Manufacturing Bangles with 3D Printers – An ultimate guide

Date: Jan 24, 2024 Category: 3D Printing for Jewelry

 

TRADITIONAL WAY OF BANGLE MANUFACTURING AND ITS LIMITATIONS


In some sections of the industry, bangles are manufactured using Wax injection and lost-wax casting. A Master Piece is created using manual techniques and then Rubber & and Silicone-based molds are created which then enables the goldsmiths to make multiple copies of the same design through wax injection. While traditional wax injection and lost wax casting have artistic and cultural significance, these limitations have led to the exploration of modern manufacturing techniques for more efficient and scalable production in the jewelry industry. However, there are limitations to this method as jewelry manufacturers are confined to the limitations of this method. The limitations of this method are;

 

·         Insistent Weights

While Injecting Wax and in the difference of Pressure either by hand grip or the Wax injection machine. There is a difference of weights in wax models.

·         Uneven Wire Gauges

When the Rubber mold is used for too long there is a difference in pressure in wax injectors. The gauges of wax models of the same design can be different.

·         Wastage of Precious Metal

To ensure the weight of each bangle same a lot of precious metal is buffed and polished. And it results in a lot of precious metal not being able to recover.

·         Time and Labor

 

As the process goes. Each new design has to be made and cast in silver to make Rubber and silicone molds. Then Wax is injected into the mold. Then every piece is carefully fixed into the casting tree. All of these steps require time and man-hours. 

 

 

 

Modern ways of manufacturing Bangles

Bangles in jewelry manufacturing have come far from the traditional methods as now industry is rapidly shifting towards 3D Printing & Automated CNC methods. While 3D Printers are capable of printing light weights Bangle designs. CNC automations is suitable for Bright Cutting complex patterns for which its uses precision jewelry tools. Sometimes a jewelry design is also made using combinations of 3D Printing and Automated CNC.


 

Need of 3D Printers for Bangles

Based on current jewelry trends of Middle East & South Asia. Most jewelry manufacturers require light weights and prefer geometrically complex patterns that are not possible without 3D Printers. 3D Printers are able to print different variations with precision while enabling high production based on the speed & build platform size. Bangle are now being 3D Printed with different methods depending upon the specific requirement of the Jewelry Manufacturers. Bangles require specific way of support structures some CAD Operators would print Bangles one by one but with Advent of Fast 3D Printers & DLP technology now the popular trend in the industry is no 3D print the whole Bangle Casting tree as it skips many additional steps in Jewelry Production.


The use of 3D printers for bangle manufacturing brings several advantages and benefits that address some of the limitations associated with traditional methods. Here are some reasons why 3D printers are beneficial for bangle production:

 

·        Design Flexibility: 3D printing allows for intricate and complex designs.

·        Rapid Prototyping: 3D printing enables rapid prototyping, allowing designers to quickly iterate and test various designs

·        Customization: 3D printing enables personalized and customized bangle designs.

·        Material Variety: 3D printing supports a wide range of materials, including various metals, plastics, and resins.

·        Reduced Waste: Traditional manufacturing methods often involve subtractive processes that generate significant material waste.

·        Scalability: 3D printing can be highly scalable, allowing for the efficient production of multiple bangles.

·        Complex Geometries: 3D printing excels at producing objects with complex geometries.

·     Cost-Effective for Small Batches: 3D printing can be cost-effective for smaller batches, prototypes, or customized pieces, reducing the need for expensive molds or tooling.

·       Digital Workflow Integration: 3D printing seamlessly integrates with digital design software, allowing for a streamlined and efficient digital workflow.

 

 


Need of 3D Printed Bangle Casting Trees

Jewelry Manufacturer with High-Scale of Production require consistent output. A most of them get the repeated orders of the same design. So by 3D Printing the Casting Ready Bangle Trees. This enables them to save a lot of time and labor spent in spruing and fixing models manually. Either by experience of the Jewelry Designers and Input from the Jewelry Casting Department. All the Spruing can be done only once and once the Casting Tree is finalized.

Components of a Bangle Casting Tree

Every Bangle Casting Tree has some of the Same Basic Components that are placed in every design intended for this purpose.

Main Design

Bangles while being circular in shape could still have simple or complex Patterns. Bangles having more surface and solid areas are easy to support but they could have more engraving or embossing patterns depending upon the design. While some Bangles could have more complex filigree or mix type of designs. There could be additional Supporting required for complex designs.

Supports

Supports are first applied to the base. Then they are used to connect all the stacking bangles. Supports should be applied keeping strength and cleaning in mind.

Base

A Base  of about .3 or .4 thickness shall be placed to provide the whole tree with strength to sustain the peeling force during printing.

Candle/Trunk

Candle or Trunk is the centerpiece of the Casting Tree that provides the main flow of metal during Casting. Candles can either be printed. Or Cages Rings can placed instead and Candle made of Wax can be inserted into it to save Resin.

Sprues

Sprues are also Channels that provide the flow of the metal fro, Candle to the main Designs. Apart from the flow they also help hold the design of the bangled together during both 3D Printing & Casting.

 

 

How to 3D Print Bangle Casting Trees?

3D Printing Bangle casting tree makes sense when the build platform is large enough to accommodate multiple Casting Trees and the 3D Printer is fast enough. Bangle Tree would require appropriate sprues and strong and even support structures to Print and hold the designs together. One has to be sure all critical areas for sprues and supports are covered. Compared to Casting Tress of other jewelry Bangles are much simpler to sprue.

Protospeed has recently shared a step by step tutorial to guide the jewelry Enthusiasts on how to efficiently make a Bangle Casting Tree. You can also download the STL file of this bangle from  Here

 Watch the complete tutorial on how to make a Bangle Casting Tree for 3D Printing & Casting