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Markforged Metal Printing Benefits

Markforged Metal Printing Benefits

okay welcome everyone to the mark forged webinar this installation is the complete metal solution I’m John Riley the VP of Product I’m here with Alexander crease one of our content engineers and we’re going to walk you through metal printing from mark forged if

if you have questions there will be a opportunity at the end of the presentation to ask them I don’t think we’ll get to all of the answers but hopefully we can get through a few questions there if we’re not able to answer them on the live webinar we’ll both have a recording of it for everyone to review afterwards in case you missed something as well as we’ll try and reach out individually and answer everyone’s individual questions

okay great let’s get started we’ll start with a brief look at the agenda I’ll begin by introducing markforged for those of you who don’t know us then we’ll talk about a customer case study and show you how they went from design to actual part we’ll review the return on investment and then the questions section I just mentioned

okay about mark forged we were founded out of MIT in 2013 we shipped our first printer in 2014 and our mission is to unlock the next 10x in innovation and design and manufacturing we’ve grown a lot since we shipped that first printer we now have a global fleet of printers we’re in thousands thousands and thousands of printers in over 50 countries worldwide because many of our printers are networked the network printers dialed home and show us their IP address you can see on this map sort of our global presence so we’re we’re expanding further and further worldwide and that’s that growth has been driven because we offer we’re the only company to offer the full range of materials from plastics to metals to fiber reinforced composites but today we’re going to focus on metals so let’s start with a customer case study dixon valve and coupling is a global manufacturer of hose fittings and accessories they’ve been in business for over 100 years they offer the broadest range of products in the market and you don’t survive a hundred years as a manufacturing company without being innovative Dickson valve has sort of led the charge on moving to automated manufacturing in their industry and that’s been able to drive a great deal of profit Villa profitability and flexibility for the product lines that they make today we’re going to look at one individual particular problem that they’re facing which is an automated manufacturing cell that makes a steam pipe coupling you’re looking here at the at the pictures of the steam pipe coupling on a tray these things are cast and then machined and galvanized and the last step of the final assembly process is to put in a polymer crush ring and they press that into the part before they ship it to customers unfortunately when they machine these things the insides of the couplings are incredibly sharp you can see that the threads are present inside those are very sharp threads and the way that they press in that crush ring they use an automated cell they have a robot arm with a gripper on it which inserts into the inner diameter of the coupling expands picks it up and moves it to the press fitting station they press fit that polymer ring in and then it puts it into the output flow what you’re looking at here that sharp thread on the inside is really abrasive to the gripper on the end of that robot arm so they’re wearing through these jaws very quickly they need to make them out of a hardened material if they need to make them out of a hard material now they’re machining things like stainless steel that’s slow difficult and expensive and if these jaws wear or break now you’ve got line stoppages Dixon has a lot of flexibility in the types of parts that they make so often they’re changing out this tool as well as they’re changing the shape or type of the cup limbs that they’re manufacturing in this automated cell so that’s the problem that they face their solution requirements they need a grip or jaw for the end of that robot arm that’s robust that has an incredibly high lifecycle high surface hardness so that there’s threads inside of the part don’t eat it I’ll eat it away and then they need the ability to quickly change the nature of that tooling to minimize the downtime of this cell in their manufacturing why okay let’s look at the solution the solution is 3d printed 17 foregrip or jaws with the 3d printing metal technology from workforce that are able to go from art to the part itself the next day they say of three hundred and three dollars per gripper jaw you’re looking at the picture of three of them here on each end effector each robot arm so that means over $1,000 per robot installation robot arm installation and then they save on average against their machine shop nineteen point five days of time that’s because their machine shop is incredibly busy they have one in-house but they’re primarily using it to machine high-value customer parts so when they need tooling for the manufacturing line machined they get in line and they have to wait so now they’re able to quickly and easily design gripper jaws for this manufacturing cell much faster and incredibly less expensive all right so to understand how that all works let’s go through the process one step at a time and explain how how it goes we’ll start with an overview you start with designing your part you design the part that you want just the way you normally would in your CAD software you print it on the mark for just metal X printer you bake it in an oven there’s a washing step between the printing and the sintering that we’ll talk about about and then now you’re left with your final part and so it’s really a you know a series of steps that go from design to part and you can do that in by the next day so let’s go step by step step one is designing your part and uploading it into the murk forge software you use the CAD software that you’re familiar with today to create the part that you want you don’t have to worry about scaling because we handle that for you to account for shrinkage during the center process in our software and then you simply upload an STL of that part to the mark forged tiger software after you’ve designed and uploaded the part