3D Systems > Case Studies > High Density Stacking Capability Enhances Productivity in 3D Part Production at Decathlon

High Density Stacking Capability Enhances Productivity in 3D Part Production at Decathlon

Technology Category

Wearables - Augmented Reality Glasses, Headsets & Controllers

Applicable Industries

Equipment & Machinery
Glass

Use Cases

Additive Manufacturing
Virtual Prototyping & Product Testing

Services

Testing & Certification

The Customer

Decathlon

About The Customer

Decathlon is the world’s largest sporting goods retailer. The company was facing a challenge with a mold injection problem on a small component for shooting glasses that connects the frame to the lenses. In order to solve this problem and increase efficiency in production, Decathlon decided to test the new 3D stacking solution developed by 3D Systems. After conducting a feasibility study, the company confirmed the productivity and economics of additive manufacturing and decided to use this solution for batch-run production of the final product. Decathlon’s additive manufacturing lab (ADDLAB) uses 3D Systems’ Figure 4 3D printing solution across a range of applications.

The Challenge

Decathlon, the world’s largest sporting goods retailer, was faced with a mold injection problem on a small component for shooting glasses that connects the frame to the lenses. The company was seeking a solution that would avoid the expense of tooling and increase efficiency in production. They decided to test the new 3D stacking solution developed by 3D Systems to evaluate additive manufacturing for production. After conducting a feasibility study on the Figure 4 solution and stacking feature, Decathlon’s teams confirmed the productivity and economics of additive manufacturing and decided that this solution could be considered for batch-run production of the final product.

The Solution

Decathlon’s additive manufacturing lab (ADDLAB) uses 3D Systems’ Figure 4 3D printing solution across a range of applications, and is now considering using the new high density part stacking capability of 3D Systems’ 3D Sprint software to facilitate direct production. The new stacking feature helps users print high volume batches with an efficient file preparation workflow. To use the stacking feature, users import a part and base file, define the stack in terms of orientation and part quantities, and use automated tools to replicate consecutive vertical stack layers and supports. Decathlon is using the Figure 4® PRO-BLK 10 material for this functional eyeglass component, citing the material’s strong rigid properties and fast print speeds as key benefits. The Figure 4 Modular system is used to print stacks of 100 parts in 85 minutes, which is equivalent to just 42 seconds per part. The high-density stacking capability of Figure 4 brings efficiencies of scale to post-processing as well as part building, allowing Decathlon to treat a batch of parts the same as a single part.

Operational Impact

The use of the Figure 4 platform and new stacking feature of 3D Systems’ 3D Sprint® software has enabled Decathlon to directly produce 3D printed end-use parts. The stacking feature has significantly reduced the print preparation process time. The high-density stacking capability of Figure 4 has brought efficiencies of scale to post-processing as well as part building, allowing Decathlon to treat a batch of parts the same as a single part. This has resulted in significant time savings and increased productivity for the company. The use of the Figure 4® PRO-BLK 10 material has also ensured high precision and quality of the parts produced.

Quantitative Benefit

Stacking has reduced print preparation time by as much as 80%
Builds that used to take 30 minutes to an hour to prepare can now be completed in six to 10 minutes
Decathlon uses the Figure 4 Modular system to print stacks of 100 parts in 85 minutes, which is equivalent to just 42 seconds per part