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Second laser sintering machine meets new demand

Edited by the Engineeringtalk editorial team Oct 31, 2003

3T RPD is installing a second EOS P700 laser sintering machine to meet increasing demands for large-scale prototypes and small-batch component runs.

The installation of a large-format EOS P700 laser sintering machine in April of this year was a significant step for 3T and made available components up to 700 x 580 x 380mm without the need for joining.

The market reaction has been such that now, just six months later, 3T is installing a second EOS P700 machine.

This increase in capacity is formidable and will bring with it the ability to handle ever-larger projects brought on by the high level of functionality that laser sintering can offer.

3T already runs two other EOS P360 machines and a DTM machine.

This collective capacity places it in the enviable position of having the largest SLS capacity in the UK and, moreover, puts it among the top three SLS providers worldwide.

Further, it not only allows for very large jobs to be processed quickly, but also allows a variety of materials to be run simultaneously without the need for constant material changes.

As the functionality of 3T's prototypes has become increasingly accepted, more and more customers have sought to produce multiple assemblies of parts, in addition to the initial form and fit components.

These are then used for a variety of test purposes when fully assembled with motors, electrics etc.

This has led to a dramatic increase in the average component count per order and to meet the stringent lead times, the need for further capacity.

It is envisaged that the vast majority of work can now be delivered in less than three weeks, irrespective of complexity and component variety.

For example, multiple design iterations can be built and tested without the need to go to silicon tooling and polyurethane, an expensive option if only a few parts of each design are required.

3T continues to work with customers to derive more data concerning what is and isn't possible with components built using laser sintering.

The nature of the process and materials are under constant review to stimulate new ideas and refine existing ones.

A recent project was launched that will see many parts from a Smart car rebuilt and fully road tested as a very clear message as to what can currently be achieved.

The ability to colour parts has had a big impact on the use of components.

Previously the only option was paint, a time-consuming post op process that could affect dimensional tolerances.

Now, with 3T's revolutionary process, whole batches can be coloured very efficiently leading to new opportunities, an apparent surface finish improvement and greatly enhanced resistance to discolouration.

Whilst the majority of 3T's activities relate to the prototyping of components, there are also new opportunities being created in manufacturing.

The capacity that 3T now has available makes the manufacturing of small production runs a reality.

Thousands of parts can be produced in a 24-hour cycle, coloured and shipped within a week, without the need for any tooling.

The potential for this is considerable and has been limited by the lack of capacity.

Projects that build on laser sintering strengths, while obviating or circumventing the aesthetic issues, will be the first to fruition.

Tim Plunkett, CEO of 3T, says: "The purchase of another P700 further consolidates our commitment to the rapid prototyping industry and supports moves made earlier this year to focus on our core business activity.

Laser sintering as a technology still has significant untapped potential that 3T intends to deliver to the market, both through prototyping and manufacturing.

This latest acquisition will allow us to focus on providing our customers with the best components available, in the shortest lead times possible".

He continues: "It is a powerful indication of 3T's capability that since conception and the installation of our first machine in December 1999, it took just over 6 months before we had to acquire a further two machines.

In April 2003 we installed the large format P700 and 6 months later we need to install a second to keep up with our developments and customer demand".