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Fused Deposition Modeling (FDM)
Material extrusion is a 3d printing process where a filament of solid thermoplastic material is pushed through a heated nozzle, melting it in the process. The printer deposits the material on a build platform along a predetermined path, where the filament cools and solidifies to form a solid object. types of 3d printing technology: fused deposition modeling (fdm), sometimes called fused filament fabrication (fff). materials: thermoplastic filament (pla, abs, pet, tpu). dimensional accuracy: ±0.5% (lower limit ±0.5 mm). common applications: electrical housings; form and fit testings; jigs and fixtures; investment casting patterns. strengths: best surface finish; full color and multi-material available. weaknesses: brittle, not sustainable for mechanical parts; higher cost than sla/dlp for visual purposes.
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Stereolithography (SLA)
Stereolithography, also known as Vat Polymerization is a 3D printing process where a photopolymer resin in a vat is selectively cured by a light source. The two most common forms of Vat Polymerization are SLA (Stereolithography) and DLP (Digital Light Processing). The fundamental difference between these types of 3D printing technology is the light source they use to cure the resin. SLA printers use a point laser, in contrast to the voxel approach used by a DLP printer. Types of 3D Printing Technology: Stereolithography (SLA). Materials: Photopolymer resin (Standard, Castable, Transparent, High Temperature). Dimensional Accuracy: ±0.5% (lower limit ±0.15 mm). Common Applications: Injection mold-like polymer prototypes; Jewelry (investment casting); Dental applications; Hearing aids. Strengths: Smooth surface finish; Fine feature details. Weaknesses: Brittle, not suitable for mechanical parts.
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Selective Lazer Melting (SLM)
Selective Laser Melting or Metal Powder Bed Fusion is a 3D printing process which produces solid objects, using a thermal source to induce fusion between metal powder particles one layer at a time. Most Powder Bed Fusion technologies employ mechanisms for adding powder as the object is being constructed, resulting in the final component being encased in the metal powder. The main variations in metal Powder Bed Fusion technologies come from the use of different energy sources; lasers or electron beams. Types of 3D Printing Technology: Direct Metal Laser Sintering (DMLS); Selective Laser Melting (SLM); Electron Beam Melting (EBM). Materials: Metal Powder: Aluminum, Stainless Steel, Titanium. Dimensional Accuracy: ±0.1 mm. Common Applications: Functional metal parts (aerospace and automotive); Medical; Dental. Strengths: Strongest, functional parts; Complex geometries. Weaknesses: Small build sizes; Highest price point of all technologies.
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Selective Laser Sintering (SLS)
Selective Lazer Sintering also known as Powder Bed Fusion is a 3D printing process where a thermal energy source will selectively induce fusion between powder particles inside a build area to create a solid object. Many Powder Bed Fusion devices also employ a mechanism for applying and smoothing powder simultaneous to an object being fabricated, so that the final item is encased and supported in unused powder. Types of 3D Printing Technology: Selective Laser Sintering (SLS). Materials: Thermoplastic powder (Nylon PA11, Nylon PA12). Dimensional Accuracy: ±0.3% (lower limit ±0.3 mm). Common Applications: Functional parts; Complex ducting (hollow designs); Low run part production. Strengths: Functional parts, good mechanical properties; Complex geometries. Weaknesses: Longer lead times; Higher cost than FFF for functional applications.
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Product Design
FORCYST is well recognized company for product design services & provide complete end to end solutions from concept design and research and development to design engineering, rapid prototyping and manufacturing. We have a strong team for Product Design. We normally take the raw or just basic idea from the client as input. We take inputs in the form of User Requirement Specifications (URS). Our Engineers then brainstorm to convert the concept into reality through various Engineering studies and expertise. Our Engineers not only develop a pen paper model but also guarantee for the working prototype to prove the concept. Once the prototype is functionally approved, we then suggest the necessary optimisation. Our team takes care of that we achieve the results in least number of iterations to progress faster and economically working on many domains simultaneously. Our engineers at FORCYST provides the product development services at any stage and can take up product at mid-stage upto final stage of production. What the concept may be, we assure that we take up the project and provide end to end solutions from product designing to prototyping to manufacturing. Contact us now to know more about us or for any queries.
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pressure vessel design service
Forcyst is a mechanical engineering firm offering specialized professional engineering and design services in asme pressure vessels, heat exchangers, piping systems and reviewing of calculations and drawings for these static equipment. We provide engineering, consulting, design and drafting services of asme pressure vessels and piping systems. we are experienced in other pressure vessel related work such as: 1. Advanced custom configurations and components 2. Specialized process applications 3. Full range of pressure and service temperatures 4. Nozzle, flange, baffle, hatch and doors 5. Tema heat exchangers 6. Api storage tanks 7. Rectangular tanks, bins, foundations and support systems
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Material Jetting (MJ)
Material Jetting is a 3D printing process where droplets of material are selectively deposited and cured on a build plate. Using photopolymers or wax droplets that cure when exposed to light, objects are built up one layer at a time. The nature of the Material Jetting process allows for different materials to be printed in the same object. One application for this technique is to fabricate support structures from a different material to the model being produced. Type of 3D Printing Technology: Material Jetting (MJ). Materials: Photopolymer resin (Standard, Castable, Transparent, High Temperature). Dimensional Accuracy: ±0.1 mm. Common Applications: Full color product prototypes; Injection mold-like prototypes; Low run injection molds; Medical models. Strengths: Best surface finish; Full color and multi-material available. Weaknesses: Brittle, not suitable for mechanical parts; Higher cost than SLA/DLP for visual purposes.
