Replacement Levers Enabling Affordable Upcycling of Industrial Ink Cartridges.
Job Information
| The Screen Hanger | Batch Production |
|---|---|
| Technology | Selective Laser Sintering (SLS) |
| Material | PA12 Nylon |
| Finish | Black Dye |
| Part Size | 29 x 54 x 23 mm |
| Quantity | 1,000 |
| Unit Cost | £1.73 |
Customer Info / Context
More than 500 million OEM (Original Brand) toner cartridges are manufactured every year. Although the cartridges can be refurbished and refilled, it is rarely done and a missed opportunity. Vitesse believes imported remanufactured toners are not the answer and therefore built their own refurbishing facility in south London.
Issue / Challenge
Some plastic components inside the cartridges need to be replaced as part of the refurbishing process. These components are complex pieces of the assembly that are injection moulded in high volumes. Vitesse PLC requires smaller batches and therefore a more affordable solution must be devised.
Solution
Using our reverse engineering and SLS manufacturing solutions, Vitesse PLC were able to have prototypes of their replacement part within 1 week. Once tested, Vitesse Nested the parts into groups of 4, resulting in a saving of 35% and placed an order of 1000 units.
What are the benefits of using 3D printing in manufacturing?
Vitesse used SLS 3D printing technology as an alternative to injection moulding for manufacturing. The key benefits were:
Fast turnaround. Vitesse received the first samples within 1 week and the full batch just 5 days later
Cost savings. The low volumes required meant they were able to save money
Simple process. Vitesse utilized our reverse engineering services to replicate the parts required
How does 3D Printing compare to Injection Moulding for this part?
The table below shows the costs to produce the cartridge lever using Injection Moulding and 3D printing.
| Process | Material | Start-up Cost | Quantity | Unit Cost | Total* |
|---|---|---|---|---|---|
| Injection Moulding | ABS | £6,000 | 1 500 1,000 4,000 8,000 |
N/A £0.29 £0.26 £0.25 £0.25 |
N/A £6,145 £6,260 £7,000 £8,000 |
| 3D Printing (SLS) | PA12 Nylon | No start-up cost | 1 500 1,000 4,000 8,000 |
£4.11 £1.98 £1.73 £1.61 £1.61 |
£4.11 £990 £1,730 £6,440 £12,880 |