Forget typical cycle times. We’re pushing the boundaries of conformal cooling.  While traditional approaches deliver reductions, at SyBridge, we see further.  By combining our expertise in 3D printing, mold tooling design, and in-house manufacturing, we engineer conformal cooling solutions that unlock the true potential of this transformative technology. Our unique synergy allows us to not just achieve impressive results, but to truly test the limits of what conformal cooling can accomplish for your product.   

Conformal cooling improves throughput 

SyBridge uses conformal cooling designs–either in retrofitting older tooling or as an initial design element–to enhance cooling efficiency, reduce cycle times, and increase productivity (Figure 1).  

In one redesign, after a mold flow simulation revealed hot spots on the tips of the parts, SyBridge experts engineered precision water channels to enhance cooling efficiency. Their unique design focused on cooling the front tip of the part, which enhanced the cooling of the rest of the part. This design change substantially reduced mold-open time. Figure 2 dives deeper into the results of these conformal cooling design enhancements. 

It takes experience to design effective conformal cooling 

Additive manufacturing (AM or 3D printing) is an excellent avenue for designing conformal cooling. AM enables intricate and complex structures that closely conform to every shape of the part in a way that–depending on the part geometry and complexity–is not always possible with subtractive manufacturing. During the design phase, long before the part is molded, SyBridge engineers use mold flow simulation, virtual testing, and digital integration to configure and test the conformal cooling capacities.  

Can we help you reduce cycle times? 

As conformal cooling experts, SyBridge engineers know how to help you get the cycle times and efficiencies your product needs. Contact our team to explore how solutions like conformal cooling can improve your injection molding process.

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In this fast-paced market, where consumers crave both luxury and sustainability, staying ahead of the curve is crucial. This article delves into the key trends transforming the industry, from captivating design elements to eco-conscious solutions, empowering you to create packaging that not only looks good but resonates with today’s savvy consumers. 

Product differentiation drives sales 

In an increasingly crowded marketplace, creating a unique style for cosmetic packaging is key to catching the eye of consumers and building brand loyalty. Consumers look for details in the design, such as embossed logos on caps, custom colors, unique materials like copper and aluminum, and exclusive shapes (Figure 1). 

Figure 1. Distinctive shapes and mixed materials help products stand out in the beauty market.  

Consumers also expect a luxe feel when purchasing a beauty product with a high price point. Using substantial materials in packaging gives even miniature products a high-end feel.  

Additive manufacturing supports new product development  

Developing products with novel designs requires expertise and options for scaling if products become popular. Since the cosmetics industry moves quickly, bringing a new product from conception to design to reveal is essential for its relevance. And because customer preferences can pivot rapidly, manufacturing a limited number of new products using cost-effective techniques to test the market is also important.  

Additive manufacturing processes like 3D printing meet both requirements—they can produce parts quickly and don’t require huge upfront costs (Figure 2). 

Figure 2. Carbon® Digital Light Synthesis is one of SyBridge’s many 3D printing techniques 

Companies can scale production with high cavitation injection molds or other production techniques if the product is commercially viable. Although specialty tooling capabilities may have a higher upfront cost, their ability to support higher production runs and longer lifetime cycles ensures they remain cost-effective. The ability to start small and scale ultimately results in the lowest overall cost of ownership for brand owners.  

Using sustainable materials and designs to appeal to consumers  

Sustainability continues to be a trend for consumer products in 2024, including cosmetic packaging. However, most consumers are unwilling to compromise on increased prices for more sustainable products. Manufacturers must find a way to produce sustainable packaging that is also cost-effective.  

Toward more sustainable cosmetic packaging  

Refillable and reusable packaging is emerging as a more environmentally friendly alternative to single-use packaging. Other sustainability trends include using either post-consumer recycled (PCR) plastic or aluminum for manufacturing or creating products made of single, recyclable plastics (mono-material) instead of a mixture of plastic and metal (Figure 3).  

Figure 3. Material selection simplifies sustainability for consumers 

Mono-material packaging simplifies recycling but does come with challenges, such as finding plastic alternatives to metal springs and other traditional metal components. Manufacturers are also limited in design by choosing mono-material packaging because they can’t use decorative metal coatings.  

A simple way to meet the demand for sustainable packaging without making consumers pay more for beauty products is by choosing a minimalist design (Figure 4). Sleek designs without added decorative features can reduce production complexity and material usage. The challenge to choosing minimalist designs is standing out in a market that relies so much on eye-catching products.  

Figure 4. Minimalist designs can reduce material usage and simplify production  

Design services help meet manufacturing challenges  

Producing flawless cosmetic packaging with the luxe feel consumers expect using sustainable materials is a serious challenge. That’s where working with companies with design services and a range of manufacturing capabilities becomes essential. SyBridge experts can complete design for manufacturability (DFM) checks and simulation analysis to identify production issues before production begins, reducing design iterations and saving on production costs (Figure 4). 

Figure 5. DFM checks help determine how to manufacture the highest-quality part at the lowest possible cost per unit. 

