3 ways to produce reliable parts faster with simulation

Last month we Markforged Simulation introduced as a free trial version in Eiger.

Simulation allows users to virtually test and validate the strength and stiffness of parts before manufacturing. What does this mean for product developers and manufacturers? Fewer iterations are required to achieve the desired final part. Ultimately, this means you can deliver reliable parts both cheaper and faster.

How can simulation optimize your product development and production processes? Here are three different ways you can use simulation to deliver reliable parts faster.

The simulation is available in Eiger as a free trial version until March 31, 2023 – Test now.

Lead Applications Engineer Charles Lu shows you how all this is possible with Simulation, the groundbreaking new feature in our Eiger software. Print the right part, the first time.

The simulation is available in Eiger as a free trial version until March 31, 2023 – Test now.

Customer trust means a win-win situation

When Pipeline Design & Engineering's client needed a custom inspection station ahead of schedule, Pipeline proposed replacing 50-60 end-user metal parts with 3D-printed Onyx parts to advance the delivery date by months.

The client, a medical device company, was skeptical about the quality of the 3D-printed parts until the final part was delivered. After seeing the result, "the floodgates opened for them," and the client recommended printing as many parts as possible in the future.

Bottom line: For risk-averse customers in a similar situation, simulation can provide tangible part performance data to increase customer confidence in part quality before printing—meaning the customer gets the part they need faster and at a lower cost.

Faster prototyping, faster production

KST Moschkau, a security systems manufacturer, is using the FX20 to replace aluminum components in one of its key products – an outdoor security camera mount – with Onyx.

For KST, the FX20 solves a critical problem in the production supply chain (read)Using aluminum parts from a machining shop meant 1) expensive prototypes and 2) highly unpredictable lead times for both prototypes and production parts. With demand for the camera mount exceeding expectations, KST was under pressure to deliver quickly.

When creating prototypes of similar parts for final production, manufacturers must test performance to ensure that the final part can reliably accommodate their customers' multi-thousand-dollar Panasonic PTZ cameras and withstand harsh outdoor conditions without deteriorating over time.

Conclusion: 3D printing saves time through faster iteration cycles – and using simulation to validate performance before printing can enable manufacturers in similar situations to create prototypes even faster and with less testing, while reducing prototyping costs even further.

Read the full report on KST Moschkau here: Read the case report

Repair chaotic supply chains without looking back

Larsen Motorsports used simulation to quickly replace an aluminum steering wheel with one made of continuous fiber reinforced Onyx, confident that it would maintain its performance even under the forces exerted on a jet-powered drag racing vehicle traveling at speeds in excess of 276 mph.

In the past, machined aluminum steering wheels took weeks or even months to arrive, as modifications were often required to meet the individual needs of the drivers. The lengthy process of modifying the stock aluminum steering wheel carries the risk of the steering wheel not being ready before the race, which can compromise safety and race performance.

ConclusionSimulation allows Larsen Motorsports to take a shortcut in the supply chain without compromising quality. The steering wheel can be easily customized and manufactured quickly without compromising performance.

How can simulation help you deliver reliable parts faster?

The simulation is available in Eiger as a free trial until March 31, 2023 – Test now.

Questions about Markforged Simulation Software

The simulation is now available as a free trial to anyone with a Markforged Eiger account. If you don't already have an Eiger account, you can register now and get free access to the simulation.

The free trial version of the simulation is available until April 2023. After that, it will continue as a paid subscription service. If you would like to take advantage of this opportunity, you can try the software for free here. Test now

Reliable and high-performance strength is necessary for 3D printed parts used in tools and demanding end applications.

Previously, this required complex and repeated design compression fracture tests, which multiplied processing times, consumed disproportionate amounts of material, and required additional labor to maintain careful testing protocols.

Alternatively, time-consuming and expensive analyses were performed, requiring highly skilled personnel and expensive software. Another option was to consistently overbuild parts with excessive infill density and reinforcement material.

Our commitment was to develop a fast and automated solution to verify the performance of your parts, ensuring smooth production of parts that meet the requirements of demanding end applications. Our in-slicer simulation feature eliminates the need for time-consuming design compression fracture tests, resulting in significant time and cost savings.

  • Thanks to powerful simulation technology specifically developed for additive manufacturing, users can conduct virtual testing to ensure their 3D-printed parts have the required strength for industrial use. Simulation also eliminates uncertainties in configuring print parameters to ensure all performance requirements are met.
  • By leveraging simulation, reliable parts can be delivered faster by eliminating design-print-test iterations and rework. Unlike traditional simulation tools that require specialized expertise and time-consuming analysis, our simulation is integrated into Eiger and specifically optimized for additive manufacturing, allowing users to test parts within their usual slicing and printing workflow.
  • Our simulation also helps reduce the cost of 3D-printed parts by automatically optimizing the required quantities of material and continuous fiber reinforcement. By adopting settings that optimize strength, cost, and print speed, you can avoid overbuilding parts and wasting material. Virtual testing replaces the typically required 5 to 25 print iterations, which can result in significant savings of hundreds or thousands of euros per part. This opens up new application areas for fiber-reinforced composite parts and allows you to replace metal tooling and end-user parts quickly, cost-effectively, and easily.
 

Simulation for validation and optimization of 3D printed parts

3D printing technology has revolutionized the way we manufacture and develop products. It offers the possibility of creating complex geometric shapes and specific parts that would be difficult or impossible to produce using traditional manufacturing methods. In this context, it is crucial that the printed parts not only have the correct shape but also have the necessary strength and rigidity to fulfill their function.

To meet these requirements, simulation offers an effective way to validate and optimize the strength and stiffness of 3D-printed parts. Simulations allow manufacturers to determine optimal printing configurations to reduce printing time or material costs while ensuring the required properties.

Printed part validation is achieved by identifying anchor and load areas, which are then evaluated using loads, safety factors, and maximum deflection (stiffness). A simulation is performed to determine whether the part meets the requirements. This allows users to quickly validate whether the printed part meets the required properties.

After validation, the optimization feature provides the ability to generate alternative print configurations that prioritize faster print times or lower material consumption while meeting part property requirements. This is done by running multiple simulations to determine the best print configurations.

Finally, with a click of the "Print" button, the user can print the part with the current configuration or a previously selected alternative configuration. This ensures that the printed part not only has the required properties but can also be manufactured in less time and with lower material costs.

Overall, simulation provides a powerful way to validate and optimize the strength and stiffness of 3D-printed parts. This allows manufacturers to quickly and effectively determine the best printing configurations and ensure that their printed parts meet the required properties.

Test the Eiger software now!

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Learn more about the applications with the MarkTwo!

Which continuous filament is suitable for which application? How do I design correctly for filament 3D printing? What do users say about it, and where can I find more information? – You've come to the right place! We've listed several information sources that will help you get the answers you need.

Construction guide

This guide is intended to help you generate ideas for better design results for your components. It's specifically designed for additive manufacturing processes.

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Stronger than aluminum

For years, a compromise between strength, delivery time, and cost had to be accepted. This can now be easily avoided!
 

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Webinar

Find out which material works for which application and how you can individually insert it into the component with EIGER.
 

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