Nir Sade presents a series of case studies into the practical uses of micro-AM in industrial applications.
Traditionally, micro-moulding involves a protracted sequence of stages, spanning mould design, Computer-Aided Manufacturing (CAM) programming, Computer Numerical Control (CNC) set-up and machining, and Electrical Discharge Machining (EDM), demanding 4-6 weeks for mould fabrication. Each iteration adds at least two more weeks, rendering the process economically burdensome, especially for high mix, low volume applications.
Micro-Additive Manufacturing (Micro-AM) is reshaping the landscape of micro parts production, challenging the limitations of conventional micro injection moulding. And among those using the technology is US-based company Nano Dimension who have developed a solution, called Tera 250vx, which aims to shorten the timeline and reduce costs in production. And Accumold, a pioneering player in micro injection molding, strategically invested in two Tera 250vx systems, signalling a paradigm shift in their approach to product development.
Nano Dimension’s Tera 250vx boasts a 50 x 50 x 100mm build volume, printing in 1–10-micron layers with an optical resolution of 4 microns, a tolerance accuracy of +/-2 microns, and achieving a surface roughness of 0.4 microns (Ra). For Accumold, this translates into accelerated production of innovative micro-sized prototypes and injection moulds, breaking the shackles of traditional micro injection moulding technologies.
Utilising micro-am
Accumold leverages the Tera 250vx for printing micro-sized prototype parts and injection moulds – this reduces time-to-market and unlocking geometric complexities impossible with conventional methods. Success, measured in microns and hours, is manifested in achieving micron-level detail without the need for moulds, allowing the creation of intricate prototypes within hours.
The Tera 250vx excels in handling complex geometries, where increased complexity doesn’t incur escalated costs, presenting a significant advantage over traditional methods, according to Accumold. Furthermore, the technology optimises workflow, diminishes iterative processes, and minimises assembly and inventory requirements, translating into tangible operational cost benefits at the micro manufacturing level.
Crucially, 3D-printed micro moulds can be employed by Accumold for injection moulding real parts, revolutionising the possibilities for mould makers and manufacturers. The expedited and cost-effective nature of printed molds presents a compelling business case for applications ranging from prototype runs to mass production, a departure from the constraints of long lead times and high costs associated with traditionally manufactured mould tools.
See real-time case studies of micro-AM here.