Our client encountered a common problem: an essential spare part for their Matrot sprayer was no longer available for purchase. This situation threatened to sideline their machine, impacting their farming operations. Faced with limited options, they turned to Omni3D’s 3D printing services for a rapid and cost-effective solution.

The Solution: Rapid Prototyping and On-Demand Production

At Omni3D’s Printroom, we understand the urgency of such situations. We leveraged our expertise in industrial 3D printing and reverse engineering to quickly address the client’s needs. The process involved:

• Part Design: Our experienced team designed a 3D model of the obsolete part based on the original component.
• Material Selection: We chose PET-G 32, a durable and versatile material, ideal for agricultural applications due to its resistance to environmental factors.
• Express 3D Printing: Using our advanced large-format FDM 3D printing technology, we produced three replacement parts in just 2.5 hours, each weighing 24 grams.

The Results: Minimizing Downtime and Maximizing Efficiency

The 3D-printed parts perfectly matched the original component, enabling the client to quickly restore their Matrot sprayer to operation. This success story highlights the key benefits of our 3D printing services:

• Rapid Turnaround: We delivered functional spare parts in a fraction of the time compared to traditional manufacturing methods.
• Cost-Effectiveness: 3D printing eliminates the need for expensive tooling and molds, making it a cost-efficient solution for low-volume production and spare parts.
• On-Demand Availability: We can produce parts precisely when needed, eliminating storage costs and minimizing downtime.
• Customization and Flexibility: 3D printing allows for the production of custom parts and design modifications to improve performance.
• Solving Obsolete Part Issues: We help clients overcome the challenges of maintaining aging equipment by providing on-demand access to replacement parts.

Why Choose Omni3D’s 3D Printing Services?

Omni3D is committed to making additive manufacturing a viable alternative to traditional production methods. Our industrial-grade 3D printers and experienced team enable us to tackle even the most challenging projects. We specialize in:

• Industrial 3D Printing Solutions: Providing high-quality 3D printed parts for various industries.
• On-Demand Manufacturing: Responding quickly to emergency situations and production needs.
• Reverse Engineering and Design: Creating 3D models from existing parts or specifications.
• Material Expertise: Offering a wide range of materials, including PET-G, ABS, PA, and high-performance polymers.
• B2B 3D Printing Services: Tailoring our services to meet the specific needs of businesses.

Contact Us:

If you’re facing challenges with obsolete parts or seeking to improve your production flexibility, contact Omni3D team today at printroom@omni3d.com.

Let us show you how our 3D printing services can help you reduce costs and maximize efficiency.

Artykuł Reviving Obsolete Machinery: On-Demand 3D Printing for Agricultural Spare Parts pochodzi z serwisu Omni3D.

Omni3D large-format industrial printers offer unmatched capabilities for producing high-quality, functional parts that can replace traditional metal components. From replacement parts to final production, Omni3D technology delivers precision, speed, and cost-effectiveness.

Download our comprehensive how-to guidelines on:

• Assessing the suitability of additive manufacturing 3D printing
• Selecting the right materials and printing parameters
• Optimizing your manufacturing processes for additive manufacturing

Learn how Omni3D can help you:

• Reduce costs and lead times
• Improve product quality and performance
• Enhance design flexibility and innovation

Become an expert in industrial additive manufacturing downloading your free guide. Stay Ahead: Get the White Paper here

Contact the Omni3D technical team to discuss your needs

Artykuł Replacing Metals With 3D-Printed: High-Performance Polymers pochodzi z serwisu Omni3D.

BOSCH’s main goal was to optimize the production process on one of their lines by designing a specialized tray for the safe transport of electronic components.

This tray needed to meet several critical requirements:

• Precisely fit the component dimensions.
• Lightweight for easy handling.
• Stackability with other trays to optimize space and ensure ergonomic transport.

BOSCH needed to validate the design’s accuracy before commissioning an expensive production mold. This is where 3D prototyping played a pivotal role.

