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3D Printing Services Available At Zeal 3D

3D Printing Service

3D Scanning Services by Zeal 3D

3D Scanning Service

CAD Services by Zeal 3D

CAD Service

Injection Molding Services By Zeal 3D

Injection Molding Service

CNC Machining Services by Zeal 3D

CNC Machining Service

Vacuum Casting Services by Zeal 3D

Vacuum Casting Service

Augmented Reality with Zeal 3d Printing

Augmented Reality

Laser Cutting Service At Zeal 3D

Laser Cutting Service

3D PRINTING PERTH

The trend of 3d printing in Perth, Sydney, and other cities globally is booming as more companies are opting for this advanced manufacturing technique. Regardless of industry and company size, it continues to grow and innovate. Additive manufacturing is a disruptive technology, and Zeal 3D Printing is proud to be a leading contributor in this current domain. Zeal brings in a full range of robust 3d printing services in Perth to help your business grow and outperform. From healthcare to automotive to architecture and the mining industry, we have all significant domains covered with our groundbreaking services.

Zeal 3D Printing Services in Perth has been recognized as one of the pioneers in the field of digital printing. With years of expertise in the field and a team full of only the best engineers and designers, we aim at providing you with the most exceptional 3D printing in Perth. Our Perth facility is equipped with the most innovative and technologically advanced 3D printers in the region – FDM 3D printers, SLS, Dimension SST 1200, you name it, and we have it.

VERSATILE RANGE OF 3D PRINTING SERVICES IN PERTH

At Zeal 3D Printing Services Perth, we do our level best to deliver best-quality services without any hidden costs to our clients. We also take extreme care about the timeliness of delivery. Get the best rapid prototyping services with a faster turnaround time with Zeal. Our team offers a wide range of prototyping services, including 3D vacuum casting and injection molding. The vast variety of services offered at the location include but isn’t limited to:

3D Printing– Our experts at Zeal offer a wide range of 3d designing and printing services to accomplish your industrial requirement with perfection. With the support of 20+ materials, we have got you covered. Regarded as the top-most 3D printing service in Perth, Zeal 3D Printing Services offer a huge diversity of printing and drafting services that allow our clients to convert their ideas and designs into the most accurate three-dimensional prototypes. Our premium services, lucrative 3D printing service cost quotes, and custom 3D printing facilities allow our clients to name us among the best 3D printing companies in Perth.

3D Designing- We not only offer 3D printing service in Perth but also assist our clients in 3D designing using only the best 3D design software available in the market. Some of the services on offer include Jigs and Fixture Design, Machine Tools Design, CAE - Static Analysis, CAE - Dynamic Analysis, Technical Publications, and much more.

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3D Scanning–Our 3D scanning facility in Perth is the fastest and the perfect way to gather large volumes of quality data. We provide innovative 3D scanning services which is useful in reverse Engineering or quality inspection, Rapid Prototyping, Computer-Aided Engineering (CAE) & Digital archiving. It will reduce the time taken for production cycles without compromising the product quality.

Vacuum Casting– The most-preferred method for high-quality prototypes, and low-volume production, Vacuum casting allows clients to create master moulds as well as cost-effectively recreate parts and components. Offering a top-in-line vacuum casting service in Perth, we provide master patterns, mould making, as well as casting copies at highly competitive costs. Our vacuum casting technology is ultimate for small-batch manufacturing of high-quality production parts and prototypes.

Zeal Digital Manufacturing– Our extremely-skilled team of digital manufactures provides our clients with a wide range of rapid prototyping services in Perth, including but not limited to investment casting, blow moulding, injection moulding, and laser cutting services. We offer a far-reaching scope of fast prototyping and 3D printing administrations including stereolithography (SLA), particular laser sintering (SLS), Polyjet™, melded statement demonstrating (FDM) and direct metal laser sintering (DMLS) to help makers and planners create and assess new items rapidly, monetarily and with less hazard.

