IPM September 2024 by rockportcustompublishing

CORRUGATEDPACKAGINGINDUSTRY

SuperCorrExpo Preview

by IndustrialPrint Magazine Staff

SuperCorrExpo is sneaking up on us, with TAPPI and AICC's premier event taking place September 8 to 12, 2024 in Orlando, FL at the Orange County Convention Center.

Following up on our first preview in theJune issue, we share more exhibitor plans here.

BW Converting's Baldwin and Winkler+Diinnebier (W+D), booth 1911, technologies position corrugated manufacturers to achieve more with less. The Baldwin FlexoCleanerBrush automated system for flexographic plate cleaning up to 126 inches wide ensures rapid, thorough cleaning without halting production. Baldwin's FlexoDry IR drying system uses patented Diamond-IR lamps to deliver focused IR radiation for up to 30 percent energy savings versus traditional IR lamps. The W+D 449 ecommerce mailing bag machine produces up to 300 bags per minute, with options for peel-and-seal strips and a four-color flexographic printer.INFO# 171

eProductivity Software (ePS), booth 1977, unveils advancements poised to reshape the corrugated industry. ePS' latest innovations, including the ePS Escada corrugator process and control systems, are setting new standards in efficiency, sustainability, and productivity. ePS' Corrugated Suite, featuring the new Auto-Count 4D system, offers real-time data insights that enhance efficiency and productivity while minimizing waste. INFO# 172

Mitsubishi Heavy Industries America (MHIA) Corrugating Machinery Division, booth 2357, showcases its latest innovations, celebrates global milestones of EVOL, and highlights significant enhancements to EVOL Digital Services, including the expanded EVOL AR Library and integration with Maintenance Agreement Visits. Additionally, the Production Improvement Program is featured, which helps maintain EVOL machines to OEM specifications. INFO# 173

Signode, booth 2101, showcases its suite of products and integrated solutions. Highlights include live demonstrations

1.SUNAutomation, booth1731,highlightstheSUN625 HDRotaryDieCutter.

of an integrated packaging system featuring the new GCU-3 strapping unitizer and the fully automatic Octopus S Series stretch wrapper. Attendees can also explore the Signode line of automatic corrugated bundling equipment, including the SIG-VCS Tandem with SIG-C and SIG-CORR. INFO# 174 SUN Automation Group, booth 1731, highlights its latest innovations and strategic partnerships. This includes the SUN625 HD Rotary Die Cutter, which offers superior container quality and production volume, and Helios, a machine learning and IIoT platform designed for predictive maintenance and real-time monitoring. SUN's global partnerships with companies enable it to provide comprehensive solutions for corrugated manufacturing. INFO# 175

Plan on More

Beyond the show floor, there is much more to experience, from the welcome reception, AICC training, and 2024 keynotes to the die cutting course, corrugated classic golf tournament, 2024 Box Manufacturing Olympics, and House of Blues Experience. /PM

INDUSTRIAL PRINT

PRINTING United Preview

The PRINTING United Expo takes place September 10 to 12, 2024 in Las Vegas, NV at the Las Vegas Convention Center. The event brings together the entire print industry under one roof from apparel decoration to labels and packaging, in-plant professionals, and graphics/wide format.

We reached out to vendors in the industrial print segment to learn more about their plans for the show.

Durst Group, booth C1543, excels as a highend manufacturer of inkjet printing solutions and plays a pioneering role in many application areas such as wide format and label. It showcases the hybrid P5 350 HS with D4 configuration, the highspeed roll-to-roll P5 350 HSR, the P5 TEX iSUB, and its Tau RSC E label printer. These printers are supported by UV and water-based inks, a comprehensive software ecosystem, and a knowledgeable team available to answer your questions in the booth. INFO# 177

INX International, booth C920, promotes new ways to boost productivity, efficiency, and sustainability with a range of advanced inks, coatings, and digital printing solutions. Checkout the variety of high-performance inks and coatings for commercial and packaging print applications. These solutions are formulated to increase productivity and reduce applied costs, and they are sustainable with the environment in mind. Digital printing solutions range from premium quality inks and service agreements to color management, color, and chemistrycompatible inkjet inks, printer conversions, and ink train warranties. INFO# 178

IST America, booth C3083, is the North American arm of IST Metz in Nurtingen, Germany. Its systems include LEDCure, Traditional LAMPCure, Low Energy, Excimer, and Hybrid UV technology for sheetfed, wide web, narrow web, digital, and industrial applications. IST America provides system sales, service, parts, and application support for the North American market to OEM manufacturers and end users for new equipment as well as retrofit opportunities. IST showcases several technologies.

FREECure is a groundbreaking approach to UV curing that utilizes a new kind of cross-linking technology, offering unparalleled results while eliminating the need for photo initiators and inertisation. SMARTcure is an AI-driven digital curing assistant that helps optimize curing and saves energy. UV Analyzer is an innovative, application-based UV radiation measuring device for quality control. SMARTcure, along with the UV Analyzer, provides a closed loop process for quality control and process stability.

