3D Printing Speeds and Streamlines Production of Custom Funnels

Additive manufacturing replaces labor-intensive, time-consuming process with faster, simpler way to make custom funnels from a more sustainable material.

Bernay Automation uses Sculpteo’s online 3D printing service for the rapid, iterative prototyping of interchangeable components made of Forward AM’s Ultrasint® PA11 bio-derived powder and SLS 3D printing technology.

Project Breakdown

Industry & Application
Industrial, Assembly and Packaging

Product
Ultrasint^® PA11

Partner & Technology
SLS 3D Printer

Why Forward AM Solutions and Materials?

Forward AM supplied a strong, sustainable material and a collaborative problem-solving approach

Key Numbers

Reduced project timelines from weeks to days

Bernay Automation of Menneval, France makes feeder systems and supporting components that present parts at the right rate and in the proper position on assembly and packaging lines. To meet the individual needs of its customers, the manufacturer produces custom corkscrew funnels that attach to its vibrating bowls for customer-specific parts.

In partnership with Forward AM and Sculpteo, Bernay Automation used additive manufacturing to quickly create interchangeable corkscrew funnels from a strong, sustainable non-metal material. In addition to supplying Ultrasint® PA11, a bio-derived polymer with exceptional toughness, Forward AM shared its 3D printing expertise.

The Challenge

Traditionally, Bernay Automation used molding and welding to produce prototype funnels for its feeder systems. Building these metal tools was labor-intensive and took weeks. If a custom corkscrew funnel didn’t meet a customer’s requirements, the material, labor, and energy that were used to produce it became a form of waste.

Metal funnels are strong and durable, but they’re not lightweight. In addition, the traditional manufacturing processes that are used to make them can pose challenges with surface quality and dimensional accuracy. Plastics weigh less and can have a smooth, uniform surface finish, but most polymers can’t match the performance properties of metals.

Bernay Automation is also committed to energy efficiency and environmental sustainability. Some metals are recyclable, but extracting and refining these materials accounts for one-tenth of global greenhouse gas emissions. To remain competitive, the company also wants to achieve greater operational efficiency while accelerating time-to-market.

The Solution

The solution to Bernay Automation’s challenges came in the form of a partnership with Sculpteo and Forward AM. Sculpteo’s online 3D printing service provided an alternative to time-consuming, labor-intensive molding and welding. Forward AM’s Ultrasint® PA11 polymer powder worked well with Sculpteo’s 3D printers and met critical requirements as a replacement for metal.

Ultrasint® PA11 has exceptionally high ductility and impact strength for applications that require durability and toughness. The custom corkscrew funnels that Bernay Automation makes need to handle many parts at a high rate of speed, so Ultrasint® PA11’s ability to withstand high mechanical stresses was especially important.

As a bio-derived powder with a CO2 lifecycle assessment, Ultrasint® PA11 also met requirements for environmental sustainability. Plus, using this material enabled the creation of multiple custom funnels that Sculpteo could 3D-print on the same machine. In turn, less energy was needed to produce parts that are lightweight, dimensionally accurate, and have a smooth, uniform finish.

The Result

The outcome of this solution enabled Bernay Automation to reduce project timelines from weeks to days. By replacing a labor-intensive process for prototyping, Bernay Automation also streamlined operations and adopted a sustainable material derived from Castor seeds for strong, durable components that withstand the demands of automated packaging and assembly.