-processing if at all Speed 3 High speed printing Self-calibrating systems requiring limited operator training Minimal to no-downtime when switching materials with almost no waste Ideal for mass customization Low total cost of ownership Low cost per printed object Reliability Flexibility Engineering polymers Our value proposition is functionality and high surface quality without sacrificing speed Copyright EnvisionTEC All Rights Reserved

6 Boulton Eyewear Boulton Eyewear is bringing a refreshing twist to the Eyewear market. Just as clothing needs to be correctly fitted to get the optimum comfort, the eyewear or sunglasses we all wear should be fitted to the wearers face exactly. They discovered that by using 3D Printing Boulton could replicate the quality, look and feel of mass production eyewear at a competitive price point By mapping the key elements of the customers face and they can producing designs that are distinctive and recognisable

7 Eyewear production with Boulton A series of pictures are taken to map the clients face and features These reproduced as 3D Data

8 Designs are selected and matched to the 3D Data

9 Production The frames are printed in R5 Acrylic Once finished lens are fitted either prescription or for sunglasses

10

11

12 Injection Moulding Developments Founded in 1977 Located in Ontario, NY near Rochester Precision injection molder and CNC machining manufacturer Early adopter of Additive Manufacturing Sustainable manufacturing pioneer +175 team members (and growing)

13 Harbec capabilites Injection Molding 34 electric presses; tons All production & prototype volumes Clean room molding CNC Machining and Tooling 42 CNC machines oin-house Engineering & Design Large team of Mold Makers & Machinists 3D Printing 1-EnvisionTec Ultra 3SP

14 Injection Moulding Process

15 Why Plastic Moulds? Advantages Lead times measured in days not weeks Significant cost reduction over aluminum and steel tooling Low volume production

16 Test Process The same injection moulding machine was used for each material trial Polypropylene was chosen as the test resin. The same moulding parameters were used for all trials.

17 Part was designed to test the process and quantify costs. 50 pcs were produced All costs were recorded

18 Inserts mounted in conventional tooling Feeds carefully positioned to avoid weak areas Conformal cooling positioned below the mould surface Mould surfaces coated to allow release

19 Build Time in 3SP 5.1 hrs. Conventional Mould Prep 4 hrs. Injection Moulding 4.8 hrs. Total 13.9 hrs. 3SP material (Etool) $375 Mould Components $167 Mould Build/Assemble Labour $ Mould Setup Rate & Run Matl $ Total $1,238 Cost Per Moulded Part-(50) $24.76 Lead time 1.5 Days

20 Conclusion Moulding of 50 parts is possible using Polypropylene resin Minimum of 3degree draft. Greater than 5 degree is ideal. Parts with small intricate features should be reviewed for feasibility. Coating tool surfaces is beneficial

21 Production Tooling Electro plated Lifetime increased X10! Conformal cooling improves cycle times Trials in PP very successful runs expected in excess of 500 Trials in ABS continue

22 Direct manufacturing of hearing aids Currently there are 10 million 3D printed hearing aids in circulation! By 2020 it estimated there will be 25 million!

23 Traditional method of manufacture Prepare impression Impression Mold Demold Hand finish 2-3 hours production time per hearing aid

24 How 3D printed hearing aids are produced scan Print in 90 mins polish An envisiontec printer can process over 350 parts per day

25 Why do the leading hearing aid companies choose EnvisionTEC 3D printing Single machine can produce 350 pieces per day vs 1x technician producing 4 pieces More complex electronic packaging can be achieved Smooth surface finish requires minimal finishing in mechanised process Wide choice of bio compatible materials Repeatability of accuracy and replacement hearing aids Material cost reduction Change of workflow resulting in higher throughput

26 The future of Direct manufacturing Design intent materials allows more low volume plastic parts to be produced by 3D printing ABS TRU from EnvisionTEC Replicates Injection moulded ABS plastic EGlass 2 High optical clarity Ideal for specialist lens manufacture

27 The future of Direct manufacturing EC 3000 Filled with 3 X more wax than than any other polymer Easily cast with traditional processes Large industrial parts easily manufactured High detail for Jewelery Fast burnout possible!

28

29 New software v 3.1 Automatic part placement and support generator incorporated Egrass Single platform software!

30 Any Questions? See us in Hall 16 on Booth B73.

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