INFO# 179

Marabu, booth SL11023, showcases the StarLam 1600R Roll-to-Roll Liquid Laminator, which applies a smooth, consistent coating of its water-based ClearShield Liquid Coatings, making protecting digital prints a quick and simple process. The StarLam handles of a variety of substrates up to 64 inches wide. Marabu is the North American distributor of LSINC’s Peri One single-spindle, cylindrical printer based on the technology of the PeriQ360. This printer provides ease of entry into the direct to

1. IST America, booth C3083, is the North American arm of IST Metz in Nurtingen Germany. Its systems include LEDCure, Traditional LAMPCure, Low Energy, Excimer, and Hybrid UV technology for sheetfed, wide web, narrow web, digital, and industrial applications.

object market, while also providing fast and efficient performance for light production, prototyping, and personalized media. INFO# 180

Mimaki USA, booth C1737, debuts four new products covering three of Mimaki’s main vertical markets. Each debut is an expansion of an existing product line, reflecting customer feedback for higher production throughput without sacrificing image quality. In addition, it demonstrates the JFX600-2531 UV-LED flatbed, an 8x10-foot model paired with the recently announced CFX-2531 flatbed cutter, highlighting a full packaging solution from a single manufacturer. The CFX-2531 cutter features the new R10 routing option for rigid substrates. INFO# 181 swissQprint, booth C2375, demonstrates its flagship Kudu, the UV LED

flatbed printer with ten color channels and 30 printheads, as well as the rollto-roll printer Karibu. These printers have significantly impacted its customers’ business results by delivering outstanding quality, precision, reliability, and versatility. At the booth, impressive print results in neon colors and various application worlds are presented that highlight the versatility of swissQprint technology. INFO# 182

Zünd, C1161, features various ways to experience the latest advances in highperformance digital cutting automation— from the latest, most advanced, industrial Q-Line system to the ultra-versatile Zünd G3 “workhorse” now available with UNDERCAM registration. This type of registration/capture technology is adapted from the Zünd Q-Line and specifically

designed for processing materials that benefit from cutting—or creasing—from the back, unprinted side. Also on display is a Robot PortaTable setup for automatic material advancing from rolls and robotic picking/placing for a fully automated, non-stop, unattended production process. And to complete the lineup of the latest workflow automation, don’t miss the fully automated inline digital print and cut setup at the Digitech booth C324 featuring the ultra-productive, dual-beam Zünd D3. INFO# 183

Take Advantage

The PRINTING United Expo takes place in the central and south halls of the Las Vegas Convention Center. Plan your days accordingly to take advantage of all there is to offer at the show. IPM

TECHNOLOGY FOR MANUFACTURERS

The Association for Manufacturing Technology (AMT) hosts the International Manufacturing Technology Show (IMTS) September 9 to 14, 2024 in Chicago, IL at McCormick Place. This year brings together creators, builders, sellers, and drivers of manufacturing technology to connect, be inspired, and find solutions.

We reached out to exhibitors to share what they plan on promoting at IMTS.

3D Systems, booth 433129, showcases its large format three-dimensional (3D) printing solutions that accelerate problem solving on the factory floor to optimize workflows, increase uptime, and extend equipment life. This includes the new EXT 800 Titan Pellet with a smaller build volume in a more compact format with lower upfront investment. Manufacturers can take advantage of the lights out, production-ready system to fabricate more modestly sized functional prototypes, tooling, fixtures, sand casting patterns, thermoforming molds, and end use parts. Additionally, 3D Systems showcases an advanced tool in its investment casting portfolio. INFO# 160

EOS, booth 432302, invites attendees to explore the EOS M 400-4 metal additive manufacturing (AM) system with the new Grenzebach Dual Setup Station – EOS Edition, a production station that eliminates the manual effort of build volume exchanges. While EOS metal industrial 3D printing has some of the most impressive build speeds in laser powder bed fusion (LPBF) technology, at the end of a build job, nearly 30 percent of valuable machine time is lost waiting for unpacking. With this new setup station, users can recuperate the previously wasted time by automating the process—pushing machine utilization for production up to 90 percent. INFO# 161

Impossible Objects, booth 433140, promotes its CBAM-25 large scale AM device. Impossible Objects’ patented composite based additive manufacturing (CBAM) technology combines long-fiber reinforced sheets with thermoplastics, delivering parts with exceptional mechanical and thermal properties at unparalleled speeds. Users can print complex composite parts

up to 15 times faster than any other 3D printing technology. It is applicable with a range of materials, including carbon fiber PEEK, carbon fiber nylon, fiberglass PEEK, fiberglass nylon, and more to come like PK5000. With CBAM technology Impossible Objects is revolutionizing many critical applications within various manufacturing industries. INFO# 162

Meteor, booth 433128, is an independent supplier of industrial inkjet printhead drive electronics, software, tools, and services to OEM builders of digital deposition systems for 3D, AM, direct to shape, and manufacturing automation. At IMTS, in addition to showcasing its complete line of scalable, production-ready controllers for all leading industrial inkjet printheads, Meteor launches MetIndustrial, a straightforward, ready-to-use digital front end for productionized inkjet in scanning applications. INFO# 163

Solukon, booth 433126, brings its team including Michael Sattler, global sales director, to discuss how intelligent automated depowdering boosts efficiency in LPBF AM production

1. Solukon, booth 433126, brings its team including Michael Sattler, global sales director, to discuss how intelligent automated depowdering boosts efficiency in LPBF AM production lines.

lines. MAHARTool Supply, certifiedSolukon partner andoneofthecompany's official U.S. distributors co-exhibits. Key topics discussed in the booth include repeatable and fully automated powder removal for LPBFparts, using SPR-Pathfinder software to know how to move the part to get the powder out, andultrasonic depowderingfordelicate structures.INFO# 164

TRUMPF, booth 135010, shows its automated arc welding, laser welding, and 3D laser marking technology. On display is the TruArc Weld 1000 automated arc welding systemfor easy and affordable high-mix, low-volume production; the versatile, compact, andfully-equipped TruLaser Station 7000 fiber laser welding system; and TruMark Station 7000 with a TruMark 6030 marking laserfor high-performance 3D lasermarking.INFO# 165

