News Archivi - Spring

Fabio Gualdo
28 September 2020
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Additive manufacturing technologies, such as Fused Deposition Modeling or FDM, allow to produce ergonomic, optimized and custom-made jigs for the production floor. To understand benefits coming from this technology, let’s have a look at an example of an alignment jig  and an assembly jig, related to the automotive field.

A custom-made alignment jig thanks to FDM technology

This jig, well-known as “Badge alignment tool”, is used by workers to accurately place a badge on a car. The Badge alignment tool is usually produced with CNC machines and metal, resulting too heavy and uncomfortable for workers.

A badge alignment tool produced with CNC machines and aluminium.

The company decides to optimize the Badge alignment tool, by choosing FDM technology, ABS-M30 material and sparse fill style.

On the left, you can see a part built in sparse fill style, on the right, you can see the same part built in solid fill style.

Sparse fill style is one of the most interesting chance offered by FDM technology. The sparse fill style, as opposed to the solid fill style, allows to develop resistant components composed of an internal grid, also with honeycomb structure. This condition enables to reduce the use of material and as a result, assures a further saving in terms of weight, time and costs, compared to an already favorable fill style such as the solid one.

The badge alignment tool produced with FDM technology, ABS-M30 material and sparse fill style.

The new custom-made Badge alignment tool has been optimized by the technical staff and produced by skilled workers. This new tool enables the company to get benefits such as:

  • Increased productivity: The Badge alignment tool weight has been reduced by 72% compared to the previous solution. Moreover, the component design has been optimized in its ergonomics. Employees have been able to increase their productivity, thanks to these new conditions.
  • Reduced time: FDM technology and sparse fill style have enabled a delivery time reduction by 92% compared to the previous solution.
  • Reduced costs: FDM technology, sparse fill style and the new “design for manufacturing” have guaranteed a cost reduction by 58% for each Badge alignment tool.
Custom-made assembly jig thanks to FDM technology

This jig is used by an automotive company’s workers, to assembly cars door seals. This jig is usually produced with CNC machines. The company needs to increase productivity related to this working step, that’s why technicians decide to develop a new assembly jig.

FDM technology, ASA material and solid fill style are chosen for this application.

In this picture you can see the assembly jig built with FDM technology, Asa material and solid fill style.

This new optimized, custom-made assembly jig has been produced by skilled workers and shows now two main features:

  • Improved ergonomics: FDM technology allows to overcome geometric limits, related to the use of more traditional methods. This chance has enabled the technical staff to re-design the assembly jig with a more focus on functionality. Indeed, it has been possible to insert internal hardwares in order to ease the working task.
In the picture you can see the assembly jig during re-design steps.
  • Reduced weight: Thanks to Asa material and the improved geometry, the new assembly jig weighs only 13 kg as opposed to the 58 kg of the previous solution.

The new assembly jig allows the company to get benefits such as:

  • Saving time : The company saves hundreds of working hours, since each employee performs on average 250,000 cycles a year and the new jig enables a reduction of 4 second per assembly cycle. Indeed, thanks to the use of FDM technology, the company has shrunk the jig production from weeks to days.
  • Saving costs: The ROI related to the jig cost is achieved within few months.
  • Boosting safety: The new lighter and more ergonomic jig enables to reduce risks related to its use.
Spring srl – the additive manufacturing service for industrial applications

Spring srl is an additive manufacturing service, with over 20 years’ experience in the production of prototypes and functional components, with thermoplastic materials, for industrial applications. (ISO 9001:2015)

Spring srl’s highly-skilled technical staff chooses additive manufacturing technologies, materials and treatments in order to meet also the most demanding needs. With a portfolio of over 20 materials, a machinery composed of 3 different additive manufacturing technologies and 12 professional systems, Spring srl offers a wide range of solutions and a very fast delivery. The company produces not only prototypes and components, but also offers services such as engineering, design for manufacturing, 3D scanning for reverse engineering and a rich selection of finishes and treatments for post processing.

Source: https://www.stratasys.com/

Click here for more info on a control jig built with additive manufacturing.

Click here to send your request.


