How Thermylene® 3DP Filament Transformed Gardening Prototyping

A Case Study on 3D Printed Soil Blocking Tools for Seed-Starting

In the rapidly advancing field of large-scale gardening, innovation, and efficiency are crucial to meet the growing demands of sustainable practices. Swift Blocker™, a Michigan-based company specializing in gardening tools, sought to improve the prototyping process of their soil-blocking tools used for seed starting. Soil blocking compresses specialized soil mixtures into cubes, increasing oxygen exposure on all sides. The cubes give seeds and new roots a quick start without being confined. Swift Blocker™ looked to develop new tools quickly, and Asahi Kasei Plastics North America, Inc., based in Fowlerville, MI, provided a groundbreaking solution with their Thermylene® P86G12 glass-filled polypropylene filament designed for FDM printing.

Innovative Solution for Agricultural Tools

Facing the challenge of developing efficient and cost-effective prototypes, Swift Blocker™ needed a material that could closely mimic the properties of steel prototypes, particularly at an 18-gauge thickness. Traditional materials like PETG and stainless steel were either too costly or lacked the necessary performance during the prototyping phase. The superior stiffness of Thermylene® P86G12 allowed for a close translation to steel, providing the ideal solution for their soil-blocking tools.

Choosing the Right Material and Technology

Thermylene® P86G12 was selected for its exceptional properties:

• Superior Stiffness: Enabled prototypes to closely replicate steel properties, crucial for functional testing at 18-gauge thickness.
• UV Stability: Allowed for outdoor testing without material degradation, essential for agricultural applications.
• Hydrophobic Qualities: Prevented moisture absorption, maintaining material integrity during use in varying environmental conditions.

Significant Cost and Time Savings

By adopting Thermylene® P86G12 filament for prototyping, Swift Blocker™ achieved remarkable cost and time savings:

• Cost Reduction: Traditional steel prototyping cost a minimum of $250 per development iteration. With four typical iterations, expenses could reach $1,000 before finalizing the design. Switching to 3D printing with Thermylene® P86G12 reduced these costs by over 90%.
• Accelerated Time to Market: The efficiency of FDM printing significantly shortened the prototyping phase, allowing for faster product development and testing.

“I dramatically reduced prototyping time and costs. Using Thermylene® P86G12 was over 90% cheaper and considerably faster.”

  Dan, Business Owner, Swift Blocker™

Asahi Kasei's Thermylene filament designs products that stand the test of time.

Asahi Kasei's glass-reinforced polypropylene is perfect for prototyping applications.

UV stability and hydroscopic qualities allowed for outdoor testing.

Stiffness and strength were key attributes of the prototype.

Dan used the prototype to develop a finished product made from stainless steel.

Processing Conditions and Expert Tips

To optimize the printing process, Swift Blocker™ applied the following conditions and tips:

• Processing Conditions:
  • Nozzle Temperature: 280°F
  • Nozzle Size: 0.6 mm hardened nozzle
  • Bed Temperature: 80°C
  • Layer Height: 0.3 mm
  • Support Material: Tree support structures
    
• Expert Tips:
  • Use glass-filled polypropylene-specific adhesive like Magigoo along with a raft for dimensional stability.
  • Orient parts in the direction of needed strength to maximize structural integrity.
  • Utilize higher bed temperatures with hardened nozzles to accommodate the material's properties.
  • Reduce print speeds to avoid surface imperfections due to the glass content.
  • Ensure the print bed is thoroughly cleaned before use for optimal adhesion.

The Outcome

Asahi Kasei Plastics North America's Thermylene® P86G12 filament provided Swift Blocker™ with a high-performance, cost-effective solution that met all their prototyping requirements. The material's exceptional stiffness and minimal warpage enabled the production of functional prototypes that closely resembled the final steel products. This innovation reduced costs and accelerated the development process, giving Swift Blocker™ a competitive edge in the gardening industry.

Conclusion

This collaboration highlights the transformative impact of advanced materials in gardening prototyping. By leveraging Thermylene® P86G12, Swift Blocker™ was able to innovate more efficiently, reduce expenses, and bring their soil-blocking tools to market faster than ever before.

Explore the Possibilities with Asahi Kasei Plastics North America

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