HP MULTI JET FUSION IMPROVES PIPE-CUTTING PROCESS IN MANUFACTURING

HP MULTI JET FUSION IMPROVES PIPE-CUTTING PROCESS IN MANUFACTURING

CUSTOMER AT A GLANCE

DI Labs is equipped with some of the manufacturing industry’s most cutting-edge technologies, including 3D scanning and 3D printing. They help solve companies’ most challenging problems related to new product development, manufacturing optimization, and customer experience design. Their services are supported by more than 25 years of combined experience in product development, design, engineering, and plastics.

THE CHALLENGE

In DI Labs manufacturing lines, corrugated pipes (with a diameter of 6 inches and larger) are cut to appropriate lengths using half-moon cutters, which are machined from aluminum and weigh 10 to 15 pounds. To cut the pipe, the operator must hold this cutter and swivel it around the pipe to cut it. Problems with the traditional design of these cutters include a heavy weight, fixed handles that are not customizable for the operator's convenience, high production costs, and long manufacturing times.

RESULTS

INDUSTRY
Industrial

SECTOR
Machinery and equipment

MATERIAL
HP 3D High Reusability¹ PA 12

POST-PROCESSING
Bead blasting

DI Labs 3D printed these cutters using HP Multi Jet Fusion technology with provisions to add blades and aid in cutting, which improved the following:

Material properties:

High isotropy and low porosity help meet or exceed finish quality and material strength.

Weight reduction:

The weight of the 3D printed device is less than 2 pounds, compared with the original weight of 10 to 15 pounds using traditional machining methods.

Redesign:

With the ability to freely design and create specific parts, engineers can make adjustable handles.

1.Based on using recommended packing densities and compared to selective laser sintering (SLS) technology, offers excellent reusability without sacrificing mechanical performance. Tested according to ASTM D638, ASTM D256, ASTM D790, and ASTM D648 and using a 3D scanner for dimensional accuracy. Testing monitored using statistical process controls. HP Jet Fusion 3D Printing Solutions using HP 3D High Reusability PA 12 provide up to 80% post-production surplus powder reusability, producing functional parts batch after batch. For testing, material is aged in real printing conditions and powder is tracked by generations (worst case for reusability). Parts are then made from each generation and tested for mechanical properties and accuracy.