A LICENCE TO PRINT TIME - HOW HP MULTI JET FUSION TECHNOLOGY COULD WIN THE AMERICA'S CUP
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CASE STUDY | A LICENCE TO PRINT TIME
HP CASE STUDY
A LIC EN C E TO P RI NT T I M E
HOW H P M U LT I J ET FUSI ON TEC HNOLOGY
COU L D WIN THE AMERI C A’S CUP
HP New Zealan d , t h e Of f i c i al PC and Print Tec hnolog y
Par t n e r of E m i rates Team New Zealand , provi d es all
the d es i g n an d i n n ovat i on com put i ng power t hey need .
CASE STUDY | A LICENCE TO PRINT TIME
Challenge
Of all the elements that go into winning the America’s Cup – talent, funding, vision,
the design of the boat, the strength of the wind, the strength of the sailors when
the race is on, it all boils down to just two things.
How fast is the boat? Did it finish first?
But speed and time behind the scenes are just as crucial to the result on the water.
Industry: Country: In the lead-up to the big event in March 2021, a race is being run inside the Emirates
Sporting New Zealand
Team New Zealand base at Auckland’s Viaduct to get the boat ready.
On any given day, up to 35 Emirates Team New Zealand designers are huddled over
IT Matters: computer screens, crunching data flooding back from the yacht and chase boat out
• Leverages local HP expertise to meet the customers’ on the water, fine-tuning different elements and at the end of the day, they send
requirements
their designs to the builder.
• Provides high-computational infrastructure
And before they’ve arrived the next morning, the new custom parts are often ready
• Bespoke tailoring of technology and outcomes
and waiting to be fitted.
Business matters:
While our America’s Cup defenders are, of course, no strangers to Black Magic, the
secret to their success this campaign is their printers - but there is nothing ordinary
• Convenient in-house automated production
about the printers at Emirates Team New Zealand.
• Increases productivity
• Supports digital transformation of the organisation
Hardware:
• HP Jet Fusion 580 Color 3D Printer
• HP ZBook 15 G5, HP ZBook 15 G6
• HP ZBook 14u G5
• HP ZBook Studio G5
• HP Z27n Display
• HP Z38C Curved display
• HP Z8 x 8 all with Nvidia Quadro P6000 cards
• HP Z4 with P5000
• HP Z1 x 4 Tower with RTX2080 cards
CASE STUDY | A LICENCE TO PRINT TIME
Story Highlights:
Approach
As the official PC and print technology sponsor, HP New Zealand has equipped the
team with a HP Jet Fusion 580 Color 3D Printer, enabling them to create functional
parts, from hydraulic manifolds to hand-controllers, literally overnight.
O NE “3D printing, the turnaround time and the number of iterations we can make, has
been an absolute game-changer,” says Emirates Team New Zealand head of design,
HP Jet Fusion 580 Color 3D Printer Dan Bernasconi. “We started off using it for proto-typing but now lots of parts are
used on the boat. We’re making elements that might be impossible to manufacture
any other way because they’re impossible to machine.”
Colleague Marty Yates, the crew’s IT manager, is equally effusive.
“The fact we can turn around parts so quickly has just been invaluable. We’re doing
two to three builds a week, so having a HP Jet Fusion 580 Color 3D Printer on-site is
absolute gold for us. We can send the designs to the printer overnight and 12 hours
3 0 MIL LIO N later the parts are ready to be pushed out on the boat, going from dreams to reality
in often under 24 hours.
drops per second are printed to provide exact
precision and dimensional accuracy “HP Multi Jet Fusion Technology gives us a real competitive edge to innovate at speed.”
Manufacturing time in 3D
While 3D printing was used in the previous Emirates Team New Zealand campaign in
Bermuda, things were different then. The crew were using a contractor to print their
components, meaning a wait of several days as parts were sent off to be printed
and delivered, mistakes crept in during the process, and the technology used meant
2 4 HOURS
limited functional parts could be produced.
As marine engineers, the Emirates Team New Zealand designers are always looking
from render to reality
for ways to go at a greater rate of knots. Their partnership with HP was a match
made in racing heaven.
As well as financial sponsorship and an on-site HP Jet Fusion 580 Color 3D Printer,
Emirates Team New Zealand also received the attentions of a very enthusiastic HP
support crew who understood their passion from the get-go.
As HP New Zealand Country Manager, Oliver Hill, explains: “This is not a typical
sponsor relationship. We’re not just providing the technology but our expertise,
and we feel very much a part of the team. We’re in there all the time helping the
Emirates Team New Zealand crew innovate and making the boat go faster.”
“HP Multi Jet Fusion
Technology gives us a
real competitive edge to
innovate at speed.”
