IPM April 2023

#8

FEATURES [ 18] Software's Turn

Increasing the Dependability of 30 Printing [ 23] Heavy Metal

AM as a Viable Manufacturing Option

Editor's Letter [3D Metal Printing Growth] ...................................................... 4

Spotlight [From Custom to On Demand] ..................................................... 14

Showtime [Next Level] ..................................................................................... 6

Spotlight [Stay Refreshed] ............................................................................. 16

Showtime [Event for Sewn Products] ........................................................... 11

Advertiser Index ............................................................................................ 22

Showtime [Find It Here] ................................................................................. 12

Companies Mentioned................................................................................ 22

ON THE COVER Prima Additive S.rJ's product portfolio includes laser technologies for metal three-dimensional printing applications. See page 23.

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Aprtl 2023 f Industrial Print Magazine J 3

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IN DUSTRIALPRI NTMAGAZINE.COM Volume 10, Number 2

EDITOR'S LmER

30 METAL PRINTING GROWTH Interest in three-dimensional (3D) metal printing is growing rapidly. Insight

Partners' report 30 Printing Metal Market Forecast to 2028 states that growth

EDITOR IN CHIEF Thomas Tetreault 978-921-7850 EDITOR Melissa Donovan mdonovan@rockportpubs.com

is driven by aerospace and defense as well as automotive industries. Both

ASSOCIATE EDITOR Cassandra Balentine cbalentine@rockportpubs.com

While these industries are early adopters of 3D metal printing, the presence of

ART DIRECTOR Sarah M. White swhite@rockportpubs.com

benefit from 3D printing's flexibility in design as well as production efficiency.

the technology is extending further.

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 efficien­

cies offered when pairing a 3D printer with automation software in Software's

Turn. To complete this issue's 3D coverage, find our Target Chart as well as a

recent webinar on 3D printing online at industrialprintmagazine.com.

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

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

the visual sign and graphics space, RAPID+ TCT by SME targets those look­

ing at additive manufacturing for their business plans, and finally Messe

Frankfurt's Texprocess Americas is an educational platform with sewing

WEB EDITOR Melissa Mueller CONTRIBUTORS Pete Basiliere, Olivia Cahoon, Kemal Carr, Maria Conrado, Mark Hanley, Melinda Tetreault ADVERTISING SALES PUBLISHER Thomas Tetreault 100 Cummings Center, STE 321E Beverly, Massachusetts 01915 Ph 978-921-7850 x110 • Fx 978-921-7870 edit@rockportpubs.com SALES Nicole Pizzi-Cerundolo Ph 978-921-7850 x160 • Fx 978-921-7870 npcerundolo@rockportpubs.com Amanda Doyon Ph 978-921-7850 x170 • Fx 978-921-7870 adoyon@rockportpubs.com

and textiles in mind.

Cheers,

��2� Melissa Donovan, Editor

CORPORATE & PUBLISHING OFFICE 100 Cummings Center, STE 321E Beverly, Massachusetts 01915 ROCKPORT CUSTOM PUBLISHING, LLC CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault CONTROLLER Missy Tyler Industrial Print magazine is published by Rockport Custom Publishing, LLC. Please

send change of address forms to: 1DO Cummings Center, STE 321E, Beverly, MA 01915. © Rockport Custom Publishing, LLC 2023. Reproduction by any means of the whole or part of Industrial Print magazine without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement.

Subscription Rates: U.S. $41.65 per year, seven issues; single copies: $5.95, Cana­ da and Mexico: $52.22 (U.S.D.), Other international subscriptions: $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 kits to Reviews Editor, Industrial Print magazine 100 Cummings Center, STE. 321E Beverly, MA 01915. We cannot be responsible for unsolicited product samples.

