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Overview: You are an employee of HP, and your boss just informed you that your team has been tasked with determining the viability of HP’s plan to manufacture components for their MJF printers using the polymer AM.
Overview: You are an employee of HP, and your boss just informed you that your team has been tasked with determining the viability of HP’s plan to manufacture components for their MJF printers using the polymer AM.
As a test you re-design a critical duct component of the HP500 printer for additive manufacturing (AM) and then determine the best process for manufacturing these ducts at a production quantity. As currently manufactured, the duct assembly comprises 5 injection molded components, several screws, and a nut and bolt. When designing for AM, the level of complexity enables part consolidation which will eliminate steps in the fabrication process.
As a test you re-design a critical duct component of the HP500 printer for additive manufacturing (AM) and then determine the best process for manufacturing these ducts at a production quantity. As currently manufactured, the duct assembly comprises 5 injection molded components, several screws, and a nut and bolt. When designing for AM, the level of complexity enables part consolidation which will eliminate steps in the fabrication process.
Figure 1: Original HP500 Duct Assembly
Figure 1: Original HP500 Duct Assembly
Figure 1: Exploded view of duct components designed for injection molding (IM).
Figure 2: Original HP500 Duct Assembly
Figure 2: Original HP500 Duct Assembly
Figure 2: Exploded view of duct components designed for injection molding (IM).
Figure 3: Case Study, Part Consolidation of a Duct
Figure 3: Case Study, Part Consolidation of a Duct
MIT Duct Consolidation Case Study.pdfFigure 3: Full Case Study. Open pdf in separate window for best viewing experience.
What:
What:
Designed for additive manufacturing (AM) through part consolidation and material efficiency
Conducted a cost assessment on manufacturing
Created a matrix of AM process recommendations after analyzing other opportunities for HP to apply AM
How:
How:
Utilized SolidWorks to design the HP500 duct
Proficient understanding of Stereolithography (SLA), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), Extrusion, Selective Laser Melting (SLM), Directed Energy Deposition (DED)
Results:
Results:
Decreased operation costs by eliminated steps in the fabrication process
Streamlined future maintenance by making "one-off" replacement components easily accessible
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