3D Printing offers a great resource for quickly and affordably creating end of arm tooling for the many tasks that collaborative robots take on.
Collaborative robots are a great resource for smaller companies looking to automate. They are a flexible resource for completing repetitive tasks in assembly and sorting because of their flexibility and ease of training. The trouble is that robot grippers are not very versatile. Often each task needs its own specialty gripper to be created to grasp the objects in that task.
Creating these grippers is both expensive and difficult due to CAD requirements and machining costs. 3D Printing makes the creation of EOAT much easier and flexible.
End of Arm Tooling Created with 3D Printing
3D Printing is a very flexible means of manufacturing EOAT. It allows users to very quickly create custom fingers or parts nests without many machining concerns or time input. That is why Schunk has started providing resources to create custom 3D Printed end effectors. EMI has also started selling 3D Printed EOAT solutions. And there is the Slant 3D Part Mason Project that provides customisable Grippers for Collaborative robots.
Since there are so few design constraints on 3D printed parts you also don't have to worry about high costs of engineering and design bottlenecks.
How to get 3D Printed EOAT
Get a Model
At Slant 3D we maintains a team of 3D modelers that can help you design a gripper for your application within hours or days. You can also access pre-made 3D models for gripper fingers and pads at Part Mason. The models are ready immediately to be printed by a service or on your in-house 3D printer.
One other option is to use online resources such as eGrip by Schunk which can generate .STEP files that can be 3D Printed very affordably.
Print the Part
Once you have the model you can print it on your In-house 3D printed, such as the Mason. If you need higher volumes of the part to outfit an assembly line, or if you need specific material properties you can submit the design for a quote. Generally it only requires 2-4 days to turn around 100 pieces at Slant 3D.
Use Your Robot
When the parts arrive they can immediately be mounted onto your collaborative robot and put to work. If you ever need more pieces they can be ordered instantly without redesign or setup.
Reduce the Cost of International Shipping by Teleporting Parts Via 3D Printing
The internet has allowed the sale of products to anyone in the world. Whether those be consumer or industrial products. But that access is ruined when the products have to cross borders or oceans. Shipping a crate overseas then paying tariff and warehousing fees significantly increases the cost of a product to the end-user. Wouldn't it be great if Parts and products could be "teleported" to the destination country with just an e-mail to save those shipping costs. With Production 3D printing that is possible.
3D Printing allows 3D models to be emailed and manufactured anywhere in the world. The trouble has always been there has never been a formal entity that can print your parts in the country where they are to be sold and ensure they are shipped to customers. 3D Printing services like Slant 3D allow products designed in one country to be produced and fulfilled in another country without the cost of shipping. And Slant 3D can hold your model in our digital inventory and produce it only when it is needed.
How it Works
By using Slant 3D you can take your product international and not have to deal with international shipping costs. And you have the huge production scale of Slant 3D. So you know that when demand rises we are able to back you up. This is a great resources of companies and entrepreneurs outside of the United States to send their production to the US without the high cost of shipping.
3D Printing is quickly becoming a best option for production of plastic parts. You have little-no inventory. You can send your parts anywhere in the world for free, and you are able to grow without any high up-front investments.
Who is Doing It.
Slant 3D already doing this with dozens of companies and entrepreneurs. They include companies like Uncommon, a project call Part Mason, and Etsy stores such as BakersStreetCuters. All of these products are manufactured and fulfilled from Slant 3D. But most of them are designed outside of the United States
Production 3D Printing is a new technology. And not everyone has interacted with it or understands what kind of pieces and features can be made with it. That is why we designed the Slant 3D Sample Brick. This 3D Printed part demonstrates many of the key features and capabilities of the additive manufacturing process. Everything from complex internal geometries to complex surface textures.
The sample Brick can be ordered for free with the form below. Just let us know where to send it and we will get it to you.
Clients may use the 3d printed sample brick as a reference for proper design of 3D printed parts. As well as a way to evaluate our high volume 3D printing processes.
Features on the Brick
3D Printing is increasingly being used by businesses. And it is not just being used for prototyping. The ability to iterate on products and create complex geometries are both enticing to create parts at production scales. And with technologies such as our Production 3D printing Farm, large scales are feasible. But during the design and prototyping stage sampling, verfication, and design can increase up-front costs to create a 3D printed product. That is why we created the Mason 3D printer for businesses
The Mason is a 3D printer derived from the production 3D printers used in our large scale 3D printing farm. Because of that, any part made on the Mason will be identical to the parts coming out of the Slant 3D Printing Factory. This means sampling is no longer necessary. Clients only need to make a prototype on the Mason that is up to Spec, and then thousands more can immediately be produced with identical settings and characteristics on the Slant 3D farm. Prototype to production with no steps in between.
There only leaves the problem of getting those settings right on your prototype. Design for production 3D printing is an entire discipline, and very few truly understand how to optimize a part for large volumes. And while the machines may be identical from prototype to production, materials could vary if the client is using a spool of filament off of Amazon.
So to standardize the workflow completely. We created OnSite. Onsite is program that connects a Mason 3D printer directly into Slant 3D. An Onsite Subscription provides stardaized materials and access to profession file preparations and optimization. So every variable is eliminated in the prototype stage. Mason+Onsite gives you completely final production-ready prototypes. Not to mention machine insurance, discounted setup, zero sampling costs, and low cost high quality filament.