4 [ lndustJial Print Magazine J Aprtl 2023

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#1

SHOWTIME

NEXT LEVEL RAPID + TCT 2023 AM Event

by Industrial Print Magazine Staff

Billed as North America's largest and most influ­ ential additive manufacturing (AM) event, RAPID + TCT is back at McCormick Place -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 confer­ ence and exhibit hall to bring attendees to the next level of their business.

The conference is held over eight tracks-au­ tomative, aerospace, defense, consumer goods, healthcare, wider industrial, research and develop­ ment, and AM ecosystem. Over 160 AM experts are scheduled to present across all of these themes.

In the Exhibit Hall

More than 350 companies plan to exhibit the lat­ est 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 re­ cently 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 remov­ able tank allows semi-automated post-processing of printed parts and thus continuous production for large series. The ma­ chine is user friendly and UL compliant. INFO# 210 3DEO, booth 5429, announces its newest material, pure cop­ per. Developed for use in 3DEO's Intelligent Layering technol­ ogy, 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 stain­ less 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 produc­ tion of powders that are truly spherical, void of porosity and satellites, with better flowability than competing technologies.

6 [ lndustJial Print MagazineJ Aprtl 2023

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 sup­ port material used in AM. At the booth learn more about pre­ mium powder offerings including nickel 718, nickel 625, tita­ nium 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 print­ er, the B9 Core 6 Series MPro and shows live 3D printing dem­ onstrations. With a build volume of 192xl08x304 mm, B9Cre­ ations' Core 6 Series MPro is ideal for customers who need an expanded design space without sacrificing the ultra-high resolu­ tion 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. Ro­ boze, 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.

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industrial metal 3D printer, and new and innovative applications leveraging ad­ vanced AM solutions. INFO# 214 HP, booth 4618, exhibits its commer­ cial Jet Fusion and Metal Jet 3D print­ ing solutions, the HP Jet Fusion 5420W and the HP Metal Jet S100. Exciting advancements to the systems are show­ cased as well as a new, strategic partner­ ship 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, in­ vites attendees to learn about compos­ ite-based AM (CBAM) and the latest material developments and recent cus­ tomer 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, highlights its MasterPrint Robotic, the robotic version of the company's family of AM equipment, which provides customers with the ability to seamlessly program, simulate, 3D print, as well as

mill large composite parts in a single piece. INFO# 217 JEOL USA, booth 4441, showcases its electron beam melting (EBM) powder bed fusion machine and displays a vari­ ety of metal parts that the 3D printer has

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Electronics, software, tools & services for industrial inkjet systems

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3 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 3. Ingersoll Machine Tools, booth 1720, highlights its

MasterPrint Robotic, the robotic version of the Ingersoll Machine Tools’ family of AM equipment.

8 [ Industrial Print Magazine ] April 2023

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

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4 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 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.

10 [ Industrial Print Magazine ] April 2023

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

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SHOWTIME

EVENT FOR SEWN PRODUCTS Texprocess Americas Preview

by Industrial Print Magazine 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, and education are all expected at Texprocess Amer­ icas. We've included a look at some of the vendors exhibiting at the show.

Eastman Machine Company, booth 1431, demon­ strates its C135, an automated conveyorized cut­ ting 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 systems for critical color matching and aesthet­ ic appraisal. GTI's CMlite D65 daylight products are designed to meet or exceed the ASTM Dl 729, SAEJ361, and MTCC Pro­ cedure #9 viewing standards for visual color matching. GTl's of­ fering includes desktop viewers, floor stand models, overhead luminaires, and color harmony rooms. All products provide com­ pliance to the standards, multiple light sources, and ship with a NIST traceable certificate of product conformance. INFO# 206 1. GTI Graphic Technology, Inc., booth 2007, manufactures tight tolerance lighting systems for critical color matching and aesthetic appraisal.