TRUMPF Inc., booth 433133, highlightsthenewTruPrint2000intheAdditive Manufacturing Pavilion. Introduced inFebruaryof2024,TRUMPF'sTruPrint 2000now featuresa larger; square build plate and is designed for more productive, reliable, and high-quality 3D printing. Optimized for serial production, the newTruPrint2000offersgreaterproductivity and qualityfor manufacturers, particularly in the tooling, dental, andmedicaltechnologyindustries.INFO#166

Velo3D, booth 433031, showcases how leaders in space, aviation, and defense are leveraging its LPBF technology to achieve manufacturing at scale. The company shares how its printers and software work together to unlock repeatability previously thought impos-

VE810 Engraver. Vision also has its 1612 Engraverwith ahigh-speed NSK spindle at NSK's booth 236717. Made in the U.S. for over 41 years, Vision manufactures quality-made precision machines for a variety of tag and parts marking applications. The company's rotary systems produce a clear crispmarkthatwon'teasilyberemovedorrubbed off. Workwith coated or uncoatedmetals, plastic, wood, and other materials. Vision Software has manyadvancedfeaturesincludingjobpreviewandautoserialization.INFO#168

Thanks AMT

AMT represents U.S.-based providers of manufacturing technologythe advanced machinery, devices,anddigital equipment that U.S. manufacturing relies on to be productive, innovative, and competitive. Located in McLean, VA, AMT acts as the industry's voice to speed the pace of insible inmetal 3Dprinting.Thecompany novation, inalso has parts on display in a variety crease global of metal alloys, including aluminum AheaddCPL INFO#167

Vision, booth 135232, demonstrates its 2525 CNC Router/Engraver and 2.3DSystems,booth433129,showcasesthenewEXT 800 Titan Pellet that has a smaller build volume in a morecompactformatwithlowerupfrontinvestment.

competitiveness, and develop manufacturing's advanced workforce of tomorrow.Withextensive expertise in

industry data andintelligence, aswell as a full complement of international businessoperations,AMToffersitsmembers an unparalleled level of support in multipleforms, suchas IMTS. /PM

OPTIMAL NUMBERS

Humidification Systems for Corrugated Printing Environments

by Industrial Print Magazine Staff

Maintaining a proper relative humidity in a print environment is important, especially with materials like paper or corrugated board. Since corrugated board absorbs moisture easily, imlpementing a humification system is essential to avoid warped or damaged material, which could also ruin a press.

Importance Restated

As mentioned, maintaining the correct humidity is important. Ideal indoor relative humidity ranges between 40 to 60 percent in a print environment.

According to David Baird, senior application engineer, DriSteem, managing humidity “is essential for preserving material integrity, ensuring high print quality, preventing static electricity build-up, maintaining machine performance, and enhancing operational efficiency.”

Corrugated board presents a particular challenge. “Cor rugated board is sensitive to moisture levels, which affects its structural integrity. Low humidity dries out the material, making it brittle, while high humidity can cause swelling and warping. Both scenarios weaken the board’s ability to protect and cushion products during shipping and handling,” explains Baird.

to shrink and curl; and misfeed. Additionally, inks may not properly transfer to surfaces including corrugated cardboard,” agrees Bud Thomas, manager, Hydrofogger, LLC.

Benefits of a Real System

An optimal humidity level assures the corrugated board maintains its proper moisture content and remains dimensionally stable. “This stability means there is less risk of warping, curling, or other forms of deformation that can compromise the quality of the printed product and cause operational issues in the printing process,” says Baird.

“Humidification is important, yet often overlooked in printing. Proper humidification will have a positive impact on print quality. If the humidity level is too low, then paper tends

Implementing a humidification system assures better quality prints, increases productivity, and minimizes downtime. There are other benefits as well.

When humidity is at the correct level, inks adhere more uniformly to the printing substrate, preventing problems such as smearing, bleeding, or blotching.

Controlling humidity allows for even ink absorption, precise color reproduction, and sharp images, lists Baird. If humidity is too low, ink can dry too quickly, which results in smearing and bleeding. When humidity is too high, dry times extend, smudging occurs, as do print defects like mottling and color inconsistency.

— David Baird, senior application engineer, DriSteem

“When humidity is at the correct level, inks adhere more uniformly

to the printing substrate, preventing problems such as smearing, bleeding, or blotching. Uniform adhesion results in sharp, clear images and text with vibrant colors true to the original design,” says Baird.

Maintaining the right humidity level in a print shop also helps manage static electricity. “When the humidity level falls in a pressroom, static electricity can build up. This can obviously cause not only printing problems and decreased productivity but damage to equipment as well,” shares Thomas.

“Low humidity levels cause static electricity to build up, causing paper and other substrates to stick together or repel each other, which leads to feeding problems. Misfeeds, double feeds, and paper jams are common consequences, disrupting the printing process and reducing productivity. Excessive static build-up can affect the electronic components of digital printing equipment. This can lead to malfunctions, errors, and potential damage to sensitive printer parts, increasing maintenance costs and downtime,” continues Baird.

Changes Over the Years

Humification systems have changed significantly over the years. They are more advanced in regards to controls and sensors, as well as more efficient.

Today’s humidification systems are easier to install, maintain, and operate. “There are several affordable options on the market that make it easy for any size printer to have adequate humidification. Also consider power consumption of your humidifier. There is a wide span of power usage for different types of humidifiers with steam basically being the most expensive to operate and adiabatic costing the least to produce,” says Thomas.

“Commercial humidification systems have changed significantly over the years. Many now use advanced controls and sensors to optimize performance and reduce both energy and water consumption, which has improved efficiency compared to older systems. Additionally, today’s humidification systems offer precise control, ensuring consistent environmental conditions with minimal fluctuations. This level of control is crucial for maintaining optimal conditions in print environments, to ensure print quality and machine performance,” shares Baird.

Get the Correct One

For corrugated printing environments in particular, it’s important to get a handle on what exactly to look for in a humification system.

