15 minute read
STAY REFRESHED
Customized Coolers and Drinkware
by Melissa Donovan
Big Frig is a cooler and drinkware brand out of North Sioux City, SD. In business since February 2016, the company began in a strip mall and moved to its current space in 2018. Working out of a facility of over 30,000 square feet—this includes a 12,000 square foot warehouse expansion that was undertaken at the beginning of 2023—it caters to the central and southeastern U.S., but serves customers in all 50 states as well as Australia, Canada, some of Europe, and Mexico. 20 full-time employees and several part time and seasonal workers are part of the business.
As a cooler and drinkware brand, Big Frig saw potential in personalization and customization early on. At the beginning of its journey, any decoration done on its products was strictly laser marking on drink tumblers and vinyl decals for beverage coolers.
Flexible and Durable
In 2017, it began looking for ways to offer color decoration on its tumblers and coolers—it turned to digital printing. “We wanted something durable with minimal changeover cost. We had very little space and only a couple of full-time employees, so whatever print process we went with had to be compact and easy to startup and shutdown,” explains Dakota Hoard, director of operations, Big Frig.
Another important piece of the puzzle, the printer needed to offer flexibility. In addition to printing to its own products, Big Frig also takes in contract work. “We pride ourselves on our nimbleness and flexibility, so many of our customers who started out buying our core products now come to us with a variety of other projects—canvas prints and laser marking leather gloves, for example—and we are happy to assist them with those as well. We make it a point to say ‘no’ only when we absolutely have to,” attests Hoard.
The founding members of the company embrace special requests, Hoard admits that saying “no” to customers is very difficult, but that they also enjoy trying out ideas on the fly. “For example, we have always made most of our own jigs and tooling—initially out of wood using rudimentary carpentry skills—now with three-dimensional printing and laser cut parts in addition to more traditional fabrication techniques. We aren’t very good at being patient when we are excited about a project,” admits Hoard.
An Inkcups Helix was initially brought in because cylindrical printing made sense for decorating tumblers. A dedicated rotary machine, the speed and print quality were just want Big Frig was looking for.
To print to the coolers, it went with the X5-T flatbed UV digital printer, also from Inkcups. It is ideal for the work Big Frig produces because of the 20-inch clearance. “Originally we had digital flatbed printers, which required that we remove the lid of each cooler from the body before printing. That was a huge expense in terms of time and effort. One X5-T station with a single operator has about twice the throughput of two of our older printers with two workers,” says Hoard.
Big Frig still conducts laser marking on its tumblers using gantry style CO2 lasers from Epilog Laser. According to Hoard, the Epilog devices are “work horses” that hardly ever give them trouble. They were easy to set up and maintenance is also simple.
It also uses a galvo-based laser from Radian Laser Systems, which was a bit more challenging to learn how to use, but the speed and quality are top notch. For example, a run of 128 oz. growlers with a large marking area once took nearly ten minutes per piece. With the Radian laser device, the decoration is complete in 28 seconds without loss of quality.
Ink Relationship
Printing direct to any object presents its challenges. Ink adherence is an issue, especially on low-energy surfaces. Furthermore, when printing to premanufactured items like drinkware, these pieces are subjected to higher wear and tear during general handling or cleaning and disinfecting after use.
Big Frig has experienced its own share of frustration with adhesion. Hoard says a few years ago acceptable adhesion of the ink on its tumblers became a struggle. “It was a real mystery as we could pull retains from previous runs, print the same art on the back with the same process, and the new print would delaminate while the old print adhered perfectly. We were down for weeks with orders piling up, but we couldn’t figure it out.”
An industry peer suggested Marabu North America and Big Frig reached out. Hoard says that despite Big Frig being a small company, Marabu representatives “dropped everything” to work through the problem and get production up and running.
A switch was made to Marabu inks, specifically Marabu UltraJet DLE-A inks on the drinkware and coolers. They are found to be more resilient with vibrant pigmentation, helping expand the attainable color gamut. Marabu primers— Primer P2 on drinkware and Primer P4 for coolers—are now used for most of the common surfaces Big Frig encounters— stainless steel, powder coat, and linear low-density polyethylene (LLDPE)—because of their one-step, flash-off application with low odor.
“Ultimately the greatest benefit is the relationship we developed with Marabu. We are usually the ones going above and beyond for our customers, so it’s refreshing to work with another business who will do the same for us,” comments Hoard.
Job Spotlight
Big Frig works with a number of customers, one of which is the Midway USA Foundation—a 501(c)(3) public charity working to sustain and grow youth shooting sports by providing long-term funding to youth shooting teams through annual cash grants. The organization wanted two different designs printed on cooler lids.
The coolers are made of LLDPE, with a low surface energy of less than 20 dynes/ cm2. “That’s great for keeping your cooler clean, but it can make getting good print adhesion a challenge,” explains Hoard.
