Aluminium PCBs - G4 LED bulbs in different Sizes, and Shapes

This technical guide examines aluminum PCB architecture, manufacturing processes, thermal characteristics, and implementation methodologies for optimal thermal performance in high-power electronic systems.

Aluminum PCB Design: Advanced Thermal Management Solutions for High-Power Electronics

In the ever-evolving landscape of precision engineering, engineers and product developers often face a crucial decision when selecting the most appropriate manufacturing method for their projects, and cost-effectiveness is often a primary concern. Electroforming has emerged as a preferable option due to its unique advantages that make it a more cost-effective choice than many other manufacturing methods in many scenarios.<h2 id="isPasted">getting to know Electroforming</h2>Electroforming is an&nbsp;<a href="https://www.vecoprecision.com/electroforming/what-is-electroforming/" rel="noopener" target="_blank">Additive&nbsp;M</a><a href="https://www.vecoprecision.com/electroforming/what-is-electroforming/" rel="noopener" target="_blank">anufacturing process</a> for the&nbsp;production of&nbsp;high-precision&nbsp;metal parts.&nbsp;It&nbsp;allows for the&nbsp;precision engineering&nbsp;of&nbsp;thin&nbsp;metal parts with&nbsp;complex&nbsp;designs and unmatched accuracy. At Veco, the feature size of&nbsp;<a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">Electroformed components</a> can be controlled down to the micron level, with accuracy as high as ±1 µm.As the world leader in Electroforming technology, Veco is the first in the industry to apply advanced Laser Direct Imaging technology (<a href="https://insights.vecoprecision.com/knol-edge-q3.-what-are-the-benefits-of-laser-direct-imaging" rel="noopener" target="_blank">learn more about the LDI technology</a>) in high-precision metal parts manufacturing. The combination of LDI and our world-leading Electroforming technology has enabled us to further push the boundaries of the industry with our Advanced Lithographic Electroforming, providing our customers with high-precision metal components of higher quality, at lower cost, and with quicker turnaround.<h2>Electroforming vs. 3D Printing:&nbsp;balancing&nbsp;precision&nbsp;and efficiency</h2>3D&nbsp;Printing is often praised for its rapid prototyping capabilities and low startup costs. However, for production runs beyond prototyping,&nbsp;Electroforming becomes&nbsp;the&nbsp;more cost-effective&nbsp;choice.&nbsp;While 3D printing might be faster for creating a single prototype,&nbsp;Electroforming can produce&nbsp;a large volume of&nbsp;parts&nbsp;in one run,&nbsp;significantly reducing&nbsp;per-unit costs. Additionally,&nbsp;high precision, high-quality components with ultra-smooth surfaces, clear edges, and high accuracy can be achieved, which might not be feasible with 3D Printing. Thus eliminating&nbsp;post-processing costs that are often necessary with 3D-printed parts.-&gt;&nbsp;<a href="https://insights.vecoprecision.com/electroforming-vs.-3d-printing-whats-the-difference" rel="noopener" target="_blank">learn more about Electroforming vs 3D Printing: Electroforming vs. 3D Printing: What's the Difference?</a><h2>Electroforming vs. Laser Cutting: the complexity factor</h2>Laser cutting is a versatile process that uses a laser to cut and engrave materials with high precision. It can be cost-effective for producing parts with relatively simple features but faces limitations when it comes to creating complex components with intricate details. As the complexity of a part increases, the production time required for laser cutting can significantly increase, as the laser beam must trace every contour and detail. Unlike Laser Cutting, Electroforming allows for the production of complex structures with fine details without additional cost or lead time.-&gt;&nbsp;<a href="https://insights.vecoprecision.com/electroforming-vs.-laser-cutting-whats-the-difference" rel="noopener" target="_blank">learn more about Electroforming vs Laser Cutting: Electroforming vs. Laser Cutting: What's the Difference?</a><h2>Electroforming vs. Stamping: when design flexibility matters</h2>Stamping is a widely used high-volume production method where flat metal sheets are formed into specific shapes using a die. It is generally a cost-effective approach for producing large quantities of simple components with uniform quality. However, the tooling costs associated with stamping can become substantial, particularly when dealing with complex features. Furthermore, the stamping process offers limited flexibility for design modifications, which can lead to additional tooling expenses. In contrast, Electroforming provides greater design flexibility without incurring extra costs, as modifications can be implemented without the need for new tooling.-&gt;&nbsp;<a href="https://insights.vecoprecision.com/electroforming-vs.-stamping-whats-the-difference" rel="noopener" target="_blank">learn more about Electroforming vs Stamping: Electroforming vs. Stamping: What's the Difference?</a><h2>Electroforming vs. Chemical Etching:&nbsp;precision and&nbsp;material&nbsp;efficiency</h2>Electroforming and chemical etching are both manufacturing processes used to produce&nbsp;<a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision</a><a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">&nbsp;metal parts</a>. However, the cost-effectiveness can vary due to their distinct characteristics.&nbsp;Chemical&nbsp;Etching&nbsp;is&nbsp;a&nbsp;Subtractive&nbsp;Manufacturing&nbsp;process&nbsp;where material is removed using chemical solutions to create precise, detailed components.&nbsp;During the subtractive process,&nbsp;more material waste&nbsp;can be generated, which&nbsp;can significantly impact costs when working with&nbsp;precious&nbsp;metals.&nbsp;Electroforming,&nbsp;as&nbsp;an&nbsp;Additive&nbsp;Manufacturing&nbsp;process, is much more material-efficient&nbsp;as the process&nbsp;deposits metal ions only where needed for the part&nbsp;and there’s no excess material to be cut away.&nbsp;-&gt;&nbsp;<a href="https://insights.vecoprecision.com/chemical-etching-or-electroforming-which-method-suits-your-goals" rel="noopener" target="_blank">learn more about Electroforming vs Chemical Etching: Electroforming vs. Chemical Etching: What's the Difference?</a><h2>Electroforming vs. Electroplating: Building versus&nbsp;Finishing</h2>Electroforming and&nbsp;Electroplating&nbsp;both involve the electrodeposition process,&nbsp;but&nbsp;they serve different purposes and have different cost implications.&nbsp;Electroplating is generally used to&nbsp;add coating to&nbsp;an existing part, often to improve surface&nbsp;performance such as wear resistance, corrosion resistance, or aesthetic appeal. While Electroplating can be cost-effective for adding a surface layer, Electroforming can lead to overall cost savings and improved supply chain efficiency by combining component creation and surface finishing into a single process.-&gt;&nbsp;<a href="https://insights.vecoprecision.com/electroplating-vs-electroforming-whats-the-difference" rel="noopener" target="_blank">learn more about Electroforming vs Electroplating: Electroforming vs. Electroplating: What's the Difference?</a>In conclusion,&nbsp;Electroforming is&nbsp;a&nbsp;cost-effective technique for producing high-precision metal components,&nbsp;outperforming&nbsp;traditional methods like 3D printing, laser cutting, stamping, chemical etching, and electroplating&nbsp;in many scenarios. Deciding when to choose&nbsp;Electroforming over other manufacturing methods depends on&nbsp;many&nbsp;factors, including the&nbsp;component&nbsp;complexity, precision&nbsp;level, production&nbsp;speed,&nbsp;design flexibility, etc.At Veco, our application engineering team is ready to assist you in evaluating your specific needs. We'll work with you to determine if Electroforming is the optimal choice for your project, ensuring the best balance between quality and cost. Talk to an engineer to explore how Electroforming can benefit your next precision metal component project.&nbsp;

This blog will explore when Electroforming might be the most cost-effective choice, compared to 3D Printing, Laser Cutting, Stamping, Chemical Etching, and Electroplating.

when to choose Electroforming over traditional manufacturing methods: a cost-effectiveness perspective

