RESEARCH & DEVELOPMENT ADDITIVE MANUFACTURING MODEL MAKING AND MOULD DESIGN RAPID TOOLING

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1 RESEARCH & DEVELOPMENT ADDITIVE MANUFACTURING MODEL MAKING AND MOULD DESIGN RAPID TOOLING

2 cirp GmbH supports you throughout the entire product creation process from the idea to the finished product! cirp GmbH, based in Heimsheim, Baden-Württemberg, is a leading service provider for prototype and small series manufacturing. Our activities centre around the key areas of research and development, additive manufacturing, model making and mould design as well as rapid tooling. cirp supports its customers from the first draft to the start of series production. As a project partner, cirp offers complete service packages from the design and choosing the materials and technology to use through to the finished product. In the process, 20 years of experience with national and international industrial orders and research projects are incorporated into the development and production of your product. Precise component testing in our quality assurance function can also be used to identify discrepancies between the component and the CAD data and eliminate cases in which the tolerances are exceeded. RESEARCH & DEVELOPMENT Over 20 years of experience Mecuris GmbH ADDITIVE MANUFACTURING Prototypes and models made directly from the 3D data We work with our customers to develop tailored solutions that meet the highest standards. We work in the fields of development and design to create your CAD models, using the latest CAD/CAM systems, 3D scanning technologies and reverse engineering. With our pool of state-of-the-art machines we also offer a variety of different generative and machining procedures in the fields of additive manufacturing, model making and mould construction as well as rapid tooling for creating your plastic pieces and tools that can be applied to your models and prototypes as required: Making complicated finished pieces and complex component assemblies out of plastic is one of our strengths. We can also assist you with surface finishing and component assembly if necessary. MODEL MAKING Rapid and precise reproduction of master patterns RAPID TOOLING Milled tooling inserts and near-series prototypes At cirp you receive the services of the whole process chain from a single source. We work with you to define the degree of detail.

3 RESEARCH & DEVELOPMENT Research Product development Innovations with respect to materials, advance specific innovative fields in Whether it s a detailed solution or the idea through to class A-quality techni- procedures and process chains have a way that neither partner could man- complete development of your product cal surfaces. Design challenges can be always played an important role in the age alone. This research into selected, - cirp supports you through the entire resolved by our experienced designers 30-year history of additive production, promising projects and compounds is product creation process from the idea or you can work hand in hand with them which cirp and many of its leading subsidised by the government. cirp is to the finished product!. on developing a design. Our company employees have been involved with more involved than most in regional relies on the CATIA, SolidWorks and from the beginning. The diversity and initiatives and invitations to tender from Even before finished data (for examp- Cimatron development and design tools dynamism of this field of production government ministries and the EU be- le for the production of the prototype) to do this. have increased as additive production cause we firmly believe that innovations is available, our product development has become a more important factor are the only thing that can guarantee department can help with your project Our many years of experience with for the economy, consumers and poli- the satisfaction of our customers and for example by supporting the design additive manufacturing methods gua- tics. Digitisation in the guise of the In- the security of our location and jobs. process, creating geometric data and rantees you the best possible design ternet of Things for commercial uses handling design tasks all the way of RP products in order to be able to ( Industry 4.0 ) is also becoming much The dynamic changes in our industry through to series maturity should you make use of all of the benefits and more important for the production of are also changing the demands placed wish. geometric freedoms, and avoid time- prototypes and small-run series in par- on our employees and their qualifica- consuming and costly finishing work. ticular. tions at a corresponding pace. Our em- Using the Rhino and Alias software Our production know-how enables ployees develop their knowledge and tools, we can offer sophisticated sur- us to advise you on the selection of Not only does cirp observe and support skills through their active involvement face modelling from the initial design suitable materials and production me- these trends but it also plays an active in innovations. Although their are some thods, and to ensure that our series role in promoting them. We do this in desires we are not yet able to satisfy, production-standard design is ideally close partnership with our customers, ask us anyway. We may already be suited to the method in question. our systems engineering, materials and working on the solution, or it may be a software suppliers, and a network of in- goal that we can achieve by working cirp is a proponent of applying a sys- stitutions and research facilities in Ger- with selected network partners. tematic and methodical approach with many and further afield that has grown the aim of making it easier to plan and considerably over the years. One important element of these research activities are the compound research projects in which institutions and SMEs often work with selected large corporations to ASSEMBLIES DEVELOPMENT Tailored design verify the development of market-ready products.

