Radford Motors: custom car manufacturing with 3D printing

Radford Motors: custom car manufacturing with 3D printing

Author : Varinex Date : 2024-08-15
Radford Motors: custom car manufacturing with 3D printing

Radford Motors: custom car manufacturing with 3D printing

Radford Motors produces small-batch, highly customized, one-of-a-kind cars. Additive manufacturing is part of the company's recipe for success – its flexibility, special materials, and tool-free manufacturing capabilities.

Radford Motors builds exclusive luxury cars with a focus on high-end craftsmanship, limited edition production, customization and performance. The company's history dates back to the original Radford Motors, a British coachbuilder founded in 1948, which built custom bodies for car manufacturers such as Bentley, Aston Martin and Austin Mini Cooper.

Challenge: small-batch, cost-effective production

Radford Motors’ first model series, consisting of just 62 units, did not allow for traditional manufacturing methods that rely on the economics of mass production. A faster and more cost-effective means of prototyping was needed than the traditional method of CNC machining foam and clay. Installing a full factory tooling kit would have involved costs and logistics that were not feasible for this highly customized, limited-run business model.

Solution: additive manufacturing

To create and produce the prototype of the Radford Lotus Type 62-2 production vehicle, the company relied on additive manufacturing, which allows for a flexible development and manufacturing process. Radford uses large-format Stratasys F770™ and Stratasys F900™ printers, which offer a spacious build volume. Thermoplastics such as carbon fiber ABS-CF10  and ASA offer the right strength-to-weight properties for tooling and production line parts.

Result: economically viable business

The combination of Stratasys 3D printing capabilities and strong, yet lightweight materials allows Radford Motors to design, iterate and build custom vehicle tools and components much faster and more economically than traditional manufacturing methods. The capabilities offered by additive manufacturing help make Radford Motors’ business model of building small, highly customized vehicles economically viable.

Radford Motors: custom car manufacturing with 3D printing
The 3D printed dashboard is covered with leather before installation.
Radford Motors: custom car manufacturing with 3D printing
ASA heating/cooling duct end-use component ready for installation under the dashboard.
Radford Motors: custom car manufacturing with 3D printing
Prototype of wheel rims made of black ASA material in the 3D printer.
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Stratasys F370CR composite 3D printer at Weber State University

Weber State University Expands Education with Stratasys F370CR Composite 3D Printer

Author : Varinex Date : 2024-02-21
Weber State University Expands 3D Printing Education with Stratasys F370®CR Composite Printer

Weber State University Expands 3D Printing Education with Stratasys F370CR Composite Printer

Weber State University's Advanced Research and Solutions Center serves as an innovation and collaboration hub for local industry, primarily in the aerospace, defense, and advanced materials industries. The institution offers students educational and hands-on opportunities, as well as access to a variety of research and development resources, including additive manufacturing.

The challenge

To give students and local industry the best chance of success, the university must provide access to current and emerging technologies, including additive manufacturing. However, Weber State University had older 3D printersthat were slow and expensive, and offered a limited selection of materials. This situation limited the university’s Advanced Research and Solutions Center from meeting the needs of students and industry.

The solution: composite 3D printing

To strengthen its 3D printing capabilities, the university has added a Stratasys F370®CR composite 3D printer to its line of manufacturing equipment.

The F370CR is capable of using two composite materials and a variety of other engineering thermoplastics. Composite 3D printing materials include FDM® Nylon-CF10 and ABS-CF10, which contain 10% shredded carbon fiber for increased strength and stiffness.

Composite 3D Printing at Weber State University

With the Stratasys F370CR composite 3D printer, Weber State University can take advantage of state-of-the-art technology with a wider range of materials, including advanced composite polymers. The F370CR’s ease of use and consistent print performance 3D printing solutions provide users with

The composite 3D printer will help the university provide innovative and cutting-edge tools to its current and future students and clients.

Nylon CF10 Dimensional Inspection Tool

Did you know that the most reliable and popular solution for additive manufacturing is Stratasys FDM technology, and within it, carbon fiber reinforced materials? 
Did you know that you can replace your metal parts with lightweight and extra-strong carbon fiber composite 3D printed parts?

Get to know Stratasys' reliable composite 3D printers from the VARINEX team!
We have been helping Hungary's leading industrial companies and their innovations with additive manufacturing for 25 years!

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Stratasys F123CR Composite 3D Printers
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9 important things about composite 3D printing

9 things you need to know about carbon fiber 3D printing

Author : Varinex Date : 2024-02-09
Stratasys composite 3D printing

9 things you need to know about carbon fiber 3D printing

Carbon fiber composite materials are pushing the boundaries of performance in 3D printing due to their strength, stiffness, heat resistance, and durability. They offer a significant performance improvement over traditional thermoplastics for demanding 3D printing applications.

