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Canada Makes renews Metal Additive Demonstration Program

Canada Makes is pleased to announce the renewal of its Metal Additive Demonstration Program for 2017/18. The program is funded by the National Research Council (NRC) through its Industrial Research Assistance Program (IRAP) Materials and Manufacturing Sector Team (MMST).

The goal of the program is to de-risk the initial trial and learn about metal additive manufacturing (AM) capabilities. Interested companies will be invited to engage with a working group expert in metal additive manufacturing who will assist in better understanding the advantages and business opportunities both in terms of cost savings and efficiency of metal AM. Once the project is deemed viable for AM and the SME is IRAP eligible a part is built and then sent to the participating SME to test.  Canada Makes pays for the work.

The programs goals are to create awareness and encourage the adoption of AM technology to improve Canada’s manufacturing and exporting sectors and develop of a Canadian metal AM supply chain.

More than 100 companies from across Canada have participated in the first three rounds of the program and the renewal offers the chance for more companies to receive financing for a metal AM project.

If you are interested in the program, please contact
Frank Defalco
frank.defalco@cme-mec.ca
(613) 875-1674

Interested companies are encouraged to view Canada Makes’ two interactive guides to learn more about metal AM.

These two guides, the Metal Additive Process Guide & Metal Additive Design Guide are designed to assist small businesses new to metal additive manufacturing (AM) wanting to learn more about process and designing for metal AM (DfAM). The Guides are easy to use and interactive offering useful information for newcomers to this technology.

Access is free although we request that you register. Thank you and enjoy!

Metal Additive Process Guide

Guide 1 – This is an introductory guide to metal 3d printing using laser powder bed technology

Metal Additive Design Guide

Guide 2 – This design guide introduces concepts needed when designing for metal 3d printing.

Precision ADM, Melet Plastics & Canada Makes partner on conformal cooling project

Precision ADM recently completed a conformal cooling mold project that developed an improved “Venturi Cup” for Melet Plastics. The project received funded from Canada Makes through its Metal Additive Demonstration Program. The goal of the project was to show how a mold optimized using additive manufacturing (AM) methods can increase quality and productivity.

AM conformal cooling mold design

AM conformal cooling mold design. CAD models supplied by Melet Plastic Inc.

“This project is an excellent example of how the Metal Additive Demonstration Program works,” said Frank Defalco Manager Canada Makes. “Learning about the capabilities offered by adopting AM is what will make Canadian industry more productive and conformal cooling is a key area that needs to be exploited.”

One of the major factors contributing to the deformation of molded plastic parts is a lack of uniform heat distribution throughout molds. Various areas of the final part created by a mold cool at different rates creating internal stresses and deformations.

Dale Kellington General Manager of Precision ADM  stated, “conformal cooling applications continue to  have a direct impact on part quality, cycle times and productivity of injection molded parts”

A warping defect was reported in the production of a “Venturi Cup” part manufactured by Melet Plastics Inc. for use in an AGCO-Amity JV air seeder. The goal was a reduction in the warping seen in the large rectangular section of the part. Proposed alterations included changes in material, wall thickness and coolant temperature, as well as an optimized mold for cooling produced by Precision ADM using additive manufacturing methods.

Molded part new - old

Using conventional mold design, coolant channels are required to be drilled as a separate operation but are restricted to a path of connecting straight lines. This restriction is the cause of non-uniform heat distribution that causes part deformation. Additive manufacturing methods can be used to create molds featuring a coolant channels that follow the contours of a mold, drastically improving heat distribution during cooling. This has the added benefit of eliminating the task of drilling cooling channels.

Dale added, “with software such as Moldex our engineers can simulate the injection molding process and demonstrate the beneficial cooling characteristics of conformal cooling molds for production”

Mold - Tradition design versus conformal cooling AM designed

Mold – Tradition designed mold versus conformal cooling AM designed mold. CAD models supplied by Melet Plastic Inc.

The project showed significant results. This application of additive manufacturing showcases the complex subsurface geometries that are possible using the method. The use of the optimized mold together with a decrease in wall thickness resulted in a warpage reduction of 42%; an overall warpage reduction of 54% was achieved with all other alterations included.