Zeal Injection Moulding– Using highly advanced machinery and a team of extremely talented professionals, our injection moulding service in Perth includes but isn’t limited to gears, enclosures, knobs, automobile parts, robot parts, and much more. We also provide our clients with a chance to upload their 2D or 3D file on our website for an instant quote on our injection molding service.

Additionally, we also offer our clients with services such as 3D modelling, .stl file format conversion, .stl file repair, as well as .stl file splitting (for large parts). Our printers are enabled to print three-dimensional objects from ABS plastic, available in various colours to suit your custom 3D printing requirements.

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Wide Range of Perth 3D Printing Service
Technologies used by Zeal for providing 3D Print Service in Perth

Modern Technologies Used by Zeal for Robust 3D Printing in Perth

FDM Technology

FDM or fused deposition modelling is a widely-used desktop 3d printing technology for producing plastic parts. It's ideal for quick and affordable functional testing and prototype building.

SLS Technology

SLS technology works with nylon-based powders in which the machine melts the particles to form a solid object. Parts made using SLS are durable and can be used to nest multiple components into a single build.

SLA Technology

SLA is a proficient 3d printing technology that is ideal for producing parts with intricate details and smooth surface finishing. It's a suitable technology for producing functional prototypes that offer tight tolerances.

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Polyjet 3D Printing

PolyJet is an advanced 3d printing technology that can fabricate components with multiple colours and other materials. It's an ideal technology for prototyping overmolded or elastomeric parts.

SLM Printing

Selective laser melting is a metal 3d printing technique in which the printer uses a powerful laser to melt and fuse metal powder and form complex shaped metal components.

DMLS Printing

DMLS is a 3d metal printing technology in which the machine spreads a thin layer of metal powder and sinters it to produce solid metallic objects.

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Where can you 3d print things in Perth?

Zeal is your one-stop-destination for professional 3d printing in Perth. We bring in a wide range of 3d printing technologies and along with 40+ materials available to print. Zeal, an ISO 9001-2015 certified company, assures you top-notch bespoke 3d printing to meet your every design goal with perfection and higher accuracy.

Whether you are looking for rapid prototyping or a small-batch production — Zeal has got you covered. Get an instant quote for your projects, and our experts are here to walk you without the best solutions available for your product manufacturing requirements. Your search for a 3d printing prototype service near me completes at Zeal.

3D Printed Part Service in Perth
Zeal 3D Printing Service Perth

Why choose Zeal for 3d printing Perth?

Zeal is an Australian ISO certified 3d printing company offering a comprehensive range of industrial services for years. 

Superior Quality

We have a team of highly-trained engineers and technicians that delivers supreme quality end products. We utilize the best 3d printing materials, including Nylon, ABS or PLA plastic, and more.

Wide Delivery

Zeal offers express and on-time delivery of end products at your doorsteps, so you don't have to wait for long. Boost your time to market with Zeal.

Transparent Pricing

No hidden costs make our pricing model entirely transparent and cost-optimized. We are among the leading preferred 3d printing companies in Perth.

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Affordable Service

With over 15 years of experience in the industry, we have developed a name for ourselves regarding quality, pricing, services, as well as timeliness. We have spent the better part of our existence in catering to various sectors and fulfilling their custom-engineered prototypes for short-run and full-scale commercial applications.

Contact us now to avail the best 3D printing service in Perth WA to scale your business and uplift product quality.

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Beginners Guide To 3D Printing

3D printing or additive manufacturing technologies have taken the world by storm. This kind of disruption was last seen during the advent of the Internet. 3d printing has gone beyond preparing decorative, and industries are leveraging this technology to simplify their long-haul traditional processes. Online 3d printing offers significant flexibility to businesses regardless of their industries to try and innovate new ideas. Be it creating a prototype or creative figurine, 3d print is a turnkey solution. Here is a beginner’s guide to how and why you should choose 3D printing services for your business today.

