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More innovative, precise and faster to the finished component
Die 1zu1 Prototypes GmbH & Co KG based in Dornbirn, Austria, was founded in 1996 by managing partners Hannes Hämmerle and Wolfgang Humml.
Today, the company has 160 employees, has been part of the internationally active Prototal Group since mid-November and produces prototypes, small series and series parts for customers from all over the world and for every conceivable industry. In manufacturing, 1zu1 uses the most important 3D printing processes such as laser sintering and stereolithography. When developing new components, 1zu1 likes to push the limits of what is feasible in terms of complexity and precision for its customers. Measurement technology plays an extremely important role in measuring and testing the finest details and the tightest form and position tolerances.
1zu1 has been using optical measurement solutions for eleven years and produces several hundred measurement reports per year. “We know the limits of optical measurement technology very well,” explains managing director Wolfgang Humml. “Given that the components we produce are becoming ever more complex and smaller, it was clear to us that we wanted to take the next, innovative step in measurement technology and that the comparisons of 3D measurement results with 3D data sets had to be better and more accurate.” When looking for a new measurement solution, several criteria were important.
The focus was on the accuracy of the measurement result over the entire 3D part and not just for the area that can be detected with optical measurement technology. Industrial computed tomography has clear advantages here. Compared to tactile or optical measuring machines, the computer tomograph (CT) can also be used to measure internal features with high precision without destruction. Optical measurement technology clearly has its limits, particularly when it comes to measuring tasks involving transparent components and parts with a high-gloss mirror surface. It is not possible to measure such parts without prior treatment with a laser scanning anti-reflective spray. In addition, the required measurement accuracy cannot be achieved with a spray application. Another major advantage of industrial computed tomography is the speed of scanning and evaluation. In this way, thousands of measurement points can be measured within seconds. In addition, carrying out so-called pallet scans (several components in one scan) shortens process cycles and increases efficiency.
After an extensive selection process, 1zu1 opted for the CT system eXact L With 150kV from WENZEL Metrology GmbH in Wiesthal. “Ultimately, the guaranteed measurement uncertainty of +/- 5 µm, the convincing CT measurement of our five benchmark problem parts and the impressive surface imaging accuracy without software smoothing are decisive for the purchased goods,” explains Humml. “The measurement results were so impressive for us that we were happy to order the first machine built with this configuration and we are happy that the system is in operation with us. The system's scan times are impressively fast, meaning that we were able to perform around 120 scans in normal working hours in the first three weeks of operation. “The high efficiency of the CT solution enables faster development times and thus saves time and money for the end customer as well.
In addition, Wenzel's CT solution has the smallest footprint in its class at 150 kV and also offers a scan volume of 400 mm in height and 235 mm in diameter. “The desire for the largest possible measurement volume with a comparatively small machine design was another important requirement criterion,” says Humml. In addition to the small footprint and the large scan volume, the eXact L offers another major advantage — the transport and assembly requires no openings in doors and corridors, which ensures quick and smooth installation without additional effort. In terms of system weight, the eXact L is also best in class, weighing just 2,650 kg, which allows flexible storage space.
The eXact L is the latest development in WENZEL's extensive eXact series. Based on a global market analysis for industrial computed tomography, the system won Frost & Sullivan's 'Global New Product Innovation Award 2020' at the end of 2020. “The eXact L has superior X-ray performance combined with a fast detector, so it can quickly measure objects and defects,” says Mariano Kimbara, senior industry analyst at Frost & Sullivan. “WENZEL has taken an important step into the market with an intuitive user interface that automates all measurement parameters with intelligent software and thus offers robust customer benefits. “Three independent travel axes provide great flexibility and enable high speeds and short measurement and testing times.
Due to its high quality awareness, 1zu1 has numerous measurement and testing tasks to solve for its customers: Obscure evaluations, compensation of shrinkage and distortion, testing for inclusions and impurities, geometric tests, assembly analyses (Multiscan) and process monitoring (measurement series), the measurement and test reports are always presented in a customer-friendly and understandable way.
1zu1 uses technologies such as 3D printing, plastic vacuum and injection molding, and mechanical manufacturing. A large part of the 1zu1 investment goes into additive manufacturing. Here, the company is one of the world's best and has been a pilot customer and development partner of new 3D printing technologies for EOS, one of the world's leading providers of industrial 3D printing systems, since 2020.
Industrial computed tomography and additive manufacturing are two relatively young technologies that can be combined excellently. While “additive manufacturing” allows new structures, the quality assurance of these novel products is carried out by a CT. Based on these results, correction data is generated, which can significantly improve both the dimensional accuracy and mechanical stability of 3D-printed parts. In particular, the complex shapes created by 3D printing often pose difficulties for conventional measurement systems. Only CT technology enables non-destructive material analysis and dimensional accuracy testing.
“We appreciate WENZEL's competent advice and sales ability to listen and understand our needs and high requirements. Our direct contact, Bernd Fleckenstein, gave us the feeling at all times that we were with the right manufacturer,” enthuses Wolfgang Humml. As managing director, he was also impressed by the preliminary inspection of the system, which was accompanied by Dr. Uwe Hilpert, CT Product Manager at WENZEL, and who was able to explain the measurement of each individual image point on the ultrafast 7.5 mega pixel detector in a well-founded and competent manner.
“The CT training was also carried out at our site in Dornbirn by Dr. Hilpert. After a week of intensive training and deep introduction to CT technology, our measurement technicians were “ready to cut” but were ideally equipped to operate the system from the very first measurement task. This makes investments fun and creates added value for us and our customers,” summarizes Managing Director Humml.
The eXact L industrial computer tomograph is a universally applicable testing and measuring device to optimize components and manufacturing processes. The measurement solution is highly efficient with significant added value for the customer. Faster development times save time and costs. If an analysis or testing of internal structures is necessary, these can be carried out without destroying the component. This also results in significantly faster scan times and less effort. With just one scan, metrological evaluations and analyses can be carried out from the generated data. The reliable measurement results are documented in a customer-friendly and understandable way. — Here's a thought about safety: Even with less complex consumer goods that are sold in large quantities, failures can occur, which also have expensive effects on the recall and the company's reputation. Archiving the measurement results enables a new analysis in the event of an error in order to enable rapid correction or refute a potential lawsuit.
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