IPM April 2023

30 METAL PRINTINGGROWTH

Interest in three-dimensional (3D) metal printing is growing rapidly. Insight Partners'report30PrintingMetalMarketForecastto2028statesthatgrowth is driven by aerospace and defense as well as automotive industries. Both benefitfrom3Dprinting'sflexibilityindesignaswellasproductionefficiency. Whiletheseindustriesareearlyadoptersof3Dmetalprinting,thepresenceof thetechnologyisextendingfurther.

Our cover story, Heavy Metal, takes a look at 3D metal printing's popularity and were it is currently in use today. We also dive deeper into the efficienciesofferedwhenpairinga3DprinterwithautomationsoftwareinSoftware's Turn. Tocompletethisissue's3Dcoverage,findourTargetChartaswellasa recentwebinaron3Dprintingonlineatindustrialprintmagazine.com.

In addition, this edition includes spotlight editorials on direct to object and directtotextileprinting.

If that isn't enough, we also preview major trade shows coming up this Spring. The International Sign Association's Sign Expo is a great take in for thevisualsignandgraphicsspace, RAPID+TCTbySMEtargetsthoselooking at additive manufacturing for their business plans, and finally Messe Frankfurt's Texprocess Americas is an educational platform with sewing andtextilesinmind.

.RIAL epftlNT

INDUSTRIALPRINTMAGAZINE.COM

Volume 10,Number2

EDITORINCHIEF

ThomasTetreault 978-921-7850

EDITOR

Melissa Donovan mdonovan@rockportpubs.com

ASSOCIATEEDITOR

Cassandra Balentine cbalentine@rockportpubs.com

ARTDIRECTOR

Sarah M.White swhite@rockportpubs.com

WEBEDITOR

Melissa Mueller

CONTRIBUTORS

Pete Basiliere, OliviaCahoon, KemalCarr, MariaConrado, Mark Hanley, MelindaTetreault

ADVERTISING SALES

PUBLISHER

ThomasTetreault 100 CummingsCenter, STE 321E Beverly, Massachusetts01915 Ph 978-921-7850 x110 • Fx978-921-7870 edit@rockportpubs.com

SALES

Nicole Pizzi-Cerundolo Ph978-921-7850x160 • Fx978-921-7870 npcerundolo@rockportpubs.com

Amanda Doyon Ph978-921-7850x170 • Fx978-921-7870 adoyon@rockportpubs.com

Cheers,

Melissa Donovan, Editor

CORPORATE&PUBLISHING OFFICE 100 CummingsCenter, STE 321E Beverly, Massachusetts01915

ROCKPORTCUSTOM PUBLISHING, LLC

CHAIRMAN

JeffreyJensen

PRESIDENT&CEO

ThomasTetreault

CONTROLLER

MissyTyler

IndustrialPrintmagazineispublishedbyRockportCustomPublishing,LLC.Please send change ofaddressformsto: 1DO Cummings Center, STE 321E, Beverly, MA 01915. © Rockport Custom Publishing, LLC 2023. Reproduction by any means ofthe whole orpart of Industrial Printmagazine without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply ourendorsement.

Subscription Rates:U.S.$41.65peryear,sevenissues;singlecopies:$5.95,Canadaand Mexico:$52.22(U.S.D.) Otherinternationalsubscriptions:$71.05(U.S.D.)

Vendors: We welcome your product news. Include prices, slides, photos, and digital files with your press release. Please forward product samples and media kitsto ReviewsEditor,IndustrialPrintmagazine100CummingsCenter,STE.321E Beverly, MA01915.We cannotberesponsibleforunsolicitedproductsamples.

NEXTLEVEL

RAPID +TCT2023 AM Event

by IndustrialPrintMagazine Staff

Billed as North America's largest and most influential additive manufacturing (AM) event, RAPID + TCTisbackat McCormickPlace-West Building in Chicago, IL from May 2 to 4, 2023. Presented by SME and the owner of the TCT Group-Rapid News Publications-it combines both a conference and exhibit hall to bring attendees to the next level of their business.

The conference is held over eight tracks-automative, aerospace, defense, consumer goods, healthcare, wider industrial, research and development, andAMecosystem. Over 160AMexpertsare scheduled to present across all of these themes.

Inthe Exhibit Hall

More than 350 companies plan to exhibit the latest three-dimensional (3D) printing technologies and applications. Here we've included some of what is expected at the show.

3DCeram, booth 4859, is a turnkey provider for 3D printing technical ceramics with stereolithography (SLA). 3DCeram recently launched the Cl000 FLEXMATIC, with a print size of 320x320x200 millimeters (mm). The ClO00 Flexmatic offers one or two laser options for industrial print speeds. A removable tank allows semi-automated post-processing of printed parts and thus continuous production for large series. The machine is user friendly and UL compliant. INFO# 210

3DEO, booth 5429, announces its newest material, pure copper. Developed for use in 3DEO's Intelligent Layering technology, the new material features excellent thermal and electrical conductivity suitable for a variety of applications and industries. 3DEO will have copper components on display, as well as parts from its library of materials including 17-4PH and 316L stainless steel. INFO# 211

6K Additive, booth 1812, produces premium metal powders for AM made from sustainable sources. The manufacturing process is environmentally friendly and allows for the production of powders that are truly spherical, void of porosity and satellites, with better flowability than competing technologies.

6K Additive's UniMelt microwave plasma process leverages sustainable sources as feedstock such as certified millings from CNC, grindings, used additive powder, or even the support material used in AM. At the booth learn more about premium powder offerings including nickel 718, nickel 625, titanium 64, SS316L, copper 18150, and GRCop. Also on display are new refractory powders that include tungsten, rhenium, and tungsten-rhenium. INFO# 212

B9Creations, booth 2259, unveils its largest format 3D printer, the B9 Core 6 Series MPro and shows live 3D printing demonstrations. With a build volume of 192xl08x304 mm, B9Creations' Core 6 Series MPro is ideal for customers who need an expandeddesignspacewithoutsacrificing the ultra-high resolution and accuracy B9Creations' platforms are known for. The MPro offers effective resolution finer than 40µm and produces parts that are within ±50µm from CAD file to 3D printed part with real-time correction of error. INFO# 213

EOS North America, booth 4612, showcases its EOS P110 Fine Detail Resolution polymer system, the AMCM M 290-2

1. JEOL USA, booth 4441, showcases its EBM powder bed fusion machine. 2. Roboze, booth 2438, exhibitsone ofthemost industrialized3D printingsolutions inthe world for the production of non-metallic parts for regulated industries-ARGO 500.

industrial metal 3D printer, and new and innovative applications leveraging advanced AM solutions. INFO# 214

HP, booth 4618, exhibits its commercial Jet Fusion and Metal Jet 3D printing solutions, the HPJet Fusion 5420W and the HP Metal Jet S100. Exciting advancements to the systems are showcased as well as a new, strategic partnership with Endeavor 3D, an AM service bureau, that will be maximizing the printing capabilities at its facility with HP technology. INFO# 215

Impossible Objects, booth 4024, invites attendees to learn about composite-based AM (CBAM) and the latest material developments and recent customer success stories. Meet its expert team and learn more about the CBAM 3D printer, which is onsite and ready for showcase. INFO# 216

