Spring srl, the Italian-based company with more than 20 years of experience in additive manufacturing of plastic materials, joins the aerospace Venetian cluster “Aerospace innovation and research“. With this new step, Spring srl becomes part of a high-performance team composed of companies and research institutes with different skills, able to meet the aerospace industry needs, completing major projects and R&D activities internationally.

Spring srl provides aviation and military industry with light and resistant components with complex geometries, that contribute to reduce bigger projects time and costs. Spring’s know-how gained in working with these industries is also transferred to the space field, guaranteeing a high-quality level.

In the aerospace industry, a close collaboration among companies with different skills is needed to complete major projects. In Italy, also for this reason, these companies cooperate through regional aerospace clusters.

In the case of the Venetian region, the “Aerospace innovation and research” cluster, founded in 2019, gathers excellent research institutes with expertise on tests, validation, aircrafts qualification, satellites and high-tech companies able to build complex space systems. The “Aerospace innovation and research” cluster’s companies work on projects related to: space exploration, building of cutting-edge technologies for the resources exploitation on extraterrestrial sites, building modular habitats suitable for astronauts during long-term missions.

By joining the Venetian cluster, Spring srl is ready to make its contribution to international aerospace companies, providing its own quality, experience and the will to work on new additive manufacturing applications in partnership with the players of this articulated ecosystem.

SPRING srl: the additive manufacturing company certified for aerospace industry

Spring srl is an additive manufacturing company certified for components production for the aerospace industry (AS 9100:2016). The company, according to the industry standards, guarantees a full traceability on materials and process. Thanks to its own know-how, Spring srl is already partner of leading aeronautical and defence companies to which it guarantees a high-quality level in terms of performance and batches reproducibility.

Spring srl provides the industry with air ducts, brackets, cable guides, electrical housings, connectors, jigs, production toolings, seat components, internal cabin components, window edges, door panels and more.

Some of the most interesting materials, chosen by Spring’s technical team for aerospace applications, are:

• ULTEM™ 9085 CG (PEI) is a fully self-extinguishing material, FST certified (Flame, Smoke, Toxicity), FAR 25.853 certified. ULTEM™ 9085 CG (Certification Grade) guarantees documented traceability from filament back to raw material lot number. Components built with this material offer an excellent chemical resistance and a great thermal, tensile and flexural strength.

• ANTERO 840CN03 (PEKK) combines the excellent physical and mechanical qualities of PEKK with electrostatic dissipative (ESD) properties. ANTERO 840CN03  is filled 3% by weight with carbon nanotubes. Components built with this material offer a great wear resistance, an excellent chemical resistance and an ultra-low outgassing.

Get in touch with us by this FORM and take benefits from additive manufacturing.

Photos:

– SpaceX e Nasa by Unsplash

– Stratasys

Source:

– Aerospace Innovation and Research – AI

Components built in BASF Ultrasint ® TPU01, from Spring’s technical team, offer a good finishing, a high level of detail, a great shock absorption, a good UV resistance.

Moreover, with BASF Ultrasint ® TPU01 we produce parts characterized by an excellent resistance to oils, greases, hydrocarbons, oxygen, ozone.

In the table below, it is possible to see some of the of BASF Ultrasint ® TPU01 mechanical properties.

In this link, it is possible to download BASF Ultrasint ® TPU01 data sheet.

BASF Ultrasint ® TPU01 for the production of components and prototypes in low volume

BASF Ultrasint ® TPU01 has been developed by Basf Group in partnership with HP, for HP Multi Jet Fusion printers.

Spring’s technical team is able to build components and prototypes in BASF Ultrasint ® TPU01, in short time and at low cost.

The technical staff is able to produce performing components in BASF Ultrasint ® TPU01, thanks to additive manufacturing expertises gained over the years.

We choose this material for projects that need flexible components, producing internal parts for automotive, ducts for liquid and gas, robot grippers, sleeves, tooling, seals and much more.

BASF Ultrasint ® TPU01: an application example

In the picture above it is possible to see an automatic machine component in TPU01, this component is known as code wheel cover.

