The system's aim was to provide protection from pressure surge and negative pressure boiler evacuation on a highly efficient domestic water heater.
Some of the tolerances required were as tight as ±0.05mm. High precision metal inserts within the silicon tooling maintained the tight tolerances required in some of the bores.
Perfect screw threads
The ultra high resolution SLA machine producedsmooth and accurate threads. The screw threads that can be seen here were all cast in without need for post machining.
Scaled down simplified data of the engineering plant was broken down into many sections representing the differing areas of the plant. Several SLA printers and SLS printers were utilised simultaneously to speed up the process.
Once the pieces were built, supports were carefully removed. As budget was limited, parts were given a light sandblast and a quick coat of paint, the colour depicted the various sectors of the plant.The parts were mounted to a custom built display board. All in all the project was completed in just over a week
How it was achieved…
The prototypes were put to use in engineering evaluation, fit and function tests and regulation approval. An increase in the test pressures for water board approval meant that initial polyurethane samples failed. However, subsequent castings, from the same silicone tools, in glass-filled polyurethane resin completed the high pressure tests at an internal pressure of 15 Bar.
The screw threads that can be seen here were all cast in without need for post machining.
All 30 sets had to have repeated accuracy with tight tolerances.
Some of the tolerances required were as tight as ±0.05mm.