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finite element analysis
Finite element analysis (fea) we at forcyst have developed a method where once the concept is designed and approved, we prepare a problem statement and set the boundary conditions and carry out the finite element analysis to validate the performance and failure modes of the designed product. this method of analysis is used to verify the designed criterias to minimise the over engineering at times. We carry out two types of fe analysis, static and linear. Static analysis basically involves zero internal effects, zero vibrations and zero impact whereas linear analysis involves, linear geometry, material and zero contact. fea is carried out through software including cfd that forcyst team use in developing product. Fe analysis does add a cost to the project but it saves the time for unnecessarily over designed or under designed prototyping. the benefits of implementing fea during the design process is that the product can be tested or analysed with actual material properties. Thus this approach, helps to reduce and time and costing of project. forcyst also uses finite element analysis as a method to carry out failure mode and effects analysis (fmea) studies. thus, finite element analysis is a method where we can validate and prove our design calculations through engineering approach and methods.
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Digital Light Processing (DLP)
Looking at Digital Light Processing machines, these types of 3D printing technology are almost the same as SLA. The key difference is that DLP uses a digital light projector to flash a single image of each layer all at once (or multiple flashes for larger parts). Because the projector is a digital screen, the image of each layer is composed of square pixels, resulting in a layer formed from small rectangular blocks called voxels. DLP can achieve faster print times compared to SLA. That’s because an entire layer is exposed all at once, rather than tracing the cross-sectional area with the point of a laser. Light is projected onto the resin using light-emitting diode (LED) screens or a UV light source (lamp) that is directed to the build surface by a Digital Micromirror Device (DMD). A DMD is an array of micro-mirrors that control where light is projected and generate the light-pattern on the build surface. Types of 3D Printing Technology: Direct Light Processing (DLP). Materials: Photopolymer resin (Standard, Castable, Transparent, High Temperature). Dimensional Accuracy: ±0.5% (lower limit ±0.15 mm). Common Applications: Injection mold-like polymer prototypes; Jewelry (investment casting); Dental applications; Hearing aids. Strengths: Smooth surface finish; Fine feature details. Weaknesses: Brittle, not suitable for mechanical parts.
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design to manufacturing software solution
FORCYST has a very strong team of Material Engineers. Once the Concept is validated and our team has developed a functional prototype, our team understands the needs from the client as per final product performance. We understand the working product environment in the form of Working Stress, Working Temperature and Handling Conditions. Our material Engineers understands the feasibility of the product in the form of market study on materials apart from the performance requirement. We have set a benchmark in setting up the most advanced design which most easy way to manufacture. The Concept of Design to Manufacture is very important because it determines the overall success of the product in market. If the Product is designed as per the manufacturing, it saves a plenty of time and investment too. The Concept to Design to Manufacture is the base line for every Product Development or Optimization project at Forcyst. Our Engineers assures the client that the product not only remains suitable for prototyping but also feasible for manufacturing. Forcyst is your one stop solution for your mechanical engineering requirements whether it is product design and development or design engineering and 3d printing, our engineers have in-depth knowledge of engineering and use their expertise to meet your requirements. Contact us now for more information.
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CONCEPT VALIDATION
FORCYST has a strong team of Mechanical, Electrical and Material Engineers to develop a market quality product. Our Team understands the User Requirement Specifications from the client very well and converts the problem statement into number of stages. Our Engineers then covert individual stage into individual problem statement and prove the concept through engineering studies. Concept Validation is the most crucial stage in any product development project as it determines the time as well as investment incurred in it. The stronger the concept, the easier and faster it is to validate the same. Our engineers are very well qualified for the same and look for the fastest and long term solution method for quality product development. Concept validation normally is the stage which determines the overall costing of end product as it involves the material study of the final developed product. We prove the concept through engineering studies and analytical studies in the the form of FInite Element Analysis (FEA) and Computational Fluid Dynamics (CFD). Once the concept is validated, we proceed for the best suitable prototyping technology for functional physical product.