Execution Process

The model was pr

inted on an Omni TECH printer using ABS-42 material and ODS-20 as a support material. The use of the soluble ODS-20 support material was particularly advantageous given the complex geometry of the model. Easy removal of supports after completion of printing eliminates the risk of damage to the model surface and increases the precision and quality of the details. This 3D techno

logy enabled exact and swift adjustments even for complex shapes, meeting BOSCH’s high-quality standards.

“Our equipment consists of many components that we need to transport between production halls. The tray must be perfectly suited to the components and to our infrastructure to ensure safe transport. Thanks to prototyping, we can verify the design accuracy in real-time before moving to final production” explained a BOSCH representative.

Results and Benefits

Thanks to the 3D technology provided by Omni3D, BOSCH was able to assess the accuracy of the tray model and make necessary adjustments, leading to a final design that met strict requirements. Using the soluble support material ODS-20 allowed for high surface quality and dimensional accuracy, expediting the design refinement process and preparing it for final production. 3D printing enabled quick and economical adjustments, avoiding high costs from potential production errors in traditional manufacturing methods and streamlining the development of the final thermoforming mold.

Part Technical Details

Artykuł Optimizing BOSCH Production efficiency with 3D Printing pochodzi z serwisu Omni3D.

Flexlink engineering team was looking for a customizable solution, which would fit to several different robotic arms. The part needed to meet several stringent requirements:

• Impact resistance: The frame had to protect electronic components from potential damage.
• Heat tolerance: The material had to withstand the elevated temperatures generated by their robotic arms.
• Lightweight design: To minimize the load on the robot and optimize its performance.
• Customization: The component needed to fit the specific dimensions and contours of each robotic arm.

The Solution

Omni3D’s engineering and technical team collaborated closely with Flexlink to develop a tailored solution, leveraging our expertise in optimizing small-batch production with additive manufacturing solutions.

• Material Selection: After careful evaluation, the team selected ABS filament for its exceptional mechanical properties and resistance to chemicals and heat. ABS’s combination of strength and durability made it an ideal choice for the demanding environment of industrial robotics.
• Design Optimization: To ensure optimal performance, the cover was designed with a 25% infill density. This approach balanced the need for strength with the requirement for a lightweight component.
• Large-Format Printing: Given the size of each robotic cover, Omni3D utilized its OmniLITE large-format 3D printer. By printing the cover in a controlled environment with a chamber temperature of 50°C, the team was able to achieve precise dimensional accuracy and superior surface finish.
• Iterative Process: Throughout the development process, Omni3D and Flexlink worked closely together to refine the design and ensure that the final product met all specifications. This collaborative approach allowed for rapid prototyping and iterative improvements to final functional part.

A Long-Standing Partnership

The printed positioning frame successfully received positive evaluations, enabling Flexlink to reduce the costs of mold production and accelerate bpth decision-making and implementation processes. The success of this project led Flexlink to choose Omni3D printers for its individual production needs, opening the door to customized solutions and faster adaptations to user demands.

Throughout the years, Flexlink has repeatedly turned to Omni3D for customized 3D-printed components for their robotic arms. This ongoing collaboration proves the value of 3D printing in the robotics industry. By leveraging the flexibility and customization capabilities of additive manufacturing, Flexlink has been able to develop innovative solutions that meet the unique demands of their customers.

Artykuł 3D Printing for Industrial Robotics: Custom Frame Component for Robotic Arms pochodzi z serwisu Omni3D.

The Idea and Initiative by HUGUP Startup

Artykuł 3D Printing on Textiles pochodzi z serwisu Omni3D.

Artykuł The Use of 3D Printing in AIRFUKA’s Touchless Car Dryers pochodzi z serwisu Omni3D.

Artykuł Aerodynamic studies on combat aircraft FA-50 pochodzi z serwisu Omni3D.

Traditionally, prototyping large parts can be a time-consuming and resource-intensive process: IDM Industrial Molding and Plastic, however, saw an opportunity to break the mold (pun intended) by leveraging the power of large-format 3D printing technology.

Enter Omni3D’s industrial workhorse, the Omni TECH.

“The sheer size of the component presented a significant hurdle” explains Ufuk Cantürk, Designer at IDM Industrial Molding and Plastic.

