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E info@novaproduct.com

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Services

Polyjet 3D Printing

Polyjet technology is similar to an ink jet printer. Droplets of a photo curable resin are deposited layer by layer. UV lamps on either side of the print heads cure the resin as it is deposited.

A separate support material is also deposited. It is gel like and is removed with a water jet leaving no marks on the parts. Parts are fully cured at the completion of the build.

  • Layer thickness is 0.0006 of an inch
  • Platform size is 13.25×12.5” or 19.7×15.7”
  • Rigid resins Vero) available in transparent, black, white, blue and light gray
  • Flexible resins (Tango) available in Black (Shore A61), Grey (Shore A75, and Plus (Shore A 27) which has amazing elongation and tear strength for an RP resin
  • Polypropylene like resin
  • Most parts require no finishing because of the fine layer thickness
  • Parts can be easily finished and painted

Best suited for:

  • Rapid modelling
  • Master models for rubber moulds
  • Models with fine details or complex geometry
  • Visual models
  • Form and fit models
  • Marketing models
nova-Polyjet 3D Printing

Fused Deposition Modelling (FDM)

FDM models are built by extruding a bead of partially melted plastic – layer after layer – to build the model.

The system can deposit a soluble material to use as support. This material is dissolved in a chemical bath after the build is finished. Non-dissolving supports would typically be difficult to remove, but this process allows more complex parts to be built.

  • Layer thickness is typically 0.010, 0.013, 0.007 of an inch (0.005 are also available)
  • Platform size is typically 10×10” and 14×16”
  • Material available is ABS Plus (an ABS with some Polycarbonate content). Also available are a Medical grade of ABS, an ABS/Polycarbonate blend, Ultem 985 (a high temp material) and PPSF (Polyphenylsufone)
  • FDM materials are versions of plastics that would be used for injection moulding or machining parts (production intent materials)
  • Parts can be easily finished and painted

Best suited for:

  • Functional models for testing
  • Form and fit models
  • Sand casting master models for prototype runs
  • Low volume production parts
nova-Fused Deposition Modelling (FDM)

Stereolithography (SLA)

The first and oldest additive manufacturing process, stereolithography uses a UV laser reflecting off an X/Y mirror to draw into a vat of liquid UV curable resin. The resin quickly hardens wherever the laser draws.

The same build resin is used to construct support structures for unsupported features. When the drawing process completes, the part emerges from the liquid and is placed in a UV oven for final curing. 

  • Layer thickness is typically .006 to .004 of an inch
  • The build platform sizes range from 10×10” to 20×20”. Larger parts can be built in sections and joined together
  • Variety of resins available with a range of properties: ABS-like, Polypropylene-like, clear and high-temperature resistant
  • Parts can be easily finished and painted

Best suited for:

  • Functional and master patterns
  • Visualization
  • Form and fit
  • Marketing
nova-Stereolithography (SLA)

Selective Laser Sintering (SLS)

SLS is a process that creates layered parts by using a laser to fuses the particles of a powder together. This is the second oldest rapid prototyping system. 

The powder that is not fused acts as a support material while the part is building and is brushed/blown off when the part is finished. SLS materials have improved significantly in recent years.

  • Layer thickness is typically 0.005 of an inch
  • Platform size is 12×12”
  • Larger parts can be built in sections and joined together.
  • Variety of available resins — DuraForm PA (nylon), DuraForm FR (fire retardant), DuraForm GF (glass filled), CastForm (for investment casting masters), LaserForm A6 Metal
  • Parts can be easily finished and painted

Best suited for:

  • Functional models
  • Durable models
  • Form and fit testing
  • Investment casting masters without tooling
  • Low volume production parts
nova-Selective Laser Sintering (SLS)

Z-Corp

The Z-Corp machines uses print heads to deposit droplets of a binder material onto a powder (similar to plaster) to solidify a part.
The build material also acts as support. The finished part is surrounded by compacted powder which is broken away to expose the final part. The part is then infiltrated with a spray or liquid to achieve a functional finish.

  • Layer thickness is 0.004 of an inch
  • The build platform 8×10”
  • Material is a plaster composite with different grades for different applications
  • Parts can be printed in monochrome or in full colour
  • Material is lower cost, so bulkier models can be produced efficiently

Best suited for:

  • Full colour marketing models (labels can be printed on the model during the process)
  • Visualization
  • Concept models
nova-Z-Corp

CNC Machining

Machining is one of the oldest forms of manufacturing. With computer control you can receive parts in a shorter time and with consistency from part to part.

Parts can be machined using many production materials. ABS, nylon, delrin, PVC, aluminum, brass or steel are all available. Nearly any size of part be produced using the CNC process.