Laser techniques are also available, including selective laser sintering (SLS) and modelling (SLM). However, newer and more sophisticated processes like digital light printing or synthesis (DLP/DLS) may be set to change the outlook for mass production.<h2 dir="ltr">Additive Manufacturing</h2>Originally known as&nbsp;<a title="3D Printing In Manufacturing" href="https://www.rowse.co.uk/blog/post/3d-printing-in-manufacturing" target="_blank">additive manufacturing</a>, 3D printing is a process of creating products by building up a 3D object. It’s based on computer-aided design (CAD), and exploits a variety of different materials and novel technologies. Materials can include anything from natural fibres and metals to chemicals and advanced plastic polymers. The developing technologies are being assisted in some instances by artificial intelligence (AI).&nbsp;The latest advances are in the field of laser printing, where&nbsp;<a title="DLP/DLS" href="https://www.sciencedirect.com/topics/engineering/digital-light-processing" rel="nofollow" target="_blank">DLP/DLS</a> is proving very innovative in producing objects in the biomedical field, such as sterilisable, organic parts like replacement organs. It’s even possible to use thermoset resins with DLP technologies to print foam structures, for products in the sporting goods, footwear, furnishing and automotive industries. With no tooling required, you can print closed-cell foam parts in much more complex designs, that will not only perform better but also reduce waste.<h3 dir="ltr">RAPID PROTOTYPING CAN ACCELERATE PRODUCTION</h3>During the early design stages of creating new products, it’s critical to have functional prototypes so you can see whether various aspects are going to work or not. Previously, you would have had to outsource the production of prototypes, which could be very time-consuming. If you adopt 3D printing methods instead, you can produce prototypes in-house. With 3D-printed rapid prototyping, you can create physical models very quickly to inspect for design flaws and functionality, then incorporate changes in repeated iterations until you get it right. All this is much faster and more cost-effective than the traditional method.<h3 dir="ltr">HYBRIDISATION</h3>Another way in which additive manufacturing is speeding up the production process is with hybridisation. This means that you still use traditional manufacturing methods, but deploy 3D printers&nbsp;<a title="3D Printing Trends" href="https://www.rowse.co.uk/blog/post/3d-printing-trends" rel="nofollow" target="_blank">to create the necessary setup</a>. For example, you can print the required moulds for injection moulding techniques, or finish precision parts with CNC machining.&nbsp;The most innovative new techniques – especially DLP/S – are capable of producing vast quantities of high-quality, end-user items. A good example of this is the printing of soles for training shoes, where one company’s patented tech has contributed to producing more than 100,000 pairs of trainers in a single year.<h3 dir="ltr">ADAPTABILITY</h3>Additive manufacturing is extremely customisable, with a constantly expanding range of materials and techniques. You might want to print the same item in different materials, to determine which demonstrates the better functionality or cost-effectiveness, or create hybrids with more than one material. It’s also extremely adaptable and is being tested for its compatibility with new technologies.You might combine it with digital twinning to <a title="3D Printing Obsolete Parts" href="https://www.rowse.co.uk/blog/post/3d-printing-obsolete-parts" target="_blank">reproduce obsolete parts</a> or use it to manufacture novel components like art objects or mathematical models. You might create and combine 3D printed products with smart Industry 4.0 equipment. For example, you can integrate 3D printing software with AI to improve print calibration and fine-tune slicer settings.&nbsp;<h2 dir="ltr">Advantages Of 3D Printing In High-Volume Production</h2>Once you have tested and finalised a working prototype, you can ramp up your manufacturing volume in various ways. Speeding up your tooling processes with printed moulds or casts gives you greater production flexibility. Individual or brand customisation also contributes to your flexibility and increases the affordability of products for customers. Things like printing custom soles for a given brand of trainers mean you can achieve higher volumes and get your product more quickly to market.<h3 dir="ltr">HIGH-SPEED MANUFACTURING PROCESSES</h3>Because it’s all digital, 3D printing technology can print products with extremely complex shapes and geometries. DLP/S, for instance, uses the properties of UV light and oxygen operating on photopolymer resins to print organic and biocompatible parts. In the DLS process patented by one market-leading company, UV images of an object are cast through an oxygen-permeable window into a photopolymer reservoir, where the layers are gradually built up, then cured in ovens to produce printed parts.<h3 dir="ltr">DESIGN FLEXIBILITY</h3>DLP processes enable you to create production-ready parts within days rather than weeks. You can use a wide range of rigid or elastomeric thermoset materials such as plastics, resins and composites. These achieve extraordinary resolution, mechanical properties and surface finish. Instead of needing to produce and combine several components for a particular part, you can consolidate them into one printed item, which also speeds up production.<h3 dir="ltr">ON-DEMAND PRODUCTION</h3>Although additive manufacturing processes offer great advantages for prototyping unusual or custom parts, the latest developments in DLP are much better suited for volume repeat production. Digital products have endless iteration potential, combined with AI-driven controls to ensure quality. Once any design is finalised, you can use it to create a digital inventory. This will allow you to switch to on-demand production and reduce your time to market.<h2 dir="ltr">Mass Production For Your 3D Printing Budget</h2>3D printing requires an initial investment in hardware, software and materials. Once you’ve assessed which printing technologies best suit your needs, chosen your materials and adapted any necessary processes, you can streamline the manufacturing process to achieve better and faster results. Manufacturers who have already upgraded to automated systems and networked services will be able to achieve savings and scalability when higher volume production runs are established.The 3D printing horizon is constantly advancing and we’re beginning to see new potential for high-volume manufacturing. More and different techniques are being developed, allowing business owners to choose from a myriad of options that might open the door to mass production. At this stage of technological development, you might want to subscribe to a leasing programme while you figure out what works best for you.

3D printing hasn’t been viable up to now as a technology for mass production. It’s still in the early stages of development and different processes are still being formulated. 

Is 3D Printing Used In Mass Manufacturing?

In our digitally connected world, seamless integration and communication between devices are not just conveniences but necessities to ensure the success of businesses, whether just starting out or firmly established.The collaboration between Monogoto and Xyte introduces a groundbreaking solution in device management and connectivity. This partnership leverages Monogoto’s robust software-defined connectivity and Xyte’s comprehensive device management capabilities to create a unified platform—Xyte Anywhere. This platform is designed not only to streamline device operations but to enrich the end-user experience with reliability and innovation at its core. As detailed in&nbsp;<a href="https://www.youtube.com/watch?v=u-K44sh9ax8" data-wpel-link="external" target="_blank" rel="external noopener noreferrer">our recent webinar</a>, this collaboration isn’t just about enhancing product capabilities—it’s about transforming devices into service platforms.<h2>Enhancing User Experiences Across Industries</h2>The real-world advantages of the Monogoto and Xyte partnership are demonstrated through its diverse applications across multiple industry sectors. Here are specific examples of how their combined capabilities transform everyday operations and user interactions:<h3>Corporate Digital Signage</h3>In corporate settings, digital signage is crucial for internal communications. With Xyte Anywhere, companies can deploy signage solutions that are instantly connected and managed remotely, bypassing traditional IT setup challenges. This not only speeds up deployment but also ensures that content updates are swift and seamless, enhancing the way information is shared across campuses.<h3>Professional Audio and Video</h3>For the professional audio and video industry, reliable device management is vital. Xyte Anywhere enables remote monitoring and updates, which are essential for events and installations that depend on the flawless operation of audiovisual equipment. This reduces downtime and improves the delivery of media content, directly benefiting event managers and attendees by providing a smoother, uninterrupted experience.<h3>Industrial Automation</h3>In the field of industrial automation, connectivity and remote management are key to ensuring machinery and devices operate without interruption. Xyte Anywhere’s capabilities allow for continuous monitoring and immediate troubleshooting from remote locations, significantly reducing response times to malfunctions and maintaining high levels of productivity.<h2>Driving Business Innovation and Revenue</h2>Beyond improving operational efficiencies, the partnership between Monogoto and Xyte facilitates new business models for device manufacturers. By transforming devices into service platforms, manufacturers can unlock recurring revenue streams through subscriptions and as-a-service models. This shift not only increases profitability but also fosters long-term customer relationships by continuously providing value beyond the initial sale.<h2>A Future-Ready Connectivity Solution</h2>As industries continue to evolve, the demand for integrated and efficient device connectivity solutions grows. Monogoto and Xyte’s partnership is a proactive response to this demand, providing a scalable and robust platform that supports the future needs of businesses and their customers.<h2>Embrace the Connectivity Revolution</h2>For stakeholders in industries ranging from manufacturing to corporate communication and beyond, adopting the Monogoto and Xyte solution means not just keeping pace with technological advancements but leading the charge. Businesses are encouraged to leverage these innovations to enhance their product offerings, improve customer satisfaction, and explore new markets. In essence, the partnership between Monogoto and Xyte isn’t just about technological integration—it’s about redefining how businesses interact with technology to create more dynamic, responsive, and user-centric environments. As we look to a future where connectivity is increasingly synonymous with productivity and innovation, embracing this partnership could be your strategic step towards a more connected and successful enterprise.Device manufacturers and businesses looking to stay ahead in the digital curve are invited to explore the possibilities that this partnership offers. Embrace the future of connectivity with Monogoto and Xyte, and unlock new growth opportunities for your business. Contact us today to learn more about how our solutions can empower your devices and drive your business forward.

In our digitally connected world, seamless integration and communication between devices are not just conveniences but necessities to ensure the success of businesses, whether just starting out or firmly established.

How Transforming Devices into Service Platforms Creates More Revenue for Your Business

This article offers an in-depth view of PVD coating in semiconductors, their underlying technology, materials, and applications crucial in today's rapidly evolving technological landscape.

