Why DarTec

DarTec possesses the following list of competitive advantages over their current and prospective competitors:

  1. Certified reverse engineering service provider for spare part localization (ISO9001:2015).
  2. Partnership with international 3D scanning expert with over 30-years’ experience.
  3. Partnerships with reputable local and international manufacturing facilities.
  4. Ability to manage the entire lifecycle of reverse engineering spare parts.
  5. No restrictions on spare part size or material composition.
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    Spare Part Localisation Services

    DarTec utilizes Reverse Engineering Processes using a plethora of 3D laser and optical scanners to facilitate the process of localizing the manufacturing of mechanical spare parts. This is achieved by providing a turnkey solution for spare parts, where replacement spare parts are delivered to the customers that are identical to the original part. Further, DarTec provides life-cycle management and inspection services by managing the different aspects of the manufacturing processes. With the goal to reduce the price of costly spare parts in mind, DarTec is capable of optimizing inventory stock using a pull vs. push system, where parts are digitized and manufactured on demand. In addition, DarTec provides onsite scanning for relatively large items that are logistically difficult to remove from the customer’s site.

    Process Flow

    Spare Part Localization Services:

    1.Develop turnkey solution for spare parts by providing replacement parts.
    2. Provide spare part lifecycle management and inspection.
    3. Reduce price of costly spare parts by localizing their manufacturing
    4. Enable breaking the monopoly of OEMs charging premium for parts that could be localized.
    5. Provide alternatives to obsolete and discontinued spare parts
    6. Reduce long-delivery periods by manufacturing parts locally and manufacturing on demand.
    7. Develop as-is engineering drawing when as-build and as-is drawings don’t match.
    8. Provide dimensional inspection to ensure compliance with required specifications.
    9. Develop 2D-to-3D CAD modelling service for archiving and bookkeeping.
    10. Provide onsite scanning for large items.

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    Additive Manufacturing

    Selecting the optimum additive manufacturing process for a particular design or application can often be challenging. DarTec helps customers navigate through the vast range of 3D printing technologies for both metal and plastic for any of the following applications:

    Industrial

    • Medical

     

    • Historical Restoration

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    DarTec leverages the following 3D printing technologies to offer customers with options that help solve their problems:

    Comparision

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    Engineering Services

    DarTec provides engineering services for power plant design, implementation, and upgrading. DarTec has extensive experience in a variety of power generation systems while providing expertise in control systems, mechanical design, and electrical engineering summarized as follows:

    • Design Specification: DarTec detailed design packages include design specifications, drawings, procedures, requirements, quality assurance requirements and material requirements.
    • Project Management: DarTec develops a realistic comprehensive plan and provides the leadership to implement the project within budget.
    • Mechanical Engineering: DarTec provides expertise in areas of structural and mechanical engineering relating to power plants.
    • Electrical Engineering: DarTec supports electrical design needs for the generation, transmission, and distribution of electrical power.
    • Control Systems: DarTec supports the design and implementation of control systems for automation, plant monitoring, and special equipment synchronization, which will maximize the overall plant efficiency, lower energy costs and emissions, and reduce maintenance costs.
  • Stereolithography – SLA

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    Stereolithography (SLA) is an additive manufacturing technology that converts liquid materials into solid parts, layer-by-layer, using a light source to selectively cure each layer in a process called photopolymerization.

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    Applications:

    1. Engineering: Helps engineers and product designers conceptualize, prototype, test, and manufacture final products. With material characteristics like tough, durable, flexible, or temperature resistant these resins are used to create functional parts from assemblies to injection molds, soft-touch surfaces, and consumer products.
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    2. Dental: Allow dental labs and practices to create a range of personalized dental products in house. These parts are based on the patient’s scan intraoral, or CBCT scan, and designed for the treatment. Specific applications include orthodontic, diagnostic, and educational models as well as biocompatible parts like surgical and pilot drill guides.SLA4
    3. Jewelry: Prototyping and casting jewelry with intricate details. Standard modeling resins are recommended for prototyping to create an inexpensive “fitting ring” or “try-on” piece to create excitement and deliver peace of mind to clients before casting. Castable resin is designed for direct investment casting, allowing jewelers and casting houses to go straight from digital design to a 3D print.SLA5
    4. Model making and development: STL helps engineers and product designers quickly verify the look, feel, and function of a design. Mechanisms and assemblies can be tested and easily modified over the course of a few days, helping drastically reduce product development time and avoid costly tooling changes.SLA6
    5. Education: SLA has one of the most forgiving design specifications of all 3D printing technologies, which is adequately suited for educational use. Depending on part geometry, positive and negative surface features can be produced at 300 microns or less. Prototypes can be designed with the manufacturing process in mind, which allows for a seamless transition from prototype to traditional manufacturing, such as machining or injection molding.

