Optical LSR is a transparent and flexible thermoset material that is increasingly replacing glass in various optical applications. Discover more about it in this Insight video.

What is Optical Liquid Silicone Rubber (LSR) ?

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of the additive manufacturing space as a cost-efficient, reliable and flexible tool that is changing how people and companies view workflow optimization and production uptimes.One of the key areas where&nbsp;<a href="https://ultimaker.com/">UltiMaker’s 3D printing solutions</a> are being leveraged is in manufacturing components with complex geometries(including lattices or internal channels), small production runs and various tooling, jigs, and fixtures used to improve existing traditional manufacturing workflows. Let’s dive into some of the key benefits that 3D printing provides and go over some application examples:<h2>Reducing material waste</h2>When compared to traditional subtractive manufacturing methods such as milling or CNC routing, which will always result in wasted material as part of the part-shaping process, 3D printers will only use as much material as needed for the part, layer by layer. This is further compounded when taking into consideration complex assemblies that often require The ability to produce parts as needed translates directly into reduced costs associated with maintaining large inventories.<h2>Accelerated prototyping and iterations</h2>UltiMaker allows companies to exponentially increase the speed with which they can prototype, test, and refine designs. This is done without needing to rely on expensive external suppliers, which, as we’ve seen in recent years, are vulnerable to supply chain delays or interruptions.Global brands such as <a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">Heineken have ensured production continuity with 3D printing</a> and decreased lead times (by as much as nine months) and production costs by 3D printing spare parts for their packaging and assembly machinery.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216290885-1733216290885.png" class="fr-fic fr-dib"><h2 id="isPasted">Eliminating tooling costs</h2>Traditional manufacturing methods often require expensive molds, dies, or tooling for each part design and more and more manufacturers are turning to 3D printing technologies to create mold inserts, assembly aids and jigs in order to streamline their production. With a market value estimated at over $73.60 billion the tooling application area is one of the fastest growing: whereas only 37% of manufacturers reported using additive manufacturing for tooling in 2019 that number grew to 57% in 2021.UltiMaker 3D printers allowed companies like <a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa to produce tools and fixtures in-house</a> and within two years see assembly-tooling cost savings increased from 70% to 95% (saving an estimated $375,000 per year).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216309556-3d-printed-wheel-protection-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">In fact, the ability to tune in and dynamically address the needs of operators working on production lines by creating various custom jigs and fixtures allows companies to streamline processes, enhance precision, and reduce the risk of human error. With more and more customer success stories such as Audi Sport’s implementation of UltiMaker’s 3D printing technology to<a href="https://ultimaker.com/learn/audi-sport-3d-printed-tools-jigs-and-fixtures-in-a-day-instead-of-weeks/" id="isPasted">&nbsp;create almost 200 new tools, jigs and fixtures</a> or <a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/">ERIKS’s improvement to their manufacturing process</a>, it’s evident that additive manufacturing is one of the key investments for businesses that want to stay ahead of the curve.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216327298-1733216327298.png" class="fr-fic fr-dib"><h2 id="isPasted">On-demand manufacturing</h2>UltiMaker's accessible ecosystem enables distributed manufacturing for custom or low-volume parts. Businesses print just-in-time components instead of mass-producing and storing potentially unused inventory and with over 200+ materials available on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> we’re already seeing costly metal parts like conveyor infeed worms being replaced.This is especially relevant when taking into consideration situations where certain machine parts can no longer be sourced as 3D printing allows manufacturers to reverse engineer obsolete parts and far extend the lifespan of existing legacy systems. Just ask one of our clients Trivium, who turned to 3D printing replacement parts for their automated packaging lines.If possible insert an image with the infeed worm that Trivium 3D printed or maybe grab a still from the video with the part being used in the production line?<h2>Easy to implement, easy to scale</h2>Leveraging 3D printing in production processes is also incredibly easy especially when compared to traditional manufacturing techniques that require experienced engineers and designers to create and operate the complex tooling involved which often comes with complicated specialized software that not only adds to the cost but technical expertise as well.With UltiMaker the design process is easily accessible through the various CAD softwares available (with some versions having a reduced learning curve) with the chief advantage being the ability to directly translate a CAD design into a 3D printed prototype faster than with any of the traditional methods currently available.Coupled with an unparalleled scaling capability through distributed manufacturing, a single engineer can upload 3D parts in Digital Factory making it available in any of the connected locations for localized production as the operation of the 3D printer itself is extremely simple.<h2>The future of manufacturing</h2>From rapid prototyping to on-demand production, 3D printing is reshaping the way manufacturers innovate, save costs, decrease lead times, maintain production uptimes, and minimize waste. If you’re looking to leverage the unique benefits of 3D printing, the Ultimaker Factor 4 printer combines state-of-the-art features with unmatched reliability, empowering your business to achieve more with less.

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of additive manufacturing as a cost-efficient, reliable, and flexible tool that is changing how companies view workflow optimization and production uptimes.

