inspirON exchange by Protolabs

The UK is the 8th largest manufacturing nation, however, the UK comes in at number 25 on the robot density league table. What are the barriers to adoption and what opportunities does robotics and automation open up? Joined by Mike Wilson from Manufacturing Technology Centre (MTC), our host Alex Edwards leads the conversation on the current state of robotics and automation in the UK, changing perspectives, and emerging technologies on the horizon.

Items referenced in this episode:

With the expected population of the UK to be 73.7 million by 2036 and increased pressure to reach net zero by 2050, how does the Agriculture industry fair when challenged with growing populations, climate change, sustainability goals and resource inefficiencies? Joined by Emilio Loo Monardez from WMG, our host Alex Edwards leads the conversation on the impact innovative technologies will have on the sector, and whether it will be enough.

Items referenced in this episode:

By definition, networking is “the action or process of interacting with others to exchange information and develop professional or social contacts”, but in more recent times, has networking become a buzzword with no action? Joined by Richard Spears from PP Control & Automation and Rowan Crozier MBE from Brandauer, our host Alex Edwards leads the discussion on what networking means in 2024, how the UK compares to other countries, and what opportunities are available through collaboration within the manufacturing industry.

Items referenced in this episode:

This series of podcasts is aimed to help you design better parts for digital manufacturing. This is just one in a series of podcasts packed with useful tips that will hopefully save you some time and money.

In this episode, we discuss design considerations for injection moulded parts, with a specific focus on overmoulding and insert moulding.

The topics we will be talking through today are:

• Overmoulding: Process, method, material selection, considerations, and chemical and mechanical bonding
• Insert moulding: Process and method
• Why use overmoulding and insert moulding?

For further reading, please see below links to the content referred to in this podcast:

In this episode we answer your questions on Family tooling, also known as branch tooling, with Richard Anthony, a Senior Application Engineer at Protolabs. See below for a list of questions answered in this session:

• What is meant by the term 'family tooling'?
• Are there any other recognised terms used in the industry?
• Why and when should I consider family mould tools?
• Will my part design be limited?
• What is the maximum part size I can expect?
• Does my choice of material impact this?
• Will material flow be effected?
• Can I expect the same quality?

In this episode, we discuss essential design considerations when 3D printing your part.

The topics we will be talking through today are:

• Rapid prototyping with Stereolithography

• Prototyping with PolyJet 3D printing

• 3D printing fully functional parts with Selective Laser Sintering

• How to use Multi Jet Fusion for functional 3D-printed parts

• The basics of metal 3D printing part design

In this episode we answer your questions on CNC optimisation with David Ewing, EMEA Product Manager - CNC Machining at Protolabs. See below for a list of questions answered in this session:

• What is CNC Machining and why is it important?
• What are the advantages of using this process rather than others?
• What advice would you give on hole depth and diameter?
• My current design is quite complex - what tolerances can I achieve with you?
• There's a threaded element to my part design, do you have any guidelines on maximum size I should go for?
• I've heard about 'burring' but can you explain what this is?
• What restrictions do I have with CNC machining?

This series of podcasts is aimed to help you design better parts for digital manufacturing. This is just one in a series of podcasts packed with useful tips that will hopefully save you some time and money.

In this episode, we talk you through some important injection moulding extras that may support your projects: family tooling and multi-cavity moulds.

For further reading, please see below links to the white papers referred to in this podcast:

In this episode we answer your questions on DMLS with Tasos Pantelis, an Application Engineer at Protolabs and our 3D Champion for Europe. See below for a list of questions answered in this session:

• In general, where is a break even point between this process and standard machine items, in reference to the number of items produced?

• How much does the resolution setting effect component price?

• What is the maximum size/mass that can currently be made?

• What level of porosity is present in a DMLS part? are secondary operations required to achieve pressure tightness?

• Cost wise, how does the cost of DMLS compare to other rapid prototype methods such as SLA/SLS? is there a part size limit?

• Can a single part be printed with 2 or more materials in one go?

• I see that you are ISO-13485 certified for medical implants with a choice of two biocompatible materials. Is there any specific process you use for them to ensure biocompatibility?

• Where does post-machining come in on DMLS? Can you polish parts? How do you ensure consistency as well as accuracy?

• Are there methods to improve the finish during manufacture, for example, for internal curves and volumes?

• What advantages and disadvantages are there regarding DMLS, and a comparison to other methods such as EBM?

• Do you employ post-printing manufacturing methods to improve the properties of DMLS made components? For example, chemical etching, hot isostatic pressing (HIP), electroplating.

• What are the main challenges you see with 3D printing metals today, and the work being done at a company like Protolabs to overcome these challenges?

In this episode we answer your questions on Liquid Silicone Rubber (LSR) with Richard Anthony, an Application Engineer at Protolabs and our Injection Moulding Champion for Europe. See below for a list of questions answered in this session:

• What is LSR?
• What industries is this application used for?
• What are the similarities between LSR and standard Injection Moulding?
• What is the maximum part size for LSR?
• What kind of finish can I expect from a LSR part?
• Would I need to consider draft?
• Should I anticipate sink with LSR?
• Is the part ejected using pins?
• Can I produce parts with undercuts and is there anything I need to consider here?
• What types of LSR do Protolabs offer?
• In optical LSR, is there any discolouration?
• Can you mould parts in different colours?
• Why am I not able to supply you with a different grade of silicone to mould my parts in?

