Prototyping investment casting sample parts to reduce costs

With the Ultimaker, designs can be tested before investing in tooling, which shrinks the percentage of required tool modifications from 30% to below 5%.

Prototyping investment casting sample parts to reduce costs

Sylatech uses the Ultimaker to prototype sample parts for its customers, allowing them to test their designs without having to invest in tooling ahead of investment casting. This yields significant time- and cost savings, as fewer tooling modifications are necessary.

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Speeding up the sampling process with 3D printing

"With the Ultimaker, we can use a 3D printed model for the creation of sample parts directly in our foundry process, without having to invest in tooling to create wax patterns. Through 3D printing we can significantly speed up our sampling process - clients can now get a prototype metal part in just seven days!" Gordon Gunn, Director of Marketing at Sylatech

Challenge and solution

Challenge

Challenge

Traditionally, design engineers would be unable to fully test the functionality of their designs without going down the route of investing in tooling for investment casting. This tooling process typically takes 3-4 weeks to complete and Sylatech customers typically incur a cost of between £2,000 to £4,000 per tool. About 30% of the tools would require alteration due to customer design modifications. This could cost the customer anywhere between £500 - £900.

Solution

Solution

With the Ultimaker, Sylatech can offer its customers a cost-effective prototyping solution. Whereas the tooling process would take about 3-4 weeks to complete, a 3D print can be undertaken within a matter of hours. The 3D printing process is popular with Sylatech’s customers due to the flexibility that it affords in the product design lifecycle. Thanks to Ultimaker, engineers can now have their designs transformed into a metal part within a number of days.

Cost comparison

Yacht propeller

Yacht propeller

6 components

Traditional tooling approach

Ultimaker 3D printing
Project development cost £17,100 Project development cost £660
Project development time 4 weeks Project development time 5 days

Note: 3D printing can typically avoid the need for undertaking tool modifications. Once the customer is ready to produce a production volume, investing in tooling is still necessary.

Results

Accelerated placement of tooling orders

Accelerated placement of tooling orders

The Ultimaker has enabled Sylatech’s customers to become more confident in their designs within a shorter time period, thus resulting in the accelerated placement of tooling orders for production.

3D printing for functional prototyping
Reduced level of tooling modifications

Reduced level of tooling modifications

Traditionally, about 30% of the tools would require alteration due to customer design modifications. This could cost the customer anywhere between £500 - £900. The Ultimaker shrunk this percentage to below 5%.

3D printing in manufacturing
Flexibility in the product design lifecycle

Flexibility in the product design lifecycle

The 3D printing process is popular with Sylatech’s customers due to the flexibility that it affords in the product design lifecycle. The Ultimaker allows for complex geometries and intricate designs to be made.

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Time- and cost savings

Time- and cost savings

The accelerated placement of tooling orders and reduced number of tooling modifications result in significant time- and cost savings. Sylatech estimates the payback period for an Ultimaker 3 desktop 3D printer to be less than 3 months.

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