The Sinterstation(R) Pro 230 SLS(R) system is able to manufacture parts of various densities by using different laser power, or spreading out the distance between the tracks followed by the laser during the scanning process. With this capability, however, maintaining the part dimensions and tolerances by changing the scaling and offset values as the part density changes becomes a challenge.
"We purchased the Sinterstation(R) Pro SLS(R) system in October 2005 to satisfy a growing customer demand for rapid manufacturing of high quality, accurate small and large parts," said James Butler, president and CEO of AdvaTech. "Soon after we installed our machine and got it up and running, one of our good customers approached us with the need to build housing with the outside diameter of the post to be held as closely as possible for a bearing fit," continued Butler. "Additionally, the inside diameter of the post had to be held as closely as possible to fit another component of the assembly."
"In order to ensure the most accurate part dimensions, we built a sample part, measured and created scale and offset values for that particular part, built in that particular orientation, surrounded by exactly the same parts in the build population." This process allowed AdvaTech to achieve better results on parts requiring extreme accuracy (less than 0.005").
This bracket's outside dimensions were approximately 1.140 (29mm) X 2.404 (61mm) X 3.170 (80.5mm). The post on this part was a feature protruding from the center of the housing that was 0.385 (9.779mm) diameter by 0.938 (23.852mm) tall, with an inside diameter of 0.179 (4.5466mm).
AdvaTech's customer requested these parts, with the most critical feature being the post dimensions. AdvaTech built one part on their Sinterstation(R) Pro SLS(R) system, orienting it for the best quality of the most important features. They then measured the part and input the measured values on Opti-Scale. "We built the entire order of parts with the new scale values for our customer, both the outside diameter and the inside diameter of the post of the three production parts were within 0.001 (0.0254mm). Providing this quality and accuracy was the expectation we were hoping to achieve and pass on to our customers when we decided to purchase the Sinterstation(R) Pro SLS(R) System," concluded Butler.
"AdvaTech's success is a testimony to both the Sinterstation(R) Pro's excellent performance and AdvaTech's commitment to providing highly accurate Rapid Manufacturing parts to industries in which meeting tolerance requirements on parts is critical to staying competitive," said Abe Reichental, 3D Systems' president and CEO. "It is companies like AdvaTech and demanding applications from various industries that inspired us to innovate and engineer selective laser sintering systems that meet and exceed our customers' stringent quality, accuracy and repeatability."
3D Systems' Sinterstation(R) Pro SLS(R) systems, Models 140 and 230, feature intelligent process controls, modular design, automated powder handling and the largest available laser sintering build volume. Designed to meet the demands of end-use parts manufacturing, these selective laser sintering systems offer excellent and repeatable part quality, significantly reduced labor intensity, clean and environmentally friendly processing and accelerated throughput. Equipped with 3D Systems' new Sinterstation(R) Pro system, customers can cost-effectively manufacture plastic parts for a variety of applications, particularly in the aerospace, electronics and medical industries, and build large, functional prototypes, molds and patterns for automotive and consumer product applications.
About Butler Tool & Design & AdvaTech
Founded in 1980, Butler Tool & Design, Inc. specializes in the design and rapid manufacturing of highly specialized engineered components, tools, gauges, fixtures and custom machinery. Butler Tool provides seamless integration for customers requiring a complete design to manufacturing solutions with a complete suite of design, development and manufacturing solutions. In 2005, Butler Tool formed the AdvaTech Division utilizing advanced manufacturing technologies. More information is available by visiting Butler Tool's website at www.butlertoolanddesign.com or AdvaTech's wesite at www.advatechmfg.com.
About 3D Systems Corporation
3D Systems is a leading provider of rapid 3-D Printing, Prototyping and Manufacturing solutions. Its systems and materials reduce the time and cost of designing products and facilitate direct and indirect manufacturing by creating actual parts directly from digital input. These solutions are used for design communication and prototyping as well as for production of functional end-use parts: Transform your products.
More information on the company is available at www.3dsystems.com, or via email at email@example.com.
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