Founded in 2007, Eastern Rail Corporation built a reputation on designing sustainable, high-quality solutions for the Metro Rail infrastructure in the US. For a specific component—an insulator that isolates the electrified third rail in underground subway systems–Eastern Rail needed to update the material to meet safety standards. A switch to Polyphenylene Sulfide (PPS) subsequently required a reevaluation of the existing mold. To tackle this issue, Eastern Rail approached Linear AMS, a Shapeways Company, seeking partnership in creating an innovative solution to enhance functionality and efficiency.

Eastern Rail is a long-standing customer, supporting transit agencies in metropolitan areas like New York City, Washington, D.C., and Miami, where urban rail systems frequently operate in underground tunnels. Such an environment demands components with specific dielectric properties, safeguarding against unwanted electrical charges and allowing for more effective management of underground train lines.

Incorporating Advanced Cooling Technology

Injection molding manufacturers often face challenges related to long cycle times, part quality, and overall efficiency. Conformal cooling technology specifically resolves these problems. Relying on 3D printing for customization and efficiency, conformal cooling adapts to fit into industrial molds. 

In contrast to conventional methods, which are restricted to machining in straight lines, conformal lines are designed to follow the shape of the part itself–leading to a more consistent temperature throughout the part’s cooling stage. This means that parts are less likely to warp, while also cooling up to 50% faster. With conformal cooling, manufacturers can reduce their cycle time and increase their throughput, all while improving part quality. 

For Eastern Rail, integrating this technology produced more consistent temperatures in tooling, leading to more efficient production cycles, satisfying stringent requirements for reliable and efficient rail systems.

Improving Tooling for Complex Materials

Initially, Eastern Rail encountered challenges due to the complex part design and core mold features, combined with the nature of Xencor PPS LGF-3045, a 45% long-glass, fiber-reinforced Polyphenylene Sulfide (PPS).

While providing beneficial properties like heat resistance and durability, PPS also presents manufacturing difficulties. Linear performed a comprehensive analysis, revealing that Eastern Rail’s existing tooling with conventional cooling–in combination with a PPS material–would not produce a moldable part.

“I was aware a new approach would be necessary with the change in material,” said Mickey Morales, CEO of Eastern Rail. “After working with Linear for the past decade, I was confident in their engineering expertise and knew they were capable of delivering the dynamic solution this project needed.”
To address these issues, Linear and Eastern Rail worked side-by-side for months in prototyping and testing, experimenting with molds and the integration of 3D printed conformal cooling lines.

Upon initial review, the team suggested making the change to a steel mold over aluminum for production volumes. The PPS material is highly corrosive and would deteriorate the aluminum mold. Transitioning to a steel mold also opened up the possibility of using conformal cooling to allow for better thermal control. Additionally, based on the molding temperature requirements of PPS, the team determined hot oil would be necessary to maintain tool temperature, as opposed to water which is more commonly used.

“The shift to steel molds significantly transformed our approach, working much better with the unique characteristics of PPS and the need for a precise, controlled molding environment,” said John Tenbusch, Director of Automotive Sales at Shapeways.

“After working with Linear [A Shapeways Company] for the past decade, I was confident in their engineering expertise and knew they were capable of delivering the dynamic solution this project needed.”

Mickey Morales, CEO of Eastern Rail

Reducing Cycle Times & Improving Part Quality

The introduction of conformal cooling was highly effective, yielding a remarkable improvement in efficiency after Linear introduced steel tooling. Implementing conformal cooling led to a design adjustment that significantly cut costs. Interchangeable inserts, usually requiring three cores, were reduced to just one.

“We had to incorporate cooling one way or another,” said David Dickerson, Manager of Client Services at Shapeways. “Without conformal cooling, we couldn’t have made the interchangeable parts we needed for the various sizes of the insulator.”

With the new steel molds and conformal cooling inserts, the Linear team was able to reduce the cycle time from 181 seconds to 138 seconds, reflecting a 23% improvement. Reduced production time allows for more parts to be made, lowering both piece cost and overall program cost, without sacrificing part quality. The more even, controlled temperatures also led to the production of higher-quality, more reliable parts.

