IPM September 2023

REVAMPING 1PM

This issue heralds a refocus on the main topics covered in IndustrialPrint magazine. After studying digital printing, its influence in industrial-type environments, and receiving feedback from readers and marketshare leaders, we look forward to increasing our coverage on additive manufacturing (AM), corrugated printing, and direct-to-object (OTO) printing.

Every issue of IndustrialPrintmagazine covers each ofthesetopics, whether it's a feature article, spotlight on a company utilizing the technology out in the field, or a chart detailing digital printers used in the process.

This month, our feature editorial touches on automation software and its importance in corrugated printing as well as a look at how UV curing systems are implemented in AM.

We also debut a new column in this edition, AM, which will rotate between three topics-hardware, consumables, and software. The articles this month share information on flame retardant powders/resins and threedimensional printers with large build sizes.

Finally, to ensure OTO printing is addressed, we include a chart with digital devices that are currently available and used for this type of process.

If you have any suggestions or comments regarding our new, streamlined approach, don't hesitate to reach out!

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QUICK LOOK

CorrExpo 2023

by Industrial Print Magazine Staff

CorrExpo 2023 took place in Cleveland, OH this August. The event was a mix of networking, exhibits, panels, and presentations, all targeted at showcasing what’s next for box plant professionals and industry leaders.

The program included in-depth panel discussions designed to address mission-critical issues impacting box plant productivity. The four topics were Equipping Team Members for Success, Maximizing the Efficiency and Quality of Existing Capital Equipment, What’s New in Digital - Printing or Trends, and Corrugator Supply Chain Issues.

Over 140 exhibitors showcased products and services including A.G. Stacker, Air Systems Design, Inc., Amtech Software, Baldwin Technology, Baumer hhs, Bobst, Domino, Durst North America, EFI, Elitron America, GMG Color, Heraeus Noblelight America, Highcon, HP, INX International Ink, Kento Digital Printing, KiwiPlan, Koenig & Bauer, Kongsberg Precision Cutting Systems, Oxytech Systems, Tesa Tape, Valet Inc., and WSA USA.

CorrExpo 2023 is just a taste of what’s to come—2024 brings with it SuperCorrExpo, September 8 to 12 in Orlando, FL at the Orange County Convention Center. To learn more about CorrExpo 2023 visit industrialprintmagazine.com! IPM

SUPER-SIZED AM

Build Size Capabilities Trend Bigger

by Cassandra Balentine

Larger build sizes are trending for three-dimensional (3D) printing. While no official measurement classifies a 3D printer as “large,” it is a feature gaining traction in the printer landscape today.

“As suppliers educate customers and engineers on advancements and expansions in greater geometric and material freedoms, solutions that were not possible just a few months ago are being developed and employed,” says Mark Norfolk, president, Fabrisonic. These expanded capabilities motivate designers and engineers to push the boundaries of existing machines, driving innovation. “As AM machine capacities and capabilities increase, engineers are leveraging these larger fabrication platforms to accommodate parts with a larger form factor to address cost and performance objectives.”

In 3D printing, larger sizes generally refer to build size—the maximum size of the object that can be printed in a single run. “This is an important factor for many applications as it determines the size of the objects that can be created and influences the efficiency of the printing process,” explains Max Siebert, cofounder, Replique GmbH.

Beth Wyatt, director of marketing, MELD Manufacturing Corporation, points out that larger size can refer to both print and printer size—but the two aren’t necessarily synonymous. “To print a large size part, the gantry and the print bed will need to increase in size to accommodate the part. But the parts that make the printer work don’t necessarily have to be larger.”

Larger size can also refer to larger volumes. For example, Hanifeh Zarezadeh, 3D product manager, Photocentric Inc., sees an increased demand from digital mass manufacturers, which means lots of small parts made without tooling.

Meeting Industrial Demands

A variety of industries benefit from larger sized AM machines, including aerospace; energy, oil, and gas; automotive; defense; industrial manufacturers; construction and architecture; and medical applications. Many of these industries require larger part production, which is a primary driver of 3D printers with larger build capabilities.

“The technology is maturing,” admits Michael Mignatti, VP, printers, UltiMaker. He

1. Fiberneering offers three versions of its XXL DLP printers, ranging up to one cubed meter in building volume.

Implementing large-scale 3D printing into the production process enables automation of the workflow and simplifies the production of parts.

— Doris Logtenberg, marketing and communication, CEAD

says improved reliability, build times, and materials allow more people to think about 3D printing as a solution and larger build volumes help improve the solvable applications.

"When you want to create a certain part of large dimensions, but you only have a 'small' printer, you need to assemble the various prints, resulting in significant extra work, but also all kinds of secondary issues derive from the assembly," shares Jasper Bouwmeester, CEO, Fiberneering.

"Larger parts are driven by companies who wish to make single large items as opposed to assembling them

from numerous separately made parts with all the extra time, potential error, and costs that brings," states Zarezadeh.

Larger sized 3D printers allow for the creation oflarger objects that may not be possible with smaller printers-at least not without following with a post-processing step like gluing or welding. "This is particularly important in industries such as aerospace or automotive, where large components are in need. Most importantly, larger sized printers can increase the efficiency of the printing process, as they allow for more objects to be printed in a single run. This results in lower base and labor cost. Also, it eliminates the need for assembly of

smaller parts, as you can fuse/ unite together

many parts to a single unit, which reduces total cost of parts significantly," points out Siebert.

