3D Printed Parts Exceed Customer Expectations for Performance, Timing and Cost Savings
Merit3D utilizes Ultracur3D® EPD 1006 to fulfill an order for over 1,000,000 hangers for Adhesives Technology by creating a multifunctional part that meets quality standards as well as eliminates the need for additional SKUs.
Merit3D, a leading additive manufacturing company, is producing one million hangers for Adhesives Technology using BASF Forward AM’s Ultracur3D® EPD 1006 and Photocentric’s LC Magna printer. The hangers are required for every project they undertake. When production was halted due to the unavailability of the injection mold tool, a collaborative solution helped Adhesives Technology eliminate the need for a costly new injection mold tool and bring manufacturing back to the USA.
Table of Content
Project Breakdown
Industry
Industrial
Material / Product
Ultracur3D® EPD 1006
Partners
Merit3D
Technology
LCD
Why Forward AM?
Material expertise ensured hangers would meet and exceed quality and performance standards
The result
Hangers
Utah-based 3D printing service provider Merit3D was tasked with fulfilling a one-million-part order from Adhesives Technology, a Florida-based manufacturer of construction and industrial-related adhesive products. After production was halted due to a significant supply chain disruption, Adhesives Technology turned to Merit3D and BASF Forward AM materials to find a workable, cost-effective solution. They required custom-designed plastic components to attach two of its related products together. They were a small, but integral part of the production process and if unavailable, thousands of orders for adhesives would be delayed.
Challenge:
Adhesives Technology faced challenges due to unforeseen and uncontrollable events which prevented- them from receiving their injection mold tool, which was required to produce the hangers keeping their epoxy cartridges and mixing nozzles together for both shipping and placement on the shelf. Production was immediately halted while the company investigated procuring another injection molding tool. When they realized that producing another tool would take an extended amount of time and incur high additional costs, Adhesives Technology turned to 3D printing as their only viable option for a solution. They then did additional research into whether 3D printing the hangers would be prohibitively expensive. (Spoiler alert: It was not.)
Solution:
Merit3D offered a solution to the challenge by modifying the molding design and optimizing it for Additive Manufacturing. Specifically, the company optimized the design for Photocentric’s Liquid Crystal Magna printers using BASF Forward AM’s Ultracur3D® EPD 1006. The iterative redesign process took a total of two weeks and resulted in a design that could be 3D printed both efficiently and cost-effectively.
Merit3D used 20 printers to manufacture the hangers, producing 400 hangers per platform and taking 225 minutes per platform. The material used was Ultracur3D® EPD 1006 from Forward AM powered by Photocentric. This innovative material provided the ideal properties required for the part and passed the brutal durability test.
Merit3D then presented Adhesives Technology with another design iteration — one that could act as a universal hanger because it would work on two products that previously had distinct hangers. This additional benefit obtained by utilizing Additive Manufacturing would eliminate an additional hanger that Adhesive Technology had to injection mold, ship, store, and apply, resulting in a cost savings for the company.
Result:
Merit3D’s Additive Manufacturing solution using BASF Forward AM’s material and Photocentric’s LC Magna printers enabled Adhesives Technology to continue production knowing the order of 1,000,000 hangers would be fulfilled in a timely manner. This innovative solution also allowed for customizations and multiple design iterations to optimize the hangers for their specific use.
Using Additive Manufacturing technology, greater sustainability was achieved through reduced waste and a lowered the carbon footprint. Photocentric’s LC Magna printers proved ideal for volume manufacturing due to their large format, high surface finish, fast production, cost-effectiveness, functionality and low energy consumption.
Merit3D’s successful production on the order of 1,000,000 hangers using Additive Manufacturing demonstrates the unlimited potential of this technology for large-scale production. By optimizing the design for 3D printing and utilizing LCM printers, high-quality and durable hangers can be manufactured efficiently and cost-effectively. The elimination of a costly injection mold tool also made production more ecologically sound and increased sustainability. As Additive Manufacturing technology continues to advance, companies can reach greater heights by implementing the innovative solutions offered through 3D printing.
“This is a huge step in the development of manufacturing to replace injection molding as we see large companies replacing their current manufacturing processes with additive manufacturing parts.”
Spencer Loveless, CEO at Merit3D
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