This series of podcasts is aimed to help you design better parts for digital manufacturing. This is just one in a series of podcasts packed with useful tips that will hopefully save you some time and money.

In this episode, we discuss essential design considerations for CNC machined parts.

The topics we will be talking through today are:

• 6 ways to cut machining costs

• Turning to Lathe for cylindrical parts

• Moving between 3D printing and machining for plastic parts

• Jigs, fixtures, and capacity relief

This series of podcasts is aimed to help you design better parts for digital manufacturing. We will provide you useful tips to save time and money, as well as looking into case studies to support your own journey to part production.

In this episode, we look at YXLON and their 3D Printing rhinoceros skull. YXLON worked with Protolabs to 3D print the skull using Stereolithography.

This series of podcasts is aimed to help you design better parts for digital manufacturing. We will provide you useful tips to save time and money, as well as looking into case studies to support your own journey to part production.

In this episode, we look at Japet Medical Devices, a French start-up specialising in medical robotics, and how they worked with Protolabs on their "Atlas" exoskeleton.

In this episode we answer your questions on DMLS with Tasos Pantelis, an Application Engineer at Protolabs and our 3D Champion for Europe. See below for a list of questions answered in this session:

• Could you give us a top level definition of DMLS and what it stands for?

• What kind of finish can I expect on a metal 3D printed part?

• Why would I use metal over plastic in 3D prinitng? What are the benefits?

• What kind of metal materials do you offer?

• Are there any post processes available for 3D printing?

• How do you select the right material?

• Can you see any future trends in metal 3D printing?

• Are there any immediate challenges I need to consider?

• Can the metal dust become flammable? If so, how can this be prevented?

• How strong are the metal 3D printed parts?

In this episode we answer your questions on post-processes performed on your parts after manufacture, or what we call Secondary Services.

Samuel Guest, a Special Operations Project Engineer at Protolabs answering your questions on the following:

· What is “secondary services”?

· Is the need for measurement increasing in the future of manufacturing?

· Is there any specific technology you would recommend?

· Would any of the secondary services available be suitable for bead blasting?

· Are all the secondary services available in the UK?

· Is pad printing a cost effective method for prototype parts?

· What is the best way to get a company logo onto parts?

· What to do if I have a surface finish different to what I can select on your quote?

· Why can I not get a benchmark cost?

· Why are secondary services not included as standard?

· I have a request for a service not shown on your website, is this possible?

· How does secondary services tie in with the Protolabs digital manufacturing model?

· What secondary services are currently available?

· How do I get a quote for a secondary service?

· What are the benefits of letting Protolabs complete secondary services?

· Are the secondary services as fast as the Protolabs standard offering?

· Why weren’t secondary services available earlier? Can I add secondary services to parts I’ve already ordered with Protolabs?

In this on-demand episode we answer your questions on Injection Moulding with Marco Tonnarelli, an Application Engineer at Protolabs. See below for a list of questions answered in this session:

· Do you offer 2K moulding solutions?

· If the priority is external face and it has no draft, is there a solution for this?

· With glass filled parts where the cosmetic element is vital, how do you recommend getting a good finish?

· Weld lines, any advice? How do I avoid them?

In this episode we answer your questions on CNC Machining with Marco Tonnarelli, an Application Engineer at Protolabs and our CNC Machining Champion for Europe. See below for a list of questions answered in this session:

· Do you offer transparent materials?

· For a few units, ideally 1 piece, what is the most valuable process, CNC Machining or 3D Printing?

· What is the value of using CNC Machining over other processes?

· What level of inspection do you apply to your machined parts?

· Can we get coloured parts?

· How do you decide which process to use, milling or lathe?

· Am I able to provide my own material to be machined?

· Can you rework a part that has features not aligned in 3-axis?

· What is the difference between 3 and 5 axis?

· Do you use dovetail cutters?

· What post-processes do Protolabs offer?

· What is the material range for CNC machining, in particular, are there any suitable for aerospace and automotive?

· How can I reduce cost through part design?

This series of podcasts is aimed to help you design better parts for digital manufacturing. This is just one in a series of podcasts packed with useful tips that will hopefully save you some time and money.

In this episode, we discuss essentials when designing your Injection Moulded parts.

The topics we will be talking through today are:

• Design Essentials
• 9 Cosmetic Defects and How to avoid them
• 3 Key design Elements for Rapid Overmoulding and
• Designing Strength to Parts with Insert Moulding

In this episode we answer your questions on 3D Printing with Tasos Pantelis, an Application Engineer at Protolabs and our 3D Champion for Europe. See below for a list of questions answered in this session:

· Are Protolabs able to give guidance on fatigue properties of metal materials?

· Do you need to perform any post-build operations in order to make the walls gas tight?

· Do you use any form of in-situ inspection to monitor build property during the build or only inspect after this is completed?

· Does morphology of the metal powder effect the build?

· How do you comprise between part strength and internal stresses?

· How well does DMLS deal with print in place parts?

· What systems are used to check density control between parts printed in the same batch?

· Why do overhangs not print on DMLS?

· Does Protolabs offer materials with flammability approvals?

· Is stress relieving a standard part of the process or must you explicitly request it?

· How does build orientation get decided?

· How is Protolabs set up to cope with the high demand of COVID19 parts?