2024 is a milestone year for Australian manufacturing. Why?
Because the Kreator has arrived. It is the first-ever large-format hybrid 3D printer + 5 axis CNC milling machine to reach local shoes. As such, this revolutionary piece of equipment is set to disrupt homegrown design and innovation.
The brainchild of Italian machinery leaders CMS and experts from Germany’s Fraunhofer Institute, the hybrid unlocks a crucial part of the manufacturing process. Once lost to offshore producers for the past decade, rapid prototyping is set to bloom. Firms now have a way to test their ideas in one-off models or small-batch production, secure in the fact that their project – and IP – stays within the country’s borders.
“In this day and age, sourcing reliable suppliers of machine tooling for composites proves to be a challenge. The Kreator is incredibly useful, and a game-changer. Just imagine being able to print your part and achieving a high-quality finish all in the same machine.” says Anthony Cruz, Advanced Materials and Plastics expert for Innovync.
The Sydney-based machinery distributor has partnered with Western Sydney Parkland Authority to bring the Kreator to their AMRF (Advanced Manufacturing Research Facility) division. Its home will be the AMRF’s Western Sydney Airport location, where parts, products, and ideas go from 3D CAD models to real-life works through a fusion of printing and milling.
This investment puts Australia at a distinctive advantage.
“There are not a lot of large-format hybrid machines that are on offer out there, leaving little for the Kreator to compete with. The primary stand-out feature is its ability to print and mill high-quality parts, especially tools, patterns, and mould-making.” says Anthony.
The array of materials able to be printed makes it extremely versatile across all industries. From aerospace, marine, motorsports and automotive to produce machine tooling and forming technology such as trimming and assembly jigs, this innovative piece crafts everything from machining fixtures and lamination masters to direct lamination moulds. The CMS R&D department tested the extruder with PLA, PP, PET, PA, ABS, PC, PEI, PESU and other thermoplastics, some reinforced with carbon or glass fibre (up to 50%). The 37.19is sets the machine up perfectly for creating high-quality tooling – using a fraction of the materials and time it would normally take to achieve the same results.
“Using a traditional process, machining of epoxy tooling boards at a size of 1000 x 600 x 300mm, made from ABS + 20% carbon fibre, weighs in at approximately 150kg. Using the Kreator, weight goes down to 40kg. That is a 60% savings in materials used and weight of the part.”, says Anthony.
The process, from start to finish is:
1, Mold production via additive manufacturing.
- Mold milling and surface finishing, and
- CFRP part lamination and curing.
By contract, the traditional process would have twice the steps – and take twice as long.
You would need to:
- Cut and bond epoxy boards.
- Do pre-form milling.
- Do the CFRP mould lamination on the pre-form.
- Do CFRP mould autoclave curing.
- CFRP mould preparation and surface finishing.
- Finally, CFRP part lamination and curing.
In a world where skilled labour is in short supply, the impact is massive. Where manual work was the only way to achieve results, the machine now frees workers up to do more of the thinking, and less of the doing. For industries where high-precision engineering is called for, this is a godsend. Ideas easily flow from the mind to CAD programs, and then directly to the machine. From there, the concept can be rapid tested and quickly refined.
Imagine an interchangeable head printing material at a rate of 10kg/hour via a single screw extruder. A build volume of up to 10m, in three different directions, offers plenty of room for big projects to be realised. Once the printing is done, the operator switches to the milling head and finishes the piece off. That is the crux of it.
For those who want a more concrete view of the Kreator in action, this year’s Australian Manufacturing Week is the place to be. Held in Sydney from April 17-19th, attendees get to check out how it works, and ask Anthony and the Innovync team any questions that come to mind.
Look for the Innovync stand, set up alongside partners AMRF. Until then, send your questions to the team via email, or on social media.