it’s really as simple as just hitting print the part takes about three hours to print I’m going to show you a series of progressive images of that part being created we would have liked to show it as a video but it doesn’t come across on the webinar very well but so once you’ve had print the printer starts to print that part one layer at a time what it’s printing is metal powder in this case seventeen four stainless steel that’s been bound in plastic and so unlike other traditional metal 3d printing technologies that powder is now rendered safe because it’s inside of a plastic binding system we heat that plastic binder and print layer at a time so here we will go through and watch that part be built one layer at a time just like in FDM style part creation process that you’re probably very familiar with and three hours later you have your part the next step is to take that part and put it in the washing station the Washington Cluett removes about half of the binding material it takes about nine hours to wash entirely through that part cleaning out all of the half of the binder materials so that you’re left with a part that sort of sponge like porous almost at this point the part is a little bit more fragile but it’s not like so sensitive that you could break it without trying but uh but it takes about nine hours of wash time it’s important to note that you cannot over wash the part so if you leave it in there longer that’s fine the only problem is under washing so you want to make sure that the part is at least in the washing fluid the recommended amount of time by the way the washing station is connected to our software as is the centering station which we’ll talk about next so will tell you exactly how long to wash it will track that washing and you’ll get an email when it’s done washing so this is really almost as simple as running your dishwasher you place the part in the basket drop it into the station close the lid and come back and get the part back out when the timer expires once the part has been washed in that first layer of binder has been removed you move on to the centering step you place the part on a ceramic bed inside of the furnace we have two options of tube furnace available you slide that into the hot zone the uniform hot zone inside of the furnace and you Center the part for sixteen hours during the sintering process the part is run through a series of ramp and hold temperatures the first hold temperature burns out the remaining binder material leaving you with powder that is held loosely together as you continue up the temperature ramp those small metal powders start to neck into each other and then eventually Center together pulling into a part that shrinks by about 20% and you’re left with a final part that’s fused up to ninety-nine ninety-eight ninety-nine point seven percent dense metal the centering time is about 16 hours and that includes the time from placing the part in hitting start until the part is cooled down and is ready to remove from the furnace you can fit multiple parts inside of the furnace so depending on which furnace you pick the center one or the center two we have larger or smaller centering areas so you can put as many parts as you can fit inside of that area for each centering rod and again the furnace is connected to our software so we will monitor the centering run for you while it’s happening you’ll be able to login to the software to see where you’re at in the process and how things are going and when it’s complete you’ll get an email that it’s now time to go get your part okay so here’s the part on the actual gripper John their line parts come off ready to be used they have full isotropic strength so if you’re familiar with sort of layer at a time manufacturing and 3d printing traditionally the z-axis strength is a little bit weaker than the other axes because those layers are being but one at a time but in the centering process you actually get crystal growth that goes across the axes I’m sure your parts are isotropically strong and then the part is just the metal that you chose to print with so in this case stainless 17-4 you can choose to do any type of post-processing that you would traditionally do on that metal the tolerance is similar to caste you should think about it like near net shape so if you have a critical tolerance you can just pop this thing and a CNC and polish up whatever that critical tolerance is to get it exactly right and then here it is in use locating that fixture on the rubber ring the the polymer ring you can see there at the bottom that will then press fit that together for final shipping okay so they were successfully able to print their gripper jaws let’s look at their return on investment when they were machining that part in house the cost was around three hundred and fifteen dollars the all up cost on the metal X is $11.45 apart that’s about six dollars of material cost and the rest is allocated across Washington and the gas that is used to run the furnace to create the atmosphere inside the furnace during sintering the savings per part then is like three hundred and three dollars which is ninety six point four percent against their traditional manufacturing mechanism and then of course time time is really critical in a manufacturing environment they’re now able to get their part by mid the next day instead of waiting around on the machine shop that cuts down weeks of time from their process and gets them to about a 92 or 93 percent savings in time so that’s why why this makes a lot of sense for them they’re able to accelerate their ability to react to changes to change parts going through the automated line and to replace broken parts incredibly quickly and save a lot of money about a thousand dollars in instants while doing it so those are the crucial benefits they get parts the next day their workflow is simplified if any of you have worked with a machine shop in the past often you need to cut drawings to mention those drawings then hand them off to the machine sometimes you need to create we’re holding fixtures there’s a lot of work that goes into having a part machine complexity is free with 3d printing so it’s a much easier problem you go straight from the design to printing the exact part that you’re going to need that let you gets get products to market much faster and