Carbon fiber reinforced materials are made by adding chopped or continuous fibers to a base polymer material to increase its toughness and strength. The fibers can be made from a variety of materials, such as carbon, glass, and Kevlar, and can be aligned in a specific direction to provide maximum strength in that orientation. The resulting composite materials are suitable for manufacturing stronger and more durable components.

What makes carbon fiber so attractive for 3D printing?
These materials have many beneficial properties. Below are 9 things you should know about using carbon fiber in 3D printing.
Keep these in mind when your 3D printing applications require a higher level of performance!

  1. Strength:
    Carbon fiber is one of the strongest materials available, and when combined with a base polymer, it can be used to make stronger parts than unreinforced materials.
  2. Light weight:
     Carbon fiber FDM materials offer a lighter alternative to metal, making them ideal for manufacturing parts that need to be strong but not heavy.
  3. Durability:
    Fiber-reinforced thermoplastics, depending on the specific base polymer, offer high durability and are resistant to high temperatures and harsh environments.
  4. Stiffness: Carbon fibers are very stiff, making them ideal for making parts that need to be rigid and retain their shape without deformation.
  5. Chemical resistance:
    Fiber-reinforced materials also provide resistance to chemicals, depending on the properties of the base polymer.
  6. Flexible design:
     Carbon fiber-reinforced FDM materials are capable of creating strong parts with complex geometries and shapes that would be difficult or impossible to make using traditional manufacturing methods.
  7. Cost-effectiveness:
     Composite 3D printing can be more cost-effective than small-batch production using traditional manufacturing methods.
  8. Less waste:
     Carbon fiber 3D printing can reduce waste by only using the material needed to produce the part.
  9. Efficiency Improvement:
    Composite materials can improve efficiency by reducing the time and labor required to create a part compared to traditional technologies or molded alternatives.

Stratasys offers three carbon fiber reinforced composite FDM thermoplastics, learn about them by clicking on the images!

Stratasys ABS-CF 10 material

Carbon fiber combined with ABS base polymer

Stratasys FDM Nylon-CF10 material

Nylon-based polymer mixed with chopped carbon fibers

FDM Nylon 12CF material

Combination of Nylon 12 base polymer and 30% by weight of chopped carbon fiber

Did you know that the most reliable and popular solution for additive manufacturing is Stratasys FDM technology, and within it, carbon fiber reinforced materials? 

Did you know that you can replace your metal parts with lightweight and extra-strong carbon fiber composite 3D printed parts?

Get to know Stratasys' reliable composite 3D printers from the VARINEX team!
We have been helping Hungary's leading industrial companies and their innovations with additive manufacturing for 25 years!

I'm looking at Stratasys composite 3D printers!
Stratasys F123CR Composite 3D Printers
5 reasons why composite 3D printing is revolutionizing manufacturing

5 reasons why carbon fiber composite 3D printing is revolutionizing manufacturing processes 

Author : Varinex Date : 2023-11-29
Struggling supply chain? Choose additive manufacturing!

5 reasons why carbon fiber composite 3D printing is revolutionizing manufacturing processes

'sIt time tomake explore the carbon fiber composite 3D printing world of, as a number of advantages that it offerscan . efficient your processes manufacturing more. Stratasys composite 3D printing is 2-4x faster than other carbon fiber solutions, depending on the geometryHere are five compelling reasons why this is cutting-edge technology revolutionizing manufacturing . 

1. Replacing or improving metal parts with carbon fiber 3D printing

One common reality concern in manufacturingis whether thermoplastic the the counterparts molds of truly matchcan metal their strength. The surprising is thatwith the FDM Nylon12CF introduction of, a Nylon 12 and shredded carbon blend of, the resulting lighter stiffness thermoplastic fiber has highest to -weight ratio FDM of any material . compressiveThis makes an excellent it , offering metal parts replacement fora 3-7x steel or , with over alternative to aluminum ?a 900 bar strength of. The biggest advantage50-70% cost savings !

2. Harnessing the benefits of carbon fiber 3D printing

Carbon fiber reinforced composite materials and of stiffness strength while ABS a higher level offersignificantly traditional compared to overall weight reducing stiffermetal options . ABS of- CF10, a %10 chopped fiber and carbon plastic blend of, a 3D printing material combination introduces in that % is and % strongerthan traditional . This and with that robust tools resultsand meet demands the factory tooling applications thecost scheduling overcome traditional manufacturing tools associated issues 15 . 50ABS 

3. Stratasys F190CR and F370CR 3D printers and composite materials outperform the competition

When reliability and accuracy it comes to, the and F370CR 3D printers and composites unmatched. With an % uptimeand impressive , 99 99 %dimensional repeatability F190CR you can trust these machines areto consistent, high- quality parts produce your for manufacturing needs. 

