In the fast-paced world of manufacturing, efficiency is paramount. Every second shaved off a cycle time translates directly to higher profits and a competitive edge. And when it comes to injection molding, tooling design is often the foundation upon which everything rests. At SyBridge, we understand this, and it’s why we’ve become the industry leader in design, engineering, and manufacturing of injection mold tooling.

Our expertise goes beyond simply creating high-quality tools. We are experts in optimization, and our dedication to understanding your specific needs allows us to craft solutions that streamline your entire injection molding process.

A Real-World Example

Supercharging Production

One client, a manufacturer of plastic dosing scoops, faced a common challenge: production couldn’t keep up with demand. They were running four 175-ton injection molding machines 24/7. Each existing 12-cavity tool had a 9.5-second cycle time and produced 110,000 parts per day, but it simply wasn’t enough.

Phase 1

SyBridge engineers evaluated the customer’s existing equipment, systems, and output needs, then designed a new 12-cavity tool using innovative solutions for filling and cooling the component. Upon installation, they realized a remarkable 5.0-second cycle time, a 47% reduction from their previous 9.5-second cycle time. This translated into an 88% increase in daily production with the same machine, producing an impressive 207,000 parts per day.

Phase 2

But SyBridge didn’t stop there. Building on this success, we engineered another tool, this time with 16 cavities; as before, the cycle time was at 5-seconds, and the higher-cavitation tool was still able to run in the same 175-ton presses. This powerhouse pushed daily production even further, reaching 275,000 parts – a 150% increase from the original tool.

The Proof is in the ROI

The impact was undeniable. The manufacturer not only met demand but was also able to get ahead of it, opening up opportunities for new sales growth. SyBridge tooling solutions delivered such significant production gains that the customer was able to recoup their tooling investment in less than 6 months, a testament to the immediate value delivered by SyBridge expertise. But even beyond the initial investment payback, with the increased output, the customer was able to better schedule planned maintenance, extending the life of the tools and leading to additional long-term financial benefits. This is just one example of how SyBridge empowers our partners to achieve remarkable results. Our commitment to precision engineering, coupled with our in-depth understanding of the injection molding process, allows us to:

• Reduce cycle times through innovative tool design, leading to greater output and increased production efficiency.
• Lower your Total Cost of Ownership (TCO) through more efficient tooling that drives lower direct and indirect material costs for molded products.

Ready to unlock the full potential of your injection molding process?

At SyBridge, we are more than just toolmakers; we are your optimization partners. We understand the unique challenges you face and are committed to developing solutions that not only meet your needs but exceed your expectations.

Contact us today to discuss your specific needs and discover how our expertise can help you achieve breakthrough results:

• Faster cycle times
• Increased production output
• Reduced total cost of ownership
• A competitive edge in the marketplace

The post How SyBridge Expertise Optimizes Your Process and Lowers Costs appeared first on SyBridge Technologies.

In this fast-paced market, where consumers crave both luxury and sustainability, staying ahead of the curve is crucial. This article delves into the key trends transforming the industry, from captivating design elements to eco-conscious solutions, empowering you to create packaging that not only looks good but resonates with today’s savvy consumers. 

Product differentiation drives sales 

In an increasingly crowded marketplace, creating a unique style for cosmetic packaging is key to catching the eye of consumers and building brand loyalty. Consumers look for details in the design, such as embossed logos on caps, custom colors, unique materials like copper and aluminum, and exclusive shapes (Figure 1). 

Figure 1. Distinctive shapes and mixed materials help products stand out in the beauty market.  

Consumers also expect a luxe feel when purchasing a beauty product with a high price point. Using substantial materials in packaging gives even miniature products a high-end feel.  

Additive manufacturing supports new product development  

Developing products with novel designs requires expertise and options for scaling if products become popular. Since the cosmetics industry moves quickly, bringing a new product from conception to design to reveal is essential for its relevance. And because customer preferences can pivot rapidly, manufacturing a limited number of new products using cost-effective techniques to test the market is also important.  

Additive manufacturing processes like 3D printing meet both requirements—they can produce parts quickly and don’t require huge upfront costs (Figure 2). 

Figure 2. Carbon® Digital Light Synthesis™ is one of SyBridge’s many 3D printing techniques 

Companies can scale production with high cavitation injection molds or other production techniques if the product is commercially viable. Although specialty tooling capabilities may have a higher upfront cost, their ability to support higher production runs and longer lifetime cycles ensures they remain cost-effective. The ability to start small and scale ultimately results in the lowest overall cost of ownership for brand owners.  

Using sustainable materials and designs to appeal to consumers  

Sustainability continues to be a trend for consumer products in 2024, including cosmetic packaging. However, most consumers are unwilling to compromise on increased prices for more sustainable products. Manufacturers must find a way to produce sustainable packaging that is also cost-effective.  

Toward more sustainable cosmetic packaging  

Refillable and reusable packaging is emerging as a more environmentally friendly alternative to single-use packaging. Other sustainability trends include using either post-consumer recycled (PCR) plastic or aluminum for manufacturing or creating products made of single, recyclable plastics (mono-material) instead of a mixture of plastic and metal (Figure 3).  

Figure 3. Material selection simplifies sustainability for consumers 

Mono-material packaging simplifies recycling but does come with challenges, such as finding plastic alternatives to metal springs and other traditional metal components. Manufacturers are also limited in design by choosing mono-material packaging because they can’t use decorative metal coatings.  

A simple way to meet the demand for sustainable packaging without making consumers pay more for beauty products is by choosing a minimalist design (Figure 4). Sleek designs without added decorative features can reduce production complexity and material usage. The challenge to choosing minimalist designs is standing out in a market that relies so much on eye-catching products.  

Figure 4. Minimalist designs can reduce material usage and simplify production  

Design services help meet manufacturing challenges  

Producing flawless cosmetic packaging with the luxe feel consumers expect using sustainable materials is a serious challenge. That’s where working with companies with design services and a range of manufacturing capabilities becomes essential. SyBridge experts can complete design for manufacturability (DFM) checks and simulation analysis to identify production issues before production begins, reducing design iterations and saving on production costs (Figure 4). 