PVD Coating in Semiconductors: A Comprehensive Guide

InDro Robotics is excited to introduce <a href="https://indrorobotics.ca/indroforge/" target="_blank" rel="noopener noreferrer">InDro Forge</a>, a cutting-edge prototyping and custom fabrication facility, situated in Ottawa. Formerly operated by <a href="https://www.investottawa.ca" target="_blank" rel="noopener noreferrer">Invest Ottawa</a> as the Bayview Yards Prototyping Lab, InDro Forge is now under the operation of InDro Robotics. &nbsp;The facility is a &lsquo;one stop shop&rsquo; for entrepreneurs and small to medium enterprises (SMEs) seeking the custom design and fabrication of prototypes.What sets InDro Forge apart is its impressive array of state-of-the-art tools and machinery, all conveniently housed under one roof. From metal 3D printing to CNC machining, silicone and urethane casting, and more, InDro Forge offers a comprehensive suite of capabilities. &nbsp;The facility features a variety of tools for additive and subtractive manufacturing along with a team with the requisite expertise.Several of the machines that distinguish InDro Forge are:<a href="https://markforged.com/3d-printers/metal-x?utm_source=google&utm_medium=paid-search&utm_campaign=11016475879&utm_content=116935563540&utm_term=metal%20x&gclid=Cj0KCQjw9rSoBhCiARIsAFOiplnGIpNm-uY8cQzD7jQMwh4onClUfu-M0rMr4biuUoWAiuiJretqerAaAmMpEALw_wcB" target="_blank">Markforged Metal X 3D Printer</a>Maximum Part Size: 235 mm x 68 mm x 66 mmMaterials: Stainless Steel, Copper, Inconel, Tool SteelsUnique Advantages:<ul type="disc"><li>When part geometries require large of amounts of waste in removing material through traditional processes, or are not possible through common subtractive machining, the Metal X shines. &nbsp;By 3D printing only the material needed and some support, the amount of material waste is limited and impossible geometries become available.</li><li>Sometimes parts need to be metal due to their environments instead of the metals mechanical properties. &nbsp;When this is the case, the Metal X allows for low density parts similar to common FDM printing.</li><li>To generate high quality finished parts there are a number of post or in-process finishing opportunities, these might include engraving part information prior to sintering or using traditional machine tools to improve the geometric accuracy of critical features after printing.</li></ul>&nbsp;<a href="https://www.omax.com/sites/default/files/2021-08/omax-a-jet-600050b_0.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Omax Tilt-Head Waterjet</a>Maximum Material Size: &nbsp;120&rdquo; &nbsp;x 60&rdquo; x 4&rdquo;Materials: Ferrous and Non-Ferrous Metals, Ceramics, Woods, PlasticsUnique Advantages:<ul type="disc"><li>Because of its rapid and accurate cutting capabilities, it allows for low-cost 2D blanks of more complex parts to be made and then moved to other machinery such as the CNC Mill, Hydraulic Break for CNC Laser for finishing.</li><li>The A-jet tilt-head function allows the head to maintain square edges regardless of material thickness or adding simple or continuously changing bevels to the edges of parts. &nbsp;A common example of this is adding hole chamfers directly into the part while cutting to reduce post-processing.</li><li>Capable of working with materials anywhere from 1/8&rdquo; Glass or Alumina Ceramic all the way up to 4&rdquo; Steel, there are few materials which this machine can&rsquo;t cut reliably and precisely.</li></ul>&nbsp;<a href="https://bigrep.com/lp/professional-3d-printer/?utm_source=google&utm_medium=cpc&utm_campaign=NA-Products&utm_content=ONE&gad=1&gclid=Cj0KCQjw9rSoBhCiARIsAFOipllG_EQoskl10Uxup1idiHJUkdDxKnmH06XC2DJOGBvMSjXPeaWcyKEaArBDEALw_wcB" target="_blank">BigRep One Large Format 3D Printer</a>Maximum Print Size: 105 cm^3Materials: PLA, PETG, Hi-Temp, TPU<ul type="disc"><li>When the part you need is bigger than your average 3D printer is capable of, but it doesn&rsquo;t make sense to deal with the high start-up cost of injection moulding, vacuum forming or casting, the BigRep One is ready to deliver.</li><li>It&rsquo;s large format allows for the printing of large enclosure or similar complex structural components which are needed to validate fit, form or function of a design.</li></ul><hr>While the lab has traditionally excelled in the realm of rapid prototyping, it now extends its expertise to a broader scope. Inventors, startups and SMEs, can walk through the door with an idea, be it for proof of concept, Minimum Viable Products (MVPs), or functional models to showcase to potential investors.Working with InDro Forge&#39;s skilled staff, clients receive a full-fledged industrial design that is then fabricated in any one (or combination) of a number of materials. &nbsp;The 3D printer alone can work with some 25 substances, including ABS and metal.Check out 3D printers <a href="https://indrorobotics.ca/wp-content/uploads/2023/09/3D-Printers-1.pdf" target="_blank" rel="noopener noreferrer" data-lf-fd-inspected-kn9eq4roawkarlvp="true">HERE</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjY3NDgxNzU1LTUxYTdiZGZhLWNiOWYtNGFlMS1hY2IyLTFjNGUzYTQzNzU5MS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 302px;" class="fr-fic fr-dib"><h2>Rapid Prototyping and More</h2>InDro Forge is an all-in-one- solution for companies that don&rsquo;t have the equipment, time or expertise to carry out this highly specialised work.With InDro Robotics at the helm, the synergy between InDro Forge and the <a href="https://areaxo.com" target="_blank" rel="noopener noreferrer">Area X.O</a> engineering team promises significant advances. InDro Forge will be able to draw on the expertise in aerial and ground robotics from our core R&amp;D engineering hub, while InDro Robotics adds the design and fabrication capabilities of Forge to its portfolio of services. What&rsquo;s more, InDro envisions expanding its offerings to include limited production runs and custom fabrication services.&ldquo;We see the value when people come to us with a napkin sketch and leave with a physical prototype they can show investors,&rdquo; says InDro Forge&rsquo;s Pablo Arzate, an industrial designer with special expertise in additive manufacturing.Below: Advanced capabilities include a water jet machine, capable of slicing through several inches of steel.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjY3NTgyNTcyLUpvZWwgVG9tIFdhdGVyamV0IENCWTA1MTE2LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"><h2>The InDro Forge Advantage</h2>InDro Forge is equipped with a&nbsp;wide array of additive and subtractive manufacturing capabilities, including:<ul><li>CNC machining</li><li>Silicone and urethane casting</li><li>Multi-element 3D printing (including metal)</li><li>Electronics and Printed Circuit Board fabrication and analysis&nbsp;</li></ul>View the full equipment list <a href="https://indrorobotics.ca/wp-content/uploads/2023/09/Full-Equipment-List.pdf" target="_blank" rel="noopener noreferrer" data-lf-fd-inspected-kn9eq4roawkarlvp="true">HERE</a>.The facility&#39;s machinery and capabilities are complemented by a team of highly skilled experts in industrial design and engineering, many of whom have years of experience in various fabrication processes.&nbsp;For those seeking custom and complex fabrication, the InDro Forge advantage is clear. The facility caters to diverse needs, from one-off prototypes to comprehensive product development. It transforms rough ideas into refined, functional prototypes, bridging the gap between concept and product. InDro Forge&#39;s expertise is invaluable for those seeking to realize their innovative visions.&ldquo;If you don&rsquo;t have these machines at your disposal, it&rsquo;s definitely great to find a place with the expertise to help you out,&rdquo; says O&rsquo;Leary. &nbsp;&ldquo;If you don&rsquo;t have these capabilities, then we are here to help create the thing that you&rsquo;re looking to create. &nbsp;We&rsquo;re set up to help anybody who comes in with anything from an engineering project to a napkin drawing.&rdquo;InDro Forge offers services ranging from one-off prototypes to full product development.&ldquo;Some of our other clients come to us where they have an early prototype that they&rsquo;ve cobbled together. It tells them that their idea is possible but it&rsquo;s not a product yet,&rdquo; says Joel Koscielski. &ldquo;So we&rsquo;ll help them turn that into a more refined version of itself. We might do one of those, we might do five &ndash; even 25.&rdquo;Projects can be big &ndash; or small.&ldquo;Sometimes it&rsquo;s just that extra bit of capacity &ndash; they themselves have never had to make a sheet metal box that looks good,&rdquo; adds Koscielski.<hr><h3>When asked about their favorite machines, team members at InDro Forge had compelling insights:</h3>Pablo Arzate highlighted the Markforged II, praising its precision and versatility in 3D printing, especially its ability to fabricate parts with carbon fiber and nylon, opening up a world of possibilities for product development and rapid prototyping. The Markforged II&nbsp;specs:<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjY5NDg2NTczLU1hcmtmb3JnZWQgMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"> Tom O&rsquo;Leary&#39;s favorite machine is the water jet, capable of cutting through various materials with precision, akin to a &quot;calligraphy pen with immense pressure,&quot; making it a versatile tool for shaping materials. &nbsp;The water jet specs:<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1NjY5OTY5MTAxLVdhdGVyamV0IFNwZWNzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 766px;" class="fr-fic fr-dib">Joel Koscielski also lauded the Markforged Mark II 3D Printer for its use of carbon fiber-reinforced nylon composite material, a true workhorse of innovation that produces high-quality, functional parts suitable for sales and demonstration purposes.<hr>InDro Robotics considers the operation of InDro Forge a significant milestone. With a strong vision for the future, the company aims to serve a broad spectrum of clients, both large and small. In the words of CEO Philip Reece, &quot;This is really just such a logical fit for InDro Robotics. Whether it&#39;s working with new clients or assisting our own, InDro Forge has all the right stuff &ndash; including the right people.&quot;For more information on InDro Forge and its comprehensive capabilities, please visit <a href="https://indrorobotics.ca/indroforge/" target="_blank" rel="noopener noreferrer">www.indrorobotics.com/indroforge/</a>.