Benefits of 3D Printing in Manufacturing

The Royal Netherlands Navy has a rich history and a modern edge. With a vast fleet of ships, helicopters, boats, and submarines, they are a global presence, often stationed far from home on challenging missions. Their commitment to excellence and innovation keeps them at the forefront of maritime defense.<h2>Spare part and logistical challenges</h2>The Royal Netherlands Navy faces the significant challenge of maintaining their fleet, wherever they are. Their assets often require spare parts, presenting a logistical dilemma. Carrying large quantities of unused spares consumes valuable space, adds weight, and incurs high costs. Transporting these spares, especially via helicopters, can take weeks and is extremely expensive, if it’s possible at all. Additionally, suppliers sometimes cease production of essential spares, complicating operations.<iframe width="640" height="360" src="https://www.youtube.com/embed/gkNm7Sl7aew?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-24="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2 id="isPasted">3D printing as a solution</h2>To tackle this major challenge, the Royal Netherlands Navy has adopted 3D printing. This allows them to produce spare parts locally and on-demand. Each ship is equipped with UltiMaker 3D printers and a variety of materials, enabling them to print a wide range of applications.Parts are designed and tested at their headquarters in Den Helder. Once approved, they are added to a digital catalog. Crew members simply need to select and print the necessary parts directly on board. The Navy also prints optimized parts for better performance, which can be distributed digitally, and produced locally.The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards. Cura is the most popular slicing software used to prepare 3D models for printing, while UltiMaker's Digital Factory platform enables users to manage and monitor their 3D printers and print jobs remotely, enhancing workflow efficiency. Even with large teams, Digital Factory prioritizes security and ensures that data remains protected throughout the process without compromising accessibility.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087595130-the-royal-netherlands-navy-fleet-of-printers.webp" style="width: 100%px;" class="fr-fic fr-dib">The Royal Netherlands Navy uses a range of filaments, including ABS, PETG, and composite carbon fiber. For instance, PETG is selected for applications that require resistance to extreme temperature, wear, chemicals, and water and moisture absorption. In this instance, the Navy needed a material that would be resistant to saltwater. Using PETG, they 3D printed a new water filter to replace an old brass one<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087624501-1732087624501.png" class="fr-fic fr-dib">Composite carbon fiber filaments are used when parts need to be both strong and lightweight, such as a landing boat antenna bracket printed by the Royal Netherlands Navy. Marine antennas are essential for communications and safety. These mounts ensure they are securely in place and allow for the safe lowering and raising of the antenna. Carbon fiber is especially valuable as it allows traditionally heavy parts to be printed with a light material, reducing weight on the carrier as well as the need to transport heavy items across the globe.This variety of materials allows the Navy to create parts suitable for any environment or condition. Parts on ships primarily require strength and wear resistance, while parts for land or air troops often need to withstand extreme heat or cold. For example, brackets mounted on land vehicles must endure prolonged sun exposure. With the Royal Netherlands Navy's global presence, these parts must be prepared for a variety of demanding conditions.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087646194-the-royal-netherlands-navy-cura.webp" style="width: 100%px;" class="fr-fic fr-dib">Thanks to Cura software's capabilities, UltiMaker 3D printers can seamlessly use both UltiMaker’s and third-party filaments, providing greater flexibility for users. Cura provides a streamlined experience with UltiMaker printers, offering optimized print profiles and faster printing, while maintaining compatibility with third-party products. UltiMaker is committed to regular security updates and providing new feature updates to its Cura users.The Royal Netherlands Navy is a classic example where local manufacturing excels over traditional spare part solutions. Having printers on their ships prevents the need for large stocks of spares on the ships. Furthermore, many parts don't have to travel to remote locations, saving time and extremely high cost. These benefits also apply to many other industries. Factories can benefit from local part production, ensuring uptime of production processes, saving on industrial space and preventing parts to be flown in.

The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards.

On-Demand Spare Parts: The Royal Netherlands Navy's 3D Printing Solution

Cutting costs during research and development (R&amp;D) is a vital goal for companies looking to maintain a competitive edge. Elon Musk’s five-step cost-reduction method, as discussed in his biography, offers a practical framework for achieving this. In this article, we will explore the steps—questioning, eliminating, simplifying, and more—that can significantly lower R&amp;D costs.<h2 dir="ltr">&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729157147715-1729157147715.png" width="602" height="116" class="fr-fic fr-dii">Musk’s Five-Step Cost-Reduction Method1. Question: Do You Really Need This?</h2>Questioning is the cornerstone of Musk’s five-step cost-reduction method, but it is also the hardest step to implement. He encourages developers to question every part of their design, challenging established norms and assumptions. As Musk famously said, “Only through relentless questioning can you truly solve problems.”Here are some examples of the kinds of questions you might ask:<ul><li dir="ltr">Why is the part’s wall thickness 4mm? You need to question it.</li><li dir="ltr">Why is the part made from carbon fiber? You need to question it.</li><li dir="ltr">Why is the part manufactured using machining? You need to question it.</li><li dir="ltr">Why does this part exist in the first place? You need to question it.</li></ul>By questioning everything, you can identify unnecessary complexity and opportunities for cost savings. For example, when designing the Starship rocket, Musk questioned the widely accepted use of carbon fiber for the rocket’s shell. After some calculations, he discovered that using carbon fiber would cost millions of dollars, while a stainless-steel alternative could be achieved for just a fraction of the cost. This level of questioning is what allows for real breakthroughs in cost reduction, while maintains the functionality.<h2 dir="ltr">2. Delete: Cut What Doesn’t Add Value</h2>After you’ve questioned every part of your product, the next step is elimination—removing anything that doesn’t directly contribute to the product’s functionality or value. As Musk advises, “Delete any part or process you can. You may have to add some back later, but if you don't end up adding back at least 10%, then you didn’t delete enough.”This process of deleting could mean removing unnecessary components, features, or processes. For instance, in the example shown in Figure-1, optimized design was simplified by eliminating one part entirely. In the original design, two components (A and B) were welded together to perform a clipping function. Part B, which was machined, was removed, and its function was integrated into Part A, a sheet metal piece. By reducing the part quantities from two to one, not only was the need for welding eliminated, but the overall cost was also significantly lowered.This method can yield substantial cost savings by eliminating unnecessary complexity right from the design phase.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729157149415-1729157149415.png" width="361" height="227" class="fr-fic fr-dii">Figure-1. Consider the Possibilities of Removing Every Part a) Original Design b) Optimized Design<h2 dir="ltr">3. Simplify: The Power of Streamlining</h2>Once unnecessary parts have been removed, the next step is to simplify or optimize. This means refining the design and processes to make them as efficient as possible. A streamlined design not only reduces costs by using fewer components, but it also speeds up manufacturing, minimizes the risk of errors, and shortens assembly times.In Musk’s five-step method, simplifying follows elimination, ensuring that the remaining components and processes are working in the most effective way. This could involve simplifying the manufacturing steps, selecting more efficient materials, or reducing complexity in the assembly process. Ultimately, optimization drives both cost savings and greater production efficiency.For more instances of simplifying and optimizing part design, you might be inspired by this article:<a href="https://www.rpworld.com/en/resources/blog/simplifying-medical-device-design.html">&nbsp;Simplifying Medical Device Design</a>.<h2 dir="ltr">4. Accelerate: Use On-Demand Manufacturing</h2>The fourth step is to accelerate the cycle time. By speeding up processes, companies can reduce development timelines and bring products to market faster, which ultimately lowers costs.One effective way to accelerate production is through on-demand manufacturing, which has transformed traditional manufacturing by allowing companies to produce only what they need, exactly when they need it. Particularly beneficial during the R&amp;D phase, where frequent design changes and iterative prototypes are common, on-demand manufacturing enables low-volume production, helping companies avoid the financial burden of overproduction or excess inventory. It also provides the flexibility to quickly adjust designs without incurring the high costs of retooling or scrapping large production runs, thus minimizing waste and accelerating time-to-market.<h2 dir="ltr">5. Automate: Boost Efficiency and Reduce Errors</h2>The final step in Musk’s method is automation. Automating processes reduces human error, increases efficiency, and shortens lead times. This could involve incorporating robotics in assembly lines or using software to streamline workflows.<h2 dir="ltr">How RPWORLD’s On-Demand Manufacturing Supports Cost Reduction?</h2>While Musk’s five-step method—questioning, deleting, simplifying, accelerating, and automating—provides a powerful framework for cutting costs, RPWORLD specifically helps innovative companies bring products to market faster and more cost-effective while maintaining high quality. Here’s how our services contribute to cost savings:<ul><li dir="ltr">Low-volume Production: RPWORLD is specialized in rapid prototyping and on-demand manufacturing services, the low-volume production offers fast turnaround time and flexibility without sacrificing quality, perfect for R&amp;D or market testing.</li><li dir="ltr">Comprehensive One-Stop Service:&nbsp;RPWORLD manufacturing services cover everything from CNC machining, injection molding, and sheet metal fabrication to a wide variety of finishing options such as painting, anodizing, printing, plating and basic assembly, ensuring that every part of your project is handled efficiently under one roof.</li><li>Advanced Quality Control: RPWORLD uses state-of-the-art inspection equipment, including CMM, 3D scanners, flash measuring machine, optical spectrum analyzers and more, to ensure every component meets your exact specifications. Our multi-stage quality control process guarantees consistency and reliability at every step.</li></ul>

In this article, we will explore the steps—questioning, eliminating, simplifying, and more—that can significantly lower R&D costs.