According to Baird, there are several factors. “The system should maintain consistent humidity levels to prevent issues such as paper curling or static electricity build up, which affect print quality. The chosen system should adapt to specific environmental conditions of the printing facility, considering factors such as temperature fluctuations and varying production levels.”

Energy saving features are also something to consider. “Look for systems that offer energy saving features to reduce operational costs. Choose systems that are easy to maintain and have a reputation for reliability and longevity. Finally, consider how the system will integrate with your existing equipment and building automation systems to ensure seamless operation and compatibility,” adds Baird.

Adiabatic or evaporative, ultrasonic, and steam humidifiers are the three different types of humidifiers to consider in a corrugated print space. “Each has its own features and benefits. Be sure to

understand the full scope of cost, installation, equipment lifetime, and maintenance when considering your humidifier,” stresses Thomas.

When it comes to a specific system, Baird suggests evaporative humidifiers for print shops. “They use the heat already present in the air to evaporate evenly distributed water droplets dispersed by the system. As atomized water droplets are absorbed, the evaporation causes air temperature to drop, saving on energy costs and reducing the cooling load. This provides significant energy savings when both cooling and humidifying are required. This energy efficiency translates to lower operational costs, which is particularly beneficial for print shops that require continuous operation.”

Look Into It

When the right humidification system is chosen, the long-term benefits are apparent. In corrugated printing environments a humidification system provides press operators with a certain level of confidence that their prints won’t bleed or smear, with inks adhering uniformly thanks to an optimum humidity level. IPM

1. An example of a finishing room that might benefit from humidification systems. Photo courtesy of DriSteem. 2. Hydrofogger is the U.S. distributor for a number of industrial humidification companies.

PERFORMING IN HIGH TEMPS

Materials Designed to Excel in Heat

by Melissa Donovan

Three-dimensional (3D) printers reach higher temperatures than ever before to fuse filaments together, creating functional parts for real world use. The filaments themselves must be compatible with high temperatures.

One example, BigRep announced in Summer 2024 its fused filament fabrication (FFF) printer, the ALTRA 280. It offers high-temperature capabilities by printing with materials like Ultem 9085 and polyetheretherketone (PEEK).

Also of note, the UltiMaker Factor 4, equipped with a new hardened steel nozzle, which is 0.6 millimeters and enables the printing of high-temperature, high-performance materials like the new UltiMaker PPS CF.

The FFF process isn’t the only additive manufacturing (AM) solution fit for high-temperature production, other 3D printing processes that handle hightemperature materials are powder bed fusion, pellet printing, selective laser sintering, binder jetting, and material jetting. This article primarily focuses on FFF.

Define High Temperature

a certain number that will fuse thermoplastic filaments effectively. In regards to the company’s ALTRA 280 and IPSO 150 printers, chamber temperatures can achieve up to 180 degrees celsius and extruder temperatures reach 450 degrees celsius.

As higher temperatures become more realistic due to advancements in both the printers and filaments that can withstand that heat, it’s important to define high temperature.

For FFF, Thomas Janics, managing director of HAGE3D, BigRep, says temperatures need to reach and maintain

...printing in higher temperatures “unlocks a new world of high-performance applications.”

—

Thomas

Janics, managing director of HAGE3D, BigRep

“In contrast to injection molding’s forced material injection and subsequent cooling, FFF builds objects layer by layer without mechanical pressure, relying on a heated environment for proper layer adhesion and uniform cooling. This method is crucial for producing robust parts with complex geometries, especially for demanding applications

inindustrieslike aviationand rail," explainsJanics.

Luis Rodriguez, senior applications engineer,UltiMaker,sayssomeFFF3D printersprintattemperaturesbetween 300 and 500 degrees celsius, which

option, and acrylonitrile butadienestyrene(ABS) with electro static discharge(ESD)properties workswellforelectronic parts. Allthesetechnical would allow them to print higher tern- and high-performance perature, stronger, and more durable materials. UltiMaker's UltiMaker Faematerials require a heated chamber above tor 4 offers a high-temperature print 80 degrees celsius. core that allows engineers to print up to340 degreescelsius.

Unlocking Possibilities

Temperatures are rising in3Dprinters because of the inherent advantages offered,includingmaterialflexibility.

"There are a few advantages to beingabletoprinttohighertemperatures. For example, it allows for printing

This ensures consistent mechanical properties, better layer adhesion, and warp-freeparts," explainsJanics.

Filament Options

Many high-performance filaments are accessible for these higher temperhigh-performance materials that offer atureprintingscenarios. 2 advanced material properties that can UltiMaker's PPS CF withstand extreme environments. This includes increased strength, stiffness, and durability, which are crucial for some functional parts, end use parts, or even tooling, in industries like automotive,aerospace,andmanufacturing," sharesRodriguez.

Janics believes3D printing in higher temperatures "unlocks a new world of high-performance applications. For example, high-temperature thermoplastics have great properties and can be a solution for any type of application. Polypropylene (PP) is excellent at chemical resistance and is often used in injection molding because it's affordable. For thermal resistance, Ultem would be the top choice. If you need robust jigs and fixtures, Carbon Fiber PA is ideal. For printed molds for thermoforming, polyetherketoneketone(PEKK)CF isagood

1. BigRep's IPSO 150 printer's chamber temperatures can achieve up to 180 degrees celsius and extruder temperatures reach 450 degrees celsius. 2. The UltiMaker Factor 4 30 printer offers a temperaturecontrolled build volume of 330x240x300 millimeters and uniform bed heating, ensuring consistent performance across the entire build plate.

isflameretardant.Itisasemi-crystalline thermoplastic material, reinforced with carbon fiber. The material has a temperatureresistancegreaterthan230degreescelsius.Itoffersahigh-performing alternativetosteeloraluminumforlessdemandingparts.

