Member Article

The future of 3D printing

Here at Harvey Water Softeners, our development process has changed significantly within the past year. Previously, our processes involved machining prototypes, testing and then refining them - a highly labour intensive process. Now we spend more time in the initial design phase instead; creating and developing the 3D CAD (using Autodesk Inventor) before we produce the prototypes.

Our initial ‘proof of concept’ designs are then tested through 3D printing. Whereas we previously machined simple prototypes, with 3D printing we’re able to produce very complex prototypes with all the ancillary details, including bosses and connections. With the additional detail the prototypes are also quicker to assemble, reducing the time in the workshop and also producing more representative prototypes for testing.

We use Selective Laser Sintering (SLS) for the prototypes that need to be watertight and pressurised, and Hi-Res Viper stereolithography (SLA) to prototype in extremely fine detail. We also use flexible 3D printing for complex seals.

Using 3D printing lets us develop more detailed and more complex design iterations more quickly and for a lower cost. We’re now able to turn a concept into a working prototype in just three days to demonstrate future product updates to our customers. These more intricate prototypes don’t require hours of machining time, freeing up capacity in our workshop and consisting of a variety of materials that better replicate the various materials in a finished product.

The biggest risk to manufacturers that I can see is the possibility of sensitive research and development data being leaked when outsourcing the 3D printing of product prototypes in competitive markets. Having a secure supply chain here, as in all areas of a business, is vital.

Within a decade it’s entirely possible that we could be using 3D printing to create finished parts on our production line, especially if the costs keeps falling as they has done to date. I can’t see us making entire water softeners that way by 2025, but certainly there will be the opportunity to produce bespoke parts for our customers.

This was posted in Bdaily's Members' News section by Rob Tomkinson .