Best suited for:

  • Functional prototypes
  • Short run or full production run parts
nova-CNC Machining

Rapid Tooling for Rigid Urethane

Rapid moulds are made in one to three days from master models. The models used can be Polyjet, SLA, FDM, CNC machined or existing parts. The models are finished and any surface texture on the master will be reproduced in the mould. The mould can be either a single or a multi-cavity mould.

Urethanes are a group of plastics that solidify when a resin and catalyst are combined. They offer a wide range of properties and we try to match the properties you require to one of the materials available. There are urethanes similar to ABS, Polypropylene, Polycarbonate and Nylon. Various properties include, fire retardant, high heat, high impact and fast de-mould time, though not all in the same material.

  • Virtually no size limit to cast parts
  • Cost effective for short runs of small parts, but especially medium or large parts
  • Materials are suitable for production parts
  • Some urethanes are neutral and so are easily coloured or the parts can be painted

 

nova-Rapid Tooling for Rigid Urethane

Rapid Tooling for Flexible and Rubber Parts

Rapid moulds are made in one to three days from master models. The models used can be Polyjet, SLA, FDM, CNC machined or existing parts. The models are finished and any surface texture on the master will be reproduced in the mould. The mould can be either a single or a multi-cavity mould.

Flexible materials that can be used are silicon rubbers and urethanes.  Both are a group of materials that solidify when a resin and catalyst are combined. They offer a wide range of properties and durometers and we try to match the properties you require to one of the materials available. Durometers range from Shore A 5 to Shore A 60 for silicon, and Shore A 15 to Shore A 95 for urethane.

  • Virtually no size limit to cast parts
  • Cost effective for short runs of small parts, but especially medium or large parts
  • Materials are suitable for production parts
  • Some urethanes are neutral and so are easily coloured or the parts can be painted
nova-Rapid Tooling for Flexible and Rubber Parts

Injection Moulding

Injection moulding is a mass production process used for producing hundreds of thousands and millions of identical parts. However, it can also be used for short runs of parts — hundreds or thousands — depending on part geometry. 

Injection moulding melts plastic, shoots it into a mould cavity where it cools and is later ejected. This cycle is repeated about every minute — 60 parts per hour.

  • Parts can be moulded in a variety of materials, colours and finishes
  • Small parts can be moulded in a mould insert tool which runs inside an existing mould base (This is less expensive and is easier to cost justify for short runs)
  • Larger parts require dedicated moulds

Best suited for:

  • Prototype parts in production materials
  • Pre-production runs while production tooling is being completed
  • Short run production requirements
  • Design for production evaluation
nova-Injection Moulding

Vacuum Forming

This is a process where a sheet of plastic is heated and placed over a form. A vacuum from below sucks the plastic onto the form and the excess material around the edges is trimmed off.

  • Vacuum forming can be used for prototypes, but is typically for production parts
  • Various kinds of sheet stock are available – ABS, HDPE, Styrene, Vivac etc…
  • Low cost tooling

Best suited for:

  • Packaging
  • Various parts
nova-Vacuum Forming

Plaster Casting

The plaster casting process uses a master model to create a mould out of plaster. The plaster mould is used to cast copies in aluminum or zinc. When the metal copy is cool, the plaster is broken away to expose the part, therefore each part requires its own mould.

  • The plaster picks up all the detail of the model
  • There is virtually no size limit to parts
  • Models from plaster moulds exhibit very good surface finish
  • There is virtually no size limit to parts
  • Masters can be SLA, SLS, FDM, Polyjet or machined models
  • Cast parts can be machined to achieve tighter tolerances

Best suited for:

  • Short run metal production parts in aluminum or zinc
  • Prototype parts in aluminum or zinc
  • Parts to simulate die cast parts
nova-Plaster Casting

Sand Cast Metal

Sand casting, another traditional manufacturing process, uses a master model or tooling to create a mould made with a specialized sand. Molten metal is poured into the sand mould and left to cool. The sand is then broken away to expose the part.

  • A variety of metals can be used — aluminum, iron, steel, brass, etc…
  • The surface finish of the cast part is not as smooth as with Plaster Metal Casting and it does not reproduce as much fine detail
  • Cast parts can be machined for tolerance and details
  • FDM models can be used as master models

Best suited for:

  • Prototype runs from a FDM master model
  • Full production runs from tooling
nova-Sand Cast Metal

Conventional Hand Crafted Models

The original prototyping process. Hand crafted models are manually machined, carved or sculpted using dimensioned drawings or sketches. Depending on the end use, models can be fabricated in various materials.

Best suited for:

  • Mock-ups of design concepts
  • Large low tolerance models
  • Sculptural objects
nova-Conventional Hand Crafted Models
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Testimonials

"We've been using Nova Product for years now for our rapid prototype needs. The delivery and quality of our prototype parts is never a concern. AS new RP technologies become available, Nova has been good to keep us abreast of the methods of producing our prototype parts."

Fred Brouwer, Senior Mechanical Engineer — RDM Corp.