3d Printing STL Files

How to Prepare 3d Printing STL Files

3d printing technology is vast and anyone who wants to explore this technology needs to know the fundamentals. As there are many vital aspects of additive manufacturing, we will have a comprehensive look at 3D printing STL files and prepare them accurately. Whether you are a beginner at 3d printing or have already started reading more about it, these free beginners guide to 3D printing at Zeal3D will help you out. In this 3D printing free tutorial for beginners regarding the STL files, we will explore the essential aspects of the STL file format and its best practices. Whether you are starting out 3D printing or already doing it for a while, this guide will help you.

Ultimate FDM 3D Printing Material Guide

The term FDM stands for Fused Deposition Modelling. In this process, the filament material is deposited in regular and predefined layers through a built nozzle that mainly melts during the extrusion process. This technology is one of the most prevalent 3D printing technologies that are excellent for basic at-home printers and professional systems used by high-tech manufacturing companies. But choosing the right type of printing materials is becoming increasingly challenging due to the availability of so many different variations. Hence, a comprehensive free FDM 3d printing material guide will explain every nitty-gritty detail about FDM printing technology seamlessly. Let's dive deep into it.

FDM part
SLS 3D Printing

Ultimate SLS 3D Printing Guide For Beginners

3d printing technology is booming across all industries, and companies are upgrading their manufacturing process. As Industry 4.0 is on the verge of transformation, more small and mid-sized companies integrate high-performance additive manufacturing services.There are multiple 3d printing technologies available to accomplish different manufacturing needs, and SLS 3d printing is among them. SLS has been a preferred choice among engineers as it offers low-cost prototyping and manufacturing. It's an ideal choice for quick small-batch production.In this SLS 3d printing guide, we will have an overview of its working, workflow, variety of materials, and SLS 3d printing applications.

ULTIMATE STEREOLITHOGRAPHY (SLA) 3D PRINTING GUIDE

Stereolithography (SLA) has become a widely-employed additive manufacturing process. With its unique ability to produce isotropic, lightweight, and higher-accuracy products, several industries use it. In addition, this method supports a wide range of materials to deliver a smooth surface finish. On this note, this SLA printing guide will help you understand this process better.

SLA Printing
CNC Machining Metal Parts

CNC MACHINING - A COMPREHENSIVE GUIDE FOR BEGINNERS

Regarding advanced manufacturing methods, CNC machining tops the list, offering a wide range of applications. Be it prototyping or mass manufacturing, this technique provides robust performance and scalability to manufacturers. This comprehensive CNC guide will walk you through all the essential elements if you're new to CNC machining.

Metal 3D Printing Beginners Guide

Metal 3d printing is the next paradigm shift that is transforming manufacturing across multiple industries. This advancement offers several benefits that allow 3d printing companies to build high-performance products at a lower price. Be it automotive, manufacturing, or construction; metal additive manufacturing offers a wide range of applications.The flexibility of creating complex geometries without compromising quality speeds up the turnaround time. Lately, drastic progress has been made in this technology and 3d printers that have made it more practical and robust. In this guide, let's explore metal 3d printing technology in detail.

Metal 3d Printing Technologies Australia

What Our Customers Say...

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Perth:

1260 Hay St, West Perth WA 6005,

Visit By Appointment Only

Email: info@zeal3dprinting.com.au

Contact No: +61 1300 719 729

We are available here also: Melbourne, Brisbane, Sydney, Tasmania, New Zealand, Canberra

Help Guide

In 3D printing or additive manufacturing, a three-dimensional object is made from a digital CAD file where materials are added in successive layers until the object is created. 3D printing is becoming popular widely due its ability to produce complex shapes, compatibility with a range of materials to produce high-volume products for different industries. Examples could be toys, footwear, eyewear, furniture, movie props, prosthetics, dental products, making replicas of ancient artefacts, etc.

The different types of 3D printing technology are:

  • Stereolithography (SLA)

  • fused deposition modeling (FDM)

  • selective laser sintering (SLS)

   • digital light processing (DLP)

    • multijet fusion (MJF)

    • Polyjet

    • Direct metal laser sintering (DMLS)

     • Electron beam melting (EBM)

For evaluating the online 3D print options, it is always a good idea to consider the factors like budget, mechanical requirements, material, complexity of geometry and cosmetic appearance.

