WEMO
An intricate surrogate stainless-steel part for improved machinery at reduced costs
The client
At Additive Center, we specialize in advancing Additive Manufacturing (AM) technologies for various industries by integrating AM into existing manufacturing processes. We've partnered with WEMO Special Projects, a leading provider of custom production lines for sheet metal processing to explore how AM can transform their production lines by introducing smarter machines and components to optimize machinery productivity, integrate lightweight parts, and reimagine design approaches. Additive Center is proud to drive innovation and deliver value-added solutions to partners like WEMO Special Projects.
The challenge
The part that we identified that could be improved was the stainless-steel sheet bending part. To eliminate tolerance build-up, our engineers explored a robust monolithic design capable of accommodating various variable inserts. The part should rotate around a connected axis at the top and be securely fixed as per the tool or insert. Specific surface areas of the part must sustain functionality.
We utilized Apex Generative Design software by Hexagon to sculpt the part based on functional features and applied forces. The final geometry preserves the functionality of the original features, ensuring sufficient material connection to support the applied forces. The optimized part underwent stress and deformation analysis, resulting in an improved, cost-effective structure. The refined design was manufactured using Selective Laser Melting (SLM) - Additive Manufacturing technology.
Original
In their line of heavy-duty sheet bending machines is a part that holds the various tools used for bending. Conventionally constructed out of 4 CNC-milled elements, this part is consecutively put together with pins, washers and screws making an assembly of 22 parts in total. The tolerance build-up in this assembly makes the milling process both complicated and costly. And that’s exactly where Additive Center could add some value!
Redesign
A single-part solution, designed to not only reduce costs and lead time, but also to transform the way you approach production. Crafted with stainless steel using cutting-edge 3D printing technology, our solution offers unmatched efficiency, precision, and quality, delivering exceptional results that will elevate the production process to a new level of excellence.
The advantages
Reduced costs
Significantly cheaper to produce
Reduced weight
60% weight reduction
Easy assembly
There is no need to piece together 22 different parts.
Lead time reduced
Lead time reduced from several months to several days
Quality control
Improved quality by avoiding tolerance build-up
Single material
Streamlining the supply chain with organic, monolithic design to reduce material waste.
Curious to see what WEMO thought of this solution? Find out in the video:
Additive Center takes great pride in being a founding member of AMcubator. This ecosystem enables us to collaborate with other top-tier companies to achieve optimal results. What distinguishes AMcubator is our steadfast dedication to delivering tangible business value. From housing leading 3D printing companies to providing cutting-edge equipment in our pilot factory, AMcubator offers a distinctive platform for collaboration and innovation. Our objective? To streamline your AM journey, enhance processes, and ultimately propel scalable applications to market success. Interested in discovering how AMcubator can add value? Click here to learn more.
The following companies contributed to this specific project:
AM Solutions plays a pivotal role in enhancing the WEMO case by providing comprehensive post-processing solutions tailored to optimize the quality, functionality, and aesthetics of Additive Manufacturing (AM)-produced components. Their expertise in post-processing encompasses meticulous removal of powder and support structures, surface smoothing, homogenization, and polishing. We work closely with WEMO to optimize part designs for post-processing, ensuring sustainability and cost-effectiveness throughout the manufacturing process.
Starting with the functional features and the forces applied, we used Apex Generative Design software from Hexagon to ‘sculpt’ the part. In the final geometry, the functionality of the original features is kept fully intact. These function features were connected with enough material to ensure support for the forces acting on them.
Finally, the new part was put to the test with a stress and deformation analysis, resulting in an optimised structure and a cost-effective improvement of the machine part. The optimised design was produced with a Selective Laser Melting (SLM) - Additive Manufacturing technology.
Impressed by our work? Tell us about your goals, and let's craft a plan tailored just for you!
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