Fabio Gualdo
1 September 2020
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Additive manufacturing technologies allow to produce grippers with complex geometries, at reduced weight, in short time and at lower costs, compared to the production with more traditional methods.

These features enable engineers to develop more performant components.

New generation vacuum grippers with Multi Jet Fusion technology

To better understand benefits of additive manufacturing, we present you a vacuum gripper example, applied to a robotic arm, for packings handling.

Since the company needs to increase productivity and to reduce costs related to the robotic arm, engineers are driven to re-design it, starting from the vacuum gripper.

This vacuum gripper is usually composed of an extruded aluminium profile with external canalizations for air management.

The technical staff wants to build a new kind of vacuum gripper, in thermoplastic material, with airtight integrated canalizations.

The production of this new component is possible thanks to the technical know-how related to the Multi Jet Fusion technology and PA 12 material, chosen for this application.

Using this innovative technology, the vacuum gripper presents a significally reduced weight, compared to the previous version. This condition allows the company to:

  • Improve performances: With a lighter vacuum gripper, the robot has increased the number of tasks carried out in an hour.
  • Reduce costs: The company has invested in a smaller robotic arm, cutting buying cost, energetic consumption and the space occupied inside the factory. The lower weight of the new vacuum gripper has reduced the wear and the mainteinance activities on the robotic arm. The vacuum gripper production cost has been reduced by 85 %.
  • Reduce time: The building time has been reduced by 70 %, since the additive method allows to deliver parts in a few days or hours. This fast delivery has enabled to quickly install the robot and make it operational in a very short time.
Spring srl – the additive manufacturing service

Spring srl is an additive manufacturing service specialized in industrial applications (ISO 9001:2015 ). Industrial automation is one of the main field served by the company, producing not only grippers, but also fittings and pallets for automated production lines, air ducts and distributors etc…

The wide range of services includes the production of functional components and prototypes with additive manufacturing technologies, engineering, re-design, post-processing, using a great variety of finishes and treatments.

Contact us for more information: https://www.spring-italia.com/contacts/?lang=en

Source: https://www8.hp.com/uk/en/home.html


Fabio Gualdo
29 June 2020
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We are proud to introduce you to the new Spring srl’s additive manufacturing service regarding the Multi jet Fusion technology, that will allow our clients to have thermoplastic components with the usual and high quality level guaranteed by Spring.

The combination between these elements is our daily challenge and today, even more, this is what we offer, thanks to new investments in terms of Know-how and production systems.

The new in-house arrival, as a result of an internal analysis, is the HP Multi Jet Fusion 5210 additive manufacturing system.

Multi Jet Fusion technology: how does it work?

Multi Jet Fusion (MJF) is a powder-based AM process that uses fusion energy and two agents; such are selectively jetted, with the fusing agent used to weld the particles that make up the finished part, while the detailing agent is used to define edges and details.

PA 12 thermoplastic of the Multi Jet Fusion technology

PA 12 is a thermoplastic used with the Multi Jet Fusion technology.

This material allows to produce structural, isotropic and watertight parts.

Click here to know the features and benefits of PA 12.

Spring srl: the additive manufacturing service of industrial quality

We work daily to assure an always higher quality level for the parts and for the services provided to our partners, through the know-how of a skilled technical staff and a top quality production (ISO 9001:2015 certification ).

Choosing our services means taking advantage of all the benefits that additive manufacturing can offer for industrial-grade applications.

We are at your disposal for any request:

Contacts


Fabio Gualdo
29 June 2020
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Companies intending to replace traditional production processes with innovative methods, such as Additive Manufacturing with FDM technology, are obtaining significant savings in terms of production time and costs; AM in fact allows them to gain an advantage over the competition.

Usually, when engineers need to produce a component with complex geometries, the process steps that are needed for its production can be several, such as milling, other CNC machining, welding etc.

The production of parts that need all these process steps requires utilization of huge economic resources and a long lead time.

A production tool, for the assembly of mechanical parts, printed with FDM technology.

The knowledge and skills in the use of FDM technology, industrial production systems and the use of high-performance materials allow you to have in a few hours light and resistant components, which can also replace metal parts.

FDM technology is particularly advantageous in the realization of small lots or single pieces with complex geometries.