This component needs to be frequently assembled and disassembled on the machine. These operations risk to damage other machine components.

The technical team has chosen additive manufacturing and BASF Ultrasint ® TPU01 material to build this component.

Thanks to additive manufacturing skills, the use of additive manufacturing technology and BASF Ultrasint ® TPU01 material, the company has taken the following benefits:

• Component design optimization: the code wheel cover has been improved for this specific additive manufacturing process. This optimization allows to assemble and disassemble the code wheel cover, without damage to the other machine components.
• Assembling and disassembling facilitation: thanks to the use of BASF Ultrasint ® TPU01 material, the code wheel cover is more flexible, this improvement allow to facilitate assembling and disassembling operations on the machine, reducing time for these operations.
• Reducing repair activities: An easier assembling and disassembling of the code wheel cover, without damage to other machine parts, allow to reduce repair activities on the machine.
• Reducing time and costs: Production time and costs have been reduced compared with standard production.

SPRING SRL – The additive manufacturing service for industrial applications

Spring srl offers 20 years’ experience in additive manufacturing, with a full service throught all process steps, guaranteeing a shipping time in few days.

The Spring’s technical team skills have allowed us to gain the certification ISO 9001:2015  in the production and supply of prototypes and industrial parts, and to gain the certification AS 9100:2016  in the additive production for the Aeronautic and Defense sector.

One of the most appreciated service is our «Design for manufacturing» that allow to optimize concepts for additive manufacturing process, guaranteeing the best value for money.

We guarantee our customers to treat confidentially all of information, data and documents of projects submitted to our attention. For more details on the Spring’s Confidentiality Agreement, click on the following link.

To have high quality components in few days and at low cost in BASF Ultrasint ® TPU01 material, contact our team on the following link.

Additive manufacturing technologies, such as Fused Deposition Modeling or FDM, allow to produce ergonomic, optimized and custom-made jigs for the production floor. To understand benefits coming from this technology, let’s have a look at an example of an alignment jig  and an assembly jig, related to the automotive field.

A custom-made alignment jig thanks to FDM technology

This jig, well-known as “Badge alignment tool”, is used by workers to accurately place a badge on a car. The Badge alignment tool is usually produced with CNC machines and metal, resulting too heavy and uncomfortable for workers.

The company decides to optimize the Badge alignment tool, by choosing FDM technology, ABS-M30 material and sparse fill style.

Sparse fill style is one of the most interesting chance offered by FDM technology. The sparse fill style, as opposed to the solid fill style, allows to develop resistant components composed of an internal grid, also with honeycomb structure. This condition enables to reduce the use of material and as a result, assures a further saving in terms of weight, time and costs, compared to an already favorable fill style such as the solid one.

The new custom-made Badge alignment tool has been optimized by the technical staff and produced by skilled workers. This new tool enables the company to get benefits such as:

• Increased productivity: The Badge alignment tool weight has been reduced by 72% compared to the previous solution. Moreover, the component design has been optimized in its ergonomics. Employees have been able to increase their productivity, thanks to these new conditions.
• Reduced time: FDM technology and sparse fill style have enabled a delivery time reduction by 92% compared to the previous solution.
• Reduced costs: FDM technology, sparse fill style and the new “design for manufacturing” have guaranteed a cost reduction by 58% for each Badge alignment tool.

Custom-made assembly jig thanks to FDM technology

This jig is used by an automotive company’s workers, to assembly cars door seals. This jig is usually produced with CNC machines. The company needs to increase productivity related to this working step, that’s why technicians decide to develop a new assembly jig.

FDM technology, ASA material and solid fill style are chosen for this application.

This new optimized, custom-made assembly jig has been produced by skilled workers and shows now two main features:

• Improved ergonomics: FDM technology allows to overcome geometric limits, related to the use of more traditional methods. This chance has enabled the technical staff to re-design the assembly jig with a more focus on functionality. Indeed, it has been possible to insert internal hardwares in order to ease the working task.

• Reduced weight: Thanks to Asa material and the improved geometry, the new assembly jig weighs only 13 kg as opposed to the 58 kg of the previous solution.

