Comparing Technologies Ben Staub, owner of Bastech, Inc. in Dayton, OH, saw how changing business conditions threatened his core business. When he started his company ten years ago, it was primarily an SLA model service bureau. As that market became more competitive and other technologies developed, he initially invested in the Keltool process available from 3D Systems (Valencia, CA) to take advantage of his moldmaking background and offer his customers more than just SLA models. "RP had gotten so commoditized, that it could only become profitable if it was used as a means to an end," states Staub. His company, which assists product developers from concept to molded parts, now uses a variety of Rapid Manufacturing Technologies. Increasing his company’s capabilities by adding a new technology may require the cooperation of a key customer. "The need is great to partner with a customer, and say, ‘We’ll buy the machine and use it on your project. This will be the first time and there may be some difficulties. But in the end, we’ll be adding a capability that will decrease your cost and help you speed your product to market,’" explains Staub. "Getting the customer’s agreement to this before the machine is even ordered helps justify a new machine purchase. The work is already there and the customer is aware of the learning curve in the beginning. And as our experience develops, there is a benefit to the customer." One example of this benefit is shown in Chart I. The Keltool process was used by Bastech and for his customer resulted in significant time and cost savings over prices and deliveries of conventionally manufactured tools. However, the longevity of this tool did not match that of a conventionally manufactured tool.
"That didn’t concern our customer," says Staub. "They wanted to get their product to market as fast and economically as possible. Then, if there was initial market acceptance, high production tooling could be manufactured after the initial investment had been recovered." Four years ago, Bastech added 3D System’s (at the time DTM Corp), RapidSteel 2.0 process. The sintered process offered many advantages over the Keltool system. It is a direct process that goes directly from CAD file to sintered insert. The RapidSteel, (now LaserForm) process has gone through three additional iterations, and the materials that are currently being used are a 420 stainless and an A6 tool steel. Each change has produced a more robust material and a more stable, repeatable process. Staub has a close dialogue with 3D Systems. "We are sharing a lot of information with them on some of the nuances that we have learned to help them push this closer to a more competitive technology," he says. The result, as shown in Chart II, has been a dramatic decrease in deliveries and costs. However, there also is a sacrifice in tool life. For this particular project, a long tooling life was not a requirement.
Bastech has augmented its investment in sintering technologies with traditional CNC machining equipment. Staub found that there are some applications where shaping cavity surfaces with what can be thought of as the ‘modified traditional’ method of high-speed CNC machining is the most competitive and cost-effective means of production. Staub agrees there are several technologies that can be chosen to accomplish these goals, and regardless of which is selected, these are just tools, and there is no one process that is the solution for all requirements. When CAD/CAM technologies began to mature, many may have felt that the big decision was which system to purchase. But regardless of the choice for a leading, capable system, success depended upon the allocation of the resources to dedicate oneself to making it a productive venture. Similar to the evolution of CAD/CAM, rapid technologies for tooling applications is at the stage where there are some methods available, but dedication and additional development work will be required. There is not yet a technology that delivers optimum results for the
desired speed, accuracy, surface finish and tool life for production
molds. But rather than waiting for an optimum method, there are
technologies available today and applications that can benefit from
what is currently available. This allows a company like Bastech to
establish itself and grow now – positioning itself for using the
advancements that will come.> For more information on
rapid technologies, contact Ben Staub at
ben@bastech.com. |
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