Prior to printing, coolers are cleaned off to remove any residue from the molding process. They are then flame treated to raise the surface energy, usually to at least 40 dynes to ensure good wetting. The Marabu primer is applied and then the coolers are blown off with compressed air to rid them of any dust.
The printing itself is straightforward. The entire cooler is placed on the bed, the z-axis height is set, and then it’s printed. Switching between art files is a matter of a few mouse clicks. Printing the Midway USA Foundation designs took about four minutes per cooler. The operator prepped each cooler while another printed, so the whole job of more than 100 coolers is completed by one person in about nine hours.
Shrinking Economies of Scale
Big Frig is an excellent example of how to bring digital printing in house and grow. Not only does it customize its own products, customers can come to them for their promotional printed pieces as well. The flexibility offered by the Inkcups printers paired with Marabu ink and primer make it incredibly easy to offer on demand runs a little as one.
“Digital decoration is at the core of a paradigm shift in the industry. Customization used to be limited to traditional techniques, which are subject to the tyranny of economies of scale. Ultimately this skewed customization to primarily large customers ordering from large printers and personalization could only be gotten with great expense,” shares Hoard.
It is now possible for a small company like Big Frig to offer customization as an add-on service inline in house. “Economies of scale are getting smaller and smaller, and the printing technology itself is getting more user friendly. I think we’ll continue to see a broadening of what can be customized and who is doing it,” concludes Hoard. IPM
Software is instrumental in creating effective three-dimensional (3D) builds. When we think of software, the category is vast and includes parts design, solutions that help collaboration efforts, and moves over toadditional parts of the workflow like platform management.
"Software will revolutionize manufacturing. The promise of machines that can effectively build what we want them to based on digital signals is becoming
by Melissa Donovan
reality. Now it's software's turn-with it ideas become manufacturable designs, ensure a quality production, and track the life of a part, influencing future designs. We can reduce the idea-to-part process from years to seconds," shares Andre Wegner, CEO, Authentise.
Step byStep
The production of a 3D manufactured part is a multi-step process. Software is available to help at every junction.
From data preparation and processing to process management, precise control and reliable monitoring of the build process, and comprehensive connectivity; software covers every step and quality assurance for additive manufacturing (AM), whether for individual production or in a digital factory, according to Jenna Phillips, marketing specialist, EOS North America.
Above: Authentise Flows AM offers order intake, production planning, digital parts library, monitoring, quality assurance and reporting, and a rules engine.
“Every part requires an understanding of upstream and downstream processes to effectively design a part for manufacturability. Each step can utilize specialized software to accomplish that step. Reducing error, creating value, and retaining design-originated features can be preserved as integrations improve between these parts, resulting in a more efficient system,” adds Mark Norfolk, president, Fabrisonic LLC.
For example, 3D Spark’s software evaluates the printability and costs of potential 3D printing applications for different technologies and materials. “Analyzation still prevents many companies from using AM on a larger scale. Alstom, Deutsche Bahn, MetShape, and ZF have shown that this can be automated with 3D Spark, saving Alstom over €1.8 million and over 20,000 days of delivery time. The software facilitates easy access to 3D printing even for untrained personnel, in the process providing an educational boost and helping to identify new applications for the entire AM industry,” explains Ruben Meuth, coCEO/co-founder, 3D Spark.
Parts design software is important, according to Blake Teipel, Ph.D., CEO, Essentium. “Currently there is a common myth that AM can be used to create any part(s) designed for traditional manufacturing. However, similar to all other manufacturing, the key to success in adopting and deploying AM is to design specifically for the 3D printing process. The combination of generative-design software and step-change improvements in 3D printing technology has led to the creation of never-before-seen next-generation tools.”
“Digital manufacturing cannot exist without 3D modeling software—without a digital model, it’s impossible to print a part. New software solutions help optimize designs for the 3D printing process, but a knowledgeable designer can make excellent designs for AM with standard modeling software. The most promising software development is for simulating sintering deformation, which improves first-shot accuracy of printed and sintered metal parts,” says Skyler Des Roches, head of customer experience, Rapidia Inc.
Florian Rapp, head of development, Multec GmbH, believes that “‘slicers’ are the most important part of the software chain, since they convert the 3D model to a printing strategy and the final part. The slicer must allow adoption of the process settings to the model and its requirements.”
Software solutions that monitor the build process are advantageous. “Quality issues have plagued 3D printing. Many problems or challenges with 3D printing come from in-process errors that software catches and fixes in a closed loop cycle. Sigma Labs is a great example of monitoring software that improves the quality of powder bed fusion prints,” shares Matt Sand, president/co-founder, 3DEO.