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Heraeus Noblelight, booth 1114, exhibits its advanced, effi­ cient, 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 work­ flows 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 ac­ curately printed fabric can be processed by combining the cradle­ feeder, over-cutter camera registration, and the Ziind DRT high­ speed rotary tool. INFO# 208

Registration Information To learn more and register to attend, visit texprocess-americas. us.messefrankfurt.com/atlanta/en.html. /PM Aprtl 2023 [ Industrial Print Magazine J 11

SHOWTIME

FIND IT HERE ISA International Sign Expo Preview

by Industrial Print Magazine 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 of their plans here.

AP Lazer, booth 4715, offers CO2 laser ma­ chines 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, and digital printing film ranges, as well as spray paint and sticker repellent anti-graffiti film, new extra hard-wearing lam­ inate, and special effect 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, booth 3110, is a wholesale supplier for Epson, HP, Mimaki, Mutoh, and Roland digital printing 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, which offers quick response code rec­ ognition with an onboard registration camera. INFO# 242 Digitech, booth 1824, shows the popular TruFire LTX2 print­ er as part of the world's first print-and-cut system for rigid me­ dia. INFO# 243

12 [lndustfial Print Magazine J Aprtl 2023

Direct Color Systems, booth 4638, showcases its patented ADA/Braille printing process with the UV84 Gen2, the me­ dium format UV53-DTS, and the small format 1800S15 and 1800S35. INFO# 244 Epson, booth 2221, leverages a surf/skate shop theme to show­ case wide format solutions in action, check out print samples, and speak with product experts about how Epson can help grow their business. INFO# 245 Fisher Textiles, booth 4021, showcases its newest print me­ dia fabrics for soft signage, up to five meters wide and its Envi­ ro-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 engrav­ er to allow users to see the working area in real time and accom­ plish quick and precise engraving and cutting jobs. INFO# 247 HP, booth 1424, focuses on sustainability and water-based inks. As part of the show, it features new HP Latex 2700 Printer 1. SAi, booth 1230, demonstrates its total-solution Flexi software for printing, cut­ ting, print and cut, direct to film, and traffic applications. 2. Fisher Textiles, booth 4021, features its newest fabric media for pillow case tension displays, D08800 Sil­ ver Back, an enhanced gray-back blackout with blended yarns and a natural stretch.

3. Lintec of America, booth 1465, offers PVC-free films for glass decoration.

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series, the HP Latex R Printer series, PageWide XL Pro 10000 printer, and the HP Latex 315 Print and Cut Plus Solu­ tion. INFO# 248 Kern Laser Systems, booth 4057, 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 print­ ing 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, dis­ plays the StarLam 1600R laminator ap­ plying 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 dual­ head printer, the XpertJet 1682SR Pro. At­ tendees 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, dem­ onstrates the newest version of its RIP and print workflow software and other solutions, including ONYX Go subscrip­ tions, ONYX TruFit automated shape­ based nesting, and the company's busi­ ness 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 demonstra­ tion of the newest, time-saving production features available in Flexi 22. INFO# 255

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Summa America, booth 2027, intro­ duces the next step in workflow efficiency and automation. The F1612 flatbed cut­ ter 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 pro­ ductivity. INFO# 256 swissQprint America, booth 4939, presents its flagship flatbed printer, Ny­ ala. The newest generation manages a maximum resolution of 1,350 dpi thanks to the latest printhead technology and precise droplet placement. INFO# 257 T rotec, booth 3325, invites attendees to witness its high-performance Speedy laser machines in action with Ruby soft­ ware 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 rein­ forced polymer. It plans to demonstrate how to join metals together without the need for any fixings. INFO# 259 Vanguard Digital Printing Systems, a Durst 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 Rout­ er/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 gam­ ut of digital cutting and high-performance routing solutions with the latest in work­ flow automation. INFO# 265 Register Now In addition to the exhibition, the ISA In­ ternational 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 men­ tioned 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

Aprtl 2023 [ Industrial Print Magazine J 13

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

1

Dye Into Print ships to customers nationally from small indifleet of dye-sub transfer devices that handle a range of products vidual users to large, multi-international corporations. Its core in up to ten-foot wide seamless prints. client base operates in the metro New York City area.