Parts such as grippers, fittings and pallets for automated production lines, air ducts and distributors achieve the maximum benefits from production through the FDM process.

In the following example, we will present how the technical department of Spring srl, a 3D printing service specialized in FDM technology, has created a suction duct achieving 3 key objectives: lowering costs, reducing delivery time and producing a component with high mechanical performance.

 Air intake duct

Previously the duct was made of steel, thus requiring cutting the various sections, welding them and milling the ends to guarantee their geometry. The traditional process involved a considerable economic expenditure and the production times were particularly long.

Spring’s proposal made it possible to produce the monolithic part without joints and welds, thus significantly reducing production times and costs.

During the “Design for manufacturing” phase, the 3D model was optimized according to the FDM technology, inserting structural ribs at the ends of the component, to ensure greater resistance in fixing the coupling sleeves.

To fulfil the requests, Spring selected Nylon 12 CF for this project. Nylon 12 CF is a thermoplastic blend consisting of Nylon 12 and 35% carbon. This material offers very high values ​​of rigidity, resistance to impacts and to chemical agents. These characteristics make such material particularly suitable for metal replacement applications.

The final component that was re-engineered and produced by Spring Srl weighs 0.15 kg, compared to 1 kg of the previous solution, a weight saving of 85%.

Click here to download the case study.

Spring srl: the italian 3D printing service for the automation industry

Spring srl is ISO 9001:2015 certified for production and supply of prototypes and industrial components through additive production technology.

The company assists its customers in co-design activities in an additive manufacturing perspective, thanks to 20 years of experience in this field.

Spring Srl has been working for years with the most important national and international players in the industrial automation sector. These partnerships are the result of important investments in terms of resources, professional production systems and a continuous improvement policy.


Fabio Gualdo
9 June 2020
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Spring srl increases its productive capabilities in the medical and healthcare field, making materials available that are resistant, biocompatible and ISO 10993 certified, such as:

-ABS-M30i Acrilonitrile Butadiene Stirene: This thermoplastic is ideal for the production of medical, surgical and pharmaceutical tools. Components manufactured with this material are sterilizable through gamma rays, ethylene oxide (EtO) or hydrogen peroxide gas plasma and can be used in direct skin-contact applications.

-PC-ISO Medical Polycarbonate: This thermoplastic is used for the production of tools for doctors, surgeons and dentists. Pieces manufactured with this material are sterilizable through gamma rays or ethylene oxide (EtO). PC-ISO offers excellent mechanical features, an outstanding traction strength and a temperature resistance up to 133 °C.

ULTEM 1010 Polyetherimide: This thermoplastic is used for the production of medical applications and tools for food manufacturing (NSF 51). Parts produced with this material are sterilizable through gamma rays, ethylene oxide (EtO), hydrogen peroxide gas plasma or in autoclave. ULTEM 1010 is a self-extinguishing thermoplastic, that offers a notable mechanical resistance and high temperature strength, up to 216 °C.

Detailed information is available on the following link: https://www.spring-italia.com/product-category/fdm-en/?lang=en

In the table below you can find the biocompatibility test results and the tested sterilization methods.

(Source: Stratasys)

Additive manufacturing for the medical field – Spring Srl

Additive production allows to obtain big benefits in terms of quality, execution speed, costs reduction and parts customization as long as professional systems, certified materials, processes that guarantee the produce traceability and know-how are employed.

At Spring Srl, with 20 years of experience, an excellent technical staff, 12 3D printing professional systems, a portfolio of more than 20 materials and an ISO 9001 certified production system, we provide appropriate solutions for the field.

The medical solutions that additive manufacturing can provide are rapid prototyping and end-use part production, medical and surgical tools.

These solutions are already available today at Spring Srl, and such allow to improve the healthcare and the creation of high-performance parts.

For any need or explanation, we invite you to contact us: https://www.spring-italia.com/contacts/?lang=en

 


Fabio Gualdo
13 March 2020
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In one of the most spectacular events of the World Championship calendar of the Moto2, at night, under the floodlights of the Losail International Circuit, in the Qatari desert, Jorge Navarro, Team Speed Up’s number 9, conquers a great 6th place.