5 Strategies to Simplify R&D and Reduce Costs

Regardless of the industry, shorter development and innovation cycles can lead to improved market performance. Faster prototyping means faster testing and validation, which in turn produces faster development and product launches. This compressed development cycle can then give a company an edge over its competitors, providing its customers with the most cutting-edge solutions.Unfortunately, various bottlenecks can slow down the development cycle, perhaps the most significant of these being supplier sourcing or procurement. An R&amp;D department might come up with several feasible product designs per day, but that counts for nothing if prototypes and components cannot be sourced in a timely manner. Finding a supplier, arranging a contract, waiting for shipments, then coordinating the process with other contractors can turn a cutting-edge product into an obsolete one.Streamlined procurement is therefore key to efficient product development. But how can that be achieved when an engineer sometimes works with separate parties for technical consulting, manufacturing, post-processing, and surface finishing?<h1 dir="ltr">Streamlined Procurement with FACTUREE</h1>Manufacturing hub FACTUREE, based in Berlin's iconic Osram-Höfe industrial business park, has addressed the issue of procurement complexity by offering a seamless process that connects customers with the right suppliers for every need, all managed through a single point of contact. Instead of dealing with multiple suppliers, customers benefit from FACTUREE's extensive network of over 2,000 qualified suppliers, all managed by FACTUREE to ensure the best match for every requirement.Finding suppliers can be one of the most frustratingly slow processes in the development cycle: companies need to find suppliers offering immediate machine availability, fast shipment, and a fair quotation — and checking all three of these boxes isn't always possible. In fact, <a href="https://www.facturee.de/en/facturee-procurement-study-26-percent-of-companies-see-high-effort-in-supplier-coordination-as-an-obstacle/" target="_blank">26 percent of companies</a> take issue with the effort required to coordinate suppliers when procuring components.&nbsp;However, with FACTUREE, customers no longer need to navigate the time-consuming process themselves. FACTUREE's digital solution efficiently manages an extensive network of qualified suppliers, ensuring that every project is matched with the best manufacturer. FACTUREE simplifies procurement for its clients by finding tailored solutions for every requirement, regardless of the quantity or complexity, and efficiently managing the entire process.&nbsp;One of the ways FACTUREE tackles the issue of supplier sourcing is through digital procurement. This means that a company uses a single digital platform to rapidly identify available suppliers for every production stage, from technical analysis to surface finishing. Moreover, FACTUREE serves as the single point of contact, managing all required liaisons and coordination between suppliers, ensuring a smooth, stress-free process that enables the end user to get their project moving almost instantly. FACTUREE utilizes cutting-edge digital technologies and artificial intelligence to improve the traditional procurement process. Their intelligent algorithms optimize supplier selection, while automated processes ensure that projects are executed efficiently and on time. This AI-supported selection ensures that the best possible finisher is chosen for each project, guaranteeing high-quality outcomes. These digital solutions enable FACTUREE's customers to respond more quickly to market changes and bring innovative ideas to life in the shortest possible time.FACTUREE acts as a strategic partner in procurement, finding the ideal manufacturer for every need and ensuring that the process is as efficient and hassle-free as possible. Through partnership, FACTUREE drives progress and creates new opportunities for innovation. They are dedicated to understanding engineers' challenges and offering tailored solutions that meet their specific needs.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDY4MzUyNTg4LWZhY3R1cmVlIDEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><h1 dir="ltr" id="isPasted">Free Advanced Tools for Manufacturing</h1>FACTUREE's approach can dramatically shorten product development cycles, and it can be applied to various forms of manufacturing, including additive manufacturing, CNC machining, sheet metal fabrication, and, as of 2024, molding and casting processes. This is in addition to surface finishing processes, large-scale series production, and other unique offerings, all enabled by FACTUREE's network of over 2,000 trusted manufacturing partners and their 15,000 individual machines.To ensure a successfully manufactured part, FACTUREE also provides free advanced tools that can help engineers with standards, fit, and tolerances. For the last few years, FACTUREE has provided two highly useful online tools to assist engineers with design and development before they send their technical drawings for manufacturing.The first of these tools is the <a href="https://www.facturee.de/en/online-tools/rz-ra-calculator/" target="_blank">Rz-Ra Calculator</a>, an industry-first online solution for converting surface roughness parameters. This is important for engineers because customers across different industries may prefer certain parameters for measuring roughness over others. For example, Ra indicates average height deviations (and corresponds to ISO N standards) while Rz indicates maximum peak-to-valley heights or extreme irregularities. The more relevant value depends on the application of the part. Another advanced tool offered by FACTUREE is an <a href="https://www.facturee.de/en/online-tools/" target="_blank">optimized fit calculator</a>. This tool calculates the maximum tolerance for a given dimension and type of fit and provides a unique reciprocal calculation function, working out clearance fit and other fit classes from a specified internal and external fit value.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDY4NDMyNzg3LWdyYXBoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><h1 dir="ltr" id="isPasted">FACTUREE Success Stories</h1>The seamless procurement solution from FACTUREE has been leveraged by many companies, large and small, across several industries. One success story was demonstrated in 2023 when ten taxi ranks and 66 electric vehicles in the Austrian cities of Vienna and Graz had to be retrofitted with all-new Matrix Charging stations from tech company Easelink. This automated, hands-free charging station makes life easier for drivers and is helping to facilitate the "eTaxi Austria" scheme to make all taxis electric by 2025.As part of the project, FACTUREE was tasked with supplying key components for the core element of the conductive charging system. For one of the two core components, various small-turned and milled aluminum parts were required. Because FACTUREE could leverage its wide range of manufacturing partners, manufacturing techniques, and surface treatments, it could meet Easelink's demands nimbly and efficiently — faster than if the customer had sourced suppliers on its own.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDY4NTY2Mzg2LWNhciBjYXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">FACTUREE supplied various small-turned and milled parts made of aluminum for the connector. Credit: FactureeAnother beneficiary of FACTUREE's services is aerospace company Space Applications Services, headquartered in Brussels, whose customers include organizations like the European Space Agency (ESA). The company required CNC machined parts for prototypes and space qualification models used in aerospace applications after its previous supplier failed to meet expectations regarding material quality, delivery times, and pricing. The high-quality parts supplied by FACTUREE have convinced Space Applications Services to continue using the service after more than two years.<h1 dir="ltr">Conclusion</h1>Finding suppliers to handle part manufacturing, post-processing, finishing, and other tasks is a challenge that adds unnecessary time and complexity to product development. By entrusting procurement to FACTUREE, companies can focus on innovation while FACTUREE manages the complexities, ensuring a smooth, efficient process from start to finish.Visit the FACTUREE&nbsp;website to<a href="https://www.facturee.de/en/inquiry/" target="_blank">&nbsp;directly request a quote</a>, or contact them with any questions to schedule a consultation.&nbsp;This article was contributed to by Benedict O'Neil