4. Speed ​​up production and improve worker safety

you with carbon fiber, composite 3D printing By using significantly reduce the tools to manufacture required lead time. Traditional metal tools often time-consuming machining processes and external suppliers rely on, resulting extended production schedules in. In addition 3D printed tools have the advantageof being significantly lighterthan metal counterparts, making them to handle, easier reducing the worker strain , and of injury risk. 

5. Apply innovation and future-proof it

technology of manufacturing , continuous advancement printing integrating composite and carbon fiber is a 3D a competitiveadvantage strategic step to Byinvesting, Stratasys - solutions from in cutting equip the tools and materials your you businesswith needed to .the efficiently effectively and With solve everyday gain challenges manufacturing .edge 

Composite materials for 3D printing can effectively overcome the schedule and budget challenges that are common in manufacturing.

Find out how you can make your manufacturing operations more efficient with composite 3D printing!

Download our 4-page Hungarian-language brochure on carbon fiber 3D printing now!

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Three inspiring stories: advancing manufacturing with carbon fiber 3D printing

Improving Manufacturing with Carbon Fiber 3D Printing: Three Inspiring Stories

Author : Varinex Date : 2023-10-26
Struggling supply chain? Choose additive manufacturing!
Improving Manufacturing with Carbon Fiber 3D Printing: 3 Case Studies

carbon fiber composite 3D printers, such as the Stratasys F370®CR, companies can leverage the benefits of carbon fiber-filled thermoplastics, revolutionizing manufacturing processes through additive manufacturing. In this blog post, we explore three notable stories in which companies have recognized the potential of carbon fiber 3D printing, demonstrating its efficiency, power, and versatility.

Graco harnesses the power of composite 3D printing

Graco: Increasing Efficiency with Ergonomic Tool Handles

Graco, a leading manufacturer of fluid and coating systems, was faced with a challenge regarding the pressure control tool for its paint sprayers. The teeth of the existing ABS plastic tool were wearing out with repeated use, requiring frequent replacement. The company sought a cost-effective, durable, and easy-to-manufacture solution that did not require frequent replacement.

The Solution: Composite 3D Printing with Carbon Fiber
a Stratasys F370®CR composite 3D printer, Graco engineers FDM® Nylon-CF10 thermoplastic, a material blended with 10% shredded carbon fiber, which provides greater strength and toughness compared to ABS. The 3D printed hand tool features an ergonomic handle that is faster and easier to produce and outperforms the traditional machining alternative.

JW Speaker: Rationalizing the production of automotive lighting fixtures

JW Speaker Corporation, a manufacturer of high-performance automotive lighting, was challenged with leak testing its newly developed luminaires. The traditional approach involved manufacturing custom mounts from aluminum, a time- and resource-intensive process.

The Solution: 3D Printing with Carbon Fiber Materials
FDM ,® NylonCF10 JW Speaker tool designers achieved remarkable results. The material mixed with carbon fiber offers increased stiffness and strength, making it suitable for more demanding applications. The Stratasys F370CR composite 3D printer allowed the team to reduce tool production time by 80%, providing greater flexibility in tool design.

Mercury Marine: Faster and more robust custom masking devices

Mercury Marine, a leading manufacturer of power systems for consumer and commercial boats, faced challenges in manufacturing custom masking tools for applying decals to engine hoods. Traditional methods were costly and time-consuming, leading to frequent replacements due to damage and wear.

The Solution: Carbon Fiber 3D Printing Technology
Mercury Marine designers Stratasys F370®CR composite 3D printer used FDM® Nylon-CF10 and FDM® TPU-92A (flexible thermoplastic polyurethane) resulted in a fixture that conforms to the curvature of the engine cover and avoids scratching the surface.

Summary

The combination of 3D printing technology and carbon fiber materials has catapulted the manufacturing industry into a new era of efficiency, strength, and versatility. With carbon fiber 3D printers like the Stratasys F370®CR Composite 3D Printer, companies like Graco, JW Speaker, and Mercury Marine have redefined their toolmaking processes, optimizing productivity, reducing costs, and enabling flexible design iterations. As the potential of carbon fiber 3D printing continues to expand, the technology holds great promise for driving innovation across a wide range of industries. Using this innovative technology is no longer about whether we can print carbon fiber, but rather as an opportunity to revolutionize manufacturing processes and stay at the forefront of development. The production of complex, undercut geometries was made possible in the examples above by the soluble support material used by Stratasys.

