Stephanie (Monsanty) Hendrixson served as a Modern Machine Shop summer intern in 2012 and joined the team as an assistant editor later that fall. She currently works on event news for MMS Online and on the production of the print magazine. She also blogs about additive technology and helps to manage Additive Manufacturing magazine as its associate editor. Stephanie holds an M.A. in professional writing from the University of Cincinnati and a B.A. in English literature and history from the University of Mount Union.
Surgery on the anterior cruciate ligament (ACL) in the knee is a complex procedure that demands precision and control. In order to repair or replace an ACL, the surgeon removes any remnants of the natural ACL and then attaches a replacement ligament (a graft usually taken from elsewhere in the patient’s body) to the tibia and femur. The positioning of the grafted ligament is critical, as it should accurately mimic that of the natural ACL.
To help make this precise surgery easier, orthopedic surgeon Dr. Dana Piasecki designed a two-part system consisting of a flexible pin (drill) and a guide for positioning the pin inside the knee. This guide is the key to a less invasive surgery, as it allows the surgeon to move and hold the pin without opening the knee or contorting it to place the new ligament.
Though 95 percent of the guide is made up of a simple shaft, the end of the device is the critical part. The shape of the neck is intended to follow the ligament’s normal path to ensure that it is placed at the right location and angle, and the tip is precisely sized to hold the 2.2-mm pin.
To machine this guide tool from a block would have required many setups with multiple angles and undercuts. Instead, Dr. Piasecki and his business partner Jim Duncan of DanaMed worked with Stratasys Direct Manufacturing to have the device manufactured with direct metal laser sintering (DMLS). This powder-bed additive process allowed the device to be built at the correct angle and build orientation to accommodate the critical features, without any machining necessary. Producing the guide additively also saved on material and reduced its overall cost, while enabling ongoing design changes.
Learn more about this device—including its design, manufacture and postprocessing—in this article from Additive Manufacturing magazine.
Machine tool distributor and systems integration expert Gosiger recently announced a new agreement to supply and service Stratasys 3D printers. The move is a natural advance for the company, whose customers are increasingly showing interest in additive manufacturing. However, the move is also strategic on the part of the 3D-printing equipment builder. Stratasys sees the future of its equipment not primarily among home or hobbyist users (though that might be a part of it) but instead in manufacturing facilities. The goal—for both Gosiger and Stratasys—is to help advance AM into applications out on the shop floor, and even into production.
As Josh Claman, chief business officer for Stratasys, put it: “The history of 3D printing is design and prototyping. The future is that, plus manufacturing.”
Claman addressed an audience at 3D4U, an event hosted at Gosiger’s Dayton, Ohio, headquarters shortly after the initial announcement was made. The June 14 open house and keynote presentation was a chance for Gosiger customers to learn about Stratasys technology as well as an opportunity for Stratasys to articulate its vision for additive manufacturing as a valuable tool for shopfloor applications as well as design and prototyping functions. Partnering with Gosiger provides necessary relationships and manufacturing expertise to help achieve that vision.
From Gosiger’s perspective, supplying 3D printing equipment is another way to serve its customers in addition to the machine tools, robotics, inspection equipment and complete turnkey systems it already provides. The company also sees great potential for using its own Stratasys machines to produce custom objects for its clients such as jigs and fixtures.
“As we expose our engineers to this technology, they are coming up with new ideas daily,” says John Haley, Gosiger CEO.
A number of sample components were on display during the 3D4U event, including some from Stratasys, but also many that were created by Gosiger employees following training on Stratasys 3D printers. These parts illustrate some of the services that Gosiger can provide with its new 3D printing capacity—and they may inspire customers to seek 3D printers of their own. A few examples of these applications are pictured below:
Gosiger frequently supplies machined custom fixtures for workholding and inspection. A metal CMM fixture such as the one on the left (holding the 3D-printed model stator) might cost upwards of $600 and take a week at a machine shop. The 3D-printed fixture (on the right) cost only $82 and was produced within a day on a Stratasys 450mc.
Robotic arms are another key component that Gosiger supplies, often as part of larger robot-tended cells. Custom grippers tailored to the customer’s application are commonly part of the package. Tools such as vacuum end effectors (like the one on the left) and jawed grippers (right) can be created and produced faster and more cost-effectively with a 3D printer than they can be machined. As an added benefit, they are also lighter than machined grippers.
1.3D-printed models can help speed the setup of CMMs and other systems. This model of an injection-molded vacuum cleaner component as well as the fixture it is resting on were 3D printed so that a CMM could be programmed before the actual parts arrived, reducing the quality control setup time from about a month to just one day.
Okuma’s Wade Anderson (left) and RPM Innovation’s Robert Mudge will present a July 20 webinar titled “Using Additive and Subtractive Manufacturing to Multiply Productivity.”
How can additive manufacturing (AM) be combined with subtractive manufacturing in a way that successfully boosts productivity? What, in practical terms, does that success look like?
A webinar taking place July 20 will address AM’s role alongside subtractive manufacturing, using real manufacturing data to demonstrate costs and benefits of both processes. Material costs, hourly shop rates and spindle utilization will be among the factors considered in this presentation.
Additive Manufacturing magazine, sister to Modern Machine Shop, is hosting a free webinar June 14 focused on quality management systems for additive manufacturing. Chris Krampitz, director of innovation and strategy for UL Additive Manufacturing, will be the featured speaker.
As additive technology moves out of development and into production, manufacturers need to adapt quality management systems (QMS) to handle the issues posed by additive manufacturing. During the webinar, Mr. Krampitz will discuss why QMS must be modified and how they can account for the AM supply chain, including raw material, internal equipment and more.
The webinar takes place Tuesday, June 14 from 2 to 3 p.m. EDT. Register here.
Design freedom is one reason to choose additive manufacturing, but it can also be a logistical solution. Heavy equipment manufacturer Caterpillar is looking at the technology from both angles, exploring how it can leverage AM to advance designs of new components but also to speed delivery on existing and legacy parts.
The fuel filter base above is one example. A component used in the engines of Caterpillar excavators and other products, the original aluminum alloy component would have been cast. “Would have been,” because the supplier is no longer operating. That means that to support aftermarket customers, Caterpillar would need a large minimum order to justify the tooling cost with a new casting supplier.
Laser melting offers an alternative to this scenario. A version of the part made with this technology offers the required functionality, but without the need for tooling or dealing with a new supplier. In this case, laser melting is also a much faster way to deliver this legacy part.
Caterpillar has recently opened an Additive Manufacturing Facility where it is exploring additive’s potential both in designing and producing parts. Read more about the company’s AM deployment strategy in this story.