First, the object is designed in a 3D model using CAD. CAD software helps in designing even the intricate, tiniest details with precision and accuracy.

Second, the model is sliced into layers, and the slicing software scans each layer of the model and tells the printer how to move to recreate that layer.

The process of 3D printing involves three steps:

    • 3D modeling software: The object is designed with intricate details in the 3D model using CAD software. The software has the ability to allow for the tiniest, and precision designs. The CAD file is then converted into STL format.
    • Slicing the model: Next, the model is sliced into hundreds or thousands of layers with a slicing software and sent off to the 3D printer via USB, WiFi or SD.
    • Final process: In a 3D printer, a nozzle moves back and forth while dispensing the material layer-by-layer waiting for a layer to dry before adding the next.

3D printers are extremely flexible, accurate and fast to print rigid materials, and even strong industrial products.

Rapid prototyping and rapid manufacturing are often confused with each other. But both are different.

In engineering and manufacturing context, prototypes are a preliminary version or model of a product. Prototypes are made before the mass production to evaluate the designs, and test the working principle. As the name suggests, rapid prototyping is the process of creating prototypes quickly to evaluate the product for design and functionality. Based on the degree of accuracy or fidelity, prototypes are classified into high fidelity and low fidelity. 

Rapid manufacturing encompasses different methods of manufacturing to produce parts quickly. Unlike rapid prototyping, rapid manufacturing is not used to produce models but the final end products. With methods like selective laser sintering, stereolithography, laser melting, rapid tooling, etc. 3D objects are created from CAD files. This method is popularly called direct digital manufacturing.

Some of the benefits of 3D printing are:

Lesser environmental impact: 3D printing needs only a few parts to be outsourced bringing in less of transportation; it generates minimal wastage that can be recycled; and there is no need to maintain an energy-consuming factory.

Cost: In contrast to traditional manufacturing that requires expensive equipment, skilled technicians and operators causing huge labour costs, 3D printing is very much economical. There is no need for additional tooling too. 

Strong and lightweight parts: The best 3D applications lie in its ability to produce lightweight, strong and sturdy parts especially for aerospace and automotive industries for fuel efficiency.

Complex designs: With 3D printing, manufacturers and designers get better design freedom to design and print complex, intricate geometries with no restrictions and limitations.

These days many industries such as aircraft, construction, mechanical engineering, jewelry, healthcare, children franchises, dentistry, education, robotics, fashion, and much more.

There are several 3D printing technologies such as:

       • Stereolithography (SLA)

      • Digital Light Processing (DLP)

      • Fused Deposition Modeling (FDM) or Fused Filament Fabrication (FFF)

      • Selective Laser Sintering (SLS)

       • Electronic Beam Melting (EBM)

       • Laminated Object Manufacturing (LOM)

       • Selective Laser Melting (SLM)

        • Material Jetting (MJ)

        • Sand Binder Jetting

         • Metal Binder Jetting

          • Digital Metal Laser Sintering (DMLS)

           • Continuous Liquid Interface Production

The 3D printing process differs for each one of these additive manufacturing technologies.

Of all the 3D printing materials, plastic is the most widely used one. However, 3D printing is compatible with a range of materials like nylon, resin, gold, powdered materials like polyamide, alumide, bronze, gold, nickel, stainless steel, titanium, carbon fiber, graphene, graphite, paper, high impact polystyrene, polycarbonate, PVA, nitinol, and more.

Stereolithography is based on vat photopolymerization or commonly referred to resin 3D printing. In this process, SLA 3D printers print 3D objects using a light source, that is  a laser or projector to cure the liquid resin into solidified plastic.  

