Langhorne Carpet Company

PRODUCING PROTOTYPES FASTER WITH HP MULTI JET FUSION

HP MULTI JET FUSION APPLIES 21ST-CENTURY TECHNOLOGY TO 20TH-CENTURY DEVICES

CUSTOMER AT A GLANCE

Langhorne Carpet Company has been weaving some of the world’s finest Wilton Jacquard wool custom carpets for the past 87 years. Now the Pennsylvania-based company is incorporating 21st-century 3D printing technology into one of their 20th-century looms.

THE CHALLENGE

Wooden cylinders crafted from extremely rare and environmentally sensitive African Rock Maple form the five-sided ‘master cylinder’ at the heart of the carpet-weaving process. Decks of connected Jacquard punch cards that contain the ‘program’ of the carpet’s intricate design scheme feed into these cylinders.
Prior to the advent of 3D printing, Langhorne had limited replacement options for these essential pieces of equipment. Without custom, 3D-printed replacement parts, the family-run mill would have needed to purchase a new cylinder via custom order or seek out a refurbished one in excellent condition. Either option would typically cost the mill an exorbitant amount of time and money.

SOLUTION

INDUSTRY
Industrial

SECTOR
Machinery and equipment

MATERIAL
HP 3D High Reusability¹ PA 12

POST-PROCESSING
Bead blasting
Dyed in black

At the suggestion of their enterprising operations manager Gerald (Jerry) Bell, Langhorne enlisted the assistance of ProtoCAM, a leading provider of Additive Manufacturing services, also based in Pennsylvania. With ProtoCAM and HP Multi Jet Fusion (MJF) technology, Langhorne began 3D printing spare parts for their looms and, as a result, achieved the following:

Customization.

ProtoCAM and Langhorne worked together to improve the design of their parts, substituting vents for drilled holes that can further enhance the weaving process.
Cost savings.

Thanks to HP MJF, Langhorne can easily clone the loom replacement parts at a reduced cost.
Sustainability.

“We followed Langhorne's exacting specifications while leveraging the capabilities of 3D printing and HP Multi Jet Fusion technology, resulting in a seamless melding of old-world craftsmanship and new-world technology," says Ed Graham, Engineering Manager of ProtoCAM.

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

CUSTOMER AT A GLANCE

Langhorne Carpet Company has been weaving some of the world’s finest Wilton Jacquard wool custom carpets for the past 87 years. Now the Pennsylvania-based company is incorporating 21st-century 3D printing technology into one of their 20th-century looms.

THE CHALLENGE

SOLUTION

Customization.

ProtoCAM and Langhorne worked together to improve the design of their parts, substituting vents for drilled holes that can further enhance the weaving process.

Cost savings.

Thanks to HP MJF, Langhorne can easily clone the loom replacement parts at a reduced cost.

Sustainability.

“We followed Langhorne's exacting specifications while leveraging the capabilities of 3D printing and HP Multi Jet Fusion technology, resulting in a seamless melding of old-world craftsmanship and new-world technology," says Ed Graham, Engineering Manager of ProtoCAM.