INTRODUCTION
Technology developed in the last decade has rocketed the agricultural industry into a new era of efficiency. With GPS mapping and advanced AI technologies, farmers have increased cost and time savings.
Now, using 3D printing and additive technology, Drift Reduction Technology Corporation (DRT) is bringing another level of optimization to field sprayers.
Specializing in the fluid dynamics and aerodynamics that affect spray application, DRT developed a product to improve commercial sprayers by minimizing spray drift and maximizing accuracy and safety. Their invention will enable farmers to save valuable time and decrease chemical waste.
Because their concept was not commercially viable with traditional forms of production, DRT teamed up with Primary Manufacturing to design and prototype their innovative spray boom recirculation system called the SRV2.
With the best design for manufacturing engineers in the industry and the most advanced additive technologies, Primary helped DRT produce a compact and durable product that was otherwise impossible to create.
KEY POINTS
Additive manufacturing was the only process by which DRT’s concept could be commercially realized.
Additive technologies enabled a strong, compact prototype.
Multi Jet Fusion was the most cost-effective production method, and PA 12 was the perfect material for the system’s harsh environment.
THE CHALLENGE
The PROBLEM OF TRADITIONAL SPRAYERS
DRT was founded with the sole focus of improving and optimizing the application of crop protection chemicals.
Current field sprayer systems waste materials in both the application and cleaning processes. Not only is this waste costly, but it is also a safety hazard for the operator and negatively impacts the environment.
TRADITIONAL SPRAYERS
Wasted chemicals in cleaning
Environmental contamination
Exposure to dangerous chemicals
Time consuming flush process
The cleaning and recapturing process for traditional field sprayers can waste up to fifty gallons of chemicals. Because the sprayer must be cleaned before the next use, all chemicals remaining in the system are wasted during the flushing process.
Cleaning can take up to an hour because the operator must remove each end cap and open each of the valves. This method of flushing is not very safe for the operator nor for the environment.
The Innovation
DRT came up with an innovative idea for a system that minimizes all of these issues. Known as the SRV2 System, their concept replaced the end caps and flush cap with a return sweep. This minimizes chemical waste by implementing an aggressive recirculation system only used while spraying. Because the chemicals are immediately and responsibly applied, they do not need to be recaptured during the cleaning process.
With the SRV2 System, the sprayer can be cleaned in less than five minutes while limiting both operator and environmental exposure to hazardous chemicals.
The First Prototype
DRT hired a draftsman and sent the designs to be manufactured with traditional methods. Two of the parts arrived broken from shipping and the remaining two parts were fragile and cumbersome.
Though these first prototypes proved the concept, conventional manufacturing methods would not be capable of producing a viable commercial part.
THE ADDITIVE SOLUTION
DRT first contacted Primary in December 2019. They described their innovative concept and explained their manufacturing challenges.
After going back and forth with ideas, Primary drafted a CAD drawing. Jacob, the engineering lead, did most of the heavy lifting with the new design.
While the functional design of DRT’s concept remained the same, Primary developed a more compact part—shrinking the size of the original prototype by more than two times.
The flow channels inside the SRV2 valve are intricate and almost impossible to manufacture by injection molding or machining. The shapes and planes necessary for DRT’s design could only be achieved effectively with the additive process.
Because 3D printing is additive by nature, shapes and structures that are unthinkable with other methods become possible—even while maintaining the strength of the part.
“Primary Manufacturing has been an incredible partner for developing and producing extremely complicated parts.”
FUNCTIONAL TESTING
Rapid Prototyping
After helping DRT transform their idea into a CAD design, Primary began prototyping. They issued the first prototype for testing and made additional design changes with DRT’s feedback. This process continued until the part was perfect.
Throughout the prototyping process, Primary added several features to DRT’s part including a basket-like accessory to hold an ultrasonic flow monitor.
With the ability to quickly make design changes and build new prototypes, Primary finalized their product within only a few months.
Because additive does not require tools or molds, it is a more expedited and cost-effective prototyping process.
Manufacturing Process & Material
Because DRT’s system was built as an after-market add-on for agricultural equipment, the parts need to be durable and resistant.
Primary offers several methods of production with a wide variety of materials—anything from flexible silicone to thermoresistant plastics.
The two companies agreed that the best production method for the innovative SRV2 System was HP Multi Jet Fusion. This process produces cost-effective, accurate parts with consistent strength throughout.
Because the SRV2 system needed to be both chemical resistant and watertight, PA 12 was the best material for the job. Strong and durable, it is able to sustain the harsh conditions endured by a commercial sprayer.
“Making design changes and testing those changes was seamless and fast. We went through several revisions and prototypes that would have previously taken years to get through, if it could have been done at all.”
RESULTS
Because of the design’s complexity, conventional methods of production rendered the part fragile and cumbersome. With additive, Primary was able to improve the design and produce a commercially viable prototype.
Without the advances of additive manufacturing, DRT would not have been able to bring their idea to life. In less than a year, what was at first just a proof of concept became a tangible and durable part. Their original design that was otherwise impossible became a reality.
DRT’s innovation is groundbreaking, and Primary was grateful for the opportunity to help them develop and design a product that will positively impact the agricultural industry.
Today, DRT Corp is working with several original equipment manufacturers (OEMs) to get the SRV2 onto new sprayer systems.
