Surefix initially approached the 3D-Consultancy (3DC) to see about manufacturing and supply of their brackets with a particular interest in 3D printing. The approach to 3DC was after they had tried for many months a host of other suppliers.  These earlier supplier discussions had all failed to achieve the essential cost and quality targets.

Surefix claim that “The new Rise and Fall Gutter Bracket saves you both time and money while adhering to new health and safety regulations.

The Surefix product solution is faster to install, stronger when in place and safer for site personnel. It has more adjustment and can be easily removed for maintenance.

Unlike the installation method of alternative bracket solutions, the Surefix Rise and Fall Gutter Bracket does not cause damage or cracking to a building’s brickwork, and has been subjected to rigorous industry testing, including pull-out and downward load testing.”

This enquiry to the 3D Consultancy was typical of many enquiries we receive.  Our initial investigation into a 3D printed solution would not deliver on the customer requirements.  However, our engineering team were able to offer alternative options which do meet the required specifications and the quality and cost targets.

Price point was key for the customer given this was a new product into a very competitive market with established solutions already available. The goal was to deliver a high-quality product that was still price comparable but with the value-add benefits the Surefix bracket brings in terms of superior quality, fit once fit well and fit quicker.

After engaging with 3D Consultancy’s manufacturing partners, a cost viable solution in a stainless-steel material SS201 was selected for a balance of good strength to economy and production samples were created. In parallel, a low cost C45 carbon steel variant was also produced with a significant cost reduction this would give our customer the option of supplying these to lower cost and affordable housing.

Dialogue was now underway with potential buyers and the first sourcing and sample making exercise was turned around in just 4 weeks. These samples were very well received aesthetically, however when pushing the samples beyond the required British Standard there was a bend failure and so further design analysis, and development work was undertaken.

These challenges are typical of what the 3D Consultancy team face and engineering performance improvements were added without adding any cost. The resulting improved C45 and SS201 samples which were supplied within only 3 weeks not only held double the required load they also held the load for over 1 hour (against a required 5 minutes) without any bend failure.

A spokesperson for Surefix commented:

‘’ Working with Brett and the 3D Consultancy to get a prototype made of our product, test on site, adjust and finalise, has been second to none.  A very reactive company, hitting all dates and deadlines required and going above and beyond to help get this product finalised ’’.

ABOUT US

The 3D Consultancy are an engineering led design and manufacturing consultancy providing technical solutions utilising CAD digital processes, advanced 3D printing/additive manufacturing, and 3D scanning.

If you have a technical challenge with very tight deadlines that require exacting specifications and an agile working approach to achieve results, then give us a call on 0203 092 4429 or send us an email enquiries@3d-consultancy.com or visit our website for more information.

An example of such a challenge was for one of our motorsport clients was looking for a material that can withstand more than 120 Degrees Celsius.

The client did not want metal and initially came to us with PEEK in mind. PEEK is a technopolymer that we also offer (3D Printing Materials Guide (3d-consultancy.com) in a variety of advanced composite blends.  PEEK would have been an ideal choice for high temperature resistance.  However, the required parts were small (inside 20mm3 and thin walls)., So, FDM processing was not suitable and couldn’t achieve the print resolution the customer needed at this very small scale.

(Above) CAD model of the component to be made with CE 221 Resin

As this was a development part with the potential to be updated after fit and function verification testing, the customer needed just an initial 2 off but with a potential volume of 10 to 50 for the final installation. This meant that we had to consider not only all the functional and aesthetic requirements, but also whether the process chosen was scalable to produce high quality, repeatable parts with a fast turnaround and better economy than is possible for a larger quantity of parts.

(Above) actual component made with CE 221 Resin

Given the very small size of the component and the high-performance requirements, this very much fitted in with Top 3D Printing Service and Additive Manufacturing | Carbon (carbon3d.com) materials. The material of choice was CE221 which is comparable to glass filled nylon and has excellent heat deflection at a temperature of 230 degrees Celsius, stiffness and strength. There are many good SLS materials that offer excellent mechanical properties and fit well for this application, however MJF, a material we often provide cannot match the temperature resistance of CE221 and the resolution when produced as small parts.

