7 Out-of-the-Box Uses for FDM

We all know about using FDM technology to build concept models, functional prototypes and end-use parts. But here are seven additional ways that FDM can be used to prevent mistakes, save time, and refine design for the manufacturing floor:

Using FDM for fixtures.1. Fixtures. Mack’s Application Development Center (ADC) uses FDM technology to print fixtures to hold complex plastic part shapes for the ultrasonic installation of metal inserts. “FDM helps us make a fixture that exactly fits the part so it self-orients for further operations, including silk screening, laser marking, pad printing, and ultrasonic inserts,” says John Zuk, director, application development.

2. Mistake-proofing. As part of Mack’s Poka-yoke initiative, the ADC designed a fixture that mistake-proofs a laser-marking process for an orthopedic application. Here’s how it works. There are five very similar parts, varied only slightly by size, which need to be uniquely laser-marked with part and size numbers after molding. Mack designed the mold to include five spokes with a part attached to each, and an arrow for orientation during secondary operations. The ADC 3D printed a corresponding fixture to hold both the parts and runner, with the arrow correctly positioning the parts in the fixture for accurate laser marking.

3. De-gating. The ADC also 3D prints fixtures to securely hold parts for precise, clean de-gating, either flush or below the surface.

4. Time-to-market. The ADC creates FDM parts before molds are completed for actual production runs so Metrology can test CMM fixtures and programs prior to tool delivery. “This allows us to improve part measurement techniques before launching into actual production, and can cut weeks off the schedule,” says Zuk.

Using FDM for mistake-proofing.5. Refined design. “We’ve also used FDM to print both an unusually shaped orthopedic instrument for hip surgery, as well as the sheet metal surgical tray that holds it,” says Zuk. “That allowed us to test the ability of the tray design to effectively hold the instrument so it wouldn’t dislodge or move around in the tray whether the lid was on or off. We sent it to the customer for verification, which allowed us to test and refine the design before any steel was cut or actual manufacturing began. You can use this method to test multiple designs before going in any one direction, saving time and money.”

6. Robotic tooling. The ADC also plans to use 3D printing for end-of-arm tooling for molding machine robots. “The custom tools would ensure proper placement of unusually shaped parts on the conveyor belt as they are transported for further secondary operations,” explains Zuk.

7. Paint masking. Likewise, the ADC plans to use FDM technology to print hard masks for complex shapes before they are painted.

Contact: John Zuk, Director, Application Development, Mack Molding
john.zuk@mack.com

Gettin’ Down & Dirty

Black River Clean-upBikes in the river? Yep, and a whole lot more! 600 pounds of metal, in fact, and a lot of other garbage! And that was just in the portion of the Black River directly behind Mack’s Cavendish, Vt., plant.

Several employees volunteered recently to help with the Black River Action Team’s (BRAT) annual RiverSweep event, hauling trash out of the river and its tributaries. The metal was sold off as scrap with the proceeds going to support other efforts of BRAT.

Founded in 2000 by Kelly Stettner, BRAT is a vibrant organization that plants native trees to stabilize stream banks; conducts a water quality monitoring program; encourages others, through its Adopt-the-River campaign, to monitor and clean selected stretches of the river; works to manage invasive plants in the watershed; and much more.

As a state-designated Environmental Leader, Mack develops an annual environmental management plan aimed at preventing pollution, complying with regulations, and minimizing environmental impacts. Helping to keep the Black River clean is a part of that plan. Kudos to all in Cavendish who helped realize that goal!

Contact: Gene Birmingham, Cavendish Plant Manager
eugene.birmingham@mack.com

Made in Vermont

'Made in Vermont' DaysOver 90 students and staff from three area high schools attended Mack’s inaugural ‘Made in Vermont’ days this fall at the headquarters plant. Later this month, many will return for follow-up workshops in specific areas of interest, including engineering, molding, manufacturing, machining, sheet metal and office/admin.

Students toured the f’real frozen beverage blender line, where virtually all of Mack’s services come together to build the very complex product, including plastics, sheet metal, machining and total product manufacturing, as well as the procurement of over 400 unique parts from 63 suppliers and distribution of the final product. In addition to standing up to the rigors of the blend-it-yourself retail scene, the ‘smart’ appliance automatically self-cleans and steam sanitizes and alerts f’real if there is ever a blender malfunction in the field.

After seeing the way it’s done in the real world of modern manufacturing, the students were put to the test of building a simulated product themselves. Directed by the Vermont Manufacturing Extension Center (VMEC), the exercise pitted teams in a race against time to see who could manufacture the most product, which had to pass a quality audit before it could be counted! The common response after the dust settled? “It’s a lot harder than it looks!”

'Made in Vermont' DaysA discussion regarding the skills needed in modern manufacturing and relative career paths at Mack wrapped up the day, followed by pizza, f’real shakes and Mack giveaways.

“Like the state, we value our youth and want them to have the choice to stay here,” says Jeff Somple, president of Mack’s Northern Operations. “They represent the future, not only for Mack, but for all businesses in the state.

“Recent studies have confirmed what we’ve already been seeing – manufacturing is returning from China to the U.S.,” adds Somple. “China is no longer the low-cost wage center it once was, which means employment in U.S. manufacturing will be on the rise. We must have an educated and well-prepared employee base from which to hire – our ‘Made in Vermont’ days represent just one of the ways we’re trying to assist with that effort.”

Contact: Julie Horst, Director of Communications
julie.horst@mack.com