Bowman International, a leading innovator in bearing design and manufacture, has invested in a HP 4200 Multi Jet Fusion 3D printer for the manufacture of end use bearings, seals and cages.  The HP machine, supplied by UK Channel partner Europac3D, will help reduce the cost of parts whilst increasing the functionality of end products and speed to market.

An Evolution in bearing case design

By embracing 3D printing technology Bowman International have been able to develop a modern, bespoke solution for the production of their bearing cages. As there are few design constraints restricting how a part can be manufactured, 3D printing has allowed Bowman to design specific products around the technology. As a result Bowman’s patented ‘Rollertrain’ cage technology is truly a stand-out innovation.

 

The Rollertrain Cage boasts a unique interlocking structure which uses the rolling elements to pin together each section of the cage. This revolutionary, design creates enough additional space around the circumference of the cage to incorporate two to four more rollers than comparative products. It is these additional rollers which allow the load to be spread over a higher number of rolling elements that increase the performance of the overall cage, making it a suitable specification choice for any application which would benefit from higher load capacity or extended life expectancy, without having to amend any other part of the bearing assembly.

Bowman have reported an up to 70% increase in the load bearing capacity of its split bearings and an increased working life increase of up to 500%. This is revolutionary for additive manufacturing as performance has been improved through the use of 3D printing.

Jacob Turner, Head of Bowman Additive Production explains; “The Rollertrain cage combines the very latest in 3D printing with world-renowned materials science. Together, this offers OEMs and plant maintenance engineers a split bearing which delivers superior performance and longer product life, alongside simplified mounting and maintenance procedures – not forgetting less vibration and noise during operation.”

The Evolution of a partnership – Europac3D & HP with Bowman International

Working alongside Europac3D, Bowman International tested the parts and were impressed both with the capabilities of the HP Multi Jet Fusion’s printed polymers as well as the speed and accuracy of the part production.

When testing the parts from the HP machine the Isotropic properties of the bearing cages were significant; the parts had equal strength in X Y and Z directions. This was a huge advantage in comparison to relative technology that has suffered from deficiencies in parts, accountable to weakness in the Z, or vertical, axis of the printer. As the HP machines has such rapid fusing speed in layers the Z axis strength passed production tests with flying colours and therefore delivered the preferred choice for Bowman.

Bowman’s HP Multi Jet Fusion machine is the first of its kind in the UK to use PA11 nylon polymer, a fine bioplastic polyamide powder which provides end products with the elasticity, durability and functionality required for use with in rolling element bearings.  The PA11 nylon has a superior thermal resistance and is characterised by good elasticity, high elongation at break and high impact resistance as well as resistance to chemicals, especially hydrocarbons, aldehydes, UV, alcohols, detergents, oils, fats, mineral bases and salts.

John Beckett, Managing Director of Europac3D, comments; “Bowman International’s use of the HP’s Multi Jet Fusion printer is illustrative of how the part production market is being truly revolutionised by 3D printing.  The new HP printers are able to accurately mass produce bespoke parts which in turn can cut costs and speed up production times.”

Since the new HP Multi Jet Fusion printer was  introduced to the market in Spring 2017, the demand for the product has been unprecedented from both bureau printing businesses who rely on the quality of build and speed of printing, through to businesses looking to 3D print bespoke parts that are robust, accurate and available for immediate use.

Crispin Orthotics are a leading HCPC registered clinic specialising in the production and maintenance of orthosis. The company provides services to both public and private healthcare sectors from the 3D design and print of orthotics through to repairs and aftercare, all undertaken by highly qualified technicians.

Crispin Orthotics approached Europac3D seeking a new 3D printing solution and Computer Aided Design (CAD) software package that could meet the growing demand for orthotics while reducing printing costs and increasing the speed of part production.

The HP and Siemens Solution

Europac3D were able to provide a solution for Crispin by introducing them to HP’s Multi Jet Fusion 3D printers which deliver a solution that is up to 10 time faster and at a 50% cost-per-part reduction, to comparable SLS technology.  The increased speed and cost reduction achieved from the new HP machines means that hundreds of customised and completely personal orthotics can be 3d printed overnight in one twelve hour build process.