Design services are essential not only for testing novel ideas but also for optimizing current production. SyBridge experts can use product data and analytic tools to create a digital thread — a centralized source of truth for the part. We use the digital thread to gain insights about a part’s lifecycle (design to final production) and see opportunities for increased efficiency and improved quality (Figure 5).  

Novel dispensing methods make for more hygienic products  

A carryover from the COVID-19 pandemic continuing to influence health and beauty products is an emphasis on hygiene. Where many skincare and makeup products require brushes or even a fingertip for application, consumers are now choosing contactless options like droppers, misters, products with internal applicators, and airless pumps.  

Airless pumps reduce the chance of harmful bacteria getting into beauty products during use or illnesses spreading between people sharing the product (Figure 6). Pump dispensers also give customers precise control over how much product they use because each pump produces an exact volume. Companies can use pumps as an opportunity to provide instant brand recognition through contoured pump heads and other unique details.  

Figure 6. Airless pumps help reduce the spread of microbes and regulate dosing. 

In addition to enhanced hygiene and dosing control, the airless packaging used in pumps and sprays can preserve the chemical composition of the formula by not introducing oxygen during use. This extends the product’s shelf life. Airless packaging can help reduce waste, and it is often made from mono-material, making it 100% recyclable.  

Manufacturing for optimal user experience and safe shipping 

A challenge for manufacturing novel dispensing methods is ensuring function. Consumers can easily become frustrated and dissatisfied when features such as pumps malfunction, ultimately costing brands the loyalty they have worked hard to gain. Precise manufacturing is essential to avoid warpages, stress cracks, and other flaws that can cause packaging to malfunction. 

E-commerce companies selling cosmetics also need packaging that meets shipping standards. Products must have the strength to withstand rough handling during transportation, sortation, and distribution.  

SyBridge helps companies manufacture uniform, strong products by incorporating quality inspection services and advanced designs, such as conformal cooling, in our manufacturing technology. Our precision manufacturing can help companies achieve high-feature, aesthetic parts that are also functional. 

Partnering with SyBridge  

Manufacturing partnerships help cosmetics companies maintain a competitive edge in the fast-paced industry. Since needs vary by product, partners with multiple capabilities are especially valuable and critical to support reduced overall tooling costs. SyBridge experts can help cosmetics packaging manufacturers wherever they are—whether seeing if a novel design is achievable or choosing the best manufacturing technology for a proven product.  

Staying ahead of 2024 beauty trends is possible with the right partners. Connect with a SyBridge expert today to learn how our comprehensive services can help you meet your goals this year.  

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Restrictions around specific materials will vary by region. This means that a device that is approved for use in the United States might not meet the European Union’s standards.

While not every medical device requires biocompatible materials, many do. If the device is intended for internal use it will face stricter scrutiny than devices that might aid in a surgery or are in contact with the skin momentarily. Common examples of medical devices intended for internal use include pacemakers, prosthetics, stents, artificial hips, and other joint replacements.

It’s important that product development teams know which biocompatible materials are best-suited for their specific requirements in order to protect the patient’s health and wellbeing, achieve ongoing compliance with stringent regulations, and mitigate risk and liability. Here are some key guidelines and grounding principles for medical device material selection.

Regulatory Standards for Biocompatible Materials for Medical Devices

The materials and components used by medical device manufacturers must meet the stringent quality and performance requirements of the international regulation ISO 10993, which deals specifically with biocompatibility. ISO 10993 lays out an approach for how to perform risk mitigation and performance testing for device materials in a consistent and uniform manner.

ISO guidelines have the backing of the FDA. In September 2020, the agency released a guidance document offering suggestions for how to implement ISO regulations and ensure that FDA-approved materials for medical devices are in alignment with international standards.

Biocompatibility is a complex and evolving subject with few simple definitions, and the latest update to ISO 10993 guidelines (10993-1:2018; updated from 10993-1:2009) reflects the latest developments in the field. Perhaps the most significant change in the latest edition of ISO 10993 involves how biocompatibility is tested.

Whereas the previous version provided specific tests for assessing the biocompatibility of different device types, the current standard seeks to better address the many variables involved in medical device manufacturing through a comprehensive process of risk assessment, mitigation, and management. This allows the standard to be applied in a wider range of dynamic medical and manufacturing contexts.

The ISO 10993 update also includes additional or updated information about contact and non-contact medical devices, as well methods for evaluating the biocompatibility of nanotechnology, gas pathways, and absorbable materials.

Demonstrating biocompatibility is generally done through a three-stage process:

1. Product teams develop a Biological Evaluation Plan (BEP), which outlines known risks and strategies to test or mitigate these concerns. This document fulfills ISO 10993-1’s requirement for an initial risk assessment.
2. The device’s materials and components are tested to address these outlined risks, which can include evaluating factors such as how the device wears over time, material toxicity, or how the device operates when it comes in contact with fluids. Often, a variety of test types and design controls for medical devices are necessary to ensure the device functions as intended.
3. Product teams consolidate test results and analyses of the data into a Biological Evaluation Report (BER), which they then submit to the FDA for approval.