The security element of AM is also handled with the help of software. “On its route from an original idea to a finished object, many people and companies contribute
Companies Mentioned
to the AM process. It first begins with the design of a digital object that represents or contains the intellectual property of its maker. In many cases, that object is only one part of a finished product assembled by another agent in that process—an integrator or, potentially, vendor. In many cases, the actual 3D printing is handled by a local service provider to save costs. At each step, intellectual property needs to be protected against theft and piracy, but still be available for legitimate agents to use, process, and reprocess. Who is allowed to access the designs—when, where, and
Spark 3dspark.de
3deo.co 187 AlphaSTAR Technology Solutions alphastarcorp.com 188Authentise authentise.com 189EOS na.eos.info
190Essentium essentium.com 191Fabrisonic LLC fabrisonic.com
Farsoon Technologies farsoon-gl.com 193Fiberneering fiberneering.com 194Formlabs formlabs.com 195HP Personalization and 3D Printing hp.com 196MELD Manufacturing Corporation meldmanufacturing.com
GmbH multec.de
Inc. rapidia.com roboze.com
Inc. trumpf.com
Wibu-Systems wibu.com how often? A system is needed to protect the underlying data and to monetize the act of printing a third-party design,” explains Tom Ricci, marketing consultant, Wibu-Systems.
Wibu-Systems’ solution protects intellectual property and manages the printing licensing process. The company’s CodeMeter technology uses cryptographic processes to encrypt digital intellectual property and create licenses for the protected intellectual property with easy integration with existing process chains.
“Reliable software is critical to the effectiveness and timeliness of the 3D printing process,” asserts Bálint Horváth, software product manager, Formlabs. “Without dependable and precise software, products will not be printed consistently or correctly, which increases overall project and printing time and the costs of materials used.”
Automated software solutions are important in today’s market. “Plagued with uncertainty and supply chain issues, 3D printing technology shores up supply chains by enabling scalable mass production for both short- and long-term solutions. The technology has the capability to react to near instant changes. The value of 3D printing also reduces reliance on manual labor and allows for complex and important parts to be rapidly produced,” explains Meaghan Ferris, global head of 3D metals go-to-market and business development, HP Personalization and 3D Printing.
“If 3D printing needs to move from art and artisan to method and mass production, automation must come into the picture. More information is needed here to get the job done right. Design/workflow and process simulation software will uncover the challenges that only the expert or artisan could discern, so that lesser humans can achieve similar, if not equivalent results,” asserts Dr. Rashid Miraj, director of technical operations, AlphaSTAR Technology Solutions.
1. Wibu-Systems’ solution both protects intellectual property and manages the print licensing process. The company’s CodeMeter technology uses sophisticated cryptographic processes to encrypt digital intellectual property and create licenses for the protected intellectual property with easy integration with existing process chains. 2. Formlabs’ Automation Ecosystem enables new levels of 3D printing productivity with Form Auto, Fleet Control, and the High Volume Resin System.
A recent trend in software includes artificial intelligence (AI). “3D printing is the perfect technology partner to consider with Smart Factories in which many laborious tasks are done with robots and production is driven by machine learning and AI. The obvious importance of this is that it pushes the technology to the very edge of what is possible with human hands and minds as well as allows advanced intelligence to help us. It’s a step towards the future, rather than using obsolete techniques that take us backwards,” shares Dr. Eliana Fu, industry manager, aerospace & medical, TRUMPF Inc.
“Until now, 3D printing production was limited by operator intervention, requiring users to remove complete printed parts, change resin cartridges, and set new printing jobs manually,” notes Horváth.
Stay Open Minded
Systems that communicate well with each other foster collaborative environments. AM is inherently deemed flexible, so it is no surprise that the software used with it be flexible as well. Open source solutions can provide this.
Open source provides full control, according to Rapp. “With non-open source software you are always depending on the publisher of the software. If you have a feature request that could improve the process and lead to better parts there is not a lot you can do. With open source on the other hand you can adapt the software to do exactly what you want, need, or expect.”
“I like the idea of open source, as it’s more collaborative. Some people like the ability to jump into problems and tear them apart from the inside out. That
Security Software Case Study
Global bus vendor Daimler Trucks and Buses teamed up with security experts at Wibu-Systems and additive manufacturing (AM) specialists Farsoon Technologies to create a novel three-dimensional (3D) printable parts service. Daimler has focused on the potential of digital production technology since 2016. Many parts for its Mercedes-Benz and Setra brands are made available in digital, 3D printable format on its OMNIplus service portal.
This includes both regularly required spare parts as well as rarely required parts for special customer requests. Bus operators and service partners can buy these for printing on site, when and where they need them. Wibu-Systems’ CodeMeter encryption and licensing solution protects the digital objects throughout the complete sales lifecycle, enabling a secure and efficient manufacturing-as-a-service process.
