Choc Factory Stratasys part
3D printed replacement machinery parts manufactured on-demand in under a week using Stratasys’ Fortus 450mc Production 3D Printer, compared to over a month using traditional methods.
A Dutch chocolate factory is replacing metal machine parts with FDM-manufactured carbon-filled thermoplastic alternatives, thanks to Visual First, a 3D printing service bureau also operating in the Netherlands.
The bureau harnessed the Stratasys Fortus 450mc Production system to produce the parts in FDM Nylon 12CF composite material. Staff from The Chocolate Factory are said to be impressed with the high stiffness-to-weight ratio of the FDM Nylon 12CF and the subsequent rigidity of the parts. They are also enjoying the ability to 3D print replacement parts for their machinery on-demand, resulting in reduced machine downtime.
Based in Rotterdam, The Chocolate Factory runs a network of packaging machines, with the company’s daily throughput relying on the smooth operation of a hook-shaped metal part that lifts wrapped bars onto a conveyor belt. This part malfunctions with regularity, needing to be replaced around three times a month. Traditionally each part is handmade, and delivery can take up to a month. Fortunately, Visual First are operating in a world of pure imagination.
“It is crucial that the packaging machine is always operational, especially during hectic periods such as Christmas,” explains Carl van de Rijzen, Business Owner at Visual First. “With Stratasys additive manufacturing, we can produce customised replacement parts on-demand that can perform just as effectively as the metal machine parts. We can 3D print and deliver production parts to The Chocolate Factory in under a week, which is vital to ensuring manufacturing line continuity.
“The success of the 3D printed part was instantly clear – the material is impossible to bend. The part withstood all tests on the machine and multiple runs were completed without incident. The factory is now enjoying increased production throughput by replacing the metal machine part with our 3D printed version.”
By selecting 3D printing as the manufacturing method, The Chocolate Factory has taken delivery of parts with an optimised design and significant weight reduction. The team has also reported a 60% decrease in cost per part. Thus, The Chocolate Factory is now highlighting other design challenges for Visual First to solve. First up, is a prototype casting mould to test acceptance of its products. The hope is for this 3D printed application to help accelerate production processes.
“We’re witnessing a growing demand for 3D printed production parts and replacement parts for industrial machinery, especially for packaging machines,” assessed Nadav Sella, Head of Stratasys’ Emerging Solutions Business Unit. “These machines require a high-level of customisation due to the large variety of products that are packaged. In many cases, the use of additive manufacturing can not only save time and cost during the manufacture of such machinery, it can also make them more efficient by reducing weight, simplifying the design and increasing functionality.”