“Producing it through conventional methods would have meant longer lead times and potentially higher costs.” However, with the impressive build volume of the Omni TECH, ORSA could tackle this challenge head-on.

The benefits of embracing large-format 3D printing extended far beyond simply accommodating the component’s size. The ability to utilize two nozzles with different materials proved invaluable. As Ufuk elaborates, “The support structures are crucial for large prints, and having the flexibility to use dedicated support material alongside the primary ABS filament was a game-changer.”

The impact of this technological leapfrog wasn’t limited to technical aspects. “The time saved by using the Omni3D printer was substantial”, Ufuk emphasizes. “Printing a single component took over 180 hours, but that’s significantly less compared to traditional methods. This allowed us to expedite the prototyping process and deliver results to the Caris Chair Company much faster.”

But the story doesn’t end there. The ability to 3D print the prototype before finalizing the mold design proved to be a strategic advantage. “We were able to identify and address potential issues early on”, explains Ufuk. “This proactive approach saved us from potential design flaws that could have resulted in costly mold rework later.”

Looking ahead, IDM Industrial Molding and Plastic is confident that 3D printing will continue to revolutionize the design and development landscape. “The ability to rapidly iterate and test prototypes is a goldmine for innovation”, Ufuk concludes.

“We’re excited to see how Omni3D’s technology can further empower us to bring groundbreaking ideas to life.”

This case study exemplifies the transformative potential of Omni3D’s large-format 3D printing solutions. By enabling companies like IDM Industrial Molding and Plastic to streamline workflows, reduce costs, and unlock design freedom, Omni3D is helping businesses across industries push the boundaries of what’s possible.

Download this case study in PDF

Artykuł From Brainstorm to Boardroom: How ORSA Streamlined Office Chair Design with Omni3D’s Large-Format Printing Powerhouse pochodzi z serwisu Omni3D.

John Cockerill Services faced a time-sensitive repair for a 200kW electric motor in the steel industry. The crucial terminal box cover was missing, leaving motor terminals exposed.

Traditional Challenges

• Lead time: Sourcing a custom injection-molded cover would incur significant cost and extended lead times, hindering repair progress.
• Cost: For a single, unique part, traditional manufacturing methods are often cost-prohibitive.
• Material limitations: Finding a material suitable for the cover’s size and application could be challenging with conventional methods.

The Solution: print big parts in engineering materials

Leveraging their in-house Incremental Manufacturing department, John Cockerill Services turned to large-format FDM 3D printing with the Omni 500 LITE printer.

Omni3D FDM technology offered:

• Rapid high-quality prototyping: A PLA prototype cover was designed and printed within 10 hours (design) +33 hours (printing), enabling quick visualization and iteration.
• Cost-effectiveness: 3D printing proved more cost-efficient than traditional manufacturing methods for a single, custom part.
• Material versatility: ABS ESD material offered the necessary strength, durability, and static dissipation properties for the large cover (410 x 480 x 120 mm).

The Results:

• Reduced downtime: The final ABS ESD cover was printed in 145 hours, significantly faster than traditional methods, minimizing repair delays.
• Cost savings: Compared to injection molding, 3D printing delivered cost advantages for this unique part.
• Improved efficiency: The success of this project led John Cockerill Services to adopt 3D printing as a manufacturing option for similar large-format replacements, streamlining their repair process.

Benefits for the Railway and Industrial Maintenance B2B Audience:

• Reduced downtime: Minimize aircraft groundings and production delays with rapid parts manufacturing.
• Cost optimization: Produce custom, low-volume parts cost-effectively compared to traditional methods.
• Inventory optimization: Reduce reliance on stocked spare parts with on-demand printing capabilities.
• Complex geometries: Create intricate parts with challenging designs impossible with conventional methods.

Upgrade your maintenance service offer with Omni3D’s large-format industrial FDM 3D printing solutions.

• Contact us today for a free consultation. 
• Discover how 3D printing can optimize your business.
• See real-world case studies of successful implementations.

Artykuł Large-format 3D printed parts accelerates repairs of legacy industrial equipment pochodzi z serwisu Omni3D.