InDro Robotics expands with InDro Forge

Prototyping, Custom Fabrication and Production

Authors:Kai Keller &lt;kai.keller@notion-systems.com&gt; and Lina M&auml;rzThis article originally appeared<a href="https://www.techblick.com/post/inkjet-printing-of-solder-mask-notion-systems" target="_blank" rel="noopener noreferrer"> here. </a><h3>Introduction:</h3>There are three big topics that shape the production environment of today and tomorrow: digitalization, additive manufacturing, and preserving natural resources/zero waste.&nbsp;Very tightly timed supply chains and globally distributed and connected production processes are already real and only possible because of digitalization. Additive manufacturing knocks on the door of many industrial areas, such as automotive and aerospace. Preserving natural resources and zero waste will become standard in many areas and will be the financially most convenient opportunity.&nbsp;Printed circuit boards (PCBs) are manufactured mainly in Asia but distributed just-in-time all over the world. In our laptops, cars, trains, planes, TV&#39;s, audio systems, mobile phones, we all use dozens of them every day, without even realizing it. The recent stress that has been put on these supply chains also lead to investments into new facilities in North America, Europe, as well as South East Asia. So many decision makers in electronics manufacturing are currently concerned with the question which technologies they are going to use for the newly built facilities.Today, the production process for PCBs is mainly subtractive, indicating that lots of expensive resources are wasted, are not reused, and eventually increase the costs.&nbsp;This means PCB manufacturing is at home in a global, digital world but will eventually suffer from subtractive processing, waste of resources, and more complex applications and layouts.&nbsp;Inkjet printing by nature is a digital technology, from image processing to discrete droplet deposition.It is also an additive manufacturing technology. Expensive materials are only deposited where they are needed, and even the amount of material can be adjusted locally. Three dimensional structures are possible without any extra effort.&nbsp;This indicates that inkjet printing is preserving resources and minimizing waste.&nbsp;This article will describe the process of applying a solder mask layer by means of inkjet printing in the PCB production. It will briefly describe a PCB and outline the benefits that inkjet printing brings. This will be followed by a detailed description of the steps that were necessary to establish a stable industrial process.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzc3NjU3MDg1LU5vdGlvbiBTeXN0ZW1zIChCRVJMSU4tT2N0LTIwMjMpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 644px;" class="fr-fic fr-dib">&nbsp;Join us at TechBlick&#39;s Future of Electroncis RESHAPED conference &amp; tradeshow in Berlin on 17-18 OCT 2023 - www.techblick.com/electronicsreshapedWhy Inkjet Printing for Deposition of Solder Mask on PCB&#39;s?Typically, a uniform solder mask layer is deposited by a coating technology such as curtain coating or screen printing. Also, dry films are available. All have in common that they cover the whole board. After a drying step, the design is transferred onto the board via a photo mask. For each design, an own photo mask needs to be created. Alternatively, direct imaging processes with a laser are used. After illumination, the dried film is developed, and the unwanted areas are stripped and washed away. A final curing step is performed in order to achieve the full functionality. Typically, this consists of a so-called UV bump and thermal curing in a belt oven.&nbsp;By summing up all the equipment needed, it&#39;s no wonder that a single production line can easily be dozens of meters long and requires a lot of staff with different skills.&nbsp;The inkjet technology in contrast locally deposits the UV-sensitive material and pins it in-situ with an LED lamp. The image is loaded digitally and can be changed after each board and even be adjusted to each board individually. It is saved digitally and does not use any footprint. After the same final cure from the conventional process, the board is finished. This indicates that PCB manufacturers can drastically reduce the amount of production steps that translates in less investment cost and space for machinery and less consumption of electricity and consumables and therefore a very fast return on investment. Figure 1 shows the process flows of the conventional and the inkjet process.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzc3NzA3ODI2LVNjcmVlbnNob3QgMjAyMy0wOS0xNSAwNzMxNTAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 540px;" class="fr-fic fr-dib">Besides, these economic and environmental aspects inkjet exclusively opens the door to a unique combination of other features that gives the PCB production industry a new level of freedom. This allows the industry to be prepared for new applications such as high frequency and 5G. Figure 2 shows an inkjet printed solder mask on a PCB and gives an overview of some unique features.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzc3NzQ3NjA1LVNjcmVlbnNob3QgMjAyMy0wOS0xNSAwNzMyNDkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 478px;" class="fr-fic fr-dib">In contrast to the conventional deposition technologies, where the layer thickness is the same over the whole board, with inkjet printing, the thickness can be adjusted locally without any extra effort. There are a lot of reasons why this is beneficial for the PCB manufacturing process. Let us name three:- &nbsp; &nbsp;Thickness zero, i.e., no solder mask where it is not required, in order to safe material or increase process stability. - &nbsp; &nbsp;A locally adapted thickness to ease subsequent SMD assembly. - &nbsp; &nbsp;Higher thickness at conductor or pad edges to reach higher break-through voltages. In a summary, the main advantages are as follows: &bull; &nbsp; &nbsp;Digital production technology &bull; &nbsp; &nbsp;Additive manufacturing allows for locally adjustable thickness of layers &bull; &nbsp; &nbsp;New features are possible &bull; &nbsp; &nbsp;Labeling functions come for free &bull; &nbsp; &nbsp;Up to 80% less ink, as it is only print where required &bull; &nbsp; &nbsp;Higher yield &bull; &nbsp; &nbsp;Reduced space &bull; &nbsp; &nbsp;Reduced energy consumption &bull; &nbsp; &nbsp;Very fast return on investment <h3>What Are the Requirements and What Makes Inkjet Printing of Solder Mask Tricky?</h3>The requirements of the solder mask are defined in several norms, mainly by the IPC &ndash; Association Connecting Electronics Industries. IPC originated from Institute for Printed Circuits.We will now describe some challenges that one faces when depositing a solder mask onto a PCB by means of inkjet printing.&nbsp;First of all, the solder mask ink itself is a sophisticated material. Actually, one has to develop two materials. As an ink, it needs to have a very low viscosity, must be a Newtonian fluid, and must allow for perfect jetting in the tiny nozzles. After curing, the material needs to be extremely stable to mechanical impact and withstand harsh temperature cycles (-30 &deg;C to +170 &deg;C) and strong chemicals, e.g., during Ni-Au plating.Another point is the surface. A board when it just arrives to the solder mask deposition consists of two different surfaces: the glass fiber compound (FR4) and the copper (Cu).&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzg3MDI3NTA5LU5vdGlvbiBTeXN0ZW1zLWJvb3RoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 531px;" class="fr-fic fr-dib">Join us at TechBlick&#39;s Future of Electronics RESHAPED conference &amp; tradeshow in Berlin on 17-18 OCT 2023 - www.techblick.com/electronicsreshapedUnfortunately, the surface energy of these areas largely differ. While the ink stays quite well on FR4, it spreads tremendously on Cu.&nbsp;In addition, the height difference between FR4 and Cu can be more than 200 &mu;m. This can have a large impact on the deposition accuracy.&nbsp;Every PCB job is different. This indicates that PCBs can vary in size and thickness. Because of previous production processes, they can have bows and warpages and because of the still often manual handling even kinks. As if this was not enough, PCBs have many holes of different radii ranging from 0.1 mm up to 5 mm, of course randomly distributed over the whole area. Still, for a good performance, often absolute drop placement accuracies in the range of &plusmn; 20 &mu;m are required. This calls for highest demands in the substrate table design and the jetting performance.&nbsp;The requirements and properties of the solder resist and the printed solder resist layer are anchored in IPC-SM-840. Properties can be verified using selected test methods. The test procedure and instructions for carrying it out can be found in the test manual IPC-TM-650. Typically, the properties are divided there into visual, physical, electrical, mechanical, and chemical properties/requirements.<h2>How to Get to Inkjet Printed PCB&#39;s</h2>To realize the application of inkjet printing, the solder mask onto PCB&#39;s different aspects have to be taken into account, such as the choice of ink and printheads, the process development, and the machine design. Figure 3 gives an overview of typical factors that define the process and printing machine. Although the overview is generic, most of the items are relevant for the inkjet solder mask process.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzc3ODE2NTU4LVNjcmVlbnNob3QgMjAyMy0wOS0xNSAwNzMzMzUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 656px;" class="fr-fic fr-dib">The process development of each application follows the following route:&nbsp;&bull; &nbsp; &nbsp;Printhead selection &bull; &nbsp; &nbsp;Ink selection &amp; material compatibility &bull; &nbsp; &nbsp;Waveform development &bull; &nbsp; &nbsp;Print process implementation &bull; &nbsp; &nbsp;System development (optional) &bull; &nbsp; &nbsp;On-site process supportIt is a common misconception, especially in time-critical projects, to take the second or third step before the first. Maybe it is possible to produce a nice appearing PCB for a proof of concept, but in production, stability and more importantly predictability are crucial.&nbsp;Solid results based on systematic and repeatable tests are helping to identify the process window, maximize customer satisfaction, and to reduce costly field operations.<h3>Data Handling</h3>In the PCB industry, gerber is the dominating file format. Like in any other area, the conversion from vector data to discrete/digital images comes at the expense of truth to detail. Photoplotters and lasers both have this loss, but as they are operating in the range of several 10 000 of dpis, the artifacts are small. For inkjet printing, with feature sizes in the range of 30 to 80 &mu;m and resolutions in a similar range, more care has to be taken for converting the print images.&nbsp;Figure 4 visualizes the challenge. The raster image processor has to make a discrete decision based on the vector layout and the printing resolution, whether it generates a printed dot or not. For low printing resolutions, this can lead to artifacts, such as visible steps and missing dots. A high resolution would increase the level of detail but would lead to an overflow of ink or increased thickness. We have developed a conversion algorithm that considers the vector file, the real drop diameter on the substrate, and the printing resolution and adjusts the droplets in such way that the maximal level of detail can be achieved without increasing the resolution and thus not compromising throughput.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzc3ODc2MTYxLVNjcmVlbnNob3QgMjAyMy0wOS0xNSAwNzM0MTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 571px;" class="fr-fic fr-dib">As mentioned before, conventional solder mask processes are subtractive, indicating that the full board is covered with ink and then structured. This indicates that the appearance and the geometry of inkjet-printed structures are by nature different. If one would now just use the conventional processing recipes, the result would be far from optimal. This is why, for inkjet, new design rules needed to be developed in close cooperation between technology providers, like Notion Systems and technology users, our partners, and clients. This ensures that the printed result looks more alike their conventional counterparts.<h2>Machine Concept</h2>At Notion Systems, we have developed a machine concept, that is shown in Figure 5 that can be used either in manual mode or be upgraded to operate fully automated with load and unload. Our print unit covers the full substrate width with up to 20 000 nozzles, each firing more than 20 000 tiny droplets per second. The vacuum table is designed in a way that it can hold different sizes of PCBs without any mechanical clamps.&nbsp;An integrated and automated non-contact cleaning system ensures that the printheads are always in good condition. The machine is easy to operate and is designed so that all important parts can be reached easily.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzc3OTE5OTE0LVNjcmVlbnNob3QgMjAyMy0wOS0xNSAwNzM0NDcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 667px;" class="fr-fic fr-dib"><h2 id="isPasted">Print Images</h2>Figures 6-10 show some examples of inkjet-printed solder masks structures. They highlight what is possible today.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzg3Mzg2NjI3LVNjcmVlbnNob3QgMjAyMy0wOS0xNSAxNDUwMTMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 608px;" class="fr-fic fr-dib"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzg3NDI5NzIxLVNjcmVlbnNob3QgMjAyMy0wOS0xNSAxNTAzMzgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 256px;" class="fr-fic fr-dib"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzg3NDQ3MTcxLVNjcmVlbnNob3QgMjAyMy0wOS0xNSAxNTAzNDcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 256px;" class="fr-fic fr-dib"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzg3NDY2OTAxLVNjcmVlbnNob3QgMjAyMy0wOS0xNSAxNTAzNTQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 250px;" class="fr-fic fr-dib">Summary and Outlook The solder mask on a PCB is perfectly suited for inkjet printing. The reduction of production steps decreases the cost and space requirements. Inkjet printing produces results that meet all requirements specified in the relevant norm for solder mask IPC 840. In addition, inkjet printing enables the implementation of useful and in its combination unique features, such as no mask in holes, locally adjusted thickness, or smart labeling. Yet, soldermask is not the end of the story, there are many more subtractive processes in electronics manufacturing that need a closer look and possibly a replacement, if one considers what is possible with additive processes in general and inkjet technology in particular, today.<h3 id="isPasted"><a data-hook="linkViewer" href="https://www.techblick.com/electronicsreshaped" target="_blank" rel="noopener noreferrer">Join us and the global community in Berlin on 17-18 OCT 2023</a> and let us together RESHAPE the Future of Electronics, making it Additive, Sustainable, Hybrid, Wearable, or 3D.&nbsp;</h3> <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0Nzg3NTM0NjgzLTIuQWdlbmRhLUV4aGliaXRpb24tTE9HT1MtKEJFUkxJTi0yMDIzKS1zbWFsbC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 702px;" class="fr-fic fr-dib">