Engineers, procurement managers, and other manufacturing professionals can streamline procurement and enhance productivity through FACTUREE's vision to simplify sourcing, reduce complexity, and save valuable time and resources by providing a single point of contact.

AI-Driven Procurement Solutions for Streamlined Engineering and Manufacturing

Every day, millions of glass bottles, cans and PET containers run through a Krones line. <a href="https://www.krones.com/en/index.php" target="_blank">Krones</a> is a leading manufacturer of complete systems for breweries, beverage bottlers and food producers. Its production lines fill packages, add labels, and perform quality control on the products. As a global market player in the beverage and packaging industry, Krones provides comprehensive solutions that customers, such as Coca-Cola and Heineken, rely on heavily.<iframe width="640" height="360" src="https://www.youtube.com/embed/fdjkrFzIk84?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <h2>When every second counts</h2>The production lines of Krones are extremely efficient in producing, filling, and packing products. But with these massive production volumes, every second counts. When a machine is not running, companies could lose out on significant revenue. This is why it’s critical to have the highest possible uptime. While Krones machines are extremely reliable, every part will wear and might need replacing for optimal performance. While most customers keep a selection of spare parts, it’s unrealistic, expensive and unsustainable to keep a large stock of spares as many of these parts will never be used. Every part needs to be produced, checked and shipped.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjM5ODg2LUtyb25lcy11c2VyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Every part produced for a Krones machine is checked for the highest quality.<h2 id="isPasted">3D printing at Krones</h2>To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. Outsourcing the production of prototypes is very expensive and often could take weeks. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases. By prototyping faster, Krones tested and iterated on their designs faster, ensuring that new parts performed better and lasted longer. This has helped customers with more reliable machines, higher uptime and a smaller environmental footprint.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjY3MDU3LUtyb25lcy1hcHBsaWNhdGlvbi02LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">3D printing in-house has enabled Krones to produce critical parts for their machines.<h2 id="isPasted">Benefits of 3D-printed parts over traditional parts</h2>By testing prototypes of parts, Krones discovered that 3D-printed parts met the performance requirements of many final parts. Not only are 3D-printed parts cheaper to produce, their reduced weight is also often a big benefit. Parts can also be printed in different materials depending on the need for different properties, such as more flexibility or ESD-safety. This enabled Krones to shift 3D printing from simply an internal tool to a new revenue stream as an added service for customers.<h2 id="isPasted">On-demand production parts for customers, anywhere</h2>When storing a huge stock of spare parts is not desirable or spare parts are needed urgently, you need to be able to acquire parts fast once they are needed. Ordering and shipping parts can take days to weeks, while local stocks or customs can make certain locations difficult to guarantee certain quality service. 3D printing on location offered a huge opportunity for Krones and its customers.When customers need a spare part for a machine, they can order the part in the Krones.shop - the online customer touchpoint. If the spare part is able to be 3D-printed, it will be produced locally on UltiMaker printers. This way, customers won’t need to store huge quantities of spare parts in all of their locations. They can simply print the parts they need, while minimizing downtime of their production lines drastically. This process reduces part delivery from weeks to days, or even hours.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzAxMjU3LUtyb25lcy1hcHBsaWNhdGlvbi0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Printing parts on-demand have shown to reduce costs and improve operational efficiency.<h2 id="isPasted">Quality assurance of 3D printed parts</h2>The functionality and durability of a part depends on many factors. While the design of a part might be the same, the choice of materials and production settings have a great influence on the performance. Krones defines the right materials and print settings for every part. When a customer orders a replacement part for their Krones line, the spare will be 3D printed using customized settings and Krones-specific materials. This results in a certified part that is sure to meet the quality standards required. Krones quality can only be found where it says Krones Quality on the label.<h2>A flexible 3D printing solution that meets strict quality and IT standards</h2>Choosing the right 3D printing ecosystem can be very challenging. For Krones, UltiMaker was the right choice thanks to its agile, open and secure solutions. UltiMaker 3D printers have been known for their reliable and consistent quality. UltiMaker’s software comes with print profiles for hundreds of materials and brands, making it easy to pick the right material for the job. However, Krones was in need of a custom material with extremely specific requirements. Thanks to UltiMaker’s open materials platform, Krones was able to develop its own material for its own parts and create reliable print profiles.UltiMaker’s professional software also helped Krones to meet the data protection standards set by IT. Print jobs on location are securely monitored by Krones through a custom software solution, assuring customers of the quality of the print job. Regular software and firmware updates also ensure Krones utilizes a future-proof 3D printing ecosystem.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzI4OTM2LUtyb25lcy1hcHBsaWNhdGlvbi00LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">UltiMaker's 3D printing ecosystem and open materials platform allowed Krones to customize their solutions to meet customer demands.<h2 id="isPasted">Moving forward with the Factor 4</h2>Krones has been printing in over 10 locations using a large fleet of nearly 50 UltiMaker S5 and UltiMaker S7 printers. Adding the recently launched UltiMaker Factor 4 to its repertoire has brought new possibilities to Krones.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzUzMDYyLUtyb25lcy1GYWN0b3ItNC0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The addition of UltiMaker's new Factor 4 3D printer has enabled Krones to provide more support to its customers.Johannes Karl, Head of Customer 3D Solutions, at Krones, stated:<blockquote>We’re excited about the potential of the Factor 4. The Factor 4 has taken our capabilities to the next level. With support for stronger and more durable materials, we're able to produce parts that are not only tougher but also offer greater flexibility with softer materials.</blockquote>The new UltiMaker Factor 4 has a direct drive printhead. This makes printing soft materials easier and even more reliable. Because of the direct drive, the Factor 4 enables users to print parts in even softer and grippier materials. These features bring new opportunities for example for grippers, flexible parts or protective parts.The new UltiMaker Factor 4 can also print at even higher temperatures, in a better isolated build chamber. This enables engineers to use materials such as UltiMaker’s PPS CF. A material that can easily substitute for PEEK or even steel.The new features of the Factor 4 push innovation at Krones even further, helping them to deliver even more service to their customers.Bernd Baldauf, Head of Global eBusiness - Global Digital Content Management - Global 3D Customer Solutions, at Krones, concluded:<blockquote>Our goal is to grow closer to our customers and become their solution partner. Providing rapid, high-quality parts on demand, and continuously improving our service offerings in Krones quality. With UltiMaker's innovative solutions, we're well on our way to achieving that.</blockquote>

Printing parts on-demand have shown to reduce costs and improve operational efficiency.

