FREE MEMBERSHIP

Get your FREE Inside Composite membership

Sign me up!

8th October 2019, Modena

Rebuilding components with Windform material

T-shaped attachment brackets for industrial blinds. © CRP Technology

T-shaped attachment brackets for industrial blinds. © CRP Technology

Advanced technologies can be applied to many cases, including the reproduction of broken or worn components, whose spare parts are difficult to obtain or no longer available. This is more and more frequent nowadays; the impossibility or delays in finding spare parts can compromise the workflow of production cycle with consequent loss of time and money.

The reverse engineering process, combined with professional 3D printing and high-performance composite materials, allows the broken or worn production tool component to be quickly reconstructed and replaced, allowing the production system to immediately return to operational status, saving a great deal of time and money.

CRP Technology, the 3D printing company based in Italy and a leader in the field of the most advanced additive manufacturing technologies and composite materials, helped in the reconstruction of a T-shaped attachment bracket using reverse engineering process, professional 3D printing (selective laser sintering technology) and carbon fibre reinforced composite material.

Advanced technologies to the rescue

The T-shaped attachment bracket is fixed to a linear actuator for large electro-mechanical blinds. Due to wear and prolonged use, this part broke into three parts, making it impossible to open and close the blinds.

T-shaped attachment brackets. Above, the original one, bonded. Below, the new 3D printed one. © CRP Technology

T-shaped attachment brackets. Above, the original one, bonded. Below, the new 3D printed one. © CRP Technology

The company’s manufacturing path started with the evaluation of the 3D file of the component to be built. Already at this point, the CRP Technology experts found themselves facing an obstacle: the impossibility to get the 3D file of the T-shaped attachment bracket.

Thanks to the experience gained and 3D laser scanning technology, the CRP Technology team has managed to overcome the issue by using reverse engineering: this is a process that replicates a design by laser scanning, to create 3D data that allows for modifications, adaptations or reconstruction of the part.

Creation of 3D file

Firstly, the T-shaped attachment bracket broken into three parts, was bonded to restore its original shape and thus ensure the correct reverse engineering procedure.

CRP Technology’s expert team then applied reverse engineering process:

  • Digitisation phase – data captured from the surface of the T-shaped attachment bracket by scanning, to obtain its initial geometry, and
  • Reconstruction phase – data processing

From the mesh, through the use of special engineering CAD software the solid geometry is reconstructed and fitted to the original shape.

  • Production phase – manufacturing of the functional part via professional 3d printing and Windform SP carbon composite material

Once the 3D .STL file was produced after reverse engineering, CRP Technology team proceeded with the creation of the T-shaped attachment bracket using Windform Top-Line composite materials and selective laser sintering technology.

Laser scan of the T-shaped attachment bracket. © CRP Technology

Laser scan of the T-shaped attachment bracket. © CRP Technology

As a manufacturing material, Windform SP was chosen, a polyamide-based carbon composite material from the CRP Technology’s Top-Line range of high-performance composite materials. “The material has excellent mechanical properties, with high level of impact strength and elongation at break, as well as excellent resistance to high temperatures,” the company reports. “The overall manufacturing, from the reverse engineering phase to the construction via 3D printing, took place in just a few days.”

Dimensional control, validation and assembly

The Windform SP T-shaped attachment bracket has been scanned again to check for dimensional accuracy to ensure its conformity with the original.

Manufacturing of the part via laser sintering technology. © CRP Technology

Manufacturing of the part via laser sintering technology. © CRP Technology

Once the validation phase was completed, the Windform SP T-shaped attachment bracket has been mounted in place of the original. “Field-tests led to excellent results, and the correct functioning of the Blinds was restored,” the company said. “The use of cutting-edge technologies has allowed the reconstruction and implementation of the component in a short time. The material used, the highly performing Windform SP, has guaranteed the full restoration of the original functions of the structure.”

www.crptechnology.com

www.windform.it

This article is also appears in...

Comments

Be the first to comment on Rebuilding components with Windform material

|

Back to Top