Additional Biocompatibility Challenges

In addition to achieving compliance with ISO and FDA regulations, biocompatible medical device design can lead to additional challenges for product teams. Medical device product development teams often have specific functional or design-related requirements by which they must adhere, and reconciling these requirements with material restrictions can be a time-consuming and intensive process. In fact, it’s not unheard of for customer requirements to necessitate a contradictory or mutually exclusive set of material properties — and it’s up to product teams to do the research that leads to an acceptable compromise.

Another key challenge involves production timelines. The testing required for toxicology and biocompatibility assessment do not produce simple pass or fail results; rather, these evaluations collectively create a demonstration of compliance or a recommendation for further research and evaluation. Because this requires a thorough and well-documented approach, the certification and approval process for medical devices cannot be rushed. Successful product teams are those with the skill and expertise to meet customers’ requirements while operating in accordance with ISO and FDA regulations.

Key Considerations for Selecting the Right Biocompatible Material

There are numerous variables and factors to take into account when designing and manufacturing biocompatible medical devices, and the specific details will of course vary based on the application.However, choosing the right material is paramount, as researchers have found that 30-40% of device recalls are caused by improper material choice. Here are three key considerations for product teams:

• Material availability: If the design of a medical device includes materials that are scarce or hard to come by, an alternative solution may be necessary. This helps to keep per-unit costs low and to ensure that the device can reach the market on schedule.
• Manufacturing process: The material requirements of a medical device or its components will help determine the optimal production method or methods. Injection molding, for instance, is a rapid and cost-effective means by which to create large quantities of precise plastic components with good surface finishes, but can be extremely expensive for low-volume production. CNC machining, on the other hand, has very few material restrictions but some significant geometric ones. Likewise, developments in additive manufacturing technologies are enabling faster production and greater customization — an especially valuable quality considering the medical sector’s large-scale shift toward patient-centric care —  though it’s worth noting that both CNC machining and additive manufacturing are compatible with a comparatively limited range of materials.
• Sterilization needs:Some medical devices and tools, such as hypodermic needles and IV tubing, must be sterilized before they can be circulated back into use. In design terms, this means the device must have a material resistance to the sterilization process. Knowing early on whether a device will have a sterilization requirement — in addition to the sterilization method that will be used — is key to avoiding expensive revisions and tests.

Maintaining an Efficient Design Process During Medical Device Product Development

Given that biocompatibility testing and approval require ongoing evaluation, product development teams will likely need to adapt or rethink their design processes based on their findings.

There are a couple of structural ways in which teams can streamline their design processes. Maintaining an accurate database of materials that includes information related to test results, material toxicology or carcinogenicity, and other characteristics laid out by the ISO 10993, is the first step to creating an archive of historical data that can be referred back to in future design efforts. Doing so not only helps to improve the efficiency of modifications during the design process, but also helps to keep the design team acquainted with the various materials that are relevant to a device’s biocompatibility and functionality requirements.

If component materials have been selected but part geometry has yet to be finalized, plaque testing is a technique that allows teams to stay productive and efficient. This technique involves producing multiple small plaques via the manufacturing method that will be used to create the final product. The plaques are then subjected to biocompatibility testing — including chemical testing and determining how the material breaks down over time — while product developers finalize the part design. This helps to establish the foundation for subsequent evaluation and can speed the regulatory approval process.

Choosing the Right Manufacturing Partner for the Job

The updated processes contained in the latest ISO 10993 seek to minimize unnecessary testing while still guaranteeing that product teams are able to account for how relevant factors like the device design, physical and chemical characteristics of the device materials, and even the manufacturing process can influence the quality of devices and how well they are able to meet patients’ needs. The strenuous design, development, and regulatory processes required for effective medical device manufacturing can present significant challenges for product teams, which is why it’s beneficial to partner with a tried-and-true manufacturer like SyBridge.

SyBridge is an innovative, on-demand digital manufacturing platform with significant experience working with medical device design teams to bring safe, reliable products to market. Our skills and techniques have been used to create cutting edge prosthetics, highly precise surgical models, and more, and our team is prepared to provide 360-degree advisory and support services from the design and prototyping stages to production and fulfillment. Ready to get started? Contact our team today.

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Outsourcing production to an experienced 3D printing partner can make all the difference in your final product. Here’s what you need to know.

Today, the 3D printing market is larger than ever, and it’s still growing as more and more people explore its many advantages. 3D printing offers quick turnaround times, relatively low costs, and increased flexibility, making it an attractive manufacturing option for teams in a variety of sectors, from the automotive industry to medical modeling companies.

Despite all the benefits, buying a 3D printer isn’t automatically the best option for everyone. Not only does it require a significant initial investment in equipment and materials, but negotiating operational costs can also be challenging. Plus, it can be expensive and time-consuming to implement the new technology and hire engineers with the necessary technical expertise. That’s where outsourcing your projects to a 3D printing service partner can help. Here are five reasons to use a 3D printing partner.

5 Reasons to Outsource Manufacturing to a 3D Printing Partner

1. Access to More Materials

Most consumer 3D printers only use light-sensitive resin or plastic filaments like acrylonitrile butadiene styrene (ABS), but 3D printing providers have industrial-grade printers and offer a wider variety of materials. If your project has specific mechanical, chemical, or aesthetic needs, it’s best to use a 3D printing partner.