4 That is why we ensure the safeguarding ponents and assemblies or the entire way. You can choose to receive the the 3D digitisation of the existing geo- of your product requirements using sui- product. Our goal is to always deliver output data either as a pure point cloud metry as described above. table simulation methods as another a result that convinces you in every or as a fully polygonised frame, depen- aspect of our integrated process chain. respect. ding on what you want to use it for. cirp can assist you in the field of rever- Regardless of whether it s a question of the statutory provisions for different 3D digitisation We can also use suitable software se engineering using the Geomagic Design X, SolidWorks, Rhino and Alias markets, directives or standards, whe- 3D digitisation is the process of recor- to assist you with the further proces- software. This allows a range of diffe- ther particular climatic conditions need ding the data of physical objects, and sing of the high-precision digital data, rent requirements to be realised, ran- to be taken into account or other quality is an established product develop- for example with respect to quality ging from parametric reconstruction requirements need to be met: with us ment tool. Optical 3D digitisation using controls involving target/actual com- and free-form surface reverse enginee- your project is in good hands. the ATOS Core system offered by the parisons or preparations for reverse ring to surface reverse engineering in company GOM allows us to make engineering. We are here to provide class A quality. From the concept through to realisati- digital models of small or large objects, competent and active assistance in on and customer support, our project regardless of whether their geometry is any situation, whether it s solving and You can work with our experienced managers have all of the processes simple or complex. processing complex measurement modellers and designers to individually within a project under control and always technology and quality assurance determine the mode of reconstruction. work with communication and transpa- The application s mobility means that tasks, creating and completing your Whether it s as a pure parametric recon- rency according to your catalogue of we can do this at your premises instead 3D digital archives and libraries, or struction, traditional surface reverse requirements and the underlying speci- of in-house. Your objects are scanned preparing data for production. engineering or a combination of the fications. without being touched, which means that the original is not harmed in any Reverse engineering two - a hybrid model consisting of surfaces and regular geometries. As a central link within a project, the Reverse engineering is the translation project management function controls of previously digitised components or We are always up to challenges such all of the necessary measures, secu- design objects into a digital CAD model as defective or worn components as res the product development at the that can be manipulated and processed. well as transparent or reflective sur- organizational level, and gives equal The main aim of reverse engineering faces. consideration to costs, quality and objects is to create a 3D model with the the time frame - always a reliable and exact same geometry as the original competent point of contact. It makes no difference whether you engage us to develop individual com- DEVIATION ANALYSIS Actual/target deviation between element scan and CAD piece. We use this process at our company if the 3D model itself or its descriptions and drawings are not available. Reverse engineering usually starts with

5 »Additive manufacturing«top-quality models and prototypes straight from the CAD data... Additive manufacturing

6 ADDITIVE MANUFACTURING Our»additive manufacturing«service, which uses the generative processes of stereolithography (SLA), digital light processing (DLP), PolyJet and laser sintering, rapidly delivers high-quality models, prototypes and end products directly from the CAD data. This can be used to produce unit volumes ranging from one all the way up to a small-run series. We also offer various different post-processing procedures to optimise the optical and functional properties of the parts produced by additive manufacturing for their intended applications. The delivery period for additive manufacturing is just a few working days. Stereolithography Our stereolithography procedure allows you to quickly produce high-precision, accurate parts with any geometry, with intricate structures and smooth surfaces. The process uses a liquid resin that is hardened in layers using a UV laser beam. Depending on the requirements, we can work with robust, flexible, transparent or water-resistant materials. We also offer a number of downstream processes in order to be able to verify certain properties of the finished product as early as the prototype phase. The portfolio includes surface finishing procedures such as sanding, polishing, dyeing, painting, printing and overall assembly. The components are particularly suitable for form, fit and function prototypes, assemblies with snap links, casings, spotlights and lenses, flow and visualisation models, electronic and electrical devices, and medical models. Digital Light Processing Our Digital Light Processing allows you to produce small, high-precision plastic parts that can be burned out without residue. Unlike the SLA process, DLP uses a projector instead of a UV laser. Our machine uses the material RS CP The components are particularly suitable as cast blanks for lost-wax casting. TRANSPARENT PIECES Surface finishing by means of sanding and polishing CONSTRUCTIVE FREEDOM Overhangs realized by support structure Additive manufacturing

7 PolyJet With our PolyJet process you can quickly produce high-precision, extremely accurate components with smooth, durable surfaces. With PolyJet technology, droplets of particularly fine liquid photpolymer are applied to a construction platform using printing heads The components are particularly suitable as grips, handles, seals, handles, pulling mechanisms, rubber linings, functional prototypes with vibration dampers, anatomy models, dental and orthodontic models, hearing aids and multi-coloured design models. Selective laser sintering Selective laser sintering can be used to quickly create complex and durable pieces that can be assessed not only in terms of their geometric form but also their functionality, and display similar mechanical properties to the seriesmanufactured product. A laser is used We can also help you incorporate thread inserts and with the overall assembly of your components. The components work particularly well as functioning prototypes and series-produced parts. Additive manufacturing and fully hardened using UV rays. This to produce localised fusing in layers of allows any combination of rigid, flexible, polyamide powder. transparent or translucent materials to be used in a single printing process. We Mechanical components such as hin- can also produce photo-realistic using more than 360,000 different colours. Multi-material printing allows you to recreate the optical, haptic and functional properties of a wide range of final products as closely as possible. Postprocessing and assembly work is redu- MULTI MATERIAL PRINTING colours can be realized in one printing process ges, undercuts, hollow pieces with spatial grid structures and interior functional elements can easily be integrated. Various different filled and unfilled polyamides and thermoplastic polyurethane can be used as materials. The surface of SLS pieces can be refined by sanding, infiltration, dyeing, painting Design by Frank Kleemann MATERIAL POLYAMIDE Elastic, strong and thermally resistant ced to a minimum. and printing.