About Precision ADM
Precision ADM is a contract engineering and manufacturing solutions provider that uses additive manufacturing (3D Printing) as a core technology. Precision ADM has created a full Advanced Digital Manufacturing hub from Design to Engineering, to Manufacturing and finishing.  Complimented by multi-axis machining capability, PADM identifies, develops, and manufactures high value components and device applications for the medical, aerospace, energy and industrial sectors. PADM is headquartered in Winnipeg, Manitoba, Canada. www.precisionadm.com

About Melet Plastics Inc.
As Leaders in Engineering Plastics Solutions, the Melet team is dedicated to engineering custom plastic products that meet the needs of Original Equipment Manufacturers. Melet offers a comprehensive array of services to ensure that every step of the development process is a success – from product design, engineering, material selection, and rapid prototyping, to mold manufacturing, injection molding, and assembly. Melet operates out of a state-of-the-art manufacturing facility complete with extensive automation and robotics. New capabilities include compression thermoforming of natural fiber composites at the Fargo location. www.meletplastics.com

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

The Metal Additive Manufacturing Demonstration Program is funding by NRC-IRAP and is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

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P&G and AMM partner with Canada Makes’ Metal Additive Demonstration Program

Procter & Gamble Belleville Plant partnered with Additive Metal Manufacturing Inc. (AMM) and Canada Makes to explore building new customized parts using additive manufacturing (AM). The project was funded through Canada Makes’ Metal Additive Demonstration Program.

“Parts can be very difficult even impossible to make with traditional subtractive machining processes,” said Haixia Jin, FullSizeRenderP&G Engineering Technical Manager. “Metal 3D printing offers an exciting alternative to commercial off-the-shelf parts that cannot achieve complicated design requirements or internal cavity geometry. Even in cases where commercial customization is available and able, it usually comes with significant additional cost or an unbearable long lead-time.”

The example piece of work is printed to serve the combined purposes to deliver fluid to designated locations with the four extended legs while minimizing disturbance to the flow that it merges in. The vast metallurgy choices also provide a wide spectrum of chemical/environmental resistance. This illustrated part was printed in Stainless Steel taking advantage of its good anti-corrosion performance.

“AMM is delighted to be partnering with P&G and Canada Makes in assisting P&G introduce 3D METAL printing into their supply chain,” said Norman Holesh, President AMM. “P&G embarked on this journey with the full understanding that to be successful, the technology must be embraced as early as possible in the design stage. This technology is neither an alternative to subtractive manufacturing nor a replacement for it but an addition to the entire manufacturing process and allows for previously unthinkable designs and a dramatic reduction in lead times.”

IMG_6928“Design rules have changed and AMM works with its customers to help them understand and embrace these changes and take full advantage of design freedom,” added Holesh

“Designing and building complex parts as well as the lead-time saved are two big advantages that AM offers users of the technology. This project certainly was an excellent example offered through Canada Makes’ Metal Additive Demonstration Program,” stated Frank Defalco Manager Canada Makes. “Canada Makes will continue to partner with Canadian companies looking to the advantages offered by having additive manufacturing as a powerful new option in creating parts previously unfeasible.”

About AMM

Advanced Manufacturing Canada
Additive Metal Manufacturing Inc. is a full-service 3D METAL printing bureau located in Toronto and assists its customers understand the additive journey from design all the way to finished printed component parts. AMM is a progressive, productive and respected leader providing integrated and advanced manufacturing technology solutions within the emerging market for AM ensuring their industrial partners have the best opportunity to excel and Take Back Manufacturing for Canada. AMM is certified with both ISO 9001 and for Controlled Goods. www.additivemet.com

About Procter & Gamble Belleville Plant
Opened in 1975, the Belleville, Ontario site now produces Always and Olay products for North America and the globe.

  • In 1984, the Belleville site started manufacturing Always feminine care products
  • The site currently manufactures the entire line of Always products, including pads, liners, Always Infinity and Always Discreet, as well as Olay Daily Facials
  • Since 2010, the site has received a prestigious manufacturing excellence award, the highest recognition among P&G manufacturing facilities

To celebrate their 40th anniversary, the site set a Guinness World Record for the largest game of “Follow the Leader” in the world.

The Metal Additive Manufacturing Demonstration Program is funded by NRC-IRAP and is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca

Media contact:
Frank Defalco at frank.defalco@cme-mec.ca

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Canada Makes releases the Metal Additive Design Guide

A new introductory design guide for metal 3D printing is now available.

OTTAWA – Canada Makes is proud to announce the launch of the Metal Additive Design Guide and invites you to explore this great new tool. The Guide was developed to assist companies interested in trying metal additive manufacturing (AM). Following the same format as the Metal Additive Process Guide, the Metal Additive Design Guide is once again a free service that introduces concepts needed when designing for additive manufacturing (DfAD).Metal Additive Design Guide

“The Metal Additive Design Guide is easy to use, interactive, offering useful information for newcomers to this technology,” said Frank Defalco, Manager Canada Makes. “Its primary function is to help guide Canadian SMEs looking at metal AM and how it might be added to their process. It’s a great educational resource bringing great value to users and it’s just plain cool.”

