The Miracle of Materialize Magics: Nissan spends seconds instead of months of work

Nissan Motor Corporation uses 3D printing to prototype and experiment with new forms of cars. Previously, these tasks required a large amount of manual work. Thanks to the Materialize software, we were able to change the whole process and make it much more efficient. Data preparation time was reduced from a few months to a few seconds.

How to dramatically reduce data preparation time and support removal

Since the 3D printer build platform is limited in size, some large parts need to be printed in parts. Until recently, Nissan used CAD software to separate large parts into smaller parts, and this process could take about three days. Now, thanks to the Materialize Magics software product, data preparation time has been reduced by 50%.

“In Materialize Magics, objects can be easily separated at a specific location, and operating time will be reduced by about half,” Nissan said. “There is also a useful feature that allows you to automatically create position pins when splitting, which makes assembly easier.”

Another problem the automaker faces is the risk of sinteringPowder components will warp or bend due to high temperatures during construction. As shown in Figure 3, this can be prevented by creating support structures. You can create a very thin connection between the supports and the component, so the supports are easy to remove, which speeds up post-processing.



Fig.
Figure 1: Automatically create positional pins on a cut (locating pins are also supported) 2: Fit grooves can also be created during separation
Fig. 3: supports and other types of supporting structures to prevent deformation can be created by simply clicking on two points that require support

Just a few clicks instead of a month of work

In addition to the separation of large parts, Nissan also pays special attention to adjusting the wall thickness. When the 3D model of the car is scaled down, the wall thickness of the part becomes correspondingly thinner, and the obtained data cannot be sent for printing. Previously, the design was changed manually in CAD, and this task required about a month of work.

“We had to search over more than 20 thousand reference points in order to find components with thin walls, and then increase their thickness. When it came to 3D printing of integral components , a lot of work was required to change the gaps between the parts in the original design, so as to provide for a connection between the parts, ”Nissan employees explain.

Since Nissan started using Materialize Magics, a number of processes can be completed in one click.

Today Nissan saves a ton of time with Magics software that automates these steps.

“Ever since we started using Materialize Magics , processes such as automatic correction of errors in data, searching for thickness by an arbitrary value and combining data can be performed with one click, which significantly reduces the working time (Fig. 4). In addition, by using the wall thickness analysis function, the thickness of each part can be visualized, due to which it is possible to recognize all parts with thin walls that cannot be printed (Fig. 5). In addition, after selecting an arbitrary area, you can change the thickness for this area. This is a function that we often use (Fig. 6). ”



Fig. 4: the automated processing of data recovery and wall thickening
Fig. 5: using the wall thickness analysis function, it is possible to visualize the thickness of each part, due to which it is possible to recognize all parts with thin walls that cannot be printed
. 6: Thickness change after selecting an arbitrary area (green area)

Auto-positioning of parts in a 3D printer: another time saving factor

Stage 1: manual placement of parts using the 3D printer software
Stage 2: there are gaps between the parts to avoid contact - this arrangement is not optimal
Stage 3: checking the contacting parts using the 3D printer software (from 10 minutes to several hours) . If any contact is found, go back to Step 1
Step 4: Starting 3D Printing

The most important aspects of the effectiveness of a 3D printer using the powder sintering method are placing parts so that the maximum number can be printed in one session, as well as a height limit after placing the parts. This approach reduces material costs and assembly time, and also optimizes the use of the machine.

Before Nissan started using the Magics Sinter software module, the software that came with the 3D printer was used. It involved the manual placement of parts so that they did not touch each other, as well as the maximum height limit (steps 1 and 2). Then the same software was used to verify the contact of the parts. Placement of parts manually took a lot of time, and reconciling the distance between them could take several hours (step 3).

“This not only slowed down the launch of 3D printing, but also made it impossible to create a production schedule, because we did not know when the calculations would end, it was very difficult for us. If it turned out that the objects were in contact with each other, we had to redo the project manually and then run another test, which was problematic both in terms of scheduling and in terms of staff time, ”the company's specialists say.



1: Magics Sinter module automatically arranges parts in optimal configuration
2: 3D printing can be started immediately!
3: protective box for small, fragile parts
4: options for optimizing placement for heat dissipation

“The Sinter module in Materialize Magics automatically arranges the components, while simultaneously ensuring the specified spacing between the parts and limiting the height, and now we no longer need to spend several hours checking touches and repeatedly repeating manual work. Parts that did not fit completely on the build platform used to be placed on several different platforms. Since the Sinter Module respects the correct spacing between components, they can now be printed in one session. By increasing the volume of one print job, we can reduce the number of working hours, the number of hours the printer is busy to perform operations such as preparing data, printing time and cooling time, as well as the amount of raw materials used. As a result, the entire 3D printing process has now become more efficient! ”

Material provided by Materialize. The original article is here .