Even if the material you need is relatively common, you may face challenges printing. Acquiring materials can be more expensive than ordering a printed part, and some materials or printing processes are not safe to use in office environments. When you use a printing partner, you won’t have to worry about buying, storing, and eventually disposing of an entire spool of a material you’ll only use once. Plus, your partner will have dedicated manufacturing areas and safety procedures for technologies and materials that your facilities may otherwise restrict you from using.

At SyBridge, we have a wide range of materials available for 3D printing, from EPX 82 to PA 12 (Nylon 12) to acrylonitrile styrene acrylate (ASA). And we’re always adding more.

2. Access to a Larger Range of Post-Processing Options

Using a 3D printing partner grants you access to a wider variety of finishing options, helping you create a final product that matches your vision. For example, depending on the process, we offer smoothing, painting, bead blasting, hydrographics, laser etching, laser surface decorating, digital texturing, press-fit inserts, heat staking inserts, black dyeing, helicoil inserts, and sanding.

While every material and 3D printing process can’t be compatible with every post-processing technique, a good partner will be able to advise you on which post-processing techniques will work best with your part’s material and functional requirements.

3. The Ability to Print Various Sizes

Not only can a 3D printing partner help you meet high levels of consumer demand and ensure reasonable lead times, but they can also offer you more flexibility when it comes to print sizes. 3D printing service partners have a selection of 3D printers, including ones with larger build plates than those you’d find in a desktop 3D printing machine. Instead of printing a part in multiple segments, you may be able to order your print from your 3D printing service in one piece. You can also order extremely small prints from a 3D printing partner, as they’ll have more sophisticated printers and expert technicians capable of producing intricate details.

SyBridge’s printers support various build volumes including:

• Carbon Digital Light Synthesis M2 printers — 7.4 x 4.6 x 12.8 inches
• Carbon Digital Light Synthesis L1 printers — 15.7 x 9.8 x 18.1 inches
• HP Multi Jet Fusion 4200/5200 printers — 14.8 x 14.8 x 11.0 inches
• HP Multi Jet Fusion 580 color printers 13.1 x 7.4 x 9.8 inches
• Formlabs Stereolithography printers — 13.2 x 7.9 x 11.8 inches
• Stratasys Fused Deposition Modeling printers 36.0 x 24.0 x 36.0 inches

4. Increased Scalability

3D printing is widely used for prototyping and low- to mid-volume production runs, but many product teams don’t know that 3D printing can be used for mass production as well. To produce a large number of parts quickly without compromising quality or adapt your production needs to meet fluctuating customer demand, you should connect with a 3D printing partner. Your partner may have the equipment to support high-volume production runs, and you’ll even be able to print parts on-demand, eliminating the need for additional storage warehouses. This also gives you the freedom to rapidly scale up or down.

5. Access to Experts and Higher Quality Parts

Between the advanced, industrial-grade machinery and the insights provided by industry experts, parts printed by a professional 3D printing partner will be more consistent, have tighter tolerances, and look more professional than those printed with consumer-grade printers.

In addition, the insights of expert engineers and technicians can be highly valuable to the 3D printing process. The optimal method for printing the same part can vary widely from technology to technology, and not every part is well suited for the same type of 3D printing. The expertise specialized professionals have about part orientation, process parameters, and design for additive manufacturing can help you overcome technical challenges, saving you time and money in the long run and helping you produce the best possible part for your budget and timeline.

3D Printing With SyBridge

When you work with an experienced 3D printing partner, you’ll be able to access more materials and post-processing options, take advantage of higher quality printers, and unlock key insights from 3D printing experts. This will help you quickly and cost-effectively create high-quality parts that meet your consumers’ expectations.

If you’re looking for a 3D printing partner, SyBridge is ready to help. We can guide you through the entire production process, from design to fulfillment, and we have a team of experts and industrial-grade machines to ensure your parts are made to your specifications. Ready to see what SyBridge can do for you? Contact us today.

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While participation in team sports decreased in 2020, many people began participating in individual forms of exercise to stay active. Bicycle makers and sportswear companies that catered to individual sports like running, biking, and yoga did particularly well. In fact, the sporting goods industry market share grew to $52.1 billion in 2021.

To appeal to the customer running around the block as well as the one running on the Olympic track, today’s manufacturers must produce lightweight, well-fitting, and high-performance athletic equipment. Find out why additive manufacturing can help manufacturers in the sporting goods industry check all three of these boxes.

Additive manufacturing in the sporting goods industry

3D printing opens up many new opportunities for sporting goods manufacturers, primarily because manufacturers no longer need to choose between having strong or lightweight final products. 3D printing allows manufacturers to produce lighter parts without sacrificing strength, thanks to additive manufacturing’s ability to create complex geometries like lattice structures. These geometries make it possible to increase strength without adding unnecessary bulk, just like the inserts we manufacture for Rawlings’ REV1X gloves using the Carbon Digital Light Synthesis (DLS) process.