The new assembly jig allows the company to get benefits such as:

• Saving time : The company saves hundreds of working hours, since each employee performs on average 250,000 cycles a year and the new jig enables a reduction of 4 second per assembly cycle. Indeed, thanks to the use of FDM technology, the company has shrunk the jig production from weeks to days.
• Saving costs: The ROI related to the jig cost is achieved within few months.
• Boosting safety: The new lighter and more ergonomic jig enables to reduce risks related to its use.

Spring srl – the additive manufacturing service for industrial applications

Spring srl is an additive manufacturing service, with over 20 years’ experience in the production of prototypes and functional components, with thermoplastic materials, for industrial applications. (ISO 9001:2015)

Spring srl’s highly-skilled technical staff chooses additive manufacturing technologies, materials and treatments in order to meet also the most demanding needs. With a portfolio of over 20 materials, a machinery composed of 3 different additive manufacturing technologies and 12 professional systems, Spring srl offers a wide range of solutions and a very fast delivery. The company produces not only prototypes and components, but also offers services such as engineering, design for manufacturing, 3D scanning for reverse engineering and a rich selection of finishes and treatments for post processing.

Source: https://www.stratasys.com/

Click here for more info on a control jig built with additive manufacturing.

Click here to send your request.

Additive manufacturing technologies allow to produce grippers with complex geometries, at reduced weight, in short time and at lower costs, compared to the production with more traditional methods.

These features enable engineers to develop more performant components.

New generation vacuum grippers with Multi Jet Fusion technology

To better understand benefits of additive manufacturing, we present you a vacuum gripper example, applied to a robotic arm, for packings handling.

Since the company needs to increase productivity and to reduce costs related to the robotic arm, engineers are driven to re-design it, starting from the vacuum gripper.

This vacuum gripper is usually composed of an extruded aluminium profile with external canalizations for air management.

The technical staff wants to build a new kind of vacuum gripper, in thermoplastic material, with airtight integrated canalizations.

The production of this new component is possible thanks to the technical know-how related to the Multi Jet Fusion technology and PA 12 material, chosen for this application.

Using this innovative technology, the vacuum gripper presents a significally reduced weight, compared to the previous version. This condition allows the company to:

• Improve performances: With a lighter vacuum gripper, the robot has increased the number of tasks carried out in an hour.
• Reduce costs: The company has invested in a smaller robotic arm, cutting buying cost, energetic consumption and the space occupied inside the factory. The lower weight of the new vacuum gripper has reduced the wear and the mainteinance activities on the robotic arm. The vacuum gripper production cost has been reduced by 85 %.
• Reduce time: The building time has been reduced by 70 %, since the additive method allows to deliver parts in a few days or hours. This fast delivery has enabled to quickly install the robot and make it operational in a very short time.

Spring srl – the additive manufacturing service

Spring srl is an additive manufacturing service specialized in industrial applications (ISO 9001:2015 ). Industrial automation is one of the main field served by the company, producing not only grippers, but also fittings and pallets for automated production lines, air ducts and distributors etc…

The wide range of services includes the production of functional components and prototypes with additive manufacturing technologies, engineering, re-design, post-processing, using a great variety of finishes and treatments.

Contact us for more information: https://www.spring-italia.com/contacts/?lang=en

Source: https://www8.hp.com/uk/en/home.html

We are proud to introduce you to the new Spring srl’s additive manufacturing service regarding the Multi jet Fusion technology, that will allow our clients to have thermoplastic components with the usual and high quality level guaranteed by Spring.

The combination between these elements is our daily challenge and today, even more, this is what we offer, thanks to new investments in terms of Know-how and production systems.

The new in-house arrival, as a result of an internal analysis, is the HP Multi Jet Fusion 5210 additive manufacturing system.

Multi Jet Fusion technology: how does it work?

Multi Jet Fusion (MJF) is a powder-based AM process that uses fusion energy and two agents; such are selectively jetted, with the fusing agent used to weld the particles that make up the finished part, while the detailing agent is used to define edges and details.

