Case History Archivi - Spring

Fabio Gualdo
28 June 2019
MOTO-1280x853.jpg

Spring srl is the leading Italian 3D printing service bureau, in the production of functional parts. In one of its latest projects, the company has created an airbox conveyor for a Moto2 team bike. The achieved results have been outstanding.

TARGETS
  • Meet tight deadlines
  • Produce a high-performance thermoplastic component
  • Save production costs
IMPLEMENTATION PROCESS
STEP 1. Design

Spring srl has designed the airbox conveyor. The 3D model has been created with ribs to improve bike fluid dynamic.

STEP 2. Production

Racing bikes are exposed to extreme conditions such as high pressure, high temperatures and hydrocarbons. This is the reason why, in this project, Spring srl has used Nylon 12, one of the best performing materials of the FDM technology. This thermoplastic absorbs the strong vibrations and repetitive stress during the race. The client’s component, made up of 2 parts, has been printed, meeting extremely tight deadlines.

STEP 3. Finishing

Racing bikes are exposed to extreme conditions such as high pressure, high temperatures and hydrocarbons. This is the reason why, in this project, Spring srl has used Nylon 12, one of the best performing materials of the FDM technology. This thermoplastic absorbs the strong vibrations and repetitive stress during the race. The client’s component, made up of 2 parts, has been printed, meeting extremely tight deadlines.

STEP 4. Quality control

Spring srl offers the highest dimensional quality control, meeting the most demanding needs of the motorsport clients, guaranteeing the required tolerances.

ACHIEVED RESULTS
 PREVIOUS SOLUTION SPRING SOLUTIONDIFFERENCE
LEAD TIME8 working days2  working days 75%
COSTS– 47%

 Send here your project, we will provide you with the best solution!


Fabio Gualdo
15 June 2018
Attrezzature-per-automazioni-industriali-anterprima.jpg

3D printing technology is increasingly approaching the industrial automation field .This Case Study explain how the automation-equipment realization process has been developed in order to significantly reduce costs and time of production.

TARGETS
  • Realize equipment for the line processing and handling of the product
  • Respect strict lead time
  • Reduce costs
IMPLEMENTATION PROCESS
STEP 1: Reverse Engineering

LThe activity starts with the acquisition of the product’s digital jig. The mathematic model of the element (customer’s product) is acquired through 3D Scanner, both the upper part, necessary to the realization of the collecting devices, and lower part necessary for the placements realization.
Attrezzature per automazioni industriali Reverse Engineering

Scanner laser necessary for Reverse Engineering activity

STEP 2:Design

The technical department, thanks to the 3D measurements obtained through 3D Scanner, designed the collecting devices and the placements. The components development was realized with Cad 3D Systems installed in the company and thereafter optimized for Additive Manufacturing.
In this phase precise customer’s specifications were followed, such as details placement and extreme envelope of the placement with respective balance and fixing.
Attrezzature per automazioni industriali progettazione

Collecting devices design (left and right)

Attrezzature per automazioni industriali progettazione posaggio

Placement design

STEP 3:Production

After a technical analysis of the customer’s requirements we suggested the usage of two different materials:

• FDM technology (Fused Deposition Modeling) with Nylon 12 for the realization of the collecting devices

•FDM technology (Fused Deposition Modeling) with ASA for the realization of the placements

Spring has 10 FDM production system machines of the brand Stratasys that allow to realize monolithic parts of big dimensions or, like in this case, group parts and small pre-series.
Attrezzature per automazioni industriali produzione

Collecting devices and placements realized with Additive Manufacturing

STEP 4:Quality control

Every realized part was tested with rigid quality controls in order to guarantee to the customer a complete service and a result that meets the initial urgent requests.

Collecting devices and placements quality control

In the following video you can see collecting devices and placements realized in Additive Manufacturing inserted in a working production line.

GAINED RESULTS
 Preavious solution Spring Solution

Difference

Lead time15 working days4 working days-74%
Costs-37%

 

Please send us your project to contatti@springitalia.com. It will be our prerogative to evaluate the technical feasibility and offer you the best possible solution!

 

 

 

 


Fabio Gualdo
15 June 2018
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Spring Srl designed and realized the inlet pipe of a Moto3 motorbike with Additive Manufacturing. The company set several targets to achieve the result:

TARGETS
  • Reduce the costs of the detail
  • Respect restricted delivery time
  • Realize a detail with high technical characteristics
IMPLEMENTATION PROCESS
STEP 1: Design

Once figured out the client’s requirement, the first activity was the inlet pipe design. The 3D model was developed with a CAD system installed in the company and successively optimized for Additive Manufacturing. During the design stage fixing points and casing for the temperature sensor were realized.

Cad design of the inlet pipe

STEP 2: Production

The applications in the Racing field require materials with high technical characteristics. The realized details needs to be resistant to extreme conditions as high temperature, chemical agents and significant mechanical stress. That’s why for the inlet pipe realization we chose Carbon Charged Nylon.
The material is composed by a mix of Nylon 15 with a 35% of carbon fiber. This combination makes it one of the hardest and with the highest resistance/weight ratio material available in the field of Additive Manufacturing.

cornetto d'aspirazione

Detail realized with additive manufacturing

STEP 3:Finishing

The detail has undergone an impregnation treatment to reduce roughness and improve performances. Afterwards, as customer’s request, inserts have been placed.

Cornetto d'aspirazione finitura

Post-finishing detail

STEP 4: Quality control

In the final phase the detail was tested with a quality control with a laser scanner. Spring Srl was able to guarantee the strict allowances requested.

cornetto d'aspirazione controllo qualità

Quality control detail

ACHIEVED RESULTS
 
Preavious solution
Spring solution

Difference

Weight-43%
Lead time2 working days1 working day-50%
Costs-31%

 

Please send us your project to contatti@springitalia.com. It will be our prerogative to evaluate the technical feasibility and offer you the best possible solution!

 

 


3D PRINTING

3D PRINTING

CNC MACHINING PROCESS

CNC MACHINING PROCESS

METAL CAST

METAL CAST

VACUUM CASTING

VACUUM CASTING

PRE SERIES

PRE SERIES

FINISHES

FINISHES

CARBON FIBER

CARBON FIBER


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