While the initial prototyping and testing phase required significant time and financial investment, the cost savings over the long term more than justified the upfront expenditure. The enhanced material durability, lower maintenance needs, and increased production speeds collectively contributed to significant long-term economic advantage for Eastern Rail.

“While we encountered a few obstacles during our journey, Linear’s team of experts was again able to provide a highly engineered solution while providing cost-saving benefits,” said Mickey Morales, CEO of Eastern Rail.

Aligning with Regulatory and Environmental Considerations

Eastern Rail’s openness to new solutions enabled improvements with both short and long-term benefits, meeting industry-specific needs while maintaining a commitment to environmentally friendly materials and regulatory compliance.

This case study offers useful problem-solving insights for issues related to materials, tooling, and cooling. These solutions may be applicable to other manufacturing sectors as well. Overall, this project showcases the value of teamwork, innovation, and excellence in manufacturing

Find out more about how Shapeways can collaborate with your company.

The post Case Study: Eastern Rail Corporation appeared first on Shapeways Blog.

We’re excited to introduce the first annual Shapeways Manufacturing Week (SWM Week), taking place from October 2-6, 2023. SWM Week offers an action-packed schedule of learning for engineers, designers, and manufacturing professionals. 

Interact with thought leaders, gain valuable insight to help redefine your approach to manufacturing, and take advantage of exclusive promotions. Shapeways brands MFG and Linear AMS will also share expertise on business evolution and innovative applications for additive manufacturing. 

Whether you’re an independent manufacturer, designer, or an industrial engineer, join us to connect with peers and leaders in your field! SWM Week is entirely virtual–just complete your registration here. 

Unable to attend live? Register for the events you’re interested in, and we’ll send you the recordings afterward.

Schedule of Events

Monday, October 2

Day 1 / Business Evolution Day – As we kick off the first day of SWM Week on October 2 with Business Evolution Day, the focus is on independent manufacturers, and how they can ramp up their business. Topics will include website optimization and use of social media platforms to engage with target audiences.

Learn from independent CNC manufacturers as they discuss strategies for business growth and offer actionable advice for taking your company to the next level. Whether you’re just starting a shop, or work at an established company, this event serves as a practical guide for modern business development strategies.

Tuesday, October 3

Day 2 / Designer Day – Designer Day is focused on designers, engineers, inventors, and innovators. 

Be sure to register for the informative tutorial with our 3D design partner CADmore, as they share advanced strategies for design. 

On the traditional manufacturing side, don’t miss ETHO founder, Dave Fustino as he outlines the process from concept to mass production, following design for manufacturing principles. Whether you’re an engineer, designer, or industry professional, this event offers valuable insights and actionable tips.

Wednesday, October 4

Day 3 / Traditional + Additive Manufacturing – Scheduled for October 4, Traditional + Additive Manufacturing Day is a chance to hear how these methods can complement each other in everything from rapid prototyping to full-scale production, and in other surprising use-cases too. Industry leaders Harold Sears, David Tucker, and John Tenbusch will lead a panel discussion, sharing their expertise on how to select the best manufacturing strategies. 

Whether you’re interested in exploring end-to-end manufacturing solutions, conformal cooling showcases, or you’re just eager to ask your top manufacturing questions, this day is designed to expand your understanding of manufacturing possibilities.

Thursday, October 5

Day 4 / 3DU Day – Join us for 3DU Day on October 5, as we learn about additive manufacturing’s role in education and explore the growth of 3D printing in the education sector.

Register to hear from Shapeways SVP of Technology, Ajay Raina, and Engineering Tech Lead, Joe Estefane, as they explore the fascinating intersection of Generative AI and 3D printing, and delve into how AI is revolutionizing development and production processes.

We’re also offering special promotions and contests for designers and engineers. As an added bonus, the Shapeways educational discount is also increased from 15% to 20% for the month of October!  

Friday, October 6

Day 5 / Shapeways Manufacturing Day – Don’t miss out on the exciting conclusion of Shapeways Manufacturing Week on Day 5. Register for a Fireside Chat featuring Shapeways CEO Greg Kress, AMUG and Layered Manufacturing and Consulting President Shannon VanDeren, and moderator Amanda Harrell, GM, eCom & VP, Marketing for Shapeways. This discussion will cover industry trends in both traditional production and 3D printing, while also discussing the future of AI in manufacturing. 

