{"id":191979,"date":"2022-08-23T00:00:00","date_gmt":"2022-08-23T00:00:00","guid":{"rendered":"https:\/\/facfox.com\/news\/north-american-lighting-accelerates-production-with-makerbot-3d-printer-hardware\/"},"modified":"2022-08-23T00:00:00","modified_gmt":"2022-08-23T00:00:00","slug":"north-american-lighting-accelerates-production-with-makerbot-3d-printer-hardware","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/north-american-lighting-accelerates-production-with-makerbot-3d-printer-hardware\/","title":{"rendered":"North American Lighting accelerates production with MakerBot 3D Printer Hardware"},"content":{"rendered":"

North American Lighting (NAL), a Koito Group Company and an automotive<\/a> lighting systems manufacturer for vehicle<\/a> manufacturers, has start<\/a>ed using MakerBot\u2019s METHOD X AM capabilities to increase the company\u2019s assembly production efficiency.<\/p>\n

With eight facilities across the US, NAL provides advanced lighting technology, engineering design expertise, and state-of-the-art<\/a> production capabilities. For a manufacturer like NAL, which works with some of the largest automotive<\/a> OEMs in America like Ford and GMC, speed and precision are critical. To that end, assembly production tools are essential to ensure that production continues smoothly. If a part<\/a> breaks \u2013 it could mean extended lead times and added costs.<\/p>\n

Joey Carpenter, production engineering technician, began using 3D printing<\/a> to bring tooling production in-house and reduce potential disruptions. Carpenter was new to 3D printing<\/a> when he was introduced to the MakerBot METHOD X series in early 2022. Since then, Carpenter, who handles robotic builds and cycles in new end of arm tools for production runs on new launches, has become the resident expert.<\/p>\n

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Before 3D printing<\/a>, Carpenter and his team relied on external vendors to design, produce, and send back part<\/a>s that they would need. Receiving a new part<\/a> could take several weeks. This was less than ideal since orders were frequently late, forcing them to readjust their timelines.<\/p>\n

\u201cNow with a METHOD X in-house, there is minimal wait time,\u201d said Carpenter. \u201cIn 12 hours, we have what we need to build an end-of-arm tool. Not only does this drastically reduce our wait times, but we are also seeing a massive cost reduction. The cost to 3D print a part<\/a> in nylon carbon fiber is one-third the price of what we were paying for outsourced aluminum part<\/a>s.\u201d<\/p>\n

\u201cIn addition, since we start<\/a>ed 3D printing<\/a>, our overhead costs decreased by half because we don\u2019t have to stock up on excess part<\/a>s,\u201d he continued. \u201cWe have reduced part<\/a> inventory by 50%. Now all of our tool designs are digital so they\u2019re easier and quicker for us to access, iterate, and print as we need. Instead of waiting weeks, we can turn part<\/a>s around in five days, from design to assembly.\u201d<\/p>\n

Printed in carbon fiber, there are about 20 grippers on this end of arm. Cost reduction on this tool alone was between 25% and 30%, with each gripper taking 48 minutes to print. <\/p>\n

In the Flora factory, the robots use around 200 end-of-arm tools a year, which are built in-house. Bringing tooling production in-house has allowed the team to significantly reduce costs while also saving significant amounts of time.<\/p>\n

While Carpenter mainly prints end-of-arm tool part<\/a>s, he has also found new application<\/a>s where he can utilize the versatility of METHOD X. \u201cWe\u2019ve also used in-house mockups and prototypes for water fittings and part<\/a>s like that for future use. We prototyped with carbon fiber in house within a matter of three days, rather than outsourcing it which could take a month to get back,\u201d he said.<\/p>\n

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\u201cWe\u2019re finding that it\u2019s very easy to replace aluminum with carbon fiber part<\/a>s. With weight reduction and durability, carbon fiber is comparable to aluminum,\u201d noted Carpenter. \u201cWith the LABS extruder, MakerBot and Jabil materials offered on the METHOD X, the tolerances and the consistency of your prints are far better than you can imagine.\u201d<\/p>\n