The benefits of SLA 3D printing are:

     • SLA parts have high accuracy and intricate details

     • Smooth finish surface

    • High resolution and accuracy and more versatility

    • SLA materials are clear, flexible and castable

SLA applications: visual prototypes, rapid tooling molds, casting patterns, ergonomics tests, marketing validation, visual tests, and more.

SLS is a powder based 3D printing technology  in which a high-powered laser sinters the particles of polymer powder into a 3D object.

Because of its high design freedom, accuracy and the ability to produce durable SLS parts that have excellent tensile strength and isotropic mechanical properties. This technique is used in jigs and fixtures, injection mold inserts, foundry patterns, investment casting patterns, electronics, military hardware, homeland security, and much more.

The SLS process has a variety of material options like nylon, glass-filled nylon, aluminium-filled, impact-resistant nylon and more. The finishing options are also more like bead blasting, painting, CA Dip Coated, and more.

Fused Deposition Modeling or Fused Filament Fabrication is a popular 3D printing technology. Here, the material, that is, a spool of thermoplastic filament is loaded into the printer, and fed to the nozzle and gets melted at the right temperature. The melted material is then extruded in thin layers to get cooled and solidified. 

The two most common materials of this plastic 3D printing are PLA and ABS which are known to have good strength, visual quality, temperature resistance and are easy to print with. However,  other materials like TPU, PEI, PETG, are also used in FDM 3D printing. FDM is cost effective with shorter lead times.

Similar to inkjet printers, PolyJet 3D printers work by jetting thousands of liquid photopolymer droplets onto a build platform. These droplets are then solidified with UV light to create objects. It is one of the fastest and accurate technologies capable of producing highly detailed parts in just hours.

One of the best features of PolyJet is that it can be printed with multiple materials making the product more diverse, colourful and aesthetic.

Metal 3D printing works on a metal powder bed in which high-powered laser beams bind the particles on the powder bed and the 3D printer distributes even layers of the powder to make the object. The metal 3D printers fall into categories of powder bed fusion, binder jetting, direct energy deposition, and material extrusion.

The best reasons to choose metal 3D printing could be:

  • It is easy to produce ultra complex 3D metal parts and cavities with strong and robust finish

  • Capable of customizing or modifying designs

  • The lightweight and complex designs make it suitable to several applications

The most common types of metal 3D printing are:

• Powder Bed Fusion

• Selective Laser Melting (SLM)

• Electron Beam Melting (EBM),

• Direct Energy Deposition or also called Laser Material Deposition,

• Electron Beam Additive Manufacturing,

• Binder Jetting,

• Bound Powder Extrusion

The opportunities that lie for 3D metal printing are high. Some their applications are listed here:

       • Making functional metal prototypes for easy design and functionality tests and changes

       • Complex bracketry

        • End-of-arm tooling

        • End use parts for low volume production

         • High-security cylinder locks and keys

          • Bone implants

Materials used in metal 3D printing are:

     • Stainless steel

      • Cobalt

      • Aluminium

       • Titanium

       • Iconel 625

Each of these 3D printing materials have their own characteristics like chemical-resistant, strength, corrosion-resistant, temperature-resistant, mechanical properties, dynamic properties and more.

Metal 3D printing technology uses powder bed technology where the laser pulses heat up the powder creating solid 3D objects. The process is also called Direct Metal Laser Sintering or Selective Laser Melting (SLM).

 Metal 3D printing consists of technologies like powder bed fusion, laser cladding, direct energy deposition (DED), wire DED, powder DED, and metal binder jetting and bound powder extrusion.

Selective Laser Melting is the best 3D printing technology for manufacturers who are looking to get near net shape parts with relative density up to 99.9%. In this manufacturing technique, high-powered laser beams melt and fuse metallic powder in additive layers to produce the part. Once the SLM parts are removed from the build plate and the supports are removed, the surface finish might be rough. Some post-processing work may also be needed based on the requirements to get that fine tolerance and features.