To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases.

Krones: Optimized 3D-printed parts & spares for customers anywhere

<a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a> is a highly accurate and precise manufacturing process that can create parts with tolerances as tight as 0.025 mm. However, being a subtractive manufacturing method, CNC machining leaves cut marks that create a level of roughness on the finished product’s surface.<h2 data-counter-attr="value0">What is Surface Roughness?</h2>Surface roughness is a measure of the average texture of a part’s surface, in this case, after CNC machining. There are different parameters used to define surface roughness. One of the most ubiquitous of these is Ra (Roughness average), which is derived from the differences between heights and depths on a surface. Ra surface roughness is measured microscopically and is usually in micrometres (x 10~⁶ m). Note that surface roughness in this context is different from surface finish. The surface finish of a machined part can be improved via various finishing methods such as anodizing, bead blasting, and electroplating. Surface roughness here refers to the as-machined surface texture of a part.<h2 data-counter-attr="value1">How Are Different Surface Roughness Options Achieved?</h2>A part’s surface roughness after machining is usually not random. Instead, steps are taken to ensure that a specific roughness is achieved. This means that surface roughness values are planned in advance. However, not just any value is usually specified. In manufacturing, there are specific Ra values that are considered industry standards, as specified in <a href="https://guide.digitalsurf.com/en/guide-iso-4287-parameters.html" target="_blank" rel="noreferrer noopener">ISO 4287.</a> These are the values that may be specified during CNC machining. They range from 25 μm to 0.025 μm and apply to all kinds of manufacturing and post-processing operations.At Xometry Europe, we offer four surface roughness levels that are also the values typically specified for CNC Machining applications:<ul><li>3.2 μm Ra</li><li>1.6 μm Ra</li><li>0.8 μm Ra</li><li>0.4 μm Ra</li></ul>Different roughness values are required for different applications. Lower surface roughnesses should only be specified when necessary. This is because the lower the Ra value, the more machining effort/operations and quality control will be required. They can significantly drive up machining costs and time. Post-processing operations aren’t usually applied when specific surface roughness values are required. This is because these operations cannot be controlled precisely and may affect the dimensional tolerance of parts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723617196640-Surface-roughness-for-CNC-milling-and-turning-compared.webp" style="width: 100%px;" class="fr-fic fr-dib">Surface roughness for CNC milling and turning comparedSurface roughness significantly affects the functionality, performance, and durability of parts in certain applications. It influences the <a href="https://www.engineeringtoolbox.com/friction-coefficients-d_778.html" target="_blank" rel="noreferrer noopener">friction coefficient</a>, noise level, wear and tear, heat, and adhesiveness of a part in use. The importance of these factors vary by application, and so while the surface roughness of a part is inconsequential in certain applications, it is critical in many others. These applications include high tension, stress, and vibration scenarios, mating and moving assemblies, fast rotating parts, and medical implants. As earlier stated, different levels of surface roughness are required in different applications.The following explores the roughness levels that we offer at Xometry Europe and all you need to know in order to select the right Ra value for your application.<h2 data-counter-attr="value2">3.2 μm Ra</h2>This is the standard commercial machine finish. It is suitable for most consumer parts and sufficiently smooth, but it contains visible cut marks. It is the default surface roughness applied unless otherwise is specified.3.2 μm Ra is the recommended maximum surface roughness for parts subject to stress, loads, and vibrations. It can also be used for mating moving surfaces when the load is light and motion slow. It is machined using high speeds, fine feeds, and light cuts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723617228659-machined-marks.webp" style="width: 100%px;" class="fr-fic fr-dib">3.2 μm Ra as machined cut marks<h2 data-counter-attr="value3" id="isPasted">1.6 μm Ra</h2>Usually, there are only slightly visible cut marks with this option. This Ra rating is recommended for tight fits and stressed parts, and is sufficient for slow-moving and light load-bearing surfaces. However, it is not suitable for fast rotating parts and parts subject to intense vibration. This surface roughness is produced using high speeds, fine feeds, and light cuts under controlled conditions.Price:&nbsp;for a standard aluminium alloy (e.g. 3.1645) this option adds approximately 2,5% to the production price. This could increase with the complexity of the part.<h2 data-counter-attr="value4">0.8 μm Ra</h2>Considered high grade, this surface finish requires very close control to produce, costing more. It is required for parts that are exposed to stress concentration. When the motion is occasional and the loads are light, then it can be used for bearings.Price:&nbsp;for a standard aluminium alloy (e.g. 3.1645) this option adds approximately 5% to the production price. This could increase with the complexity of the part.<h2 data-counter-attr="value5">0.4 μm Ra</h2>This is the finest (“least rough” in technical terms) and highest quality surface roughness that are offered. It is suitable for parts that are under high tension or stress. It is also required for rapidly rotating components such as bearings and shafts. This surface roughness takes the most effort to manufacture and should only be specified when smoothness is of primary importance.&nbsp;Price:&nbsp;for a standard aluminium alloy (e.g. 3.1645) this option adds approximately 11-15% to the production price. This could increase with the complexity of the part.At Xometry, we can manufacture your <a href="https://xometry.eu/en/cnc-machining/" target="_blank">CNC machined parts</a> with any of these surface roughnesses options. Simply upload your model on our <a href="https://get.xometry.eu/?locale=en" target="_blank">instant quoting platform</a> and select your preferred surface roughness to get a quote in a second.&nbsp;

The article overviews standard surface roughness options for CNC machining and their application (from 3.2 to 0.4 μm Ra).

Selecting Right Surface Roughness for CNC Machining

Explore die casting's intricacies, principles, and evolving technologies redefining industry standards. Understand the challenges and critical considerations in mastering this process, highlighting its profound impact on contemporary manufacturing.

