When HPL Prototypes, a bespoke automotive parts company, wanted to reduce the costs and delays associated with outsourcing additive manufacturing (AM), it approached Tri-Tech 3D, provider of Stratasys, One Click Metal and XJet 3D printing solutions, for support.
Based in Coventry, HPL Prototypes specialises in the manufacture of bespoke show cars, with clients including prestigious brands like Bentley, Aston Martin, McLaren and Jaguar Land Rover. The company produces prototypes and concepts with different aesthetics for its clients before they enter full-scale production.
While HPL had on-site equipment for CNC machining, it would outsource 3D printing when parts required certain properties that its in-house methods couldn’t provide. For example, CNC machines are incapable of producing functional ultra-clear components. Therefore, when producing a new set of ultra-clear headlights, HPL would outsource to a 3D printing bureau that could facilitate its requirement for specialist materials that offer high optical clarity.
While outsourcing enabled HPL to deliver specialist, highly accurate parts, it also added delays and costs, with one supplier charging tens of thousands each month. HPL knew that outsourcing wasn’t a sustainable long-term approach, and that it would need its own in-house AM capability.
The trouble with outsourcing
“While outsourcing 3D printing helped us deliver essential parts for customers, there were also drawbacks,” explained Glyn Horsfield, finance director at HPL. “As well as the expense that comes from working with a third-party, relying on bureaus introduced the risk of delays to production schedules and a loss of control over our profit margins because we couldn’t determine every single cost.
“We were working with both international and UK-based suppliers, which could easily extend lead times, especially if there was a delay in transportation or shipping,” continued Horsfield. “Outsourcing would delay the speed to quote because we would need to contact the bureau to get the necessary data on the build and receive their estimates before we could send a final quote to the customer.”
“Outsourcing made things difficult from a delivery perspective,” added Tom Spicer, sales manager at HPL. “Bureaus are working with several customers at any time, so our parts would be built according to their schedule and workload. If a customer requested a part turnaround in, say, three days, there was no guarantee we could deliver this on time without being in complete control.”
Bringing AM in-house
To help HPL reduce its reliance on outsourcing, Tri-Tech 3D supplied the Stratasys NEO800 stereolithography (SL) system, which is designed to produce large parts with high accuracy and quality. It has a large build area of 800 x 800 x 600 mm, and a 2-Watt variable beam laser with dynamic and variable beam size options.
The Stratasys NEO800 combines high laser power with advanced control to increase print speed and throughput — delivering highly accurate parts with superior surface quality. It is also an open-resin system and is compatible with all 355 nm SL resins, allowing freedom of material selection.
“The NEO800’s print bed provides a competitive advantage for HPL because it can print large parts like seat backs in one build, rather than in segments,” added Joe Godfrey, 3D print specialist at Tri-Tech 3D. “Not only does this improve aesthetics by avoiding split lines, but it can also reduce labour because further assembly is not required.
“We evaluated three systems — the NEO, and two other systems from Union Tech and 3D Systems — and the NEO was the obvious choice,” added Horsfield. “Tri-Tech 3D presented an offering that encompassed return on investment, delivering quality to our customers, and a level of technical support that felt right for us.”
Getting the right support
“The NEO800 is a user-friendly machine, and it runs on a really intuitive operating system, which has made adoption straightforward,” added Oliver Browning, CNC team leader at HPL. “Overall, the response from our team has been very positive and the system is already benefiting our North West office in Stoke-on-Trent, which previously outsourced all of its 3D printing work.
“If issues do occur, Tri-Tech 3D is always on hand,” added Browning. “We once had a problem with the surface finish on some parts that were coming off the NEO800, and the support team quickly realigned the laser to prevent the issue from reoccurring. We also had an incident where the load trolley failed, which stopped us getting the completed builds off the printer. The team came out and fixed this in just one hour.”
A valuable investment
“Already, the NEO800 has paid for itself, and we are seeing its financial value,” continued Horsfield. “The system became cash flow positive from month one, which equates to a return on investment in the first year. This is virtually unheard of when investing in new production technology! It’s easily one of the best investments that HPL has ever made.”
With the NEO800 now in place, HPL is using the Somos® WaterShed XC 11122 low-viscosity material, which produces strong, water-resistant parts with ABS-like properties. The resulting parts are durable, clear and have the look and feel of engineered plastic, with a smooth finish.
As well as producing parts that can only be 3D printed, HPL is using the NEO800 to supplement the capacity of its CNC machines. Some automotive components like bevel gears can be both machined and printed, so having the NEO800 readily available means that HPL’s engineers can still produce critical parts while the CNC machine is busy.
The NEO800 has also opened HPL to new business opportunities. HPL recently started working with Cranfield Aerospace Solutions, a Bedford-based company specialising in hydrogen-electric propulsion systems for aircraft. By having the NEO800 in house, HPL can facilitate Cranfield’s requirements and build bespoke powertrain components without having to outsource to a bureau.
HPL recently launched Allesley, a coachbuilder offshoot specialising in multi-million pound, highly personalised cars. With the NEO800 now installed, Allesley clients can visit HPL’s site and see how their bespoke motor is coming along.
“Having its own AM system has been critical for HPL reducing the costs and production delays associated with outsourcing 3D printing and has created new business opportunities. The NEO800 makes us more competitive, by enabling us to produce high-quality, accurate components for prestigious brands from the comfort of our own facility,” concluded Horsfield.