Figure 5. DFM checks help determine how to manufacture the highest-quality part at the lowest possible cost per unit. 

Design services are essential not only for testing novel ideas but also for optimizing current production. SyBridge experts can use product data and analytic tools to create a digital thread — a centralized source of truth for the part. We use the digital thread to gain insights about a part’s lifecycle (design to final production) and see opportunities for increased efficiency and improved quality (Figure 5).  

Novel dispensing methods make for more hygienic products  

A carryover from the COVID-19 pandemic continuing to influence health and beauty products is an emphasis on hygiene. Where many skincare and makeup products require brushes or even a fingertip for application, consumers are now choosing contactless options like droppers, misters, products with internal applicators, and airless pumps.  

Airless pumps reduce the chance of harmful bacteria getting into beauty products during use or illnesses spreading between people sharing the product (Figure 6). Pump dispensers also give customers precise control over how much product they use because each pump produces an exact volume. Companies can use pumps as an opportunity to provide instant brand recognition through contoured pump heads and other unique details.  

Figure 6. Airless pumps help reduce the spread of microbes and regulate dosing. 

In addition to enhanced hygiene and dosing control, the airless packaging used in pumps and sprays can preserve the chemical composition of the formula by not introducing oxygen during use. This extends the product’s shelf life. Airless packaging can help reduce waste, and it is often made from mono-material, making it 100% recyclable.  

Manufacturing for optimal user experience and safe shipping 

A challenge for manufacturing novel dispensing methods is ensuring function. Consumers can easily become frustrated and dissatisfied when features such as pumps malfunction, ultimately costing brands the loyalty they have worked hard to gain. Precise manufacturing is essential to avoid warpages, stress cracks, and other flaws that can cause packaging to malfunction. 

E-commerce companies selling cosmetics also need packaging that meets shipping standards. Products must have the strength to withstand rough handling during transportation, sortation, and distribution.  

SyBridge helps companies manufacture uniform, strong products by incorporating quality inspection services and advanced designs, such as conformal cooling, in our manufacturing technology. Our precision manufacturing can help companies achieve high-feature, aesthetic parts that are also functional. 

Partnering with SyBridge  

Manufacturing partnerships help cosmetics companies maintain a competitive edge in the fast-paced industry. Since needs vary by product, partners with multiple capabilities are especially valuable and critical to support reduced overall tooling costs. SyBridge experts can help cosmetics packaging manufacturers wherever they are—whether seeing if a novel design is achievable or choosing the best manufacturing technology for a proven product.  

Staying ahead of 2024 beauty trends is possible with the right partners. Connect with a SyBridge expert today to learn how our comprehensive services can help you meet your goals this year.  

The post 2024 Trends in Cosmetic Packaging appeared first on SyBridge Technologies.

Defects can reduce the speed and cost-efficiency of the entire product development process, and can potentially shorten product life spans if left unchecked. Injection molding issues and defects can be caused by a host of reasons, including poor design, production process mistakes, quality control failures, and more. As such, it’s important to take a proactive approach to risk mitigation throughout the product development process so as to reduce the chances of potential injection molding defects.

Here are a few of the most common defects that may occur in plastic injection molding — and how product teams can avoid them.

1. Flow Lines

Flow lines are off-color lines, streaks, and other patterns that appear on the surface of a part. These are caused by the shot of molten plastic moving at different speeds throughout the injection mold, which ultimately causes the resin to solidify at different rates. This is often a sign that injection speed and/or pressure are too low.

Flow lines can also appear when the thermoplastic resin moves through parts of the mold with different wall thicknesses — which is why maintaining consistent wall thickness or ensuring that chamfers and fillets are an appropriate length is critical. Placing the gate in a thin-walled section of the tool cavity can further help to reduce flow lines.

2. Sink Marks

Sink marks appear as depressions, dents, or craters in thick sections of a part. Thicker sections take longer to cool, which can have the often unanticipated side effect of the inner portions of the part shrinking and contracting at a much different rate than the outer sections.

Though most often an indicator that the plastic needs more time inside the mold to properly cool and cure, sink marks may sometimes be remedied by reducing the thickness of the thickest wall sections, which helps to ensure more even and thorough cooling. Inadequate pressure in the mold cavity or higher-than-desirable temperatures at the gate can also contribute to the development of the defects.

On the design side, the risk of sink marks can be minimized by ensuring proper injection molding rib thickness and wall thickness. These actions can also help to increase the overall strength of the part.

3. Surface Delamination

What is delamination? Delamination is a condition that causes a part’s surface to separate into thin layers. These layers, which appear like coatings that can be peeled off, are caused by the presence of contaminants in the material that do not bond with the plastic, creating localized faults. An over-dependence on mold release agents can also cause delamination.

To encourage delamination repair and prevention, teams should increase mold temperatures and tailor the mold ejection mechanism to be less dependent on mold-release agents, since these agents can increase the risk of delamination. Properly pre-drying the plastic before molding can also help.

4. Weld Lines

Also called knit lines, these defects mark where two flows of molten resin came together as they moved through the mold geometry. This happens around any part of the geometry that has a hole. As the plastic flows and wraps around each side of a hole, the two flows of plastic meet. If the temperature of the flow isn’t just right, the two flows won’t properly bond together and will instead cause a visible weld line. This reduces the overall strength and durability of the component.

Raising the temperature of the molten resin can help to prevent the solidification process from beginning too soon, as can increasing injection speed and pressure. Resins with lower viscosity and lower melting points are less prone to developing weld lines in injection molding, which can also be eliminated by removing partitions from mold design.

5. Short Shots

“Short shots” refer to instances in which the resin doesn’t entirely fill the mold cavity, resulting in incomplete and unusable parts.

What causes short shots in injection molding? Typically, they are the result of restricted flow within the mold, which can be caused by gates that are too narrow or have become blocked, trapped air pockets, or insufficient injection pressure. Material viscosity and mold temperature are also contributors. Increasing mold temperature and incorporating additional venting into mold design to allow air to properly escape can help prevent the occurrence of short shots.

