Additive Manufacturing

Ogle is able to offer its clients a range of advanced additive manufacturing processes to fulfil the most complex model demands.

Additive manufacturing is a term that refers to a range of processes that have emerged during the last 25 years for a host of applications including concept models, functional prototypes, tooling patterns and, more recently, production parts. Other terminology that can be used to describe these processes includes Rapid Prototyping, 3D Printing, Additive Layer Manufacturing, Digital Manufacturing and Freeform Fabrication.

In contrast to traditional prototyping and manufacturing methodologies, additive manufacturing processes build parts layer by layer, at the micron level, to achieve the required shape. This, in turn, has opened up new possibilities in terms of realising more complex shapes — in a single model — eliminating the need for multiple parts and their assembly.

From the earliest origins of the technology, when additive processes were more limited in terms of accuracy, repeatability and material characteristics, ongoing improvements now mean that some of the processes can be utilised to build final production parts. In particular, for low volume, high value applications additive manufacturing can offer a viable and economic alternative to traditional methods of manufacture, which require machining or expensive tools.

Experience of additive technologies has brought a depth of understanding to the team at Ogle, a company that finds the right solution for every individual client. As such, additive manufacturing is not regarded as a replacement technology for traditional ways of working, rather, it provides a valuable alternative — often fulfilling applications that could not be made in any other way.

One of the most accurate additive manufacturing processes is Selective Laser Sintering (SLS), and the experts at Ogle have worked with this technology since 2000. The company is able to offer a wide selection of nylon materials for building uniquely complex parts. Indeed, Ogle Models and Prototypes was one of the first companies in Europe to offer a fire retardant nylon with a UL94 V0 rating (with wall thicknesses of 2mm). The PA2210FR nylon material has proved particularly useful for many client applications at Ogle, where flame retardance was a prerequisite. The material has also been approved for use in aerospace applications.

One extremely successful case study of an additive manufacturing application was for a client that required a range of fibre optic trays for the telecommunications industry. To date, these parts have been produced in volumes of several thousand — and counting — with delivery of small batches organised to suit manufacturing requirements.

The project originated as an order for a typical one-off prototype — for design approval — using the stereolithography (SL) process. The follow up requirement from the client was for a small quantity of parts for trial build, which produced successful results. As a consequence, the question was raised of manufacturing these parts in a suitable UL94 V0 material. The only option at the time was to use the vacuum casting process, but this presented several drawbacks in terms of difficulties with the process for this application together with cost and lead-time implications for the client. First, the materials required for this project would be very aggressive towards the silicone mould material — limiting the mould’s life to around 10 production parts. Second, the design of these components is quite complex with numerous large undercuts that would require core pins. This made each part very time-consuming therefore expensive to produce. Finally, the part materials are relatively brittle making them less suitable for production line assembly techniques.

At the time that these options were under consideration, Ogle researched alternative production methods and discovered that an SLS material was in development — a material that would overcome all of the problems for this project. As a result, Ogle became involved in the material development process at the earliest opportunity — an action that has resulted in vastly reduced costs and lead-time for the client. Moreover, for this specific application, further progress with the material has enabled easy manufacture of specialised variants of the part with zero impact on original costs and time constraints.

This case study truly exemplifies how Ogle can — and does — work in collaboration with every client to find the right solution for models, prototypes and production parts as well as demonstrating the real capabilities of additive manufacturing for real world applications.