What is Die Casting: A Technical Perspective Guide for Engineers

The rapid prototyping industry is incredibly efficient — and hugely competitive. Thanks to the internet, engineers can instantly upload their designs and receive a quote within hours. Depending on the manufacturing process, these parts can often be shipped just a few days later.Perhaps the only problem for engineers and product designers is the sheer number of companies offering third-party manufacturing services. Across China and other parts of the world, a huge number of rapid prototyping companies, machine shops, and low-volume manufacturers are competing to provide the best, fastest service.Engineers, therefore, need to find out what distinguishes one prototyping company from another. Guangdong’s <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN Rapid's</a> unique selling point is a suite of high-end manufacturing equipment not always offered by other low-cost prototyping companies.<h2 dir="ltr">Why quality matters in rapid prototyping</h2>In the world of <a href="https://www.wevolver.com/article/rapid-prototypings-transformative-role-to-the-future-of-manufacturing" target="_blank">rapid prototyping</a>, it’s tempting to assume that the two most important factors are speed and cost. After all, the faster a prototype can be delivered, the sooner a product can undergo testing, validation, and production. Faster rapid prototyping means a shorter time-to-market.Cost would also seem to be a major factor. Most companies will understandably appreciate a smaller invoice from their prototyping partner, and one would expect engineers to prioritize low costs for prototyping and high quality for production, since nobody will see or use the prototype except company insiders.However, there are many reasons why a bad prototype can have negative consequences for product designers. Quality matters at all stages of product design, and prototyping is no exception. Below are just some of the reasons why high-quality prototypes are beneficial.<ul><li dir="ltr">Final parts fidelity: Well-made prototypes — those made with skill using professional manufacturing processes — will closely resemble end-use production parts. This means that any testing and validation performed on the prototype will provide more genuine insight about the performance of the final part.</li><li dir="ltr">Showcase potential: Product designers don’t just make prototypes for testing. They might also need a visual or functional prototype to show to investors or business partners. In such cases, the visual and mechanical quality of a prototype is virtually as important as the quality of the final parts, as the entire business proposal may depend on it. Quality machining, clean and smooth surfaces, and consistent coloration can all contribute to a successful demonstrator part.</li><li dir="ltr">Bridge production: A high-quality prototype isn’t a dead end in the product development cycle. If the prototype is made to a high standard (using the kind of processes and materials that will be used for the final part), its design can be the basis for part production. In some cases, the prototyping company may even provide the first low-volume production run, saving the product designer money.</li><li dir="ltr">First-time success: Cutting corners can shorten product development times, but it can also result in prototypes that are simply unusable. Prototypes made without care using low-quality equipment may not meet the designer’s specifications, requiring repeat orders that actually increase the total time and money spent.</li></ul>In summary, high-quality prototypes provide many benefits. Although end-users won’t see them, quality prototypes can lead to effective testing, persuasive showcasing, and a smoother transition to production.&nbsp;<h2 dir="ltr">Why high-end equipment is key to successful prototyping</h2>We have seen above why it is important to carry out rapid prototyping to a high standard. But how does one ensure that prototypes ordered from a third party are in fact built to a high standard?&nbsp;One key factor is human skill. While many prototyping processes involve digital manufacturing — in which the part is fabricated by a computer-controlled equipment rather than by human hand — these processes still demand a high level of expertise. For instance, project managers require a broad knowledge of different processes, materials, and surface treatments, enabling them to instantly identify the ideal manufacturing solution for a design. These skilled professionals must also be able to read technical drawings (in both 2D and 3D) and understand geometric dimensioning and tolerancing to quickly ascertain the scope, complexity, and feasibility of a design. This degree of knowledge requires many years of training and experience.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1OTU0NzUzMTk1LUNOQyBtaWRkbGUuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">BoenRapid's machine floor. Credit: BoenRapidAll workers at the facility must possess a similar level of expertise in their designated role. Engineers must validate the proposal in terms of design for manufacturing (DfM), expert machine operators must set up the machines with the correct digital parameters and physical considerations (workholding, clamping, etc.), and finishing specialists must carry out processes like sanding and painting with a high level of manual skill.&nbsp;Another element to consider is the raw materials used for the prototype. While many designers use slightly less expensive materials for their prototypes — especially when working with metals — these materials affect the quality of the final prototype. A reliable prototyping company will be able to recommend material choices for a high-quality prototype that remains within the project budget.&nbsp;An equally important consideration for making quality prototypes is the quality of the manufacturing equipment. In virtually every area of manufacturing, there is a huge range of machinery available, from budget equipment to the best industrial-grade units used by the world’s most profitable companies. Take fused filament fabrication (FFF) 3D printing, for example. Entry-level machines can cost just a few hundred dollars, while industrial-grade systems with multiple extruders and supreme speed and accuracy often cost six figures.At prototyping company BOEN Rapid, the decision was taken to use the best possible equipment to guarantee high-quality prototypes for all customers. This is made apparent in the company’s CNC machining offering, in which it uses 5-axis machines from world-leading hardware companies like DMG MORI (Germany) and HERMLE AG (Germany). 5-axis machining centers provide a much greater degree of geometric flexibility than traditional 3-axis machines and also require fewer setups, greatly reducing cycle times. However, due to the complex toolpath generation required by 5-axis machining, it pays to use only the best hardware and software to eliminate manufacturing errors.The quality control stage of rapid prototyping also benefits from high-quality equipment. Here too BOEN Rapid has invested in the best metrology and inspection equipment available, using coordinate measuring machines (CMMs) from ZEISS (Germany) to guarantee that all prototypes meet design specifications within acceptable tolerance limits.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1OTU0Nzg2MzYwLWNuYyBjZW50ZXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Part of BoenRapid's CNC floor. Image credit: BoenRapid<h2 dir="ltr">Working with BOEN Rapid</h2>BOEN Rapid works with customers of all sizes from a broad range of industries, from automotive and aerospace to medical devices to consumer goods. Regardless of whether you need a single 3D printed prototype or 1,000 aluminum extrusions, BOEN Rapid will make your parts to the highest standards using its high-end equipment. Moreover, the majority of BOEN Rapid engineers have more than a decade of experience and, therefore possess the knowledge and skills required to realize even the most complex prototyping requirements.Request a quote from <a href="https://www.boenrapid.com/" target="_blank">BOEN Rapid</a> to discover how this trusted company can become your go-to prototyping and low-volume manufacturing partner.

Rapid prototyping company BOEN Rapid offers a wide range of services, from CNC machining to 3D printing. Behind these processes is an arsenal of high-quality manufacturing hardware.

Why quality equipment matters to cutting-edge prototyping

By definition, networking is “the action or process of interacting with others to exchange information and develop professional or social contacts”, but in more recent times, has networking become a buzzword with no action? 

Networking: just a buzzword or pivotal for manufacturing success?