Direct Metal Laser Sintering is popular to print rapid prototypes quickly. In this method, an object is made using a laser that sinters each layer of the metallic powder. First, a CAD model is created and sliced. Once the model is sent to the printer, the printer is filled with the particular metal powder and heated to the desired temperature. Next, very thin layers of metal powder are dispensed which the laser then sinters into solid forms. The process repeats until the final end product is made.

DMLS is suitable for mass production of accurate, quality parts and complex geometries and shorter manufacturing times.

Direct Energy Deposition is generally used for repairing or adding more material to existing components. Here, material in wire or powdered form  is melted and deposited onto the surface in layers through a nozzle. The melted material is then solidified. The materials which are usually metals and ceramics are melted with a laser or electron beam or plasma arc.

This additive manufacturing technology is called by different names like directed light fabrication, 3D laser cladding, laser deposition welding, rapid plasma deposition, and more.

Highly popular for printing sand molds and casts patterns, Binder Jetting (BJ) is one of the fastest manufacturing techniques. With BJ, manufacturers can get quick, affordable, complex, and accurate geometries. An object is made by depositing a liquid binding agent or binder into the powder bed, bonding the particles to form a solid one layer at a time. The commonly used materials are sand, metal or ceramics.

Due to its ability to produce coloured 3D parts, binder jetting is used to print 3D figurines, topographical maps, etc.

In its simplest terms, metal casting is a process of pouring hot liquid metal into a mold that has a cavity of the desired geometrical shape. The end product is achieved by removing it once the metal is cooled and solidified.

Additive manufacturing and subtractive manufacturing could be said as a complementary technology for metal casting as 3D printing is ideal for low-volume casting jobs, facilitating greater design freedom.

Think of animation, graphics, video games, architecture, illustration, advertising, and other creative careers. The primar, integral element of all these are 3D models. A 3D model is a three-dimensional representation of any object created using CAD software or 3D scanning.

To upload a 3D model design for 3D printing:

   • Convert 3D file into STL format

    • Slice the model with any slicing software

    • Use your 3D printer

Another best alternative would be to choose an online professional 3D printing service depending on your need and budget.

The acronym STL stands for STereoLithography or Standard Tessellation Language. Any product before going for 3D print must be designed in CAD and converted into STL format. sTL describes the surface geometry of a 3D object and uses a series of triangles to reproduce the surface geometry of the model.

As the name suggests, in multi-jet modelling (MJM) the material thermoplastics are jetted as drops and polymerized by UV light with the help of a print head and several nozzles. Thermoplastics are more like a wax with a resolution of 300 dpi. The model is created in layers directly from the 3D CAD file.

MJM 3D printing produces excellent surface quality with short production times, no geometrical restrictions and with high resolution and fine details. 

Polylactic acid commonly called PLA plastic or bioplastic is obtained from renewable sources like cornstarch and sugarcane. It is highly cost-efficient and makes it one of the best choices of material for fusion deposition modelling 3D printing. PLA plastic comes in different colors, shades and styles making it ideal for several applications. 

Plastic Injection molding or injection molding  is used in producing high volume plastic parts. In this method, a molded product is formed by injected melted material pellets into a mould where the liquid is cooled and solidified.

Benefits of  injection molding are:

 • Low scrap rates: Unlike CNC machining and other traditional manufacturing processes, the 3D printing technique generates less waste making it more economical.

• Suitable for high volume: As the second part is going to be identical to the first one there is no way of missing out on consistency even if there are more than a thousand parts at a time.

 • Material choice: Multiple plastic materials could be used simultaneously.

 • No need of skilled technicians: the entire process is automated reducing any labour costs

The injection molding process undergoes three stages: Product Design, Mold Design and the final Manufacturing process. Let’s break them down into small steps.

    • The product is designed by a skilled professionals with CAD software

   • Once the design is tested, the mold is designed with either hardened steel, aluminium or copper alloy.

   • In the final stage, thermostat or thermoplastic material in pellet form is fed into a heating barrel where it is heated to a predetermined temperature. The molten material is then injected into the mold quickly

   • Once it cools and solidifies into the desired shape, the part is ejected from the mold.