PA 12 thermoplastic of the Multi Jet Fusion technology

PA 12 is a thermoplastic used with the Multi Jet Fusion technology.

This material allows to produce structural, isotropic and watertight parts.

Click here to know the features and benefits of PA 12.

Spring srl: the additive manufacturing service of industrial quality

We work daily to assure an always higher quality level for the parts and for the services provided to our partners, through the know-how of a skilled technical staff and a top quality production (ISO 9001:2015 certification ).

Choosing our services means taking advantage of all the benefits that additive manufacturing can offer for industrial-grade applications.

We are at your disposal for any request:

Contacts

Companies intending to replace traditional production processes with innovative methods, such as Additive Manufacturing with FDM technology, are obtaining significant savings in terms of production time and costs; AM in fact allows them to gain an advantage over the competition.

Usually, when engineers need to produce a component with complex geometries, the process steps that are needed for its production can be several, such as milling, other CNC machining, welding etc.

The production of parts that need all these process steps requires utilization of huge economic resources and a long lead time.

The knowledge and skills in the use of FDM technology, industrial production systems and the use of high-performance materials allow you to have in a few hours light and resistant components, which can also replace metal parts.

FDM technology is particularly advantageous in the realization of small lots or single pieces with complex geometries.

Parts such as grippers, fittings and pallets for automated production lines, air ducts and distributors achieve the maximum benefits from production through the FDM process.

In the following example, we will present how the technical department of Spring srl, a 3D printing service specialized in FDM technology, has created a suction duct achieving 3 key objectives: lowering costs, reducing delivery time and producing a component with high mechanical performance.

 Air intake duct

Previously the duct was made of steel, thus requiring cutting the various sections, welding them and milling the ends to guarantee their geometry. The traditional process involved a considerable economic expenditure and the production times were particularly long.

Spring’s proposal made it possible to produce the monolithic part without joints and welds, thus significantly reducing production times and costs.

During the “Design for manufacturing” phase, the 3D model was optimized according to the FDM technology, inserting structural ribs at the ends of the component, to ensure greater resistance in fixing the coupling sleeves.

To fulfil the requests, Spring selected Nylon 12 CF for this project. Nylon 12 CF is a thermoplastic blend consisting of Nylon 12 and 35% carbon. This material offers very high values ​​of rigidity, resistance to impacts and to chemical agents. These characteristics make such material particularly suitable for metal replacement applications.

The final component that was re-engineered and produced by Spring Srl weighs 0.15 kg, compared to 1 kg of the previous solution, a weight saving of 85%.

Click here to download the case study.

Spring srl: the italian 3D printing service for the automation industry

Spring srl is ISO 9001:2015 certified for production and supply of prototypes and industrial components through additive production technology.

The company assists its customers in co-design activities in an additive manufacturing perspective, thanks to 20 years of experience in this field.

Spring Srl has been working for years with the most important national and international players in the industrial automation sector. These partnerships are the result of important investments in terms of resources, professional production systems and a continuous improvement policy.

Spring srl increases its productive capabilities in the medical and healthcare field, making materials available that are resistant, biocompatible and ISO 10993 certified, such as:

-ABS-M30i Acrilonitrile Butadiene Stirene: This thermoplastic is ideal for the production of medical, surgical and pharmaceutical tools. Components manufactured with this material are sterilizable through gamma rays, ethylene oxide (EtO) or hydrogen peroxide gas plasma and can be used in direct skin-contact applications.

-PC-ISO Medical Polycarbonate: This thermoplastic is used for the production of tools for doctors, surgeons and dentists. Pieces manufactured with this material are sterilizable through gamma rays or ethylene oxide (EtO). PC-ISO offers excellent mechanical features, an outstanding traction strength and a temperature resistance up to 133 °C.

–ULTEM 1010 Polyetherimide: This thermoplastic is used for the production of medical applications and tools for food manufacturing (NSF 51). Parts produced with this material are sterilizable through gamma rays, ethylene oxide (EtO), hydrogen peroxide gas plasma or in autoclave. ULTEM 1010 is a self-extinguishing thermoplastic, that offers a notable mechanical resistance and high temperature strength, up to 216 °C.