Ultem 9085 is particularly of note. A high-performance polymer, it is ideal for aviation and rail applications due to its high heat resistance and mechanical strength.JanicsalsocitesUL94VOforits flameretardancyandchemicalresistance.

"Forfunctionalparts builtforaircraft andhelicopters,reducingweightisabig deal-high-performance polymers like Ultem9085.Forexample,partsofventilationsystemsneedtobelightweightbut alsomeetstrictrequirementslikeUL94 VOflameretardancyandchemicalresistance,"saysJanics.

Inaddition,"polycarbonate,ABS,and PPareotherhigh-performancematerials thathavehighstrength,impact,andheat resistancethatcancreaterobust,durable parts,"addsJanics.

ABS ESD is "lightweight and rigid, protects against electro static

discharge," says Rodriguez. Another filament option-PEKK-A, which offers highermechanical, thermal, andchemicalresistance,headds.

These products are used to create a varietyof end parts. "Examples include engineparts,ductingorexhaustcomponents,orotherpartsforareasthatneed towithstandhighheat; functionalprototyping; electronics and other electrical components; jigs, fixtures, and tooling," saysRodriguez.

BASF's Ultrafuse high-temperature materials like its Ultrafuse PPSU is worthnoting.Itisinherentlyflameretardantandoffersashort-termtemperature resistanceupto220 degreescelsius.

Evonik's INFINAM PEEK 9359 F filament is for industrial 3D printing of high-temperature, lightweight parts using FFF technologies. Compared to 3D printedstainless-steel parts, PEEKbased3Dprintedobjectsare80 percent lighterinweightand30percenttougher withexcellentfatigueresistancemaking them applicable as asubstitutionto3D printingmetal.Duetothesuperiorwear resistance and low sliding friction of

PEEK lightweight structural parts, they can be manufactured easily.

Lubrizol 3D Printing Solutions offers an expanding portfolio of ESTANE 3D thermoplastic polyurethane (TPU) for use in FFF 3D printers. Engineered to meet high-performance demands, TPU is used across a variety of applications. ESTANE 3D TPU F94A-055 OR HH

PL in particular is designed to perform in high heat.

What’s on the Market

Here’s more information on both BigRep and UltiMaker’s FFF high-temperature 3D printers.

BigRep engineered the ALTRA 280 as a high-performance industrial powerhouse with an expansive build volume. HAGE3D, a company specializing in large format high-temperature machines that are part of BigRep

through a planned acquisition, originally built the ALTRA 280. The machine delivers unmatched reliability with up to four state-ofthe-art extruders, each with its own backup. Built on CNC technology with ball screws and servo motors, the ALTRA 280 3D printer is precise, large, and fast. Its high-temperature capabilities allow for peak-level 3D printing, making it ideal for demanding applications in industries like aerospace, defense, and automotive.

The UltiMaker Factor 4 3D printer offers a temperature-controlled build volume of 330x240x300 millimeters and uniform bed heating, ensuring consistent performance across the entire build plate. Designed for manufacturing and industrial sectors, it can print high temperatures with a new high-temperature print core that allows engineers to print up to 340 degrees celsius. This enables a broader range of high-performance, temperature-resistant, and durable materials. The machine efficiently uses the heated bed and actively controlled chamber airflow to manage the build volume temperature up to 70 degrees celsius, ensuring optimal material-specific processing conditions and consistent part quality wherever the 3D printer is located.

Heating Up

FFF is well suited for high-temperature builds as it relies on heat for proper layer adhesion. Manufacturers up the game by creating printers that can print at temperatures reaching up to 500 degrees celsius. With these achievements the possibilities of which filaments to print with grows.

3. BigRep engineered the ALTRA 280 as a high-performance industrial powerhouse with an expansive build volume.

ENGINEERINGBRIDGES

WiththeHelp of3D Printing

by IndustrialPrint Magazine Staff

The building and construction industry isagreatstagetoshowcasetheunique, innovative successes of three-dimensional (3D) printing projects. MX3D, a manufacturer of robotic wire arc additivemanufacturing (WAAM),recognizes additive manufacturing's (AM's) role in meeting challenges in the building construction sector. Its technologies are designed to produce complex components while offering flexibility in design.

Two case studies showcase MX3D's commitment to bringing AM to architecture, engineering, and construction.

MX3D Bridge

The MX3D Bridge is a 12-meter-long

stainless steel pedestrian bridge. The bridge was fully func- teamed up with mathematicians and internet of things speciational and installed in the city center of Amsterdam in 2021 lists to develop a smart sensor network to monitor the bridge's over one ofits canals. Partners ofthe MX3D Bridge project in- health in real time. elude Arup, Autodesk Inc., The Alan Turing Institute, the Am- The team from The Alan Turing Institute designed and insterdam Institute for AdvancedMetropolitanSolutions (AMS), stalled a sensor network on the bridge. The sensors collected andJoris Laarman Lab. structural measurements such as strain, displacement, and

over its lifespan.

Designed byJoris Laarman Lab of The Netherlands, with vibration, as well as measured environmental factors such as Arup as lead engineering partner, it was an 18 month process of engineering, designing, re-engineering, re-designing, air quality and temperature, enabling engineers to measure the bridge's health in real time and monitor how it changes discovering the world behind permits, safety measures, canal wall renovation, and test printing to finalize the MX3D Bridge. Joris Laarman Lab finished printing the bridge in early 2018 using an MX3D 3D printer.