For B2C it completes a lot of home décor products through The company targets drop ship fulfillment as both business to busiwell as print on demand ness (B2B) and business products for large retailto consumer (B2C) cliers. Its range of offerentele. In the B2B space ings include banners, this is primarily visual back drops, barricade merchandising display, covers, table throws, special event, hospitality, — Sam and Jake Smith, co-owners, Dye Into Fabric 1. Dye Into Print utilizes its Kornit and creative marketing Presto S Max to print directly onto cotton and other natural fabrics. businesses. It operates a

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

14 [ Industrial Print Magazine ] April 2023

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C O M PA N I E S M E N T I O N E D

See page 22 for more information.

INFO# COMPANY

WEBSITE

168

kornit.com

Kornit Digital

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.

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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

#4 April 2023 [ Industrial Print Magazine ] 15

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

1

In 2017, it began looking for ways to offer color decoration on its embrace special requests, Hoard admits that saying “no” to tumblers and coolers—it turned to digital printing. “We wanted customers is very difficult, but that they also enjoy trying out something durable with minimal changeover cost. We had very ideas on the fly. “For example, we have always made most of our little space and only a couple of full-time employees, so whatever own jigs and tooling—initially out of wood using rudimentary print process we went with had to be compact and easy to startup carpentry skills—now with three-dimensional printing and laser and shutdown,” explains Dakota Hoard, director of operations, cut parts in addition to more traditional fabrication techniques.

Big Frig.

We aren’t very good at being patient when we are excited about Another important piece of the puzzle, the printer needed to a project,” admits Hoard. offer flexibility. In addition to printing to its own products, Big An Inkcups Helix was initially brought in because cylindriFrig also takes in contract work. “We pride ourselves on our nimcal printing made sense for decorating tumblers. A dedicated bleness and flexibility, so many of our customers who started out rotary machine, the speed and print quality were just want Big buying our core products now come to us with a variety of other Frig was looking for. projects—canvas prints and laser marking leather gloves, for exTo print to the coolers, it went with the X5-T flatbed UV digiample—and we are haptal printer, also from Inkpy to assist them with cups. It is ideal for the those as well. We make work Big Frig produces it a point to say ‘no’ only 1. & 2. North Sioux City, SD-based when we absolutely have Big Frig works with hardware from to,” attests Hoard.

Inkcups and ink from Marabu to — Dakota Hoard, director of operations, Big Frig The founding memprint directly to its coolers and drinkware products. bers of the company

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

16 [ Industrial Print Magazine ] April 2023

industrialprintmagazine.com

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

C O M PA N I E S M E N T I O N E D

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 See page 22 for more information.

INFO# COMPANY

WEBSITE epiloglaser.com

108

Epilog Laser

109

Inkcups

inkcups.com

110

Marabu North America

marabu-northamerica.com

111

Radian Laser Systems

radianlaser.com

industrialprintmagazine.com

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

April 2023 [ Industrial Print Magazine ] 17

WEBINAR

---------, industrialprintmagazine.com

S

oftware is instrumental in cre­ ating effective three-dimension­ al (3D) builds. When we think of software, the category is vast and includes parts design, so­ lutions that help collaboration efforts, and moves over to additional parts of the work­ flow like platform management.

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

18 [lndustfia/ Print Magazine J Aprtl 2023

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 We­ gner, CEO, Authentise.

Step by Step

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

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

Above: Authentise Flows AM offers order intake, pro­ duction planning, digital parts library, monitoring, qual­ ity assurance and reporting, and a rules engine.

industrialprtntmagazine.com

“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.”

#7 industrialprintmagazine.com

April 2023 [ Industrial Print Magazine ] 19

1

2

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

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

C O M PA N I E S M E N T I O N E D

See page 22 for more information.