On completion of this project our client commented:  “The 3D-Consultancy always provides us with very innovative solutions and great advice when it comes to 3D printing. They are very responsive and their very quick turnaround means that we lose no time in our development projects.”

Please view our materials catalogue here if you would like to compare all advanced 3D Printing materials properties 3D Printing Materials Guide (3d-consultancy.com)

Carbon Digital Light Synthesis^™ (Carbon DLS^™) is a breakthrough resin-based 3D printing process that uses digital light projection, oxygen-permeable optics, and engineering-grade materials to produce polymeric parts with exceptional mechanical properties, resolution, and surface finish.

The smaller build sizes and speed of processing, lends itself to building small batches or a larger series (dependent on component size and parts nesting). The more the print bed fills up the better the unit cost economy becomes.

CE221 has some excellent additional material properties that allow it to be used for specialist and end-use applications, not just prototyping, applications such as:

BIOCOMPATIBLE
Carbon has performed biocompatibility testing with documentation to support the material passing ISO 10993-5 for cytotoxicity.

UV AGEING RESISTANT
CE 221 exhibits very low natural polymer ageing in the presence of UV over hundreds of hours.

CHEMICAL RESISTANCE
CE 221 exhibits very low mass gain with most household chemicals, industrial fluids, and strong acid, alcohols, and bases.

Below are some examples of further uses for this fantastic material.

(Above) Fluid Manifold component made with CE 221 Resin

Fluid and gas manifolds require strength, stiffness, temperature resistance, in addition to isotropy, smooth finish, and ability to print fine features.

(Above) A cold-gas thruster for NASA’s robotic free flier inspector, made with CE 221 Resin

ABOUT US

The 3D Consultancy are an engineering led design and manufacturing consultancy providing technical solutions utilising advanced manufacturing technologies and CAD/ 3D Scanning digital processes.

If you have a technical challenge with very tight deadlines that require exacting specifications and an agile working approach to achieve results, then give us a call on 0203 092 4429 or send us an email enquiries@3d-consultancy.com or visit our website for more information.

An electric boat with unique technological and environmental credentials, starting a new chapter in luxury marine cruising.

The high detail model was created as a visualisation tool for the engineering team and for potential buyers to get a better feel for the concept design.  A useful feature in the model is that the Coupe roof section lifts off to allow both of the proposed versions to be visualised as shown below.

A range of digital and traditional modelmaking processes were utilised throughout the build. The hull section was CNC machined for high detail and accuracy for aerodynamic surfaces and preserving crisp detail on edges.

Many of the interior parts, furniture and sterndrive assembly were 3d printed using SLA process in resin. The Coupe roof was made from vacuum formed clear plastic created from a forming tool.

Benefits of the Furyan F35 Eco Hybrid includes:

Improved performance:

Greater torque enabling full power from a stationery position and quieter running (less noise pollution) than fossil fuelled alternatives;

Lower costs:

A 70% saving on diesel fuel costs and 90% saving on routine maintenance – combined saving of up to £50,000 over the first five years of ownership;

Eco friendly:

ZERO harmful emissions (NOx, SOx, HC, CO2 and PM) on electric propulsion and a 60% reduction when in hybrid mode.
The Furyan hull is made from natural fibre with a negative CO2 footprint, is fully recyclable and has a low CO2 manufacturing ratio;

Safe at sea:

Battery packs and e-motors are on separate circuits; the range extending generator recharges the batteries when required and can drive the boat safely back to port at 12 knots.  Almost uniquely amongst this type of boat, it is designed to meet Type Approval CE category B offshore – boats operating offshore with winds of 40 knots and significant seas to 13 feet (4 metres); and

Regulatory compliance:

Fully compliant with the increasing regulatory environment across Europe.

Visit our web site for more information www.furyanmarinetechnology.com

ABOUT US

The 3D Consultancy are an engineering led design and manufacturing consultancy providing technical solutions utilising advanced manufacturing technologies and CAD/ 3D Scanning digital processes.

If you have a technical challenge with very tight deadlines that require exacting specifications and an agile working approach to achieve results, then give us a call on 0203 092 4429 or send us an email enquiries@3d-consultancy.com or visit our website for more information.