Beyond working with Joris Laarman Lab and Arup, MX3D

The data from the sensors were input into a digital twin ofthe bridge, a living computer model that reflected

1. & 2. The MX3D Bridge is a 12-meter-long stainless steel pedestrian bridge constructed with the help of AM. The bridgewasfullyfunctionaland installed in the city center of Amsterdam in 2021 over one ofitscanals.

the physical bridge in real time as data wasgenerated.Theperformanceandbehavior of the physical bridge was tested against its digital twin, which provided valuable insights to inform designs for future 3Dprintedmetallicstructures.

Autodesk supplied the cloud services thatpoweredthebridge'sdatacollection

and processing. IT also worked with The Alan Turing Institute researchers todevelopmachinelearningalgorithms to enable the bridge to interpret and to react intelligently to its environment. AMS implemented new ways to use, visualize, andconnectthebridge'sdatato other sources of environmental data in

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the metropolitan area ofAmsterdam.

The bridge was officially installed in 2021 and opened to the public. It closed in 2023 and the collaborative team is currently looking for another spot to placeit.

Structural Steel Connector

Another interesting use case in the construction industry is the fully printed, optimized, and organic duplex steel connector MX3D manufacturedincollaborationwiththeengineers ofTakenaka in 2018. Takenaka is an architecture, engineering, and constructionfirm inJapan.

The application showed accelerated progress in the production of highly customized and engineered steel connectors using robotic 3D metal printing, specifically WAAM. An MX3D MetalXL printer was tasked with printing the connector using Duplex stainless steel. The alloy was chosen for its good mechanical properties and excellent corrosion resistance.

According to MX3D, the goal of this project was to automate boththedesign andproductionofcomplexconnectorsfor large structures in the building industry. As the complexity of structures increases and skilled labor in countries with aging populations is less available such innovationisrequiredinthebuildingindustry.

Thefinalsteelconnector's netweight is 40Kg reaching up to 45Kg after its hollowcorewasfilledwith approximately 2.5litersofmortar.

Creditable Examples

MX3D has many years of experience in the architecture, engineering, and construction space. Its work shown here is just two of many examples ofAM out in the wild. /PM

UVPrintingandCuringTechnologyforIndustrialOTOApplications

byCassandra Balentine

Digital printing isused to decorateobjects made of various materials. UV inks are commonly utilized for direct to object (DTO) printing. UV printing in particular as well as the subsequent UVcuring technologiestraditional or LED-enable high-resolution printing and deliver sharp, vibrant images. There is also the capability for print embellishments with speciality inks, coatings, and varnishes.

such as printing on solder masks and industrial parts in automotive, lists Stacy Hoge, Phoseon marketing manager, Excelitas Technologies Corp.

Hugo Gonzalez, senior segment specialist, industrial products, Mimaki USA, Inc., notes that UV curing in the industrial DTO print space is a transformative technologythat enables printing ofhigh-quality images and designs directly onto a variety of substrates.

"UV curing systems in digital DTO printing have expanded rapidly in the last few years," comments Many Uses of UV Paul Edwards, VP - digital division, INX International Digital UV printing supports a variety of DTO ma- Ink Co. "Today, DTO is commonly used to print glass terials from cylindrical hollow bodies like bottles, cans, tubes, cartridges, and cups; to flat surfaces like flooring, tiles, signs, promotional items, and decals, as well as non-packaging industrial applications

Above:ExcelitasTechnologiesisanindustrialtechnologymanufacturer focused on delivering innovative, market-driven photonic solutions to meettheillumination,optical,optronic,imaging,sensing,anddetection needsofitsOEMandendusercustomers.

bottles, cups, tubes, formed boxes or cartons, cans, and containers of all types.”

The potential doesn’t stop there. For instance, the technology prints onto planks of wood flooring. “Considering the breadth of substrates, UV ink technology makes a lot of sense as it adheres well to all of the substrates mentioned,” comments Edwards.

Juan Kim, CEO, Valloy Inc., suggests that UV curing for imaging and coating on industrial substrates is quite popular and is easily found in various fields already today. “Many interior glasses are decorated by UV inkjet and displays from cell phones to larger TVs are coated by UV-curable inkjet technology. Anodized and chemical treated aluminum plates are digitally printed by solvent ink. Metal cans are also digitally produced,” he offers.

Thomas Lang, digital applications manager, Inkcups, also reports growth in industrial applications where DTO

printing is replacing adhesive labels, such as for industrial parts and medical items.

Outlining the Process

UV curing is integral to industrial DTO inkjet printing.

The process involves applying tiny droplets of UV-curable ink onto plastic, glass, metal, and other materials through a printhead. These are then instantly “cured” in UV light. “It is the instantaneous nature of this drying process that is so important, because it ensures that each ink droplet stays exactly where it should, with no bleeding or spreading. This makes for a sharper image, allowing for precise reproduction of vividly colored digital images or fine lines, text, and numbering. UV-cured ink fits in perfectly with the fast-paced customization market, with instantly cured products coming off the machine making for a perfect process for print on demand that can accommodate next-day or even same-day shipping,” explains Lang. Michael Perrelli, sales and marketing director, Innovative Digital Systems, points out that without UV curing, there

would be no UV printing. “The lamps, the power, and the speed in which the ink can be cured on materials that span such a wide range continues to grow and evolve.”

The process typically employs UV LED curing technology due to its efficiency and precision. “In inkjet printing, LED pinning is used for initial curing, while a final cure is often achieved using either LED or traditional UV lamps, depending on the desired surface characteristics and finish. The choice between LED and traditional curing hinges on factors like the ink formulation, the nature of the substrate, and the specific surface properties required,” explains Chris Davis, head of sales, web and industrial, IST America.

LED based UV curing is ideal for applications that require heat-sensitive substrates due to the low heat, shares Hoge, adding that the longer UV LED wavelengths naturally penetrate deeper into the ink delivering stronger color, greater adhesion, and a better depth of cure.

