Metal additive manufacturing is changing the way industries approach product design and manufacturing, offering unprecedented design flexibility, shorter lead times and more cost-effective manufacturing.
This case study between Autodesk and Unverferth shows how Meltio technology can overcome numerous challenges in the agricultural sector, such as the production of spare parts in small batches and the redesign of components without the need for expensive tooling.
Autodesk is a global leader in design and engineering software, offering powerful tools like Autodesk Inventor and Autodesk Fusion 360 that drive innovation across industries. Unverferth Manufacturing, a prominent manufacturer of agricultural equipment, is constantly looking for ways to improve the efficiency and performance of its manufacturing processes.
A harsh environment for even the most durable components
Injection blades are key consumable components in agricultural equipment, responsible for cutting the soil and injecting fertilizer or liquid. They are traditionally produced by casting and machining, but they face a number of problems:
- High wear and corrosion due to friction with the ground and exposure to chemicals
- Hard-to-machine features, such as narrow slits in hard-to-reach places
- Risk of deformation due to the high geometry of the component
- Long delivery times and high costs due to tooling and casting
- Low demand for spare parts, making traditional methods unprofitable
Most farm equipment has been in use for decades, so maintaining cost-effective production for current and older models is an increasing challenge.
A new injection knife to solve old problems
The component is traditionally a cast blade made of hardened steel, which is difficult to machine due to narrow slots and height, which can lead to deformation.
To overcome these challenges, Autodesk used Meltio Engine for CNC – an integration kit for vertical machining centers that enables hybrid manufacturing, combining wire laser metal deposition with a classic CNC platform.
They redesigned the component taking into account that thanks to the Meltio hybrid system, many previous manufacturing and design obstacles no longer exist. The component can now be printed even in hard-to-reach slots. Also, it is printed in two stages, adding material exactly where it is needed and avoiding deformation due to the height of the component.
Advantages:
- Tool-free prototyping
- Efficient production in small batches
- Improved material flexibility
- Hybrid production capability
- Safer working environment
- Better return on investment (ROI)
Same features, lower costs and shorter deadlines
- Print time: 15 hours (previously 8-10 weeks)
- Total Cost: $612.52 (Previously $6000-$8000)
System: Meltio Engine for CNC
Sector: Agriculture
Material: Stainless steel 316L
Printing time: 15 hours
Application of Meltio technology in agriculture
Prototyping new designs of cast or forged parts without investing in expensive tooling, with a very short lead time, enables faster design development.
Small batch parts: Most agricultural equipment has a long life, often decades. For older machines that require spare parts that are sold in small quantities, the Meltio hybrid method is cost-effective. This eliminates the need to store, set up and maintain multiple tools for small batch production. The same applies to casting/forging, where small batches are economically unviable, especially in the current supply conditions.
Source: https://meltio3d.com/enhancing-durability-injection-knife-flexible-design-production/