Stratasys, Minneapolis, reports that GKN Aerospace has been able to reduce production time for assembly tools from several weeks to a few hours since integrating Stratasys additive manufacturing machines into its Filton manufacturing site in the United Kingdom.
According to Tim Hope, Additive Manufacturing Center Manager at GKN, the company decided to invest in the Stratasys F900 Production 3D Printer to cut lead times for production-line tools, and to create complex parts that are impossible to make with traditional manufacturing methods.
“Since integrating the F900, we have dramatically reduced production-line downtime for certain teams and are enjoying a new found freedom to design complex tools,” he says.
“We can now cost-effectively produce tools for our operators within three hours. This saves critical production time, and by printing in engineering-grade thermoplastics, we can produce 3D printed tools with repeatable, predictable quality every time. All while matching the quality of a traditionally-produced tool, and reducing the costs and concessions compared to equivalent metallic tooling.”
While GKN Aerospace is using a standard thermoplastic today, it is experimenting with Stratasys’ high-strength, heat-resistant ULTEM 1010 Resin material for these applications.
In addition, GKN Aerospace is reporting unprecedented levels of design freedom since investing in the Stratasys F900 into its operations.
“One of the key benefits of additive manufacturing is the creative freedom this technology affords users,” explains Mr. Hope. “The F900 offers the largest build-size of any FDM 3D printer, enabling us to rapidly produce tools to meet any requirements. Most notably, complex geometries and cavities that would otherwise be problematic are now practical with the F900. We’re utilizing it to design and 3D print previously inconceivable tools that enable us to manufacture complex parts that are uneconomical or just physically impossible by other methods.”
