From Prototyping to Production

 

No other Irish service bureau offers the complete suite of manufacturing services the way we do. From 3D printed prototypes to final production, we provide additive manufacturing services such as Stereolithography (SLA), Selective Laser Sintering (SLS), MultiJet Printing (MJP), Fused Deposition Modeling (FDM) and Direct Metal Printing (DMP) as well as subtractive technologies, such as CNC machining, Injection MouldingSheet Metal Parts, Metal Die Casting and Investment Casting.

 

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Access the Best Technologies & Local Support

 

3D Technology On-Demand works together with a network of advanced manufacturing facilities around the world. Our team of application engineers provides expertise and support for Ireland. Contact our office to talk through your next project.

Choose the Manufacturing process that’s best for you

Stereolithography

Great for concept models, rapid prototypes, master patterns, snap fit assemblies, and form-and-fit testing.

Highest accuracy and smoothest surface finish of all 3D printed parts. Print highly detailed parts ranging from just a few mm in size, all the way up to 1.5 m, with exceptional resolution and accuracy and virtually no part shrink or warping.

Stereolithography (SLA) utilises a vat of liquid photopolymer resin cured by an Ultra Violet (UV) laser to solidify the pattern layer by layer to create a solid 3D model from customer supplied 3D data. The SLA process addresses the widest range of rapid manufacturing applications.

  • Highest accuracy and smoothest surface finish of all 3D printed parts
  • Large material selection – rigid, durable, clear and high-temp
  • Wide variety of post-processing options
  • Prototypes for form and fit testing
  • Presentation models for displays and tradeshow models
  • Short lead times
  • High-resolution settings
  • Large build platforms available

Tolerances for standard resolution:

  • X/Y planes: +/- .1 for the first 25mm, plus +/- .05 for every 25mm thereafter
  • Z plane: +/- .25  for the first 25mm, plus +/- .05 for every 25mm thereafter

Tolerances for high resolution:

  • X/Y planes:+/- .1 for the first 25mm, plus +/- .05 for every 25mm thereafter
  • Z plane: +/- .25  for the first 25mm, plus +/- .05 for every 25mm thereafter

SLA printers are able to print highly detailed parts ranging from just a few millimetres in size, all the way up to 1.5 meters, with exceptional resolution and accuracy and virtually no part shrinkage or warping.

Key Features: Smooth surface finish, high precision, short lead times, a wide variety of materials and post-processing options.

Applications

The SLA process’ high accuracy, the large variety of material selections, smooth surface finish, and a wide variety of post-processing options make it the perfect choice for a wide range of rapid manufacturing applications.

Rapid Prototypes:
•  Design Appearance Models
•  Proof of Concept Prototypes
•  Design Evaluation Models (Form & Fit)
•  Engineering Proving Models (Design Verification)
•  Wind-Tunnel Test Models

Tooling and Patterns:
•  Investment Casting Patterns
• Jigs and Fixtures
• Cast Urethane Master Patterns

Custom industry applications such as healthcare with biocompatible materials for surgical tools, dental appliances, hearing aids.

SLA Finishes

Strip & Ship
Remove supports, wash & post cure
Standard
Remove supports, wash, post cure, sand areas where supports were attached with 220 grit sandpaper, water hone (150 white grit sand)
[Note: ABS Black parts receive an additional coat of black spray paint.]
Pattern
Standard plus remove all layer lines on the outside surface with 320 grit sandpaper, water hone (150 white grit sand)
Primed
Pattern plus spray with primer
Paint
Pattern plus spray with paint
QuickClear
Standard plus spray with clear coat
Gloss
Standard plus spray with clear coat
WaterClear
Standard plus sand all layer lines (inside and outside) with 600 grit sandpaper and spray with clear coat

Selective Laser Sintering

Perfect for functional testing, rapid prototyping, high-heat and chemically resistant applications.

SLS uses a high-powered C02 laser to fuse small particles of powdered material to create 3-dimensional parts.  The laser selectively fuses powdered material by scanning X&Y cross-sections on the surface of a powder bed.  The model is built one layer at a time from supplied 3D CAD data. SLS is capable of producing highly durable parts for real-world testing.

  • Produce highly complex geometries
  • Durable, high-heat and chemically resistant applications
  • Impact-resistant parts for rigorous use
  • Ideal for snap fits and living hinges
  • Low-volume production solutions
  • Major time and cost benefits
  • Large build platforms available

Tolerances for standard resolution:

  • X/Y planes: +/- .005” for the first inch, plus +/- .005” for every inch thereafter
  • Z plane: +/- .010” for the first inch, plus +/- .005” for every inch thereafter

SLS produces parts from impact-resistant engineering plastic, great for low- to mid-volume end-use parts, enclosures, snap-fit parts, automotive components and thin-walled ducting.

