SK Industriemodell Provides Spare Parts on Demand with xMOLD 3D Printed Tooling
SK Industriemodell (SKI) is a fully integrated provider of development and manufacturing services to customers in the automotive, medical device and other demanding industries, with almost a decade of experience with the use of 3D printed injection molds. Boasting a fully-fledged tool shop, and with extensive experience in lead-time compression, they provide product development support as well as manufacturing services to a large number of companies in northern Europe.
SKI decided to implement Nexa3D Freeform Injection Molding to offer shorter lead-times on complex injection molded parts in challenging materials. At the same time, SK Industriemodell saw an attractive opportunity in supplying injection-molded parts in quantities that would normally be too low for conventional injection molding due to the costs of tooling. Spare parts on demand is one of the most interesting applications for this kind of manufacturing models, and one that is well suited to the unique design freedom and selection of materials offered by Freeform Injection Molding.
Challenge
Complex fan wheel for high-temperature application needed in low volumes
Vespa, an Italian luxury brand of scooters and mopeds manufactured by Piaggio, has gained a very large following, and some of their vintage models are in high demand because of their bold designs and the unique driving experience. However, wear and tear eventually result in the need for parts to be replaced, and owners sometimes struggle to find qualified spare parts.
One of the more challenging parts is the air fan that rams air into the Vespa engine compartment to cool the engine. This fan runs at high speeds while being exposed to temperatures up to 80 degrees C as well as salt spray, dust and a number of other stress factors resulting from the outdoor use.
In the spring of 2024, SK Industriemodell was approached by members of a local Vespa community looking for ways to source spare parts for Vespa vintage models. First among the sought-after parts was the air fan, and the community had evaluated a range of low-volume manufacturing alternatives without finding a solution that would offer the desired combination of cost, performance and quality.
“Freeform Injection Molding has enabled us to expand the use of injection molding into low-volume applications normally reserved for milling and 3D printing while still offering the quality, versatility and scalability known from injection molding.”
– Sebastian Krell, CEO, SK Industriemodell
Customer
Vespa Vintage Community
Industry
Personal Transport
Products
- XiP Desktop 3D Printer
- xMOLD 3D printed tooling resin
Application
Spare Parts Manufacturing
Advantages
- Validated high-performance materials readily available
- Part quality on a level with conventional injection molding, without investments in molds
- No minimum order quantities – injection molding on demand enabled
- Lighter weights, lower costs achievable by use of polymers instead of metals
Solution
Freeform Injection Molding Enables 3-Piece Batches in Field-Validated Material
SK Industriemodell is an experienced supplier to the automotive industry, where high heat tolerance is important for engine compartment parts. PA6 GF30, a glass-filled nylon, is one of the industry gold standards for these applications, and SKI decided for this particular polymer to provide the needed combination of strength, heat resistance and durability. Freeform Injection Molding was selected as the manufacturing method, due to the complex design of the air fan and the customer’s need for on-demand injection molding of small batches. Printing of molds was done on the Nexa3D XiP desktop 3D printer, with the xMOLD soluble tooling resin providing the needed design freedom. And first injection-molded parts were provided to the customer less than two weeks after receipt of the first order.
Benefit
Complex spare parts injection-molded on demand in validated material
With Freeform Injection Molding, SK Industriemodell was able to supply spare parts on demand, in a quality that met demands for high heat tolerance and durability, at an acceptable cost level.
No Minimum Order Quantities
Freeform Injection Molding is ideal for low-volume injection molding due to a unique combination of simplicity, versatility and easy run-in. The first batch of 3 parts was produced with 5 shots, including the two shots needed to dial in the parameters for the first round of molding. And once parameters have been dialed in, subsequent productions will require no run-in of molds or parameters
Design Freedom
The soluble xMOLD tooling resin used in the Freeform Injection Molding process enables the injection molder to sidestep the cores, sliders and other mold action normally required for the molding of complex parts, and which drive up the cost, complexity and lead time on conventional injection molds.
Versatility
Another key benefit of solubility is that even materials that will normally tend to adhere to the mold surface can be easily demolded. xMOLD soluble tools have been successfully used in the injection molding of the entire range of thermoplastics, as well as metals, ceramics, silicones and a number of other thermoset materials.
Precision
Freeform Injection Molding exploits the precision and high surface qualities available from resin printing, combined with the repeatability and process control from injection molding. This combination resulted in the air fans being usable straight out of the tool, with no post-processing needed before assembly into the engine.
Customer Impact
Supply of injection-molded spare parts on demand enabled
The supply of spare parts is one of the most challenging fields in the manufacturing industry. Suppliers will either have to warehouse large numbers of parts to ensure availability, or alternatively develop on-demand manufacturing solutions where such solutions are able to comply with part performance and other requirements.
SK Industriemodell was able to leverage Freeform Injection Molding to produce spare parts in a heat-resistant engineering polymer that has an established track record in similar applications. The parts produced met performance and quality requirements, and enabled SKI to start supplying cost-competitive air fans to a large base of dedicated customers.
At the same time, SK Industriemodell has demonstrated how xMOLD 3D printed molds allow injection molders to leverage injection molding for the manufacturing of complex items in ultra-low volumes that would normally be entirely outside the domain of injection molding. This has enabled SKI to expand the range of injection molding services offered into the domain of spare parts on demand, a very significant business opportunity for the company.
Download the Design Guide for 3D Printed Tooling
Comprehensive set of design guidelines for Freeform Injection Molding