“CodeMeter security technology provides unique opportunities for creating ecommerce solutions for 3D printed parts. A system is built around a marketplace or e-store, which registered customers could buy 3D printed products. The store can be seamlessly integrated with established ecommerce systems to automate the buying and ordering process as completely as possible. Instead of physical products shipped by expensive and wasteful logistics, the buyer now receives the object design in the form of an encrypted file. The protected file is accompanied by a specific pre-processing license to prepare the 3D printing process. Another printing license then determines how many physical copies the client is allowed to create from the design he has purchased,” explains Tom Ricci, marketing consultant, Wibu-Systems.
This is a collaborative effort, thanks not only to Wibu-Systems’ CodeMeter but specially certified printers made by Farsoon. The OMNIplus service portal files are sold as encrypted downloads and the buyer receives a license to use for pre-printing as well as an actual printing license that allows as many copies to be printed as the buyer paid for. Once the license is granted it is used with Makestar software on specially certified Farsoon 3D printers.
“The successful implementation of an AM digital rights management system means that our partners and us have made a real mark in the digital 3D printing business. This opens up completely new vistas for our service operations and for the availability of products where they are needed at the point of sale, both commercially speaking and thinking about the good of our environment,” shares Ralf Anderhofstadt, head of center of competence AM, Daimler Trucks and Buses.
kind of creativity thrives better in an open source type of environment,” says Fu.
While open source is not a requirement, it certainly is beneficial. “I see a number of customers doing incredible things with Blender, which is fully open source. In some respects the mesh-based engine these kinds of programs run on are better aligned with freedom of shape that’s possible with 3D printing—compared to traditional solid based CAD,” explains Jasper Bouwmeester, CEO, Fiberneering.
Specifically in terms of AM, “it’s more important that we focus on open technologies—those that allow simple integration by API—because the end-to-end value chain of turning an idea into a part will require many software tools to work together. We need the suction of profit to bring more entrepreneurs to the software market to deliver improved tools. Focusing too much on open source may undermine that,” says Wegner.
Easy Benefits
For someone undecided on implementing 3D workflow solutions the benefits are apparent almost right away. With the help of return on investment (ROI) assessments, it is easy to see how favorable automation and AM are in comparison to conventional manufacturing methods.
According to Miraj, frequent use or use with complex builds increases the value and necessity of the software. "The future of 3D printing involves more sophisticated materials, complex geometries, greater number of parts, and more opportunities for failure. The cost of machines, materials, and personnel demand methods to increase efficiency and productivity. Design/ workflow and process simulation software canaddressmost ofthoseconcernsand ultimatelyreduce costs."
"Implementing 3D workflow solutions can increase business' demanding and unique needs by providing a quick, affordable solution. All workflow solutions can be designed and managed in house to speed up the workflow from idea inception to an end-use product," says Horvath.
Advantages to look for in 3D software include smooth integration into existing CAD/CAM and simulation environments, intuitive usability, effective monitoring, real-time availability, transfer of production data, and compatibility with many other systems, according to Phillips.
Of course, certain solutions are not a fit for everyone. "There needs to be a clear reason to adopt a new technology. The best way to ensure that a solution is worth pursuing is a clear understanding of the ROI. Typically this ROI calculation requires a good technical understanding of the process as well as the needs of the business," suggests Chase D. Cox, VP, MELD Manufacturing Corporation.
Initial ROI comes from efficiency, specifically faster quoting, fewer wasted resources and failed builds, and reduced meeting schedules, lists Wegner. "But the true ROIis felt down the linewhenthe data collected from the digital thread helps operations become more resilient, deliver insightthat canyielda competitiveadvantage with the help of AI and machine learning, and captures tribal knowledge;'
"The first step before entering and thus investing in AM should always be a potential assessment with regard to costs-ROI, technical printability, delivery time savings, and sustainability on the basis of one's range of components," notes Meuth.
Rapp suggests that, "from a financial point of view just take a few use cases of that person and do the calculation for different manufacturing processes. Chances are AM is less expensive and faster than any conventional production process."
"The more information you can give someone the better their informed final decision will be," agrees Fu.
''.,\s technology continues to improve the solutions will be even more capable of applying data and digital technologies, and the entire end-to-end lifecycle will be further streamlined and accelerated as a result of implementing 3D software and solutions," foresees Ferris.
Continued Improvement
Automation software is designed to increase efficiencies at every part of the AM process. As 3D printing becomes more sophisticated, the value of automation software subsequently grows.
"There is a need to develop solutions that make the process from creation to production of finished parts increasingly efficient, with rapid response to various configurations of production systems. This is from a technical point of view, as well as from a business and environmental perspective," notes Ilaria Guicciardini, head of marketing, Roboze.
Learn more about 3D printing in our most recent webinar, accessible at industrialprintmagazine.com/webinars. /PM