SLS produces complex geometries, for low-volume parts that would typically require assembly using traditional manufacturing methods.

Applications

Rapid Manufacturing

  • Aerospace Hardware
  • UAS – Unmanned Air Systems Hardware
  • UAV – Unmanned Aerial Vehicle Hardware
  • UUV – Unmanned Underground Vehicle Hardware
  • UGV – Unmanned Ground Vehicle Hardware
  • Medical and Healthcare
  • Electronics: Packaging, Connectors
  • Military Hardware

Rapid Prototypes

  • Functional Proof of Concept Prototypes
  • Design Evaluation Models (Form, Fit & Function)
  • Product Performance & Testing
  • Engineering Design Verification
  • Wind-Tunnel Test Models

Tooling and Patterns

  • Tooling and Manufacturing Estimating Visual Aid
  • Investment Casting Patterns
  • Jigs and Fixtures

SLS Finishes

Standard Uncoated
Loose powder removed and bead blast
Standard Coated
Loose powder removed, bead blast & apply sealant
Primed
Loose powder removed, bead blast, apply sealant, sand to remove any starting with 80 grit sandpaper and then 150 grit sandpaper, apply primer, sand using 220 grit, apply more primer and then finish with 320 grit sandpaper
Painted
Primed finish and painted
Dyed
Standard uncoated finish with dye

Direct Metal Printing

Quickly and accurately manufacture complex metal parts.

Direct Metal Printing (DMP), also commonly known as Direct Metal Laser Sintering (DMLS), is an additive manufacturing technology that builds high-quality complex metal parts from 3D CAD data. In the machine, a high precision laser is directed to metal powder particles to selectively build up thin horizontal metal layers one after the other. This cutting-edge technology allows for the production of metal parts with challenging geometries, not possible using traditional subtractive or casting technologies. A variety of functional metals are available to print designs, from prototypes to production series of up to 20,000 units.

  • Production of small and extremely complex shapes with no need for tooling
  • High-quality parts ideal for R&D and serial part manufacturing at the tightest tolerances
  • Industry’s best surface finished parts with exceptional accuracy
  • Accommodate innovative part design versus conventional processes
  • Topology optimised parts and mass customisation
  • Complex and thin-walled structures allow significant part weight reduction

Application

  • Machine construction
  • Tool and die making
  • Food and pharmaceutics
  • Chemistry and petrochemistry
  • Aerospace engines
  • Automotive parts
  • Veterinary and medical devices
  • Heat Exchangers
  • Air/Oil/Fuel mixing devices
  • Customised sporting goods
  • Weight-reduction parts utilising Topology optimisation
  • Industrial burner parts
  • Radiation collimators
  • Semicon and wafer handling equipment
  • Customised production line equipment

DMP Finishes

Standard
Sand surfaces to remove build lines and bead blasted
Anodized
Electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish
Heat Treated
Use of heating or chilling, normally to extreme temperatures, to achieve the desired result such as hardening or softening of a material
Polished
Sand surfaces to remove build lines and then apply polishing compound until the desired surface finish is reached
Additional post-processing
Includes CNC milling, lathing & EDM

Cast Urethane

Achieve parts that accurately mimic the physical properties, colour, texture and feel of injection moulded parts.

Vacuum Casting provides high-quality parts production at low- to mid-volumes without the cost and time of hard tooling, using 3D printed masters and silicone moulds that defy traditional production timelines.

Key Features: Wide range of polyurethane materials, smooth surfaces, colours available with RAL or Pantone number.

From product development models and prototypes to low-volume production runs, this rapid prototyping process allows us to produce parts that accurately mimic the colour, texture, feel and physical properties of injection moulded parts.

  • Accurately mimic production colours and textures
  • Large material selection – rigid, flexible, durable, transparent and high-temp
  • Offers similar physical properties to injection moulded parts
  • Used for pre-production runs
  • Parts made for marketing samples and test prototypes
  • Low-volume manufacturing

Cast Urethane parts can be completed and delivered in days after completing SRM tooling (Silicone Rubber Molds). Short runs of several hundred pieces can be delivered within weeks in most instances.

One of the most significant benefits of the Cast Urethane process is the ability to over-mould existing parts or hardware with a second material.

