Why Combine 3D Printing and Industrial Automation Applications?

3D printing is widely used in the field of automation such as in compression molding. It’s a formative manufacturing method, currently popular in industry, that involves compressing the desired amount of molding material between two heated presses to give it its final shape. It is cost-effective compared to other production processes, allowing both small parts and large components to be designed. In addition, the base mold can be 3D printed, giving manufacturers more flexibility and geometric freedom. That’s why one electrical manufacturer has invested in several 3D printers from Flashforge, including 11 Creator 4 models. With this investment, the company was able to reduce its labor costs by 80% and cut delivery times by 50%.

Flashforge is a Chinese manufacturer that entered the 3D printing market in 2012. Since then, it has offered a wide range of solutions worldwide and caters to applications in education, healthcare, jewelry, and more. Among its wide range of 3D printers is the Creator 4, an industrial FDM machine with two independent extruders and different extrusion options to expand the range of compatible materials. It’s a ideal solution for multiples industries such as automotive, medical or consumer goods. It boasts a printing volume of 400mm*350mm*500mm, a heating plate capable of reaching 130°C and a closed chamber that can rise to 65°C. It is a solution that offers optimal temperature control combined with production flexibility, allowing it to be combined with automation processes, such as compression molding.

The Creator 4 offers two independent extruders

Integrating 3D Printing into the Compression Molding Process

One of the challenges of compression molding is the design of the hoppers and mold: each hopper must match the mold cavity exactly so that the material can flow properly. However, the molds used are not all the same shape, with different or irregular cavities, which multiplies the number of hoppers needed. Flashforge’s customer, which specializes in the manufacture of electrical equipment, explained: “Each project involves dozens, if not hundreds, of different shaped molds. Each size requires over a hundred hoppers. So, a completed project represents tens of thousands of hoppers. In the past, we have had to hire trade experts or even outsource the order. However, whichever solution we chose, it was costly in time and money, as was post-project maintenance.”