Articles

RSS

Northrop Grumman, Benet Laboratories and DaimlerChrysler earn top honors

3D Systems, Inc. recently announced the winners of the 2001 3D Systems North American Stereolithography Users Group (3DSNASUG) Excellence Awards, which were given to three users group members for their utilization of the technology.

Northrop Grumman's Air Combat Systems group (El Segundo, Calif.) won the grand prize for its aircraft repair kit, which is used for in-the-field aircraft modifications. The kit comprises a guide unit that attaches to the inside of the aircraft, allowing a tool to pinpoint the area to be modified or repaired.

Conventional repair methods involve dismantling parts of the aircraft, which can result in significant costs. The repair kit enables technicians to run a tool on a specific track without removing aircraft components.

align=left border=0>"The improvements in durable materials, as well as the capabilities of stereolithography technology, have allowed us to solve very complex problems in aircraft production and maintenance," said Chris Farren, technology applications manager at Northrop Grumman. "We've got a thousand applications in which stereolithography has played or is playing a part. Conventional tooling methods would cost 10 to 100 times more."

Northrop Grumman used an SLA® 250 system to produce and test the aircraft repair kit as well as train technicians on its use.

First runner-up award went to Benet Laboratories, a research arm of the U.S. Army in Watervliet, N.Y., for its fire-suppression service unit for the M1A1/A2 Main Battle Tank. Using the SLA 3500 system, the lab produced prototype models for functional testing, molds for soft tooling, and QuickCast™ build-style patterns of the molds for aluminum tooling.

Under federal mandate to eliminate all ozone-depleting substances, Benet's task was to produce a fire-suppression service unit that used dry powder. Part of the project included developing two different-size refill bottles, several of which are used to recharge the onboard systems located in the main engine compartment and the auxiliary power unit. Using stereolithography, the group finished the project six months ahead of schedule with savings of $45,000 versus conventional mold fabrication.

"We're always pushing the envelope with stereolithography technology," said Tim O'Connor, mechanical engineering technician at Benet. "Our goal is to get the products out the door more quickly with the highest accuracy, and we've seen great results from the SLA system and QuickCast process."

DaimlerChrysler (Detroit, Mich.) was second runner-up with its method for "stressfreezing" scaled prototype automotive components.

The company built scaled prototype parts of the chassis, suspension and engine using its multiple SLA systems. The parts were then put under scaled model loads at 190 degrees Fahrenheit for two hours. To analyze the parts, the team used a circular polariscope, which reveals the deflections of the test part as a series of colored lines, or "fringes." More fringes mean higher sheer stress.

"After we've analyzed the stress of a prototype part, we can then make recommendations to the engineers to structurally optimize it," said Tom Sorovetz, rapid prototyping supervisor at DaimlerChrysler. "If an area of the part doesn't show stress, we can remove material reducing the overall weight. We can add material to counteract the load in an area under too much stress.

"This process allows us to perform scaled testing without building expensive models to do stress cracking or strain gauges. It can be done within two weeks," he said.

"We learn a lot from our customers and their cutting-edge applications with stereolithography," said Chuck Hull, 3D Systems' founder and chief technology officer. "The feedback we get from them allows us to make improvements to our products and offer better solutions.

"Over the years we've seen this industry continue to grow. With the expansion of our technology into metal, ceramic and composite materials as well as improvements in hardware, 3D Systems looks forward to an ever-expanding horizon of applications," Hull said.

The Excellence Awards were presented at the 12th annual 3DSNASUG conference, which took place March 19 - 22 in Destin, Fla., and was attended by nearly 300 worldwide users of the technology. At the meeting, members share information on applications and other products and offerings useful for operating 3D Systems' stereolithography equipment. Each year the organization presents the Excellence Awards for the most outstanding work in stereolithography.

About 3D Systems
3D Systems provides solid imaging products and services that substantially reduce the time and cost required to design, test and manufacture products. The company's systems utilize patented technologies that create physical objects from digital input.

3D Systems currently offers the ThermoJet® office printer and SLA® industrial systems, which include proprietary software and materials. Product pricing in the U.S. begins at $49,995 for the company's entry-level printer and extends up to $799,000 for its feature-rich industrial SLA system. The company also licenses the 3D Keltool® process, a complementary application that produces injection molding and die casting inserts from SLA system master patterns.

Based in Valencia, Calif., 3D Systems was founded in 1986 and is recognized as the world technology and market leader in solid imaging. For additional information, visit the company's website at www.3dsystems.com or phone (888) 337-9786, ext. 765. For an investor packet, call the company's shareholder communications service at (800) 757-1799.

3D Systems, Inc., 26081 Avenue Hall, Valencia, CA 91355 USA. Tel: 661-295-5600, ext. 2886. Fax: 661-294-8406.

Source: 3D Systems