6. Warping

Injection molding warping refers to unintended twists or bends caused by uneven internal shrinkage during the cooling process. Warping defects in injection molding are generally the result of non-uniform or inconsistent mold cooling, which creates stresses within the material.

Preventing warpage defects in injection molding is a matter of guaranteeing that parts are given enough time to cool — and at a sufficiently gradual rate — to prevent internal stresses from forming and damaging the piece. Uniform wall thickness in mold design is crucial for many reasons, critical among them being that it helps ensure that the plastic flows through the mold cavity in a single direction.

It’s worth noting that materials with semi-crystalline structures are more likely to develop warping.

7. Jetting

Jetting defects in injection molding are another potential result of an uneven solidification process. Jetting occurs when an initial jet of resin enters the mold and has enough time to begin setting before the cavity fills. This creates visible, squiggly flow patterns on the piece’s surface and decreases the strength of the part.

Reducing injection pressure is often the best way to ensure more gradual fills, but increasing the mold and resin temperature can also help to prevent any jets from preemptively setting. Placing the injection gate so that the flow of material runs through the shortest axis of the mold is another effective means of minimizing jetting.

Prevent Injection Molding Defects and Causes

Injection molding can be a highly efficient manufacturing method for producing highly repeatable plastic parts, but, as with many processes, producing high quality end-parts requires a high level of attention to detail and a proactive approach to risk management. Everyone involved in the product development process — from the initial design and proof-of-concept stages all the way to fulfillment — needs to do their due diligence to ensure products meet the highest quality standards and avoid these common plastic injection molding issues.

Choosing a manufacturing partner like SyBridge, who is well-versed in common defects in injection molding and their troubleshooting, can mean the difference between high-quality parts — produced on-time and within budget — and those marked with weld lines, jet, flash, sink marks, and other defects. In addition to being an experienced on-demand manufacturing shop, we also provide design consulting and optimization services that ensure we’re able to help every team create functional, elegant, high-performance parts as efficiently as possible. Contact us today to learn more about our injection molding services.

The post 7‌ ‌Common‌ ‌Injection‌ ‌Molding‌ ‌Defects‌ ‌and‌ ‌How‌ ‌to‌ ‌Avoid‌ ‌Them‌ appeared first on SyBridge Technologies.

The urethane casting build process involves first creating a master pattern — essentially a replica (often 3D printed) of the final part. The pattern is then fully encased in liquid silicone and allowed to cure. The mold is cut into halves and the pattern removed. From there, the process can be repeated using the proper urethane casting resin.

Polyurethane casting materials are capable of providing performance characteristics comparable — if not superior — to the thermoplastics used in injection molding. However, as with other production methods, the process of casting high-quality parts that meet all performance requirements also requires that product teams follow design for manufacturability (DFM) best practices. Here are some of the most important guidelines for product teams to keep in mind:

Tolerances

Some degree of variation is inevitable in manufacturing (though teams should endeavor to account for as many of the variables as possible), and tolerances are the acceptable amount of dimensional variation between individual units. Cast urethane tolerances are typically around  ± 0.015” or ± 0.003 per inch, whichever is greater. Tighter tolerances may be offered on a case-by-case basis.

In general, a shrinkage rate of +0.15% is typical. This is caused by the thermal expansion of the urethane casting material and how the flexible silicone mold warms in response.

Additionally, it’s important to note that while urethane cast parts take well to post-processing (though additional processes, such as polishing or custom finishing, can quickly drive up production costs), some design features like sharp corners or lettering may experience slight rounding in the cooling process, impacting the definition of finer details. That said, it is possible to add a finish to the master pattern that mimics an SPI finish or texture. You can also paint urethane cast parts to match Pantone colors, and certain color and pigments can be added directly to the casting materials, as well.

Wall Thickness

Parts produced with urethane casting should have a minimum wall thickness of 0.040” (1mm), though walls as thin as 0.020” (0.5mm) can be achieved for some small components. Larger parts generally require thicker walls in order to ensure the piece’s structural integrity.

Urethane casting does allow for parts with varying wall thicknesses or irregular geometries, but designing parts as such should be done only when strictly necessary. Maintaining a consistent thickness helps to minimize the potential for improper shrinkage and deformation during the curing process.

Undercuts and Draft

While undercuts can quickly complicate injection molding design, the flexible nature of the silicone molds used in urethane casting typically allows for parts to be removed easily and without damage.

The same is true for draft angles: they are a necessity for ejecting pieces from metal molds, but less essential for urethane-cast parts. That said, incorporating 3-5 degrees of draft into part design can significantly reduce strain on your mold and extend its life cycle.

Ribs

Ribs add stability and strength, but it’s important to ensure that they are oriented so as to maximize the bending stiffness of the walls they support. As a general rule of thumb, the rib’s height should be no more than three times its width, and the width of the rib where it meets the part wall should be between 40-60% of the wall thickness. Lastly, to maximize the strength of the rib, all interior corners should have a fillet radius of at least 25% of the part’s wall thickness.

Bosses

Bosses allow secure mating parts to be attached through the use of screws, pins, and other fasteners. As with ribs, the base radius should be about 25% of the part’s wall thickness, which has the added benefit in this case of helping to prevent the fastener from burning when it’s set into the boss.

Interior boss corners should use a 0.060” (1.5mm) fillet radius to minimize thickness and reduce the likelihood of sinks developing. Ensuring that bosses are no more than 60% of the nominal wall thickness also helps to minimize shrinkage.

Leverage the Benefits of Urethane Casting Today

The advantages of urethane casting — short lead times, low cost, and design and material flexibility, to name a few — only truly pay off if you adhere to design and manufacturing best practices. This means paying attention to variables like urethane casting material properties, general tolerances for rubber parts, and everything in between — which quickly becomes complicated without the assistance of an experienced manufacturing partner.

With our agile approach, we’re able to significantly shorten lead times and increase operational efficiency for product teams of all shapes and sizes. And at SyBridge, our business isn’t just based on manufacturing superior parts — we also work tirelessly to make sure that our production processes are as efficient as possible, even if that means using a combination of techniques to get the job done. Contact us today to learn more.