it increases your profitability of your manufacturing line so that will be hosting is going to take place on October 3rd and in that webinar we’re going to tell you how this process scales from printing prototype parts to high-volume production all using the very same printing and sintering process that you’ve seen today I’ll give you a hint here that the answer is through parallelization just like computers have gone from large mainframes to farms of blades this process will scale through multiple printhead installations and call them print farms that will be able to mass-produce parts at scale competitive with today’s existing production technologies for metal parts so you’ll be able to use the same exact process to prototype test iterate and then manufacture your final metal part an invitation to that webinar will be going out on October 3rd ok if you’d like to learn more you can visit mark 4.com slash metal dash x and let’s now go to the questions ok bear with us here while we try and expand the questions pane ok people are asking again if the webinar will be recorded for later viewing the answer is yes okay here’s someone’s asking if they can demo the metalic software so in I think one week you will now be able to see the metalic software working in Uyghur so you can go online and create an account that’s a software demo tab that pops up on the right hand side of the screen on Mark Forge comm you just have to put some information in because we make that account unique to you then you can upload your part it’ll tell you material x center x weight estimates costs etcetera so you’ll get all the information you need to know about your part you’ll be able to select stainless steel of course you can also play around with using the other materials that we have the composite materials and reinforcement so I do encourage everyone who’s interested to check out the software solution that can be found at Mark Forge calm okay we have some questions about the kind of washing fluid the washing fluid is a thing called opt-ins ion it’s from Khmers if you’re interested in learning more about that you can find some information online or you can request it from us we have safety data sheets and and other types of information on it the washing station takes about eight gallons of fluid to fill and you only need to replace that fluid about you replace a few gallons of it about once every couple of months and let’s say there’s some other questions on the washing station is it an ultrasonic bath know the way the washing station works is there’s a clean and a dirty tank the parts are in the clean tank the tank is constantly draining into the dirty tank the dirty tank has heated to the boiling temperature of the fluid which then evaporates above the clean tank and is condensed back into the clean tank so the washing station is running a continuous cleaning cycle on the fluid accumulating removed to binder in the dirty tank so when you’re ready to change out that washing fluid you just go to the back of the wash one you open a valve that drains fluid out of the dirty tank and then you pour more fluid in through the open top into the clean tank like I said even under heavy usage you may go through a gallon of that fluid like month or two and so even even in house when we’re using the thing 24/7 I think we first it took us four months to use our first gallon so that’s probably a conservative estimate you don’t lose a lot of it because it’s convinced carefully to stay within the machine okay let’s see how do we deal with supports supports are printed in such a way that they’re easy to remove post centering there’s two types of supports there’s printing supports and centering supports both of those are designed to automatically make it so that your part is easy and ready to go at the back end of the centering process okay I’m going to keep going here what kind of tolerances can I hold the tolerances are similar to near-net shapes so you can expect a few thousand ton part geometry what kind of gas is required for the centering furnace okay there’s two gases that go into the centering furnace the first is argon you connect a Dewar of argon so incredibly cheap that’s used for most of the sintering cycle and then for the critical part of the sintering cycle where you’re we’re at like Final Center temperature you use an argon with four percent hydrogen mix in the case of stainless steel the gas mixture is always like that it’s either a forming gas or a argon and that kind of depends on the material that you’re using but the sintering furnace will be capable of covering a wide variety of the materials we’re going to be introducing there’s a question about the software doesn’t know to scale the part correctly to compensate for the shrinkage yeah of course that’s the the trick of uploading the STL file is then calculating what will happen as that part is then centered and making sure that we print the part that results at the end in a part that is exactly or as close to the shape of your intended and part as possible okay let’s keep going keep scrolling when will aluminum material be available so I will be starting with stainless steel I would expect aluminum sometime early next it’s in beta now does the centering time depend on part size it can but typically we’re for the sake of simplicity I’m going to start by having a a one time centering profile that’s the same because you could put a bunch of different size parts into the furnace so we don’t want to make it look really easy for users to ensure that they get a good result over time we might look to introduce some software that helps us to tell which part you’re putting in you might be able to pick the part on the screen for example in that case we could Center out the shortest time for your individual part okay let’s continue scrolling through let’s see what what what size it is of oso4 specifications I’m sorry if you’ll look in the handout section of the webinar and we’ve uploaded the data sheets for the metal printer the two centering furnishes and the wash one so a lot of these questions on the size of the print the geometry limitations things like that are all answered in those data sheets I encourage everyone to take a look and then that should cover most of the questions here including including the costs let’s keep going so what’s