Plastic injection molding PLC machine is used to produce plastic parts through injection molding method. It is categorized into: hydraulic injection molding, electric injection molding and hybrid injection molding.

 • Hydraulic Injection Molding: It is easier to operate and has excellent clamping force. With better injection rates, this holds good for valve gates, ejectors, thick walled parts, etc. .

 • Electric Injection Molding: These machines have less down time and energy efficiency. The production is faster without any  supervision required.

 • Hybrid Injection Molding: It is flexible with lesser downtimes, combining the superior camping force of hydraulic machines with precision and repeatability and the reduced noise of electric machines, the hybrid model is highly energy efficient.

CNC (Computer Numerical Control) machining is a subtractive manufacturing process in which a product is created by removing material layers from the workpiece with the help of software. CNC makes it an ideal choice for low to medium volume production for materials like glass, foam, plastic, composites, etc.

There are three different types of CNC machining operations:

 • CNC drilling: Drilling is the act of making holes in unbroken surfaces with a hand drill machine. CNC drilling is done on CNC milling machines and lathes.

 • CNC milling: Milling is the process of machining using cutters to shape a workpiece, usually metal or wood. In the CNC milling process, computerized controls to operate and manipulate machine tools.

   • CNC turning: Turning is a subtractive process. CNC turning is a manufacturing process in which material bars are held in a chuck and rotated while a tool is fed to the piece to remove material to create the shape.

CNC machining is used to manufacture many products like signage, musical instruments, cabinets and furniture, aluminium and brass machining, computers, motherboards, firearms, engraving systems, and more. It is used by both industries and home hobbyists. CNC services are hugely popular due to the technology’s efficiency, versatility and precision.

As stated above, CNC can produce parts with utmost accuracy and precision, faster, efficient and contributes to cost savings. 

       • Cost effective: there is less skilled workforce training for operation and lesser number of mistakes in the end product

       • Productivity: CNC machines need no out-of-hours, hugely increasing the production.

       • Safety: Unlike conventional manufacturing, there are no machining errors like jams.

Vacuum casting or thermoforming is a casting method for elastomers polymers that use vacuum to draw liquid material into the mold. With this reproduction technology, it is easy to produce flexible, rigid parts that are of different textures and colours.

Following are the steps involved in vacuum casting process:

• First, a master model is created by stereolithography or laser sintering. Next, a two part silicone rubber mold is made and the master model is fixed in it. The mold is then cured under high temperatures for durability.

• Once the mold is cured, there would be a cavity at the centre with the same dimensions as the master mold.

• Next, the mold is filled with the material and placed in the vacuum chamber to remove air bubbles. The mold is cured and removed to make further copies or replicas.

Vacuum casting machine uses a vacuum to suck the molten metal into the silicone mold. A steady, constant pressure, force is needed to overcome the surface tension of the molten metal else the metal would blob. The tool is then placed inside the vacuum casting chamber and when it is at the right temperature, the resin is poured through a funnel into the tool. Once the part is cured and cooled, the tool is separated and part is removed.

The uses of VC (Vacuum casting) are aplenty. To name a few:

       • Product marketing

       • Medical devices

       • Plastic prototypes

        • Home decor items

        • Concept models

The most common materials compatible with vacuum casting are:

      • Polypropylene (PP): widely used and easy to mold

      • ABS: suitable for low cost production

      • Wax: easy to form in any forms or shapes

      • Polycarbonate: known for high impact resistance

      • Glass-filled materials: increase rigidity and structural strength

       • Rubber: tough with good tear strength

A host of benefits using vacuum casting are that there is a good choice of material selection with mechanical performance, there is not much post processing work required, it is a flexible method for high-quality prototypes and master patterns can be tweaked with no special tooling.

Vacuum casting is employed in several industries. For example, lenses for automotive and aerospace industries, household products, housings and casing for consumer white goods, IOT products, flexible medical parts, enclosures, and more.

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