Page 29 - 3DMP Spring 2022

Prototype Metal Parts at One-Tenth the Cost 3D
our own hands to allow for quicker itera- tions on our product development,” shares deNormand.
The Solution
In 2017, Caldwell Manufacturing sent members of its team to a manufacturing trade show, viewed the Markforged metal 3D printing platform, and ultimately decided to purchase a Markforged Metal X system capable of printing in 17-4 PH stainless steel, Inconel and copper.
Caldwell also purchased a Mark Two 3D printer, along with the Metal X, that can print in continuous carbon fiber as well as other reinforcing materials. The team initially brought in this printer for R&D purposes but has since started to use it for internal tooling.
The Metal X system, say Mertz and deNormand, has enabled Caldwell’s engi- neers and designers to print prototype metal parts that would traditionally be cast from zinc or aluminum. “The metal 3D printer has enabled us to prototype those parts in which we weren't in a posi- tion to be able to do before,” says deNor- mand. “The same parts that would previ- ously cost anywhere between $300 and $5000 made using traditional methods now cost $30 and take three days to pro- duce instead of up to eight weeks.”
The team now can test the 3D-printed metal parts, share them with customers for evaluation and collect feedback to help in the design of their products. “It changes the design cycle to more of a fail-fast mode,” says Mertz. “It really changes our mindset about how we design, the way we test and the way we validate. It changes the way we put products into production. It’s changed everything.”
Bottom Line
Caldwell has well and truly integrated 3D printing into everything aspect of its company, from R&D, developing robotic parts for testing, assembly fixtures and tooling, all the way to post-processed parts for customers. The team 3D prints tooling for the shop floor, and the assemblers can provide feedback and suggestions for improvement.
“If an assembler feels like there's a change that must be made, I have no hes- itation making a change,” says manufac- turing engineer Phillip Cole. “We quickly make a design change, send it to the print- er, and swap it out. What used to take 6 to 12 months to accomplish now takes the team 6 to 12 weeks.”
Overall, the addition of the two Mark- forged 3D printers has removed bureau- cracy and added autonomy, according to
Caldwell Manufacturing 3D prints holding fixtures, assembly fixtures (shown here) and error-proofing fixtures—all of which the firm designs inhouse. Until recently, the fixtures were fabricated by a third- party supplier. Now, 3D printing the fixtures inhouse “has removed bureaucracy and added autonomy,” says company CEO Eric Mertz. “It’s given (the employees) the tools they need to put their thoughts into parts.”
Mertz. “It’s given them the tools they need to put their thoughts into parts,” he says. “And ultimately, I think it’s bigger than that. I think that those things create more engagement from our employees. It’s reduced turnover, and it’s part of our cul- ture now. I mean, it's kind of hard to believe that a 3D printer could do that. But I do believe that.”
Moving Forward
While Caldwell Manufacturing has come a long way in reaping the benefits from its 3D printing investments, the team recognizes that there’s still a long way to go. “I think we’re just scratching the surface for what the technology can do, will evolve into, and how it can change low-volume production,” says Mertz. The company expects that in 5 yr., each of its manufacturing plants will have Mark- forged 3D printers for small-volume, low- run, custom-production parts. As of now, it has installed Markforged printers in two of its four North American manufac- turing facilities, in use for producing some 18 low-volume end-use components. By the end of 2022, the team expects to add printers to its other two North American locations.
“We continue to realize the benefits of owning this technology and are gen- uinely excited about its future,” says deNormand. “Our 3D printers have become the most utilized equipment in our R&D model shop. Our new products and assembly processes are more robust, and we can introduce them to the market more quickly.” 3DMP
Article provided by Markforged: www.markforged.com.
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