INFO# Company

Website

185

3D Spark

3dspark.de

186

3DEO

3deo.co

187

AlphaSTAR Technology Solutions

alphastarcorp.com

188

Authentise

authentise.com

189

EOS

na.eos.info

190

Essentium

essentium.com

191

Fabrisonic LLC

fabrisonic.com

192

Farsoon Technologies

farsoon-gl.com

193

Fiberneering

fiberneering.com

194

Formlabs

formlabs.com

195

HP Personalization and 3D Printing

hp.com

196

MELD Manufacturing Corporation

meldmanufacturing.com

197

Multec GmbH

multec.de

198

Rapidia Inc.

rapidia.com

199

Roboze

roboze.com

200

TRUMPF Inc.

trumpf.com

201

Wibu-Systems

wibu.com

20 [ Industrial Print Magazine ] April 2023

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.

industrialprintmagazine.com

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

industrialprintmagazine.com

SECURIT Y SOF T WARE 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.

April 2023 [ Industrial Print Magazine ] 21

According to Miraj, frequent use or use

way to ensure that a solution is worth pur­

"The more information you can give

with complex builds increases the value

suing is a clear understanding of the ROI.

someone the better their informed final

and necessity of the software. "The future

Typically this ROI calculation requires a

decision will be," agrees Fu.

of 3D printing involves more sophisticated

good technical understanding of the pro­

''.,\s technology continues to improve

materials, complex geometries, greater

cess as well as the needs of the business,"

the solutions will be even more capable

number of parts, and more opportunities

suggests Chase D. Cox, VP, MELD Manu­

of applying data and digital technologies,

for failure. The cost of machines, materi­

facturing Corporation.

and the entire end-to-end lifecycle will be

Initial ROI comes from efficiency, spe­

als, and personnel demand methods to in­

further streamlined and accelerated as a

crease efficiency and productivity. Design/

cifically faster quoting, fewer wasted re­

result of implementing 3D software and

workflow and process simulation software

sources and failed builds, and reduced

solutions," foresees Ferris.

can address most of those concerns and ul­

meeting schedules, lists Wegner. "But the

timately reduce costs."

true ROI is felt down the line when the data

Continued Improvement

"Implementing 3D workflow solutions

collected from the digital thread helps op­

Automation software is designed to in­

can increase business' demanding and

erations become more resilient, deliver in­

crease efficiencies at every part of the AM process. As 3D printing becomes more so­

unique needs by providing a quick, afford­

sight that can yield a competitive advantage

able solution. All workflow solutions can

with the help of AI and machine learning,

phisticated, the value of automation soft­

be designed and managed in house to

and captures tribal knowledge;'

ware subsequently grows.

speed up the workflow from idea incep­

"The first step before entering and thus

"There is a need to develop solutions

tion to an end-use product," says Horvath.

investing in AM should always be a poten­

that make the process from creation to

Advantages to look for in 3D software

tial assessment with regard to costs-ROI,

production of finished parts increasingly

include smooth integration into existing

technical printability, delivery time savings,

efficient, with rapid response to various

CAD/CAM and simulation environments,

and sustainability on the basis of one's

configurations of production systems.

intuitive usability,

range of components," notes Meuth.

effective monitoring,

Rapp suggests that, "from a financial

real-time availability, transfer of production

This is from a technical point of view, as well as from a business and environmen­

data, and compatibility with many other

point of view just take a few use cases of

tal perspective," notes Ilaria Guicciardini,

systems, according to Phillips.

that person and do the calculation for dif­

head of marketing, Roboze.

Of course, certain solutions are not a

ferent manufacturing processes. Chances

Learn more about 3D printing in

fit for everyone. "There needs to be a clear

are AM is less expensive and faster than

our most recent webinar, accessible at

reason to adopt a new technology. The best

any conventional production process."

industrialprintmagazine.com/webinars. /PM

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� Get more information from vendors appearing in this issue! Visit IPMagdirect.com.