The post Critical Design Guidelines for Urethane Casting appeared first on SyBridge Technologies.

In this downloadable guide, we’ve compiled eight common DFM considerations that should remain top-of-mind when designing parts for CNC machining. You can save significant time and cost by checking your design against this list before submitting it for manufacturing.

Top 8 Design for Manufacturing Considerations for CNC Machining

1. Are there any deep pockets in the design?

Deep-narrow pockets or slots must be machined by longer tools, and longer tools are more prone to breakage, and can also cause chatter, or machine vibrations. Additionally, it takes several passes to machine a deep pocket, which drives up machining time and manufacturing costs.

Avoid designing parts with deep pockets whenever possible. If a deep pocket cannot be avoided, engineers and designers should decrease its depth as much as possible or increase the cross-section area of the pocket. As a rule, pocket depth shouldn’t exceed 3x the diameter of the tool being used to make it. For example, pockets should be no deeper than 1.5” when using a 0.5” cutter.  Engineers may have to adjust this figure based on the material they are using and the tools that are available to them.

2. Are there any narrow regions?

Narrow regions are difficult to manufacture because the size of the cutter is restricted by the smallest distance between the various faces of the feature. Long and small diameter cutters are prone to breakage and chatter.

Avoid designing features or faces that are too narrow for a cutter to easily pass through. If narrow regions cannot be avoided, however, they must not be too deep. Remember that the depth of any feature should be less than 3x the diameter of the tool.  As a best practice, wall sections should be greater than 0.01 inches thick. A shorter cutter with a larger diameter can also be employed to reduce chatter.

3. Are there any sharp internal corners?

Since all CNC drill bits are circular, it’s difficult to achieve sharp internal corners. Instead, the drill bit will leave behind a pocket of unmachined space called an internal corner radius. It’s possible to machine sharp internal corners using workarounds, like electrical discharge machining, but these methods tend to be expensive.

Avoid sharp inside corners whenever possible. Ideally, a corner radius needs to be slightly larger than the cutter. If a corner radius is the same diameter as the cutter being used to form it, it can cause chatter and premature tool wear.

Increasing the corner radii beyond the standard value by as little as 0.005” can give the tool enough room to move around and follow a more circular path.

4. Are there any inaccessible features?

Inaccessible features like counterbores that open inside another pocket or pockets with negative drafts take longer to machine— if they’re even possible — because the cutting tool cannot easily access them, which in turn drives up costs.

You should ensure a cutting tool has full access to all features within a part without being blocked by another feature.

5. Are there any outside fillets?

Outside fillets, or fillets on the top edges of pockets, bosses, and slots, require an exceptionally sharp cutter and a precise setup. Both of these requirements can be prohibitively expensive for some product teams. To avoid incurring these costs, bevel or chamfer — rather than fillet — the outside edges of features.

6. Are the part’s walls too thin?

When it comes to CNC machining with metal, thin walls increase chatter, which can compromise the accuracy of the machining process and the surface finish of the part. With plastics, thin walls can cause warping and softening. As such, you should do your best to avoid designing parts with thin walls.

The ideal minimum wall thickness for metals is 0.8 mm for metals and 1.5 mm for plastics. You may be able to achieve thinner sections without significant risk, but this needs to be assessed on a case by case basis.

7. Are there any flat-bottomed holes?

Flat-bottomed holes require advanced machining operations and often cause problems down the line for subsequent operations like reaming. Avoid creating blind holes with a flat bottom — especially small holes — and instead use a standard twist drill to create holes with cone-shaped bottoms. Cone angles are commonly 118° or 135°.

8. Can the CNC machine’s drills enter and exit easily?

A drill tip will wander when it comes into contact with the material’s surface if that surface isn’t perpendicular to the drill axis. Also, uneven exit burrs around the exit hole will make removing the burr difficult. To ease entry and exit, avoid designing hole features with start and end faces that are not perpendicular to the drill’s axis.

Recap of All 8 Design Considerations for CNC Machining

1. Avoid designing parts with deep pockets whenever possible because deep-narrow pockets can drive up machining time and cost.
2. Avoid designing features or faces that are too narrow for a cutter to easily pass through to prevent tool breakage and chatter.
3. Radiused corners (middle) or “dog bones” (right) are good alternatives to sharp internal corners.
4. Ensure a cutting tool has full access to all features within a part without being blocked by another feature
5. Avoid outside fillets (shown left) and opt for chamfered edges (right) to save time and cost.
6. Avoid designing thin walls, as they’ll increase chatter in metals and cause warping or softening in plastics.
7. Avoid Flat-bottomed holes that can cause problems for subsequent operations like reaming.
8. Whenever possible, design hole features with start and end faces perpendicular to the drill’s access.

Get Started With a DFM Expert

Designing for manufacturability accelerates the CNC machining process, reduces operating costs, elevates energy efficiency, and helps product teams create clean, functional parts. Refer to this short checklist often to make sure your designs are on the right track, but an experienced manufacturing partner like SyBridge can offer more nuanced insights.

The SyBridge team can help engineers, designers, and product teams ensure they don’t miss the mark when it comes to DFM. We have access to the latest digital design technologies available so our partners can take their designs to the next level, while we provide expert advice on manufacturability and part quality. What’s more, our experts are prepared to assist customers with design and prototyping for a range of manufacturing methods — from CNC machining and injection molding to urethane casting and 3D printing. Let’s create something incredible. Contact us today.

The post The Ultimate CNC Design for Manufacturability (DFM) Checklist appeared first on SyBridge Technologies.

Multi Jet Fusion enables the efficient production of end-use nylon parts using additive technologies. Here’s a checklist for design teams.

Introduction

What is Multi Jet Fusion?

Multi Jet Fusion (MJF) is an industrial form of 3D printing that can be used to produce functional nylon prototypes to higher volume production parts with exceptional design freedom and mechanical properties. The MJF process works by using inkjet nozzles to selectively distribute fusing and detailing agents across a bed layered with nylon powder. Unlike selective laser sintering, which uses lasers to fuse the powder into solid material, the MJF printer uses a continuous sweeping motion to distribute agents and apply heat across the print bed layer by layer until the part is finished, MJF can produce high-quality parts at high speeds.

