INTRODUCTION

When Primary first opened for business, we were only using Carbon DLS machines. As the company grew larger, we began using the 3D Systems Figure 4 machine and materials. With multiple technologies and processes, we were able to expand our application of 3D technologies into other industries.

Jack First, a replacement parts distributor located in Rapid City, South Dakota, was one of the first new customers we served. Because they are located in South Dakota, they were excited to work with us and support another local business.

As one of our consistent, repeat customers for short-run manufacturing with 3D printing, they regularly order new parts—such as buffers and spacers—and reorder previously built parts.

Before working with Primary, Jack First offered limited plastic parts to their customers. Injection molding companies would not serve their low quantity needs, and while they did offer some plastic parts, they were cast and often low-quality.

Since Jack First has made the transition to 3D printing and additive manufacturing for their plastic parts, they have been able to supply a variety of high-quality components to their customers.

KEY POINTS

1. 3D Printing with advanced additive technologies was the perfect solution for short-run needs

2. Unlike cast parts, 3D printed components have a high-quality finish and strong material properties

3. Because we use several different additive processes and carry a wide variety of materials, Primary serves a range of industries and applications.

THE CHALLENGE

While Jack First offered a variety of metal parts, they did not have a source for high-quality plastic components. The few plastic parts they did offer were cast. These components, however, had a low-quality finish and weak material properties.

Before transitioning to 3D printing and advanced additive manufacturing, they had attempted to work with injection molding companies but had been largely ignored or rejected. Because Jack First requires orders from the hundreds up to 1,000, many companies refused to work with them. With low quantity needs, it is often not worth their time and resources.

Additionally, if Jack First had decided to work with an injection molding company, each mold would have cost thousands of dollars. For their short-run manufacturing jobs, it would not have been worth the high-cost investment of a mold.

Now, because they have partnered with Primary, they are able to offer high-quality plastic replacement parts to their customers—injection mold quality without the costly investment.

THE SOLUTION

Alternative to injection molding

To source short-run quantities of production-quality plastic parts, 3D printing was the perfect solution for Jack First. For companies who order between one and ten thousand parts, additive manufacturing provides a more cost-effective alternative to injection molding. Like injection molding, production level 3D printing offers high-quality finishes and strong material properties.

While injection molding is built for mass production—tens of thousands of parts—3D printing and advanced additive technologies are built for rapid prototyping and manufacturing of several hundred parts. Unlike injection molding companies, which often require thousands of parts, our minimum order is the size of our build platform. Depending on the size of the part, this could be anywhere four to sixty components.

When companies use injection molding, they pay thousands of dollars for a mold—in addition to materials and time. Because 3D printing does not require any molds, the customer does not incur a high, upfront cost. They simply pay for materials, machine time, and post-processing. Thus, the cost for short-run production (up to about 10,000 parts) with 3D printing is lower than the cost of injection molding.

Parts & Materials

We manufacture all of the Jack First parts on the 3D Systems Figure 4 machine. With a wide range of materials, we can design, prototype, and manufacture their parts quickly and efficiently.

For new parts, the order process is simple: they call, send a diagram, and we respond with a quote. Either Jack First will design the part in CAD and send it to us or we will design the part in CAD for them.

For example, this press fit replacement part is made from FLEX-BLK 20.  We prototyped this part in a variety of materials, but FLEX-BLK 20 was the only material that didn’t break. Created to be flexible, durable, and resistant to fatigue, this was the perfect material for their press fit part.

In addition to prototyping this part in several different materials, we also designed eleven variations for testing.  Ultimately Jack First settled on these designs and specs.  They order these parts about one hundred at a time, and to date, they’ve ordered around 1,400 of these press fit components.

RESULTS

While it is currently more cost-effective to use injection molding and other traditional processes for mass production, additive technologies are continuing to advance and will soon be a viable method for high quantity manufacturing. 3D printing is becoming more efficient and companies like 3D Systems are developing machines and systems to accommodate mass production. But for now, 3D printing is the most cost-effective method for rapid prototyping and manufacturing of low quantity parts production.

For Jack First, advanced additive manufacturing was the best solution for their plastic parts needs. In just a short period of time, they have come to understand the 3D printing process and know exactly what material they want for each particular part.

Currently, we manufacture around twenty-five parts for Jack First. Most of the components we print for them are no longer produced by the original manufacturers. And for many of these plastic parts, Jack First is the only company which offers them.  Other distributors purchase the plastic parts from Jack First and resell them.

These 3D printed parts have an injection-molded finish without the high investment cost. With a production-level quality and isotropic strength, these parts have received great reviews from both Jack First and their customers.