– Marty Yates, Emirates Team New Zealand IT manager
CASE STUDY | A LICENCE TO PRINT TIME HP New Zealand technical consultant Carl Hansen has been hands-on with the whole process. “I had my first opportunity to go sailing when I arrived in Auckland 20 years ago, I’ve loved it ever since. Working with Emirates Team New Zealand has been amazing because I get to be part of the Formula One of sailing.” Hansen and the HP team worked closely alongside the Emirates Team New Zealand designers to train them on the HP Multi Jet Fusion Technology, making sure everything was set up to meet the need for speed. Because the technology is so much more advanced than people realised, a lot of the job early on was helping designers understand everything the machines were capable of. “There are many different 3D print technologies”, Hansen explains. “HP’s Jet Fusion 580 Color 3D Printer takes voxel control to the next level by delivering strong, accurate, functional parts in full colour, in a fraction of the time. “HP’s Multi Jet Fusion Technology processes parts in two fast area wide passes to achieve top speed part production. The process begins by applying a layer of material in a work area, in one continuous pass it prints fusing and detailing agents across the full working area. This pass combines the printing with the fusing energy which bonds the part layers together. The build platform is then lowered layer by layer. The process is then repeated until the complete part is printed. “HP’s proprietary architecture is capable of printing 30 million drops per second, enabling extreme precision and dimensional accuracy. “You can’t get any other printer to print like that,” Hansen says proudly. “HP Multi Jet Fusion Technology is innovative, and it’s opened up so many more opportunities to print things that couldn’t have been done before. It provides strong, accurate, waterproof components, and in colour, which is unheard of.” “HP’s Jet Fusion 580 Color 3D Printer takes voxel control to the next level by delivering strong, accurate, functional parts in full colour, in a fraction of the time.” – Carl Hansen, HP New Zealand technical consultant
CASE STUDY | A LICENCE TO PRINT TIME
“You wouldn’t have dreamed of being able to do something like this”
The HP Jet Fusion 580 Color 3D Printer is now being used by Emirates Team
New Zealand to create everything from hydraulic manifolds to button covers,
shaving hours of precious time off the design, test and build process every single
day. If something doesn’t work today, it can be switched out tomorrow.
“Even things as simple as earpieces for our comms headsets, which we go through
regularly. Things like that mean we can just keep moving forward, smashing it out
on the water,” says Yates.
Because multiple items can be printed at once, it saves even more time. Designers’
imaginations are only limited by the size of the build chamber, about the size of an
A4 sheet of paper1.
But it’s not only time they’re manufacturing.
“We also use HP Multi Jet Fusion Technology to custom mould the controllers
[skippers] Peter Burling and Blair Tuke use so they have better control of the
foils. Ten years ago, you wouldn’t have dreamed of being able to do something as
customised as this, having that level of control,” Yates says.
HP is also supporting Emirates Team New Zealand with office and wide-format
printing for plans, as well as HP Z Book laptops and powerful Z Workstations to drive
the high-end graphics and rendering of the designs before the boat is even built.
During a nationwide lockdown in April 2020 because of the COVID-19 pandemic, HP
and Emirates Team NZ even got together to make PPE equipment like face shields
while the base was closed. Thousands of face shields were printed and delivered to
essential workers via not-for-profit community organisation ShieldsUp.
“Our cultures are very closely aligned,” explains Hill. “They’re always innovating at
speed to make the boat go faster and the “keep reinventing” motto is what drives
HP both locally and globally. When we first started supporting Emirates Team New
“We started out Zealand it was as a supplier only, but now we’re a sponsor. And our technology has
evolved alongside our relationship with Emirates Team New Zealand too.”
being able to print
in black only, now At the moment, all parts are made from PA-12 Nylon which is incredibly light and
strong to help the boats go faster, but some components still need to be made of
we have full colour metal. Hill says next year HP will be launching the HP Metal Jet2.
and next year we’ll “That’s going to completely change the game and make creating even more
have metal, so we’re components possible. We started out being able to print in black only, now we have
looking forward full colour and next year we’ll have metal, so we’re looking forward to evolving even
further for the next America’s Cup.”
to evolving even
further for the next
America’s Cup.”
– Oliver Hill, HP New Zealand
country manager
Actual dimensions, 332 x 190 x 248mm
1
https://www8.hp.com/us/en/printers/3d-printers/products/metal-jet.html
2CASE STUDY | A LICENCE TO PRINT TIME
Benefits Laying the course to NZ’s business future
Hill hopes to see New Zealand organisations learning from Emirates Team
Accelerate productivity: New Zealand’s success and recent accolade as the third most technologically
innovative sports teams in the world3, realising the boundless potential of HP Multi Jet
Fusion Technology. In the post-COVID world, diversification and a competitive edge are
going to be even more important to business resilience (and New Zealand’s economy).
“3D print technologies are gaining new capabilities all the time and what we’re doing
Create, test, iterate in here shows a massive opportunity to bring manufacturing jobs back to New Zealand.
just hours The opportunities are endless, from aerospace to automotive,” Hill says.
“The key is training New Zealanders to apply this technology to everything we do.”
Designer Dan Bernasconi agrees 3D printing is going to revolutionise the way we do
Ensure accuracy: business, just as it has the future of yachting.
“We’ve seen a massive gain in productivity as a result. We couldn’t imagine how
much we were going to use it. Any manufacturer or design business is going to see
the same.
“It’s completely changed the way we work as designers.”
Produce engineering-grade
thermoplastic parts Learn more at
hp.com/ETNZ
hp.com/multi-jet-fusion-500-300
Be future-ready:
hp.com/workstations/overview
Stay ahead of the curve
and support digital
transformation
References
3
https://emirates-team-new-zealand-media.s3.amazonaws.com/files/m4421_Sports-Technology-Annual-Review-2020.pdf
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