Increased customer expectations for metering equipment and stricter environmental standards led the company to take on the challenge of reducing the noise generated by volumetric metering equipment – rotary gas meters. In addition, an out-of-the-box solution was required to obtain patent protection and tap into new markets.

For the project, due to the large number of tests, it became necessary to find a new technology that would allow the low-cost manufacture of complex prototypes with a high dimensional accuracy of <0.1 mm. Traditional methods proved too costly and did not offer satisfactory results for the company. The cycloidal outer profile was extremely difficult to produce on a machine tool, and the openwork honeycomb inner structure proved impossible to achieve.

Application

With its experience and technical know-how, Common S.A developed a pulseless, low-noise rotor gas meter with high measuring performance. The solution turned out to be the creation of a pair of screwed rotors in the form of a roofed gear with a cycloidal profile, working together in a closed measuring chamber. The result is a pulseless volumetric device with elimination of axial forces on the rotor shafts – an ideal solution for comfortable operation and long service life.

However, the production of the device required very high dimensional accuracy, and its complex geometry meant that it was only possible to produce using 3D printing. The company’s analysis showed that the use of FDM technology would be ideal for this type of application. The challenge for Common S.A., however, was to select a 3D printer that would ensure dimensional accuracy of surface reproduction of less than 0.1 mm and provide the possibility of achieving parallelism of planes in the axial direction of less than 0.05 mm.

Selected design considerations for the printed components:

1.Two parts rotate without touching each other – 0.1 mm gap between parts.

2. The parts are connected by a top and bottom casing – 0.1 mm gap between the parts and housing.

3. The top and bottom surfaces are perpendicular to the central axis.

4. The entire outer surface shall not deviate from its axis by more than 0.08 mm.

5. Holes are positioned with an accuracy of 0.05 mm.

Solution

After testing a number of machines and reference prints from leading 3D printer manufacturers, it became apparent that the clever Factory 2.0 (OmniNOVA) design combined with precisely aligned axes with zero-backlash screw-nut drives could meet the challenge.

„The project was demanding not only in terms of design, but also for the printer itself. We had to develop a special test print and calibration process to ensure that the final rotor print would meet very high dimensional precision requirements. Many people understand accuracy by meeting the requirements for linear dimensions in the X, Y and Z axes. However, in an industrial environment, more is required, where dimensional deviation across the entire surface of the object is important. Key in achieving final success were Factory 2.0 printer systems such as automatic perpendicularity of the X and Y axes, automatic platform levelling and precisely manufactured axes with screw drives.” – Krzysztof Kardach, 3D Printing Technologist at Omni3D

Preparing the profile for the material used was a mere formality. Due to the specific nature of the application, the material used for the printing was PET-G ESD, which is designed for printing electronic equipment components exposed to damage as a result of electrostatic discharge. In the case of measuring devices for flammable gases, it is crucial to prevent electrostatic discharge in order to avoid the risk of explosion. ESD filaments, thanks to special additives, dissipate built-up charges and prevent the formation of discharges. In addition, the material guarantees high durability and strength thanks to its high impact strength. An optimized code enabled a single rotor to be printed in less than 4h.

Final printout of rotors

Effect

The result of the extensive cooperation with Omni3D, was the relatively fast and 5 times cheaper production of precision rotors from PET-G ESD. Currently, Common S.A uses several Omni3D systems on which series production is carried out.

In addition, the completion of the necessary research has allowed the company to apply for a patent application to the European Patent Office, which has resulted in ten years of patent protection for the designed devices. Common S.A is continuing its research to expand the possibilities for high-pressure gas measurement applications. The CGR-05 rotary gas meter received a medal at the 12th Gas Technology Exhibition EXPO-GAS 2023.

Prototype measurement units: left, pulsed measurement unit, right, pulseless measurement unit
non-pulsating with rotors printed on Factory 2.0 (OmniNOVA)

Cross-section of the CGR-05 gas meter

Artykuł Rotor for pulseless gas meter CGR-05 pochodzi z serwisu Omni3D.