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FDM, fused deposition modeling, is an additive manufacturing process that creates three- dimensional objects by depositing plastic materials in layers. Unlike traditional subtractive manufacturing (machining) which removes material, additive manufacturing adds material through extruding thermoplastics. As a result, this reduces waste and allows businesses to produce parts faster and at a lower cost than traditional subtractive techniques. FDM printers are becoming very common in the workplace with desktop versions and commercial versions. The desktop printers are great for hobbyist and personal use. The commercial printers give the users more material options, larger build envelopes and higher quality parts with multiple layer thickness options. Cyb Llings uses Stratasys 400mc and 450mc FDM printers which are commercial grade printers to print parts for our customers.

The FDM process is best described by drawing a similarity to how a hot glue gun functions. A solid monofilament line of plastic is fed into a print head where it is melted and then extruded along a path on the build tray layer by layer following the part profile to build a part.

To prepare the print data, a CAD file is created by the engineer/designer for the desired part and is converted into a STL file format for the 3D printer software to read. The 3D printer software then slices the STL file into layers and creates sliced profiles used to create extrusion paths for the print heads to follow. This software used for the FDM printer provides options to change the fill the interior cavities on the part. The three options are sparse fill (honey comb), double density (honey comb with thicker walls) and a solid fill. Once the print data is prepared, the plastic filament line is fed into a heated print head then extruded out into the heated build chamber. The print head is mounted on the two axis (x-y plane) gantry systems that outline the part. The print tips can also be changed to switch the layer of thickness. The smaller the print head, the more finer features on a part and it provides a smoother surface finish. The build chamber is heated to stabilize the material as it is being printed, preventing warpage and delamination. The heated material is then placed on the build tray along the printing path that forms the contour of the part. The build tray moves in the z-axis and lowers as each layer is placed onto the part outlined. The amount of time it takes for each part to be built depends on a few things, fill volume, model complexity, print head size, model size, and the amount of support material required. There are two materials that are required for a part, the plastic filament and support material. The plastic filament has a variety of types of plastics (ABS-M30, ABS-M30i, PC-ABS, and ULTEM 9085). These materials are ideal for functional prototyping, manufacturing tools, end-use parts or concept models. Now, the support material is the foundation for the model and provides support for any cantilevered features. This support material is removed when the part is complete in the printer. There are two ways the support material can be removed, by breaking it away and/or dissolving it away in solvents.

The FDM additive manufacturing process creates high strength and durable parts, parts can withstand heat, it can be used in a variety of ways (functional parts, prototype parts or space claim models), it is typically cost-effective, and has a high turnaround rate compared to traditional manufacturing. The FDM process helps to make your ideas become reality.

The rapid growth of Covid-19 has put hard tension on many healthcare providers as they provide treatment and care to affected patients. Along with the stress of treating a disease with many unknowns, healthcare providers are also in an environment with a lack of personal protection equipment. Back in March, this pandemic called for the world to unite, for people to come forward to help one another and create a call of action.

3D printing companies were among many industries that joined the forces to ameliorate the tension of our healthcare providers.

How?

3D printing companies have the materials to help ease supply chain issues for critical care equipment, such as face mask respirators or “ear guards”. Cyb Llings Inc. 3D printing was among those companies that responded. Cyb Llings Inc. partnered with Star EMS and GoEngineer to convert snorkel masks into a respirator for the EMS at Star EMS in Pontiac, MI. The team of businesses collaborated on their CAD software, computer simulation, and 3D printers, which resulted in a prototype being developed in less than 24 hours. EMS at Star EMS used the face mask respirators while supplies were difficult to procure.

Here at Cyb Llings Inc. we acquired the knowledge of an “ear guard” design created by a Canadian Scout named Quinn. Cyb Llings Inc. followed suit and printed these ear guards here in Downtown Pontiac and donated them to local hospitals. The purpose of the ear guards is to provide healthcare workers that wear masks all day, more comfort, and eliminate pain behind their ears.

