On a recent hike, we came across a project of ours hard at work, literally in the field. A client asked us to reverse engineer and manufacture tooling that we used to injection mold plastic cups, so it could monitor insect activity. What a treat to see them in action! We felt like we were doing our part to support the environment.
The Tigard location is filling up quickly. Both our HP Jet Fusion and HAAS CNC machines were delivered this week. And they're being installed as this post is being written. RapidMade is on track to move in and start up operations on August 1 as planned. Help us fill up our new and existing equipment.
In a mere 66 hours (but who's counting), our HP Jet Fusion will be delivered to our new location. If you are as excited about our new 3D printer as we are, why not see what it can do for you? Fill out the Quick Quote and get in the queue. Try the latest breakthrough in Additive Manufacturing... the
“commercial 3D printing system that delivers superior quality physical parts up to 10 times faster and at half the cost of current 3D print systems.”
Look for updates and pictures.
Growing up in Pittsburgh, if you weren't directly connected to the Steel industry, you complained about the rotten egg smell and pollution. But when the industrial giants went silent in the 70s and 80s, the complaints shifted dramatically to the economic tragedy that was unfolding - the flight of life-long residents and well-paying jobs. Rhetoric from the recent election aside, Pittsburgh's manufacturing base is both alive and well...
But as we've continued to see, the type and number of jobs that have been created don't resemble those of the steel-era in any way.
“Manufacturing is the most active sector in southwestern Pennsylvania,” explains PRA President David Ruppersberger. “But as technology and automation continue to transform this legacy sector, the reality is that manufacturing facilities will be smaller-footprint, high-efficiency environments where fewer workers, with advanced skills including STEM proficiency, will produce more goods. This is a trend that won’t reverse at any time in the foreseeable future.”
Hearing of Pittsburgh's adoption of additive manufacturing and other advanced technologies is encouraging if the resulting economic turnaround benefits the greater community.
RapidMade will be celebrating its 6th anniversary in its new Tigard location! Having outgrown our current SW Kelly space, we are moving August 1 into a 3500+ square foot production facility conveniently located just off I5.
Our improved floor plan expands our manufacturing capabilities to include more robust finishing, inspection, assembly and production capacity. We've also purchased an HP Jet Fusion 3D printer and a HAAS CNC Mill. The Jet Fusion is considered a technological breakthrough as it is the first
“commercial 3D printing system that delivers superior quality physical parts up to 10 times faster and at half the cost of current 3D print systems.”
Until now, additive manufacturing's speed and accuracy, coupled with higher material prices and limited material options, have made it harder to produce end-use production parts at a competitive cost, which in turn, has slowed, its acceptance rate.
These new production-ready machines will compliment our existing additive and traditional manufacturing, thermoforming, 3D scanning, product design, rapid prototyping and engineering services.
Our new address is 15883 SW 72nd Avenue, Portland, OR 97224.
Rapid Thermoformed Trays – Applying 3D and 2D Printing Technology to Create Unique Solutions
A RapidMade White Paper
By: Marriah Pilcher
The cost advantages and creative applications of thermoforming, or vacuum forming as it is also known, are accelerating its use in multiple industries including manufacturing and medicine. Recently, in a new study on medical trays, they found that thermoforming customized trays for procedures cut prep and operation times by 59% and lowered expenses. Having these customized trays better organizes procedures and improves medical staff utilization.
These unique trays are being adopted by various industries including manufacturing, medical, aerospace and other fields. Thermoforming customizable trays to fit tools, parts and equipment better organizes production runs, maintenance activities, and operational procedures thereby significantly:
- cutting work times
- reducing space requirements
- improving inventory control and tool transportation
- improving safety and sanitation conditions
Conveniently keeping all the tools and parts needed, organized, compact and ready to go, enables employees to quickly check items in and out and ensure they have everything they need before reporting to the work site.
When this occurs the 5S in a LEAN workplace - sort, set in order, shine, standardize and sustain, can be met with ease.
A new breed of additive manufacturer is combining 3D printing technology with vacuum or thermoforming to create solutions for these 5S challenges in a cost-effective way. RapidMade will offer these custom trays in quantities up to 5,000 with MOQ (minimum order quantities) of 50, turnaround times from quote to 1st article of less than 10 days and the option to provide recurring small quantity batches with no additional set up fees. Design Guidelines for the types of trays being offered are broad:
- Forming Area Bed size of 20" x 18" with a deep draw of 11.5"
- A wide plastic variety of plastics can be used including PETG, HIPS, ABS, PC, Acrylic, TPO as well as food-safe materials.
