How Slant 3D Created Golf Tee Markers for the Zurich Classic with Production 3D Printing
Back in the beginning of April, Slant 3D was approached by Natureworks to do custom Golf Course hole markers for the Zurich Classic in Louisiana. The idea was to have two block tee markers with the Zurich Classic logo at the beginning of each hole so that when the event was broadcasted on television, the Zurich Classic logo would be seen everywhere.
When Natureworks reached out to us the Zurich Classic golf tournament was only a month away. This is why they looked into mass 3D printing the marker cubes with Slant 3D to ensure that they would be finished in time for the tournament and made affordably. There was no time for delays or mistakes in the manufacturing process. Slant 3D worked with Natureworks to design a 3D model of the hole marker and finalize a design. Natureworks was able to see exactly what the final product was and what it would look like without having the physical partl. Once the 3D model was approved, Slant 3D manufactured, assembled, processed, and shipped more than 1,000 parts within 2 weeks. A project that would have taken 30 weeks worth of print time was able to be completed in just under 14 days using the largest print farm in the world.
This would have been impossible with traditional processes. Using Injection molding the cost alone would have been 10-20x the cost of 3D Printing, if it could be done with such a large part at all. But the lead time would have also been 6-12 months.
We were super excited to work with Natureworks using their environmentally conscious material Ingeo. Ingo is a sustainably produced biopolymer with a small carbon footprint produced by Natureworks. Natureworks uses plants like corn and beets to transform greenhouse gases into long-chain sugar molecules, which are then fermented into lactic acid and used to create the material Ingeo. This process of making this specific type of PLA is only the beginning. Everyday the 3D printing industry is becoming more and more environmentally conscious and Slant 3D is happy to be a part of it.
Working with Naturworks and the Zurich Classic was a great project to work on and a great testament to how quickly and effectively we can deliver on a major time crunch. It also was an added bonus to see the products we manufactured on live television. If you have a project you would like to get quoted for contact us today to see how we can produce your product.
Slant 3D Helped Haddington Dynamics Produce Their Advanced robot Arms. Now they have Sold for 25 Million Dollars.
Haddington Dynamics started out with a Kickstarter for a DIY advanced collaborative robot called Dexter. The arm used a new type of control chip and advanced dynamics to attain very high precision at a very low cost.
The Kickstarter was successful with Haddington gaining $108,000 dollars in preorders. But there was a problem. They did not have the capacity to fulfill them. So they reached out to Slant 3D in 2017 and our large scale 3D Printing farms. So started a long relationship. Slant 3D ended up producing thousands of parts for Haddington that met the quality and scale that they needed as they grew. And along the way they transitioned from standard plastic components to Carbon Fiber Re-enforced parts.
Today we are very happy to see Haddington hit a new milestone by being purchased by British online supermarket Ocado. Haddington's technology will be deployed as a way to help with warehouse management and distribution.
Haddington was purchased for 25 million dollars in cash and stock and can look forward to having their 3D Printed robot arms helping to delivery groceries to thousands of happy customers.
Mass Production 3D Printing is a very affordable means of producing custom shipping trays and packaging. Since there is no molding cost, but a still a high production capacity, custom packaging solutions can be created for the same of less cost as traditional methods. And, and since it is always a custom solution the results are often better.
PCB's come in all shapes and sizes. Because of this transport can sometimes be difficult. The pieces need to be well protected (both from physical harm and ESD dangers). Very often PCB makers and chip manufactures will resort to traditional generic packaging solutions. Such as vacuum-formed plastic trays and injection molded ESD safe waffle trays.
But these have a limited viability. A chip may need special features to help with manufacturing or just a shape that works with a PCB that is outside the norm.
3D Printing can quickly create custom trays at volume without a long lead time or high expense. Generally it takes about a 1-2 weeks to complete production of several hundred trays. And depending on material the cost per chip for the packaging can be between $0.10 and $0.50, comparable to traditional solutions.
But since 3D Printing is a different process these trays need to be designed slightly differently. Here are some basic notes for your internal design teams if they are looking to design custom PCB trays. Though we also offer Design services if needed
Use Nubs or Tabs as Finding Features
Traditional designs would just have a peg with a hole to act as a finding feature when trays are stacked. This does not work with 3D Printed PCB trays because that would create an overhangin during printing. And overhang is a feature that juts at 90 degrees from a part, like the branch of a tree. Most trays are printed on end so finding pegs become that overhang.
The best alternative it to just a use small nub. This will will still prevent shifting without creating an overhang.
The other option that perfectly replaced the peg is a slot and tab. Just make certain to have the the them positioned parallel to the longest side of the tray (Again because the part will be printed with its longest side vertical on the print bed.)
Angle the Chip Slots if Overly Large
FDM 3D Printing is used to create these types of trays therefore there is a limit to how large of an bridging overhand, like the top of a chip slot, can be. generally if that upper surface is greater than 1 inch wide then this option needs to be used.
Basically, the rotate chip slots so that they no longer follow a rectangular pattern. Instead of squares they become diamonds. This eliminates the overhang and instead gives each slot a slanted roof.