Whether you’re in business, design, or academia, you won’t want to miss this comprehensive wrap-up to a week focused on manufacturing’s evolving landscape. Mark the date–the Fireside Chat is a must-attend event!

SWM Week Contests and Promotions

Be on the lookout for special prizes, promotions, and exclusive savings during SWM Week. For instance, you can nominate an engineer in our Engineer Appreciation Contest for the opportunity to receive a $500 Amazon gift card—or enter our Design Contest for a chance to receive $100 in 3D printing credit for High Definition Full Color.

Don’t miss the chance to participate in a week filled with rewarding opportunities and events, exciting contests, and exclusive promotions. For complete event details and to register, visit the Shapeways Manufacturing Week website.

The post Your Guide to Shapeways Manufacturing Week 2023 appeared first on Shapeways Blog.

• Why manufacturers have relied on injection molding for so long but are turning their interest toward offering 3D printing too.
• What’s involved in the decision making process, whether to choose 3D printing or injection molding.
• The pros and cons of each technology, and why it is often important to narrow down decisions case by case.
• Why strategy in scaling is so important for any type of manufacturing.

The decision making process may depend on a traditional manufacturer exploring 3D printing services like Shapeways in order to make new offerings available to their customer base, or a dedicated 3D printing enthusiast may be dealing with larger volumes in terms of orders and wondering if they should make the move to injection molding.

Scaling successfully is key in manufacturing, and business, today, but it can be challenging when growing from 1 to 1,000 units, 10,000 units, or even 100,000 in the luckiest of scenarios. There are many factors to consider when scaling production, but one of the most obvious concerns is how to actually go about creating a product. There are usually requirements for controlling expenses, providing fast turnaround times, and dealing with all aspects of customer service as efficiently as possible too.

Looking Deeper into Additive Manufacturing and Injection Molding

Unfortunately, there is no single manufacturing method that is perfect for every part and situation, but it is critical to understand the advantages and disadvantages associated with methods like 3D printing and injection molding.

When focusing on plastic components and products, there are traditionally few manufacturing methods available, the oldest and most common being injection molding. While injection molding has dominated the manufacturing landscape for decades, newer techniques like 3D printing, have begun to gain traction by offering an alternative, as well as advantages over traditional methods; for example, a company may go straight to injection molding to manufacture plastic products in a high volume of 10,000 parts or more–or they may choose 3D printing for greater flexibility in making designs, multiple iterations, and the ability to make complex geometries not possible before.

Injection Molding

Injection molding is one of the oldest high-volume manufacturing processes, wherein a molten material (such as a thermoplastic) is injected into a metal mold. Once injected, the thermoplastic takes on the mold cavity’s shape, is cooled, and is ejected as a solid part.

Injection molding is typically used for producing high volumes of the same object. The method does have its pitfalls though. First, there is a large upfront investment involved in making a mold. Molds can be reused to make hundreds of thousands, if not millions of parts, but can cost anywhere from a few thousand dollars to over $100,000. As a result, there is an inflexibility that comes with needing to create a new mold for every new or modified part. Still, injection molding is a complex but powerful process that has been the go-to solution in the plastic part manufacturing market for years.

3D Printing

3D printing is also referred to as additive manufacturing–in stark contrast to subtractive manufacturing–as the process involves adding material together to create the end part. This is opposed to cutting material away, like in milling, or reshaping it  in injection molding.

There are many benefits inherent to this process, such as the ability to produce completely custom parts with virtually no upfront cost. With 3D printing, the efficiency is incredible: all you need is a digital file. Due to the additive nature, less material is used, and for technology like selective laser sintering, much of the powder can be recycled.

3D printing does have some disadvantages though too, especially as some 3D printing processes are still prohibitively expensive, slow, and may produce parts that are not up to industry quality or material standards. Because it can be difficult to decide between the two, and somewhat complicated, considerations are usually case-specific.