- A range of plastic gauges from 0.020" to 0.250" thick are available
And custom forming for special components within the tray is achieved by following some simple rules:
- Forming windows are 12" x 12" and 6" x 6" to reduce material consumption for smaller parts.
- Draft for Female molds is preferred to be 5 degrees or greater and for Male molds are preferred to be 8 degrees or greater.
This is a fast and low-cost way of creating these trays. The step-by-step process combines engineering, forming and additive manufacturing knowledge to create the solution. The dimensions of the tool are determined by 3D software modeling. Using additive manufacturing the tool can be produced directly from the 3D model at a fraction of the price and time compared to traditional steel or aluminum machining processes. This allows the entire process of selecting, designing and producing these trays to be completed in days rather than weeks without sacrificing customization.
Similarly, we found a company who is uniquely combining 2D pre-printed images and 3D printed tooling technology to create eye catching effects, highlight details or spot color text and components on trays and vacuum formed parts. In the above photo the thermoformed tray mirrors a wood-grain finish. This is achieved by using a stretch-able ink that is printed onto the plastic before it is formed. With this capability, the end customer can print colors, effects, text, and images. Printing before forming reverses the order of a traditional manufacturing process which helps lower cost and time to produce. This application has many potential uses in the manufacture of thermoformed trays and parts.
These examples show how a new breed of manufacturing companies are using additive, digital and traditional technologies to create unique, customized, on demand, small batch run solutions. If you have dismissed vacuum thermoforming trays and parts as too expensive in the past, it might be time to take another look.
FASTER NYLON PARTS – A New Age for 3D Printing
A RAPIDMADE WHITE PAPER
By Mark Eaton
Getting parts on demand has been a manufacturer’s dream for many years. Since 2005, see M. Park, UNSW article, there have been cries from the 3D printing industry that additive technology would replace the need for injection mold tooling, that it would eliminate the need for machining, that casting would become obsolete. Finally, that dream is becoming a reality.
While there have been success stories such as the use of Stratasys Ultem for aerospace parts and selective laser sintering (SLS) nylon for automotive parts, until today, these components have all had restrictions on where and how they could be used. One of the biggest drivers for this has been the speed and the part cost. Siemens, according to a recent article in Plastics Today, is using 3D printed fire, smoke and toxicity-compliant polymers to replace parts in trams, and they cite part availability as being the primary driver. The US Marines have recently experimented with printing replacement Humvee parts in the field. What all these examples have in common is they are limited in scope by the 3D printing technology restrictions. While the FDM process eliminates tooling, it is still 100x slower than injection molding or machining, and while SLS material prices have been reduced, they are still 10x more expensive than injection molding or nylon bar stock prices. So, the extent to which these older 3D processes can be deployed is still limited by cost and speed.
This is beginning to change. A new breed of additive manufacturers is arriving on the market who are focused on truly using 3D printing to create production parts at costs comparable to injection molding and machining prices. These “new age” additive manufacturing companies combine faster printing technology with engineering resources to convert and certify part performance. They have integrated quality systems to ensure material, process and part conformity. And they offer parts at competitive prices compared to injection molding or machining costs without the need for tooling, set-up costs or inventory carrying costs. An example of one company taking advantage of this new age in additive manufacturing is Daimler, cited in a recent Reuters report, who has announced it will start offering plastic replacement parts printed at local service centers from a library of 3D files.
As an executive board member in the additive manufacturing community, I recently got to profile one such Portland-based 3D printing company, RapidMade. After 6 years developing prototyping, tooling and engineering services to support 3D printing, this company is reinventing itself to use the new breed of additive technology being offered by companies such as Hewlett Packard and Carbon 3D. These companies have developed much faster 3D printing technologies that use faster curing, less expensive materials with all the properties of traditional polymers. The new HP MJF is being showcased by RapidMade as part of its expansion in 2017. With speeds that are 10x faster than current SLS technology and material prices equivalent to injection molded nylon or machined bar stock, RapidMade can now offer its customers a wide range of new and replacement part solutions. Where precision tolerances are required, the company uses automated machining centers linked with the printers to provide finishing operations.
Without the need for tooling, customers can now order parts to print using their 3D library or one provided by the service provider. The shorter printing cycle times mean that it is no longer necessary to hold more than 1-2 days’ inventory for quick use parts, and less frequently used parts can be ordered as needed with zero inventory requirements. For very low order quantities (less than 10 parts), it has always generally been cheaper to 3D print versus using traditional manufacturing. With the lower cost breakeven point of these new age 3D printing technologies, minimum order quantities (MOQ) of 500 or 1,000 will be converted to printing versus injection molding or machining. For customers already using SLS technology, they will see an immediate cost and turnaround benefit from switching to this new breed of 3D printing technologies.
