leaders in additive manufacturing - FDM Digital Solutions€¦ · FDM Digital Solutions —...
Transcript of leaders in additive manufacturing - FDM Digital Solutions€¦ · FDM Digital Solutions —...
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
leaders in additive manufacturing
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
about us Founded in 2012, FDM Digital Solutions has grown to be one the largest Additive Manufacturers (3D printing) in the UK.
With the largest commercially available FDM (Fused Deposition Modelling) build envelopes and capacity in the UK, FDM Digital Solutions offer a wide range of engineering solutions in
sectors as diverse as Aerospace, Motorsport and Healthcare.
Managed by experienced engineers, our promise is to offer the best possible service and solutions regardless of whether the customer requires a straightforward build using an
existing 3D model, or if the design requires reverse engineering and our expert input in design optimisation for additive manufacturing. Either way we aim to provide the best
possible solution to the end client.
At FDM Digital Solutions we utilise the benefits of additive
manufacturing across many different applications in many different
sectors. Particular areas of focus include:
• Carbon forming soluble/lay-up tools
• Jigs and fixtures for fabrications and assemblies
• Flight ready components for aircraft interiors
• Metal-plated components
• Design for additive manufacturing consultancy
• Reverse engineering
• Short run production components
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
forming tools carbon-fibre
Top-left - ULTEM Lay-up tool Above - Soluble pipe mandrel Left - Tool and finished part
FDM Digital Solutions has great experience in the design and manufacture of carbon-fibre forming
tools.
Having helped develop soluble tooling solutions for several Formula 1 teams, we are capable in the
design of complex ducting and panels, using soluble core technology to build a 3D-printed mandrel
upon which carbon-fibre can be laid. Once the core is extracted, the carbon-fibre component
remains.
Our ULTEM-9085 high temperature FDM material also allows us to design and manufacture com-
plex lay-up tools that can withstand high temperatures and pressures. The inclusion of scribe lines
and other features adds little to the cost using additive manufacturing.
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
Additive manufacturing allows complex patterns, jigs and tools to be built without the need for hours of
machining with the added benefit of turn-around times of days rather than weeks. Produced straight
from CAD these solutions are a quick and simple alternative to traditional methods.
jigs and fixtures
Above: Anchor nut marking templates and be-
spoke packaging
Right: Drill template for accurately drilling on a
complex surface
Below: Jig to ensure pipe components are glued
together accurately
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
ULTEM flight ready components
Utilising ULTEM 9085 material, FDM Digital Solutions produces many flight ready
components that are manufactured to AS9100.
Taking advantage of the flexibility that additive manufacturing can provide, BE Aerospace
have utilised FDM Digital Solution’s ability to build non-load bearing components in a
flame retardant material with full material traceability.
With greater design freedom than traditional methods, complex shapes can be created
without needing to consider tooling design limitations.
The systems managing the production facility at FDM Digital Solutions allow our team to
keep track of orders providing parts on-time and in labelled, job specific bespoke
packaging.
Above: A selection of ULTEM 9085 components in bespoke laser-cut
packaging
Left: Completed 9085 flight ready components
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
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Above: FARO scanner in action Right: Reverse engineered custom steering wheel
FDM Digital Solutions has full reverse engineering and design capabilities. With a FARO
blue laser scan arm, we are able to capture complex data and convert it to a point cloud
then an stl mesh.
From this we can reverse engineer using a variety of software including SpaceClaim,
PolyWorks, Catia, SolidWorks and Cimatron.
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
other applications Above: 3D Printed last Above Right: Nickel plated panel Right: Nickel plated engine parts
Keen to provide alternative solutions for our customers, at FDM Digital Solutions we have explored
the use of different technologies and conducted research into new applications for additive
manufacturing.
With the East-Lancashire NHS we are producing 3D printed rubber insoles using our Polyjet process in
order to reduce pressure on lesions that develop on diabetic patients. This rapid intervention is
intended to reduce the number of amputations carried out by the trust.