With the Mason 3D printer combined with an Onsite subscription we have made is possible for businesses to create, and quickly scale 3D printed products as easily as a software company might make an app.
Sculpteo's annual "State of 3D Printing" for 2019 shows how enterprises are increasingly using 3D printing and additive manufacturing for end-use products.
These and many other fascinating insights are from Sculpteo’s 5th edition of their popular study, The State of 3D Printing (29 pp., PDF, opt-in). The study’s methodology is based on interviews with 1,300 respondents coming from Europe (64%), United States (16.6 %) and Asia (20.2%), which is the fastest growing region internationally today as measured by this survey over five years. Eight industries are included in the research design including Industrial Goods (13.6%), High Tech (10.6%), Services (9.9%), Consumer Goods (8.6%), Health & Medical (6.2%), Automotive (5.7%), Aerospace & Defense (5.5%), and Education (4.9%). For additional details on the methodology, please see pages 6 and 7 of the study. Key takeaways from the survey include the following:
3D Printing is an ideal means of manufacturing custom electrical enclosures.
We have worked with many industrial clients that have utilized our large format 3D printing capacity to produce electrical enclosures. The reason they prefer 3D printing is to traditional machining is primarily based on cost.
The additive nature of 3D printing reduces the amount of material needed to create an enclosure when compared to subtractive machining. After all a delrin block is far more expensive than a kilogram of ABS. Injection molding is not an option because with larger enclosures, greater than 12 inches cubed, the cost of the mold is very prohibitive. Not to mention the time to have just 10-20 enclosures produced is too long. But 3D printing can produce the pieces in 1-2 weeks.
But as is the problem with most items submitted for 3D printing, the engineer of the enclosure does not design for 3D printing. They take a traditional enclosure and expect 3D printing to create a result that is identical to other processes. It will not be. So we wanted to compile some tips for designing electrical enclosures.
Design a Foundation Layer
When printing any part a decision must be made about what side of the part will be against the print bed. Traditionally this will be the largest single flat surface. This is used to have maximum bed adhesion which limits warping and failure of parts. Generally this side is the back or bottom of the enclosure that might be mounted against a wall.
Ideally this side should have no complex features such as text. Just holes. If there is text, they it can become unreadable as the first layer is often "squashed" in order to help with adhesion.
When designing your enclosure try to create a large simple side which can serve as the foundation
If all side of an enclosure require critical details there are multiple solutions.
Printing the part with the open face down will require a longer set-up period. This orientation is difficult tp print reliably. It also requires that the enclosure be printed with support material throughout. This results in a rough interior texture and more expense, due to the support material. There is also the risk of any interior bosses or features losing detail because they printed on support material. You can see a comparison of sections of the same part printed open side down and up in the photos below.
Infill or Ribs
When a part is 3D printed there is the ability to either create a solid piece or reduce the density of thick areas of the part by using internal lattices. This "infill" reduces print time and material used and is highly recommended.
The infill makes the part behave like a sandwiched composite. So even though it uses less material it is structurally very strong at low infill percentages of less than 50%.
However if more structure is required we recommend adding ribs. These are simple to print and provide a large amount of strength. Using ribs with thin walled enclosures are ideal as they result in even less material used than infill and better control the structure of the enclosure.
Since electrical enclosures are generally purely functional, they are often printed at the lowest resolution possible. The layering is visible, but it reduces lead time and has not structural downside.
If a more refined surface is necessary the layering can be be made to nearly disappear with high resolution printing. The downside is that the printing time per part can go up as much as 300%. And the smooth surface can only be created on straight vertical surfaces. Any sort of incline or vertical curve will make the layering more visible. All of this is well defined in the part below, where it was printed with high resolution.
Reduce Rims and Overhangs
It is very common to create a rim around the top of an enclosure or case. This improves rigidity for a lid or for ejection from a mold. These rims often protrude some distance horizontally from the part with little filleting below them. This is done to reduce material used, but that is unnecessary for 3D printing (infill eliminates excess material from thick areas).
These rims in fact increase the cost and difficulty in manufacturing the part with 3D printing, because they must be supported. In the case of the part above an entire secondary structure of support material from the base of the case to the rim must be built simply to support the rim in the last 0.25 inches of the part. This adds a great amount of print time and material, therefore increasing the cost of the part.
The way to avoid this is simple to add a chamfer of fillet underneath the rim, so that it seems to gradually protrude from the case as it is grown layer by layer. Examples of this filleting are shown below.
In this particular case, the enclosure actually has an overhang angle of 90 degrees, thus requiring support. If a 45 degree chamber was adding it would greatly reduce the cost of the part.
Hopefully these pointers will help you when working on your next enclosure. When working with Slant 3D one of our engineers is always available to help you through the process. And when you submit a design for quotation we will always be willing to make recommendations in order to reduce cost.
3D Printing is a very viable manufacturing option for electrical enclosures. But to use the process effectively you must design for it. Pressing an part designed for injection molding into a 3D printer will never created an injection molded part. Better to design a part for 3D printing.
We are happy to announce that Slant 3D can now manufacture pieces as large as 400 x 400 x 400 millimeters in size. Making it possible to prototype and produce produces such as furniture, large decorative pieces, and even industrial electrical enclosures. Get a quote for your 3D printed product to take advantage of this new capability.