Examine Specific Parts and Production Requirements

Aside from unit cost and order volume, there are other considerations that come into play when choosing between injection molding and 3D printing:

• Complexity – Whether an object is organically shaped or has ultra-sharp edges, its type and degree of complexity can help inform which manufacturing method is best. Ultimately, common sense usually dictates using the most suitable form of manufacturing. When thinking of ‘creative’ or organic shapes as complexity, 3D printing wins. When thinking of hard engineering constraints and tolerances, injection molding wins most often.
• Production Time – Production time is typically determined by the manufacturer’s capacity and the size of the production run. The many steps required to get something into production can factor into this timeline, from sourcing a manufacturer, to making a mold, to quality control, shipping and eventual delivery. Other factors include the manufacturer’s location, steps to getting to production, and guaranteed delivery time.
• Iteration & Change – As with all competitive products and services, being able to iterate often and maintain agility is key to innovation. For businesses at the beginning of a long product development journey, spending a few thousand dollars on a mold that cannot be changed will most likely slow down the innovation cycle; however, if the focus is intense mass production without much worry for customization, then injection molding may prove to be more fitting over 3D printing.

Manufacturing Tools for the Future

The future looks exciting for 3D printing, injection molding, and manufacturing overall. These advancements are making it easier and faster to get things made, and will hopefully lower the barrier so that more and more people can make the products they dream up.

To get the perfect look and feel for any 3D printed part, check out the material options that Shapeways offers. Each material listed notes the available finishing options to ensure that your aesthetic parts look good, and your functional parts perform how you need them to in the end. 

Upload your design and get an instant quote now!

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.  

The post Making the Call in Mass Production: 3D Printing or Traditional Manufacturing? appeared first on Shapeways Blog.

Create a First-Rate 3D File

Quality designs lead to quality parts, but it’s not always an easy process. Some very important steps must occur before it is possible for a 3D model to make it into a 3D printer. A healthy dose of inspiration and motivation is required first—leading to the ideation phase—which must be accompanied by tools meant to streamline the process from modeling to manufacturing.

Shapeways works with customers every day who are dedicated to designing unique 3D models for a tremendous range of projects, varying in requirements that affect options in terms of settings, materials, and technology. This is why the ongoing design partnership with ZVerse has been so positive for simplifying the customer experience. ZVerse was a logical partner due to the massive scope of 3D printing going on at Shapeways—leading to the need for a professional design team with broad resources.

The ZVerse platform is uniquely AI-enabled, allowing for better automation in file creation workflow, along with helping Shapeways scale to customer needs better. Every customer has access to comprehensive design solutions offering the most streamlined path from concept to 3D model.

3D printing experts from the Shapeways User Application Team are also available for one-on-one consultations to discuss the best fit for materials and manufacturing methods, as well as finding ways to overcome typical issues with printability.

“We are here to help with any and all questions about design, materials, or the processes that make our customers’ models come to life,” says Zach Dillon, User Application Team Lead at Shapeways.

Get the most out of product development

While 3D printing allows for incredible creativity, innovation, and the ability to make products with complex geometries that simply were not possible previously, this technology lends itself to superior product development processes, beginning with rapid prototyping. Models can be designed and 3D printed, offering detailed visualization of products, along with the ability to test and validate parts according to project specifications. A good example would be checking for proper fit in new automotive parts or aerospace applications where there is absolutely no room for error. Rapid prototyping has played a major role for customers like Tilt Hydrometer, with CEO Noah Neibaron designing and 3D printing over a hundred iterations with Shapeways before settling on the final design for his free-floating monitoring device used in homebrewing.

Shapeways 3D prints products in over 90 materials and finishes, with over 11 technologies to choose from. Thermoplastics like Nylon 12 [Versatile Plastic] are extremely popular for a wide range of applications, from drone technology for customers like Quantum-Systems, to a luxury jewelry series of cuff bracelets for Dutch designers Groen & Boothman. All of these companies have used Nylon 12 [Versatile Plastic] for both extensive prototyping to ‘get it just right,’ along with making it the final choice for high-performance, functional products. That does not mean, however, that as longtime customers they haven’t delved into a variety of metals, to include other thermoplastics like MJF Plastic PA12 or precious metals like silver. Along with these materials come a variety of different colors and finishes, along with our latest offering in Nylon 12 [Versatile Plastic] Smooth.  