This manufacturing process also does not require support structures to produce parts, making it possible to create complex geometries like internal channels or co-printed assemblies. MJF parts have mechanical properties comparable to injection-molded ones, but without the need for expensive tooling.

Designing for manufacturability will go a long way in ensuring optimal part quality and yield, minimizing post-processing needs, and driving cost reductions. Here’s a quick checklist to help your team ensure that you’re following MJF design best practices.

1. Is MJF a suitable process for my project?

Before diving into design changes, it is important to ensure that the MJF process will meet all product requirements. Here are a few questions to ask yourself:

Do any of the material offerings meet my product requirements?

While MJF has many strengths, it has a limited list of approved materials. PA12 and its glass bead counterpart are fairly versatile for rigid plastic applications. TPU, a flexible polyamide, can find use where an elastomeric material is required. If the available materials do not meet a specific requirement, you may need to consider a different process.

Does my part fit in the build volume?

One key limiting factor is the machine’s build volume, which is 380 x 380 x 284mm for the Jet Fusion 4200. In some cases, large parts can be printed as smaller subcomponents and assembled using adhesive or mechanical joints. In this case, design features such as dovetail joints may facilitate alignment and adhesion.

Do I have any tight tolerances I need to hit?

While the gap between additive and injection molding tolerances is narrowing, it is important to make sure that MJF’s tolerances are sufficient within the context of your assembly.

2. Are there areas where I can use less material?

In most cases, MJF defects are caused by thermal gradients that develop during the build. If the material cools unevenly, the piece may warp or develop sinks. Parts that are long and thin, have abrupt changes in cross-sections, or have thin curved surfaces are especially prone to shrink-induced warp.

Removing material from part designs wherever possible through the use of pockets, shelling, lattices, and topology optimization is key to mitigating and preventing these defects. Avoiding large changes in cross-sections is another way to limit warp. Ensure that chamfers and fillets are incorporated where needed throughout the part design to make the transitions between different features more gradual.

3. Are my features above the minimum threshold size?

In general, the wall thickness of MJF-printed parts should be a minimum of 1.5mm. Small design features should also be no smaller than 1.5mm, though some features such as slits, embossing, engraving, or the diameters of holes and shafts can be as small as 0.5mm. For embossed or debossed text, the font should be no smaller than 6pt (approximately 2mm) and should be a minimum of 0.3mm deep.

If a part includes screw threads, they should be M6 or larger. Where smaller, more precise, or more durable threads are needed, consider using threaded inserts. Beyond feature resolution, you should also consider how small, slender features might break off in post-processing.

4. Have I taken assembly tolerances into account?

Even with the greater geometric flexibility provided by the MJF process, some applications may still require a part to be assembled from multiple components. In general, mating faces should have 0.4 – 0.6mm of clearance to ensure that the components can properly fit.

If your project involves co-printing assemblies, the components printed together should have at least 0.5mm of clearance, but may require more, particularly when there are thick cross sections or there is a significant contact surface area.

5. Is my part design optimized for post-processing?

If your part requires post-processing, there are a few things to double-check in your design to help make secondary operations more effective.

1. Ensure that there are no unvented or trapped volumes in the design.
2. Avoid blind holes whenever possible — these are hard to clean, which can quickly drive up costs.
3. Add fillets to corners where the powder can cake and become difficult to remove through standard tumbling and bead blasting.

6. Have I seized every opportunity to lower part costs?

Besides improving part quality, intelligent DFM changes can drive cost savings. Lightweighting your part, for example, reduces the risk of defects and lowers the material cost per part. The other main consideration when designing for MJF and cost is optimizing nestability in a build. Adding draft or altering the position of printed assemblies may increase the number of parts that can fit per build and distribute fixed costs over more parts, lowering the overall part cost.

In addition to optimizing designs for manufacturability, additional factors to consider include your part’s cosmetics, surface finish, and ease of storage and transportation. MJF parts are naturally grey, but can be dyed black easily. If painting, priming, or other processes are not essential to the part’s function, they can be foregone to reduce expenses. Most MJF-printed parts will have a 125-250 microinches RA finish — if a smoother surface is needed, the part can undergo a variety of surface treatments, including sanding, tumbling, or vapor smoothing. Texturing can be an effective design technique to improve part aesthetics without additional post-processing.

Getting Started With a DFM Expert

Adhering to DFM principles is key to the success of manufacturing processes for a number of reasons. It helps to keep your operating expenses as low as possible, allows you to detect and address design issues early, and improves your overall part quality. This checklist is a valuable resource for making sure your MJF parts are optimized and refined before production begins.

The added advantage of partnering with SyBridge is that your team gains access to the latest in digital design technologies and expert advice. Our team is standing by to help guide each project from design and prototyping through to fulfillment, ensuring that you receive superior-quality parts on time and at the right price. Contact us today to get started.

The post HP Multi Jet Fusion Design Guidelines appeared first on SyBridge Technologies.

by Charlie Wood, Ph.D.
VP of Innovation, Research & Development

As a part of the SyBridge team, I’ve witnessed the remarkable evolution of design and engineering tools over the past decade. These digital advancements have revolutionized our approach to manufacturing, allowing for more data-driven processes and insights. But it can be difficult to know where to start, or even to understand where there are opportunities to implement.

At the heart of our approach lies the concept of the “Digital Thread,” a framework that interconnects data across the entire lifecycle. This concept enables us to leverage the wealth of design and operational data across our data lake that is generated in the manufacturing process, from CAD designs to inspection results. While the industry is still moving towards seamless integration, we’ve made significant strides in creating workflows that prioritize data-driven decision-making.

Streamlining Injection Mold Design Workflows

One key area where data is contributing to efficiencies within manufacturing is that of injection mold tooling design. By utilizing virtual component libraries for mold designs, we’ve been able to streamline the complex process of coordinating and collaborating on intricate assemblies for mold making. In these libraries, we have standard blocks, system approaches and components stored in a way that allows us to quickly identify and digitally pull components. This approach offers lots of flexibility when it comes to customer requests and needs, all while keeping standard practices built right into our tools. Over the course of many years, we’ve built software-driven processes to design new builds based off of these standard components, allowing us to quickly handle new requests from customers and build a learning feedback loop to avoid costly mistakes.