The benefit of these “new age” additive manufacturing companies like RapidMade is being immediately felt by the machinery manufacturers and end users of such equipment. There is a significant cost benefit in current supply chains, PWC Strategy& estimates there will be a 20% gain in TCO (total cost of ownership) from 3D printing replacement parts. It is estimated 70-80% of that can be delivered to the end users when they engage with a “new age” additive manufacturing company. Lower prices for spare and replacement parts are possible with piece of mind that the part has been certified for use. No longer are machinery manufacturers tied to traditional injection molders who retain tooling that cannot be easily moved. Parts produced offshore can now be re-shored without needing to recreate tooling. PWC Strategy& predicts German spare parts manufacturers will derive $3Bn in benefit from adopting 3D printing. Additive manufacturing by its nature is a non-labor intensive process, and the new breed of technologies produces 10x the number of parts in the same time lowering the overhead cost per part and making larger MOQ more attractive. Companies like RapidMade retain digital libraries and ship direct, on demand parts in quantities of 1 to 1,000 in less than 24 hours. They do this by not only having faster 3D printing technologies but also using automated transaction systems, integrated engineering and lean techniques to optimize printing uptime.
Whether it is Daimler, deciding to print plastic parts locally to save warehouse, shipping and logistics costs or Siemens citing the increased ability to service multiple customers with parts on demand, times are changing for the benefit of producers and end users. And to support the changing demands, these companies are turning to the ‘new age’ additive manufacturers who, in turn, are enabling US companies to re-shore production, improve turnaround time and lower part costs. If you have dismissed 3D printing in the past, it might be time to take another look.
HP's Jet Fusion 3D Printer is gaining marketplace momentum. Last week, senior management announced its Global Reseller Program and Open Materials Ecosystem Expansion at the Rapid + TCT conference. Executives expect these networks to accelerate customer interest and technology adoption.
Rolled out late last year, the Jet Fusion is considered a technological breakthrough as it is the first
Until now, additive manufacturing's speed and accuracy, coupled with higher material prices and limited material options, have made it harder to produce end-use production parts at a competitive cost, which in turn, has slowed, its acceptance rate. Recognizing the importance of material development, HP has created an Open Materials and Applications Platform to
The long-awaited arrival of true Additive Manufacturing may finally be here.
When I shattered my wrist in 2014, the surgeon pieced together the fragments using a standard-issue, low-tech wrist plate and permanently screwed it into place. Now, with the recent FDA approval of Additive Orthoapedics' 3D printed Locking Lattice Plating System, patients may soon have access to customized plates for "stabilization and fusion of fractures, osteotomies and arthrodesis of small bones."
Since I have subsequently broken a foot and my other wrist, I will be sure to keep this company in mind, just in case.
It seems that 3D printed shoes are one step closer to reality. This is a timely story for me as I just went shoe shopping this week... Every time I need new tennis shoes, I go through the same routine: choose from the limited selection of wide sizes and then, through process of elimination, find a pair that I can tolerate. I speed walk, so the shoes have to be large enough to fit my feet but be snug enough to stay in place while I put them through their paces. Based on this week's workout, the pair I just selected are not working out. So I'm always interested in hearing about 3D printed shoes.
Adidas is apparently leading the pack pursuing a technology to allow mass produced custom shoes. They announced a
The Futurecraft 4D shoe's introduction is planned for 2018 with the intention of offering shoe soles for individual fittings and limited editions.
The partnership with Carbon should allow Adidas to reduce the time it takes to produce shoes by additive manufacturing. Its 3D printer design is reportedly 10 times faster than traditional 3D printer designs, printing soles in as little as 20 minutes.
Thermoforming is a fast, cost-effective manufacturing technology that allows customers to prototype and manufacture production parts. RapidMade's ability to design and 3D print tooling in house reduces lead times and unit costs.
Watching the thermoformer in action is an added perk. See for yourselves. Ask us how thermoforming can transform your packaging, storage, retail display, automotive, aerospace, medical device and signage needs.
HP just opened a new research facility in Corvallis, Oregon devoted to testing new materials to improve their speed and performance in 3D printing. Known for its expansion into additive manufacturing by means of its new industrial printer, the Jet Fusion, HP's 3D Open Materials and Applications Lab is a joint venture with various materials suppliers.