Get to market fast—and effectively

Products that are already in high demand can be 3D printed in customized bulk orders, and for businesses experiencing higher volume in orders, Shapeways recommends that they work with the User Application Team directly for streamlining production and bridging the gap from concept to printability and ultimately, quality manufacturing.

“Our goal is to make the customer experience as seamless as possible,” says Matthew Nadler, User Application Materials Specialist at Shapeways. “We unlock all that Shapeways has to offer for our customers, and enable them to leverage our full capabilities.”

Add-on services are available in manufacturing also, to include product assembly. Shapeways customers like LuxMea have been able to pass on the benefits of customized, on-demand printing and assembly to their own clients as bespoke masks—which include an ergonomic valve system design—are measured to fit with AI software and then completed with a personalized label.

Scale for success

Shapeways 3D prints the masks and also ships them out for LuxMea too, offering total order fulfilment that includes customized packaging for continued brand recognition, along with the opportunity to take advantage of other marketing opportunities at the same time, like adding custom inserts or promotional materials. Shapeways ships orders out to over 160 countries, with bulk pricing available. Proprietary software also makes it easy for other manufacturers to offer 3D printing with fast turnaround, including secure uploading and ordering, instant quotes, and streamlined ordering.

Scaling production is critical to modern businesses of all sizes serving a wide range of applications, and Shapeways is always ready to assist in helping customers grow—whether through 3D printing or other traditional manufacturing methods. In some cases they may begin on the smaller scale with low-batch production in highly customized, 3D printed products and then move on to more traditional methods like injection molding for precise mass production due to customer demand. In other cases, customers may want to navigate manufacturing processes in reverse, or begin employing a hybrid combination of additive and traditional manufacturing.

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for 3D printing creations for the classroom with accuracy, complex detail, and no limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Inclusive Manufacturing: Streamlining & Scaling Production for Customers appeared first on Shapeways Blog.

Additive Manufacturing Offers More Choices and More Freedom in Design

Relying on popular methods like Selective Laser Sintering (SLS), for example, to heat up powder particles and meld them together into a prototype or part, or Binder Jetting for fusing together stainless steel particles via a binding agent, additive manufacturing offers many new and exciting options in manufacturing. With the ability to create complex geometries previously impossible through traditional methods, unprecedented freedom is available in design and production, from the small to the large scale. In comparison to traditional manufacturing, there are minimal restrictions with a multitude of options for materials as well as a wide range of choices in terms of affordability, whether choosing thermoplastics or metal.

Maximizing customization while also minimizing the need for inventory is another benefit many businesses never considered possible, along with the possibility of cutting out warehouse space altogether. With on-demand 3D printing, custom parts can be produced based on need, in small volumes with the same accuracy and repeatability.

Traditional Manufacturing Empowers Repeatability and Mass Production

Conventional methods continue to stand the test of time, offering undeniable power in production. With the ability to manufacture thousands—and even millions—of parts in mass production without any deviation in quality or detail, traditional manufacturing is often the most proficient route for satisfying customer demand.

Similar materials may be available also for customers who were previously engaged in additive manufacturing but have grown to the point where moving up to a different process is more suitable. This is evidenced in methods like CNC machining and injection molding especially.

Computer Numerical Vontrol (CNC) Machining

Pre-programmed computer software controls the subtractive manufacturing of industrial parts, issuing instructions centered around a 3D file. Performed through a variety of methods such as milling, drilling, turning, and cutting, CNC machining offers outstanding dimensional accuracy in parts, capable of surpassing 3D printing or other manufacturing processes—often making it a better fit for customers seeking more fine-tuned precision.

Shapeways offers a range of materials for use with CNC machining, some of which are used in additive manufacturing too, like thermoplastics, nylons, and metals.

Injection Molding

Patented in the 1870s, injection molding is commonly used for mass production of parts, relying on the use of molds which are typically made with plastic or steel.

Often heavily customized, depending on the requirements for specific applications, the molds can be used with materials like thermoplastics, nylons, or metal. The materials are heated to a molten state and then left to cool inside the molds, solidifying into the desired industrial part. There is generally little need for post-processing, with the molds being used over and over, offering incredible repeatability in parts for productions on the large scale. 