Investment Casting Patterns

Accelerate your casting production timelines with high quality, fast prototype and production casting patterns with 3D Technology On Demand Manufacturing services

Investment casting, often known as lost-wax casting, is a manufacturing methodology that has been around for thousands of years. While there has been some degree of automation in the foundry industry, the need for the pattern around which to make the cast shape remains a constant – and waiting for tooling to create the patterns can take weeks or months, costing tens to hundreds of thousands of dollars.

3D printed casting patterns offer a tool-free, fast, reliable and accurate alternative to patterns created using tooling, reducing the costs of creating a pattern by as much as 90%, and produced in one-tenth of the time. With two key 3D printing materials – SLA plastic and wax – that are fully industry-tested, your casting patterns can be completed in days or a couple of weeks, with little to no restriction on the size of the casted part.

3D Technology On-Demand Manufacturing offers rapid production of casting patterns from its partner production facilities in the UK. With expert teams who have been producing investment casting patterns for more than 20 years, using additive platforms and materials that are being continually refined and updated to meet ever more rigorous standards, On Demand Manufacturing can meet your needs for prototype and production-grade casting patterns.

3D printed patterns can be created quickly, and deliver more complex parts than injection moulded wax patterns. We use both a plastic process and a wax process depending on the needs and applications of our customers.

SLA Cast Patterns

The SLA Cast build style consists of a hollow SLA pattern with an internal hexagonal support structure that adds strength to the pattern, allows for easy drainage, and facilitates collapse of the pattern during thermal expansion to help avoid shell cracking. SLA Cast patterns offer invaluable shrink and gating information before hard tooling, large pattern size, smooth surfaces, and accelerated timelines over tooling to create wax patterns.

  • Hollow build style reduces the amount of material to burn out
  • Commonly used by the casting industry
  • Capable of producing large assemblies
  • Highly stable CastPro™ resins developed specifically for foundry applications
  • Rapid production compared to traditional tooling
  • Provides invaluable shrink and gating information before hard tooling
  • Low moisture absorption and expansion of the pattern
  • High dimensional stability
Image: Vaupell

ProJet® Wax Patterns:

Many foundries like working with wax patterns. Whether only one or hundreds of patterns are needed quickly, you can count on our ProJet® 3D printed wax patterns to fit into your foundry processing procedures, just like any injection moulded wax pattern. We provide high detail, high-resolution ProJet wax patterns with the highest levels of surface finish required for demanding casting applications.

  • Excellent for high detail, high resolution builds
  • Highest surface level finishes and complexity
  • Quick lead times
  • Can be created without tooling
  • Accelerates the casting process
  • No special finishing required
  • Lower cost of initial development
  • Capable of producing the finishes required by the aerospace and medical industries
  • Easiest patterns to process
SLA Cast Patterns ProJet Wax Patterns
Build Envelope 25x29x21 11.75”x7.3”x8”
Melt out?

No

The pattern must be burned out of shell.

Yes
Accuracy Excellent Excellent
Surface Finish Excellent Very Good
Ease of Casting Good Excellent

Finishes

QUICKCAST PATTERNS

  • Fine finished

PROJET WAX PATTERNS

  • Three levels of finishing are available:
  • Supports intact
  • Supports removed
  • Enhanced finish, our best

 

Applications

QUICKCAST PATTERNS

The QuickCast build style for investment casting is preferred in medical, aerospace & defence applications because of accuracy and high-level surface finish.

PROJET WAX PATTERNS

Preferred by the jewellery, medical and aerospace industries, ProJet Wax patterns are built by printing thin layers of wax materials to quickly create the highest levels of surface finishes for casting patterns.

CNC Machining

Build parts in final production materials

CNC refers to cutting material with a computer numerical control machine. The CNC machining process interprets your 3D CAD model and translates data to CNC machines. The main benefit of the process is that CNC will produce parts that can replace the additive manufactured prototypes with production grade materials. This method allows you to build your parts in the featured material that you intend for use in production. CNC machining is the best choice for rapid prototyping of high-quality metal and plastic parts requiring the highest degree of dimensional accuracy, critical surface finishes, material-specific properties.

Whether for rapid prototypes or production parts, we have the right CNC machining options for your metal and plastic part needs.

  • wide range of materials
  • Ability to hold tight tolerances
  • Parts machined directly from 3D CAD models
  • Standard delivery time of 1-2 weeks based on an order
  • Shorter lead time (2-5 business days) available per open capacity

Tolerances for feature size:

  • Standard +/- .005
  • Minimum +/- .002 for metal and +/- .003 for plastic

Tolerances for hole diameter:

  • Standard +/- .005
  • Minimum +/- .001 for metal and +/- .002 for plastic

Tolerances for Flatness, Run Out, Cylindricity, Perpendicularity, and other Geometry:

  • Standard +/- .005
  • Minimum +/- .001 is possible per geometry dependent

The tolerances above will not apply when machining a weldment, or a plate below 1/4″ thick at length above 20″ or 1/8″ thickness at length exceeding 10″ long. In that case the tolerances need to be reviewed by the MFG team.