Simple, yet crucial questions like, “how big can my parts be” or, “what materials can I use” are answered in this interactive app. The Guide is not designed for the experienced metal AM user but rather someone looking for quick and straightforward answers regarding DfAM.

Screen-guide

“Canada Makes’ goal is to assist Canadian industry in adopting additive manufacturing and the Metal Additive Metal Additive Process GuideDesign Guide continues in that vain where the Metal Additive Process Guide left off,” added Defalco.

Time saving is one of the major advantage in adopting AM processes versus traditional manufacturing. Through this free resource SMEs can receive quick answers to certain concepts about metal additive. The Guide will help speed up Canada’s manufacturing sector in understanding the capabilities of metal AM. This knowledge should expand AM adoption and invigorate Canada’s burgeoning AM supply chain, growing Canada’s competitiveness.

Canada Makes would like to state how greatly it appreciates the assistance to all those that made the Metal Additive Process Guide possible.

Altair Canada Mazak
Autodesk Microfabrica
Prof. Mike Ashby, Cambridge University MIT Aero/Astro
Burloak Technologies Moog Inc
Boothroyd Dewhurst Reaction Engines
Cranfield University Renishaw
Dassault Systemes Robarts Research Institute
ExOne Senvol
FusiA solidThinking
GE Aviation U.S. Navy ManTech Navy
Gradientspace Metalworking Canter/Cocurrent
HiETA Technologies Corporation
Lawrence Livermore National Laboratory

The Metal Additive Design Guide was funded through the National Research Council Canada Industrial Research Assistance Program in accordance with the Metal Additive Demonstration Program.

Canada Makes is looking forward to partnering once again with NRC-IRAP and deliver the Metal AM Demonstration Program. The program plans to continue to expand the AM knowledge base for Canada’s manufacturing sector and work with all stakeholders to grow the sector.

The Metal Additive Manufacturing Demonstration Program is delivered by Canada Makes through funding by NRC-IRAP. The program is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca

Media contact:
Frank Defalco at frank.defalco@cme-mec.ca

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Canada Makes, Fusia & MDA team up for space-bound part

Canada Makes, FusiA and MacDonald, Dettwiler and Associates Ltd. (MDA) partnered to build a part to be launched into to space later this year. Additive manufacturing projects like this highlight how the technology is rapidly changing the economics of space. Canada Makes helped with funding through its Metal Additive Demonstration program supported by NRC-IRAP, MDA designed the part and FusiA built it.

“We are accelerating our adoption of additive manufacturing for space,” says Joanna Boshouwers, MDA’s Vice President and General Manager. “The FusiA built part shown will be tested structurally in order to qualify the rest of the batch to fly in space. The support MDA received by Canada Makes’ program has proved to be valuable, allowing us to explore more complex parts produced with this technique.”

“Canada Makes primary goal is to reinforce Canada’s additive manufacturing supply chain and this project is a big step in that direction,” said Frank Defalco, Manager Canada Makes. “This is the third round we have partnered with NRC-IRAP on the Metal AM Demonstration Program, and we are very pleased that many others projects are also helping companies learn how to use additive manufacturing to innovate.”

MDA-Fusia-part

Spacecraft interface bracket for an antenna

The parts are spacecraft interface brackets for an antenna and been optimised for a flight project.

Various satellite manufacturers are using additive manufacturing to reduce the cost and time required to build spacecraft parts. Boeing recently announced they will begin incorporating the technology, another recent announcement from Poland that they will use 3D printing to develop the country’s first satellites.

3D printing offers new possibilities for manufacturers of satellites. The building of parts with additive manufacturing allows new capabilities not available using conventional manufacturing, although it can be expensive and difficult so it is crucial to use the technology correctly where it offers true benefits.

The Metal Additive Manufacturing Demonstration Program is delivered by Canada Makes through funding by NRC-IRAP. The program is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

About MDA
MDA is a global communications and information company providing operational solutions to commercial and government organizations worldwide.

MDA’s business is focused on markets and customers with strong repeat business potential, primarily in the Communications sector and the Surveillance and Intelligence sector. In addition, the Company conducts a significant amount of advanced technology development.

MDA’s established global customer base is served by more than 4,800 employees operating from 15 locations in the United States, Canada, and internationally. www.mdacorporation.com

About FusiA
With more than 40 years of expertise, FusiA Impression 3D Metal Inc specializes in metal additive manufacturing (3D printing) of precision metal parts for the aerospace, space and defense and they have been a key partner for research and development projects of aeronautics for the past five years. www.fusia.fr

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative,  Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

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