Additionally, through the use of parametric component libraries, we’ve been able to significantly reduce design complexity and incorporate our own manufacturing intelligence into these components, allowing us to directly check for design issues and integrate manufacturing information into CAD files. This process creates a flow of information from the conceptual stage of the design through manufacturing and approval, extending our Digital Thread from end to end. This information flow can also go backwards, tying quoting, estimation assumptions and specifications directly to tool designs. These advancements in our design approach have not only made the job of a tool designer a bit easier, but have improved quality by creating
more explicit feedback loops in our design processes.

Innovations in Conformal Cooling

As many know, 3D printing has unlocked incredible design freedom for manufacturing engineers around the world. However, what can be overlooked is how impactful it has been for system designers, like toolmakers, who can utilize that design freedom and low cost of complexity to create components that radically improve performance. In the case of toolmaking, 3D printing has unlocked new cooling channel designs simply not possible before.

Although increasing numbers of toolmakers are using these advanced manufacturing techniques today, the new design space is so complex it can be hard to probe. In the past, conformal cooling channels were fairly straight, in-plane paths driven by tool access limitations in machining. With metal 3D printing, the limits are far less restrictive and allow designers to pursue more creative and complicated structures.

Using advanced data-driven methods with virtual design and testing capabilities, we’ve been able to uncover non-obvious opportunity areas in the design space. Through these novel design and
manufacturing workflows, we’re optimizing cooling performance and achieving remarkable improvements in tool performance as measured through cycle time. Through our approach, we’re seeing cycle time reductions as high as 50%. These successes have inspired us to further integrate and enhance these workflows, driving continued innovation.

AI Tools for Manufacturing

The Fast Radius Portal’s AI-powered DFM checks

Looking ahead, we’re enthusiastic about the possibilities that emerging technologies like machine learning (ML) and artificial intelligence (AI) offer. These novel data modeling approaches have shown incredible potential, and the pace of technological advancement is rapidly accelerating. We’ve been able to use ML models to build data models faster than through simple bottom-up logic, particularly for complex problems that contain many correlating factors.

The critical ingredient in implementing AI for manufacturing are large data sets that provide a source of truth for model training and validation. By leveraging our existing datasets, we aim to predict defects, optimize designs in real-time and ultimately revolutionize quality control processes. These technologies are not a distant vision; they’re an integral part of our current digital platform, with features like instant quoting and DFM checks based on captured manufacturing data. And this is just the beginning of what’s possible.

Unlocking Manufacturing Innovation via the Digital Thread

Our journey in harnessing digital workflows for injection molding design has seen remarkable progress and tangible results. The end-to-end integration of data into the Digital Thread, combined with the power of ML and AI, holds the key to unlocking even greater innovation. As we continue to push boundaries and explore new frontiers, we’re excited about the advancements at the interface between the physical and digital worlds.

Are you ready to harness the power of the Digital Thread for your organization? Contact us today to get started.

The post The Digital Thread: End-to-End Data-Driven Manufacturing appeared first on SyBridge Technologies.

Choosing the right tooling materials for manufacturing medical parts can be complicated, but with the right expertise and partner it can be a smooth process for long-term results.  

This is where having options makes a difference. Steel (hard) and aluminum (soft) tooling are both good options for creating the components used to manufacture medical parts. Selecting the option that will deliver the most value depends on your volume requirements, design complexity, and the lifespan of the mold. 

Aluminum Tooling: Fast Turnaround, Limited Cycles    

Specialized tool manufacturers can generally build aluminum tooling quickly, Aluminum tools are compatible with a variety of materials, cost less than steel, and have better heat conductivity. The ability to quickly gain or dissipate heat shortens production cycle times and offers a more consistent mold temperature, reducing the chances of warpage and increasing yields.    

Although aluminum boasts better heat conductivity and shorter production time than steel, its main drawback is that it can begin to wear down more quickly (typically after tens of thousands of production cycles) than steel. Worn tooling increases the chances for imperfections, a deal breaker for medical applications. Manufacturers may need to replace or repair aluminum tooling more often than steel tooling.    

Steel Tooling: High-Volume Production, Higher Upfront Costs  

Steel is a harder material than aluminum. This gives steel tooling many advantages: components can produce millions of parts over years without diminishing quality, the material allows for more complex designs, and the material is resistant to scratches and erosion. Steel tooling supports high-volume production runs for an extended period.  

However, steel tooling is also more expensive, and because steel is so hard, tooling may become difficult to repair or modify once produced. Steel doesn’t allow as much heat conductivity and so, molds take longer to heat and cool, increasing cycle times, potentially introducing warpage, shrinking, or sink marks. Additionally, high-featured designs or those that have unique requirements (e.g., thin, non-uniform walls) may require the use of steel molds to provide the required results. 

Choosing Your Tooling Material 

Both steel and aluminum tooling can be suitable options once the complete part design, budget and volume scenarios are fully considered. While the raw costs are distinctively different, the overall return on investment will depend on the lifespan of the tool and its usage.  

The decision comes down to the intended use of your tooling. Figure 1 shows a simplified version of the three factors to consider when determining which tooling material to use.  

Figure 1. Decision chart for steel vs. aluminum tooling 

Prototypes and Aluminum Tooling  

Prototypes are essential to developing new medical devices and other types of health technology. They allow engineers to test how their concept works in the real world, answering important questions, such as how well the part addresses the treatment’s core problem, how it fits with existing systems, and how easy it is to access and maintain. Without prototyping, these essential questions go unanswered, and the product is less likely to succeed during later stages.   

Consider using aluminum tooling for early prototypes if your volume needs are low – for example: less than 50,000 parts. Aluminum tooling will maintain its quality and reliability for the number of runs required to produce the prototype. Creating steel tooling for these low-volume runs may not provide the return on investment that aluminum will. Steel tooling is a more viable investment for high-production runs when volumes increase.   

Medical Industry Solutions From SyBridge  

Choosing the appropriate tooling for manufacturing your medical parts is crucial. The right tooling material will help guarantee the reliability of parts in high-volume production or the cost-effectiveness of parts in low-volume runs. Consider working with a tooling design and manufacturing expert to ensure consistent, reliable and high-quality outcomes. 

At SyBridge, our expert engineers can help you select the right tooling material to meet your needs. We bring decades of expertise in tool design and manufacturing of various types and levels and can guide you with the right choice for your application. 

Contact us  today to discover how SyBridge can produce the excellence you desire. 

The post How to Choose Tooling Materials for Medical Applications appeared first on SyBridge Technologies.

When designing a part, it’s important to understand critical differences between comparable materials. For instance, substituting a thermoplastic instead of a thermoset to create a product that’s meant to withstand high temperatures would have disastrous results. 

The terms “thermoplastic” and “thermoset” appear in many of the same conversations regarding plastic part manufacturing, but they’re not interchangeable. This article breaks down the major differences between thermoplastics and thermosets, as well as key advantages and best applications for each material.

Thermoplastics: What You Need to Know

Mechanical/Chemical Properties

A thermoplastic is any plastic material with a melting point that becomes molten when heated, solid when cooled, and can be re-melted or molded after cooling. The process is completely reversible, and doing so will not significantly compromise the material’s physical integrity. 

Thermoplastics are usually stored as pellets to facilitate easy melting during the injection molding process. Common examples of thermoplastics include acrylic, polyester, nylon, and PVC.

• Nylon: Nylon provides a unique combination of strength and wear resistance that makes this family of materials well-suited for a range of applications.
• TPE and TPU: When product designers and engineers want a part to have certain properties like shock absorption, flex rebound, or high impact strength, they often turn to polymers made out of thermoplastic elastomers. 
• ULTEM (PEI): ULTEM® is one of the only resins approved for use in aerospace settings. It is also among the most versatile plastics on the market. 

Advantages of Thermoplastics

Thermoplastics are strong, shrink-resistant, and relatively easy to use. Their inherent flexibility makes them an excellent choice for manufacturers who require shock-absorbent products that can withstand wear and tear while retaining their shape. 

Thermoplastics are generally more cost-effective than thermosets because they’re easier to process. This is because thermoplastics are made in higher volumes and don’t require post-processing. Plus, thermoplastic molds can be made from affordable materials like aluminum. Thermoplastics are highly compatible with injection molding processes, and are ideal for making repeatable parts in high volumes. 

Additionally, thermoplastics are some of the more environmentally friendly plastics on the market as they are highly recyclable by design. As an added benefit, manufacturing with thermoplastics produces fewer toxic fumes than working with thermosets. 

Common Thermoplastics Applications

Manufacturers often use thermoplastics for prototyping because if the final product doesn’t meet certain standards, they can easily melt the part down and start over without producing a lot of scrap material.

Beyond part prototyping, thermoplastics can be used to create a range of familiar consumer products, as well as medical devices, automotive components, and more.

Thermosets: What You Need to Know

Mechanical/Chemical Properties

In contrast to thermoplastics, a thermoset is any plastic material that hardens once cured by heat and cannot be reshaped after the curing process. During curing, valence bonds in the polymer cross-link together to form three-dimensional chemical bonds that cannot be undone, even under extreme heat. 

Thermosets are usually stored in liquid form in large containers. Common examples of thermosets include epoxy, silicone, and polyurethane.

• Epoxy (EPX 82): An additive material developed by Carbon for its DLS process. This material is ideal for automotive, industrial, and consumer applications. 
• Silicone (SIL 30): SIL 30 is an additive material developed by Carbon® for its digital light synthesis (DLS). Also known as SIL 30, this silicone urethane offers a unique combination of biocompatibility.
• RPU 70: Known for its toughness, strength, and ability to withstand heat, RPU can be used across multiple industries including consumer products, automotive, and industrial. 

Others like Phenolics are available as a granular product.

Advantages of Thermosets

Thermosets offer a wide range of benefits; overall, they are strong, stable, chemical-resistant, and have outstanding electrical properties. They won’t warp, degrade, or break down easily in extreme temperatures. 

Due to their strength and durability, thermosets are often used to reinforce another material’s structural properties. Among the most impact-resistant materials on the market, they are frequently used to seal products to protect them against deformation. 

Common Thermosets Applications

While thermoplastics offer a more diverse range of high and low functionality applications, thermosets can be used to create high-performance products in a wide variety of industries. 

Thermosets are ideal for building anything that comes into contact with extreme temperatures on a regular basis, such as kitchen appliances and electronics components.  

Start Building With Us

The crucial difference between thermoplastics and thermosets boils down to how they react to heat. Thermoplastics can be molded and remolded in the presence of heat without losing structural integrity, while thermosets can be molded only once. Of the two, thermoplastics are better suited for all-purpose products that need to be strong and flexible, while thermosets make better high-performance products. An experienced manufacturing partner can help you decide which material best fits your needs. 

When you partner with SyBridge, you partner with a dedicated team of engineers and manufacturing experts who will help you take your project to the next level. We’ll match your vision with optimal materials, manufacturing processes, and post-production services to ensure that you end up with a product of unmatched quality. Contact us today for a quote.

The post Thermoplastics vs. Thermosets: What’s the Difference? appeared first on SyBridge Technologies.

To provide NFL and D1 players with enhanced protection with greater comfort, VICIS collaborated with the advanced manufacturing team at SyBridge, 3D printer/materials manufacturer Carbon and the digital customization experts at Toolkit3D to create player-specific 3D printed pads for ZERO2 MATRIX football helmets.

SNAPSHOT

Challenge

The team at VICIS was seeking a way to manufacture football helmet pads that offer greater comfort, safety and durability to provide players with improved protection against head injuries.

Solution

Drawing upon the expertise of the teams at SyBridge and Carbon, VICIS 3D printed these advanced new helmet pads with Digital Light Synthesis™ (DLS) technology, utilizing lattice structures made from a new energy-damping, strain-rate-sensitive elastomer (EPU 45). To achieve a truly custom fit, VICIS turned to sports body equipment customization specialists Toolkit3D to perform 3D head scans of individual players. With SyBridge’s digital manufacturing capabilities and expertise in 3D printing, VICIS was able to create pads that conform to each player’s unique head shape, providing custom-fit comfort, enhanced protection and greater durability.