There are three big topics that shape the production environment of today and tomorrow: digitalization, additive manufacturing, and preserving natural resources/zero waste. Learn how inkjet printing achieves these in PCB manufacturing. 

Inkjet Printing of Solder Mask

Demystifying Overmolding: A New Approach with the APSX-PIM&nbsp;In the dynamic manufacturing realm, innovations often redefine conventional processes, leading to improved outcomes and enhanced efficiency. One such transformation can be observed in overmolding applications, where the <a href="https://www.apsx.com/desktop-injection-molding-machine" target="_blank" rel="noopener noreferrer">APSX-PIM injection molding machine</a> challenges the traditional myth associated with vertical injection molding machines. Let&#39;s explore how the APSX-PIM is changing overmolding by offering a new approach and efficient solution.&nbsp;Rethinking Overmolding with the APSX-PIM&nbsp;Historically, vertical injection molding machines have been the go-to choice for overmolding applications. The reasoning behind this preference lies in the idea that gravity assists in ensuring seamless adhesion of the overmolded material to the existing substrate.&nbsp;Introducing the APSX-PIM: A New Overmolding Paradigm&nbsp;The APSX-PIM, an innovative horizontal injection molding machine, has emerged as a transformative solution for overmolding applications. Unlike traditional vertical machines, the APSX-PIM introduces a fresh perspective, addressing the shortcomings and inefficiencies of the conventional approach.The APSX-PIM suggests using magnets behind the mold to hold the overmolded metals. The user can place the metal parts in specifically designed slots because the magnets behind them are strong enough to hold them precisely. For plastic parts, a snapping mechanism can be used instead of magnets.&nbsp;Advantages of the APSX-PIM for Overmolding&nbsp;Versatile Design: The horizontal configuration of the APSX-PIM allows for more flexible mold designs and adaptability, accommodating diverse overmolding projects.Space Efficiency: The compact footprint of the APSX-PIM optimizes floor space in manufacturing facilities, contributing to a more efficient workspace layout.Simplified Maintenance: The modular design of the APSX-PIM streamlines maintenance procedures, minimizing downtime and ensuring consistent production.Cost-Effective Operation: APSX-PIM&#39;s cost-effectiveness in terms of initial investment and ongoing operational expenses positions it as an attractive option for various business scales.&nbsp;Illustrating the APSX-PIM Approach to OvermoldingConsider a scenario where an ergonomic plastic grip needs to be overmolded onto a metal part. The APSX-PIM&#39;s approach to this process is outlined below:Material Selection: Choose compatible materials for the metal part and the overmolded grip, considering material compatibility, adhesion, and desired properties.Mold Design: Develop a mold design that accommodates the metal part and integrates necessary injection channels. The horizontal orientation of the APSX-PIM facilitates straightforward mold designs.Injection Process: Load the selected materials into the APSX-PIM&#39;s hopper. Configure injection parameters like temperature, pressure, and cycle time based on material specifications.Injection and Cooling: The APSX-PIM injects the molten plastic material over the metal part. The horizontal setup promotes uniform material distribution and efficient cooling.Completed cycle: After the overmolded part solidifies, the mold opens, and the finished product can be picked up.&nbsp;The APSX-PIM&#39;s novel approach to overmolding showcases its advantages over traditional vertical injection molding machines. Through its horizontal design, simplified maintenance, and cost-effective operation, the APSX-PIM demonstrates how it can streamline overmolding processes.&nbsp;ConclusionThe APSX-PIM challenges the status quo by offering a fresh outlook on overmolding, countering the notion that vertical injection molding machines are the sole solution. As industries evolve, embracing such advancements can lead to a more streamlined, adaptable, and cost-efficient overmolding process.

Innovations often redefine conventional processes, leading to improved outcomes.

Demystifying Overmolding: A New Approach with the APSX-PIM

On 12 July, Unitree unveiled its latest quadruped robot - the Unitree Go2, which features embodied AI technology, standard 4D ultra-wide LiDAR and GPT empowerment. This product is expected to revolutionize the consumer-grade quadruped robots industry, leading to a transformation of the sector.  