It’s a good start in the 2020 season for the valencian pilot of Moto2, whose step change has begun in 2019 when he joined the Speed Up team, closing the season with 226 points, vs 58 points in 2018.

Spring srl, technical sponsor of the team, is proud to support the big progress of one of the most famous constructors of the championship, providing additive manufacturing solutions able to optimize the performance of the SF20T Speed Up motorbike.

Spring srl: the ideal partner for the motorsport companies

Spring srl, 3D printing service bureau, specialized in the FDM technology, produces monolithic functional parts and prototypes up to 900X600X900 mm.

Spring’s know-how, the FDM process and the high-performance materials guarantee light components, able to withstand extreme conditions like high temperature, chemicals and mechanical stresses.

Spring’s technical department supports constructors also in co-designing, to review parts drawings for additive manufacturing.

Some of the most required components from the field are end-use parts, soluble cores, tooling application for composites etc..

In the following case studies you will discover how the Spring’s technical department has built the inlet pipe and the airbox conveyor of a competition bike achieving 3 key targets: cost savings, delivery time reduction and production of high-technical feature components.

  • Inlet pipe:

The selected material for this project has been Nylon 12 CF, a thermoplastic blend with 35% of carbon fiber, specific weight 1.15, bend resistance 142 MPa. This material offers the best results in terms of tensile modulus and specific stiffness; these features make Nylon 12 CF suitable for metal-replacements initiatives. Click here to download the case study in PDF format.

  • Airbox conveyor:

The selected material for this project is Nylon 12, specific weight 1.28, tensile strength 48.26 MPa, bend strength 68.95 MPa. This material is capable of withstanding to strong vibrations and fatigue, particularly suitable to absorb stresses during the race. Click here to download the case study in PDF format.

Soluble cores allow for production of carbon fiber parts. These “sacrificial tools”, produced using ST-130 material, are covered by carbon fiber sheets and then undergo the autoclave treatment. At the end of this production process, the soluble cores are dissolved into a water-based solution.

As the materials market is in constant evolution, Spring srl offers  increasingly new solutions. Among the most interesting materials for your field we suggest you to discover PEKK, Ultem 1010 and Ultem 9085 properties. You can find these materials at the following link: https://www.spring-italia.com/prototyping/3d-printing/?lang=en


Fabio Gualdo
30 January 2020
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Companies producing drones can benefit from knowledge and use of innovative 3D printing technologies, as for example FDM technology. This technology allows to optimize the end-use parts design and the related production process. Leptron, leader in drones production, has increased its competitive advantage thanks to FDM technology.

In this case study, the company analyses the most proper production approach to make different versions of complex components. These plastic parts, that will be used in the drone fuselage, need to pass functional tests. Leptron therefore needs a fast production process, capable to reduce the time-to market in order to beat the competition.

The traditional approach would have used the injection moulding. Through this method the company would have delayed the production of the tooling and the components by 14 months. Components design changes would have forced the staff to build new tooling, with further delay and increasing costs.

In order to cut on time and costs the company has opted for 3D printing, with FDM technology. Such technology brings huge advantages to the production of plastic parts with complex geometries. This new approach has allowed to meet the mechanical requirements for each part utilized  in the drone fuselage.

Thanks to expertise in Additive Manufacturing, use of professional 3D printing systems and to the high performance materials, the produced parts are capable of passing the needed tests, making the project a success.

The total parts production time is reduced from 14 months, with the traditional approach, down to 8 months, through 3D printing. Moreover, this innovative technology allows for cost savings of around 59%.

Leptron, choosing FDM technology, has performed many design changes without delaying the development time and without increasing costs.

The picture shows the RDASS 4 drone produced with FDM technology for Leptron.

Spring srl: the best 3D printing service bureau for aerospace companies

Spring srl is specialized on FDM technology. For over 20 years, Spring srl has worked with highly innovative companies. The technical staff is capable of supporting customers in co-design, to provide the best technical solutions. In order to meet the tough aerospace industry requirements, Spring srl has obtained the AS 9100. This certification is designed to meet the aerospace and defence industry on production of end-use parts. As of today, Spring works with the major players in the defence and aerospace field.

