DFAM & PPE PART 2: THE NEED FOR SPEED
BY John E. Barnes (TBGA) & Buck Helfferich (TRONIX3D)
The Barnes Group Advisors (TBGA) and TRONIX3D have teamed up as small businesses to provide a unique perspective on how Additive Manufacturing (AM) can support COVID-19 efforts. In Part 1 of our blog series, we discussed the vital role requirements play in making more than a shape with AM and examined several applications of DfAM for time and cost savings.
In this second installment, we discuss one of the primary drivers for the use of AM in the fight against COVID-19. The virus is fast, and supplies are low. Therefore, everyone is looking for ways to reduce the delivery time of proven solutions.
AM SUPPORTS THE NEED FOR SPEED
Right now, we are seeing AM support the need for speed in two primary areas:
1) Rapid Design Iterations
Single port design
2) Short Lead Time Manufacturing
A Speedy Example
TRONIX3D was approached by a well-known AM community at Penn State to assess a face mask design for COVID-19 relief efforts at Hershey Medical Center. Penn State specifically wanted TRONIX3D to convert the mask design from a central single port filter design to a symmetrical dual port filter design.
72 hours after the initial request, TRONIX3D delivered the masks with the double port functionality using their DfAM skills. This displays the first DfAM area to rapidly design, iterate and print options. In the long run, TRONIX3D would recommend a technology like injection molding which can produce more parts at a lower price; this option would take several weeks to get spun up. Using DfAM, Penn State was able to assess multiple design options in days, not weeks.
The TRONIX3D solution also checked the box for low lead time manufacturing as the Multi Jet Fusion (MJF) produced masks could be deployed more rapidly than other manufacturing routes due to the lack of tooling.
Dual port design created by TRONIX3D
A Speed Bump
The mask design needed to be tested by Hershey Medical Center as clinical physicians would be wearing them during long shifts. This highlights another critical step to the overall process: testing. Many PPE designs exist today but ensuring they are designed to the appropriate requirements and then having a process to test them is a definite speed bump.
Expertly applied DfAM can fulfill the need for speed in a multitude of circumstances. To do so, a keen focus on nailing down the correct requirements and understanding the entire manufacturing route, including testing, is paramount.
Next Week: DfAM & PPE PART 3: IS AM THE RIGHT TOOL FOR THE JOB?
ABOUT TRONIX3D
Tronix3D is greater Pittsburgh’s first high-volume 3D/additive contract manufacturer and innovation center. The company provides concept-to-finished product design and development expertise and collaborates with companies in the aerospace, automotive, medical and electronics industries to deliver high-volume 3D printed end-use parts and rapid prototyping services. Whether you’re just beginning to explore the power of 3D printing or have been harnessing its potential for some time, we invite you to bring us your challenge. We will help you produce one prototype part to validate your design or hundreds of strong, functional end-use parts.
LinkedIN: https://www.linkedin.com/company/tronix3d/about/
Website: https://tronix3d.com/
Email: info@tronix3D.com
ABOUT THE BARNES GROUP ADVISORS
Formed in 2017 due to the rapid expansion in additive manufacturing (AM), The Barnes Group Advisors LLC (TBGA) seeks to fill a market gap in seasoned engineering and strategy specifically suited to the field. The advisors have a combined experience of 130 years in additive manufacturing, aerospace requirements, research and development and highly complex product development. We have participated in world’s first endeavors and OEM qualification. We offer specialized services in Materials, Systems, Techno-Economics, Digital, Economics and Strategy for advanced manufacturing, specifically, AM.
Materials
From metal powders, to wire, each feedstock brings its own requirements and each materials system its own processing sweet spot. We bring deep and intimate knowledge of where the material feedstock comes from, what the risks are and who are the major players as key to a successful engagement in AM. This includes powder production, system optimization, metallurgy, and post processing with an eye on part requirements.
Systems & Process Economics
An AM factory is a system of systems. TBGA offers advice on factory layout, machine selection, parameter development and machine customization to improve economics. We can help with quantifiable, analytical advice. TBGA can model your system to identify growth scaling issues, cost impacts and sensitivity guidance to help you achieve shorter development times and better process economics.
Digital
TBGA offers modeling and simulation support to reduce risk and offer insight to multiple processes. TBGA can assist in projects to capture existing data and make better use of it.
Professional Services, Strategy & Communications
Currently, companies know they want to participate in the value being created with additive manufacturing, they just don’t know exactly how. TBGA can use its profound knowledge to help you with your strategy. TBGA provides advice for the VC and equity markets on trends in the industry and which groups have the magic to travel the distance. Lastly, because we understand the depth and breadth of the AM market, we can help shape the communications strategy and bring efficiency to the message AM companies intend to bring.
Workforce Development and Training
TBGA develops AM specific workforce development strategies and deploys on site and online training.