Revolution: A New Quadruped Robot of Embodied AI

Have you sacrificed many good product design features because you thought you could not make a specific precision part or it would be too expensive to outsource? That&rsquo;s ok because traditionally, it was the norm when we only had large, sophisticated, and expensive industrial machines. Not anymore since the introduction of the <a href="https://www.apsx.com/apsx-machines-compact" rel="noopener noreferrer" target="_blank">desktop machinery concept</a> hit the market. Let me explain further.In the rapidly evolving field of manufacturing, adopting advanced machining technologies is paramount for achieving precision, efficiency, and cost-effectiveness in manufacturing processes. While traditional, large-sized Swiss lathes have long been the standard for machining high-precision, turned small parts with small diameters, the emergence of desktop Swiss CNC lathes such as the APSX-NANO (costs less than $10K) has opened new avenues for machinists to expand their capabilities while simultaneously reducing outsourcing costs. This article delves deeper into the technical aspects and benefits of using a desktop Swiss CNC lathe over a traditional-sized Swiss lathe, focusing on reasons such as time savings, material efficiency through remnant utilization, extended tolerance ranges, and elimination of secondary operations.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688574931645-Outsourcing-vs-In-House-Production.jpg" style="width: 428px;" class="fr-fic fr-dib">In addition to the advantages over traditional-sized Swiss lathes, a desktop Swiss CNC lathe offers compelling benefits compared to outsourcing part production to a machine shop. This article will also delve into the advantages of in-house production using a desktop Swiss CNC lathe, focusing on cost savings, increased control, flexibility, faster turnaround times, confidentiality and intellectual property protection, and the potential for innovation and skill development.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688574953248-SwissCNCLathe-Large.jpg" style="width: 494px;" class="fr-fic fr-dib"><h3 id="isPasted">Why desktop size has advantages over regular-size Swiss lathes?</h3>Simplified Setup for Small Quantities: Small quantity needs can be too much hassle for large Swiss lathe setup and programming times. One significant advantage of desktop Swiss CNC lathes is the simplified setup process for small-quantity production runs. In contrast to traditional machining methods, which often involve complex and time-consuming setup procedures for large Swiss lathes, desktop Swiss CNC lathes streamline the setup and programming requirements. This enables engineers to swiftly transition from design to production, saving valuable time and resources.Time and Operation Efficiency: Time savings compared to regular CNC machines by reducing the number of operations and machine changeovers. Desktop Swiss CNC lathes are designed to save more time than regular CNC machines by minimizing the number of operations and machine changeovers. By integrating advanced automation features and efficient tooling, these machines can perform multiple operations within a single setup, significantly reducing production lead times. This enhanced efficiency empowers engineers to meet stringent project deadlines and improve productivity.Material savings by using remnants out of regular Swiss lathes: Using remnants from regular Swiss lathes is a significant advantage offered by desktop Swiss CNC lathes. In traditional machining processes, material remnants are often discarded due to insufficient length for further machining operations. However, desktop Swiss CNC lathes can effectively utilize these remnants, minimizing waste and optimizing material usage. This feature reduces material costs and contributes to sustainable manufacturing practices. You can also use precision ground bar stocks from the market. Even if you do not need to use the whole bar, you can spare it for another project.Good tolerance ranges for your precision targets: Desktop Swiss CNC lathes offer engineers ample tolerance ranges to meet their precision targets. Swiss machines&#39; distinctive sliding headstock and guide bushing enable precise machining of different diameters, complex holes, hex edges, slots, and threads without requiring multiple setups or additional equipment. This capability ensures that engineers achieve their machined components&#39; desired precision and dimensional accuracy, even for highly intricate designs.Eliminate secondary operations by using live tools for milling and drilling: The integration of live tooling in desktop Swiss CNC lathes allows engineers to eliminate the need for secondary operations. Live tools enable milling and drilling operations to be performed directly on the machine, eliminating the requirement for additional equipment or setups. This streamlining of processes saves time and enhances overall machining accuracy and consistency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688574980383-APSX-NANO-CNC-SWISS_8.jpg" style="width: 300px;" class="fr-fic fr-dib"><h3 id="isPasted">Reasons to Opt for In-House Production</h3>One of the primary benefits of using a desktop Swiss CNC lathe in-house is the potential for significant cost savings. Outsourcing part production to a machine shop often incurs substantial costs, including markups on labor and materials, transportation expenses, and additional fees for setup and programming. By bringing production in-house with a desktop Swiss CNC lathe, these costs can be greatly reduced or eliminated altogether. The initial investment in the machine can be quickly recovered through long-term cost savings, especially for projects involving regular small-scale production runs.Increased Control and Flexibility: Maintaining control over the production process is crucial for ensuring quality, precision, and timely delivery of parts. Using a desktop Swiss CNC lathe in-house gives engineers and machinists full control over every aspect of production, from design to final machining. This level of control allows for greater flexibility in adapting to design changes, accommodating urgent orders, and making adjustments to meet specific requirements. Making real-time modifications and optimizations can result in higher-quality parts and improved overall performance.Faster Turnaround Times: Outsourcing part production to a machine shop often delays the production timeline. The need to communicate design specifications, coordinate with the machine shop&#39;s schedule, and account for shipping and delivery times can add significant lead times to the project. In contrast, using a desktop Swiss CNC lathe in-house allows for faster turnaround times. Design changes can be implemented immediately, and production can begin without external dependencies. This accelerated timeline enables engineers to meet tight deadlines and respond quickly to market demands.Confidentiality and Protection of Intellectual Property: Outsourcing part production may pose risks to intellectual property and design confidentiality. Sharing sensitive designs and proprietary information with external vendors can introduce the potential for unauthorized use or leakage of valuable intellectual property. By utilizing a desktop Swiss CNC lathe in-house, companies can maintain strict control over their designs and protect their intellectual property. This ensures that confidential information remains secure and minimizes the risk of competitors gaining access to proprietary knowledge.Potential for Innovation and Skill Development: Bringing part production in-house with a desktop Swiss CNC lathe presents an opportunity for innovation and skill development within the organization. Operating the machine internally allows engineers to explore new design possibilities, test innovative techniques, and iterate on prototypes more efficiently. The close proximity to the production process fosters a deeper understanding of the machining principles and enables engineers to enhance their skills and expertise. This continuous learning and development contribute to the company&#39;s long-term growth and competitiveness.<h3>Why a Swiss CNC is better than a traditional CNC lathe</h3>While traditional CNC lathes offer their own advantages, Swiss CNC lathes excel in specific areas in traditional and desktop sizes. Swiss turning is a process used for machining high-precision, turned small parts with small diameters. Swiss lathes&#39; sliding headstock and guide bushing system are key differentiating factors. Its sliding headstock and guide bushing set Swiss machines apart from other turning machines. The sliding headstock feeds the bar stock through a guide bushing (z-axis), which supports and stabilizes the bar stock near the cutting point. This helps prevent workpiece distortion and enables the machine to accurately create different diameters, complex holes, hex edges, slots, and threads without the need for multiple setups or additional equipment.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688575007394-20220112_FR_Render_Turning_Swiss_02-1024x576.png" style="width: 300px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688575017710-20220112_FR_Render_Turning_01-1024x576.png" style="width: 300px;" class="fr-fic fr-dib">In contrast, traditional CNC lathes lack the sliding headstock feature and are more suited for larger parts and different machining requirements.Swiss machines are also better suited for machining long parts than traditional CNC turning machines, as they are less likely to cause deflections. Industrial Swiss lathes can machine the other side of the part by using the secondary sub-spindle and chuck once the regular machining operation is done. The desktop Swiss CNC lathe may not have these capabilities.<h3>Industry applications for Swiss machining</h3>Swiss machining was initially used to create the tiny, intricate parts used in watches, and it&rsquo;s still used to create long, small, or slender turned components across various industries.In the defense sector, Swiss machining&#39;s high accuracy makes it ideal for manufacturing small, complex geometries with tight tolerances required for military hardware.The medical industry benefits from Swiss machining&#39;s precision capabilities in producing components such as electrodes, anchors, and surgical tools. Precision machining processes are well suited for components such as complex hinges, pull rings, anchors, and electrodes and components for various medical instruments and devices in the diagnostic, surgical, and drug delivery fields.Aerospace applications include the production of components with extreme precision, ranging from mechanical parts for spacecraft motors to electrical components for cockpit controls.The automotive industry utilizes Swiss machining for fabricating bushings, pins, brake systems, and suspension components.Additionally, the electronics industry relies on Swiss CNC machined parts for communication, defense, and electronic equipment, such as fine-threaded screws, lens housings, mounts, and connectors.&nbsp;<h3>The Cost Considerations for Traditional Large Swiss CNC Lathes</h3>Operating traditional Swiss CNC lathes can be cost-intensive due to their technologically advanced controls and high-precision capabilities. Additional expenses associated with regular-size Swiss lathes include:<ol><li>PREP WORK FOR THE GRIPPER: Bar stock diameter reduction and chamfering processes must be performed before loading into the machine.</li><li>CENTERLESS GROUND BAR STOCKS: The length of bars is too long and gets expensive to be grinded for precision ground operation. Otherwise, the entire Swiss CNC operation would stop in case of a small jamming instance. The bar can not be too small either because it will be wiggled inside the guide bushing, deteriorate the surface finish, or break the cutting tools.</li><li>WASTED MATERIAL DURING THE WARM-UP: Draft parts are typically produced during the warm-up phase, and most of them are discarded.</li><li>CLEANING THE CHIP TANKS: Regular cleaning of chip tanks is necessary to prevent clogging of pumps and avoid expensive repairs. The machining area must also be kept free of accumulated chips to prevent jamming.</li><li>OIL CONTAMINATION: The oil coolant used in Swiss lathes can adhere to parts, machine handles, and surfaces, requiring daily cleaning to maintain optimal performance.</li><li>UNNECESSARY SPEED FOR LOW-VOLUME PRODUCTION: The high speed of traditional Swiss lathes may not be cost-effective for low-volume production. The total cost of owning a Swiss lathe can be substantial, considering additional expenses such as transportation, mist collectors, oil drums, bar feeders, and pressurized oil systems. What if you make a part in 20 seconds in a traditional Swiss machine vs. in 60 seconds in a Swiss desktop lathe? Do your math to justify the cost of a machine. They can cost $300K minimum when you add optional items to operate efficiently. That&rsquo;s not always the end of the story. Things add up. You must also pay thousands of dollars for transportation to your job floor. The mist collector can be at least $5K. You pay about $2K for a drum of oil constantly. The bar feeder mechanism can cost you about $20K, which is required for a Swiss lathe. Another $10K for the pressurized oil system must be added to your system for a proper cooling process.</li><li>RISK OF FIRE: Machining materials like titanium and stainless steel using hot and pressurized oil coolant pose a fire hazard. Fire extinguisher systems may be required to mitigate this risk, incurring additional costs. You may be required to pay a minimum of $10K for a fire extinguisher system.</li><li>SETUP and PROGRAMMING TIME: Traditional Swiss lathes often require extensive setup time, including accurate programming, which can take days before production can commence.</li><li>LABOR COST: Skilled operators are needed to handle the entire Swiss lathe process, including programming, setup, machining, and <a href="https://www.apsx.com/5-tips-for-swiss-cnc-lathe-operators" target="_blank">troubleshooting</a>, resulting in higher labor costs.</li></ol>These cost considerations emphasize the potential financial and operational advantages offered by desktop Swiss CNC lathes, which may present a more cost-effective solution for engineering applications, especially for projects involving smaller quantities or specialized requirements. The labor cost, setup time, fire risk, contamination-free parts, and material waste savings are possible with desktop Swiss CNC lathes.<h3>Conclusion</h3>The emergence of desktop Swiss CNC lathes has opened up new horizons for engineering professionals seeking to enhance their capabilities and reduce outsourcing costs. With benefits such as simplified setup and programming, time and operation efficiency, material savings, good tolerance ranges, and eliminating secondary operations, desktop Swiss CNC lathes offer a compelling solution for engineers working with regular-sized Swiss lathes or traditional CNC lathes. While traditional-sized Swiss lathes continue to play a crucial role in precision manufacturing, the unique features and cost considerations associated with desktop Swiss CNC lathes make them an attractive option for engineering professionals aiming to optimize performance and reduce overall expenses.While the benefits of using a desktop Swiss CNC lathe over traditional-sized Swiss lathes are substantial, opting for in-house production with this portable machine also offers advantages over outsourcing to a machine shop. Cost savings, increased control and flexibility, faster turnaround times, confidentiality and protection of intellectual property, and the potential for innovation and skill development are key factors that make in-house production a compelling choice. By investing in a desktop Swiss CNC lathe, companies can streamline their production processes, improve quality control, and position themselves for long-term success. <h3 id="isPasted">References:</h3>What it takes to operate a Swiss lathe (<a href="https://youtu.be/F_HZS_QKNmE" target="_blank">https://youtu.be/F_HZS_QKNmE</a>)Complete guide to CNC Swiss machining (<a href="https://www.fastradius.com/resources/complete-guide-cnc-swiss-machining/" target="_blank">https://www.fastradius.com/resources/complete-guide-cnc-swiss-machining/</a>)5 Tips for Swiss CNC Lathe Operators (<a href="https://www.apsx.com/5-tips-for-swiss-cnc-lathe-operators" target="_blank">https://www.apsx.com/5-tips-for-swiss-cnc-lathe-operators</a>)Discover APSX Machines: COMPACT (<a href="https://www.apsx.com/apsx-machines-compact" target="_blank">https://www.apsx.com/apsx-machines-compact</a>)