Given its industrial target market, it's understandable why HP would want to focus on material capabilities, one potential hurdle to widespread adoption of additive manufacturing of mass production-grade parts.
Come join us for a unique way to celebrate St. Patrick's Day, next Friday, March 17...
The Current and Future State of Advanced and Additive Manufacturing
Advanced and Additive Manufacturing (AM) has seen an explosion in investment, growth, and development in the last decade. For metals alone, AM means a shift from mold-based component concepts and the constraints that go with them to rapid iteration, development of ideas with full geometric freedom. Advantages include faster processing times, lower-cost components, and a level of design freedom that is so far unheard of. The main forces behind this momentum include the automotive, medical technology, and aerospace industries. Come hear a short presentation on the current and future state of this amazing technology.
Kristofer Beem- Business Development Director. Kristofer has a degree in Entrepreneurial Business and is one of the first four members of RapidMade, Inc. He has a combination of ten years of sales and marketing experience in B2B and B2C environments. His working knowledge of 3D printing and additive technologies enable him to quickly work with clients in a collaborative manner. In the past five years, he has built a strong client base of almost 400, including several Fortune 500 clients, and globally renowned brands.
What: The Current and Future State of Advanced and Additive Manufacturing When: Friday March 17th, 2017 11:30 – Doors open, Lunch – order from Sidebar menu 12:00 – 1:00 Presentation
Where: Sidebar – 3901 N. Williams Ave
Cost: Free entrance, order lunch off Sidebar menu RSVP: Space is limited.
- 3D print preparation
- 2D to 3D conversions
- Design for manufacturing conversions
- Contract design work
- Custom design
- Product design
- Conceptual design
- Proof-of-concept design
- Design for manufacturing
- Stress analysis
- Motor/actuator sizing and selection
- File Conversions
- Existing part to 3D CAD
- 3D scan to parametric CAD model
- Manufacturing drawings
- Machine layouts
- User manuals
- On-site installation
This week, Paper Packaging closes after 53 years in business. Why would RapidMade be marking this occasion you may ask? Its founder, Dan Unico, who worked every day in 2D printing and box making, is the father/grandfather of three of RapidMade's owners.
Dan, who also turned 90 this month, will continue to work along with his wife Joan, 85, and two sons Ken and Mark to dismantle, crate and ship equipment to new owners. In the spring, they anticipate - finally - retiring. Maybe...
Dan and Joan taught us that starting a business was - and is - a path to a better life. And we learned that lesson at an early age. As children, we would play in the factory, sometimes doing odd jobs until age and experience allowed us to "graduate" to working on the various print and die-cutting machines. This was NOT additive manufacturing. The work could be hard, dirty, and monotonous.
It is a testament to Dan that his wife, three of his four children, one son-in-law and one of his grandchildren (so far) has chosen manufacturing as a career. That is a legacy one can be proud of. Happy Birthday and Happy Retirement!
The popularity of Industrial Design, also known as Product Design, has accelerated due, in part, to a new wave of designers and advances in technology, materials, processes, and capabilities which has dramatically improved the design options available to clients. Working closely with Engineers, Industrial Designers are trained on function, aesthetics, ergonomics, anthropometrics, and manufacturing processes to provide you with the best “working” concepts from sketches, to renderings, to CAD models that create your final product.
RapidMade recently expanded its capabilities by including Industrial Design into our Product Design Process. In doing so, this lets us help our clients move from product conceptualization to launch much faster and more efficiently with better end results.
When clients first come to RapidMade, sometimes they have a complete design ready to be made, but often they only have an idea of what they want. Introducing our new Industrial Design capabilities is a critical step toward helping the customers make their vision a reality.
Once a client completes a Quick Quote, we will arrange a meeting with our team of engineers and designers to discuss your concept. Our Industrial Designer then works with you to create multiple rough 2D sketches for the conceptual form that evolves into a final realistic 2D rendering (that you may keep). When you choose a final form, we add additional aesthetics. These can be anything from color, to contour lines, or personal brands and logos to get your finalized look. Our engineers then take this design you and our Industrial Designer created and make a CAD model with your specific dimensions, which is used to 3D print a prototype. We work with you on any additional iterations and source the final manufacturing for you.
Before starting RapidMade, Renee Eaton worked in higher education teaching management classes and career counseling at Oregon universities for almost a decade. While she loves the world of 3D printing, engineering, product design and additive manufacturing, she sometimes misses working with college students.