Ingersoll Machine Tools, booth 1720, mill large composite parts in a single highlights its MasterPrint Robotic, the piece. INFO# 217 robotic version of the company's family JEOL USA, booth 4441, showcases its of AM equipment, which provides cus- electron beam melting (EBM) powder tomers with the ability to seamlessly bed fusion machine and displays a variprogram, simulate, 3D print, as well as ety of metal parts that the 3D printer has

Electronics, software, tools & services for industrial inkjet systems

Production-ready, scalable drive electronics for all leading industrial inkjet printheads

Comprehensive software for single-pass or scanning applications including development kits, workflow solutions and advanced print quality tools

DropWatchers and waveform development services for jet evaluation and optimisation

World-wide sales and support from industrial inkjet experts

built, highlighting the aerospace, medical, and energy fields with samples from Ti64, nickel alloy 718, and pure copper. JEOL invites attendees to explore the capabilities of this dynamic system. The new JAM-5200EBM EBM powder bed fusion 3D printer improves productivity, quality, and reliability to produce stronger and lighter parts for AM. INFO# 218

Lubrizol 3D Printing Solutions, booth 5438, features an extensive material portfolio including the ESTANE 3D TPU range, which can be used in powder bed fusion or fused filament fabrication 3D printers. ESTANE 3D is a versatile elastomer with exceptional abrasion resistance, high elasticity, and excellent flexibility over a wide temperature range. A new grade ESTANE 3D M88A is available under a selective availability program. This soft and flexible polymer is exclusively designed and certified for HP’s Jet Fusion 5200 series, offering a friendly

unpacking process, ability to dye parts for bright colors, and ideal for complex lattice design. INFO# 219 Mantle, booth 1528, encourages attendees to stop by its booth to see the future of injection mold tooling. The company’s innovative metal 3D printing technology is designed specifically for printing injection mold tooling, delivering the tolerances, surface finish, and material properties required for precision tooling. Molders, tool shops, and OEMs use the technology to simplify tooling creation, reducing lead times and costs by as much as 70 percent. Mantle showcases its innovative TrueShape printing technology and case studies with a number of partners. INFO# 220

Materialise, booth 4830, launches its new version of Magics, a powerful data and build preparation software for AM. The new release includes the full integration with the CO-AM Software Platform, which allows users to trace work with CO-AM and automate workflow through the dedicated automation module. With the new Machine Manager integration, AM users maintain control of build files, ensuring machine connectivity on their factory floor and scaling up their AM operations. INFO# 221

MELD Manufacturing, booth 4641, showcases its line up of 3D metal printers utilized for large-scale parts. Everyone is invited to attend presentations featuring the machines along with information about the company’s no-melt technology for printing metal. Video is displayed throughout the booth spotlighting each of the machines and showing the MELD open atmosphere technology. Schedule a private meeting with a

MELD expert in its in-booth conference room during the show. MELD’s newest machine, 3PO, is its first to offer hybrid capabilities. It features MELD’s additive technology with an integrated subtractive capability. It accommodates a build volume of 157.5x106.0x39.4 inches. K2 is designed for production and repair of large parts and boasts a build volume of 82.7x43.3x39.4 inches. L3 offers a generous workspace while having a smaller footprint. It features a build volume of 45x23x23 inches. INFO# 222

Meteor Inkjet Ltd., booth 3956, is an independent supplier of electronics, software, tools, and services for industrial inkjet. Expanding 3D printing beyond prototyping and into the manufacturing space, inkjet technology enables two of the most flexible AM processes, binder jetting and materials deposition. In Chicago, Meteor shows its full range of solutions for 3D and AM print systems including drive electronics for all major industrial inkjet printheads; ready-to-use digital front ends that integrate with commercially available 3D build tools; software development kits allowing custom printers to be built from the ground up; and a complete suite of tools and services to support the design and optimization of print systems. INFO# 223

Photocentric, booth 1715, showcases production parts from its print farm, photopolymer resins, and LCD-based 3D printers. Visitors can admire large format prints with optimized topology printed with LC Titan, with a build volume of 27.6x15.6x47.2 inches. Also on display, proprietary resins including 50 percent plant-based range and Photocentric’s 3D printers; large format LC Magna and Opensource LC Opus. Photocentric and BASF Forward AM collaborate to create and validate a line of resins for both Photocentric and thirdparty printers. Photocentric showcases scalable technology to make mass manufacture of affordable components a reality. INFO# 224

3. Ingersoll Machine Tools, booth 1720, highlights its MasterPrint Robotic, the robotic version of the Ingersoll Machine Tools’ family of AM equipment.

Prima Additive, booth 1615, exhibits its specialized metal AM systems, equipped with powder bed fusion and directed energy deposition technology. Among the peculiarities of this brand is the presence in its product portfolio of systems equipped with green and blue lasers, particularly performing when it comes to working with highly reflective materials. Furthermore, the open configuration of the systems makes them suitable for process and new materials research purposes. At the booth it is possible to see one of the 150 series machines, a consolidated product already sold in dozens of units in Europe, equipped with powder bed fusion technology and a work area six inches in diameter by 6.3 inches in height. INFO# 225

Rapidia, 4243, manufactures equipment to bring high-speed metal 3D printing to anyone, anywhere. Rapidia’s AM platform is powered by Metal Paste Deposition, a powder-free metal 3D printing process that can scale from lab-based rapid prototyping into an affordable smallscale production solution. Rapidia showcases its Conflux 1 metal printing solution. By using Metal Paste Deposition, Conflux 1 makes production of complex metal parts faster, easier, more affordable, and safe. The complete system, consisting

of a paste printer and vacuum sintering furnace, eliminates the debinding step, and supports removal to produce functional parts in under 24 hours. INFO# 226

Roboze, booth 2438, exhibits one of the most industrialized 3D printing solutions in the world for the production of non-metallic parts for regulated industries—ARGO 500. ARGO 500 is an AM solution developed by Roboze that shifts the focus of 3D printing from simple prototyping to the production of finished parts with production standards comparable to traditional methods. The high know-how of the team in materials science and mechatronics results in a repeatable and therefore scalable system, for the production of components with super-materials such as PEEK, Carbon PEEK, ULTEM AM9085F, and Carbon PA PRO. INFO# 227

Stratasys, booth 5012, is leading the global shift to AM with innovative 3D printing solutions for industries such as aerospace, automotive, consumer products, and healthcare. Through smart, connected 3D printers, polymer materials, a software ecosystem, and parts on demand, Stratasys solutions deliver competitive advantages at every stage in the product value chain. The booth features a variety of 3D printers and printed parts showcasing five different technologies—fused deposition modeling, PolyJet, SAF, P3, and SLA. Visitors see

real-world examples of how customers use Stratasys technologies to bring agility to manufacturing and supply chains, transform product design, and improve patient care. INFO# 228

TRUMPF, booth 4218, introduces the TruPrint 1000, a productive and compact entry-level system for additive processing of metal powders using the laser metal fusion process also known as powder bed fusion. Thanks to improved gas flow, the new TruPrint 1000 ensures high productivity and quality and is easy to operate, which shortens production time. A new multiplate function makes the TruPrint 1000 even better suited for series production. Due to its robustness and quality in 3D printing, the TruPrint 1000 is ideal for manufacturing dental prostheses or medical technology, but is also impressive in research and development or small series production. TRUMPF’s booth also highlights the TruPrint 5000, a highly productive, semi-automatic laser metal fusion machine that meets the highest industrial 3D printing requirements. Combined with external part and powder management and monitoring solutions, the TruPrint 5000 is ideal for industrial AM. INFO# 229

Xact Metal, booth 4836, exhibits the XM200G, a dual-laser powder bed fusion metal 3D printer. This system is compact, high performing, and easily configurable to the user’s needs with options of 100W, 200W, or 400W of power usage. With the ability to print an array of materials—from steels to alloys—the XM200G can span industries, from industrial tooling to dentistry and remain a low-cost option. Visit the Xact Metal team to see it for yourself and learn more about the XM300G, the next generation of XM machines coming later this year. INFO# 230

Register Today

A visit to Chicago this Spring will bring you up to date on the newest 3D printing technologies and applications. Visit rapid3devent.com today and register. IPM

4. MELD Manufacturing, booth 4641, showcases its K2, designed for production and repair of large parts. K2 boasts a build volume of 82.7x43.3x39.4 inches.