The desktop Swiss CNC lathe will open a new opportunity window for you to expand your capabilities and reduce your outsourcing cost. 

The Advantages of a Desktop Swiss CNC lathe

With its reasonable print quality, heated bed, and tiny price tag, the Creality Ender 3 FDM 3D printer is the go-to machine for 3D printing hobbyists and DIYers. However, one of its main limitations is its fairly small build volume.Although Creality sells some larger printers such as the Creality CR-10, many users prefer the Ender 3 (and its V2/Pro variants) for its low price and familiarity. So they have naturally sought after ways to maximize or extend the build area of the budget machine via firmware and hardware modifications.This article looks at how to exploit the entire print surface of the Ender 3 without investing in a bigger printer.<h1 dir="ltr">Ender 3 dimensions</h1>According to Creality’s official website, the Ender 3 (and the V2/Pro) has a print area of 220 x 220 x 250 mm.[1] However, if you get out your ruler, you’ll find that the Ender 3 print bed dimensions are 235 x 235 mm.The full machine size of the Ender 3 varies by model:<ul><li dir="ltr">Ender 3: 440 x 440 x 465 mm</li><li dir="ltr">Ender 3 V2: 475 x 470 x 620 mm</li><li dir="ltr">Ender 3 Pro: 440 x 420 x 465 mm</li></ul><h1 dir="ltr">Difference between Ender 3 bed size and print area explained</h1>The difference between the Ender 3, Ender 3 Pro, and Ender 3 V2 bed size and print area is, as we can see from the dimensions above, 15 mm on both the X and Y axes. In other words, every edge of the bed has 7.5 mm of unprintable space. But why is this?<h2 dir="ltr">Clips</h2>The principal reason why the print volume of the Ender 3 differs from the actual dimensions of the build plate is clips.The Ender 3’s removable build plate is attached to the print bed with standard office binder clips, which encroach upon the usable area of the build plate. Accordingly, Creality has written the 220 x 220 mm print size into its firmware, helpfully preventing users from printing over those clips and getting failed prints.The problem here — and the reason why many Ender 3 users have been tackling this issue for years — is that you don’t have to use clips to attach a build surface if you swap out the Creality-supplied equipment with a replacement. In fact, the Ender 3 Pro actually ships with a magnetic build surface.It’s also possible to use clips that are more compact than binder clips, freeing up more potential printing space around the edges of the build surface. Alternatively, users may only put clips on two of the four sides of the bed, giving them something like 220 x 235 mm of potentially usable print area.<h2 dir="ltr">Extra allowance</h2>The other reason why Creality adds 15 mm of buffer on the X and Y axes is to anticipate misalignment and other errors that could cause the printhead to deposit material off the edge of the print bed.Just as a 2D printer prints within a margin to avoid printing over the edge of the page, a 3D printer works best when it isn’t instructed to print right up against the edge of the build surface.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc3MjIyNzAxNDMxLTNkX3ByaW50ZXJfbm96emxlLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="Ender printhead">The Ender 3 has a buffer zone so it doesn't print off the edge of the bed<h1 dir="ltr">How to increase the print area of the Ender 3</h1>If 220 x 220 mm won’t cut it for your prints, there are a few ways to increase the Ender 3, Ender 3 Pro, and Ender 3 V2 bed size (or simply exploit more of it), though the most effective ways may be unsuitable for beginners. The three possible strategies involve adjustments to firmware, hardware, and slicing software.<h2 dir="ltr">Firmware upgrade</h2>The Ender 3 print area of 220 x 220 mm is specified in the 3D printer’s firmware — the basic machine software that enables the hardware to function. This means that you can’t just tell your slicing software to print over and above these limits: the firmware will tell the machine that such an action is impossible.Fortunately, if you’ve made physical space at the edge of your build surface (by swapping the clips for smaller ones, for example, or replacing the build surface with a magnetic one), you can update your Ender 3 firmware to specify a larger build area, permitting marginally bigger prints.The Creality-installed firmware can’t be modified, so you’ll need to replace it with either Marlin or Jyers firmware. This is easier to do with the Ender 3 V2 because it comes with a pre-installed bootloader, but is trickier with the other models.The <a href="https://github.com/Jyers" target="_blank">Jyers Github page</a> contains several optimized versions of Marlin firmware that can be flashed onto the Ender 3 V2 using a micro SD card. This process replaces the Creality firmware with Jyers firmware, which permits changing of the print volume.Although it is possible to specify a print size of 235 x 235 mm, most users will stick to 230 x 230 mm, which still adds a significant 10 mm to the X and Y axes without running the risk of failed prints.<h2 dir="ltr">Physical bed extension</h2>If you’re desperately trying to squeeze another 10–15 mm out of your X and Y axes, chances are the Ender 3 bed might simply be too small for you.Fortunately, it is possible to modify the printer and physically extend its print bed. Again, this is much easier with the Ender 3 V2, as a physical bed extension will require a firmware upgrade and adjustment of parameters so the printer knows how much bed area it has to print on.Products like the Ender Extender and Endzilla are kits that allow for DIY replacement of the print bed, typically containing parts like a new build plate, frame parts, screws, washers, and nuts.With such a modification, the Ender 3 V2 bed size can be increased. Both the Ender Extender and Endzilla brands have kits that boost the Ender 3 (V2/Pro) bed size to 400 x 400 mm — much larger than the original dimensions, and also larger than any printer in Creality’s Ender range.One obvious drawback of this approach is the price of a bed extender. The Ender Extender 400 currently sells for $179, taking the total price of the printer plus the modification to almost $400. At that point, buyers might consider buying a larger printer.<h2 dir="ltr">Priming and skirt settings</h2>A slicer such as Cura can’t trick your Ender 3 into printing beyond its 220 x 220 mm boundary. However, if your settings aren’t configured the way you want them, you might be getting even less printing area than that.The key settings to look into here are skirt settings. In Cura, skirt parameters fall under Build Plate Adhesion settings in Print Setup. In 3D printing, a skirt is an outline of extruded filament that goes around the printed part but doesn’t actually connect to it. It is principally used to prime the extruder and ensure that the printhead is depositing material smoothly and evenly before it begins extrusion for the actual part.[2]Although useful, skirts reduce the printable area, because they must fully surround the printed part. Reducing the skirt line count to 1 or even 0 may be necessary in order to exploit the full size of the print surface.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc3MjIyNzUyNTUyLXNraXJ0cy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="skirts">Printed parts with thin skirts surrounding themRecommended reading: <a href="https://www.wevolver.com/article/best-ender-3-pro-cura-settings-temperature-speed-retraction-more" target="_blank">Best Ender 3 (Pro) Cura settings: temperature, speed, retraction, more</a><h1 dir="ltr">Creality 3D printers size chart</h1>Within the Creality Ender range, the larger build areas can be found in the various “Plus” and “Max” models. Newer models with the “Neo” tag tend to have a similar or identical build volume to their specific predecessor but with additional features.Within the wider Creality range, large-format printers like the CR-10 Max ( &nbsp; &nbsp;450 x 450 x 470 mm) offer even larger print areas but at significantly higher prices.<div align="left" dir="ltr"><table><tbody><tr><td> </td><td>Ender 3</td><td>Ender 3 V2</td><td>Ender 3 Pro</td><td>Ender 3 S1</td><td>Ender 3 S1 Plus</td><td>Ender 3 Max</td><td>Ender 5 Pro</td><td>Ender 5 Plus</td><td>Ender 7</td></tr><tr><td>Print area (mm)</td><td>220 x 220 x 250</td><td>220 x 220 x 250</td><td>220 x 220 x 250</td><td>220 x 220 x 270</td><td>300 x 300 x 300</td><td>300 x 300 x 340</td><td>220 x 220 x 300</td><td>350 x 350 x 400</td><td>250 x 250 x 300</td></tr><tr><td>Price ($)</td><td>189&nbsp;</td><td>208</td><td>236</td><td>329</td><td>529</td><td>259</td><td>399</td><td>579</td><td>489</td></tr></tbody></table></div><h1 dir="ltr">Key takeaways</h1>Hands-on users of the Ender 3 might feel that a firmware upgrade and small or large physical modification of the printer is well worth it to achieve larger builds. Beginners and casual users, on the other hand, might find it more trouble than it’s worth.Recommended reading: <a href="https://www.wevolver.com/article/petg-vs-pla-how-do-they-compare" target="_blank">PETG vs PLA: How do they compare?</a><h1 dir="ltr">References</h1>[1] Ender-3 3D printer [Internet]. Creality. [cited 2023Feb21]. Available from: <a href="https://www.creality.com/products/ender-3-3d-printer" target="_blank" rel="noopener noreferrer">https://www.creality.com/products/ender-3-3d-printer</a>[2] Dave HK, Patel ST. Introduction to Fused Deposition Modeling Based 3D Printing Process. Fused Deposition Modeling Based 3D Printing. 2021:1-21.

