Dear All,

If you met me at TCT recently (more on that shirt next month!), I'm sure like me, you felt the energy and vibe in the industry despite the threat of the dreaded 'recession'. I started Formation way back in '91 in the last recession and from that point in time the industry has exploded. RP holds the key to survival.

To stay ahead in today's climate you need a bureau with a 'can do' attitude, willing to push the boundaries and above all one that works for you. Here at Plunkett Associates we are committed to staying one step ahead, finding the solutions and keeping ourselves well and truly 'Outside the Box'.

Let's not be beaten by the economic climate, let's do what we are good at and fight back.

Read on for more survival tactics that will make the difference to you and your company

I remain, at your service,

tim@plunkettassociates.co.uk

Did You Know?

Objet has launched a small desktop machine that may just be what your company needs in house. It offers just under a 300 x 200 x 150 mm build envelope, 28 micron layers and 600 x 600 dpi resolution. A solution when you need fast, short life concept models.

Steering Ahead

In the mighty quest for enhanced functionality, F1 has been metal plating both SLA and SLS, for some years. This technique is not exclusive to the racing guys. There are opportunities for you where strength is an issue. The part is hermetically sealed in a layer of metal, which also demolishes any question of long term performance in Rapid Manufacturing!

Material Gain

Nylon (PA) has been the standard material for laser sintering for many years. Whilst research into other materials continues, these have so far been generally constrained to PA with a variety of fillers.

At TCT, 3D Systems had some of the first PP parts that I've seen and whilst this material is not on general release yet, Plunkett Associates can now offer access to this material. He who dares?

How Can You Cut Costs and Risks and Still Look Good?

We all like something for nothing; it's human nature. We're seduced by adverts that use words like 'free' or 'buy one get one free'. Let's face it - the issue we're all searching for is better value for money. Simple. Defining 'value' depends upon your own individual circumstances. Perhaps you want faster, lower cost, greater quantity, or higher quality, improved functionality, better aesthetics or enhanced design. The current economic conditions are driving this search further. How can you cut costs and still look good?

Productivity

What if you could reduce your design time by 30%? What would that be worth in your company? How can you do it? Through communication, through having all your stakeholders buying in and really understanding the implications. This may seem obvious but if it is, why don't we see it? If you want to be understood in China, talk Chinese. Take this principle across your company and don't expect everyone to understand 'design'. Deliver your design in their language. Marketeers speak 'product' so give them one. Production speak 'manufacturing', so let them make. Accountants speak 'money' so let them save it. The result - better understanding, less objections, better product.

Innovation

What if, in addition to the above, you were able to deliver a 'better' design? Define better design, functionality, aesthetics, reduced assembly time, lower production cost; the list goes on and on. Design is the key to everything that follows. This is the opportunity to differentiate your product. Why are we so constrained at the design phase when it's so important? A lot of design is trial and error - you experiment, you make mistakes, you improve; iteratively towards the goal. You do this to increase the overall return, or profitability of your product.

Tools

You can see where this is going! Rapid Prototyping has been with us for over 15 years; it's an incredibly powerful tool that can be used to address the above issues, and surely at this time we need every tool we can get. We can do far more with it than even 5 years ago and it's changing all the time. Try some of the following actions to make sure you get the most from it, or just send your data to Plunkett Associates and we'll do the leg work for you.

The Way Forward - Actions for You to Take:

• Prototype multiple variants simultaneously and earlier in your project. Making two extra versions of a particular component at the same time can frequently have minimal effect on the overall cost, yet open up new possibilities.
• Don't put the parts in the bottom drawer. Use them to communicate with Marketing and Production to make sure the design is on the right track and can be made economically. Show them the alternatives; speak their language!
• If the components are large, look at making interchangeable inserts within the part to evaluate different configurations and thus save on cost.
• All RP process costs are driven by size; if you need large parts (dimensions over 300mm) consider CNC as an option. Potentially better accuracy, improved material properties, better finish and lower cost.
• If you need small parts, especially laser sintered, assemble multiple copies on to a sprue and avoid the minimum piece part prices frequently levied by bureaux. Two important notes: only use this for multiple parts of the same geometry, otherwise you could force the bureau to compromise build orientation; secondly stick to small parts such that the complete sprue comes in at less than 100 x 40 x 40mm otherwise you could impact 'packing'. (This principle can work for dissimilar parts and different technologies but be very careful - surprisingly the bureaux are not too helpful on offering guidance on this!)

And to Justify it?

Don't look at the costs of the prototypes; look at the costs of not having them (note plural!). Try equating RP costs to tool correction costs; or the cost to your company of all the people spending just one hour in the design review meeting; or how the 5p that the manufacturing department has saved on a component multiplies up at 50,000 units per year, year on year.

And this is all before you start talking costs of slipped launch dates or being second to market - costs of six figures, for starters!

How can you save time and money through rapid prototyping? Click here to tell me what you think, or challenge my view.

To Prove It?

We live Rapid Prototyping, so pick up the phone and give us a chance to change your expectations. We did for Carlin Motorsport: