How BMF GmbH uses Digital Source

The Customer

BMF GmbH has developed a device to automate the media blasting of small parts, a process that was previously manual and often error-prone. Founder Ronny Bernstein created the Twister blasting cabinet, which features removable, tree-like workpiece holders that securely suspend multiple parts. These holders can be customized for different geometries and are mounted on a rotating platform, improving the efficiency of the blasting process.

BMF uses automated centrifugal streams for efficient cleaning of rotating parts, improving speed and consistency while reducing labor. With over 200 Twister customers worldwide, the company transitioned from CNC machining to 3D printing its components using Onyx after acquiring a Markforged Mark Two printer in 2018. BMF also offers CNC machining services to an expanding client base.

The Challenge

The abrasive blasting medium causes 3D printed and CNC-machined parts in the blasting cabinets to wear down, leading BMF to recommend replacements every six months. As BMF's operations grew, the production and shipping times for these replacement parts increased, resulting in delays for customers. “In some cases, clients had to wait up to six weeks for parts, which is an unacceptable downtime,” recalls founder Ronnie Bernstein.

BMF's workers were struggling to schedule printing for new Twister machine parts, and the expanding Twister parts business was disrupting CNC work for other clients. Additionally, the logistics team found printing, packing, and shipping parts to customers increasingly time-consuming, with two members dedicated full-time to fulfilling orders. This issue was worsening as the customer base continued to grow.

Thomas Mueller, a development engineer at BMF, notes that downtime can be very costly for customers. Each work-holding fixture holds 10 parts, and the blasting cabinet platform can accommodate 10 fixtures. With Twister's short cycle times, a day of inactivity can mean up to 50,000 parts left unprocessed.

While customers value Twister's performance, many rely on BMF for custom fixture designs, straining the company’s limited resources. A more efficient solution is necessary to effectively serve their global customer base.

“Through the Digital Source platform, the customer can print the component they need the moment a failure or wear is detected. The part is available in a matter of hours and the machine can continue to run. We can collapse downtime from an average of 14 days to one day.”

– Ronny Bernstein (Owner, BMF GmbH)

The Solution

Markforged Digital Source enables companies to create a digital warehouse for secure purchasing of spare parts for on-demand printing. Bernstein notes that both Digital Source and Markforged printers are user-friendly for BMF’s customers, who can access a digital inventory of approved replacement part designs through this platform.

Berstein highlights that many customers experience 3D printing for the first time when they print replacement parts for their Twister machines using Markforged printers. He notes that Digital Source's key advantage is its ability to eliminate long lead times in 3D printing and shipping parts globally, resulting in reduced downtime for BMF's customers.

Bernstein appreciates the level of security that’s built into Digital Source, which not only protects BMF’s intellectual property but helps ensure that customers are only using OEM-approved parts in their Twister machines.

“Our machines use high-quality, expensive components. All parts, including spare ones, must meet the same strict quality standards as those shipped directly from Markforged. It’s essential that these parts cannot be altered, allowing customers to print only the exact originals,” he emphasizes. Bernstein states that Digital Source addresses part versioning issues. When BMF updates a part, the latest print file is automatically added to all customer inventories, while the old version is removed.

Furthermore, Digital Source has opened new business opportunities for BMF, as each unique part design requires a custom-built work-holding fixture for secure sandblasting.

Fixture design is an iterative process. Bernstein notes that Digital Source allows BMF to upload fixture designs for customers to print and test on their Twister machine. If adjustments are needed, Mueller can easily update the CAD drawing and re-upload the revised design, helping BMF increase profits without printing and shipping costs.

With some customers printing their own replacement parts, BMF can respond more quickly to 3D printing and CNC machining jobs. Mueller adds that the team can also print parts for new Twister builds without delays in production scheduling.

The Future

BMF has 20 customers using Digital Source, and Bernstein seeks to expand this as its value becomes clear. For those unable to invest in a Markforged printer, partnering with local 3D printing services offers a quick way to obtain replacement parts. Bernstein notes that Digital Source will enable BMF to grow without straining its limited resources, allowing employees to focus on more valuable tasks. He concludes, “With Digital Sources, Markforged work can become more creative.”

“The Metal X system has allowed us to participate in funded projects and to collaborate with companies by making customized models for some applications.”

– Aitor Zuriarrain Professor of Engineering