     

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  • Digital Light Processing – DLP

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    DLP is a form of stereolithography that is used in rapid prototyping services. The main difference between DLP and SLA rapid prototyping is the use of a projector light rather than a laser to cure photo-sensitive polymer resin.

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    A DLP 3D printer projects the image of the object’s cross-section onto the surface of the resin. The exposed resin hardens while the machine’s build platform descends, setting the stage for a new layer of fresh resin to be coated to the object and cured by light. Once a complete object is formed, additional post processing may be required such as removal of support material, chemical bath, and UV curing. DLP will produce parts with resolutions under 30 microns; the equivalent to other stereolithography machines. Ultimately, production time does depend on the size of the model.

     

    Applications:

    1. Rapid prototyping

    There are times when engineers want to quickly design solutions that would help develop the end-product through rapid trial-and-error design iterations. DLP 3D printing enables engineers to think with their hands to facilitate reaching the final solution in rapid time.

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    1. Fit and function models

    DLP 3D printing enables engineers to test the type of fit (loose, tight, or shrink) in products before finalizing the design and moving into production.

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    1. Molds for tooling and metal casting

    3D printing injection molds using DLP technology are not meant to replace conventional mass manufacturing process. Rather, if one is looking to perform short runs without custom making tool template, 3D printed molds are best fit to create perishable molds if the customer requires low quantities (5 – 100 pieces), mid-sized parts (<165cc [10 cu. in.]), or if the required tolerances > 0.1mm (0.004in), where tighter tolerances can be attained depending on the post processing used.

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    1. Medical implants

    DLP enables medical doctors to precut required metal plates based on a representative 3D printed version of the patient’s skull to reduce the possibility of infection by reducing the procedure duration.

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    1. Dental restorations

    Dentists can now perform the following list of procedure using DLP additive manufacturing; Orthodontic applications, Denture bases, Partial dentures, Temporaries, Night-guards bite splints, Crown and bridge wax-ups, Indirect bonding trays, Surgical drill guides

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    1. Jewelry casting

    DLP 3D printing offers superior detail, precision, and a smooth surface finish that requires less finishing. Additionally, 3D print jobs go straight to the customer for review to casting and molding.

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    1. Automotive components

    3D printing in the automotive industry is now essential, where additive manufacturing applications become more numerous; conversely resulting in driving the development and adaptation of processes to meet the specific needs and address the constraints of this rapidly evolving sector.

    DLP 3D printers has opened new paths at each stage of production of motor vehicles; from the functional prototyping phases, design, and tooling production to parts manufacturing, the automotive industry is one of the pioneers in the use and integration of 3D printing in its processes for both new and antique vehicles.

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    1. Aerospace components

    Aerospace is one of the main industries that can benefit from developments in 3D Printing. This is not only because this sector has a long history of an early adopter of latest technology inventions, but also because it needs these inventions. Environmental performance restrictions, competitive market conditions, and high manufacturing cost are just some of the challenges that aerospace faces today. This is exactly where the benefits of additive manufacturing come into play, which helps in producing products in shorter production time, no required additional tooling, material savings, and cost-efficiency are just some of the good reasons why aerospace companies have started integrating 3D printing in their production strategies.

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  • Selective Laser Sintering – SLS

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    SLS technology uses a laser to harden and bond small grains of plastic, ceramic, or other materials into layers in a 3D dimensional structure. The laser traces the pattern of each cross section based on the 3D design onto a bed of powder. After one layer is built, the bed lowers and another layer is built on top of the existing layers. The bed then continues to lower until every layer is built and the part is complete. One of the major benefits of SLS is that it doesn’t require the support structures that many other additive manufacturing technologies require to prevent the design from collapsing during production. Since the product lies in a bed of powder, no supports are necessary. This characteristic alone, while also conserving materials, means that SLS is capable of producing geometries that other technology cannot. In addition, one needs not to worry about damaging the part while removing supports, where complex interior components and complete parts could be built. As a result, one could save time on assembly. As with other 3D printing technologies, there’s no need to account for the problem of tool clearance that subtractive methods often encounter.

     

    Applications

    1. Automotive

    SLS is capable of producing highly durable parts for real-world testing with highly complex geometries. Parts produced using SLS are durable, which could be used for high-heat and chemically resistant applications. Additionally, parts produced using SLS are impact-resistant for rigorous use and are ideal for snap fits.