Even more than that, Cyb Llings Inc. is affiliated with FIRST Robotics and we donated PPE to families that are involved in the medical community. Also, Cyb Llings Inc. donated more PPE to Beaumont Hospital.

The pandemic has brought the world many challenges, and here at Cyb Llings Inc. we are taking on those challenges together with our community. If you have a need, together we can find a solution and we, the team at Cyb Llings Inc., can print the outcome. We appreciate our healthcare and essential workers.

cyblingsblog1wecanprintCyb Llings Inc., an innovative 3D printing company, discovered in 1991, it is a family-made business, hence the name Cyb Llings (siblings). At Cyb Llings, our team of Engineers provide 3D printing/Additive Manufacturing services; creating rapid prototypes and functional parts in a high quality, cost effective manner. We work with engineers, entrepreneurs and manufacturers across all different industries to take their concepts and help it become reality.

So, why choose 3D Printing for your business?

  • 3D printing allows you to design, iterate, and perfect your designs in the prototyping stage both efficiently and cost effectively. 
  • Know exactly how your product will look and perform before investing in any costly tooling. 

Cyb Llings Inc. offers FDM and Polyjet printer technologies with a range of plastic and rubber like materials. We can 3D print tough functional prototypes, highly realistic and precise models. Our technology and materials change the game; having a printer that can create accurate details with large build envelopes.

Companies are turning to 3D printing with more and more advantages being discovered. If you are in the industry of aerospace, medical, dental, automotive, consumer products, education, or art and fashion 3D printing is a resource to you.

  • Do you need a model of your product for a tradeshow? We Can Print It.
  • Need a spare part for a machine? We Can Print It.
  • Do you need a mold of your patient's jaw? We Can Print It.
  • Does the car you are building need a steering wheel prototype? We Can Print It.
  • Do you need a model of the brain to educate your classroom? We Can Print It.

 

Customer’s today are very different from 10 years ago.

The world is different from 10 years ago.

Today’s customers demand different services like, flexibility and speed. Manufacturing industries are always searching for new techniques to decrease costs and materials, and expand their capabilities to meet those demands of their customers.

With different demands and continued industry growth, comes additive manufacturing, this is the next industrial revolution, also called Industry 4.0.

The traditional manufacturing method, which has been the go to process since the 40s, refers to a subtractive method and typically implemented in a commercial space. Traditional manufacturing is still used today, but companies are starting to use more and more additive manufacturing methods for their businesses.

Additive manufacturing, also referring to 3D printing, is changing the manufacturing process.

Why is that?

Companies are transitioning to 3D printing to increase speed, to increase design freedom and customization, and to become more cost-effective.

Increased speed and design freedom with 3D printing, but how?

When comparing the two methods of manufacturing, additive manufacturing is much faster, taking only a couple of days for an application to be printed, shipped and in hand, where traditional manufacturing can take upwards of 15 days to 2 months. This difference in speed is because additive manufacturing does not need tooling in the process, eliminating that time that tooling would be built, unlike traditional manufacturing.
Additive manufacturing offers more freedom in designing applications. This is because additive manufacturing can print in low volumes, resulting in the ability to make an unlimited amount of changes to a design. The printing speed also allows for more design freedom because companies can get their applications in their hands in roughly two days compared to a few weeks.
For example, Ford used 3D printing to print brackets for the parking brake system on the Ford Mustang. They had a total of 19 different design iterations where they could address all the failures that came across during the validation process. They had one instance that the bracket cracked, they figured out why it cracked and redesigned it and had another one printed the next day being cost-effective and timely.

How does 3D printing become more cost-effective than traditional methods?

Additive manufacturing can have low production volume and remove the tooling, compared to traditional manufacturing where mass production would have to take place to even out overhead costs, like tooling, labor and production. With additive manufacturing, the cost remains the same no matter the amount, resulting in lower costs and the ability to produce low volumes.
For example, again, when Ford used 3D printing to print brackets for the parking brake system on the Ford Mustang. They had a cost avoidance that came from tooling, where traditional manufacturing would require stamping the tooling.

3D printing is the new today.