The Journey: Transitioning from Additive to Traditional Manufacturing

For most businesses, the manufacturing goal is to make quality parts that last. Weighing out the pros and cons and making a final decision can be overwhelming at first, not to mention dealing with budget concerns over investments in hardware, software, and materials. Shapeways is a world leader in digital fabrication, but also remains agnostic in terms of all technology.

“Our focus is on working around customers’ needs in terms of matching the correct materials and processes to a specific application,” says Zach Dillon, User Application Team Lead.

Key points in choosing additive manufacturing usually boil down to the infinite level of innovation possible in 3D design, along with the ability to customize products intensively. Many Shapeways customers are dedicated to AM processes, and tend to use them as long as possible, especially because they are able to 3D print hundreds or even thousands of parts in one run. If customer demand has increased exponentially though, it could make greater economic sense—as well as increasing speed and efficiency—to scale up to mass production, using traditional methods for large volumes of identical parts.

Today, many businesses also rely on different types of hybrid technology. This could mean that they rely on a mixture of AM processes and CNC machining, for example, at one facility, or they may have turned to machinery that encompasses both AM and traditional manufacturing all in one. For businesses requiring true versatility, hybrid technology can be the answer in terms of having it all in terms of retaining all the benefits possible, with AM complementing traditional manufacturing, and vice versa.

Learn More about Working with Shapeways

Contact us now to find out more about which technology suits your needs, enjoying the benefits of 3D printing and traditional manufacturing without having to spend precious business capital on advanced hardware, software, or material inventory.

Find out more about manufacturing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post When Does it Make Better Sense? Additive Manufacturing vs. Traditional Processes appeared first on Shapeways Blog.

3D Printing vs. Traditional Manufacturing—Making the Right Choices

Shapeways is a world leader in digital manufacturing, but also offers a wide range of other choices for making products that can be customized, made with precision, and produced accurately every single time. While additive manufacturing is beneficial in many industrial scenarios today—and increasingly, this includes the larger scale too—when innovation and extraordinary demand from the public converge, businesses must often turn to mass production to meet their ongoing goals for continued growth and success.

When is it Time to Turn to a Conventional Technique?

Despite the ongoing trend to move toward mass customization with additive manufacturing, traditional manufacturing still has an enormous hold over industrial production and may simply be the best choice for a specific product, or line of products being created on the large scale.

The goal for any business is to offer a quality product and then to grow over the years. Traditional methods of manufacturing allow Shapeways customers to leap forward while still relying on ongoing support from their manufacturing partner. Deciding when it is best to transition to conventional techniques can be tricky, and is a continued discussion between the Shapeways production team and customers who are in the enviable position of providing increased numbers of unique products to a growing base of customers.

Companies like 67 Designs are committed to 3D printing via Shapeways as long as possible because of the ongoing benefits such as durability and the quality of finish available through Selective Laser Sintering (SLS) technology with Nylon 12 [Versatile Plastic]; however, CEO Gavin Stener also has realistic expectations regarding a potential transition to injection molding for larger manufacturing volumes of his company’s high-end accessories.

Other customers like Quantum Systems have been using 3D printing since their inception. They have streamlined their processes by integrating 3D printing with other traditional manufacturing like injection molding and CNC machining, making high-performance drones that are capable of revolutionary services like flying medical samples to labs in minutes.

Find out more about these companies and their choices in manufacturing by downloading their case studies here.

CNC Machining

A traditional subtractive, or reductive, manufacturing process around since the late 1970s, Computer  Numerical Control (CNC) machining is directed through computerized controls which cut or carve materials into geometrical shapes that eventually become industrial parts. After a CAD file is created, it is converted into language for CNC machining software instructions. The operator positions materials, machining tools are attached, and the manufacturing process begins.

Typical materials used with CNC machining for drilling, milling, and turning include metals like aluminum and steel, thermoplastics, nylons, and acrylics. High volumes can be manufactured to meet customer demands, maintaining accuracy and quality.

In comparison to additive manufacturing where structures are built by adding materials meticulously, layer by layer, subtractive processes basically revolve around beginning with a piece of material that is manipulated into the desired shape by cutting away from a piece of metal, for example. Parts are made quickly, accurately, with tight tolerances, good surface finishing, and minimal post-processing effort is required.