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    1. Medical

    Some of the other medical marvels accomplished using SLS 3D Print technology include surgery planning for human face reconstruction to help those with bone and birth defects or those who sustained injuries. Additionally, 3D printed dentures that could be printed on demand.

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    1. Prototyping

    SLS 3D printing technology enables designers to refine and perfect their designs by enabling a relatively inexpensive way for them to test their design and think with their hands. For example, producing a unique honey comb sole that is excellent for impact and shock resistance, where SLS is being developed to produce the final product rather than just being restricted to rapid prototyping modelling.

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  • Selective Laser Melting – SLM

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    Selective Laser Melting – SLM is an additive manufacturing technique that can print metal parts in 3D, where a laser is used to melt metallic powder in specific places. Further, SLM uses a laser to melt successive layers of metallic powder, where the laser heats-up particles in specified places on a bed of metallic powder based on the 3D CAD, where the CAD file dictates where melting will occur. Then, the machine will successively add another bed of powder above the melted layer, until the object is finished. Different materials are available with SLM technology; namely, steel, titanium, aluminum, cobalt-chromium, and nickel alloys.

     

    Applications:

    1. Aerospace:

    Reduction of weight results in reduction of energy consumption. SLM technology helps aerospace industries to use multiple material and an open system to go for many design changes and to get a specific solution. SLM technology becomes more financially viable if one can reduce the post manufacturing processes currently used in conventional manufacturing processes; such as welding by combining a couple of parts into one single part that could be printed in one-shot.

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    1. Medical:

    SLM technology is already being used commercially with many metallic biomaterials; such as, titanium alloys, Cobalt-chromium alloys, and stainless steel. For applications in the medical industry; Joint replacement comes to mind; especially knees and hips in orthopedic surgery in addition to bore replacement in dental, oral, or maxilla-facial surgeries. In addition to individual implants, highly specialized surgical instruments and spinal fusion cages with enhanced functions can be manufactured using SLM.

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    1. Industrial:

    When time is money and money is time, SLM brings great opportunity to create wings to one’s creativity. Be it a tail lights for Limousine or racing parts, SLM can be cost effective and time efficient; especially for hard-to-source obsolescence items.

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  • Direct Metal Laser Sintering – DMLS

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    Direct Metal Laser Sintering – DMLS uses a precise laser beam to micro-weld powdered metals and alloys to form fully functional metal components based on CAD data. DMLS eliminates time-consuming tooling, and creates complex geometries not possible with other metal manufacturing processes (undercuts, hidden features, internal cavities, etc…). Made from materials such as Inconel, Aluminum, Stainless Steel, and Titanium, DMLS parts are strong, durable, and heat-resistant. Additionally, DMLS parts are also denser than investment casted metal parts because the grain structure is more controlled and packed closely together than in conventional casting methods. This accurate metal 3D printing process provides fine feature detail; making it ideal for complex oil and gas components, custom medical guides, consolidated aerospace parts, and tough functional prototypes.

    The main difference between SLM and DSLM technologies is the degree to which the particles are melted; where they are not completely melted with DMLS. In other words, if one is working with an alloy, one would use DMLS since it does not melt the entire metal powder completely; where if one is working with pure titanium for example; they would use SLM to get a homogeneous material.

     

    Applications

    1. Aerospace

    One can consolidate design and optimize value by allowing users to integrate multiple components; such as, air ducts, fixtures, or mountings holding specific aeronautic instruments into a single, strong metal part. This reduces weight, cuts down waste, and saves the time and resources needed for assembly.

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    1. Industrial

    Because DMLS can use most alloys, prototypes can be functional hardware made from the exact same material as the eventual production parts. This technique makes adding internal features and/or passages into the part’s design since it’s created layer by layer. DMLS produces metal parts with the same speed as plastic parts and has the potential to transition into metal injection molding once the need for increased production is identified.

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    1. Medical

    When it comes to applications in the medical sector, proof must often be provided of the origins and composition of the material used. The patient’s individual anatomy is the key factor in medical implants and meeting the patient’s specific anatomic requirements reduces not only the length of time spent in hospital, but also the risk of infection normally caused by ill-fitting implants, which consequently reduces healthcare costs.

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    1. Prototyping

    During the early stages of product development, DMLS can help by making design and functional prototypes available. As a result, functional testing can be initiated quickly and flexibly. At the same time, these prototypes can be used to gauge potential customer acceptance. Internal communication within and between teams can be facilitated by the availability of product models. This results in reduced time to market and shortened reaction times to current customer demands. Gradually, the risks involved in developing new products decrease, because problems can be detected sooner and be directly addressed. Development costs are reduced, and at the same time, consumer response is accelerated.