The development of unmanned logistic vehicles is revolutionizing last-mile deliveries! However, these vehicles, equipped with advanced technologies like artificial intelligence and autonomous navigation systems, have faced significant investment in their research and development. In this article, let&rsquo;s delve into how on-demand manufacturing holds the potential to accelerate the development of unmanned logistic vehicles, leading to more efficient and agile industry practices.<h2 dir="ltr">The Need for Rapid Development</h2>As e-commerce continues to soar and consumer expectations for fast and efficient services rise, traditional logistic systems are facing significant challenges. Unmanned logistic vehicles offer a solution by augmenting existing infrastructure and enabling faster and more flexible delivery options. From autonomous drones for last-mile deliveries to self-driving trucks for long-haul transportation, these vehicles offer increased speed, reduced operational costs, and improved safety.The need for rapid development of these vehicles is paramount to meet the evolving demands of the industry, optimize resource utilization, and ensure timely and reliable deliveries to customers worldwide. However, the lengthy and rigid manufacturing processes involved in traditional vehicle production often delay the development and deployment of these technologies. On-demand manufacturing addresses this issue by offering a streamlined and accelerated manufacturing approach.<h2 dir="ltr">On-Demand Manufacturing Fuels Unmanned Logistic Vehicle Development</h2>On-demand manufacturing is an agile and flexible approach that leverages advanced technologies such as CNC machining, 3D printing and more to enable rapid prototyping and end-use production of unmanned logistic vehicles. It can quickly help iterate designs, produce vehicle components, and optimize performance. This agile manufacturing approach allows for faster development cycles and facilitates the incorporation of emerging technologies into the vehicles.<h3 dir="ltr">Customization and Scalability:</h3>One of the key advantages of on-demand manufacturing is its ability to customize vehicles according to specific requirements. Unmanned logistic vehicles often need to adapt to various operating environments and cargo types. On-demand manufacturing enables the production of vehicles tailored to unique specifications, ensuring optimal performance and efficiency. Moreover, as the demand for unmanned logistic vehicles grows, on-demand manufacturing offers scalability, allowing for the rapid scaling of production without the need for extensive retooling or setup.<h3 dir="ltr">Reduced Costs and Time-to-Market:</h3>Traditional vehicle manufacturing processes involve significant upfront costs and long lead times. By contrast, on-demand manufacturing minimizes these hurdles. With the elimination of expensive tooling and reduced material waste through advanced manufacturing technologies, costs are significantly reduced. Additionally, the streamlined production process enables faster time-to-market, allowing manufacturers to respond swiftly to market demands and stay ahead of the competition.<h3 dir="ltr">Collaboration and Innovation:</h3>On-demand manufacturing approach fosters collaboration and innovation within the unmanned logistic vehicle industry. By providing a platform for manufacturers, designers, and engineers to collaborate, share ideas, and access advanced manufacturing capabilities, on-demand manufacturing facilitates the development of cutting-edge technologies. This collaborative environment encourages the exploration of new concepts, materials, and designs, ultimately pushing the boundaries of unmanned logistic vehicle development.<h2 dir="ltr">About RPWORLD On-demand Manufacturing</h2>RPWORLD&#39;s on-demand manufacturing capabilities have been accelerating the emerging automotive product development, including new energy vehicles, unmanned vehicles, and unmanned logistic vehicles. With extensive manufacturing experience, RPWORLD offers unparalleled advantages in the following areas:Shortest lead time: RPWORLD guarantees a minimum lead time of just 3 days, ensuring quick delivery of parts and components.Customized CNC machining and injection molding:&nbsp;RPWORLD specializes in providing tailored manufacturing solutions to meet specific requirements.One-stop manufacturing solution: RPWORLD handles all stages of production, from prototyping to end-use production, from quality control to surface treatment.Design for Manufacturability (DFM) services: RPWORLD&#39;s in-depth DFM services minimize manufacturing risks and ensure smooth production.

In this article, let’s delve into how on-demand manufacturing holds the potential to accelerate the development of unmanned logistic vehicles, leading to more efficient and agile industry practices.

How On-Demand Manufacturing Powers Unmanned Logistic Vehicles Revolution

<h2 dir="ltr" id="isPasted">Introduction</h2><a href="https://ultimaker.com/learn/metro-plastics/" target="_blank" rel="noopener noreferrer">Metro Plastics</a>, a specialized firm in custom injection molding, has significantly enhanced its operational efficiency by integrating the Ultimaker S5 Pro Bundle into its manufacturing processes. Spearheaded by Scott Adams, the Engineering Manager with a 14-year tenure at the company, Metro Plastics has not only reduced lead times but also achieved substantial cost savings. This article delves into the technical aspects of how 3D printing technology has revolutionized Metro Plastics&#39; workflow.<h2 dir="ltr">The Genesis: Tackling Operational Delays</h2>Initially, Metro Plastics faced considerable challenges in obtaining end-of-arm tooling components from their in-house tool shop. The lead times varied dramatically, ranging from a week to several months, depending on the workload of the tool shop. Recognizing the inefficiency, Adams began exploring additive manufacturing technologies as a potential solution.<h3 dir="ltr">The Decision-Making Process</h3>After consulting with Matt Torosian, Director of Jabil&#39;s Additive Manufacturing Materials division, Adams was introduced to Ultimaker&#39;s range of 3D printers. The Ultimaker S5 Pro Bundle was selected for its large build plate, superior air quality management, and flexibility to switch between a wide array of materials through its open material platform.<h3 dir="ltr">Rapid Implementation and Skill Adaptation</h3>Upon the arrival of the Ultimaker S5 Pro Bundle, the engineering team at Metro Plastics quickly adapted to the new technology. Leveraging their existing 3D CAD skills, they mastered the Ultimaker Cura software and commenced printing components on the same day the printer was set up.<h1 dir="ltr">The Revolution of End-of-Arm Tooling (EOAT) through 3D Printing</h1>EOAT parts enable machines to complete specialized tasks such as picking, placing, sorting, and assembling. As industries evolve, there is an increasing need for custom and adaptable EOAT solutions. This is where 3D printing steps in, reshaping how EOAT is conceptualized, produced, and implemented.<h3 dir="ltr">Traditional Challenges in EOAT Production</h3><ol><li dir="ltr">Customization Constraints: Traditional manufacturing methods often come with design restrictions, making it challenging to produce unique or complex EOAT designs tailored to specific tasks.</li><li dir="ltr">Lead Time:&nbsp;As highlighted by Metro Plastics&#39; experience, obtaining specialized tooling parts can sometimes take weeks or even months, creating delays in the production line.</li><li dir="ltr">Costs: Bespoke tooling parts are often expensive, primarily when produced in small quantities using conventional manufacturing techniques.</li></ol><h1 dir="ltr">3D Printing: The Game-Changer for EOAT</h1><ol><li dir="ltr">Rapid Prototyping: 3D printing allows manufacturers to swiftly move from a design concept to a physical prototype. This ability to quickly iterate designs means that EOAT can be optimized for performance with fewer delays.</li><li dir="ltr">Customization:&nbsp;With 3D printing, the complexities and intricacies of design are not a hurdle. EOAT can be tailored precisely to the requirements of a task, ensuring better functionality and efficiency.</li><li dir="ltr">Weight Reduction:&nbsp;3D printed parts can be designed to be lightweight without sacrificing strength, especially when using materials like carbon-fiber filled nylon. Lighter EOAT can lead to faster robotic movements and less wear and tear on the robotic system.</li><li dir="ltr">Cost-Efficiency: 3D printing can be more cost-effective for producing specialized parts in small to medium quantities, reducing the overheads associated with mold creation and material wastage in traditional manufacturing.</li></ol><h2 dir="ltr">Beyond Initial Expectations: Versatile Applications</h2>Initially, Metro Plastic had envisioned using the 3D printer solely for end-of-arm tooling. However, the team soon discovered a plethora of other applications, including:<ul><li dir="ltr">General and assembly fixtures</li><li dir="ltr">CMM (Coordinate Measuring Machine) components</li><li dir="ltr">Equipment casings and brackets</li><li dir="ltr">Prototypes for both internal design and customer requirements</li><li dir="ltr">Financial and Operational Benefits</li></ul>The integration of 3D printing has led to remarkable cost efficiencies. For instance, sensor brackets, which would typically cost between $40 to $50 and take days to arrive, can now be printed in-house for just $5 per part. Moreover, the production department now consults the engineering team for 3D printing possibilities before considering outsourcing or purchasing from catalogs.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzMjM1MzY3MTM1LXF1YWxpdHktY29udHJvbC1maXh0dXJlLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">Metro Plastics found many more 3D printing applications, like this quality control fixture.This proves that 3D printing is not only making impact on industrial-grade manufacturing outcomes but can positively impact through the shop floor. Fast, affordable and highly-customized solutions for an array of challenges are now solvable by in-house teams.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjkzMjM1NDA1MjQ4LXBhY2thZ2luZy1uZXN0LmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">A 3D printed packaging nest to help organize parts.<h2 dir="ltr">Conclusion</h2>Metro Plastics has successfully leveraged the Ultimaker S5 Pro Bundle to optimize its operations, achieving up to 90% cost reduction in certain components and significantly reducing lead times. The technology has not only solved immediate operational bottlenecks but has also opened doors to various other applications, making it an invaluable asset for the company.To learn more about the impact of 3D printing on the manufacturing industry, read the other articles in our series. <a href="https://www.wevolver.com/article/how-3d-printing-is-enabling-faster-design-higher-productivity-and-more-customization-in-manufacturing" target="_blank" rel="noopener noreferrer">A deep-dive into how 3D printing is enabling faster design, higher productivity, and more customization in manufacturing</a> and another case study about how <a href="https://www.wevolver.com/article/how-zeiss-is-using-3d-printed-parts-in-serial-production" target="_blank" rel="noopener noreferrer">Zeiss is Using 3D Printed Parts in Serial Production</a>.Future articles will examine the impact of 3D printing on packaging, STEM, and transportation.&nbsp;