EVENTFORSEWNPRODUCTS

TexprocessAmericas Preview

by IndustrialPrintMagazine Staff

Texprocess Americas takes place this year from May 10 to 12, 2023 in Atlanta, GA at the Georgia World Congress Center. Co-produced by SPESA, the event creates an opportunity for retail, brand, manufacturing executives, and professionals in the sewn products industry to meet with leading international manufacturers and distributors of machinery, equipment, parts, supplies, systems, technology, supply chain solutions, and other products and services used for the development of sewn products.

To See

Innovation, new business, diverse product groups, andeducationareall expected atTexprocess Americas. We've included a look at some of the vendors exhibiting at the show.

Eastman Machine Company, booth 1431, demonstrates its C135, an automated conveyorized cutting machine. The C135 is capable of single- to low-ply cutting while conveying rolled goods with consistent speed and control. Additional automated equipment displayed includes the ES-960 spreading system, the EFL-200 fabric loading machine, and the Power Cradle feeding system. Separate demonstrations with Eastman's line of manually operated fabric cutting machines, configured with the apparel industry in mind, are held within the booth as well. INFO# 205

GTI Graphic Technology, Inc., booth 2007, manufactures tight tolerance lighting systemsfor critical color matching and aesthetic appraisal. GTI's CMlite D65 daylight products are designed to meet or exceed the ASTM Dl729, SAEJ361, and MTCC Procedure #9 viewing standards for visual color matching. GTl's offering includes desktop viewers, floor stand models, overhead luminaires, and color harmony rooms. All products provide compliance to the standards, multiple light sources, and ship with a NIST traceable certificate of product conformance. INFO# 206

Heraeus Noblelight, booth 1114, exhibits its advanced, efficient, and cost-effective infrared technologies, including Infradry Combi, which combines IR heat with controlled air extraction to more quickly and efficiently dry water-based inks and coatings. Its compact design makes it easy to retrofit onto existing textile wide web coating and decorating lines. Also see Carbon Infrared or CIR emitters ideal for drying inks on fabrics, sewn products, and many other applications. INFO# 207

Zi.ind, booth 1319, showcases a dual-beam D3 L-3200 system demonstrating a variety of highly efficient digital cutting workflows that facilitate nesting, picking and sorting, and pattern matching. The focus is on how to make single-ply cutting much more productive than multi-ply and how quickly, easily, and accurately printed fabric can be processed by combining the cradlefeeder, over-cutter camera registration, and the Ziind DRT highspeed rotary tool. INFO# 208

Registration Information

To learn more and register to attend, visit texprocess-americas. us.messefrankfurt.com/atlanta/en.html. /PM

1. GTI GraphicTechnology, Inc., booth 2007, manufacturestight tolerancelighting systemsforcriticalcolormatchingand aestheticappraisal.

FINDITHERE

ISA International Sign Expo Preview

by IndustrialPrintMagazine Staff

Take advantage of everything the International Sign Association (ISA) has to offer by visiting its flagship event in Las Vegas, NV at the Mandalay Bay Convention Center from April 12 to 14, 2023.

The ISA International Sign Expo encourages all members of the sign and graphics industry to attend and create lasting connections with fellow attendees, exhibitors, and presenters.

Hit the Floor

The show floor is packed with new and established vendors. We include some oftheir plans here.

AP Lazer, booth 4715, offers CO2 laser machines that cut and engrave full sheets of material such as wood, acrylic, and plastics. Thanks to the 1 open architecture design, there are no weight or size restrictions. INFO# 236

ASLAN, booth 2257, highlights its popular memoboard, glass decoration, anddigitalprinting film ranges, as well as spraypaint andstickerrepellentanti-graffitifilm, newextrahard-wearinglaminate, and specialeffect films. INFO# 237

AXVZ, booth 4728, demonstrates cutting on the AXYZ Trident CNC router, featuring acrylic routing and knife cutting on printed foam board. INFO# 238

Budget Inks, booth3110, isa wholesale supplierfor Epson, HP, Mimaki,Mutoh, andRolanddigitalprinting inks. INFO#239

Caldera, booth 2022, demonstrates Caldera PrimeCenter for high-performance nesting and job preparation. PrimeCenter helps print businesses streamline and automate print-and-cut workflows. INFO# 240

CET Color, booth 4457, showcases its Q6-500 Flatbed and K2250 Hybrid unit. Additionally, it plans to unveil its newest product launch and is delighted to share more details. INFO# 241

Colex Finishing Inc., booth 4430, introduces Colex Cut Center 8-Production Automation, whichoffers quick responsecoderecognition with an onboard registration camera. INFO# 242

Digitech, booth 1824, shows the popular TruFire LTX2 printer as part of the world's first print-and-cut system for rigid media. INFO# 243

Direct Color Systems, booth 4638, showcases its patented ADA/Braille printing process with the UV84 Gen2, the medium format UV53-DTS, and the small format 1800S15 and 1800S35. INFO# 244

Epson, booth2221, leverages a surf/skateshopthemeto showcasewide format solutions in action, check out printsamples, and speak with product experts about how Epson can help grow their business. INFO# 245

Fisher Textiles, booth 4021, showcases its newest print media fabrics for soft signage, up to five meters wide and its Enviro-Tex lineup made with 100 percent post-consumer recycled yams. INFO# 246

GCC America Inc., booth 4139, exhibits its latest positioning system, SmartEYES CCD, integrated with its S400 laser engraver to allow users to see the working area in real time and accomplish quick and precise engraving and cuttingjobs. INFO# 247

HP, booth 1424, focuses on sustainability and water-based inks. As part ofthe show, it features new HP Latex 2700Printer

1. SAi, booth 1230, demonstratesitstotal-solution Flexi softwareforprinting,cutting, print and cut, direct to film, and traffic applications. 2. FisherTextiles, booth 4021,featuresitsnewestfabricmediaforpillowcasetensiondisplays,D08800SilverBack,anenhancedgray-backblackoutwithblendedyarnsandanaturalstretch. 3.LintecofAmerica,booth1465,offersPVC-freefilmsforglassdecoration.

series, the HP Latex R Printer series, PageWide XL Pro 10000 printer, and the HP Latex 315 Print and Cut Plus Solution. INFO# 248

Kern Laser Systems, booth4057,shows its flagship large format CO2 laser, the OptiFlex; and the sheet metal cutter, the FiberCELL. It also displays an assortment of materials and samples that are cut by these machines.INFO# 249

Kongsberg PCS, booth 1239, highlights the power, performance, and versatility of its Kongsberg and MultiCam solutions when it showcases four market-leading machines. INFO# 250

