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Stanley Black&Decker and Markforged: 3D metal printing of the PD 45 part.

Stanley Black&Decker and Markforged: 3D metal printing of the PD 45 part.

February 19, 2019 in Case study, Case study, Case study, Case study, News, News, News, News
Stanley Black & Decker and its history.

Based in New Britain, Connecticut, Stanley Black & Decker is the world’s largest manufacturer of tools, fasteners, storage and other equipment. As a tool and hardware company, it constantly innovates in its products and processes. Above all, Stanley Black & Decker is interested in integrating more 3D printing into its production process than it already does.

What is Stanley PD 45?

First of all, the Stanley PD 45 is a high-performance hydraulic pile driver. In order to operate the hydraulic drive mechanism, the actuator housing contains the bearings in series to transfer the tractive force around an elbow. Then, each box is tested each time the operator pulls the trigger.

Originally, the actuator housing consisted of four parts: a molded and machined main housing, a laser-cut cover plate and two bolts to secure the entire housing.

3D printing and new design thanks to Markforged

First, Stanley Black & Decker engineers redesigned the part to print it on Markforged’s Metal X. Instead of a four-part assembly, the “redesigned” part is printed in one go without support material.

Then, the engineers rigorously tested the performance, durability and life cycle of each of the two parts and approved them for end use.

As a result, Stanley Black & Decker chose Markforged’s new Metal X additive manufacturing technology to produce reliable 3D printed production parts and reduce their investment costs and lead times.

The advantages of 3D printing

First, by replacing the drive shaft with Markforged’s printed flange, the final results have improved. Stanley Black & Decker saves between 34% and 48% on manufacturing costs and reduces parts production time by 69%.

As their existing process only produced parts in series, printing unique parts with Metal X is 12.5 times cheaper and 20 times faster than using current processes.

Above all, the parts printed with Metal X allow manufacturers to save a significant amount of capital if the machine is used correctly.

The testimony of Stanley Black&Decker

Thanks to this printer, it is certainly possible to produce high quality parts at a much lower cost than traditional manufacturing.

“It is quite possible to take advantage of Metal X in the additive manufacture of the actuator housing with a lower investment in capital and time.

Moreover, engineers believe that this technology can save money, while reproducing the quality and reliability they expect from machined parts.

In a few words: 3D printing on metal with Stanley Black Decker

In a few words: 3D printing on metal with Stanley Black Decker

  • CRITICAL PART – This part contains ball bearings that transmit the release force to a PD45 hydraulic cylinder.
  • HIGH OPERATION PART – An operator exerts a force on the housing each time he engages the driver.
  • CONSOLIDATED – Metal X has replaced a four-part assembly with a single piece that works instantly.
  • SAVINGS – Stanley Black & Decker realized 12 times less costs and 20 times less time on this part.
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