Popular Materials

As previously discussed, UV printing technologies in the industrial DTO space enable printing images and designs directly onto a variety of substrates including plastics, metals, glass, and wood.

Because UV curing fixes each ink droplet into place instantly, Lang says a DTO UV inkjet printer can be configured to print on almost any type of substrate, although in some cases, pretreatment may be needed and specialized inks are used to further improve adhesion. “This

1. UV LED curing is especially beneficial for applications that require immediate handling or further processing post-printing. Image courtesy of Mimaki.

versatility in terms of materials is one of the major factors driving the growth in popularity of UV inkjet printing.”

Plastic substrates dominate the DTO printing market, according to Davis, necessitating careful consideration of surface conditions and the material’s inherent energy properties. Surface modification techniques are often employed to enhance ink adhesion.

Plastic tubes and containers are popular. “Depending upon the type of plastic and any materials used for processing on the surface, it can be more challenging. With UV inks, most substrates can be effectively addressed. Hence, the growth into many new applications has been observed,” says Edwards.

Gonzalez adds that plastic materials are often used as manufacturing

materials. “Plastics are favored for their versatility and cost effectiveness in promotional items and consumer goods.”

Perrelli argues that the term “plastic” covers a range of materials and products. “However, that isn’t meant to imply that metal and wood aren’t equally viable and extremely popular materials to print.”

Kim believes plastic and wood stand out in terms of top materials for UV DTO printing. “This is because special ink is preferred for metal and glass/ceramic due to durability issues.”

Davis admits that metal decoration is also prevalent, valued for its durability and aesthetic appeal.

“Metals are commonly used for industrial components and high-end promotional products due to their durability

and aesthetic appeal,” echos Gonzalez. “Wood is often chosen for custom, rustic, or artisan products,” he adds.

“Glass is popular for its premium look in decorative items and awards,” comments Gonzalez.

Lang agrees that glass is a popular DTO material, but admits that it needs to be pretreated before inkjet printing.

Perrelli explains that powder-coated materials and glass are more popular on a rotary printer than a flatbed printer.

Edwards finds it difficult to really point to a material which is most favored. “Glass bottle printing is used quite often due to the wonderful looks which can be achieved on a glass bottle, and the structure which can be created with the use of clear inks. Equally, printing onto two-piece aluminum

(metal) cans has recently become very popular. It is mostly being driven by the rise and popularity of craft breweries and the unique looks which can be achieved.”

Hoge stresses that UV LED curing enables users to process a variety of materials, including heat sensitive and thin substrates, at maximum production speeds with low input power requirements. “UV LEDs allow high adhesion on covering inks, enabling strong colors on the more difficult substrates. Due to narrow, high UV-A wavelength, UV LEDs produce significantly less heat. The UV-A wavelength also allows for a more penetrative cure, which is an advantage when faced with thicker sections. Digital printing is often short run with frequent stops, so immediate ‘on/off’ with UV LED curing technology yields greater productivity and revenue.”

“Each material presents unique challenges and opportunities, requiring tailored surface preparation and curing strategies to achieve optimal print quality and durability,” concludes Davis.

Special Effects

In addition to standard CMYK printing, UV curing systems enable special effects on printed objects.

Kim confirms that digital embellishment is a hot topic and UV curing is at the center of it, from spot varnishing to glossy and matte varnish effects, and cold foiling with varnish ink.

“When it comes to UV printing, the time in which the print is cured, or the segmentation of the UV lamp, or the amount of lamp power used, can yield varying effects in regards to the finish of the ink,” explains Perrelli.

Special effect possibilities offered by UV range from full, seamless wraps or raised varnish for a 3D look and feel, largely because of the technology’s ability to instantly cure inks and varnishes, comments Lang.

Many DTO UV printers use UV ink layering to create raised relief textures, as well as matte and gloss effects, adding a tactile dimension to the printed objects. “Additionally, the use of opaque white inks enhance color vibrancy on dark substrates, while primers expand the range of printable materials by

improving ink adhesion. These capabilities enable unique finishes that elevate the final product’s visual and tactile appeal,” notes Gonzalez.

Hoge adds that digital printing processes that utilize UV LED curing achieve matte and gloss effects, tactile surfaces, cold foil, and other special effects, creating a multi-sensory experience. “Users have the option for pinning to ‘freeze’ ink drops and immediate overprint.”

Many effects require the precise application of LED light to penetrate opaque or optically challenging media. “Understanding how UV energy interacts with the embellishment is crucial. This involves determining the correct energy dosage and distribution to ensure the desired visual and tactile effects are achieved without compromising the integrity of the substrate or the print,” notes Davis.

To create these layer effects, Gonzalez recommends that the layer be fully cured before applying the subsequent layers. “If the layer below, for example with white ink, is not cured to the touch, it may blend with and ’muddy’ the color ink over it instead of giving it a vibrant pop.”

Working through the Process

Davis admits that UV curing can integrate at various stages of the printing process, including inline, offline, or nearline, depending on the application’s requirements. “Inline curing is common for high-volume, continuous production, such as beverage cups, where curing is synchronized with the printing process. Offline or nearline curing is more suitable for complex or lower volume items

like washing machine displays, where curing occurs downstream to accommodate additional processing steps or to ensure uniformity across complex geometries.”

“Unlike solventand water-based inks, which typically dry through evaporation using heat, UV inks are cured through a chemical reaction that occurs when they are passed under UV light. In addition to allowing operators to package and ship products directly after decorating, an added benefit of this is that UV curing doesn’t generate pollutants and also consumes less energy,” says Lang.

