Industrial

Our Rapid Prototyping and Innovative Tooling Design-Print services help Industrial/Manufacturing clients achieve significant Productivity gains

Rapid Prototyping

Audi tail lamp
Audi uses Stratasys 3D printer to produce ultra-realistic, multi-colored, transparent tail light covers in a single print (Courtesy: Stratasys)

All industries are faced with a need to accelerate product development and its production. It is also now commonplace that larger teams are involved in the process of prototyping. In this scenario, the usefulness of having visual mockups, early stage prototypes and ability to do multiple prototypes before finalising the production version is seen as a ‘Good Industry Practice’.

Accreate Labs offers end to end System Engineering services to help clients do rapid prototyping. We use state of the art design Software suited for collaborative virtual design teams, a wide range of 3D printers covering both Plastics, Polymers and metal. We could enhance design number of times and iteratively printing the part till the design team finalises production specifications. At this stage we could 3D print a Master or representative component for reference in Mass Production.

The Volvo Truck, an ultra-reliable paradigm of automotive innovation, is built for the long haul. And like the truck itself, the tools used  to build its engine need to be rugged, streamlined and efficient.

To produce these tough manufacturing and assembly tools in 94 percent less time, Volvo Trucks now 3D prints them on Stratasys Fortus 3D Production System.

Volvo clams
Volvo Trucks has reduced turnaround times on certain clamps, jigs and supports from 36 days to just 2 days. Courtesy: Stratasys

 

 

 

Accreate Labs offers the same rugged Stratasys Fortus 450 Production System for your 3D-Printing requirements,
to create custom-designed lighter-weight tools and fixtures in production-grade ABS-Plus thermoplastic.

 

 

 

 

 

 

Reverse Engineering

There are many times when clients have single components or spares with limited or no ability to reproduce them in small quantities economically. It might also happen that overseas suppliers have declined to provide additional parts and permit a client to make it themselves. We could help in these cases and recreate the complex geometry to components, sub assemblies by using highly accurate Industry grade 3D scanners.

Accreate Labs further optimises the design, incorporate strengthening features, with improved surface finish and enhancing other performance characteristics. These are then be 3D printed in metal, plastic or polymers in small quantities to secure the machine's future maintenance.

Post Processing

Postprocessing
Finishing touches to a FDM part with a water-jet wash. Courtesy:Stratasys

 

Accreate Labs has a comprehensive facility for post processing to further augment the aesthetic and functional characteristics of the final product. Our range of services in post processing include Burring, Electroplating, Dying, Chemical treatment for surface finishing, polishing and sand blasting. 

Examples of real-world applications of the smoothing process cover the entire spectrum from painted marketing samples to finished goods manufacturing. Typical Post-processing applications include: 1. Finishing master parts by painting or electroplating; 2. Tooling masters; 3. Sealing parts for liquid applications; 4. Thermoforming moulds; and 5. Investment casting.

Painting:

Painting

A leading automobile manufacturer estimates that it takes three days and $700.00 to prepare a prototype front-end grill for painting. With 3D-printing the same grill is smoothened and ready for paint in under two hours and at supplies cost less than $10.00. 

For tough, production–grade thermoplastic parts built with FDM Technology on our Stratasys Fortus 450, we recommend sanding to smoothen and then painting the part for attractive functional prototypes and end–use parts. 

Parts built with PolyJet technology on our Stratasys Connex3 are smooth and beautiful right out of the build chamber. They accept paint without polishing, to give a prototype with the exact look and feel of the finished product.

Thermoforming:

A manufacturer of food packaging uses FDM tools for its thermoforming process when it conducts design validations. The advantage of an FDM tool is that it can be built porous, which allows a vacuum to be drawn through the entire part. This allows the company to use the FDM tools as soon as the build is complete.