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COMPUTATIONAL FLUID DYNAMICS (CFD)
Computational Fluid Dynamics is the the latest design and Analysis approach to solve the problems of fluent flow across a profile, within or on the component or inside a system. COMPUTATIONAL FLUID DYNAMICS (CFD) approach in Product Design CFD is simulation software used by the FORCYST to validate our concepts and designed product. It is the best tool to demonstrate the effect of the fluid flow at various temperatures with variable velocities. We normally use these kind of analytical design approach for the product which has pressures variations at multiple points, heat variation at inlet and outlet in a system as well as fluid flow effect on the entire component or system. The Computational Fluid Dynamics Design approach though adds an additional cost to the development of the product or system but it saves the unwanted repeatable cost on prototypes and thus saves substantial time. The chances of success through CFD validation approach is more than the traditional methods of the design. Our team has successfully executed projects for the Automobile and Medical industries by improving the effectiveness and efficiency.
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AERODYNAMIC DESIGN STUDY
FORCYST has a specialised team for carrying out the Aerodynamic studies on the required product, component or part. Our Engineers carry out the Aerodynamic studies through the strong basics of Computational Fluid Dynamics Approach. Our Engineers understands the requirements from clients in the form of performance output and then defines the boundaries to form the problem statement or statements. Once the Problem statement is ready, it is then easy for our Fluid Dynamics Engineers to carry out the Analytical Studies. Through the Aerodynamic Studies, we can save substantial time and the chances of the successful performance of the product increases to almost 99%. This kind of product development and optimization saves the number of iterations and unwanted prototyping expenses. Our Team will ensures that the client gets the world class Aerodynamic Analysis software support so that the concept is validated across and around the world.
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3D Printing Technology
3d printing or additive manufacturing is a process of making three dimensional solid objects from a digital file. Working of 3d printing it all starts with making a virtual design of the object you want to create. This virtual design is made in a cad (computer aided design) file using a 3d modeling program (for the creation of a totally new object) or with the use of a 3d scanner (to copy an existing object). A 3d scanner makes a 3d digital copy of an object. 3d scanners use different technologies to generate a 3d model such as time-of-flight, structured / modulated light, volumetric scanning and many more. Processes and technologies not all 3d printers use the same technology.
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Designing
prototyping
analysis
product development
When you’re choosing an engineering consulting firm to work with, you want a team that you can count on for all aspects of product prototyping, engineering and development. The engineers at forcyst engineering firm rely on 3d computer-aided design (cad), finite element analysis (fea) and design failure mode and effects analysis (dfmea) to solve problems in the virtual domain and bring the industrial designers’ vision to life. We employ a design, build, test, and repeat process during the engineering phase to ensure the best results for our clients. the hardware development happens alongside the engineering phase. This helps to ensure a minimal number of revisions to both the mechanical and hardware components. As we develop your product’s hardware, we create breadboard prototypes to better define potential components, system architecture and firmware. put simply, our engineering consulting services are unmatched when it comes to turning an idea or concept into a new product that functions properly and is cost-effective to manufacture. forcyst, as a leading product development company in mumbai offers end to end product design, development and product optimization to multiple sectors like medical, automotive, aerospace, consumer, energy and industry globally. From research & development to design engineering, prototyping, analysing and manufacturing and plastic injection moulding services, we provide complete one stop solutions.
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product optimization
Forcyst offers a very pertinent mix of expertise that can be used to customize solutions to product. We can help you in optimizing many aspects of your product and increase your reliability profitability and competitiveness. Typically, our goal is make your product more desirable and to increase marketing metrics. we at forcyst, develop a product with real time advantages such as; -identifying the target market- exactly who the intended user is. -conducting extensive market research to identify customer/user needs, wants and preferences and to define what customer sees a better product. -translating customer needs or problems into technically viable solution-product features, attributes, requirements and specifications. -defining the product concept- what the product will be and do, and the benefits to be delivered. -testing and verifying-to ensure that the final product scores high with the customer. The customer should be exposed to the product as it takes shape, not solely or an after the fact check. forcyst is considered as one of the best product optimization company in mumbai offers 360 degree solution from product design and development to multiple sectors like medical, automotive, aerospace, consumer, energy and industry globally. From research & development to design engineering, prototyping, analysing and plastic injection moulding services, we provide complete one stop solutions.
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REVERSE ENGINEERING-3D SCANNING
Our 3d scanning facilities technologies will capture 3d measurements from objects as small as a pin head or as large as a production factory. When we remove the constraints imposed by conventional measurement technologies, the scope of applications becomes virtually limitless with 3d, digital data in hand. While much of our work is in reverse engineering and product inspection, there are so many other uses for our 3d laser scanning and 3d measurement data. Our team of highly skilled professionals can transform the raw point cloud or cmm data into output formats that are the foundation for design, documentation, visualization, and analysis as well. 3d laser scanning is a non-contact, non-destructive technology that digitally captures the shape of physical objects using a line of laser light. 3d laser scanners create “point clouds” of data from the surface of an object. In other words, 3d laser scanning is a way to capture a physical object’s exact size and shape into the computer world as a digital 3-dimensional representation. 3d laser scanners measure fine details and capture free-form shapes to quickly generate highly accurate point clouds. 3d laser scanning is ideally suited to the measurement and inspection of contoured surfaces and complex geometries which require massive amounts of data for their accurate description and where doing this is impractical with the use of traditional measurement methods or a touch probe.
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