this one okay some people are asking if they’re using third-party centering furnaces how will they know time and temperature to use will share that information with you on the central profiles one way to think about this is the post-processing the washing and centering technology is the same as metal injection molding if you’re familiar with that there’s plenty of production grade metal injection molding furnaces that are available today and so any if you already have one of those furnaces and the washing station for parts for metal injection molding then you’re good to go you don’t need to buy those components of the solution from us if you’re doing incredibly high volume of parts it’s probably recommended that you have one of those production level solutions okay let’s keep going many of these we’ve already answered the materials are stated in the datasheet the ones that are in beta at a high level the way to think about it is any metal that can be powdered and sintered can be produced through this process so the list of materials that we’ve been sharing today is very similar to the list of materials it can be extended to cover the range of metal injection molding materials so you can have like hundreds of different types of metal over time we’re going to try and prioritize the material introduction by demand so if there’s a specific metal that you’re interested in please let us know and we will we will take that into consideration in the roadmap for materials okay let’s keep going someone is asking if more than one part can be put in the bath in the oven at the same time yes you can put more than one bath more than one part in the bathroom in the centering furnace you can live those up to the full area of their working volume and the software will account for the longest washing time necessary dependant on part geometry so again it’s kind of set it and forget it but depending on you know the part that takes the longest to wash we’ll make sure that the rest of the parts wash for at least that long and then the centering run as I mentioned earlier is uniform so for all the parts we put in we’re going to run the same full centering profile to begin with so that we’re sure that the parts have good outcome properties okay let’s see we’re still scrolling through these some people are asking for information about heat treating parts if you need to do a post printing Center and heat treating process you can do that just like you would on a typical part made of that material okay let’s keep going how easy is it to switch metal materials it’s very easy you just swap out the material cartridge with whatever material type you want next you purge the nozzle a little bit to clean out all remaining of the previous metal and now you’re printing with your new metal material can you drill tap ream after centering absolutely absolutely you can you can do that you can basically post-process these parts in the same way you would post process the underlying material that you choose to print with okay so I’m seeing a lot of repeat questions now we’re still scrolling through them we’ll try and take a couple more somebody is asking when the middle X will be available we’re shipping our first systems to government clients this month we’ll be shipping more throughout the rest at the end of the year if you haven’t ordered by now there’s an incredible backlog I would not expect to get your machine and system until early next year okay some people are asking if we sell the washer yes we do you can find the data sheet for the wash one in the handouts for the presentation as well as the available material sorry okay and then it is worth noting some people are asking about the environment for the printers and the washer and the centering furnace it’s evident in the datasheet but I’ll state it here for fully AK fully accuracy that you do need to provide ventilation at about a hundred cubic feet per minute to the outside for both the washing station and for the center and furnace that’s just to be sure that everything goes outdoors and is not in any way dumped into your working environment this is pretty traditional in a shop shop environment okay you asked is the fluid by-product toxic this opt-ins on fluid is sort of well-known it’s a reason it’s a very safe fluid they were regulated these types of fluids were regulated a while back because they were damaging to the ozone so this one was developed because it breaks down in sunlight it doesn’t have time to damage the ozone so it’s sort of a new generation of cleaning solutions that are actually more environmentally friendly you do want to vent the dragging station which is the place where you put the parts to dry that takes about 10 minutes after washing to the outside which is there’s a port on the back of the washing station you just hook your ventilation up to the stuff is heavier than air but that’s just mixtures make sure that any remaining vapor from it is just vented outside of the building where it’s dispersed it’s not particularly toxic you can smell the material orders of magnitude before toxicity so it’s reasonably safe and easy to use and your main your main objective is to sort of keep the lid closed when you’re washing it so that you don’t have a lot that’s evaporating and so it all it all works well and is safe when you’re disposing of the used material you simply call for a chemical pickup it’s kind of like disposing of household paint if you have any other chemical pickup going on you already know how to do that if you don’t it’s reasonably easy to sign up for low-level chemical pickup creation services we did that internally it took us very little time and it’s very easy to just put this in a chemical container and then someone comes and picks it up okay I that’s probably enough questions for now and we’re seeing a lot of repeat questions in here so it’s it’s hard to parse through the others if you have asked a question that we didn’t get to we are going to come back and try and answer everybody so expect us to follow up via email or from a phone call to like help answer your individual questions thank you very much for attending the webinar and I look forward to having you on the next one where we talk about scaling from from predator to production thanks everyone

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