• high-performance engineering development of conventional, hybrid and full electric vehicles and powertrains, for motorsports and automotive solutions;

• innovative manufacturer within the food service and hospitality industry;

• university spinout business whose technology characterises nanomaterials;

• manufacturer of nanoparticle dispersions for numerous applications across a range of industrial sectors

• company that develops transformative, systems, platforms and products for the defence sector;

• defence sector training and simulation consultancy;

• F1 motorsport;

• design led start-ups and spin-outs in the agri-tech, med-tech, clean-tech, construction, fashion and interiors sectors;

• PCB and LED design, assembly and contract electronic manufacturer;

• premier new home builder;

• manufacturer of modern home furnishings;

• company that designs and manufactures passenger information systems for the transport industry;

• designer and manufacturer of gym and fitness equipment; and

• designer and manufacturer of bedding, seating, furniture and flooring to the transport sector.

If you have a challenging project and need some help, then give us a call on 0203 092 4429 or send us an email enquiries@3d-consultancy.com or visit our website for more information.

Yellow Collective approached the 3D-Consultancy (3DC) to package their novel photocatalytic technology into an air purifier prototype that would be suitable for testing onboard the train for a major rail operator and that would give them further learning on the application and performance of their technology. The opportunity came about during unprecedented covid times and a government keen to get people back to travelling safely on trains. A device that could clean the air and kill the covid virus was highly desirable.

Before we were even at this point. Yellow Collective were in touch one weekend requesting a demonstration model to pitch their idea. Working from a concept render and given the urgency a 3d model was created in a matter of hours and then manufactured using FDM 3D printing process to allow a demonstration model to be presented in front of the target customer within 4 days.

Initial concept render which provided basis for the air purifier enclosure design

Given the success of the pitch, the focus then turned to fast tracking the idea to a working prototype. The brief was one of the most challenging 3DC had faced.

In 10 weeks, produce a fully integrated air purifier, shock and vibe, EMC tested and nineteen copy devices for a live passenger test across two rail carriages. Two devices also required integrated sensors to measure air quality improvement.

To keep track of the task with so much to deliver in so little time, short daily stand-up team meeting between all parties were installed.  This ensured quick decision making, and any concerns quickly addressed. As there was the need to bring several key components together safely in a functional system the onus was simplicity, limiting the use of bespoke design components and using off the shelf parts as much possible (this also helped with regulatory and safety compliance).  A simple cylindrical enclosure design was selected to enable easy sheet metal fabrication and protection for all the functional elements and sensors inside.

There were some changes mid project to specification and performance areas but the project was eventually successfully completed in 12 weeks which was a monumental effort from all parties involved.

Yellow Collective CEO & Founder Mark Cusack with Version 1 prototype & installation for train test

A spokesperson for Yellow Collective commented that “Vital to the success of the project was being able to deliver in time and on full in Covid times. We went from a blank sheet of paper to full delivery of tested devices within 3 months. From initial discussions to final delivery 3DC were responsive, understanding and laser focused on delivery. The inevitable challenges that a project such as this threw up were dealt with professionally and effectively. Would thoroughly recommend, excellent value and collaboration.”

As a result of success from this first project a more advanced specification was targeted for v2.  The customer targeted this v2 model for further learning from smart sensoring and to measure a full complement of airborne particles.  Consideration was also given to a more aesthetic design that resembled more the initial concept render. By the time, this project had been completed, the last two versions of the v2 batch were setup and performing excellent as plug and play devices pushing live data to the cloud to show how much air quality improvement has been made in real time.

Version 2 air purifier which was used for further customer testing in a variety of environments

ABOUT US

The 3D Consultancy are an engineering led design and manufacturing consultancy providing technical solutions utilising CAD digital processes, advanced 3D printing/additive manufacturing, and 3D scanning.

If you have a technical challenge with very tight deadlines that require exacting specifications and an agile working approach to achieve results, then give us a call on 0203 092 4429 or send us an email enquiries@3d-consultancy.com or visit our website for more information.

