Product category:
Rapid Prototyping
News Release from: Moog FCS | Subject: ThermoJet solid object printer
Edited by the Engineeringtalk Editorial
Team on 22 August 2000
Solid object printer for aerospace
casting company
A ThermoJet solid object printer from 3D Systems Europe Limited has been installed at the Honeywell Precision Casting Facility (Normalair-Garrett Limited) in Chard, Somerset.
A ThermoJet solid object printer from 3D Systems Europe Limited has been installed at the Honeywell Precision Casting Facility (Normalair-Garrett Limited) in Chard, Somerset The system is being used to produce both 3D output for design verification and prototype patterns for lost wax investment casting processes Since its installation in November 1999, the ThermoJet system has enabled Honeywell to significantly reduce development lead times, enhance the 'first run' product and minimise manufacturing costs, through the elimination of errors at the design stage, before costly tooling is produced
This article was originally published on Engineeringtalk on 20 Jun 2008 at 8.00am (UK)
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Prior to the introduction of the ThermoJet system, Honeywell subcontracted the production of 3D prototypes to an external bureaux service.
This procedure, however, was both costly and time consuming, with Honeywell feeling it had little control over the process.
"It was at this stage that we decided to investigate bringing the facility in-house," explains Derek Shipp, Principal Engineer.
"We examined various RP technologies, before deciding on ThermoJet, but none were able to offer the high tolerance surface finishes we require and were more costly, both in terms of capital outlay and expenditure on training." He continues, "With the ThermoJet system we are able to produce prototype patterns with production quality finishes, quickly and easily.
Furthermore, the system is so easy to use that investment in training was negligible.
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In fact, we were producing production quality parts the day after the system was installed and have been using it almost constantly ever since." One of the particular benefits of the ThermoJet system to Honeywell, is the ability to use the ThermoJet output as the master pattern for prototype and very low volume castings, as the thermopolymer material used by the system is very similar in its characteristics to the wax patterns used for larger volume production runs.
In essence, the ThermoJet pattern is assembled onto a runner system, which provides the means whereby the molten metal can pass into the mould and fill the cavities - so producing the casting form.
A ceramic mould is created by dipping the assembly alternately into a water based refractory slurry and fluidised bed of stucco.
Mould strength is established by altering the number of coats, with each coat being set by forced air drying.
The ThermoJet pattern and runner assembly is removed from the mould by melting the material out in an innovative flash dewaxing system - Honeywell being the first foundry in the UK to employ such a unit - leaving a clean, high quality ceramic mould for the casting process.
For full volume production Honeywell uses high pressure wax injection moulding machines to produce multiple wax patterns.
"As investment casting becomes more complicated it has become more difficult for even the most experienced personnel to fully appreciate the complexity of a component from the drawing or from a 3D representation on a CAD monitor," comments Derek Shipp.
"With ThermoJet, we are able to produce accurate 3D output for review at design meetings, making it extremely easy for all concerned to visualise and review the component at any stage of the design process." The Honeywell Precision Casting Facility at Chard is dedicated to the lost wax investment casting process.
The foundry produces a range of ferrous and aluminium castings for the aerospace industry, such as fuel vaporisers, heatshield castings, seal segment castings, reheat nozzle petals and nozzle guide vanes.
Additionally, the company also manufactures specialised components, such as aerofoil sections, cast in highly-alloyed, heat-resistant materials.
Honeywell has ISO 9001 and UK Civil Aviation Authority DA1/2539/47 approvals, as well as quality approvals from the all major aerospace manufacturers, including Rolls-Royce, British Aerospace, GKN Westland Helicopters, Vickers and many more.
Derek Shipp concludes, "The installation of the ThermoJet solid object printer from 3D Systems has brought many benefits to our business in terms of process efficiencies and cost reductions at the design stage.
It is an effective tool which has enabled us to gain the edge in what is a very competitive market world-wide and has definitely been instrumental in helping us to win new contracts in recent months.".
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