Lintec of America, booth 1465, offers PVC-free films for glass decoration. It has offered these for decades and made them compatible with the latest UV inkjet printing technology. The benefits of decorating glass with polyester film are that if printed and installed properly it looks as if the glass was directly printed. INFO# 251

Marabu North America, booth 1021, displays the StarLam 1600R laminator applying a smooth consistent coating of its water-based ClearShield liquid laminates. Handling a variety of substrates up to 64 inches wide, the StarLam makes liquid lamination consistent, quick, and easy to use. INFO# 252

MUTOH, booth 1039, debuts its dualhead printer, the XpertJet 1682SR Pro. Attendees can explore this printer's unique capabilities and learn about the new technology the Pro Series of printers are equipped with. INFO# 253

Onyx Graphics, Inc., booth 2753, demonstrates the newest version of its RIP and print workflow software and other solutions, including ONYX Go subscriptions, ONYX TruFit automated shapebased nesting, and the company's business management tools. INFO# 254

SAi, booth 1230, demonstrates its total-solution Flexi software for printing, cutting, print and cut, direct to film, and traffic applications. Witness a demonstration of the newest, time-saving production features available in Flexi 22. INFO# 255

Summa America, booth 2027, introduces the next step in workflow efficiency and automation. The F1612 flatbed cutter is equipped with a conveyor extension and new Board Feeder. This system is developed to automate loading sheets on the F1612 flatbed cutter and boost productivity. INFO# 256

swissQprint America, booth 4939, presents its flagship flatbed printer, Nyala. The newest generation manages a maximum resolution of 1,350 dpi thanks to the latest printhead technology and precise droplet placement. INFO# 257

Trotec, booth 3325, invites attendees to witness its high-performance Speedy laser machines in action with Ruby software for improved workflow and watch live laser demonstrations on large format SP laser cutters. INFO# 258

TRUMPF Power Tools, booth 4529, shows off the latest tools for cutting steels, plastics, and carbon fiber reinforced polymer. It plans to demonstrate how to join metals together without the need for any fixings. INFO# 259

VanguardDigitalPrintingSystems,aDurst Group Company, booth 4239, showcases an entire collection of flatbeds, roll-to-roll, and hybrid printer solutions. INFO#260

Vision Engraving & Routing Systems, booth 2367, demonstrates print-to-cut and ADA Braille on its 2525 CNC Router/Engraver and 1624 Pro Engraver. The 2525 CNC Router/Engraver has many options including an Auto Raster Braille Inserter, DACS Print-To-Cut system, and Oscillating Knife. INFO# 261

Ziind, booth 3939, exhibits a full gamut of digital cutting and high-performance routing solutions with the latest in workflow automation. INFO# 265

Register Now

In addition to the exhibition, the ISA International Sign Expo hosts a number of off-site events including ISA ROCKS, billed as the party "for the industry" and held at the Luxor pool; ISA INSTALL, a speed networking event that connects national sign companies to local sign and install companies across North America; and a meet up organized for young professionals.

If you are a member of the sign and graphics community, the exhibitors mentioned in this preview as well as a host of others encourage you to attend the ISA International Sign Expo in April. Visit signexpo.org to register. /PM

FROM CUSTOM TO ON DEMAND

Meeting Evolving Demands in Custom Décor

by Cassandra Balentine

Digital dye-sublimation (dye-sub) printing enables custom, commercial work for industries like fashion and hospitality. The latest digital direct to fabric printing technologies bring this down to an individual level of customization. An added bonus, these devices offer the ability to print to natural fibers, which is a growing trend in nearly all industries.

Dye Into Print, established in 1998, is a full-service, dye-sub heat transfer and direct to fabric print provider offering production, cutting, sewing, and fulfillment services to the visual merchandising display and specialty events industry. The textile printer’s two print facilities are based out of Clifton, NJ.

A second generation, family-owned company, it is currently operated by Sam and Jake Smith. The brothers joined the business about nine years ago and haven’t looked back.

Custom Linens

Dye Into Print ships to customers nationally from small individual users to large, multi-international corporations. Its core client base operates in the metro New York City area.

The company targets both business to business (B2B) and business to consumer (B2C) clientele. In the B2B space this is primarily visual merchandising display, special event, hospitality, and creative marketing businesses. It operates a

fleet of dye-sub transfer devices that handle a range of products in up to ten-foot wide seamless prints.

For B2C it completes a lot of home décor products through drop ship fulfillment as well as print on demand products for large retailers. Its range of offerings include banners, back drops, barricade covers, table throws,

1. Dye Into Print utilizes its Kornit Presto S Max to print directly onto cotton and other natural fabrics.

We saw a need to give our hospitality clientele more customizable options for their special events.

— Sam and Jake Smith, co-owners, Dye Into Fabric

silicone edge graphic framed banners, pillows, blankets, table linens, napkins, and cushions.

Digital printing has been at the forefront of Dye Into Print’s business for more than 20 years. For the past 15 to 20 years it focused on transfer dye-sub processes. At the start, Sam and Jake’s father, Mitchell, worked closely with party planners to mainly create custom tablecloths. Dye-sub and supported fabrics suit this niche well, but the opportunity is expanding.

“Servicing the party and events industry in New York City, we constantly got requests for unique patterns, designs, and prints,” share the Smiths. “We saw a need to give our hospitality clientele more customizable options for their special events.”

As print technologies advance, the textile print provider is also evolving, adding new markets to its radar. “The home décor market is a driving force in requesting cotton and natural fiber products. We listened to customers and decided to partner with a like-minded company focused on near-shoring, printing on demand, and environmentally friendly,” say the Smiths.

All of these factors helped determine Dye Into Print’s investment in Kornit Digital technologies. “It was the right partner for us to get more immersed in the direct to fabric space, as we were impressed with the quality of the machines as well as the sustainable initiatives,” they state.

Specifically, the custom textile manufacturer relies on the Kornit Presto S Max for direct to fabric work. Targeting the needs of top fashion and home décor brands, the direct to fabric press enables three-dimensional effects with Kornit XDi tech, neon colors, and white prints on colored fabrics.

In terms of available ink sets, the press uses pigment water soluble inks. It also features new NeoPigment Robusto Softener, a dry digital softening process that adds an extra touch of sustainable fashion on demand.

The Kornit Presto S Max is mainly utilized to print directly onto cotton and other natural fabrics. The Smiths admit there is demand for pigment printing on polyester, which is also handled by the device.

Targeting Décor

Custom home décor is a growing space that Dye Into Print is well poised to service. “We’re at the perfect intersection of print on demand and ecommerce,” shares Sam Smith.

In addition to its primary website, the company owns and operates the URL tablecloth.com where it is able to attract ecommerce work. It also partners with popular platforms like Amazon to fulfill custom orders.

The Kornit Press S Max allows the business to be flexible and nimble, cashing in on every holiday cycle—from Valentine’s Day to Christmas. The team offers custom designs on its website, and touts a fast turnaround of same or next day for 99 percent of orders.

Beyond ecommerce, the custom textile provider finds its dye-sub and direct to fabric technologies to be extremely complementary to its traditional base, especially as new demands emerge.

For instance, it often acts as a behindthe-scenes manufacturer for brands hosting galas, dinner parties, award shows, and other high-end events. The industry is always changing and while custom linens were typically produced using polyester materials, its same customers are exhibiting an interest in natural fibers. Therefore, the ability to offer options is crucial to Dye Into Print’s ongoing success.