SCG once again passed the reliability tests with flying colours getting both cars home again this time with car #709 coming in 3rd place making SCG, the first American manufacturer to podium since 1967.
24 Hours of Le Mans Press Release (mailchi.mp)

Building on the foundations of the launch car that performed so well in its very first Le Mans it was more refinement and performance improvements rather than a completely new race car.

The 3D Consultancy have provided design and engineering support and supplied over 500 components to Podium Advanced Technologies for testing, development and homologation, including brake duct and powertrain integration components.

The 3D Consultancy provide a one-stop shop for design, engineering and production of 3D printed and composite components for motorsport.

As one door opens so another closes.  The 3D Consultancy (3DC) co-founder Roberto Paduano has resigned as Director of the company and will no longer be involved in the management of the business.  After several years of involvement with 3DC, Roberto is stepping down to focus his time on other interests.  His colleagues at 3DC wish him well for the future and are grateful for the excellent contribution he has made to the business.

In strengthening and broadening the skills and capabilities of 3DC, notable additions to the team in recent times include:

Dr Ian Halliday, a pioneer in Additive Manufacturing, experience as a Chief Engineer and the CEO of a manufacturing business taking it from small plastic prototyping provider, to one of the world’s leading Metal and Plastic AM Production companies.

Greg Edwards, whose early years included working for F1 champions Mercedes-AMG and McLaren Automotive before moving into the marine world and leading a team developing electric propulsion systems for yachts.

John Travis, who has been in the world of top-level motorsport in both Europe and the USA working for many of the top names of the industry.  John has had significant involvement in hybrid and electric vehicle projects including the recent design and development of the Furyan F35 hybrid marine cruiser.

The 3D Consultancy is an engineering led design and manufacturing consultancy providing technical solutions utilising advanced 3D scanning, 3D printing/additive manufacturing and CAD digital processes using the latest materials and processes, with industry leading expertise in composite materials technologies.

For more details about our services and to discuss your engineering project requirements please get in touch.

Given that this was for a one off and there were internal water pipe routings this project did favour 3d printing processes where internal supports could be removed. The only things that would need to be reviewed and explored was the surface quality (customer required high level detail) and durability, weather proofing (this will be a fixed functional display for many years outside).

After an initial meeting with the client, we elected to explore both 3d printing and resin casting with moulds, to assess the best surface finish option and to see what would give the best result and for what price.

After working through all the options, we found that we could employ multi material 3d print processes to build the display. This would make the low detail, larger item built on the Fortus 900 machine using FDM process and UV stable ASA material, the smaller high detail items built in HP MJF PA12 material at a much sharper 80-micron resolution. This saved significant time and cost versus tooled methods such as resin and bronze foundry casting. There would be added cost with surface finishing, especially with creating a bronze coating effect but the savings were still there when all aspects were factored in making the 3d printing route cost effective.

Given this was a step outside traditional process route and a large build, we proposed a 3-stage process to de-risk the proposition and offer the customer full flexibility. This gave the customer the opportunity to get more of a feel for the quality and the finishes available, as the aesthetic was a priority for the customer.

The first stage was to build some MJF samples with a reduced scale version of one of the otters in the main display to show the customer the section through the material and coating process and to evaluate the detail in the finish. Two scenic bronze finishes were provided to give the customer the choice of a full smooth bronze and a more aged, distressed bronze finish.

The bronze finish acts like normal bronze, it oxidises when out in the open, but can be polished to go back to its original shade, like real metal. Bronze powder combined with a resin-based mixture makes the surface as close to bronze as you can get without it being solid bronze.

The next two stages are a full-sized otter, then full remainder of the fountain display and animals dependent on whether the customer continues down this process path with 3DC. Look out for more updates as this project continues through the summer.

If you need to create a metallic finish on your parts, or any other type of advanced material finishing or coating we can assist you.

The 3D Consultancy is an engineering led design and manufacturing consultancy providing technical solutions utilising advanced 3D scanning, 3D printing/additive manufacturing and CAD digital processes using the latest materials and processes, with industry leading expertise in composite materials technologies.

If you have a technical challenge with very tight deadlines that require exacting specifications and an agile working approach to achieve results, then please contact us.