Last week, she had an opportunity to return to the classroom. Each year, at her youngest daughter's school, St. Mary's College of Maryland, Renee presents an Interviewing Skills Workshop to its Senior class. In addition to giving back to the community, Renee gets to practice her own interviewing skills - which she put to good use this past year. An added bonus was the event's timing which coincided with the horrendous Portland snow and ice storms. She's calling it Karma.
Braving the ice and rain, RapidMade joined other manufacturers and suppliers at this week's Northwest Food and Beverage Manufacturers Expo and Conference. The Expo is a familiar event for RapidMade's management team which has more than 40 years of experience in food processing and material handling as an Original Equipment Manufacturer (OEM), engineer, manufacturer and 3D printer.
OEMs turn to RapidMade for our engineering design services. Once equipment is operational, using our engineering staff and additive manufacturing allows food processors to 3D scan, reverse engineer and produce components - either using 3D printing or traditional manufacturing.
Held annually, the Expo offers "leading-edge educational sessions with the largest regional trade show in the industry."
RapidMade Accelerates Pace and Elevates Quality of Product Launch
Injection Molding Case Study
3D Printing, or Rapid Prototyping as it is also known, is a much faster and cost effective solution for testing and perfecting digital designs. Its ability to fabricate parts overnight without any direct labor, programming or tooling means 3D printing technologies carry many advantages over traditional technologies like injection molding for short turns and small-batch production.
Sometimes 3D printing only goes so far when developing and manufacturing products in their early stages. In those instances, Rapid Injection Molding can take products to the finish line.
An American-made LED light bulb manufacturer engineered a version that was bigger and brighter than its competition. The company quickly learned that RapidMade's injection molding expertise could test, validate and even manufacture its light bulbs in ways that 3D Printing simply could not match.
RapidMade accelerates the typical injection molding process by providing a short cut between prototyping and production tooling. After the rapid prototyping client finalizes its product for injection molding, RapidMade creates a cheaper and better solution by making pre-final tooling out of aluminum. This option allows customers get to market sooner than other injection mold processes and helps gain customer feedback to improve products. Getting a product to market sooner generates more revenue to invest in further product development and long-term tooling.
Since the customer didn't know what the final material of the bulb should be, cutting the mold and testing multiple materials, including different grades of ABS and Polycarbonate, helped pinpoint the final material and even helped estimate eventual mass manufacturing costs. Additionally, electronics products must go through rigorous UL testing to ensure consumer safety before the product can be sold in stores.
Color and clarity are other traits vital to the lighting industry. Because 3D printers must run manufacturing-grade material that is unadulterated, optimizing these characteristics can be difficult. With injection molding, however, one can custom blend different clear and opaque pigments with clear plastic to prototype different levels of clarity and color. So the company could test very specific color profiles to perfect its formula in the final product.
Finish is extremely important when working with lighting, as well as other consumer products. A matte finish diffuses light at a very different rate than a polished one. Due to the layered nature, inherent in the 3D printing process, even the highest detail machines will have some level of surface striation. Additionally, most filament or powder technologies will have a very rough finish beyond the layer lines. Achieving custom finishes requires polishing, sanding, and painting of each individual unit, making it is extremely labor intensive and expensive.
Alternatively, injection molding shoots molten plastic into a cavity which picks up the texture of that cavity. That means one only needs to finish a mold once to get repetitive shots of that finish. And molds can be polished and textured to prototype a variety of finishes before settling on the desired one.
A light bulb is a relatively low-cost consumer good. These goods are meant to be sold in large volume at low cost. Tooling to produce those volumes inexpensively enough can take months to make and require high upfront investment. Many businesses are interested in small and medium-batch options that are more cost effective and higher quality than 3D printing to excite investors, test markets and stoke demand.
The company secured a prototyping option with relatively little upfront investment that served as a bridge tool to get actual product out into the marketplace. Aside from the aforementioned quality concerns, this could not have been cost effectively achieved with 3D printing; one cannot sell a light bulb where the housings cost $38 to the manufacturer. Creating large volumes of parts on a 3D Printer can also take much longer than injection molding, making it harder to fill orders. Injection Molding can really provide exceptional value to early-stage manufacturers when producing runs of hundreds or thousands of parts for low cost very quickly.
We've written before about the exciting progress in wearable technology - that not only lets you look good but helps you feel good too. Portland neighbor Intel's latest project accomplishes this objective in grand style. A collaboration with fashion designer Hussein Chalayan produced 3D printed belts - in both white and black - that gathered bio metric data to measure and track the stress levels of the models who wore them. The information
The logic is that providing biofeedback allows the wearer to take proactive steps to reduce his or her stress levels.