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Mark Two: Applications for glazed windows and extruded profiles

Mark Two: Applications for glazed windows and extruded profiles

September 18, 2017 in Case study, Case study, Case study, Case study, News, News, News, News

Problems in prototyping

 

Windows and buses are the main product line of “Arow Global“, a company based in Wisconsin, specialized in the production of windows for the means of transport. The company is committed to improving the simplicity, robustness and design of the product on a daily basis in order to increase the safety of drivers and passengers. Joseph Walters, a new product development engineer, is at the forefront of product development research and, in order to improve the company, he realized that it was necessary to improve the prototype flow of “Arow Global” in order to achieve a more efficient process.

The company often works with extruded aluminum and rubber, which are coupled to the glass by means of a sliding and assembly process that can take a lot of time and money. “We currently do a lot of extrusion work, both in aluminum and rubber,” said Walters. “There is no way to prototype quickly without having to spend hundreds of dollars for a piece just four inches. Essentially this is an EDM (electro-erosion) machine that goes to work (remove material) to a four-inch aluminum block , time required: 2/3 weeks … Last time I designed a new type of engraving (aluminum, rubber and glass) I had to develop 6 prototypes for a total of over $ 1500. ” Just experimenting with new ideas was becoming too expensive, so Walters needed a new prototyping method: “Our company is always looking to be more cost-effective, but continuing to produce a high quality product. That’s why which prompted us to look for rapid prototyping machines. “

Meeting Mark Two

 

Walters knew he needed a rapid prototyping machine to improve the prototype process. “When developing profiles there are many variables. For example, for rubber at the moment we do not have a system that allows us to prototype extruders without having to pay for: cutting the mold, taking samples, developing unavoidable revisions, and restarting with the process … “said Walters. “Instead, with 3D printing we can make extruded at night … Designing, printing, editing the design, printing it again, making another change all very quickly, so we have evaluated 3D printers.

Prototyping becomes expensive whenever you make a change and create a new revision, but this is the nature of the parts that Arow plans to develop, realizes head and sells, and this is why a fast and extremely precise prototyping technology is needed. To prototyping correctly, Walters was looking for a printer capable of handling the wear and tear variables of the piece, in order to manage and approach the actual piece: “We wanted a prototype that could be used, so we did not need a” Cube Pro ” pieces in PLA and ABS because they are too fragile.

This was one of our requirements and this has led us to meet Markforged … that with the possibility of introducing carbon fiber to create harder parts like aluminum really gained us, “he said. Once the Markforged Printer , Walters had to convince the superiors about the goodness of the investment, and that the technology would not have caused any problems. “Thanks to our enthusiasm for using a new technology and high return on investment (Mark Two), the approval was immediate,” said Walters. Mark Two could dramatically lower prototyping costs and delivery times while at the same time could increase efficiency and production times, and this also meant simplifying and improving the design process Arow Global.

“We wanted a prototype that could be used, so we did not need a” Cube Pro “to make pieces in PLA and ABS because they were too fragile. This was one of our requirements and this has led us to meet Markforged … that with the ability to introduce carbon fiber to create durable parts such as aluminum has really gained us “

Joseph Walters

New Product Design Engineer Arow Global

The first cracks

Joseph Walters, a design engineer at the Arow Global transportation window manufacturer, was tired of high prototype costs and long delivery times.

 

The repair

Walters knew that “Arow Global” needed a prototype machine, and after discovering Mark Two, he realized that his ability to make parts that were precise, durable and usable in a real context was exactly what was missing from the flow prototype.

 

Breakthrough

Mark Two took the cost of $ 400 to a few dollars, from two weeks to one night, and changed the way Arow Global designs and manufactures its own parts.

Numbers comparison

 

CostTime
Printed Part Markforged$1.591.92 hours
Machined part (workshop)$400.00420 hours

Redesign with Mark Two

 

After buying the Mark Two, Arow could dramatically improve the prototype process. “I was working on a project, and thanks to the opportunities of Mark Two we got to get a profile with rubber inserts that would simplify the placement of the glass during the assembly,” said Walters.

We’ve improved the workpiece features in order to simplify the mounting phase … otherwise the fitters would have assembled roughly based on methods used in the past and instinct regarding glass positioning, increasing the error rate“. Now with the Markforged printer, they can afford to print multiple prototypes, edit them, and test the various revisions without having to spend the time and money they spent before. “But with Mark Two,” Walters continued, “we can go further, we can test the piece and get the information needed to develop reviews, and even make three or four revisions in a week. Previously, we had to cut the mold and check them out of time and money … The printer has drastically contributed to reducing inventory waste (waste molds and prototypes) and reducing work time. ”

“Making a template from our vendor cost us $ 400 and delivered us in two weeks, now we can make it through 3D printing on a weekend”

Joseph Walters

New Product Design Engineer Arow Global

Mark Two in Arow Global has shown its value in several areas. In addition to prototyping, the company also used the printer to produce mounting dimes. Walters describes the process improvement: “Making a Dima from our vendor cost $ 400 and delivered us in two weeks, now we can make it through 3D printing on a weekend and the results are great … just think that many Dime 3D prints continue to be used today. ” Some Dime have been widely used during the assembly process, approaching 1000 cycles: “We currently do not see any visible signs of wear on nylon dime and are not even scratched, whereas earlier with aluminum dime could occur (rubbing with materials harder), but with Nylon this problem does not exist 

Now Walters and Arow Global are looking to increase the use of the Markforged printer to reduce costs and reduce production and assembly times: “We are fully rethinking the design of Drilling Dimes. Now we can make complex designs that we could not do in past because there was no possibility … thanks to Markforged, being an additive machine, and not subtracting, we no longer have to worry about this. ” The Mark Two has allowed them to simplify and expand prototyping and offer them the opportunity to re-evaluate the level of efficiency of design and production of parts thanks to an alternative system to the traditional solution.

“Now we can realize more complex projects that in the past were not even contemplative”

Joseph Walters

New Product Design Engineer Arow Global

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