Cincinnati, OHIO --- Morris Technologies, Inc. (MTI), a service bureau
providing product development, rapid prototyping, advanced 3D CAD solid
modeling and engineering services, reports that newly available DSM Somos
10120 WaterClear™ prototyping resin has enabled MTI to make significant
strides in providing multiple benefits to a client that is a world-leading
manufacturer of Fire and Health Self Contained Breathing Apparatus (SCBA’s).
Somos 10120 WaterClear™ is a unique new composite of many desirable
engineering properties mimicking the flexural strength and modulus of
polycarbonate, the notched izod impact strength of Nylon 66 and the tensile
strength of ABS. Ideal applications for this epoxy-based photopolymer include:
flow visualization, complex assembly analysis, form/fit analysis and
functional testing.
According to Bill Noack, president of MTI, “Somos 10120 WaterClear™ provides
optical clarity that allowed our client to test their product design earlier
than used to be possible. The result was a time savings of many valuable weeks
in getting the product to production tooling and making it a more functional
product due to an enhanced ability to modify the design. We found Somos 10120
WaterClear™ to be robust enough to perform select functional testing and
excellent for handling of components that require form/fit applications.
Additionally, for certain applications, not only have early prototypes been
used to test product, but that same part is then used in the production of RTV
Tooling for urethane reproductions. This has resulted in a large cost-savings
to our clients and reduced lead times.”
MTI’s client manufacturers all components that go into a complete SCBA
including the regulators, pack frame, face shield and fitting components
around the face. These products are, literally, the lifeline for those who
wear them...ranging from industrial uses such as cleaning the inside of
storage tanks to fire fighting...basically any environment where atmospheric
conditions are inhospitable to a human.
Because the environments in which SCBA’s are worn are so potentially harsh,
testing standards for these units are extensive and rigorous. The single-most
important attribute is that of product reliability. Unlike other products, if
a SCBA fails at the wrong time the consequences have the possibility of being
tragic. In addition, it is imperative that the fit be very comfortable due to
the fact that the user will often be wearing the SCBA for an extended period
of time.
Understandably, a tremendous amount of testing is involved in designing and
prototyping new units. Prior to six years ago, many SCBA components would be
hand made and then fitted to a human model, adjustments made and the process
repeated. That was a time-consuming process with significant margin for
errors.
In the past 5-6 years, with the great advancements in CAD, this ‘hand’ process
has been eliminated by the precision of CAD models and highly accurate rapid
prototypes. Now, the process has been accelerated and many more iterations of
the design can be produced prior to committing to production tooling. This
ability to modify designs has lead to greater reliability and more
experimentation of the designs in order to overcome any potential problems.
MTI’s ability to simulate the production parts in their appearance and their
durometers has also meant near real-life testing of the SCBA’s.
Until recently, however, there remained the challenge of finding a prototyping
resin that could meet the many demands of the testing process. Resins were
available to create molding masters that would, in turn, be used in the
production of clear urethanes for the face shield and also mold masters for
the creation of the face masks and nose cups that are a lower durometer
urethane. This led to masters of acceptable dimensional stability providing
stiffness that was adequate to finishing to a high level, thereby achieving
production-looking urethane reproductions.
The drawback was the time factor involved. Low-durometer components usually
are built around the face shield, and to accurately test the face shield it is
necessary to have a clear material. Making clear urethanes is, under the best
of circumstances from start-to-finish, a 1-1/2 to 2 week process involving
building an SL master, finishing it to a high level of polish, creating an RTV
Tool and then shooting a clear urethane material. Only after the first article
has been produced, can other testing begin.
The release of DSM Somos 10120 WaterClear™ resin has significantly reduced the
time constraints of this process. It is now possible to produce a highly
accurate, yet clear part, in approximately the same time required to finish an
RTV master. MTI was are able to finish WaterClear™ parts to an optically clear
end-result. Consequently, MTI’s SCBA-manufacturing client now has the ability
to produce an SL part, test it for form/fit and then decide if additional
parts are required or if changes to the files need to be made. Using Somos
10120 WaterClear™ in this particular application has allowed near-production
testing of the unit and this in turn has generated more accurate feedback from
the individuals who wear the mocked-up masks.
Moreover, the advantages of this resin go beyond optical clarity. MTI has
found Somos 10120 WaterClear™ to be a strong, robust resin able to withstand
moderate flexing and functional testing. This is advantageous for its ability
to work in applications where a part might be functionally tested or handled
frequently.
MTI has determined that Somos 10120 WaterClear™ also works very well as mold
masters for RTV Tooling. This has meant that not only can MTI use a particular
part for form/fit and limited functional testing, but can then use that same
part as a mold master once it has been returned from the client.
FOR ADDITIONAL INFORMATION ABOUT MORRIS TECHNOLOGIES:
Morris Technologies utilizes the most advanced technologies available to aid
in accelerating the product development cycle. MTI’s rapid prototyping and
rapid tooling services include Stereolithography, Laminated Object
Manufacturing, High Speed CNC Machining, Urethane Reproductions, Rapid Metal
Castings and Rapid Plastic Injection Molding.
For further information on Morris Technologies:
Bill Noack <
bnoack@morristech.com>
Tel: 513-733-1611
www.morristech.com
FOR ADDITIONAL INFORMATION ABOUT DSM SOMOS:
DSM Somos is the leading materials supplier for the rapid prototyping
industry. Located in New Castle, DE, DSM Somos has developed a full line of
ProtoFunctional materials that replicate the performance parameters of
production materials, saving both time and money in new product development.
DSM Somos is part of DSM Desotech, a leading innovative formulator and
manufacturer of high quality ultraviolet and electron beam (UV/EB) curable
materials. DSM is a highly integrated group of companies with worldwide
interests in life-science products, performance materials and chemicals. DSM
recorded sales of EUR 6.3 billion last year and employs a total workforce of
some 22,000, distributed in more than 200 operations throughout the world.
For further information on DSM Somos:
Melisa Lasell <
Europe@dsmsomos.info>
DSM Somos External Affairs Europe
Via
della Stazione 7F
00042 Anzio (Roma), Italy
Tel. ++39.06.986.5179
Cell. ++39.339.526.3828
www.dsmsomos.com
PHOTO CAPTION:
Caption for Photo #1
It is imperative that the SCBA face shield be very
comfortable due to the fact that the user will most likely be wearing the SCBA
for an extended period of time.
Caption for Photo #2
A production SCBA face shield, shown here prototyped
out of Somos 10120, will be worn by firemen in hazardous atmospheric
conditions.