Plus, manufacturers can create customized gear that’s more comfortable for athletes to wear, improving their performance on the field and the protective equipment’s function.

Additive manufacturing applications in the sporting goods industry

Many sporting goods manufacturers are already using additive manufacturing, and 3D printing in the sports industry is likely to grow as companies discover more about the customization and optimization opportunities that additive manufacturing offers. Here are a few of the most popular additive applications in sports:

Helmets

To effectively protect athletes’ heads by absorbing impact, helmets must have a strong structural design and a proper fit. Ill-fitting helmets may not sufficiently protect an athlete and an improper fit can distract athletes during play, both of which can cause injury.

3D manufacturing is a great choice for creating custom-fit helmets. After taking measurements of athletes’ heads, manufacturers can 3D print lattice structures that will help the helmet contour to the wearer’s head. Using lattice structures also produces lighter, well-ventilated helmets that can safely distribute or absorb impact.

Mouthguards

Athletes wear mouthguards to reduce their risk of concussion and protect their jaws, teeth, and faces. However, off-the-shelf mouthguards often don’t deliver the best protective performance. Instead of using molds and casts, manufacturers can use a 3D scan of an athlete’s mouth to 3D print custom-fitted mouthguards that stay in place and are more effective.

Footwear

3D printing can be used to create insoles that uniquely fit the shape of the wearer’s feet. Also, manufacturers can use additive manufacturing to place flexible geometric shapes inside the shoe along with the insoles to offer the wearer additional support where they need it the most. These custom products will be more supportive and comfortable to wear, improving an athlete’s control and performance.

Shoes incorporating 3D-printed lattice structures are increasingly popular among athletes, like the Adidas Futurecraft 4D shoe that features a midsole printed with The Carbon DLS Process. The unique capabilities of 3D printing allowed Carbon and Adidas to design a midsole that addressed precise movement, cushioning, stability, and comfort needs and provide a better experience for athletes.

Equipment for paralympic athletes

3D manufacturing is also ideal for creating equipment and prostheses for paralympic athletes. Using additive processes to manufacture prostheses, wheelchairs, or specialized equipment will provide athletes with light, strong, well-fitting gear that meets their exact needs.

Getting started with additive manufacturing

3D manufacturing is positioned to grow within the sporting goods industry as more companies discover its benefits. 3D-printed sporting goods fit athletes and their needs perfectly to improve performance and give athletes a competitive edge. Plus, it enables manufacturers to produce lighter equipment without sacrificing strength.

To start using additive manufacturing to create high-quality sporting goods, reach out to an expert consumer goods manufacturer like SyBridge Technologies. Our Cloud Manufacturing Platform is robust, reliable, and simplifies the manufacturing process. Plus, our team of expert designers, engineers, and advisors is there to help you every step of the way. Contact us today.

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The automotive industry is changing. Around the globe, manufacturers are forming strategic partnerships to optimize asset deployment, making their supply chains more resilient, and shifting to recurring revenue streams. As a result, manufacturers have begun to incorporate cutting-edge technologies like additive manufacturing into the automotive manufacturing process. Take a closer look at how 3D printing in the automotive industry can help shorten product development lifecycles, streamline design processes, reduce costs, and much more.

The benefits of using additive manufacturing in the automotive industry

Only six years ago, 16.1% of all additive manufacturing expenditure was attributed to the automotive industry. The automotive industry is expected to consume around $530 million worth of 3D printing materials in 2021 and some industry leaders predict 3D printing in the automotive industry will generate $9 billion in revenue by 2029. Clearly, automotive industry leaders and innovators increasingly see the benefits of incorporating additive into their manufacturing strategies. Here are four key advantages of additive in the automotive industry:

1. Speeding up prototyping

Prototyping is an essential part of the automotive design process. Not only do designers use accurate, scale prototypes to communicate ideas, but they also use them to test performance, fit, and aerodynamics. Having a physical model for each product variation simplifies comparing versions and identifying potential issues, enabling designers to accurately refine products, improve aesthetics, and meet performance requirements.

With additive manufacturing, designers can simulate various parameters before printing, reducing the number of iterations needed before production and speeding up the development process. Product teams can also use additive to create prototypes of molds, thermoforming tools, grips, jigs and fixtures on-site.

2. Simplifying the supply chain

3D printing can also simplify an automotive company’s supply chain. Most automotive manufacturers have incredibly complex supply chains because they outsource many parts. Additive manufacturing enables manufacturers to print components near the final assembly facility, minimizing waste, shipping costs, and downtime.

Manufacturers must supply service parts in addition to creating original parts. This traditionally involves creating and storing many spare parts, and most part distributors only have common replacement parts readily available. Parts with low demand are often expensive and can be discontinued. However, additive manufacturing enables companies to 3D print less-requested parts on-demand, eliminating the need for smaller remote warehouses and reducing operational costs.

3. Lightweighting

Lighter parts mean reduced fuel consumption and emissions in gas-powered vehicles, but they’re also essential for electric vehicles. Heavier vehicles require more battery capacity to meet performance goals, but batteries are heavier than other vehicle components. Therefore, increasing battery capacity disproportionately increases vehicle weight. Teams can use lattice generation and topology optimization tools to create a complex component and reduce weight without sacrificing functionality. 

