In August 2019, 3D printer supplier Markforged announced that British automaker Dunlop Systems and Components has been using its 3D printer to make custom tools and has saved thousands of dollars in the process.
It is reported that during the normal production process, the automaker's tool department encountered many problems related to outsourcing customization. Later, they decided to use 3D printers to make tools themselves, so Dunlop Systems purchased a Markforged desktop 3D printer.
Mark Statham, production and engineering manager at Dunlop Systems and Components, commented: "Since we bought a 3D printer, we haven't used the manufacturing method of the past. This is the best thing we have ever bought."
Bringing 3D printing production into internal processes
Dunlop Systems and Components manufactures anti-vibration solutions for automobiles, including automotive air suspension components OEMs and electronic control systems for vehicle applications.
Dunlop Systems has many old machines and internal tools installed in its facilities that often need to be replaced. For this reason, requirements are usually sent to third-party tool manufacturers. However, this often extends tool delivery cycles and further delays due to customer design changes, resulting in increased costs and sometimes losses. Statham explained: "You spend money and then wait two or three weeks to receive it, and then the customer will call you again and tell you what they want to change."
Attended a seminar organized by Mark3D, a British Markforged 3D printer dealer. Statham said, "I'm very open. When I see what a printer can do, I think why can't we make the tools ourselves?"
There he learned about the capabilities of the Markforged 3D printer. Statham has validated the company's continuous carbon fiber material for the production of rugged tools that withstand corrosive environments. After discussing the 3D printer with Dunlop Systems Director, a verification review was conducted to determine suitability, and a Markforged 3D printer was purchased.
Break through the bottleneck
Since the use of the Markforged 3D printer, Dunlop Systems' tool division has used it to produce prototype parts for electric vehicles, meters, and molds. Tools can now be manufactured directly in-house based on customer needs, dramatically reducing lead times and costs. "Our department can say with great confidence that if you want to complete certain tasks, we can now print them out within a few days." Statham added.
Markforged's Onyx and continuous carbon fiber materials have also proven to be perfect choices for the Mark team. For example, they replaced the nylon material used in some lamps with Onyx materials. In the hot summer, nylon will warp, but with Onyx, it is not affected by thermal deformation. "We are now replacing all tools with Onyx," Mark said. The team typically spends around ￡ 20,000 ($ 24,300) on molds, but due to additive manufacturing, the unit has cut spending this year to ￡ 11,000 ($ 13,300). Stanson added:
"We have already saved ￡ 20,000 in six months, so if we take this approach, we will save ￡ 40,000 this year."
Dunlop Systems is now using Markforged 3D printers to print custom tools for prototype electric vehicles for large car companies. The car is currently on the road and is equipped with 3D printed Onyx prototype parts. Previously, the company spent a lot of money on outsourcing prototype molds, some of which cost about ￡ 500 ($ 630) in manufacturing costs. With a Markforged 3D printer, the cost of printing the same part is only ￡ 15 ($ 18), so thousands of dollars can be saved.