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Mass Production 3D Printing Hack Chat

Down of the print farm

Wednesday, August 23, 2023 12:00 pm PDT Local time zone:
Hack Chat
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Gabe Bentz will host the Hack Chat on Wednesday, August 23 at noon Pacific.

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We'll take a wild guess and say that right now, within arm's length of wherever you're reading this, there's something that was produced by injection molding. Look around; it's there someplace, and whatever it is, thousands or perhaps millions of other identical artifacts were produced along with it, all by squeezing hot plastic into intricately machined metal tools.

It's not much of an overstatement to say that, for good or for ill, the world is made from injection-molded plastic. But not every product can support the often considerable up-front costs associated with injection molding. The tooling needed is often remarkably complicated and correspondingly expensive, and running the machines that actually do the molding is expensive and highly specialized. Unless you're committed to making a lot of parts, injection molding might just be out of your league.

But does that mean that medium-sized runs of parts are out of luck? Not at all! Gabe Bentz, founder and CEO of Slant 3D, is passionate about filling the manufacturing void where injection molding is prohibitive, either by virtue of start-up costs or because the part design is just not possible to manufacture. His massive print farms are busy day in and day out cranking out parts for customers that otherwise couldn't be made. So if you've ever wondered what it takes to run a print farm, and what kinds of design considerations make a part a candidate for mass production by 3D printing, drop by the chat and we'll see what he has to tell us.

  • Transcript Page 2

    Tom Nardi08/23/2023 at 20:13 0 comments

    Layer adhesion has a number of solutions. But really it is more of a DFAM issue from people attempting to 3D Printe injection molded designs that don't have the needed cross sectional area to compensate
    george.graves  3:59 PM
    May we ask where your engineering degree is from?
    Thomas Shaddack  3:59 PM
    Would PCTG solve the layer adhesion for PETG? What materials have the best/worst adhesion?
    ISO would be more the entity to drive standards. But the tech is still so fragmented that they can't nail it down. It is an unprecendents quantification problem
    Thomas Shaddack  4:00 PM
    Now the question is what's worse - more time without de-iure standards, or premature standardization.
    I went to Embry Riddle Aeronautical University. Mechanical Engineering - Robotics
    Premature standardization is worse.
    george.graves  4:01 PM
    Graduate or attended?
    salec  4:01 PM
    If there was a laser coupled with nozzle preheating previous layer at the point of contact with gooey thread from the nozzle, I guess the fusion between layers would be stronger
    TPU is the best for layer adhesion. Filament manufacturers should just make a high stiffness TPU and drop basically every other material. It is a perfect material in basically every relevant way
    Thomas Shaddack  4:04 PM
    @george.graves I never saw a job where paper credentials were more important than real results. Why is this "important"?
    Nicolas Guilbert  4:04 PM
    So you mainly print TPU?
    @george.graves I was the top graduate in my year.
    Dan Maloney  4:05 PM
    Whoop - we're past the top of the hour now. We've got to let Gabe get back to work if he needs to, but of course we can keep going too. I'm easy ;-) Either way, I just want to say a big thanks to Gabe and Chris for hanging out today and opening our eyes to what it means to scale up to mass production. Really interesting challenges!
    We print in whatever material the client needs that comes in a spool.
    Thanks @Dan Maloney
    Thank you everyone who stopped by. Good talking with you.
    Nicolas Guilbert  4:06 PM
    Thank you!
    joshua.vader  4:06 PM
    Thanks @Slant 3D - Gabe Bentz ! Great conversation! Thanks @Dan Maloney and hackaday for continuing to be awesome!
    Thanks!!!!
    Dan Maloney  4:06 PM
    Thanks Gabe! And thanks to everyone for the great questions and interesting discussion
    salec  4:06 PM
    Thank you Gabe and Chris
    Slant Media  4:07 PM
    Thanks guys!
    Thanks @Dan Maloney , @Slant 3D @Slant Media . good hackchat!
    Dan Maloney  4:07 PM
    Thanks all!
    Thomas Shaddack  4:07 PM
    Do you work with nylons/polyamides? What are the most common problems with them?
    Carlo Clores  4:07 PM
    thanks guys
    Thomas Shaddack  4:07 PM
    ...thanks, too!
    Dan Maloney  4:09 PM
    Transcript coming up

  • Transcript Page 1

    Tom Nardi08/23/2023 at 20:13 0 comments

    Slant 3D  3:05 PM
    What's up yall. sorry about that. Gabe Bentz here
    addodesign  3:05 PM
    Hello everyone
    Slant 3D  3:05 PM
    Hows it going Dan?
    Hi Gabe & Chris.
    eeprom  3:05 PM
    Good afternoon!
    mbrown  3:06 PM
    Is there a presentation that will accompany the chat?
    Dan Maloney  3:06 PM
    Great, and welcome to the chat! Can you kick us off with a little background info on yourself?
    Slant 3D  3:06 PM
    Well I was born on a dark stormy night...
    Dan Maloney  3:06 PM
    @mbrown - it's usually more of an AMA session, so if you've got questions, fire away
    eeprom  3:06 PM
    Thank you for your time today! Can you tell us from the experience you gained form Slant what features/specifications do you look for/must have in a printer to print in production mode reliably with a wide array of material support?
    Slant 3D  3:07 PM
    lol. Robotics engineer originally. Worked in product design for many years. Now Slant 3D focuses on makeing a warehouse when the shelves make the product
    We really don't consider any off-the-shelf machine to be viable for large scale print farms. Products targeted at consumers generally are not ideal for production
    Mark J Hughes  3:08 PM
    How are print prices calculated/estimated?
    @Mark J Hughes You stole my question. I dont have anything to ask now :)
    Pricing takes into account ~20 different variables. They include the obvious print time and material. But then take into account complexity and specific QC standards from the client that might increase rejection/recycling rate
    John Vaccaro  3:09 PM
    Is Slant 3D making its own printers, then?
    Yes. We only use our internally developed machines
    eeprom  3:10 PM
    Then what are your focus when designing a printer? Or is it too much information on the ''secret sauce''?
    John Vaccaro  3:10 PM
    and custom firmware as well, then
    Mark J Hughes  3:10 PM
    Do you have a DFM guide? So laypeople can make better design choices?
    Reliability and scalability are the driving goals. The details of the machine fall out from those north stars. A products should never be an amalgum of "features"
    Nicolas Guilbert  3:11 PM
    What makes off-the-shelf machines unviable for large scale production? Print quality?
    Our entire channel is really committed toward showing how to design real products for real mass production with 3d printing. https://www.youtube.com/channel/UC6QNjBn6KMq5-pe3OE11zZg
    Cost wise... how would 3d printing compare to injection molding, for small batches?
    Off-the-shelf machines are designed to become increasingly "user-friendly" which is not a design feature in mass production. The user in a production context has very different needs from a user in a garage. What is designed for a person can very rarely be used in a factory.
    eeprom  3:14 PM
    Is there a specific thing that you think is not though of enough when designing 3d printed products?
    Thomas Shaddack  3:14 PM
    Any specific show-stoppers for the off-the-shelf? What are some of the example differences?
    Our metric is that 3D Printing is generally a more cost effective alternative up to 100,000 units. But if a client commits to the process there is really no ceiling because the savings in shipping and wasted inventory make up for a potential higher unit cost with printing.
    Chamfers are not...
    Read more »

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