Fashion Forward

The investment in direct to fabric technologies, specifically the Kornit Presto S Max, enables Dye Into Print to offer more to its existing customers as well as capitalize on new revenue streams, like custom home décor. IPM

STAY REFRESHED

Customized Coolers and Drinkware

by Melissa Donovan

Big Frig is a cooler and drinkware brand out of North Sioux City, SD. In business since February 2016, the company began in a strip mall and moved to its current space in 2018. Working out of a facility of over 30,000 square feet—this includes a 12,000 square foot warehouse expansion that was undertaken at the beginning of 2023—it caters to the central and southeastern U.S., but serves customers in all 50 states as well as Australia, Canada, some of Europe, and Mexico. 20 full-time employees and several part time and seasonal workers are part of the business.

As a cooler and drinkware brand, Big Frig saw potential in personalization and customization early on. At the beginning of its journey, any decoration done on its products was strictly laser marking on drink tumblers and vinyl decals for beverage coolers.

Flexible and Durable

In 2017, it began looking for ways to offer color decoration on its tumblers and coolers—it turned to digital printing. “We wanted something durable with minimal changeover cost. We had very little space and only a couple of full-time employees, so whatever print process we went with had to be compact and easy to startup and shutdown,” explains Dakota Hoard, director of operations, Big Frig.

Another important piece of the puzzle, the printer needed to offer flexibility. In addition to printing to its own products, Big Frig also takes in contract work. “We pride ourselves on our nimbleness and flexibility, so many of our customers who started out buying our core products now come to us with a variety of other projects—canvas prints and laser marking leather gloves, for example—and we are happy to assist them with those as well. We make it a point to say ‘no’ only when we absolutely have to,” attests Hoard.

The founding members of the company

embrace special requests, Hoard admits that saying “no” to customers is very difficult, but that they also enjoy trying out ideas on the fly. “For example, we have always made most of our own jigs and tooling—initially out of wood using rudimentary carpentry skills—now with three-dimensional printing and laser cut parts in addition to more traditional fabrication techniques. We aren’t very good at being patient when we are excited about a project,” admits Hoard.

An Inkcups Helix was initially brought in because cylindrical printing made sense for decorating tumblers. A dedicated rotary machine, the speed and print quality were just want Big Frig was looking for.

To print to the coolers, it went with the X5-T flatbed UV digital printer, also from Inkcups. It is ideal for the work Big Frig produces

1. & 2. North Sioux City, SD-based Big Frig works with hardware from Inkcups and ink from Marabu to print directly to its coolers and drinkware products.

Digital decoration is at the core of a paradigm shift in the industry.

— Dakota Hoard, director of operations, Big Frig

because of the 20-inch clearance. “Originally we had digital flatbed printers, which required that we remove the lid of each cooler from the body before printing. That was a huge expense in terms of time and effort. One X5-T station with a single operator has about twice the throughput of two of our older printers with two workers,” says Hoard.

Big Frig still conducts laser marking on its tumblers using gantry style CO2 lasers from Epilog Laser. According to Hoard, the Epilog devices are “work horses” that hardly ever give them trouble. They were easy to set up and maintenance is also simple.

It also uses a galvo-based laser from Radian Laser Systems, which was a bit more challenging to learn how to use, but the speed and quality are top notch. For example, a run of 128 oz. growlers with a large marking area once took nearly ten minutes per piece. With the Radian laser device, the decoration is complete in 28 seconds without loss of quality.

Ink Relationship

Printing direct to any object presents its challenges. Ink adherence is an issue, especially on low-energy surfaces. Furthermore, when printing to premanufactured items like drinkware, these pieces are subjected to higher wear and tear during general handling or cleaning and disinfecting after use.

Big Frig has experienced its own share of frustration with adhesion. Hoard says a few years ago acceptable adhesion of the ink on its tumblers became a struggle. “It was a real mystery as we could pull retains from previous runs, print the same art on the back with the same process, and the new

print would delaminate while the old print adhered perfectly. We were down for weeks with orders piling up, but we couldn’t figure it out.”

An industry peer suggested Marabu North America and Big Frig reached out. Hoard says that despite Big Frig being a small company, Marabu representatives “dropped everything” to work through the problem and get production up and running.

A switch was made to Marabu inks, specifically Marabu UltraJet DLE-A inks on the drinkware and coolers. They are found to be more resilient with vibrant pigmentation, helping expand the attainable color gamut. Marabu primers— Primer P2 on drinkware and Primer P4 for coolers—are now used for most of the common surfaces Big Frig encounters— stainless steel, powder coat, and linear low-density polyethylene (LLDPE)—because of their one-step, flash-off application with low odor.

“Ultimately the greatest benefit is the relationship we developed with Marabu. We are usually the ones going above and beyond for our customers, so it’s refreshing to work with another business who will do the same for us,” comments Hoard.

Job Spotlight

Big Frig works with a number of customers, one of which is the Midway USA Foundation—a 501(c)(3) public charity working to sustain and grow youth shooting sports by providing long-term funding to youth shooting teams through annual cash grants. The organization wanted two different designs printed on cooler lids.

The coolers are made of LLDPE, with a low surface energy of less than 20 dynes/ cm2. “That’s great for keeping your cooler

clean, but it can make getting good print adhesion a challenge,” explains Hoard.

Prior to printing, coolers are cleaned off to remove any residue from the molding process. They are then flame treated to raise the surface energy, usually to at least 40 dynes to ensure good wetting. The Marabu primer is applied and then the coolers are blown off with compressed air to rid them of any dust.

The printing itself is straightforward. The entire cooler is placed on the bed, the z-axis height is set, and then it’s printed. Switching between art files is a matter of a few mouse clicks. Printing the Midway USA Foundation designs took about four minutes per cooler. The operator prepped each cooler while another printed, so the whole job of more than 100 coolers is completed by one person in about nine hours.

Shrinking Economies of Scale

Big Frig is an excellent example of how to bring digital printing in house and grow. Not only does it customize its own products, customers can come to them for their promotional printed pieces as well. The flexibility offered by the Inkcups printers paired with Marabu ink and primer make it incredibly easy to offer on demand runs a little as one.

“Digital decoration is at the core of a paradigm shift in the industry. Customization used to be limited to traditional techniques, which are subject to the tyranny of economies of scale. Ultimately this skewed customization to primarily large customers ordering from large printers and personalization could only be gotten with great expense,” shares Hoard.

It is now possible for a small company like Big Frig to offer customization as an add-on service inline in house. “Economies of scale are getting smaller and smaller, and the printing technology itself is getting more user friendly. I think we’ll continue to see a broadening of what can be customized and who is doing it,” concludes Hoard. IPM

Software is instrumental in creating effective three-dimensional (3D) builds. When we think of software, the category is vast and includes parts design, solutions that help collaboration efforts, and moves over toadditional parts of the workflow like platform management.

"Software will revolutionize manufacturing. The promise of machines that can effectively build what we want them to based on digital signals is becoming

by Melissa Donovan

reality. Now it's software's turn-with it ideas become manufacturable designs, ensure a quality production, and track the life of a part, influencing future designs. We can reduce the idea-to-part process from years to seconds," shares Andre Wegner, CEO, Authentise.

Step byStep

The production of a 3D manufactured part is a multi-step process. Software is available to help at every junction.

From data preparation and processing to process management, precise control and reliable monitoring of the build process, and comprehensive connectivity; software covers every step and quality assurance for additive manufacturing (AM), whether for individual production or in a digital factory, according to Jenna Phillips, marketing specialist, EOS North America.

