Challenges
Before integrating the Flexbot into their organization, project operators Jakob Haerting and Severi Salmirinne had limited experience in large-scale 3D printing. The challenge was to produce a complex windshield tool, consisting of two parts, interconnected with a hinge. The mold would serve as a press to shape PC/PET sheets into the desired shape of a windshield. Despite it being one of their first projects after receiving CEADs operator training, they did not hesitate to take on this challenge.
Flexbot solution
The Flexbot, a cutting-edge robot based additive manufacturing technology platform, emerged as the perfect solution to REDU’s challenge. This modular 3D printer provided the necessary flexibility in printing and machining varying parts, a cost-competitive alternative to traditional metal molds, as well as a resource efficient, i.e. sustainable, solution for creating a windshield mold for industry use. Moreover, this case study, sheds light on an additional layer of complexity: Jakob and his colleague, with backgrounds in law and carpentry had almost no prior experience in 3D printing, except for some prints on FDM/SLA machines. New to industrial 3D printing, they navigated this new territory with the mold being their first actual project. Prior to starting the project, they received an on-site operator training facilitated by the CEAD team as part of the Flexbot installation. This way, new operators are trained to independently use the Flexbot system.
The material chosen for the molds was UPM Formi 3D 20/19. Right after receiving the training, they started successfully printing test cubes and fine-tuning the settings, before proceeding with the mold. This marked a significant leap, considering the shape to be far more complex than a cube. To add, the project wasn’t solely about 3D printing: machining of the part would ensure the desired finishing of the mold. For this, they could also utilize CEAD’s Flexbot, since it is a hybrid technology platform, which allows the operator to switch between a 3D printing pellet extruder to a CNC milling head to finish the part.