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    DSLM

  • Electron Beam Melting – EBM

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    Electron Beam Melting is similar to laser melting, but working with an electron beam instead of a laser. The machine distributes a layer of metal powder onto a build platform, which is melted by the electron beam. The build platform is then lowered and the next layer of metal powder will be coated on top. The process of coating powder and melting where needed is repated and the parts are built up layer-by-layer in the powder bed. Electron beam melting requires support structures, which anchor parts and overhanging structures to the build platform. This enables the heat transfer away from where the powder is melted. Therefore, it reduces thermal stresses and prevents wrapping. The build envelope can be filled by several parts, which are built in parallel as long as they are all attached to the build platform. Noteworthy, parts are built under vacuum.

    Compared to laser melting, EBM produces less thermal stress in parts and therefore requires less support structure and builds parts relatively faster. Additionally, EBM is quite similar to Selective Laser Melting – SLM, where EBM uses an electron beam in a vacuum, SLM uses laser in a chamber of inert gas.

     

    Applications

    1. Aerospace

    Some of the most reputable aerospace companies have already started adapting the use of EBM additive manufacturing. For example, Honeywell Aerospace uses EBM to work with nickel-base super alloy Inconel 718, which is ideal for intense heat and pressure situations. Because EBM operates above 1,000°C, Honeywell can produce and research parts for extreme temperature environments. Furthermore, Bradshaw believes that for aerospace, the initial adoption driver is cost reduction using additive manufacturing to redo existing parts, as in the case of the Honeywell.

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    1. Automotive

    In the automotive industry, weigh reduction translates directly to savings in fuel consumption. The result of using EBM additive manufacturing helps reduce feature thickness due to the dense compacting of EBM manufacturing, which results in weight saving of over 25%.

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    1. Medical

    In recent years, EBM has matured as a technology for rapid manufacturing of fully dense metal parts. With EBM, it is possible to create parts with geometries too complex to be fabricated using conventional methods; such as, fine network structures, internal cavities and channels. For example, EBM technology is a cost-efficient production process for both press-fit and cemented implants. Solid and porous sections of the implant are built in the same process step, eliminating the need to apply for example plasma sprayed porous materials through expensive secondary processes.

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  • Continuous Liquid Interface Production – CLIP

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    Although 3D printing is now possible using relatively small and low-cost machines, however, it’s still a fairly slow process. This is because 3D printers require a series of steps to cure, replenish, and reposition themselves for each additive cycle. Recent developments in additive manufacturing devised a process to effectively grow solid structures out of a liquid bath. The key to the process is the creation of an oxygen-containing “dead-zone” between the solid part and the liquid precursor, where solidification cannot occur. The precursor liquid is then renewed by the upward movement of the growing solid part. This approach made structures tens of centimeters in size that could contain features with a resolution below 100µm.

    CLIP technology makes a range of features and applications possible for industries as varied as automotive, medical, and consumer electronics.

     

    Applications

    1. Automotive

    More than a century ago, Ford Motor Company’s iconic Model-T made automobiles affordable to the masses with assembly line production and efficient manufacturing. That legacy has continued, with ground-breaking research to design and develop the future of mobility and manufacturing by adapting CLIP additive manufacturing technology. Recently, Ford needed to address a major engineering issue when placing a V8 engine into a new vehicle body design. The vehicle’s design created an unreachable oil filler cap because the engine sat lower and farther back under the hood. The product engineering team realized the opportunity to quickly address the issue using CLIP technology. The team was able to rapidly design, prototype and manufacture an oil connector using rigid polyurethane and elastomer materials to access the oil fill tube without needing major redesigns to several components of the vehicle.

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    1. Dental

    Dental and orthodontic labs provide time sensitive services to many dentists in the Kingdom of Saudi Arabia. These labs are always looking for new technologies to make dental models that are: accurate, fast, and of high quality. For most of the labs, investing in new digital technologies is important while maintaining cost effectiveness and simplicity of the model-making process. Therefore, for any new technology to get adopted by these labs exceeding the above defined criteria is critical, which is achievable when using CLIP technology.

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    1. Consumer Electronic

    Reputable companies such as Oracle are among the early adapters of CLIP technology, where Oracle required the material properties that CLIP technology provided, and in a production run of 10,000 board alignment brackets. Printing these with standard 3D technology would require months of printing, a total non-starter. CLIP technology ingenious solution to dramatically increase print speed and managed to produce the required boar alignment brackets in a fraction of the time it would have taken alternative 3D printers to complete the job.

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