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یکی از کاربردهای چاپگرهای سه بعدی به عنوان روش نوینی در ساخت ابزارها و قطعات در تعداد محدود، اهمیت این فن آوری را بالابرده و باعث شده پرینت سه بعدی و نمونه سازی سریع تبدیل به یک روش استاندارد در توسعه محصولات جدید گردد. تکنولوژه های ساخت افزایشی در فرآیند طراحی و توسعه محصولات جدید به خصوص خودرو و قطعات و مجموعه های آن طی دو دهه اخیر رشد چشمگیری داشته است. به عنوان یک نمونه کاربردی و عملیاتی در شرکت BMW فن آوری FDM نقش مهمی در فرآیند نمونه سازی و طراحی خودرو دارد. اما در این شرکت به غیر از نمونه سازی قطعات متعلق به محصولات جدید ، از این تکنولوژی در سایر حوزه های تولید نیز استفاده می گردد.
واحد ساخت جیگ و فیکسچر این شرکت ابزار دستی مورد نیاز مربوط به مونتاژ و تست قطعات خودرو را با بکارگیری تجهیزات چاپ سه بعدی شرکت Stratasys تولید می کند. به گفته آقای گونتر اشمید، “در شرکت BMW این موضوع که تکنولوژیFDM می تواند یک جایگزین برای روشهای معمول و متداول تولید قطعات مثل فرزکاری، تراشکاری، و… باشد، مطرح شده است. ”
مهندسان این شرکت به این نتیجه رسیده اند که استفاده از چاپگر سه بعدی مزایای بسیار زیادی برای ساخت ابزارهای دستی مورد نیاز در خطوط تولید و به خصوص مونتاژ قطعات تزییناتی خودرو دارد. با این روش می توان ابزارهایی با کارایی بالا و لحاظ نمودن شرایط ارگونومی به مراتب بهتر از روشهای متداول، طراحی و تولید نمایند.
جهت بهبود بهره وری، راحتی کارگر، سهولت استفاده، و تکرار پذیری فرآیند، این شرکت فن آوری FDM را به منظور بهبود شرایط ارگونومی تجهیزات مونتاژ دستی بکار گرفته است. عدم محدودیت در ساخت قطعات با این روش، آزادی لازم به طراحان را می دهد تا ابزارهای را طراحی کنند که از نظر جابجایی و حمل شرایط بهتر، وزن کمتر و بالانس خوبی داشته باشند. به عنوان مثال شرکت BMW با ساخت ابزاری بصورت متخلخل حدود 72 درصد از وزن ابزار را کاهش داد. یعنی با ساخت قسمت تو پر قطعه به صورت مشبک حدود 1.3 کیلوگرم از وزن ابزار کم شد. شاید این عدد زیاد به نظر نرسد اما زمانیکه یک کارگر صدها بار در هر شیفت کاری از این ابزار استفاده می کنند تأثیر بسیار زیادی در کاهش خستگی و مشکلات جسمانی برای او دارد.
یکی دیگر از مزایای تولید مستقیم دیجیتال (Direct Digital Manufacturing) بهبود قابلیتهای عملکردی می باشد. از آنجا که روشهای ساخت افزایشی می تواند به راحتی هندسه های پیچیده را بدون محدودیت ایجاد نماید، لذا طراحان ابزار می توانند ابزارآلات با حداکثر قابلیت عملکردی و در عین حال شرایط بهتر حمل و جابجایی را طراحی نمایند. لذا ساخت قطعات بصورت لایه لایه و افزایشی این امکان را به مهندسان می دهد تا قطعاتی که با روشهای متداول کاهشی و یا ورقکاری قابل ساخت نیستند و یا هزینه ساخت بالایی دارند، به راحتی و با هزینه کمی بسازند. به عنوان مثال ابزاری که برای اتصال تکیه گاه سپر به بدنه (Bumper Support) استفاده می شود. این ابزار دارای قسمتهای لوله ای شکل با فرم و خمهای پیچیده است و فیکسچر مغناطیسی را دقیقا” در محل مناسب قرار می دهد.
واحد طراحی و ساخت جیگ و فیکسچر این شرکت مشخصه هایی را در قالب نمودار فرآیندی تعریف کرده اند که تعیین می کند چه زمانی بکارگیری تکنولوژی FDM برای ساخت جیگ و فیکسچر مناسب می باشد. این معیارها شامل دما، قرار گرفتن در معرض مواد شیمیایی، دقت، و بار مکانیکی می باشند. با استفاده از پلاستیک ABS ارائه شده توسط شرکت Stratasys ، که مهندسان به لحاظ خواص مکانیکی آن را با پلی آمید (PA 6) قابل قیاس می دانند، ابزار های بسیاری برای مونتاژ قطعات خودرو می توان ساخت که معیارهای مورد نظر را برآورده می نمایند.
مهندسان معتقدند که هیچ شرکتی نمی تواند بدون استفاده از فن آوری پرینت سه بعدی و نمونه سازی سریع محصولات جدید و قابل رقابت در بازار را طراحی و تولید نماید. لذا بکارگیری تکنیکهای تولید قطعات و ابزارآلات به روش افزایشی و به طور خاص تکنولوژی FDM به عنوان یکی از روشهای تولید برای تیراژ محدود و کم دارای اهمیت و کاربرد بالایی می باشد.
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