MSA AUER Relies on Dimension for Protection Solutions
"Our ability to produce a number of different variants in a short period of time greatly increases the design reliability of our products. In addition, we save money in development by being able to produce our own models in-house." —Detlef Kielow, Senior Engineer, MSA AUER
attended the PTC user conference, where he became acquainted with the Dimension 3D Printer technology. MSA AUER received its first few prototypes produced with the Dimension 3D Printer, with results that impressed the company's management. A short time later, in June 2005, MSA AUER integrated the Dimension BST 768 into its design process, giving CAD (computer-aided design) users a fast, economical and environmentally friendly means of producing functional 3D models.
Neptec and Dimension Bring Endeavour Home Safely
On August 13, 2007, just after lift off, the space shuttle Endeavour’s Thermal Protection System (TPS) suffered damage due to falling foam from the fuel tank. Sensors detected damage to the heat-resistant tiles lining the orbiter’s underbelly, posing a threat to the shuttle’s safe reentry to Earth. NASA called on Neptec Design Group, a prime contractor to NASA
Neptec’s LCS, designed specifically for these situations, is a permanent part of the 50-foot inspection boom, used by the Canadarm, which flies on every Space Shuttle mission. Using the LCS, Neptec collected detailed 3D images of locations where sensors detected possible damage to the Shuttle’s outer surface.
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MSA is the world's leading manufacturer and supplier of high-end safety products and gas measuring systems. Berlin-based MSA AUER, the company's largest subsidiary and European headquarters, develops and produces protective equipment and gas measuring instruments for a great many branches of industry. Upon entering the company's headquarters in the Neukolln district of Berlin, visitors are left with no doubt that MSA AUER gives top priority to high-tech personal protection solutions. Protective helmets. goggles and clothing look like they came straight out of a science fiction movie. Face masks, compressed-air breathing systems, oxygen apparatus and hearing protection equipment are products that must meet top safety standards in order to protect and save human lives in disasters and emergencies.
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since 1995, to collect three-dimensional information to evaluate the severity of the situation. Neptec’s Laser Camera System (LCS) was used to collect 3D images, which provided NASA with the tangible information required to test the damaged tiles.
Using a Dimension 3D printer, Neptec was able to use the three-dimensional information from the LCS to print a 3D model of the damage aboard the Endeavour. The model provided visual representation of the tiles and was used to evaluate the damage to the shuttle’s Thermal Protection System. “The LCS data gave NASA the tangible information they needed to test the damaged tiles,” said Maureen Campbell, marketing and communications manager for Neptec. “This allowed NASA to make a very confident and educated decision about bringing the shuttle home without filling the damaged area.”
“The LCS data gave NASA the tangible information they needed to test the damaged tiles. This allowed them to make a very confident and educated decision about bringing the shuttle home without filling the damaged area.”
– Maureen Campbell, Marketing and Communications Manager, Neptec
– Maureen Campbell, Marketing and Communications Manager, Neptec
On August 21st, the Endeavour. space shuttle and its seven-astronaut crew returned safely to Earth. The shuttle’s landing completed a 5.3 million-mile, 13-day flight for the orbiter. On the mission, Endeavour.’s astronaut crew performed four spacewalks and primed the station for the delivery of its fourth and final set of U.S. solar arrays on a future shuttle flight. NASA plans to launch Endeavour. back into space in February 2008.
“Due to the extreme nature of the environment, every space mission presents an elevated level of risk,” Maureen Campbell said. “By providing accurate, three-dimensional information and clearly communicating the extent of the damage, NASA was able to make a better educated decision, which, in turn, brought the Endeavour. crew home safely.”
This is not the first time Neptec used its Dimension 3D printer to assist engineers. Neptec uses its 3D printer to aid in the design and development of its product lines. “The 3D printer allowed us to do a variety of testing issues, including a certain amount of fit and interference checking,” Campbell said. Dimension 3D printing can quickly fine tune designs and cut weeks — even months — from your development schedule. Now, with the ability to evaluate more design iterations, you can test form, fit and function right from a desktop.
This is not the first time Neptec used its Dimension 3D printer to assist engineers. Neptec uses its 3D printer to aid in the design and development of its product lines. “The 3D printer allowed us to do a variety of testing issues, including a certain amount of fit and interference checking,” Campbell said. Dimension 3D printing can quickly fine tune designs and cut weeks — even months — from your development schedule. Now, with the ability to evaluate more design iterations, you can test form, fit and function right from a desktop.
Detlef Kielow, an engineer with MSA AUER, is responsible for developing protective systems and equipment. A team of 16 designers works in the company's development department, using state-of-the-art techniques along the entire process chain from idea to final product. Three years ago, Kielow and his colleague CAD System Manager Hans-Jorg Fengler,
Dimension 3D Printers create a buzz at user conference
Twenty-four months later, the Dimension 3D Printer has accomplished a great deal for MSA AUER. Layer by layer, engineers build accurate models made of durable ABS plastic nearly every day. As far as Detlef Kielow is concerned, there are two main reasons for choosing Dimension: "Our ability to produce a number of different variants in a short period of time greatly increases the design reliability of our products. In addition, we save money in development by being able to produce our own models in-house." The investment in the Dimension BST 768 paid off in as little as one year.
Hans-Jorg Fengler, senior CAD system manager, coordinates the in-house use of the printer. Other departments have since discovered the advantages of in-house modeling: "Over the course of two years, we produced 700 models with the Dimension 3D Printer," says Hans-Jorg Fengler. "Our machine runs at full capacity even over the weekend, since it works smoothly without supervision."
Hans-Jorg Fengler, senior CAD system manager, coordinates the in-house use of the printer. Other departments have since discovered the advantages of in-house modeling: "Over the course of two years, we produced 700 models with the Dimension 3D Printer," says Hans-Jorg Fengler. "Our machine runs at full capacity even over the weekend, since it works smoothly without supervision."
Precision has priority
MSA AUER does not manufacture consumer goods. In some cases, products entering production remain in use for up to 20 years, and the development cycles are equally precise and time-intensive. Protective equipment and gas measuring instruments protect lives and help save lives. Therefore, approval and patent protection are necessary processes for all equipment and apparatus produced by MSA AUER. Once again, the Dimension technology helps shorten processes. "We can use a model that closely resembles the end product to optimally prepare a product for approval," says Kielow. "For example, if I can submit a precise model to the approval authority, this gives me a time advantage." The same is true for patent protection. The use of a model enables patent attorneys to initiate all steps necessary for protection.
Test phases and optimization
The ABS plastic used by Dimension is highly durable, which gives users such as MS AUER's designers a further advantage. "Of course, we subject our products to extensive tests and also use models from the Dimension 3D Printer for this purpose. This may involve drop tests in which we drop the model onto concrete from a defined height. Anything that breaks during this test could also become a fracture later on. The steps for designers derived from the test result can then be used for further optimization," explains Kielow.
“Due to the extreme nature of the environment, every space mission presents an elevated level of risk. By providing accurate, three-dimensional information and clearly communicating the extent of the damage, NASA was able to make a better educated decision, which, in turn, brought the Endeavour crew home safely.” – Maureen Campbell, Marketing and Communications Manager, Neptec
The Dimension 3D model of the damage to the heat-resistant tiles assisted NASA mission managers in gaining an appreciation as to the extent of the damage. Although the gouge was deep, mission managers believed it posed no risk to the space shuttle’s reentry into the Earth’s atmosphere.
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