March 23, 2004 — With the introduction of DSM Somos 9120 ProtoFunctional®
resin to its production line, Malcolm Nicholls Ltd (MNL) has been able to cut
prototype build times of Panasonic’s new X70 camera phone by one third.
The decision of Panasonic to specify Somos 9120 for the X70 camera phone
prototypes was based heavily on the need for part flexibility. The clam shell
for the phone assembly utilised snap fittings and, since functional testing
was required, these would need to reliably withstand repeated clipping and
unclipping.
Richard Haines, Design Engineer for Panasonic Mobile Development
Communications of Europe Ltd (PCMDE) explained, “We needed the prototypes for
trial assembly to carry out over packing detection, and to test fit mock up
PCBs. In addition, we used them to carry out RF testing to ensure that the
case and the components functioned correctly. These trials required us to open
up each clam shell several times, thoroughly testing the integrity of the clip
fastening.”
To meet the delivery requirements of Panasonic, MNL built multiple masters
simultaneously in 9120 to be used directly for evaluation. They were pleased
with the results.
“Some resins we have worked with are very brittle and have caused serious
problems for the workshop,” says MNL Technical Director Ross Nicholls. “The
simple act of removing supports from a model could result in its damage, which
would then require repair or actual rebuilding of the SL master.”
“With Somos 9120, part breakage has been virtually eliminated, and in addition
we have achieved around 30% reduction in build times on our SL machine through
faster resin reaction times, combined with zero pre-dip delay and zero Z-wait
periods. Furthermore, we have found that 9120 is very process tolerant, so,
for example, we can increase hatch spacing and simplify support positioning
without reducing model quality.”
For multiples of parts, MNL uses the SL master to create a silicone mould.
Ross Nicholls sees further benefits from the properties of Somos 9120: “We
find that, depending on the shape of the model, it is possible to reuse the
master to create additional moulds. The brittle resin we used in the past
would result in the master shattering during demoulding. Furthermore, we find
that 9120 does not distort during the curing process required for silicone
moulds, which can reach temperatures of 60ºC.”
MNL was the first rapid prototyping service bureau in Europe to specify Somos
9100 for all its SL models, after positive trials of the material in 2000. A
natural transition to Somos 9120 coincided with the upgrade of the laser on
its SLA® 500/40 machine from argon ion to solid state in 2002
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