4. Supporting customization 

Additive manufacturing is also commonly used to produce customized parts. Not only can you 3D print one-of-a-kind parts for vintage car models, but you can also produce customized parts on a driver-by-driver basis. For example, you might use additive to create personalized aesthetic components. You can also produce customized car assembly tools with additive manufacturing, making it easier to efficiently manufacture high-quality products. Customized tools should perform better than their mass-produced counterparts, helping improve productivity down the line. 

Get started with additive manufacturing today

Today, manufacturers use additive manufacturing to reduce costs, create accurate prototypes, simplify their supply chain, and even produce lightweight final products. As hardware, process automation, and materials continue to improve, automotive manufacturers may create larger parts at higher volumes and offer more mass customization with additive. To get started with additive manufacturing, connect with an experienced automotive manufacturing partner like SyBridge.

With a robust cloud-based manufacturing platform, advanced tools and technology, and a team of expert machinists, designers, engineers, and advisors, SyBridge can help you create automotive-quality parts with additive manufacturing. Contact us today.

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If you look closely at the innovations coming out of the top industries today — automotive, medical, aerospace — odds are you’ll find some form of robotics technology. Recent advancements in computing and sensory technology have inspired explosive growth in advanced robotics manufacturing, and the applications are wide-ranging. Within the last few years, we’ve seen surgical robots perform intricate procedures, robot dogs assist military and law enforcement officials, and much more.

Even though the robotics industry changes rapidly and capitalizes on the most cutting-edge technologies available, the processes used for manufacturing robotics parts also include tried-and-true traditional processes like CNC machining and urethane casting.

Urethane casting is typically associated with prototyping and low-volume production runs of consumer goods like ergonomic grips and skateboard wheels, but this process plays a surprisingly important role in advanced robotics manufacturing. Here’s what you need to know:

An overview of urethane casting

Urethane casting is a versatile manufacturing process that allows you to create high-quality flexible and rigid plastic parts without the expenses associated with injection molding or the costs of laborious hard tooling.

During the urethane casting process, a master pattern — created using 3D printing or CNC machining — is placed in a mold box and then filled with liquid silicone. Once the silicone has cured overnight, the silicone block is cut into two pieces, revealing the mold that will be used to create additional copies of the part. Each piece of silicone is reassembled, filled with urethane casting resin, and placed in a heated vacuum chamber to cure. Once cured, you’ll have a 1:1 scale replica of your master pattern that requires little if any post-processing.

Ideal for low- to medium-volume production runs, urethane casting is easy to use and boasts faster turnaround times than injection molding. However, the cost per part can be high, and strict thickness requirements can limit design flexibility. These pain points notwithstanding, product teams can still manufacture many different kinds of high-quality parts with urethane casting. Common applications include logos, molded bearings, mechanical joints with overlapping features, as well as robot parts.

Common urethane casting applications in the robotics industry

In general, the mechanical and chemical properties of urethane casting resins render them excellent materials for advanced robotics manufacturing. Urethane casting materials are known for their wear, abrasion, corrosion, and chemical resistance. Plus, urethane casting parts are excellent for minimizing unnecessary vibration.

These characteristics are advantageous to industrial robot manufacturers, designers, and engineers who need parts for robots that will be operating in extreme weather conditions or on rough terrain and uneven surfaces. Common applications include wheel systems for robotic forklifts, bomb disposal robots, and other robotic applications in the military and law enforcement sectors.

Urethane casting is also showing a lot of promise in soft robotics, a specific subgenre of robotics engineering that deals with constructing robots from highly compliant materials to mimic the way living organisms move and adapt to their environments.

In the early days of advanced robotics manufacturing, robots were primarily relegated to test laboratory settings. Today’s robots see a high degree of field use and are more frequently used for applications that come into close contact with humans. For example, industrial robot manufacturers in Tokyo have developed a wearable robot exosuit that contours to the wearer’s body to improve their strength, balance, and endurance. Industrial robot manufacturers are also developing robots that can safely and comfortably support the elderly or injured and help healthcare practitioners mobilize them.

Soft robotics use-cases like these wouldn’t be possible without soft gripping elements, for which urethane casting is ideal. The polyurethanes used in urethane casting are tough enough to grip hard-to-handle objects without slipping, but gentle enough to handle delicate objects like an arm in a cast. Urethane casting plays a major role in robotics used in a wide variety of real-world applications.

The future of advanced robotics manufacturing with urethane casting

It’s challenging to predict exactly how the robotics sector will evolve because the possibilities are so vast and technology is advancing at an unprecedented rate. However, if industrial robot manufacturers continue to pursue soft robotics innovations designed to work alongside humans, we can expect to see more urethane casting in the robotics sector very soon. Product teams can break into this dynamic industry as soon as possible with the help of an experienced manufacturing partner.