Used on the assembly line to hold part<\/a>s in place while the machine is working on them, NAL printed nest blocks for a fraction of the cost and in a fraction of the time, compared to outsourcing. <\/p>\n

Carpenter\u2019s team isn\u2019t the only one using METHOD X at the Flora facility. The Assembly and Lighting team at NAL also began using the printer to produce nest blocks for the assembly line. The nest blocks go into the tooling on the assembly line and are used to keep part<\/a>s in place while the machine is working on them. Before METHOD X, the team would have to bring in one of their tool shop vendors to access their needs. They would have to then wait for the vendor to design the part<\/a> and build it as well as wait for a quote for the part<\/a> to be approved, before receiving the final product.<\/p>\n

\u201cThere would be a four-to-six-week lead time before getting a part<\/a> back,\u201d said Dee Jay Griffith, manufacturing engineering technician. \u201cAnd the cost would be pretty high \u2013 With METHOD X, we\u2019re able to print a full nest for less than 10% of the cost and we\u2019re able to do that faster.\u201d<\/p>\n

\u201cThe METHOD X and 3D printing<\/a> helped my workflow by enabling faster lead times and cost savings that comes with being able to print my own things,\u201d Griffith noted. \u201cWe\u2019re now able to accomplish what we need to on these assembly lines faster and without having to rely on vendors\u2019 timelines.\u201d<\/p>\n<\/p>\n

Primarily printed in carbon fiber and PolyMax PC \u2013 the nest blocks are lightweight and durable. Since printing them months ago, Griffith has not yet seen any wear on them. He is also experimenting with different materials, constantly finding things they would like to print. For example \u2013 camera mounts, grease tips, leak test seals, and more.<\/p>\n

While the teams at NAL are experiencing a significant savings in cost and time when using 3D printing<\/a>, those are not the only factors for their use of METHOD X. Its ease of use and seamless ability to print carbon fiber as well as other industrial-grade materials with the MakerBot LABS Experimental Extruder have made METHOD X a must-have in their facility.<\/p>\n

\u201cWe\u2019ve already ROI\u2019d this machine and we\u2019ve only had it for a few months. Just in the savings of what we\u2019ve already printed, not to mention the time we\u2019ve saved doing it ourselves as opposed to waiting for a shop to come in to get it done,\u201d said Griffith.<\/p>\n

\u201cI work for a multi-billion dollar company and can afford any 3D printer out there but yet we have five MakerBots in house right now and there\u2019s a reason for that,\u201d concluded Carpenter.<\/p>\n

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You might also like:<\/h5>\n

Scaling composites 3D printing into a new dimension: <\/a>Martin Eichenhofer (CEO), Giovanni Cavolina (CCO) and Chester Houwink (COO) founded 9T in 2018 with the goal of delivering the next generation of high-performance manufacturing and aspiring to mass-produce high-performance composites as easily as metals by automating and digitizing the production workflow of composite production. The only way to do this, they realized, was to address the complexities of anisotropic materials and the manual-labor-intensive continuous fiber reinforced thermoplastic polymers (CFRTP) manufacturing.<\/p><\/blockquote>\n

* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author: Edward Wakefield<\/p>\n","protected":false},"excerpt":{"rendered":"

North American Lighting (NAL), a Koito Group Company and an automotive lighting systems manufacturer for vehicle manufacturers, has started using MakerBot\u2019s METHOD X AM capabilities to increase the company\u2019s assembly production efficiency.<\/p>\n","protected":false},"author":3,"featured_media":191981,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"fifu_image_url":"\/news\/wp-content\/uploads\/2022\/08\/8429183422833548816.png","fifu_image_alt":"","footnotes":""},"categories":[58],"tags":[4883],"class_list":["post-191979","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-technologies","tag-3d-printer-hardwareon-demand-manufacturing"],"yoast_head":"\nNorth American Lighting accelerates production with MakerBot 3D Printer Hardware - 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