Advantages

  • Email your 3D CAD data, define your project specs and we will quote you in 24 hours or less
  • Turning, Dual Turret Lathe with Live Tooling, 3-, 4-, and 5-Axis Machining, Heat Treating/Stress Relieving, Welding, Anodizing, and Powder Coating
  • CNC Machined Parts in as little as 6-8 business days, depending on the geometry

Applications

  • Electronics Parts Manufacturing
  • Engraving Machine Applications
  • Machining Composites
  • 5 Axis Machining
  • Micro Hole Drilling
  • Machining Aluminum
  • Machining Plastics
  • And more

CNC Materials

  • Stainless Steel
  • Ren
  • POM (Acetol)
  • Polycarbonate
  • PMMA ( Acrylic)
  • Nylon
  • Aluminium
  • ABS
  • Brass
  • Copper
  • Mild Steel
  • Magnesium
  • Foam
  • Delrin

CNC Finishes

CNC machining is a subtractive manufacturing process by which material is cut away from the source to create a finished component. Our standard surface finish is 63-125 RMS. However, we can grind or polish the part to 4-8 RMS.

  • Bead Blasting
  • Electro-Polishing
  • Heat Treatment
  • Sand Blasting
  • Vapour Polishing

ColorJet Printing

Create vibrant, full-colour concept models, architectural models and demonstration models.

ColorJet Printing (CJP) is an additive manufacturing technology which involves two major components – core and binder.  The Core™ material is spread in thin layers over the build platform with a roller.  After each layer is spread, a colour binder is selectively jetted from inkjet print heads, which causes the core to solidify. The build platform lowers with every subsequent layer which is spread and printed, resulting in a full-colour three-dimensional model.

  • Full-colour concept models
  • Architectural models
  • Demonstration models
  • Highly complex geometries
  • Quick production times

Whether printed with colour or in standard white, parts can be additionally clear coated to add a hard, smooth coating or wax coated to smooth out the surface finish.

Applications

Excellent for demonstration models with full-colour printing.

CJP Materials

VisiJet PXL
Uniquely Full Colour
Safe, Office Friendly & Easy To Use
Fastest Print Speed
Lowest Operating Cost

CJP Finishes

ColorBond
Instant-cure infiltrant ideal for colour models to improve strength and colour vibrancy and retention.
ColorBond Wax
ColorBond with wax coating

Fused Deposition Modeling

Great for proving designs, fit and function testing, small production runs, jigs, and fixtures.

Fused Deposition Modeling is a solid-based rapid prototyping method that extrudes material layer-by-layer to build a model. The system consists of a build platform, extrusion nozzle, and control system. This is a fast and cost effective process great for proving designs, fit and function testing, small production runs, jigs, and fixtures.

  • Large material selection – including production-quality ABS and food-grade ABS
  • Short lead times, standard lead time – 3 to 5 days.
  • High strength
  • Extremely durable
  • Concept models
  • Engineering models
  • Functional testing
  • Consumer products
  • High-heat applications
  • Initial prototypes

Tolerances for standard resolution:

  • X/Y planes: +/- .005” for the first inch, plus +/- .002” for every inch thereafter
  • Z plane: +/- .010” for the first inch, plus +/- .002” for every inch thereafter

Using engineering-grade thermoplastics such as ABS and polycarbonate materials, this technology builds parts in an additive process that enables complex geometries that are often difficult to duplicate with traditional manufacturing methods such as CNC machining.

Advantages

Customers in aerospace, automotive, healthcare and other industries rely on our capabilities for rapid delivery of dimensionally accurate, functional prototypes and small-quantity production parts that are able to resist high temperatures, mechanical stresses and chemical degradation. This process allows parts to be made directly from 3D CAD to thermoplastic materials without tooling.

Applications

  • Concept
  • Engineering models
  • Functional testing
  • Consumer products
  • High-heat applications
  • Initial prototypes

 

FDM Materials

ABS
Thermoplastic polymer often used in the injection moulding process
PC Poly-carbonate
Strong & tough material. Easily worked
PC/ABS
The superior strength and heat resistance of PC and the flexibility of ABS
ABSi
Superior to standard ABS, translucent
ABS-M30
25 to 70 percent stronger than standard ABS
ABS-M30i
Bio-compatible material. Gamma or EtO sterilized and complies with ISO 10993 and USP Class VI standards
PC-ISO
Polycarbonate with Biocompatibility. Gamma and EtO sterilizable and complies with ISO 10993 and USP Class VI standards
ULTEM
Used in medical and chemical instrumentation. Heat resistance, solvent resistance and flame resistance. Easily machined with excellent strength and rigidity
PPSF
Combines strong mechanical performance with high temperature and chemical resistance for demanding applications like under-hood automotive scenarios and heat, chemical, plasma and radiation sterilization.