Another consideration for Crispin is that the parts produced were strong enough and have enough flexibility to endure the rigours of every day human movement. The sample parts produced on the HP machine passed all the tests and what is particularly significant with the HP multi jet fusion technology is that the parts produced have homogeneous strength in all three axes of build and therefore the orientation of build does not affect part strength or quality.

The HP 3D printer was paired with Siemens NX software featuring topology optimisation, which not only enables technicians to strip weight from the design but also add strength to key areas.  The software also provides a ‘nesting’ capability which organises multiple 3D parts to fit perfectly together on the printer bed, reducing the number of print runs needed – thus increasing the speed while reducing the cost of production.

Crispin orthotics was able to use their Siemens NX CAD software and HP Multi Jet Fusion printer for a recent project. The new 3D technologies allowed Crispin to develop a 3D printed orthotic for the arm with an integrated joint at the elbow and an attachment at the end of the device which allows for the use of prosthetic devices.  The single printed part was made from durable nylon material which is also very light weight and durable.

Mark Thaxter, Managing Director of Crispin Orthotics, comments: “3D scanning and printing has revolutionised the speed and quality of parts we’re able to produce for clients.

“Having the ability to create a bespoke devise that is lightweight, durable and accurate to 0.2mm has obvious benefits to the user.  The business also benefits from the speed of 3D printing parts as well as cost savings of approximately 40% on each part by removing the need for multiple components in the supply chain and assembly.

“Using 3D scanning and printing also provides greater freedom on the design of products particularly those with complex geometry.  Having the ability to vary the thickness of the device in certain parts also allows us to produce devices not possible with current methods of manufacturing.”

Digital manufacturer, Fluxaxis, is the UK’s first bureau 3d printing company to invest in HP’s new 4200 Jet Fusion 3D printing solution.  The high-tech, high-investment start-up is a new venture from Stage One, the creative manufacturing & engineering services company supplying projects to architects, designers, producers and artists.

Investment

The investment will open the technology up to a wide customer base allowing more to benefit from the machine’s faster and higher print quality at a 50% cost-per-part reduction.

The HP 4200, supplied by Europac3D, was chosen for its ability to produce parts for prototyping and final use manufactured parts at a speed previously unachievable by other technologies.  A full build, regardless of the number of parts contained within it, takes just 10 hours to complete and looks set to disrupt the 3d printing services market of traditional SLS parts.

Edwin Stokes, Director at Fluxaxis, comments; “We are thrilled to be amongst the first to back the HP Multi Jet Fusion. We were attracted not only by the speed and quality of printing but by the fact the HP Multi Jet Fusion is an open platform that allows external companies to create new materials with enhanced properties and at lower costs. The next couple of years are going to be extremely exciting as new materials are developed for applications across the medical, engineering and creative industries.”

The new HP Jet Fusion printer, with the additional purchase of a HP fast cooling station, allows for continuous 24 hour 3D printing.  After a print is complete, a build unit can be removed from the machine and immediately wheeled into the fast cooling station, which rapidly cools the parts contained within. This is a huge leap forward dramatically reducing cooling times.

The addition of an extra build unit allows for this to be inserted into the 3D printer immediately after the last build has finished, thus meaning a continuous rotation of build jobs throughout a 24 hour period.

Europac3D

These benefits have helped Europac 3D secure more than £1m in sales in the first six months of the printers being available in the UK, as companies and organisations look to benefit from the technologies.

John Beckett, managing director of Europac 3D, comments; “It’s becoming increasingly evident that these new technologies from HP are going to revolutionise 3D printing and open up the technologies to new and exciting markets.  Coupled with an open platform system we’re excited by the opportunities and look forward to further developments in months to come.”

The print services supplied by Fluxaxis will be looking to gain new customers in a wide variety of verticals and gain market share in the 3D printing bureau industry throughout the UK and Europe.

Europac 3D, headquartered in state of the art facilities in Cheshire, offers a full spectrum of services from the supply of cutting-edge scanners, printers and accessories to installation, maintenance and training of staff in the usage of 3D hardware and software.