Above: Authentise Flows AM offers order intake, production planning, digital parts library, monitoring, quality assurance and reporting, and a rules engine.

“Every part requires an understanding of upstream and downstream processes to effectively design a part for manufacturability. Each step can utilize specialized software to accomplish that step. Reducing error, creating value, and retaining design-originated features can be preserved as integrations improve between these parts, resulting in a more efficient system,” adds Mark Norfolk, president, Fabrisonic LLC.

For example, 3D Spark’s software evaluates the printability and costs of potential 3D printing applications for different technologies and materials. “Analyzation still prevents many companies from using AM on a larger scale. Alstom, Deutsche Bahn, MetShape, and ZF have shown that this can be automated with 3D Spark, saving Alstom over €1.8 million and over 20,000

days of delivery time. The software facilitates easy access to 3D printing even for untrained personnel, in the process providing an educational boost and helping to identify new applications for the entire AM industry,” explains Ruben Meuth, coCEO/co-founder, 3D Spark.

Parts design software is important, according to Blake Teipel, Ph.D., CEO, Essentium. “Currently there is a common myth that AM can be used to create any part(s) designed for traditional manufacturing. However, similar to all other manufacturing, the key to success in adopting and deploying AM is to design specifically for the 3D printing process. The combination of generative-design software and step-change improvements in 3D printing technology has led to the creation of never-before-seen next-generation tools.”

“Digital manufacturing cannot exist without 3D modeling software—without a digital model, it’s impossible to print a part. New software solutions help optimize designs for the 3D printing process, but a knowledgeable designer can make excellent designs for AM with standard modeling software. The most promising software development is for simulating sintering deformation, which improves first-shot accuracy of printed and sintered metal parts,” says Skyler Des Roches, head of customer experience, Rapidia Inc.

Florian Rapp, head of development, Multec GmbH, believes that “‘slicers’ are the most important part of the software chain, since they convert the 3D model to a printing strategy and the final part. The slicer must allow adoption of the process settings to the model and its requirements.”

Software solutions that monitor the build process are advantageous. “Quality issues have plagued 3D printing. Many problems or challenges with 3D printing come from in-process errors that software catches and fixes in a closed loop cycle. Sigma Labs is a great example of monitoring software that improves the quality of powder bed fusion prints,” shares Matt Sand, president/co-founder, 3DEO.

The security element of AM is also handled with the help of software. “On its route from an original idea to a finished object, many people and companies contribute

COMPANIES MENTIONED

to the AM process. It first begins with the design of a digital object that represents or contains the intellectual property of its maker. In many cases, that object is only one part of a finished product assembled by another agent in that process—an integrator or, potentially, vendor. In many cases, the actual 3D printing is handled by a local service provider to save costs. At each step, intellectual property needs to be protected against theft and piracy, but still be available for legitimate agents to use, process, and reprocess. Who is allowed to access the designs—when, where, and

Spark 3dspark.de

3deo.co 187 AlphaSTAR Technology Solutions alphastarcorp.com 188Authentise authentise.com 189EOS na.eos.info

190Essentium essentium.com 191Fabrisonic LLC fabrisonic.com

Farsoon Technologies farsoon-gl.com 193Fiberneering fiberneering.com 194Formlabs formlabs.com 195HP Personalization and 3D Printing hp.com 196MELD Manufacturing Corporation meldmanufacturing.com

GmbH multec.de

Inc. rapidia.com

roboze.com

Inc. trumpf.com

Wibu-Systems wibu.com

how often? A system is needed to protect the underlying data and to monetize the act of printing a third-party design,” explains Tom Ricci, marketing consultant, Wibu-Systems.

Wibu-Systems’ solution protects intellectual property and manages the printing licensing process. The company’s CodeMeter technology uses cryptographic processes to encrypt digital intellectual property and create licenses for the protected intellectual property with easy integration with existing process chains.

“Reliable software is critical to the effectiveness and timeliness of the 3D printing process,” asserts Bálint Horváth, software product manager, Formlabs. “Without dependable and precise software, products will not be printed consistently or correctly, which increases overall project and printing time and the costs of materials used.”

Automated software solutions are important in today’s market. “Plagued with uncertainty and supply chain issues, 3D printing technology shores up supply chains by enabling scalable mass production for both short- and long-term solutions. The technology has the capability to react to near instant changes. The value of 3D printing also reduces reliance on manual labor and allows for complex and important parts to be rapidly produced,” explains Meaghan Ferris, global head of 3D metals go-to-market and business development, HP Personalization and 3D Printing.

“If 3D printing needs to move from art and artisan to method and mass production, automation must come into the

1. Wibu-Systems’ solution both protects intellectual property and manages the print licensing process. The company’s CodeMeter technology uses sophisticated cryptographic processes to encrypt digital intellectual property and create licenses for the protected intellectual property with easy integration with existing process chains. 2. Formlabs’ Automation Ecosystem enables new levels of 3D printing productivity with Form Auto, Fleet Control, and the High Volume Resin System.

picture. More information is needed here to get the job done right. Design/workflow and process simulation software will uncover the challenges that only the expert or artisan could discern, so that lesser humans can achieve similar, if not equivalent results,” asserts Dr. Rashid Miraj, director of technical operations, AlphaSTAR Technology Solutions.

A recent trend in software includes artificial intelligence (AI). “3D printing is the perfect technology partner to consider with Smart Factories in which many laborious tasks are done with robots and production is driven by machine learning and AI. The obvious importance of this is that it pushes the technology to the very edge of what is possible with human hands and minds as well as allows advanced intelligence to help us. It’s a step towards the future, rather than using obsolete techniques that take us backwards,” shares Dr. Eliana Fu, industry manager, aerospace & medical, TRUMPF Inc.

“Until now, 3D printing production was limited by operator intervention, requiring users to remove complete printed parts, change resin cartridges, and set new printing jobs manually,” notes Horváth.

Stay Open Minded

Systems that communicate well with each other foster collaborative environments. AM is inherently deemed flexible, so it is no surprise that the software used with it be flexible as well. Open source solutions can provide this.

Open source provides full control, according to Rapp. “With non-open source software you are always depending on the publisher of the software. If you have a feature request that could improve the process and lead to better parts there is not a lot you can do. With open source on the other hand you can adapt the software to do exactly what you want, need, or expect.”

“I like the idea of open source, as it’s more collaborative. Some people like the ability to jump into problems and tear them apart from the inside out. That

SECURITY SOFTWARE CASE STUDY

Global bus vendor Daimler Trucks and Buses teamed up with security experts at Wibu-Systems and additive manufacturing (AM) specialists Farsoon Technologies to create a novel three-dimensional (3D) printable parts service. Daimler has focused on the potential of digital production technology since 2016. Many parts for its Mercedes-Benz and Setra brands are made available in digital, 3D printable format on its OMNIplus service portal.

This includes both regularly required spare parts as well as rarely required parts for special customer requests. Bus operators and service partners can buy these for printing on site, when and where they need them. Wibu-Systems’ CodeMeter encryption and licensing solution protects the digital objects throughout the complete sales lifecycle, enabling a secure and efficient manufacturing-as-a-service process.