Detailed information is available on the following link: https://www.spring-italia.com/product-category/fdm-en/?lang=en

In the table below you can find the biocompatibility test results and the tested sterilization methods.

(Source: Stratasys)

Additive manufacturing for the medical field – Spring Srl

Additive production allows to obtain big benefits in terms of quality, execution speed, costs reduction and parts customization as long as professional systems, certified materials, processes that guarantee the produce traceability and know-how are employed.

At Spring Srl, with 20 years of experience, an excellent technical staff, 12 3D printing professional systems, a portfolio of more than 20 materials and an ISO 9001 certified production system, we provide appropriate solutions for the field.

The medical solutions that additive manufacturing can provide are rapid prototyping and end-use part production, medical and surgical tools.

These solutions are already available today at Spring Srl, and such allow to improve the healthcare and the creation of high-performance parts.

For any need or explanation, we invite you to contact us: https://www.spring-italia.com/contacts/?lang=en

In one of the most spectacular events of the World Championship calendar of the Moto2, at night, under the floodlights of the Losail International Circuit, in the Qatari desert, Jorge Navarro, Team Speed Up’s number 9, conquers a great 6^th place.

It’s a good start in the 2020 season for the valencian pilot of Moto2, whose step change has begun in 2019 when he joined the Speed Up team, closing the season with 226 points, vs 58 points in 2018.

Spring srl, technical sponsor of the team, is proud to support the big progress of one of the most famous constructors of the championship, providing additive manufacturing solutions able to optimize the performance of the SF20T Speed Up motorbike.

Spring srl: the ideal partner for the motorsport companies

Spring srl, 3D printing service bureau, specialized in the FDM technology, produces monolithic functional parts and prototypes up to 900X600X900 mm.

Spring’s know-how, the FDM process and the high-performance materials guarantee light components, able to withstand extreme conditions like high temperature, chemicals and mechanical stresses.

Spring’s technical department supports constructors also in co-designing, to review parts drawings for additive manufacturing.

Some of the most required components from the field are end-use parts, soluble cores, tooling application for composites etc..

In the following case studies you will discover how the Spring’s technical department has built the inlet pipe and the airbox conveyor of a competition bike achieving 3 key targets: cost savings, delivery time reduction and production of high-technical feature components.

• Inlet pipe:

The selected material for this project has been Nylon 12 CF, a thermoplastic blend with 35% of carbon fiber, specific weight 1.15, bend resistance 142 MPa. This material offers the best results in terms of tensile modulus and specific stiffness; these features make Nylon 12 CF suitable for metal-replacements initiatives. Click here to download the case study in PDF format.

• Airbox conveyor:

The selected material for this project is Nylon 12, specific weight 1.28, tensile strength 48.26 MPa, bend strength 68.95 MPa. This material is capable of withstanding to strong vibrations and fatigue, particularly suitable to absorb stresses during the race. Click here to download the case study in PDF format.

Soluble cores allow for production of carbon fiber parts. These “sacrificial tools”, produced using ST-130 material, are covered by carbon fiber sheets and then undergo the autoclave treatment. At the end of this production process, the soluble cores are dissolved into a water-based solution.

As the materials market is in constant evolution, Spring srl offers  increasingly new solutions. Among the most interesting materials for your field we suggest you to discover PEKK, Ultem 1010 and Ultem 9085 properties. You can find these materials at the following link: https://www.spring-italia.com/prototyping/3d-printing/?lang=en

Companies producing drones can benefit from knowledge and use of innovative 3D printing technologies, as for example FDM technology. This technology allows to optimize the end-use parts design and the related production process. Leptron, leader in drones production, has increased its competitive advantage thanks to FDM technology.

In this case study, the company analyses the most proper production approach to make different versions of complex components. These plastic parts, that will be used in the drone fuselage, need to pass functional tests. Leptron therefore needs a fast production process, capable to reduce the time-to market in order to beat the competition.