Click here to know some of our references.

Images: https://www.stratasys.com/it/resources/search/case-studies/leptron


Fabio Gualdo
22 November 2019
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Nowadays, thanks to the knowledge and expertise in state-of-the-art additive manufacturing technologies like fused deposition modelling (FDM), manufacturers can develop high-performance solutions.

One outstanding example is Genesis Systems Group, specialist manufacturer of robotic systems for welding and water-jet cutting.

The company needed to develop more high-performance positioning systems, so the technical staff decided to revolutionise their conventional approach to building components and try out the FDM process, using ULTEM 9085 to create their complex monolithic parts.

It was a success, bringing together the elements which help them reach their set project targets. These elements are:

·       Professional additive manufacturing systems

·       High-performance materials

·       Knowledge of the FDM technology

In the past, the company used to build their metal parts using conventional technologies and lead time was about 20 days. Today, thanks to the new solutions offered by additive manufacturing, parts are ready after only 3 days, with an 85% reduction in time and 94% in costs.

Another benefit of this new engineering approach is that it significantly reduces the weight of the finished component, now weighing only 1 kg compared to 15 kg.

SPRING Srl for production excellence

Spring Srl has been using additive manufacturing technologies for 20 years and its technical staff is the driving force behind the company. The technical skills which Spring brings to the table mean it can co-design components with its clients to deliver the best possible technological solutions.

Parts produced using FDM technology are of such a high quality standard they can be used repeatedly in production lines. Furthermore, top-performance production systems guarantee the quality of the manufactured parts and the repeatability of batches, as well as compliance with the requested specifications.

 

 

FDM automation industry

Spring Srl’s portfolio of plastics is extensive and some of the most effective materials it uses include: Ultem 9085, Ultem 1010, Nylon 12 CF, ABS-ESD7 and PEKK.

ULTEM 9085: Thermoplastic with a specific weight of 1.34, V0 flame-retardant, self-lubricating and certified for use in the aerospace industry.

ULTEM 1010: Thermoplastic with a specific weight of 1.27, V0 flame-retardant, high heat resistance (up to 216° C).

NYLON 12 CF: Thermoplastic with a blend of Nylon 12 and 35% carbon, specific weight of 1.15 and flexural strength of 142 MPa. Ideal for producing lightweight but very strong production equipment.

ABS-ESD7: Thermoplastic with static dissipative properties and a specific weight of 1.04. ABS-ESD7 prevents a build-up of static electricity and stops fine particles and powders sticking to it.

PEKK: Thermoplastic with very high chemical resistance and MIL-STD-810G certification. It is recommended for the automotive, aerospace, railway and oil and gas sectors to manufacture parts which come into contact with oil, fuel and hydraulic fluid.

To learn more about the materials used by Spring Srl, click here.

To sum up, choosing Spring Srl’s cutting-edge production systems and materials, combined with its outstanding know-how, will give you the edge over your competitors, thanks to new innovative solutions.


Fabio Gualdo
6 November 2019
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Over the next couple of years, passenger traffic will grow exponentially, forcing airlines to order thousands of new aircraft.

Major investments will be made primarily in innovating interiors. The solutions will not only offer passengers a positive flight experience but will also meet construction standards in terms of sturdiness, cost-effectiveness and reduced weight.

Interiors: the main areas of development
Peacock Suites by Paperclip Design can be transformed from a suite with two bedrooms into a family room with bunkbeds.

Redesigning interiors will lead to the creation of new modules for cabins, seating, onboard kitchens and bathrooms. The innovations will also include the air conditioning, electric, electronic cabin management, drinking water and waste systems.

Another interesting area of development is the in-flight entertainment and connectivity market. This sector includes software and design aimed at entertaining passengers as they travel.

The “windows” in the centre suites of the Emirates’ B777-300ERs are actually displays.
The dawn of a new age

Unlike other sectors, such as the consumer electronics market, whose regulations are less stringent, the aerospace industry is rather conservative. However, we are at the dawn of a new age which is witnessing widespread implementation of innovative technologies.

According to Airbus, amongst others, 3D printing will have a revolutionary effect on the sector. So, it is no surprise to learn that the company has introduced more than 2,700 3D-printed plastic parts in its A350 XWB.