FDM Finishes

Standard
Remove supports and any burrs or ticks
Primed
Standard plus spray with primer
Paint
Primed plus spray with paint
THE POWER TO 3D PRINT

 

On Demand 3D Printing

We offer you easy and quick access to the widest range of 3D printers and materials.

12  |  Facilities located around the world

14  |  Different processes available

2,000,000+  |  Parts manufactured per year by our trusted partners

Material Selection  |  Offering Specialty and Custom Materials

3dsystems_120918_0442v2
Rapid Prototyping Functional Prototyping Low-Volume Production
Stereolithography (SLA)  
Selective Laser Sintering (SLS)
Direct Metal Printing (DMP)
ColorJet Printing (CJP)
MultiJet Printing (MJP)
Cast Urethane/Vacuum Casting
CNC Machining
Sheet Metal
Die Casting
Low-Volume Injection Mold Tooling & Parts
Investment Casting Patterns

Process Comparison Table

 

Stereolithography (SLA) Selective Laser Sintering (SLS) Direct Metal Printing (DMP) ColorJet Printing (CJP) Fused Deposition Modeling Cast Urethane
Applications
  • Excellent for fit and form testing
  • Best surface quality and highest resolution, ideal for trade show quality parts
  • Easily finished and painted for demonstration, presentation models
  • Ideal for durable, functional parts with a variety of applications
  • Capable of producing snap fits and living hinges
  • Heat and chemically resistant
  • Perfect for complex metal parts that need to be manufactured quickly and accurately
  • Fully dense parts with an excellent surface finish
Excellent for demonstration models with full-colour printing. Perfect for architecture, consumer product design, healthcare, educational models, crystallography, medical teaching models and more Ideal for Conceptual models, Engineering models, and Functional testing prototypes.
  • Ideal for marketing samples
  • Production-like attributes (surface finish, colour, accuracy & material properties)
Maximum Dimensions Normal Res: 29″ x 25″ x 21″
High Res: 10″ x 10″ x 10″
30″ x 20″ x 20″ 10.6″ x 10.6″ x 15.7″ 10″ x 15″ x 8″ 14″ x 16″ x 16″
Layer Thickness Normal Res: .004″
High Res: .002″
Normal Res: 0.004″ Normal Res: 0.0024″
High Res: 0.0012″
0.004″ Standard Resolution: 0.01″;
Material Options Technician’s Choice, Accura 25 (ABS/PP-Like), Accura Xtreme White, Accura Xtreme Grey (High-Impact ABS-Like), Somos Next (High-Impact ABS-Like), Accura SL 7820 (ABS-Like), Accura 60 (PC-Like), Accura ClearVue (PC-Like), Accura Bluestone (High-Temp ABS-Like), Accura 48 (High-Temp PC-Like) Nylon (Duraform PA), Glass-Filled Nylon (Duraform GF), Durable Nylon (Duraform EX Black & White) Titanium (Ti6Al4V Grade 5), Stainless Steel (316L) VisiJet PXL ABS-M30, PC-ABS, Ultem, Polycarbonate ABS-Like, PE-Like, PP-Like, Elastomer (25A, 30A, 40A, 50A, 60A, 70A, 80A, 90A), Clear, High-strength, High-temp ABS-Like, Custom (Glass Filled, MRI Transparent, ABS-Like, FDA Approved Rigid, FDA Approved Elastomeric, UL94VO Polypropylene, UL94VO ABS-Like
Finish Options Standard, Pattern, Primed, Paint, Quick Clear, Gloss, Water Clear Standard Uncoated, Standard Coated, Primed, Painted, Dyed Anodized, EDM, Grinding, Heat Treated, Milling, Polished, Turning, Welding Standard (With ColorBond Infiltration) No finish, Standard, Primed, Paint Functional, Show, Clear (Polished)
Lead Time Options As little as 2 days As little as 3 days As little as 8 business days Standard (5 -7 Days) Standard (3 – 5 days) The first article in as little as 6 days
Recommended Minimum Feature Size Normal Res: 0.025″ – 0.035″
High Res: 0.010″ – 0.015″
0.030″ 0.010″ .060″ 0.025″ 0.025″

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