When you partner with SyBridge to manufacture urethane casting parts, you can expect quick turnaround times, low-upfront costs, and unmatched material flexibility. All of the polyurethane materials we offer come in a variety of colors, durometers, and textures that are sure to fit your unique project requirements. If you’re looking to push the envelope and venture into advanced robotics manufacturing, we can also help you reach those goals. Contact us today to learn more about how we can turn your robotics designs into reality.

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The circular economy is an alternative to the linear economy, in which resources are extracted, used, and promptly discarded. The circular economy, on the other hand, disassociates economic growth from finite resource constraints and value creation from consumption, instead finding value throughout the continued lifecycle of a product. 

The goal is to eliminate waste by monetizing it. If manufacturing companies see their products and their waste as valuable inventory, they’ll use their resources more efficiently and uncover new ways to increase value and meet customer demand. In fact, research from McKinsey indicates that the transition to a circular economy could generate almost $2 trillion in revenue per year by 2030. 

Still, inverting entire industries’ outlooks on value and the economy isn’t easy. Digital manufacturing is a central change driver needed to shift toward a circular economy in three major ways. 

Balancing supply and demand through agility

To produce less waste from the outset, manufacturers should strive to balance supply with demand. The traditional manufacturing model, in which manufacturers estimate customer demand based on projections, makes this challenging. If a company overestimates demand it may end up with a warehouse of un-recyclable, unsold products that will just end up in a landfill. What’s more, this method is not agile enough to account for the volatility of the on-demand economy. 

Digital manufacturing makes use of agile technologies to bring supply and demand into harmony. Digital manufacturing refers to the application of computer systems to the manufacturer’s supply chain, products, and processes. From a supply-demand perspective, digital manufacturing allows manufacturers to use customer data to better anticipate demand and produce only what they need when they need it. 

When manufacturers can make products on-demand, they avoid the high initial costs of a traditional production line and enhance their ability to respond nimbly to demand. When manufacturers can print parts near their customers, they also dramatically shorten their supply chains. Since the average supply chain accounts for more than 80% of a consumer product company’s carbon emissions and 90% of the impact on natural resources, more efficient supply chains can help materially mitigate negative environmental impacts.

Reducing economic and environmental waste

Recycling, remanufacturing, and reusing products in order to preserve and enhance capital — natural and otherwise  — is the primary thrust behind the circular economy. Getting more value from existing stock reduces structural waste, boosts economic growth, and empowers manufacturers to think outside the box for the greater good. Digital manufacturing, powered by additive manufacturing, helps engineers and product designers make the most of the waste they produce by optimizing material usage.

The use of renewable, recyclable, non-toxic materials in manufacturing is still emerging, but additive manufacturing leads the charge. 3D printing is compatible with biodegradable and bio-based materials like PLA bioplastics, plastics that break down in natural environments and only leave behind biomass, carbon dioxide, and water. Taking advantage of materials that are safe to cycle and designed to cycle is an easy way to contribute to the circular economy and reduce one’s environmental impact.

Even if eco-conscious materials can’t be used with the manufacturing process needed for a project, digital manufacturing alone can help reduce waste and increase profits. To start, there are inherent material savings in additive processes. Instead of machining out of a solid block of material, leading to a lot of scrap, you are building up the material one voxel at a time. The increased design freedom of additive also allows you to take advantage of lattice structures and complex geometry to dramatically lightweight parts. Additionally, manufacturing polymer products with 3D printers can reduce energy consumption by 41 to 64%. Overall, research suggests that 3D printing can reduce manufacturing costs by up to $593 billion by 2025, and critically accelerate time to market. Digital manufacturing supercharges the circular economy by putting more renewable resources into it and maximizing its output. 

Designing with sustainability in mind

The linear economy also impacts product design. For example, mechanical components are primarily designed with manufacturability in mind, not necessarily re-use. This is why some designers join pieces to each other rather than connect them using removable fasteners. However, small design choices like these render the product disposable from the beginning, and greatly limit the product lifecycle.

Designing for the circular economy means creating products that are durable, reusable, and profitable over the long-term — digital manufacturing can help. Digital manufacturing optimizes the design process so manufacturers can maximize value in multiple ways. Virtual modeling makes it easier for product designers to collaborate in real-time and think critically about ways to make a design conducive to reuse, repair, and recycling. Any design changes can be made inexpensively and quickly before production begins, which reduces cost and waste.

Also, since on-demand digital manufacturing is directly in line with customer needs, designers can transition from thinking along the lines of, “How can I make this product manufacturing-friendly?” to, “How can I design this product so it consistently meets end-user needs?” Human-centric design thinking is inherently sustainable, as it leads to products built to generate intuitive, meaningful experiences. Products designed with end-users in mind tend to bring greater value to the end-user, and therefore often enjoy extended lifecycles — which, as a result, ultimately minimizes material and energy waste. 

According to McKinsey’s research, about $2.6 trillion of material in high-turnover consumer goods — about 80% of material value — are discarded and never recovered. If product designers can create products that are built to last or at least built to recycle, they can close the loop and fuel the circular economy.

