CHALLENGE

Nesting and fixtures are essential for smooth and consistent automated manufacturing processes. A high number of manufacturing cycles can cause nests or fixtures to lose tolerance, become ineffective and cause items to be manufactured out of tolerance. The challenge is to find a material that will remain durable and strong while also not damaging the items that are being held in position in them. Nesting and fixtures in an industrial setting are often exposed to high compression forces, stamping and impacts from industrial machines, but must be able to handle fragile class-A surfaces without damage.

Moreover, many nests and fixtures are routinely exposed to common shop and industrial cleaners, solvents, and coolants. As a result, they must be made of highly chemically resistant materials that also provide high impact and abrasion resistance.

New nests and fixtures are often required with very short lead times to ensure that manufacturing operations are not interrupted. Cast urethane has previously been the preferred solution for manufacturing nests and fixtures, but the process is time consuming, messy, expensive, and limits the geometries that can be created.

SOLUTION

Forerunner 3D, a 3D printing service bureau and designer of automated machines and robot cells, uses Lubrizol 3D Printing Solutions’ ESTANE 3D TPU M95A thermoplastic polyurethane (TPU) via powder bed fusion to produce high-performing nests and fixtures that are long lasting and durable. Not only is the 3D printing process faster and offers more design freedom than traditional manufacturing, the abrasion resistance of ESTANE M95A is excellent.

ESTANE 3D TPU’s impact resistance is higher performing compared to more rigid materials (like PA12) that will shatter or crack when subject to repeated impacts. M95A is also a class A finish safe material, it has been tested on painted, chrome plated, mold-in-color, and lenses, without scratching any of these finishes over 100,000 of cycles. Lastly, the TPU’s chemical resistance ensures that exposure to common shop chemicals will not permanently degrade or warp the nest or fixture.

RESULT

The application of ESTANE 3D TPU has improved the chemical, impact and abrasion resistance of the nests and fixtures that are being used, while maintaining consistency in dimensional stability. The high abrasion resistance allows for many cycles without a loss of tolerance of the jig and fixture or damaging the finish of the part.

Additive manufacturing (AM) allows for the best customer experience when facing different part designs, making it easier to design with a more cost-effective solution. Larger freedom of design is possible with AM as this is not as limited as in cast urethane and allows for more complex structures.

Not only are the process and resulting part improved, but Forerunner 3D can also achieve a Class A surface safe finish because lots of nests and fixtures are designed to handle high value surface parts during manufacturing (chrome parts, automotive paint…). Damage to the high value parts that they are in contact with can be avoided.

For examples of M95A testing being used by Forerunner 3D visit: https://forerunner3d.com/3d-printing-for-automated-equipment/

The information contained herein is believed to be reliable, but no representations, guarantees or warranties of any kind are made as to its accuracy, suitability for particular applications or the results to be obtained. The information is based on laboratory work with small-scale equipment and does not necessarily indicate end product performance. Because of the variations in methods, conditions and equipment used commercially in processing these materials, no warranties or guarantees are made as to the suitability of the products for the applications disclosed. Full-scale testing and end product performance are the responsibility of the user. Lubrizol Advanced Materials, Inc. shall not be liable for and the customer assumes all risk and liability of any use or handling of any material beyond Lubrizol Advanced Materials, Inc.’s direct control. The SELLER MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Nothing contained herein is to be considered as permission, recommendation, nor as an inducement to practice any patented invention without permission of the patent owner.

Product safety information required for safe use is not included. BEFORE HANDLING, READ PRODUCT AND SAFETY DATA SHEETS AND CONTAINER LABELS FOR SAFE USE, PHYSICAL AND HEALTH HAZARD INFORMATION. THE SAFETY DATA SHEET IS AVAILABLE FROM YOUR LUBRIZOL REPRESENTATIVE, OR DISTRIBUTOR.

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ESTANE® 3D TPU for Durable and Strong Nesting and Fixtures

ESTANE^® 3D TPU for Durable and Strong Nesting and Fixtures