Outcome

Worn by some of the world’s best football players, VICIS helmets featuring these individually-customized 3D printed pads are now the top rated helmets for safety according to the NFL and NFLPA.*

*Data and rankings as of April 2023

“Just as in football, precision, speed and agility were key components when selecting a manufacturing partner for the 3D printed pads used in the Zero2 Matrix helmet. With SyBridge’s engineering expertise and advanced manufacturing technologies like Carbon® DLS™ and the Fast Radius Portal, we were able to incorporate feedback from the field to develop this helmet with player-specific customization in mind, bringing next-level design, protection and performance to the D1 and professional players of this sport we love.”

— Cord Santiago, Senior Design Engineer, VICIS

In the world of professional football, player safety is of utmost importance. With a growing concern about head injuries and the long-term effects they can have on athletes, leading helmet manufacturer VICIS set out to create an improved football helmet that would reduce impact force during head collisions.

To make this possible, the team at VICIS turned to SyBridge and Carbon in order to design and manufacture protective helmet pads, leveraging the digitization and customization expertise of Toolkit3D to achieve a custom fit for each player’s unique head shape.

The Challenge

REPLACING FOAM AROUND THE DOME

With traditional football helmets, including many of those used by professional and D1 athletes, foam is used as the primary material for padding and impact absorption. However, there are several key issues with foam pads that prevent them from being ideal for this application.

Foam pads:

• Offer little ability to fine-tune for specific impacts, limiting performance and safety
• Lack durability and require frequent reconditioning
• Cannot be customized without machining or other labor or material-intensive processes
• Trap heat and moisture

Recognizing the limitations of traditional foam pads, VICIS aimed to create helmet pads that not only remain structurally intact over time but also prioritize player comfort and offer unparalleled safety against head impacts. This required an innovative manufacturing approach, along with expertise in material science and engineering, leading VICIS to the advanced manufacturing experts at SyBridge and Carbon, and the sports body equipment customization specialists at Toolkit3D.

About EPU 45

EPU 45 is a new energy-damping elastomer developed by the material science engineers at Carbon. It prints four times faster than traditional elastomeric polyurethanes and is a strain-rate sensitive material that stiffens to absorb energy at higher impact rates, enabling the design of highly breathable lattice structures tuned for comfort at low-impact speeds and energy absorption at high-impact speeds.

Advantages of Lattice Structures

In addition to enhanced breathability, the lattice structures of the 3D printed helmet pads allow for optimal energy distribution upon impact. Combining this structural design with the unique properties of EPU 45 makes these advanced helmet pads a superior alternative to foam padding traditionally used in football helmets, as they offer greater durability with superior impact absorption.

The Solution

CRAFTING A NEW PLAYBOOK FOR IMPROVED CRANIAL PROTECTION

Working closely with the designers and materials scientists at Carbon and manufacturing engineers at SyBridge, VICIS determined that Digital Light Synthesis™ (DLS) was the right technology to manufacture these advanced helmet pads due to material compatibility and a focus on customization. With a lattice-structure design consisting of the new EPU 45 material, the 3D printed helmet pads would offer an ideal combination of enhanced protection and greater durability.

To create a truly custom fit for each player, VICIS leaned on the expertise of Toolkit3D, specialists in digitizing and automating the customization of high-performance medical and sports body equipment, to create a digital model of each player’s unique head shape. Then, collaborating with the engineers at SyBridge and Carbon, VICIS was able to optimize each pad’s design for manufacturability and cost-effectively 3D print the custom elastomeric helmet padding.
For additional customization and traceability, each pad is printed with the player’s name, pad set, print date and serialization, ensuring that players use the correct pads for their specific cranial geometries.

In the event a replacement pad is needed, utilizing the design flexibility that 3D printing provides combined with the on-demand digital manufacturing capabilities of SyBridge’s Fast Radius Portal, players can receive new pads that match their original head scans in as fast as 2 days, ideal for reconditioning equipment during bye weeks.

The Outcome

LEADING THE LEAGUE IN HELMET SAFETY

The agility of digital manufacturing and the rapid production times that 3D printing offers have allowed VICIS to manufacture these new pads for their Zero2 Matrix helmets with mass customization in mind. When it comes to comfort, one size doesn’t fit all, and sacrificing safety for an improved fit should never be a consideration.

Worn by some of the world’s best football players, VICIS helmets featuring these individually-customized 3D printed pads are now the top rated helmets for safety according to the NFL and NFLPA.*

With these helmets, players get enhanced safety without the impediment of additional size or weight, and a truly customized fit for improved security and performance.

*Data and rankings as of April 2023

The NFL in collaboration with the NFLPA, through their respective appointed biomechanical experts, annually coordinate extensive laboratory research to evaluate which helmets best reduce head impact severity. The results of those tests, which are supported by on-field performance, are set forth on this poster.

The helmet models are listed in order of their performance, with a shorter bar representing better performance. The rankings are based exclusively on the ability of the helmet to reduce head impact severity measures in laboratory testing. Performance variation related to helmet fit, retention, temperature-dependence, and long-term durability are not addressed in these rankings.

All helmets in green are recommended for use by NFL players. Based on a statistical grouping analysis, helmets in the Top-Performing group have been further distinguished into two green categories. The darker green group represents those that performed similarly to this year’s top-ranked helmets, while the light green group performed similarly to the lowest ranked dark green helmet. Helmets with poorer laboratory performance were placed in the yellow or prohibited groups. Yellow and newly prohibited red helmets are not permitted for new players and players who did not wear them during the 2022 NFL season. Newly prohibited helmets will be prohibited for all players in 2024.

The laboratory test conditions were intended to represent potentially concussive head impacts in the NFL. The results of this study should not be extrapolated to collegiate, high school, or youth football.

The post Tackling Football Head Injuries With Manufacturing Innovation appeared first on SyBridge Technologies.