“CodeMeter security technology provides unique opportunities for creating ecommerce solutions for 3D printed parts. A system is built around a marketplace or e-store, which registered customers could buy 3D printed products. The store can be seamlessly integrated with established ecommerce systems to automate the buying and ordering process as completely as possible. Instead of physical products shipped by expensive and wasteful logistics, the buyer now receives the object design in the form of an encrypted file. The protected file is accompanied by a specific pre-processing license to prepare the 3D printing process. Another printing license then determines how many physical copies the client is allowed to create from the design he has purchased,” explains Tom Ricci, marketing consultant, Wibu-Systems.

This is a collaborative effort, thanks not only to Wibu-Systems’ CodeMeter but specially certified printers made by Farsoon. The OMNIplus service portal files are sold as encrypted downloads and the buyer receives a license to use for pre-printing as well as an actual printing license that allows as many copies to be printed as the buyer paid for. Once the license is granted it is used with Makestar software on specially certified Farsoon 3D printers.

“The successful implementation of an AM digital rights management system means that our partners and us have made a real mark in the digital 3D printing business. This opens up completely new vistas for our service operations and for the availability of products where they are needed at the point of sale, both commercially speaking and thinking about the good of our environment,” shares Ralf Anderhofstadt, head of center of competence AM, Daimler Trucks and Buses.

kind of creativity thrives better in an open source type of environment,” says Fu.

While open source is not a requirement, it certainly is beneficial. “I see a number of customers doing incredible things with Blender, which is fully open source. In some respects the mesh-based engine these kinds of programs run on are better aligned with freedom of shape that’s possible with 3D printing—compared to traditional solid based CAD,” explains Jasper Bouwmeester, CEO, Fiberneering.

Specifically in terms of AM, “it’s more important that we focus on open technologies—those that allow simple integration by API—because the end-to-end

value chain of turning an idea into a part will require many software tools to work together. We need the suction of profit to bring more entrepreneurs to the software market to deliver improved tools. Focusing too much on open source may undermine that,” says Wegner.

Easy Benefits

For someone undecided on implementing 3D workflow solutions the benefits are apparent almost right away. With the help of return on investment (ROI) assessments, it is easy to see how favorable automation and AM are in comparison to conventional manufacturing methods.

According to Miraj, frequent use or use with complex builds increases the value and necessity of the software. "The future of 3D printing involves more sophisticated materials, complex geometries, greater number of parts, and more opportunities for failure. The cost of machines, materials, and personnel demand methods to increase efficiency and productivity. Design/ workflow and process simulation software canaddressmost ofthoseconcernsand ultimatelyreduce costs."

"Implementing 3D workflow solutions can increase business' demanding and unique needs by providing a quick, affordable solution. All workflow solutions can be designed and managed in house to speed up the workflow from idea inception to an end-use product," says Horvath.

Advantages to look for in 3D software include smooth integration into existing CAD/CAM and simulation environments, intuitive usability, effective monitoring, real-time availability, transfer of production data, and compatibility with many other systems, according to Phillips.

Of course, certain solutions are not a fit for everyone. "There needs to be a clear reason to adopt a new technology. The best

way to ensure that a solution is worth pursuing is a clear understanding of the ROI. Typically this ROI calculation requires a good technical understanding of the process as well as the needs of the business," suggests Chase D. Cox, VP, MELD Manufacturing Corporation.

Initial ROI comes from efficiency, specifically faster quoting, fewer wasted resources and failed builds, and reduced meeting schedules, lists Wegner. "But the true ROIis felt down the linewhenthe data collected from the digital thread helps operations become more resilient, deliver insightthat canyielda competitiveadvantage with the help of AI and machine learning, and captures tribal knowledge;'

"The first step before entering and thus investing in AM should always be a potential assessment with regard to costs-ROI, technical printability, delivery time savings, and sustainability on the basis of one's range of components," notes Meuth.

Rapp suggests that, "from a financial point of view just take a few use cases of that person and do the calculation for different manufacturing processes. Chances are AM is less expensive and faster than any conventional production process."

"The more information you can give someone the better their informed final decision will be," agrees Fu.

''.,\s technology continues to improve the solutions will be even more capable of applying data and digital technologies, and the entire end-to-end lifecycle will be further streamlined and accelerated as a result of implementing 3D software and solutions," foresees Ferris.

Continued Improvement

Automation software is designed to increase efficiencies at every part of the AM process. As 3D printing becomes more sophisticated, the value of automation software subsequently grows.

"There is a need to develop solutions that make the process from creation to production of finished parts increasingly efficient, with rapid response to various configurations of production systems. This is from a technical point of view, as well as from a business and environmental perspective," notes Ilaria Guicciardini, head of marketing, Roboze.

Learn more about 3D printing in our most recent webinar, accessible at industrialprintmagazine.com/webinars. /PM

Rm R5 R UIRBLE mRnUFR[TURln6 OPTIDn

by Melissa Donovan

Three-dimensional (3D) printing or additive manufacturing (AM) is a cost-effective and efficient method to produce metal parts. Once only seen as effective when manufacturing smaller runs, today's technologies are ready to manufacture at industrial levels. Aerospace, automotive, medical, jewelry, and consumer product buyers recognize the potential of 3D metal printing

in their production practices. Reasons include design flexibility, reduced inventory, enhanced environmental impact, and supply chain sustainability.

Above: An example of a metal impeller printed using Prima Additive technology. PrimaAdditive'sproductportfolioincludesmultiplelasertechnologiesformetal30 printingapplications.

Growth in Metal Printing

Insight Partners' latest research study, 3D Printing Metal Market Size, Industry Share, Trends and Forecast to 2028, finds that the global 3D printing metal market size is expected to grow from USD 4.5 billion in 2021 to more than USD 13 billion by 2028 at a compound annual growth rate of16.5 percent between 2022 and 2028.

"The data supports an increased interest in metal 3D printing capabilities by multiple primes across various industries. Supply chain issues resulted in these primes searching for alternative solutions to source their parts from and alleviate

the production challenges of enduring long lead times;' notes Chase D. Cox, VP, MELD Manufacturing Corporation.

Donghi Arturo, CEO, Sharebot, agrees, and explains that this is why the company concentrates its efforts on selective laser sintering and direct metal laser sintering, as these will be future disrupters.

Part of why 3D printing is increasingly used in metal parts production is accessible education, creating more familiarity. "Businesses understand the potential benefits that using this technology could have on their production efficiency, environmental impact, and supply chain sustainability. 3D printing is cost competitive with traditional manufacturing methods and can be applied across a variety of industries. The use of3D printing contributes to an overall healthier and more efficient global supply chain," states Meaghan Ferris, global head of 3D metals go-to-market and business development, HP Personalization and 3D Printing.

According to Skyler Des Roches, head ofcustomer experience, Rapidia Inc., metal 3D printing was originally reserved for high-value, niche industrial applications. "Metalmanufacturing has been off limits to most people because it requires a lot of skill

and knowledge to safely operate a milling machine, lathe, welder,orlaser powder bed fusion machine. But, material extrusion style printing automates most of the skill and eliminates the safety concerns."

For those utilizing conventional manufacturing methods, 3D printing presents greater flexibility. "The biggest advantage lies in the freedom of part design, which doesn't depend on any tool or mold.A product is built up layer by layer from 3D CAD data. This reduces costs, resources, and time expenditure in many areas beyond just large series industrial production. Prototypes are built quickly and cost efficiently. End products for individual or series production can be flexible and made on demand," shares Jenna Phillips, marketing specialist, EOS North America.

Mark Norfolk, president, Fabrisonic LLC, also notes increased interest thanks to design flexibility. "Solid-state metal processes like ultrasonic additive manufacturing (UAM) extend design freedom further.