The exact process is dependent upon the application. “The curing of the ink is almost always done inline with the printing process and relatively close to it. Sometimes, due to the configuration of the printing system, you can pin the inks first. This means you cure just enough for the inks to stop being mobile, and then the final cure can take place a bit later. This is mostly done inline,” explains Edwards.

The way in which a UV ink is cured is very important to the process. “It controls the spread of the drops, which in turn has a big effect on print quality as the size of and interaction between the drops needs to be well controlled,” shares Edwards.

Sometimes in DTO printing, the user may want to print one color at a time or print after all the colors are applied as part of the process. “There is flexibility in how and where the UV inks get cured. However, it is essential that the system is

designed in such a way as to maximize the print quality and adhesion. Curing too late in the process can lead to challenges in handling the product. The inks may still be quite soft and prone to damage,” adds Edwards.

When curing inline, Lang says images can hold a tighter registration for high-quality imagery.

Perrelli adds that inline curing allows operators to go directly from print to package or retail shelf.

UV curing inline allows printers to quickly change the design printed on a product or its packaging without disrupting the process. “The inline process is a flexible technique that allows a digital printer to print on surfaces with different textures. It is designed to be agile without compromising on the production speed, quality, or reliability,” states Hoge.

Many digital printing machines come equipped with multiple printing stations that utilize UV curing for pinning, full curing, or a final coating. “A pinning station utilizes a UV

light source for the pinning process to ‘freeze’ ink drops before overlaying other colors or doing a full cure. A full cure station would typically include a fourcolor process with CMYK or singlecolor inkjet printing. Sometimes both pinning and full cure UV light sources are integrated into one station. A final coating station utilizes UV curing for top coating,” shares Hoge.

Gonzalez says curing inline also ensures that design lines and boundaries are maintained. “If the wet ink is allowed to settle before curing, edges and boundaries may spread and be blurred reducing the overall quality of the print.”

The Name of the Game

When it comes to the benefits of UV DTO printing, versatility stands out. From plastics to glass, metals, and wood, UV inks and varnishes are cured directly onto a usable product. In addition to CMYK printed output, the UV process allows for speciality finishes including matte and gloss, metallics, and even textures. IPM

UV-CURABLE DIRECT DECORATION

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“There is significant scope for 3D printing in this market. Especially in buildings, street furniture, and the like, where a certain uniqueness is sought. 3D printing can be utilized effectively to create unique designs in small numbers. New technologies allow for larger objects and more durable materials,” explains Barry Schulte, director, Fiberneering.

According to a representative from ADDiTEC, “the construction and building segment presents a significant growth opportunity for 3D printing due to its unparalleled design flexibility, material versatility, cost efficiency, and sustainability.”

“We have seen an increase in the integration of 3D printing into multiple building and construction sectors. For example, 3D printing is used to produce

critical components locally, reducing dependence on global supply chains,” shares Xavier Llobera, competitive intelligence WW manager/partner manager, HP Inc.

Growth is there, admits Ethan Rejto, director of marketing, Mantle, but it depends on the application. “3D printing needs to continue to be applicationfocused, targeting parts that have challenges—supply chain, cost, lead time, material, impossible geometry—where printing has proven to add value.”

Defining Verticals

Materials manufacturers, energy companies, and traditional construction firms use 3D printing technology to build warehouses, retail stores, commercial

buildings, and much more. They are ideal candidates for AM.

One reason 3D printing is so alluring for companies like the ones referenced here is because they “have a history of not possessing the most sustainable of practices, resulting in industry-wide criticism. By placing a greater focus on 3D printing, these verticals can begin to change how their supply chains operate from the bottom up and introduce sustainable practices,” explains Llobera.

“3D printed materials have a minimal environmental impact when compared to traditional materials as the technology uses the least amount of material required to manufacture a specific part. These verticals are all known for constantly producing or needing to produce new materials, so by using 3D printing they can begin to negate that impact,” suggests Llobera.

The representative from ADDiTEC agrees that 3D printing helps minimize material waste, making it a more sustainable practice. In addition, the ability to

1. The Meltio M600 wire laser metal 3D printer, with its built-in three-axis probing system and work-holding solutions, is the ideal companion for manufacturing operations.

print on demand is enticing, especially when printing metal parts.

“It allows for the creation of new metal parts with multi-material capabilities and the possibility to produce parts on demand for equipment used at construction sites, especially in remote areas where parts may not be widely available. It also offers the capability to repair broken metal parts on site without delays, which is a significant advantage given the extensive use of metal parts and tools in construction machinery,” explains the ADDiTEC representative.

Playing devil’s advocate, Schulte says that these verticals—materials manufacturers, energy companies, and traditional construction—have “a high level of technology demonstration around them, which is great and it is hugely beneficial

to the industry that key players set up and take the initial risk. However, it is not a long lasting model.”

“In order to create a lasting market for 3D printing, the technology should be applied on its merits for end users having a certain view or requirement, which can sometimes be best met through 3D printing,” adds Schulte.

What’s Being Printed

Small parts, tooling, and prototypes are main categories in any vertical. The building and construction space is no different.

In general, “3D printing thrives in low-volume, high-value applications,” says Rejto.

“3D printing can be used for tooling to help workers during the construction process, as well as to develop structural

components that are unique and require one-off, tailored manufacturing,” states Llobera.

One-off parts are more common. While production level creation isn’t quite there yet, we are constantly getting closer. “AM has evolved over the years and is used for a range of applications across several industries. From prototyping tooling, spare parts, repairs as well as fully printed serial production applications, end use products, and mass customization. On many levels, metal parts are now being printed. From small to very large parts, for various materials and in many different applications,” notes a representative from MX3D.

“The capabilities of 3D technologies are compatible for large-scale production needs as well as one-off applications.