The American company Merit3D, thanks to the support of a 10-million grant for the modernization of the industry in Utah, USA, is probably carrying out the largest order for parts printed on 3D printers in the history of the industry. Adhesive Technologies has placed an order for over 1 million parts to be shipped at a rate of 40,000 per week.
Last year, Merit3D produced 60,000 parts in less than eight hours using British Photocentric’s Liquid Crystal Magna large format photopolymer 3D printers. The event took place on January 25, 2022 at the Merit3D plant and was witnessed by many local officials and business owners who, in addition to watching it live, had a unique opportunity to learn about the possibilities of additive technologies in the context of their commercial activities. Now the company has set about setting another record in terms of speed and efficiency of 3D printing technology.
Merit3D reports that despite advances in mass production processes and expansion of production capacity, the company had to compete with manufacturers in Asia in terms of cost and the ability to mass produce using injection molding technology. According to the company, the industry modernization grant “significantly narrowed” this gap, increasing the ability to produce parts using photopolymer UV LCD 3D printing technology at an affordable price for the customer, allowing Merit3D to compete with companies specializing in plastic injection and foreign (Asian) suppliers.
Spencer Loveless, owner of Merit3D, said: “Competition abroad has always been very difficult due to low production costs, but now that we have been able to invest in modern equipment, we have taken a huge step forward, leveling the playing field.” The company highlighted four key aspects of the project for Adhesive Technologies:
The product went from design to production in two weeks. The client moved production back to the country, bypassing the use of injection molds abroad. The first order exceeded 1 million units. The printed product is more durable than its equivalent made of HPDE. The Merit3D design team worked to create a high-quality part that could be made within the target price range, allowing Adhesive Technologies to place the order. The manufactured part is the epoxy product holder, used to fix the mixing nozzle with the epoxy tube.
Adhesive Technologies typically uses specially designed injection molded plastic components to assemble the small handle. These holders ensure that the mixing nozzles are attached to the epoxy cartridges and do not become separated during transport or on the shelf.
“This is a huge step forward in modernizing manufacturing and transforming companies that traditionally manufacture overseas to be able to move production back to the United States using new technology,” said Blake Merrell, Chief Operating Officer of Merit3D. “This part is used in epoxy applications around the world. It’s sold at every home improvement store in the country, including Lowes and Home Depot.”
Loveless added: “There is a perception that if you have a digital part design, you can just go from injection molding to 3D printing. But that usually doesn’t make economic sense. Just as the original part was designed for injection, redesigning it for 3D printing was the only way forward.”
Loveless and the Merit3D team initially spent two weeks evaluating the grip’s purpose and properties and redesigning it. According to the company, they were able to develop a part that was smaller, lighter, aesthetically appealing and required less material to make. In addition, one of its 24 Photocentric Liquid Crystal Magna photopolymer 3D printers holds 400 parts and each run takes just under four hours.
After receiving the order, which secured the needs of Adhesive Technologies for several months, Merit3D presented the company with another version of the project. A universal holder was created that can be used for two products that previously required separate holders, eliminating another part that would have to be injection molded, then shipped, stored and installed.
“At 500,000 units, we plan to make it even better,” said Loveless. “Currently we have the mixing nozzle, handle, stopper as three separate injected parts, but our plan is to see if we can combine everything into one part?”
Merit3D says this order “sets a precedent” for how parts are made, as traditionally every order between 50,000 and 250,000 units must be injection molded. Merit3D says that the use of 3D printing allows companies to take their production and design processes to the next level.
An order of 1 million units is delivered at a rate of 40,000 units per week, as required by the customer. Loveless adds: “It’s a huge relief because you don’t have to order millions of parts at once and wait for long delivery times. Necessary parts can be supplied according to the ‘just in time’ production model.”
Currently, Merit3D is working with Photocentric and its material suppliers to find the optimal combination of properties and costs for a new 3D printing resin that will allow for more innovation and potentially also thinner holders with equal or better mechanical properties than the current version.
“At Photocentric, our goal is to provide additive manufacturing solutions that are industrial, scalable and affordable,” says Sally Tipping, Sales Director at Photocentric. “There is still a difference in cost between remanufacturing and injection, but our goal is to reduce material costs.”
Speaking about the benefits of repatriation grants at the U.S. state level, Loveless added: “We are very active on this front with the United States and Utah to find new ways to relocate production back home. This is a perfect example. This is possibly the largest order for parts in the history of 3D printing.”
Source: www.merit3d.com
Photo: www.merit3d.com (press materials / all rights reserved)