Recent years has seen Dubai working towards becoming a hub for 3D printing technology in the region with an increasing demand for applications that can utilize 3D printing technology.
We at Immensa have a dedicated team to cater to the Additive Manufacturing requirements of customers in the United Arab Emirates and GCC region by working with them in transitioning from their conventional and traditional systems to additive manufacturing technologies’. Immensa focuses on value-based solutions such as (1) reduction of lead times; (2) reduction of component weight; (3) reduction of both production and operational costs; and (4) Minimizing inventory costs via print-on-demand solutions. The industries that Immensa identified as presenting the biggest opportunity to leverage additive manufacturing are Oil & Gas, Marine, Construction related businesses, and the Tooling Industry for Injection Moulding.
Tooling – Print-on-Demand Solution
One example of such a value-based solution provided by Immensa to a large industrial manufacturing company in the UAE is comprised of a centre forming tool. The lead time for procuring this part was extensive and maintaining inventory was costly. Keeping physical stock of the part was necessary as non-availability of part during part breakdown creates operational delays. Immensa mechanical engineering team reverse engineered the existing part and did some basic topology optimization achieving weight reduction of 25%. The optimised part was 3d printed used Maraging Steel (MS1) and provided same functionality as the conventional part, therefore, eliminating the long lead time required for procuring it and significantly reduced cost of carrying inventory as the client has now the option of print-on-demand solution.
Injection Moulding – Conformal Cooling Channels
Another important application of Metal Additive Manufacturing includes conformal cooling design in injection moulding, which was otherwise difficult to achieve via traditional machining.
Cooling channels are responsible for dissipating heat in tooling inserts used in injection moulding. The production process using Additive Manufacturing technology can furnish the core inserts with optimally designed cooling channels. For the above case, the heat was evacuated far quicker form the tool insert, cutting the existing production cycle from 14 seconds to just 8 seconds, and bringing about a 56,000 unit rise in monthly production. The quality of the end-product improved thanks to the use of Additive Manufacturing.In addition, the reject rate fell from 2.0% to 1.4%, bringing cost savings and a reduction in the environmental impact of the production process.
Oil & Gas & Marine Applications – Spare Parts
In the Oil & Gas sector, there is a huge interest for print-on-demand solution for spare parts that are getting obsolete or difficult to source.
3TRPD produced a Titanium Gateway Manifold for pipelines using their metal Additive Manufacturing technology, and it has just been certified as the first additively manufactured part for the Oil and Gas industry by global engineering firm Lloyd’s Register.