8 »Model making and mould design«models and prototypes fit for testing... Model making Mould design

9 MODEL MAKING AND MOULD DESIGN Our trained model makers use their expertise and the moulding processes of vacuum moulding and metal casting to translate your ideas into testable models and prototypes. We define the level of detail in consultation with you. The models and prototypes can be used in a variety of applications. The broad spectrum of potential uses includes functional models, presentation models and trade fair models. Vacuum casting The vacuum casting process allows master patterns to be reproduced. The master pattern is formed in silicon rubber before being cast with polyurethane (PU) resins. A casting resin is chosen based on the material properties required for series production. The removal of the parts from the silicon moulds depends on their geometric complexity, which limits the number of duplicates possible. Typical batch sizes range from 5 to 100. Metal casting The vacuum differential pressure casting method allows metal prototypes with complex geometries to be cast at an early stage. You can choose from all common aluminium and zinc high pressure die casting alloys, as well as various non-ferrous metals. Functional prototypes with the qualities of series-produced products can be manufactured rapidly and without incurring substantial tooling costs using our vacuum precision casting facilities. A pressure differential during the casting process ensures that the mould is filled ideally, allowing parts to be cast with thicknesses of less than 1 mm. The product is almost entirely non-porous, and has a structure similar to die casting. The surface texture is comparable to series-produced precision cast parts. HAND IN HAND With precision throughout the entire process chain SURFACE FINISHING Finish and lacquer - all from a single source Schroeder Valves GmbH Co. KG ASSEMBLY Demonstration model from the production to mounting Christian Baumann FAZUA GmbH DUPLICATION Prototypes of castings per silicon tool Model making Mould design

10 »Rapid tooling«because we have what it takes... Rapid tooling

11 RAPID TOOLING As part of our»rapid tooling«services, we prepare milled tooling inserts (usually from aluminium) for injection moulding. Our injection moulding machines process all commonly used thermoplastic injection moulding materials. The process can be used to prepare prototypes, preproduction series and small-run series using original materials. The delivery times and costs are much lower than for conventional series production tools. Small-series production We are happy to support your series start-up if your series production tools will not be available on time. By optimising our processes and thanks to consistent internal standardisation, we can offer short throughput times at attractive costs. We usually work with standardised aluminium tooling inserts reproduced internally using one of our injection moulding machines. This allows us to react quickly and flexibly. In addition to helping you produce your prototypes or series products, the team at cirp will provide assistance with putting together your component assemblies if necessary. Mechanical processing We use Cimatron CAM systems for mould design and NC programming. Mechanical processing is carried out at one of our 5-axle or 3-axle CNC machine centres. The maximum processing volume is 1050 x 550 x 450 millimetres. In addition to applications for injection moulds, we also produce milled parts made from steel and aluminium. The use of small tool diameters means the downstream process of erosion can often be left out. The surface of the cavity is milled to a high resolution. The surface can be adapted to your requirements based on the DIN VDI 3400 standard with a brush finish, gloss finish or a grain using a jet or erosion process. Rapid tooling

12 Injection moulding Quality assurance Finely detailed or large components We attach great value to transparent with a maximum shot weight of 1700 processes and the professional pro- grams can be produced within a short cessing of orders. Thorough quali- lead time using all common series pro- ty assurance checks are carried out duction materials (thermoplastics). We throughout the entire process in order make components in all colours from to safeguard this high standard. There hard and soft plastics, including two- is also our CNC-controlled 3D meas- PROTOTYPES Test-quality pieces made using series-production materials BIT BY BIT Rapid reproduction of both dlicate and large components part components that can also consist of a combination of hard and soft plastics, as shown in the image on the left. We will assemble multiple parts and urement machine. The results of this monitoring are documented, evaluated and used to improve the process even further. The latest equipment supplied components on request. Typ- and software allow us to professional- ical batch sizes for manual extraction ly measure and monitor shape and po- range from 20 to 1000 units, or 1000 sitional tolerance as well as to provide to 10,000 units for automated tools with high-quality 3D measurement. sliders. Improved-cycle series production tools can be made from steel on request. TWO-PART PIECES Combinations of hard and soft materials possible SMALL-RUN SERIES Electronic devices can be assembled Surface quality that can be achieved after milling the cavity using HSC Rapid tooling

13 cirp GmbH Dipl.-Kfm. Ralf-D. Nachreiner Dipl.-Kfm. Petra Nachreiner Römerstraße 8 D Heimsheim Phone: Fax: info@cirp.de