With just a few clicks, order FREE information from dozens of companies covered in this issue. '\

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Canon Solutions America Meteor lnkiet Ltd. Mutoh America Inc. Nanase Snecialtv Materials NA LLC

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Sions365 SME Wibu-Svstems Zund America Inc.

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COMPANIES MENTIONED Company

30 Soark 3DEO 3DEO AlohaSTAR Technoloav Solutions Al�haSTAR Technology Solutions Authentise Authentise EDS EDS

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22 [ lndustfiaf Print Magazine Aprtl 2023

185 170 186 171 187 172 188 173 189

Company

Eoiloo Laser Essentium Essentium Fabrisonic LLC Fabrisonic LLC Farsoon Technolooies Fiberneerinq Formlabs HP Personalization and 30 Printino

108 174 190 175 191 192 193 194 176

Company

HP Personalization and 30 Printino lnkcuns Kornit Diaital Marabu North America MELD Manufacturin□ Cor□oration MELD Manufacturino Cor□oration Multec GmbH Multec GmbH Prima Additive S.rJ

195 109 168 110 177 196 178 197 179

Company

Radian Laser Svstems Ranidia Inc. Raoidia Inc. Roboze Sharebot TRUMPF Inc. TRUMPF Inc. Wibu-Svstems

111 180 198 199 181 182 200 201

industrialprtntmagazine.com

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 industri­ al levels. Aerospace, automotive, medical, jewelry, and consum­ er product buyers recognize the potential of 3D metal printing

industrialprtntmagazine.com

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.

Prima Additive's product portfolio includes multiple laser technologies for metal 30 printing applications.

Aprtl 2023 [ Industrial Print Magazine J 23

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 bil­ lion in 2021 to more than USD 13 billion by 2028 at a compound annual growth rate of 16.5 percent between 2022 and 2028.

"The data supports an increased inter­ est 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

24 [lndustfia/ Print Magazine] Aprtl 2023

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 sinter­ ing, as these will be future disrupters.

Part of why 3D printing is increasingly used in metal parts production is acces­ sible education, creating more familiarity.

"Businesses understand the potential ben­ efits that using this technology could have on their production efficiency, environmen­ tal impact, and supply chain sustainability.

3D printing is cost competitive with tradi­ tional manufacturing methods and can be applied across a variety of industries. The use of 3D 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 of customer experience, Rapid­ ia Inc., metal 3D printing was origi­ nally reserved for high-value, niche industrial applications. "Metal manu­ facturing has been off limits to most people because it requires a lot of skill

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

For those utilizing conventional manu­ facturing 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 prod­ uct 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. Pro­ totypes are built quickly and cost efficiently.

End products for individual or series pro­ duction can be flexible and made on de­ mand," shares Jenna Phillips, marketing specialist, EOS North America.

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

1. Prima Additive's powder bed fusion technology is ideal for processing reflective materials. 2. MELD holds more than a dozen patents for its MELD technol­ ogy, an innovative process for metal manufacturing.

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

industrialprtntmagazine.com

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

industrialprintmagazine.com

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.

4 “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.

April 2023 [ Industrial Print Magazine ] 25

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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.”

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

C O M PA N I E S M E N T I O N E D

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, See page 22 for more information.

INFO# Company

Website 3deo.co

170

3DEO

171

AlphaSTAR Technology Solutions

alphastarcorp.com

172

Authentise

authentise.com

173

EOS

na.eos.info

174

Essentium

essentium.com

175

Fabrisonic LLC

fabrisonic.com

176

HP Personalization and 3D Printing

hp.com

177

MELD Manufacturing Corporation

meldmanufacturing.com

178

Multec GmbH

multec.de

179

Prima Additive S.r.l.

primaadditive.com

180

Rapidia Inc.

rapidia.com

181

Sharebot

sharebot.us

182

TRUMPF Inc.

trumpf.com

26 [ Industrial Print Magazine ] April 2023

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

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