Injection Molding

Patented in the 1870s, injection molding is one of the most commonly known—and used—forms of traditional manufacturing for mass production. Parts are created as materials like metal, thermoplastics, and more are heated in molten liquid under pressure and then poured into custom molds. As the liquid material begins to solidify, the industrial structure begins to form, and is ready after cooling. Little post-processing is required.

Extremely prevalent, to the point of maintaining a presence in nearly every application, injection molded parts can be made in a versatile range of geometries, resulting in strong yet lightweight parts with excellent detail. Consistency is usually guaranteed, especially as the same molds can be used over and over. Little post-processing is required. Other advantages include great latitude in design, a wide range of materials and finishes to choose from, and overall efficiency, speed, and repeatability in production of large volumes—even in the millions.  

Machine Tooling

Another versatile method that is also effective and streamlined for mass production of parts, machine tooling opens up a wide range of choices for businesses engaged in industrial manufacturing. Shapeways  manufactures molds for making high-performance parts through conventional processes like injection molding, as well as offering machine tool molds to be purchased on their own. Tooling options can be designed to customers specifications, heavily customized, and produced in large volumes.

Providing a range of molds, from simple designs to those including complex details, undercuts, inserts, and more, they can be used repeatedly over the long-term with many different materials. Currently, Shapeways primarily offers aluminum and steel for machine tooling related to industrial applications.

Sheet Metal Fabrication

Using a wide range of metal materials to make critical industrial parts for industries like automotive and aerospace, sheet metal fabrication is comprised of many different processes. Used with materials like aluminum, stainless steel, copper, and more, sheet metal fabrication is used to make many commonly used products. 

In forming, metal is shaped into a required structure through stamping, bending, and rolling. Cutting may include basic methods, the use of lasers, powerful water jetting, compressed gas, or machining with milling or drilling. Joining sheet metal relies on typical processes like welding, using bonding agents for adhesion, or connecting with embedded screws.

One of the most highly industrial forms of manufacturing—and often used for serious applications in construction, sheet metal fabrication is beneficial due to the lightweight yet durable nature of the materials, its ability to hold up in outdoor environments, and ease in repairs. The ability to form metal also leads to the production of many versatile, highly customized parts.

Urethane Casting

In urethane casting, multiple products can be manufactured in one silicone mold, to be filled with polyurethane. High-quality parts can be made in versatile large-volume production or on-demand, allowing businesses the advantages of decreasing the amount of standing inventory on-site, as well as eliminating the need for warehouse space altogether in some cases.

Shapeways 3D prints the silicone master patterns for molds, producing high-performance parts with industrial materials. The process is fast, efficient, and suitable for components being made on any scale. Parts can be over-molded combining two materials, used with inserts, and the sheet metal requires little post-processing work.

Vacuum Casting

Typically used to make small, intricate parts, vacuum casting is another versatile form of manufacturing offering enormous potential for low- to high-volume production of parts in varying textures. Silicon molds are used in this process, which is unique in relying on a vacuum chamber to pull liquid into molds where high-quality structures are formed, whether for models or functional, end-use parts.

Shapeways offers a wide range of materials for vacuum casting, whether they must possess flame-retardant qualities, or require flexibility or rigidity.

Making Mass Customization and Production on Any Level Available to All

The Shapeways mission continues to revolve around making 3D printing accessible for everyone, offering resources like advanced technology and materials to other companies not currently ready to invest in highly industrial machines. Shapeways provides expertise in mass customization and mass production, promising the same level of service and quality as companies transition into using other manufacturing methods. In the end, businesses are able to grow and distribute their products with an improved flow in the supply chain and a focus on greater efficiency.

“So many companies working with Shapeways today have grown with us throughout the years—from making prototypes and small numbers of customized products to evolving into thriving businesses exploring a variety of different technologies and materials as demand has continued to grow,” said Miko Levy, Shapeways CRO. “While they may have started out with 3D printing and are still using that technology for many products, our job as a long-term manufacturing partner is to direct them to the most suitable and efficient forms of production.”

About Shapeways

Enjoy the benefits of advanced technology and a wide range of materials from Shapeways for manufacturing parts with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Traditional Manufacturing Services from Shapeways appeared first on Shapeways Blog.