Creality Ender 3 users can extend their build area

The Creality Ender 3 and its V2/Pro variants have a stated print area of 220 x 220 mm, but the actual bed dimensions are 235 x 235 mm. So can you print right up to the edges or not?

Ender 3 (V2,Pro) Bed Size: What You Need to Know

Veco's Advanced Lithographic Electroforming process is a unique combination of unparalleled electroforming industry experience, advanced lithography technology and in-depth knowledge of metallurgy. It includes 6 steps.1) Cleaning A sheet substrate is cleaned and degreased. 2) Coating The cleaned metal "raw part" is then coated with a light-sensitive photoresist. 3) Exposure The metal sheet is then exposed to ultraviolet light which cures the photoresist layer. 4) Development After the image has been transferred by UV exposure, the substrate is developed, rinsed and dried. 5) Deposition An electrolytic bath is used to deposit metal onto the patterned surface. 6) Removal The electroformed part can be removed from the substrate after the material has been plated to the desired thickness. 7) Inspection Comprehensive inspection by experts.

Electroforming: Additive Manufacturing Atom by Atom

Electroforming is an additive manufacturing process specialized for the production of high precision metal parts. Its uniqueness is that you can grow metal parts atom by atom, providing extreme accuracy and high aspect ratios.

Advanced Lithographic Electroforming: process animation step by step

Julio Aleman, a Bioengineering PhD student at the University of Pittsburgh Swanson School of Engineering is performing research in microphysiological systems.Like many researchers, Aleman needed a microwell array system with individual wells that have a specific size, shape and density. In fact, Aleman needed two different microwell arrays that would support the injection moulding of hydrogels and serve as “master moulds” – the original moulds that he could replicate. In turn, these replicate moulds would be used for microwell fabrication. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869692139-PittsburghCaseStudy2.png">Hydrogel mould of 484-microwell arrayTo produce master moulds like this, photolithography (optical lithography or UV lithography) is often used. The process begins by spin coating a negative photoresist on a wafer to establish mould thickness and microwell depth. Photopatterning is achieved by light exposure through specialised high-resolution masks and finalised by chemical development of the master mould. Then, replicas of the master mould are made by casting pre-polymers over the negative template and polymerising them by thermal curing.Polydimethylsiloxane (PDMS) silicone is the biocompatible polymer that is most often used. Typically, the production of master moulds and masks requires specialised facilities and equipment. Micro-injection moulding can also produce master moulds, but the tooling is expensive and time-consuming to produce. <h1>An Alternative to Clean Room Photolithographic and Injection Moulding</h1>Projection Micro Stereolithography (PμSL) from Boston Micro Fabrication (BMF) allows for the rapid photo-polymerisation of a layer of resin with a flash of ultraviolet (UV) light at micro-scale resolution. PμSL offers an alternative to photosoft lithography, etching, deposition, micro-injection moulding, and other traditional microfabrication methods.PμSL, a form of micro 3D printing, can produce small components with fine features and tight tolerances that are otherwise impossible to create. PμSL is capable of achieving a resolution of 2µm~50µm and a tolerance of +/- 5µm~25µm, thus providing ultra-high-resolution that is mould-free and mask-free for fast prototyping and end-use parts.  <h1>Project Requirements for Two Master Moulds</h1>The University of Pittsburgh project needed master moulds for replicate silicone moulds that, in turn, would be used to make biomaterial-based microwells. Normally, master moulds require a cleanroom and can be challenging to characterise. Researchers can’t perform profilometer measurements until the moulds are baked, and a mould with the wrong dimensions means lost time and money.Julio Aleman’s project required fast turnaround times and high-volume production. Accuracy, resolution, and precision were critically important. Several PDMS replicas that were cured at 80° Celsius were needed and the repeated processes on the master mould had to have little to no impact on the dimensions while the master mould was also securely fixed in a substrate. Aleman knew that he would need moulds in two different sizes, and that the silicone moulds should allow for the bottoms of the hydrogel micro-wells to have constant and defined amounts of biomaterial once injected and polymerized onto a glass slide. After some preliminary discussions, he ordered parts from BMF.The master moulds that the University of Pittsburgh asked BMF to produce were square with a defined hole–pattern. The first mould was for a 64-microwell array. It had an overall area of 20 mm x 20 mm and a thickness of 1.65 mm. The diameter for each hole and the distance between holes was 600 microns, or 0.6 mm, and the base of each of the microwells had a height of 50 microns from the surface. The second mould was for a 484-microwell array. The overall area was the same as for the first mould (20 mm x 20 mm), but the thickness for the second mould was significantly less at 1 mm. There were also more holes – and the holes were smaller. These wells measured just 150 microns, or 0.15 mm, in diameter with a similar base height of 50 microns.3D printed mould for 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869775020-PittsburghCaseStudy3.png">3D printed mould for 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869800497-PittsburghCaseStudy4.png">3D printed mould for 484-microwell array<h1>Expert Advice and Flexible Material Selection</h1>BMF’s application team reviewed the designs for the University of Pittsburgh moulds. They recommended increasing the thickness of the second mould to greater than 1 mm. Otherwise, a mould that is too thin may experience part distortion or internal stresses during the printing process. Aleman revised the thickness and BMF then created sample parts using GR resin, a high-performance engineering material that is black in colour, able to withstand temperatures up to 102°C, and that supports sterilising.Because the COVID-19 pandemic limited Aleman’s access to university facilities, the graduate researcher limited his mould evaluation to microscopy. In turn, this meant that parts made of a dark resin would be more difficult to inspect. To support microscopic techniques, Aleman needed a resin that would allow more light to pass through so that the features of the resin mould could be more clearly seen. The solution was to use an HLT resin instead. This yellow resin from BMF offers greater transparency but still provides good impact strength, heat resistance, and support for autoclave sterilisation.<h1> </h1><h1>Speed, Accuracy and More</h1>&nbsp;Julio Aleman was pleased with the quick lead time – the moulds were delivered in just two weeks. Instead of waiting months to get a single injection-mould, he could provide a master mould to each member of the research team. The moulds also exhibited dimensional stability and, unlike spin coating in photolithography, did not require multiple fabrication steps. After hard baking some master moulds in an oven overnight, Aleman attached them to a surface with double-sided electrical tape. The moulds experienced only a 10 to 20-micrometre reduction in size, and that may have been caused by pressing the moulds against the surface or the tape while the moulds were still malleable from baking.Aleman also reported that after approximately 10 cycles of PDMS moulding, the BMF master moulds did not exhibit any bending or deformation. To prevent sticking, the replicate moulds were salinated with Vapor Phase Deposition (VPD). This treatment, which is also used with the SU8 moulds in photolithography, permitted the easy detachment of the PDMS moulds from the BMF master moulds. Aleman reported that the master mould with the larger features was easily salinated over one hour of exposure while the mould with smaller features required five hours or overnight exposure.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869860170-PittsburghCaseStudy5.png">PDMS replica of 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869888883-PittsburghCaseStudy6.png">PDMS replica of 484-microwell array<h1> </h1><h1>Proof-of-Concept for Your Next Project&nbsp;</h1>As the University of Pittsburgh project demonstrates, researchers can use micro 3D printing to speed microwell array fabrication. If your application requires proof-of-concept parts such as master moulds, BMF can harness the power of PμSL technology on your behalf. We can also help you with material selection and recommend the best microArch printer from our growing family of ultra-high resolution 3D printers.In an exclusive partnership with BMF, CREATE Education are sharing their knowledge, support and experience, to bring micro 3D printing technology to the forefront of their education community in the UK and Ireland, enabling breakthrough research and development.CREATE Education are committed to supporting educators, educational institutions, outreach and community programs with the aim to bring cutting edge technologies throughout the world, such as 3D printers, into education.To learn more about PμSL technology and micro 3D Printing for research, please contact <a href="https://bit.ly/ContactCREATEEd" rel="noopener noreferrer" target="_blank">CREATE Education’s specialists</a>.

Julio Aleman, a Bioengineering PhD student needed two different microwell array system with individual wells that would support injection moulding of hydrogels and serve as “master moulds”

low-cost fabrication

Profiles