Again using our Polyjet process we are able to finish components with metal plating, which increases
rigidity, strength and thermal dissipation.
At FDM Digital Solutions we are always happy to develop new processes and ideas with customers, if
we don’t have the answers we are happy to work with our clients until we are confident to go to
production.
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
FDM Digital Solutions has a suite of 9 Stratasys and HP machines — the largest commercially
available capacity in the UK with the largest build envelopes for the following processes.
The FDM process uses common engineering thermoplastics, enabling high quality engineering
components to be produced. Unlike many other processes these aren’t simulants and so they
represent typical material qualities of parts made in similar materials using different processes.
The Polyjet process enables greater design freedom, allowing us to mix materials of different
properties (i.e. ABS simulant and Rubber simulant) at any stage of the build process whilst printing
in fine 0.03mm build layers. This process produces great aesthetic models and allows us to develop
components for unique applications
The MJF process uses the latest technology available to the market, allowing tough, flexible parts to
be produced at very attractive prices for small runs where conventional mould tooling could be cost
prohibitive.
machine capacity
Fortus 400mc Fortus 450mc Fortus 900mc Connex 500 HP MJF
Build Envelope (XYZ) mm
406 x 355 x 406 406 x 455 x 406 914.4 x 609.6 x 914.4 490 x 390 x 200 380 x 284 x 380
Our Capacity 4 2 1 1 1
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
FDM 900 specification
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
FDM 400/450 specification
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
HP MJF specification
Build envelope 384x280x384mm
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
case study airbus a330 neo demo box
Creation of a life size replica of a complex wing-box section from existing CATIA CAD data. This project helped prove
the design change from CEO to NEO by ensuring all engineering tolerances were workable.
This is the largest 3D-printed model used by Airbus and the Launch Team concluded that ‘this was an excellent
application for 3D modelling to de-risk the design solution before production commences later in 2016’.
Prior to this model being created, there were doubts as to whether pipes and cabling could be assembled through the
wing. Once the model had been created, the design was quickly proven, however if there had been any tolerance
issues the consequences could have been extremely expensive.
Above Left: Completed demo box Above: A330 Neo Below Left: Demo box in testing
Business Case:
• Design Improvements - Helped prove the design change from CEO to NEO
• Greater Accuracy - Ensured all engineering tolerances were workable
• Clive Devey - Head of Industrial Launch ‘The project assists with the overall objectives of
weight reduction, reduced parts count and savings on installation time‘
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
FDM Digital Solutions have been fully ISO-9001 approved since March 2016 across
all operations including purchasing, order processing and design.
We currently supply BE Aerospace with non-structural flight ready components
built to AS9100 standards. We are aiming to gain full AS9100 approval in early
2017
Direct digital manufacture alongside our Sage Manufacturing business system
allows full traceability of materials within our component builds and ensures that
the progress of orders through our production cells is optimised.
quality systems
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
Airbus Tier 1 Supplier — FDM Digital Solutions have been
awarded tier 1 status as an Airbus supplier since June 2016
BE Aerospace Approved Supplier — Approved supplier of
non-structural flight ready components.
Formula 1 team supplier — Supplier of several leading Formula
1 teams particularly specialising in the production of Carbon-
Fibre forming soluble and lay-up tools.
Approved supplier to several aerospace OEMs including Safran
Nacelles, Kaman, Sonaca and EDM
quality approvals
FDM Digital Solutions — [email protected] — +0044(0)1282 872 370
Address: FDM Digital Solutions
Suite 17, Lancashire Digital Technology Centre
Bancroft Road
Burnley
BB10 2TP
Contact Us At FDM Digital Solutions we are always happy to discuss ways that we can help engineer solutions for you and your business. Feel free to contact any of our
team listed above.
To e-mail us for a quotation or enquiry, please e-mail [email protected] . For a quotation all we require is a 3D model, preferred formats be-
ing .stl, .stp or .iges files, although we can convert from most other file formats.
To speak to one of the team call +0044 (0)1282 872 370. Our team will be more than happy to discuss and advise on your needs.