[  English    |    Français    |    Deutsch    |                   ]

SpaceClaim LinkedIn Group Follow SpaceClaim on Twitter SpaceClaim Facebook SpaceClaim Youtube.com Channel

The SpaceClaim Blog

Marking the expansion of 3D modeling software to all engineers

3D Printing Customer Success Story: FORMRISE GmbH

Over the next couple of weeks, we will be sharing with you some of our more recent customer success stories. The first one is below.

 "Compared to classic CAD, this represents a huge advantage."

Rapid option for 3D printing: Laser sintering on the EOS P110 Laser sinter machine - high stability and quality

With its comprehensive know-how about the new technology of laser sintering, FORMRISE GmbH in Germany is one of the few suppliers already producing small-scale series of technical parts for numerous branches of the industry. The 3D modeling system SpaceClaim has proven itself to be the perfect tool for transfer, processing, design and modification of 3D models for production.

In the additive production technology of laser sintering, a workpiece is built by depositing material on the basis of digital 3-D design data in layers. “This type of 3D printing furnishes very precise, mechanically highly resilient components suitable for serial production”, says Peter Spitzwieser. For fourteen years he counseled industrial clients who sought economical solutions for special production tasks with systems for laser sintering. In his opinion there is a great market potential apart from fast prototyping. “However, only for one in every ten potential users did I find sufficient substance for utilizing their own production facilities”, reports the skilled tool and die maker. Today he handles the remaining 9 out of 10 cases. The company he founded in 2014 with business partner Robert Razavi, FORMRISE GmbH supports companies in all areas of industry with 3D printing services: Specific component development; technical consulting, and design workshops for the various procedures. The serial production of plastic parts in laser sintering is the main focus. 

In the production hall a FORMIGA P 110 is running, a flexible and highly productive system for effective small series production of individualized products with complex geometries. Another, larger EOS P 396 permits the highly efficient production of serial components in an installation space of 300 x 300 x 600 millimeters. Replacement parts, functional prototypes, or models can also be manufactured. During production process a thin layer of the powder material is applied to the build platform. A high performance laser melts the powder exactly onto the places that specify the computer generated component design data. After that the production platform lowers itself by a layer thickness of between 40 and 150 μm. The next powder application follows. The material is melted on again and combines with the underlying layer at the defined places. As a result, internal structures and undercuts as well as nested components can be produced in one operation.

Larger series are produced at FORMRISE on the new EOS P 396 with the highest precision

3rd Party 3D-Models as Starting Point

The economic advantages usually result from the fact that the components are developed directly from 3D CAD models without intermediate steps and tools. “To do this, you have to know how such a component has to be built”, says Peter Spitzwieser. “There still aren’t any design or production principles for this young technology.” FORMRISE communicates this knowledge to potential clients in consultations and workshops. In addition, said clients can also have access to the services of the company. “We contract out larger design projects to freelance employees“, says Peter Spitzwieser, and carry out smaller drawing modifications or developments ourselves.” 

Peter Spitzwieser discovered the ideal 3D modeling solution for these tasks at a trade show by coincidence. Wolfgang Geist, managing director of the distribution partner Conweb, gave him a presentation at the show about the possibilities of the software program ANSYS SpaceClaim. The comprehensive system makes it possible to influence the geometry directly, without regard for structure tree or design history. “By simply modeling I can immediately implement my technical concepts”, says Peter Spitzwieser. “Compared to classic CAD this represents a huge advantage.” The investment costs were only about a third of the estimated price for a CAD workstation – with a double license: “The home license of SpaceClaim lets me also work at home on my projects without having to remove the software dongle each time.” Without prior knowledge of CAD the skilled tool and die maker was able to familiarize himself with the system using online tutorials. 

3D Model in ANSYS SpaceClaim

Simple Functioning – High Productivity

As a rule, clients provide their data in IGES or STEP formats; Parasolid files can also be completely imported without problems. Then comes the detailed work: the components are optimally placed, tolerances and surfaces are verified, radii adapted, off sets attached. The models have to be prepared for laser sintering, so that the output is as wanted. Small changes can result in significant improvements with regard to strength, shape accuracy and function. “I find the right tools for all of these changes in SpaceClaim, which I can immediately apply to the geometry”, says Peter Spitzwieser. Only in exceptional cases, for example if replacement parts have to be produced, for which there is no 3D model yet, does he create the design file. For that purpose, there are numerous different possibilities that quickly result in the desired effect. “The program is perfect if you only want to make changes to something. However, creating new models without a structure tree is just as easy.” When the preparatory changes are completed, the models are converted to STL data and saved. With this, the layers are defined that the systems have to apply. Also, there are further options for influencing SLT files like scaling, modeling or cutting.

In a few steps the bracket is modeled in SpaceClaim - and subsequently produced from the model

Solid Business Model

Although the conventional drawing functions are not often required, there are advantages to having a comprehensive and full-blown 2D/3D system like SpaceClaim on hand. For example, you can quickly derive drilling templates from a model or document production-related changes while the machines are busy producing the model. The machines work the night shift and on weekends – it doesn’t really matter when the parts are removed and freed from the remaining material. By the way, this material is collected in its entirety and mixed with new powder to be reused in the next production. Peter Spitzwieser is certain: “This makes laser sintering an economical production process. It off ers constructive freedoms that are not possible with other production methods. SpaceClaim is the right system to exploit these freedoms.”

Download the case study

-Rebecca Dilthey, Senior Product Marketing Manager, ANSYS SpaceClaim


Facebook Twitter Digg It! StumbleUpon Technorati Del.icio.us NewsVine Reddit Blinklist Add diigo bookmark LinkedIn

Video RSS Feed SpaceClaim Blog RSS Feed