The traditional approach would have used the injection moulding. Through this method the company would have delayed the production of the tooling and the components by 14 months. Components design changes would have forced the staff to build new tooling, with further delay and increasing costs.

In order to cut on time and costs the company has opted for 3D printing, with FDM technology. Such technology brings huge advantages to the production of plastic parts with complex geometries. This new approach has allowed to meet the mechanical requirements for each part utilized  in the drone fuselage.

Thanks to expertise in Additive Manufacturing, use of professional 3D printing systems and to the high performance materials, the produced parts are capable of passing the needed tests, making the project a success.

The total parts production time is reduced from 14 months, with the traditional approach, down to 8 months, through 3D printing. Moreover, this innovative technology allows for cost savings of around 59%.

Leptron, choosing FDM technology, has performed many design changes without delaying the development time and without increasing costs.

Spring srl: the best 3D printing service bureau for aerospace companies

Spring srl is specialized on FDM technology. For over 20 years, Spring srl has worked with highly innovative companies. The technical staff is capable of supporting customers in co-design, to provide the best technical solutions. In order to meet the tough aerospace industry requirements, Spring srl has obtained the AS 9100. This certification is designed to meet the aerospace and defence industry on production of end-use parts. As of today, Spring works with the major players in the defence and aerospace field.

Click here to know some of our references.

Images: https://www.stratasys.com/it/resources/search/case-studies/leptron

Nowadays, thanks to the knowledge and expertise in state-of-the-art additive manufacturing technologies like fused deposition modelling (FDM), manufacturers can develop high-performance solutions.

One outstanding example is Genesis Systems Group, specialist manufacturer of robotic systems for welding and water-jet cutting.

The company needed to develop more high-performance positioning systems, so the technical staff decided to revolutionise their conventional approach to building components and try out the FDM process, using ULTEM 9085 to create their complex monolithic parts.

It was a success, bringing together the elements which help them reach their set project targets. These elements are:

·       Professional additive manufacturing systems

·       High-performance materials

·       Knowledge of the FDM technology

In the past, the company used to build their metal parts using conventional technologies and lead time was about 20 days. Today, thanks to the new solutions offered by additive manufacturing, parts are ready after only 3 days, with an 85% reduction in time and 94% in costs.

Another benefit of this new engineering approach is that it significantly reduces the weight of the finished component, now weighing only 1 kg compared to 15 kg.

SPRING Srl for production excellence

Spring Srl has been using additive manufacturing technologies for 20 years and its technical staff is the driving force behind the company. The technical skills which Spring brings to the table mean it can co-design components with its clients to deliver the best possible technological solutions.

Parts produced using FDM technology are of such a high quality standard they can be used repeatedly in production lines. Furthermore, top-performance production systems guarantee the quality of the manufactured parts and the repeatability of batches, as well as compliance with the requested specifications.

Spring Srl’s portfolio of plastics is extensive and some of the most effective materials it uses include: Ultem 9085, Ultem 1010, Nylon 12 CF, ABS-ESD7 and PEKK.

ULTEM 9085: Thermoplastic with a specific weight of 1.34, V0 flame-retardant, self-lubricating and certified for use in the aerospace industry.

ULTEM 1010: Thermoplastic with a specific weight of 1.27, V0 flame-retardant, high heat resistance (up to 216° C).

NYLON 12 CF: Thermoplastic with a blend of Nylon 12 and 35% carbon, specific weight of 1.15 and flexural strength of 142 MPa. Ideal for producing lightweight but very strong production equipment.

ABS-ESD7: Thermoplastic with static dissipative properties and a specific weight of 1.04. ABS-ESD7 prevents a build-up of static electricity and stops fine particles and powders sticking to it.

PEKK: Thermoplastic with very high chemical resistance and MIL-STD-810G certification. It is recommended for the automotive, aerospace, railway and oil and gas sectors to manufacture parts which come into contact with oil, fuel and hydraulic fluid.

To learn more about the materials used by Spring Srl, click here.

To sum up, choosing Spring Srl’s cutting-edge production systems and materials, combined with its outstanding know-how, will give you the edge over your competitors, thanks to new innovative solutions.