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Summary Unit 2 Assignment A Distinction
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Unit 2 Assignment AApprentice Name: Nicole Senyurt
Company: Parvalux Electric Motors Ltd.
Product: Electric Motors
Introduction:
I am a final year apprentice working at Parvalux Electric Motors Ltd. And my manager has
asked me to produce a report discussing the manufacturing processes of electric motors in the
company. Before I discuss in my report about the processes, safety and human factors, I would
like to clarify that Parvalux Electric Motors Ltd. is a British Manufacturer based in Wallisdown,
which produces fractional horsepower geared electric motors. The company fabricates and
assembles different parts varying from AC, DC to brushless motors which are allocated in 3
different factories.
Electric Motor Manufacturing Processes:
As technology and engineering is advancing every day, the manufacturing processes used are
changing vastly going from traditional methods like Casting to alternative methods like Additive
Manufacturing. Here at Parvalux Electric Motors Ltd., we use 3 type of Additive Manufacturing
processes and they all involve 3D printing.
Used processes:
Selective Laser Sintering (SLS):
What is SLS?
The first type of Additive Manufacturing we use is Selective Laser Sintering which involves the
use of 3D printing and a high-power laser in order to expose small particles of typically glass,
plastics or ceramics through heat and fuse the particles together in order to form the 3D printed
object either of plastics, glass, ceramics or metal.
How does this process work?
This works by creating a Computer Aided Design (CAD) file which is a file that includes the
detailing of the software design of the object you want to print. This file is then converted into
STL format, which is read by the SLS machine, which then the printing process begins.
However, a quick note before we print the object, the 3D printing materials that we use in
the SLS machine must be powdered and then thinly dispersed above the build platform
which is found inside the SLS machine. Next, we get the high-power laser and direct it down
to the platform, which is controlled by the computer so that the designer can easily determine
what will be manufactured through the laser. Once this is done, the laser starts to trace the
cross sections of the digital object that has been designed onto the powdered material. Since
the laser is used mainly to heat the powder just below its melting point and merges the tiny
particles together in order to form the 3D object, it straight away forms the first layer of the final
product. Then the SLS machine drops by roughly 0.1mm to reveal a new layer of the material so
that the laser fuses the particles together, traces and forms another cross section. This process
is repeated until the whole of the 3D printed object has been produced. Once the whole process
, is complete, allow some time for the final product to cool off before you remove it from the SLS
machine.
(Diagram of the process)
How is this process handled safely?
As a matter of fact, before SLS is carried out it must be safe for the employees to work in. The
employer must make sure that the machinery is safe to use. For instance, the high laser must
be at a safe level for employees to use, as there have been reported incidents about laser
exposure. Therefore, the employer must provide undamaged laser safety eyewear to every
employee who is working in the laser area so that they are protected from the harsh laser
radiation.
Also, the employer must make sure that the powder they use, has minimal damage to an
employee’s respiratory organs. This is due to reported incidents of employees who have
experienced inhalation or dermal exposure to the powder they used when handling SLS.
Therefore, it is crucial for the employer to make sure that when they hire any potential staff, that
they do not have any respiratory conditions such as Asthma, Bronchitis and others. working in
that specific area. Even if the worker does not have any respiratory condition, it is still crucial for
all the employees to wear breathing mask PPE that block the powder from entering the masks
and to wear undamaged fire-proof clothing as well since the high laser could accidentally get in
contact with the powder if it is made from metal and cause fumes or explosions as it works in a
hot environment around the 3D printer. Employer must provide AC too to minimize incidents due
to thermal changes. In case of any fire explosion, it is crucial that the employees are informed
about how to exit the area safely and be trained by the employer at the beginning of their work.
Why would someone choose SLS?
If you want a cost-effective process that requires no supports and makes both shaped and
formed Quality Prototypes and Final Products with high accuracy. Also, when it comes to
manufacturing strong, durable parts that require complex shaping then SLS is the choice for you
which can lead to more profit and mass production.
Why would someone not choose SLS?
• It requires very skilled machine operators and materials which can cost more than £250000.
So, if you can afford that then buy it! And make sure when you hire someone, they have
expertise or experience of the machine or else you will have a slower manufacturing process.
• Half of the cooling down time for the manufactured product takes up to 12 hours, which can
waste time in the manufacturing process as we need mass production of electric motors in a
short time. This is a huge problem in an engineering industry as it can cause the workers to be
pressured due to time and more stressed which are limitations to the activities that the individual
can undertake either working themselves or within a team.
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