The aforementioned companies have already recognized the potential of carbon fiber 3D printing, its efficiency, strength, and versatility.

Download the extended version of the 3 inspiring case studies in Hungarian now!

Three inspiring stories: advancing manufacturing with carbon fiber 3D printing
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Struggling supply chain? Choose additive manufacturing!

PRESS RELEASE: Stratasys Expands F123 Series with Two New 3D Printers Optimized for Composites Manufacturing

Author : Varinex Date : 2022-05-13

Stratasys Expands F123 Series with Two New 3D Printers Optimized for Composites Manufacturing

New printers and nylon-carbon fiber material bring new applications of additive manufacturing to the production line

Stratasys, a leader in polymer-based 3D printing solutions, today announced the addition of the F190™CR and F370®CRmodels to its F123 Series™ 3D printer family, along with the introduction of new carbon fiber-reinforced FDM®Nylon -CF10 material. The new printers also feature materials with superior stiffness and durability, and are engineered for reinforced composite manufacturing. The new composite 3D printers are designed for manufacturers and industrial operators to complement traditional manufacturing technologies with the 3D printing of heavy-duty composite materials. The printers enable faster and more cost-effective production of end-user parts, making them ideal for the production of tooling, assembly seats and other workpiece holding tools.

“I have been in engineering for over 35 years and I am passionate about innovation – not just in the development of new products, but also in the processes and tools used to develop those products. Stratasys has been enabling me to do that for over 20 years through 3D printing,” said Dave Thompson, vice president, global engineering, customer service and subcontract equipment, Graco Inc., a global leader in fluid handling equipment and a beta customer for the F370CR.

 

New 3D printers and nylon-carbon fiber material bring new applications of additive manufacturing to the production line

“Over the years, we have expanded our Stratasys printer fleet and their applications beyond prototyping to include tooling, assembly seats, and the gripping tools used by our robots. The new Stratasys F370CR printer allows us to take our advanced manufacturing applications to the next level, increase tool life, and even achieve better surface quality.”

The new 3D printers include integrated GrabCAD Print™ software, which provides a simple, intuitive workflow between CAD files and 3D printing, and advanced features to ensure print success. Stratasys also provides connectivity to enterprise applications through the MTConnect standard and its GrabCAD software development kit. Optimized for composite manufacturing, the F123 series of 3D printers feature reusable print trays, a built-in camera for remote monitoring, and a 7-inch touchscreen control panel. The F370CR printer also features automatic material change, meaning there is no need to interrupt the print to change materials – the system simply inserts a new cartridge and the print continues.

 

New composite 3D printers are designed for manufacturers and industrial operators to complement traditional manufacturing technologies with 3D printing of heavy-duty composite materials

“Stratasys provides 3D printers and materials that help advance advanced manufacturing across the production line, such as these new CR 3D printers that enable us to print with stronger, stiffer materials and greater accuracy,” said Dick Anderson, vice president of manufacturing at Stratasys. “These new printers have proven with verified and published data that they can achieve up to 99% dimensional repeatability regardless of part size and geometric complexity. Combined with 99% uptime and dedicated service and support, manufacturers can confidently accelerate their transition to additive manufacturing.”

Compared to other printers, Stratasys’ F123 series of printers optimized for composite manufacturing offer a wider range of substrates with greater print capacity, soluble support materials and lower printing costs due to a larger build area. Additionally, compared to other printers, the F370CR’s larger, fully heated build chamber, which can be combined with stabilizer walls, allows users to print taller parts with superior mechanical and aesthetic quality.

Stratasys has also introduced a new composite material called FDM Nylon-CF10 for the F123 Series printers. This material is more than 60% stronger and nearly three times stiffer than its base nylon material. The chopped carbon fiber material is just one of several thermoplastic materials available for the F123 Series printers. When combined with Stratasys’ soluble support materials, manufacturers can print any geometry without limitations. The F190CR and F370CR printers also support a number of other modified thermoplastic materials.

The new composite-compatible F123 Series printers and FDM Nylon-CF10 material are available to order now, with shipping expected in June. Stratasys live event shared information about the new manufacturing solutions during Stratasys F123 Series product page optimized for composite manufacturing .

Stratasys is leading the global shift to additive manufacturing technologies with innovative 3D printing solutions for industries such as aerospace, automotive, consumer products and healthcare. Stratasys solutions provide competitive advantage across the product value chain with intelligent and connected 3D printers, polymer materials, software ecosystem and made-to-order parts. The world's leading organizations are transforming product design, increasing the flexibility of their manufacturing and supply chains, and improving the quality of patient care with Stratasys. To learn more about the above products, contact VARINEX Zrt., your distributor of Stratasys products in Hungary (3dp@varinex.hu,)