Injection molding company Metro Plastics used 3D printing solutions from UltiMaker to solve long lead time issues on their shop floor.


Fast turnaround end-of arm tooling solutions with advanced 3D printing

RPWORLD, one of the leading mechanical parts manufacturers in on-demand manufacturing, is proud to celebrate its 20th anniversary in 2023. Founded in 2003, RPWORLD has been dedicated to providing rapid prototyping and on-demand production services tailored to the diverse needs of innovative industries all over the world. Over the past two decades, RPWORLD has successfully completed over 20,000 projects for more than 3,000 customers from 40+ countries, establishing itself as one of the fastest and most comprehensive manufacturing suppliers in the industry.The key to RPWORLD&#39;s achievements lies in its comprehensive manufacturing model, which combines the changing customer needs with the on-demand manufacturing services. This approach allows RPWORLD to produce custom or complex-geometry components in the shortest time, also ensures the flexible and rapid manufacturing to help customers stay ahead in the competitive market.To meet the increasing demand for its services, RPWORLD has continuously expanded its manufacturing capabilities. RPWORLD&rsquo;s recent acquisition of advanced equipment has enabled faster turnaround times and rapid iteration for customer product development. Ranging from 10 to 1,000 pieces, RPWORLD CNC machining delivers accurate and consistent parts in as fast as 3 days and meets DIN ISO 2768 M (F) standards. And the highly automated injection molding allows production runs ranging from 100 to over 100,000 pieces. The enhancement of its manufacturing capabilities makes it easier and faster for product developers to get prototype parts and high-volume parts and to accelerate product development cycles.In celebration of this significant milestone, Simon, RPWORLD&#39;s CEO, expressed his gratitude to the customers, employees, and partners who have contributed to the company&#39;s growth and success over the past 20 years. He highlighted RPWORLD&#39;s unwavering commitment to delivering high-quality manufacturing solutions and its dedication to continuous improvement.Steve, the General Manager of RPWORLD, also emphasized the company&#39;s achievements in revolutionizing the manufacturing industry. He stated, &ldquo;Our customers are seeking manufacturing solutions that can adapt to the increasingly shorter product development life cycle, and RPWORLD is uniquely tailored to meet their needs, offering a comprehensive and one-stop manufacturing solutions from rapid prototyping to on-demand production. RPWORLD has successfully made the advanced manufacturing technologies accessible to innovative industries, from automotive parts, medical devices, scientific instruments and more.&rdquo;RPWORLD&#39;s digital manufacturing capabilities, which include CNC machining, injection molding, vacuum casting, sheet metal fabrication, and surface treatment, have significantly accelerated time to market for customers while reducing development and production costs. By leveraging the power of expertise and infinite manufacturing capabilities, RPWORLD continues to minimize risk and enhance the overall product life cycle for customers.As RPWORLD enters its 20th year of business operation, the company remains committed to pushing the boundaries of on-demand manufacturing and delivering innovative solutions that meet the evolving needs of its global customer base.

Over the past two decades, RPWORLD has successfully completed over 20,000 projects for more than 3,000 customers from 40+ countries, establishing itself as one of the fastest and most comprehensive manufacturing suppliers in the industry.

RPWORLD Marks 20 Years of On-demand Manufacturing with Further Production Enhancement

Ender 3 Pro bed leveling results in better prints

The Creality Ender 3 Pro offers good value for money but lacks an automatic bed leveling feature. Fortunately, Ender 3 Pro bed leveling can be painless with the right tools and preparation.

Ender 3 (V2, Pro, S1, Neo) Bed Leveling: A Comprehensive Step-by-Step Guide

Improve your Ender prints by adjusting retraction settings

The Creality Ender 3 is a reliable 3D printer, but it can still suffer from issues like oozing and stringing. Adjusting your Ender 3 retraction settings can help solve these problems.

The Best Ender 3 Retraction Settings

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On-Demand Manufacturing

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