In this edition, sponsored by Dimension:

• Simplifying Power Tool Prototyping
• 3D Modeling Consumer Products
• Designing Capacitor Tooling

Simplifying Power Tool Prototpying

Black & Decker, the world's largest producer of power tools and accessories, has seen product development cycles in the UK decrease significantly over the past decade as global competition increases along with consumer demands. New product lines, for example in garden equipment, are expected to be launched yearly. The pressure to constantly launch new ranges means that the company is always looking for faster ways to get products developed and into stores. Previously Black & Decker used a combination of in-house CNC milling for tooling while outsourcing stereolithography ( SLA ) and laser sintering (SLS) parts. Eighteen months ago the company made the decision to purchase a 3D printer which would enable them to produce more prototypes in-house and shorten their development cycles.

The company chose the Dimension 3D Printer from Stratasys, which prints tough, durable, high-quality ABS models. Having the machine in-house completely changed their product development cycles by making the process shorter and more efficient. According to Steve Swaddle, manager of technology at Black & Decker UK, "Before using a 3D printer it would typically take three to five days to get a prototype back from the service bureau. Having the machine onsite has made a phenomenal difference to this procedure. Parts that previously took three days can now be ready in just a few hours".

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Sponsor Message

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3D Modeling Consumer Products

Founded in 2006 in Traverse City , Michigan , Tape Wrangler is a woman-owned product development and manufacturing company that brings innovative, high quality products to the marketplace. Among its offerings are a line of specialty consumer products including its popular Tape Wrangler™ heavy-duty tape dispenser. During its first year of business, Tape Wrangler worked with several different design bureaus to create 3D models for product development and was unsatisfied with the results. "Outsourcing proved to be too costly, time-consuming and inefficient," said Wendy Steele, Tape Wrangler co-founder and CEO. "In addition to time and expense, we had to go through the trouble of getting the design service bureaus to sign non-disclosure agreements to protect our intellectual property."

All that changed when Wendy and her husband, Rick Steele, Tape Wrangler co-founder and COO, invested in a Dimension 3D printer and added it to their design shop. The printer allowed the company to produce functional 3D models of their designs that they could take on the road and demo at trade shows without the expense, delays and privacy issues associated with service bureaus. One of Tape Wrangler's biggest successes with the Dimension 3D printer came when they met with a major national retail chain about having one of their tape dispenser designs marketed under a private label brand. After reviewing the original design, the mass retailer suggested a few tweaks to increase the product's appeal to consumers. Tape Wrangler was able to quickly incorporate and demonstrate the changes with a functional 3D model produced on their Dimension printer.

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Sponsor Message

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Designing Capacitor Tooling

Ioxus develops, manufactures and distributes ultracapacitor technologies for a wide range of energy storage markets. Its innovative products extend the charge time and reduce the use of batteries for electronics, hybrid vehicles, wind farms, and other green technologies. Ioxus' parent company, Custom Electronics, Inc. (CEI) has been manufacturing high voltage capacitors since 1964. To maintain its position at the forefront of ultracapacitor technology, Ioxus and CEI employ multiple designers and invest significant time and money in the research and development of new products.

CEI began to investigate 3D printing as a way to cut the cost and turnaround times for tools and fixtures they were producing through outside machine shops. They were also looking for a way to produce housings and molds for prototypes. After researching a variety of options, CEI purchased a Dimension 3D Printer and used it to create nesting jigs and fixtures for assembly and soldering processes. The impact of the Dimension 3D Printer on the two businesses has been dramatic. Ioxus estimates that their small shop has saved over $100,000 in machining and prototyping since purchasing the printer three years ago.

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Sponsor Message

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- Bruce A. Bennett, Editor

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