Close the loop with SyBridge Technologies

Today, at least 97% of all solid waste comes from manufacturing; the sector is long overdue for a sea change. Transitioning from the linear economy to a circular one might seem daunting, but digital manufacturing is disruptive enough to kickstart a more sustainable future. With on-demand digital manufacturing and additive technology, product teams can balance supply and demand, reduce their environmental impact, and create products that are sustainable from the very beginning.

At SyBridge Technologies, we’re passionate about moving the manufacturing industry forward, and sometimes that means going in a circle. We do our part to stimulate the circular economy by offering multi-process, on-demand digital manufacturing services to product teams of all shapes and sizes. By partnering with our customers from concept to delivery, our team of experienced engineers and designers streamline every phase of design and production. We are equipped to manufacture parts of varying geometric complexities, materials, and sizes at scale using the best technologies, and the latest design knowledge. Let’s work together to create better parts and a better world. Contact us today to get started.

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3D printing was pioneered by Charles W. “Chuck” Hull, who had the idea to use computer-aided design software to create three-dimensional objects. Hull built a machine that used a UV laser to engrave layers of acrylic into shapes before stacking the layers to build objects. He patented the “apparatus for production of three-dimensional objects by stereolithography” in 1984, marking the birth of 3D printing.

In the three decades since, 3D printing has found applications across industries, including healthcare. As 3D printing becomes more advanced and more economically accessible, its medical applications continue to broaden. 3D printing can even be credited with some of medicine’s most impressive recent advancements, including 3D printed vascular tissue, prosthetic devices, and bones, as well as a slew of medical devices, including surgical guides, pacemakers, and more.

How 3D Printing has Helped Transform Healthcare

The healthcare industry was one of the earliest adopters of 3D printing technology. As early as the late 1990s and early 2000s, 3D printing was being utilized to produce dental implants and custom prosthetics, surprising even Charles Hull, who admitted to never having anticipated 3D printing’s effect on medicine. Since then, the technology’s medical applications have evolved considerably, particular in the last half decade.

Because 3D printing is agile, allowing for rapid iterations and alterations, it’s uniquely suited to products like prosthetics and dental implants, which demand both high customization and low volume production. For example, Coapt, a Chicago-based company that produces myoelectric pattern recognition systems for upper limb prostheses, uses additive manufacturing technology to build fully responsive prosthetic arms, customized to each patient’s biology.

3D printing offers the potential to transform other fields of medicine, as well, particularly orthopedics. With 3D printing, orthopedic surgeons are able to create structures that perfectly mimic a patient’s biology, which may one day aid in eliminating the discomfort and degradation associated with “one size fits all” artificial bone implants. While 3D printed bones aren’t in regular clinical use, the success of several headline-making implants has demonstrated the technology’s progress and promise.

Where We’re Going: 3D Printed Biomaterials

While 3D printed bio-devices such as prosthetics and bones have been tried, tested, and put into practice, the next frontier in medical 3D printing, organic mimetic devices, remains on the horizon. In the early 2000s, a team of researchers at Boston Children’s Hospital successfully built replacement bladders of collagen and synthetic polymer by hand using a construction method called “scaffolding.” They layered the scaffolds with cells from the trial’s patients, allowing them to grow into functioning organs. Seven years after the organs were implanted, all of the trial patients remained in good health.

Unfortunately, building organs in this manner is not only incredibly costly, but also extremely time-intensive. Seeking a less time-consuming and more easily replicable means of producing synthetic organs, a research fellow named Dr. Anthony Atala founded the Wake Forest Institute for Regenerative Medicine (WFIRM) in 2004. Soon after, WFIRM researchers began experimenting with 3D printing synthetic human organs, eventually developing machines capable of consistently printing organs and tissues for use in clinical trials.

However, despite the relative success of synthetic bones, 3D printed organs remain far from ready for clinical use. The gap between experimental synthetic organs and clinically viable ones may lie at the cellular level; that’s why researchers are attempting to apply 3D printing to living cells, replicating human tissues. In 2019, a team of Brazilian researchers successfully bioprinted “organoids” that perform all of the functions of the human liver, including building proteins, storing vitamins, and secreting bile.

These miniature livers aren’t yet ready for transplantation, but many experts believe that, as soon as we can successfully replicate human tissue via 3D printing, the path to creating fully-functioning human organs will be cleared — and medicine will be forever changed.

The Future of Medical 3D Printing

It is difficult to overstate the potential that 3D printing has to transform healthcare. As additive manufacturing technology becomes more accessible and more affordable, meaningful medical innovation seems more achievable than ever before — and it’s increasingly clear that 3D printing services will play an important role in revolutionizing medicine in the next decade and beyond.

Primed for on-demand manufacturing, 3D printing allows medical researchers to create small volumes of parts for niche applications — and to pivot quickly when new needs arise.

However, harnessing 3D printing technology — choosing the right materials, the most effective processes, and the best workflows — can be difficult. By partnering with the experts at SyBridge, you can rest easy knowing that we’ll work with you during every phase of the design, prototyping, production, and fulfillment processes. We’ll ensure that every design is optimized for manufacturing and that your choice of materials and production method align with your specific requirements. Ready to get started? Contact us today.

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