Stress Testing 3D printed parts on a Trumpf Press Brake
Objective: Lance and form 14 gauge steel plate using a 3D printed Punch and Die
Material Tested: Onyx – Nylon with embedded carbon filament Part Design: Actual customer part. Required lancing of 0.250” per drawing.
Part Material: 14 gauge sheet metal. Plate was laser cut to overall dimension and parallel lines cut for the lancing.
View of the printed punch with and without the 14 gauge sheet metal piece
Before and After view of Sheet Metal
Engineering Modifications: Inserts were designed to provide additional support to the Onyx material. 14 gauge material was utilized for these inserts. Printing of the part was paused at strategic points to insert the metal supports.
Results: Lancing of the part was successful. Customer depth specifications were achieved. Formation was more concave than customer design.
Commentary: The cost to print both parts on a Markforged - Mark II printer was less than $200.00. The question is often…How long did it take to print these parts? In total hours, it was about 48 hours. The printer ran through the day and night with zero attention. The printer automatically stopped to allow for the insertion of the metal pieces. The metal inserts were designed into the part for the purpose of creating more structural support. We have observed that inserting steel pieces within the 3D printed design can make the parts more rigid and absorb greater forces without compromising the 3D printed part.