Newsletter January 2010

In this issue:

• Build bigger parts. Use our NEW digital manufacturing machines

• Polycarbonate (PC)

• We resolve to serve you better.

• Communicate with Concept Models

Build bigger parts. Use our NEW digital manufacturing machines.

Fortus 900 mc Production System

Building larger parts helps manufacturers decrease production time and cut costs by thousands.

1. For example: While implementing 2 tooling changes, a major automotive manufacturer decreased production from 12 weeks (for each tool) to only 10 days. With RedEye's digital manufacturing services, they completely eliminated the need for traditional machining. The result was a decrease in the cost of pre and initial production saving them $235,000.

Last month we showed you a massive turbo-prop aircraft engine that spanned 10 feet long and 10 ½ feet wide (blade span). The truth is, now we can build any plastic part regardless of size.

Yes, any part. With more than 100 systems in our facilities, we can split your STL file to build parts across several machines decreasing lead time. Then, we simply assemble and bond your parts together. And, because we use production-grade thermoplastics, your part maintains its accuracy and can stand up to real world testing.

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Polycarbonate (PC)

PC parts are created for a wide variety of industries.

PC is a great material for rapid prototyping and end use part production (aka: digital manufacturing) because it creates accurate, durable and stable parts. PC possesses superior mechanical properties you’ll find essential: high tensile strength, heat resistance and scratch defiant.

These critical material properties allow you to create end use parts, a feat unrealizable for those choosing lower cost resins used in SLA or SLS prototyping processes.

Material Specifications
Material specifications vary not only on the supplier of plastic, but on the process you choose to manufacture your parts.

Our digital manufacturing services create PC parts using Fused Deposition Modeling (FDM) technology. The material specifications below show you what you can expect when creating production parts to prototypes at RedEye On Demand.

Polycarbonate (PC)

• Tolerances. PC is a dimensionally stable material.

  • Tensile Strength¹. 7,600 psi (52 MPa)

  • Tensile Elongation. 3%

  • Flexural Strength. 14,000 psi (97 MPa)

  • Izod Impact, notched. 1ft-lb/in (53.39 J/a)

  • Heat Deflection Temperature @ 66 psi. 280° F (138° C)

  • Rockwell Hardness. R115²

  • Maximum Build Dimensions. 16" x 14" x 16" (larger parts can be built in pieces and bonded together)

  • Accuracy. +/- .005 inch or +/- .0015 inch per inch, whichever is greater (+/- .127mm or +/- .0015mm per mm whichever is greater. Note: Accuracy is geometry dependent.

• Wall Thickness. To produce optimal parts in PC, you should design wall thicknesses at 0.04 inches (1.016mm).

  • You may produce PC parts with a minimum wall thickness as low as .020 inch successfully, however; it is geometry dependant.

  • Part thicknesses greater than an inch are easily achievable.

• Radiusing. PC is not a notch-sensitive material; however, radiusing the corner of a PC part created via FDM improves its strength by distributing corner stresses over a broader area.

  • Inside corner radiuses should be limited to not less than 25% of the part's wall thickness.

  • For maximum strength the radius should be 60% of wall thickness. Larger radiuses can be specified, but this will not significantly increase part strength.

  • It's a good idea to apply the same design techniques as you would to injection molded parts; however, the FDM build process allows you the design freedom to create straight non-radiused areas as needed.

• Draft Angles. PC parts can be created with no draft angle.

  • The FDM build process allows you the design freedom to create the part for its intended application without the worries of how it's going to be manufactured.

• Cavities & Internal Features. You can create holes, cavities and internal features of almost any size with PC.

  • Uniquely, the FDM build process allows you to build internal features that snake around the inside of the part and virtually any depth.

Download PC Material Spec Sheet

Get a free copy of our Materials Comparison Chart

¹Tensile strength data is based on ASTM standard D-638
²Rockwell hardness data is based on ASTM test method D785

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We resolve to serve you better.

Our digital manufacturing center is available online, 24 hours a day - 7 days a week. Just upload your CAD file and go.

The new year is a perfect time to reflect and make a fresh start.

Nearly 5 years ago, Stratasys launched our service center bringing digital manufacturing to engineers, designers and manufacturers worldwide.

Over the years we've learned so much from you. We know what you like, what you dislike and what other services you'd like us to provide.

Our New Year's resolution:

• Listen more than we speak

• Make your job easier by offering more materials and services

• Deliver on time & on budget

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Communicate Better with Concept Models

A dynamic light fixture created at RedEye ARC.

If you're an artist, architect or entertainment designer, save money by bringing your ideas to life faster.

Concept models help you communicate:

• spatial orientation

• high definition detail

• complex surfaces

You can count on RedEye ARC. Our staff not only understands 3D Printing technology, but many helped invent it. Best of all, they understand the importance of design quality.

Don't wait. Find out how RedEye ARC can save you time and money creating dynamic 3D concept models.

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