This is a very simple rule. But it provides a huge advantage because it can reduce cost and improve quality at the same time. Just eliminate any sharp edge, and if a fillet can be made larger, make it larger.
Add Labeling and Branding
While 3D Printing requires some shifts in design thinking due to manufacturing limitations, there are a few things that it contributes that can vastly improve your product. Since there is no mold involved you can actually create features for free that were not even possible before. Labeling is one of those.
This labeling can be something as simple as the name of the company producing the chips, or information about the batch and chip name for us in production. An example of branding is shown below for one of our clients Silicon Mountain Contract Services
Not many trays are able to actually retain the chip in place so that it won't fall out. These features are exceptionally difficult to mold affordably. But with 3D Printing they are free to add.
Production 3D Printing can create exceptionally complex mechanisms, again without significant added cost depending on the cost. But for specialty applications systems can be created that control chips in just the right way so that they are not damaged but are released when needed in a production line. When working with Plexus we created a simple locking tab system that was able to hold the proprietary chips from the side but them lock open so that they could be removed on the factory floor.
3D Printing is very affordable and very flexible, it is an ideal way to create custom packaging solutions for PCB's or any other type of product. Why we have even done consumer packaging at times.
But the quickest way to find out if 3D Printing is right for your application is to submit a quote with your needs and specifications and one of our account engineers will be in contact with you soon.
We have begun production of a low cost, recyclable, 3D printer filament spool, that is an improvement on the tradtional MC-008W 1KG SPool.
With all of the innovation in the 3D Printing space, the MC-008W spool has stayed relatively unchanged. But why? They are expensive to ship, nearly impossible to recycle, and in production they are not efficient or easy. Not to mention that new covid restrictions and tarriffs on the chinese-made spool have increased so that they have become expensive. But it is what there is.
There are some filament suppliers that use cardboard spools, but those are not ideal for 1KG material. The community have created reusable spools. But these are not universal and can lead to tangles. There just is not a good alternative to the tried and true MC-008W 1KG filament spool. So we made the SlantSpool V3
The SlantSpool V3 was created in order to allow for a US supplier of good quality, recyclable 1KG spools for 3D Printer filament.
The SlantSpool V3 is modeled off the MC-008W spool. The core interface is dimensionally identical so that it can fit on existing fixtures. The outer cardboard flanges are stamped from white-coated cardboard to prevent dust contamination of filament. The entire spool is half the weight of traditional MK-008W spools so shipping costs are lower both from Slant 3D and to customers, saving filament suppliers thousands of dollars.
We have also adjusted the design to make use simpler. The Core has 4 primary anchoring holes for the filament that are over-large to make starting the spool easier on the winder machine. And the hole is curved to ensure that filament is not kinked at the end causing a jam in the 3D Printer when it is used.
The Core of the SlantSpool is manufactured with 3D printing in our production 3D Printing Farms. This manufacturing method not only allows it be made affordably at the same quantities as injection molding, but allows the design to be easily changed. We can create custom spools with the logo of the filament supplier and we can adjust the hub configuration for different fixturing. We are not limited to the 1KG MC-008W. We can make any spool you want.
The cardboard flanges serve a number of functions. First of all they can be recycled easily, eliminating the piles of spools 3D printing users have to deal with. They are also cut in an octagon so they can be stored on a standard shelf without stacking to keep them from rolling off. And last of all the cardboard can be slit to anchor the end wherever it is without having to trim of kink filament to hit the one hole.
Overall the SlantSpool was designed by 3D Printer users and a Filament production line. Making it optimal for all. Not just "the spool that works." We are working with several filament suppliers now to get the spools into production and they are obviously in use on our own production lines and printer farms. Small labs and 3D Filament producers can purchase the spools quickly and painlessly at the listing above. It you need special hub design or quote please contact us.
As the pandemic continues to drag on, we are seeing more and more depression partially from the imposition of current masks. They are uncomfortable, and they really hinder interaction. But the team at TrueContour lead by Jonathan Swartz are looking to change that.
The TrueContour Mask is a fully custom and transparent protective facemask. So it fits to your face perfectly and allows other people to still see you. This not only improves protection from the better fit, but it also improves interaction and human connection, something that seems to be waning with current masks and work at home trends.
The TrueContour is manufactured through a number of steps. First the customer scans their face using the TrueContour app on a iPhone. This scan is then converted into a 3D model that is used as a mold for the mask.
Slant 3D has partnered with TrueContour to produce these molds on demand as orders come in. Our 3D Printing farms, composed of hundreds of 3D Printers, ensure that demand will never outstrip production capacity.
Once the molds are 3D Printed, then the masks are vacuum-formed and final processing produces the final mask.
This design and method of manufacturing is brilliant. True contour is fixing many of the primary problems with current masks by improving the seal and just allowing people to not look like a bank robber everywhere they go.
They are also taking advantage of a perfectly flexible supply chain brought on by Production 3D Printing and lean manufacturing principles. They will never have excess inventory and will be able to produce perfectly custom items quickly and on demand. We are very excited to be working with such a great and forward thinking company.