1. Prima Additive's powder bed fusion technology is ideal for processing reflective materials. 2. MELD holdsmorethanadozenpatentsforitsMELD technology, an innovative process for metal manufacturing.

3. Example of a manifold printed with Rapidia waterbased 3D metal printing technology. 4. TRUMPF's TruPrint portfolio offers the right solution for any metal AM application.

With UAM, designers and engineers have expanded material freedom by bonding dissimilar metals or embedding reinforcement materials or temperature-sensitive devices within a metal matrix.”

3D printing is “no longer a gimmick, it is now a viable manufacturing process, where it makes sense to deploy rather than forging, casting, machining, or injection molding. Advantages include improved designs, reduced part count, shortened lead time, and better use of materials. AM has even encouraged the development of new materials, including those previously considered ‘un-weldable’ by conventional methods,” notes Dr. Eliana Fu, industry manager: aerospace and medical, TRUMPF Inc.

Despite movement in the space, there “is still a general lack of awareness and education about 3D metal printing and how it can help manufacturers overcome their biggest challenges,” according to Blake Teipel, Ph.D., CEO, Essentium.

“Compared to three years ago, there is a significant uptick in companies taking AM more seriously. The truth is that only few understand the scale of investment needed to understand the technology. We’re still at the beginning of a journey,” asserts Andre Wegner, CEO, Authentise.

Forward Momentum

Multiple industries benefit from 3D metal printing. While aerospace and automotive are some of the earliest adopters, today’s users include consumer, medical, and even art and jewelry.

“3D printing improves overall efficiency by allowing manufacturers to maintain ideal inventory levels. Second, they can reduce the time and money it once took to transport parts, thus tightening the supply chain. Finally, they can greatly speed time to parts,” explains Teipel.

Any business 3D printing customized components at point of need understands the aforementioned advantages. “These include aerospace and defense, automotive, and electronics manufacturing—all benefitting from the ability to 3D print service

parts, manufacturing aids, and tooling jigs. For instance, an aircraft may require specific tools that often have to be custom made. With AM, printing those tools on demand is now possible,” continues Teipel.

In metal 3D printing, the clearest answer is industries that benefit from part geometries that are impossible to machine, says Des Roches. “Typically, that means complex internal shapes for fluid flow—maybe cooling channels in an injection mold, manifolds, rocket engines, or fluid diffusors. In metal 3D printing, that means tool and die manufacturers, aerospace, and the energy sector.”

Norfolk believes that “industries competing in highly competitive markets and that need to rethink their product design to optimize material use by combining dissimilar metals to optimize SWaP, displace a problematic metal joining manufacturing process, embed temperature-sensitive devices, or all three benefit the most from UAM. Those companies are typically in the aerospace and automotive industries.”

Aerospace, space, ground vehicles, and naval industries are MELD’s primary customers. MELD technology makes the material malleable without melting. As an example, MELD was tasked with manufacturing a tank hatch. This tank hatch would have a traditional manufacturing lead time of one-and-a-half years. Using the MELD process, the near net shape geometry was printed in 30 hours and weighed 800 lbs. The final part geometry was then machined out from the near net shape.

“Industries adopting AM most widely now are lower volume, higher value industries like medical and aerospace. There is a very high willingness to pay

for performance and/or customization in these industries, which plays perfectly into 3D printing’s strengths,” says Matt Sand, president/co-founder, 3DEO.

Daniele Grosso, marketing manager, Prima Additive S.r.l., believes growth in 3D metal printing is driven by aerospace. “An industry in the last year that equipped itself with increasingly large systems and gave great ideas from the point of view of process optimization to machine manufacturers.”

There is also the automotive sector. “The electrification of vehicles leads to ever heavier cars and AM will prove to be a great ally in their lightening, with a trajectory that will start from motorsport to move later towards mass production. Finally, we must not overlook the biomedical, jewelry, and all those sectors that need to work with highly reflective materials, which opens important use cases for laser sources other than infrared, such as green and blue lasers,” continues Grosso.

“Any industry can benefit from metal 3D printing, but only where it makes sense,” cautions Fu. Automotive, aerospace, military, space exploration, medical, dental, and art/jewelry and consumer segments benefit from designs with thin walls, intricate features, or steep overhangs unable to be produced with traditional methods.

Popular Metals

A range of materials are 3D printed including stainless steel; alloys like nickelbased, aluminum, titanium, and copper; refractories; and precious metals.

Everything in AM is market driven, according Dr. Rashid Miraj, director of technical operations, AlphaSTAR Technology Solutions. “Choice of metals, processes, and applications must have the potential of improving efficiency, reducing waste, increasing quality, and making or saving more money. Accordingly, the herd seeks to explore metals and processes that have an established record before venturing out to more exotic options.”

Popular metals are titanium, aluminum, and stainless steel, according to Sand. “Titanium is used in aerospace and medical, and stainless steel is seen in a range of industries. Engineers and manufacturers need metal for more demanding applications than plastics, such as air frames, implants, and end effectors on surgical robotics.”

Stainless steel metals are widely used because they are alloys that cover a range of needs and are less reactive than other metals, according to Des Roches. “This also makes sense if you look around to the products we interact with daily; steel alloys are really a workhorse material, in cars, buildings, roads, and appliances. More reactive metals, such as aluminum and titanium alloys, are quite dangerous in loose powder form, so tend to be reserved for specific applications.”

While the aforementioned are metals that have always had a presence in 3D printing, there is consistent growth in demand for pure copper applications and precious metals such as gold or silver alloys, says Grosso.

“In my opinion all metals that are hard to process—due to hardness or abrasive behavior—in a conventional process benefit the most from AM,” says Florian Rapp, head of development, Multec GmbH.

Fabrisonic UAM has made significant contributions within the aerospace and automotive industries, optimizing SWaP,

which means it routinely welds aerospace aluminum for strength/weight as well as copper alloys for thermal conductivity. “Recently the explosion of electrification applications led to growth in printing complex shapes from high-conductivity aluminums, nickels, and coppers,” adds Norfolk.

HP offers two stainless steel powders— HP Metal Jet SS 316L and HP Metal Jet SS 17-4PH. HP Metal Jet SS 316L provides resistance to corrosion and high temperatures. HP Metal Jet SS 17-4PH is a martensite precipitation hardening stainless steel, most frequently used in applications requiring high strength and mechanical properties with good corrosion and wear resistance.

At MELD, customers are interested in “unweldable” materials, primarily aluminums. “These materials cannot be processed at large scales in an open-air environment by other metal 3D printing technologies. Titanium is another material of interest. Customers use the MELD process to achieve forged equivalent properties in these materials,” explains Cox.

Massive Metal

3D metal printing expands beyond its intentioned industries as new materials and processes are developed. In addition, more people are becoming educated about the advantages of 3D printing and how it can truly be a powerhouse in mass production.

“Through 3D printing capabilities and design freedom, engineers can do things that simply aren’t possible with traditional manufacturing. This unlocks new levels of performance and product functionality, and gives engineers a competitive edge across the development landscape,” notes Sand.

Visit industrialprintmagazine.com if you want to learn more about 3D metal printing from some of the vendors mentioned in this article. Under “Web Exclusive Edit” find various articles, visit “Target Charts” for a chart detailing 3D devices, and switch over to our “Webinars” page to sign up and view a recent webinar on the topic. IPM

5. Sharebot’s metalONE is a direct metal laser sintering 3D printer.