3D printing with FDM technology

FDM technology is a 3D printing process. Thermoplastic material is heated and goes from a solid to a semi-liquid state, enabling adjacent layers to be welded together. The FDM technology used by Spring S.r.l gives a significant reduction in time, weight and costs compared to producing the same parts using more conventional methods. Furthermore, 3D printing can produce highly complex geometries. This technology opens up a new world of possibilities, meaning engineers can completely rethink every single object. These important benefits have caught the attention of the aerospace industry.

Spring S.r.l: the number one partner for the aerospace industry

Companies can benefit from the wealth of knowledge, know-how and expertise Spring S.r.l has built up in over 20 years in the additive manufacturing business. The level of excellence achieved by Spring in manufacturing parts for the aerospace industry has led to the company being awarded AS9100:2016 certification, designed to meet the strict requirements of the sector.

Choosing the experience of Spring gives companies the edge over their competitors, allowing them to place innovative products with high added value on the market.

Images taken from: https://www.aircraftinteriorsinternational.com/features/the-top-24-aircraft-innovations-to-watch-in-2019.html


Fabio Gualdo
30 August 2019
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For more than 20 years, prototyping and high-end production have been our core business. We use the latest cutting-edge 3D printing technologies (Additive Manufacturing).

3D printing is revolutionising product development in the fashion industry, and five aspects are the main focus of its interest:

1 – Product personalisation

2 – Prototyping

3 – Experimentation

4 – Production efficiency

5 – Cutting lead time

Product personalisation is the main objective of many companies, ranging from accessory to clothing manufacturers.

3D printing, which takes personalisation to the next level, is being used more and more to create products tailored to consumer tastes.

“We offer designers an extremely high degree of personalisation. There are hundreds of thousands of colour combinations we can experiment with on shoes, bags and eyewear. Innovative materials allow us to come up with new accessories. We invest our resources in expertise and this enables us to deliver consistently high results.” – Fabio Gualdo, owner.

The company has acquired a new production system called Stratasys J750. It enables highly qualified personnel to produce prototypes and products in multiple colours and materials.

“As a frontrunner in design and fashion, it’s no surprise that Italy is one of the leading adopters of the J750. The ability to produce ultra-realistic parts that match Pantone color standards and in a range of materials like no other, makes the J750 the only 3D printing technology that can truly deliver the needs of these industries. Spring is a testament to this – incredibly, buying its thirteenth 3D printer from us. With its impressive expertise in optimizing the use of additive manufacturing, we’re excited to see how Spring continues to push the boundaries of the technology with this latest addition.” – Giuseppe Cilia, Area Sales Manager, Stratasys.

Technological revolution

Being able to print multi-colour and multi-material objects is a recent accomplishment. Aesthetic prototyping was limited in what it could achieve and 3D models could only be produced in one colour or material. This was holding back innovation in the fashion world. The advances in additive manufacturing and the Stratasys J750 printer now enable Spring, one of the leading companies in the field in Europe, to produce multi-colour and multi-material prototypes. This is a milestone for the sector.

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New possibilities

This technology offers:

  • 360,000 combinations: There are 360,000 possible colour combinations which we can apply to your accessories.
  • PANTONE colours: To make life easier for you, we can use PANTONE certified colours.
  • Photographs and graphic designs: To take personalisation to the next level, we can print photographs and graphic designs on the surface of shoes, bags and eyewear.
  • Realistic textures: Let your touch talk. We can personalise the surface of your objects. Do you want your customers to feel the rough texture of wood? Or the wefts of a fabric? Thanks to us, you can.
  • Different materials: Want a transparent bag? Shoes in a rubber-like material? A pair of glasses with one temple in a rubbery material and the other one stiff? We can do all this, and a lot more besides.

Learn about all the materials, click here.

Source: Lushan Sun & Li Zhao (2018) Technology disruptions: exploring the changing roles of designers, makers, and users in the fashion industry, International Journal of Fashion Design, Technology and Education.

Images and video: Designers from Hong Kong presented a collection of shoes printed on Stratasys J750 printer – Wordy Boar


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