Blake Teipel, Ph.D., CEO, Essentium Inc., sees increased

demand to manufacture large scale, complex components and prototypes. In fact, he cites independent global research conducted by Essentium on the current and future use of industrial 3D printing, which revealed that 81 percent of manufacturing companies have increased their use of AM by more than halfin the last year. The survey results showed that AM use has evolved from simple prototyping to manufacturing aids and tooling-74 percent; complex and integrated prototyping-52 percent; and full production runs-44 percent.

Dr. Kartik Rao, strategic marketing director, Additive Industries, notes a clear interest from AM system manufacturers to keep growing the size of the build chambers to increase the application size, and says that overall, the total build envelopes for AM are increasing. "Previously, powder bed fusion (PBF) was limited to roughly 300 millimeter (mm) cubes as build envelopes. Current market reports indicate that the PBF build envelopes that have the largest market size are now in the range of 300 to 600 mm," he explains.

Larger volumes are also possible with bigger build capacities. "Productivity goes up quite significantly as the batch wise nature ofthe printing process is divided over a much larger number of parts," states Bouwmeester.

Automation is another consideration, according to Doris Logtenberg, marketing and communication, CEAD

industrialprintmagazine.com

Group. “This is due to the complex, labor intensive, and time-consuming nature associated with traditional manufacturing methods for producing large composite parts. These traditional manufacturing methods typically require an around-the-clock, skilled workforce that is increasingly challenging to find.”

As a result, companies often choose to outsource part of their production to different regions around the world. However, there is a growing trend to bring production processes back in house. “Implementing large-scale 3D printing into the production process enables automation of the workflow and simplifies the production of complex parts. By replacing traditional manufacturing methods with large-scale 3D printing, manufacturers can streamline their operations and decrease the reliance on manual labor,

reducing costs and lead times. It also allows companies to switch from large stock inventories to local, on demand production strategies. Besides the above, one other reason for the growing interest in large-scale 3D printing is the heightened emphasis on reducing environmental impact. By bringing production processes back in house, carbon emissions can be reduced. Moreover, the materials employed in large-scale 3D printing, such as thermoplastics, can be recycled and repurposed,” offers Logtenberg.

Kyle McNulty, SLA product lead, Formlabs, points out that creating large prototypes and parts was once a very expensive endeavor, but as 3D printing—and now large format 3D printing—is more accessible and affordable it helps companies print bigger prototypes and parts directly in house, significantly

reducing the costs and turnaround times associated with outsourced production. “Investing in a large format 3D printer can more quickly have a positive return on investment due to the high cost of outsourcing large parts. Users eventually create prints that exceed the build volume of a desktop 3D printer.”

Waste reduction is another driver. “Traditional manufacturing often involves subtractive processes. This leads to significant waste, especially when producing large parts. AM adds material only where needed. This reduces material waste, resulting in cost and time savings along with environmental benefits,” comments Wyatt.

Norfolk says designers, design engineers, product engineers, and product managers have fully realized the benefits of printing smaller parts using AM.

TECHNICAL CERAMICS

The use of technical ceramics is one factor driving demand for larger capabilities in additive manufacturing. This is a result of many companies shifting from metal parts to ceramic materials for space, defense, oil, and gas applications, with ceramics being more durable and longer lasting than metal parts when it comes to extreme applications.

Kareen Malsallez, marketing manager, 3DCeram, says the use of technical ceramics has transcended the realm of prototyping and is now integral to production processes. “Consequently, there is a growing demand for ever-expanding build platforms to meet these production needs.”

“We are noticing that there is a need for larger, three-dimensional (3D) printed ceramic parts across many industries—in this context, meaning larger in the sense of bigger in volume. With industries now well aware of the enormous flexibility offered by 3D printing, combined with the advantages of ceramic material over metal, we have seen this significant rise in demand for larger sized ceramic applications printed with the established Lithoz lithography-based ceramic manufacturing or LCM technology, particularly focusing on fully dense parts with thicker walls and often using dark ceramic materials,” seconds Isabel Potestio, director of sales and marketing, Lithoz.

Those who understand the extensive geometric and material freedom that ultrasonic AM (UAM) offers are driving industry innovation to build machines that can accommodate parts and devices with larger form factors. As these geometric and material freedoms are leveraged, 3D printing is seen across a wider range of parts, devices, and components, often combining several parts into one continuous part and flattening the bill of materials (BOM). Innovation leaders that leverage the ability to bond

COMPANIES MENTIONED

dissimilar metals without creating brittle intermetallics while each metal retains its original physical properties are seeing the ability to combine parts made of different materials, further reducing the part count and BOM. This ability to form one part from many smaller parts without the restriction of a homogeneous metal composition will see form factors grow and, therefore, require larger fabrication machines.”

All the above factors contribute to increased efficiency, freedom in design,

See

cost savings, reduced environmental footprint, and improved competitiveness for businesses, adds Logtenberg.

Semantics

When it comes to defining what larger means, it is a bit complicated as there is no official measurement to help categorize build sizes.

It really depends on the application and purpose of the particular part, notes Jeffrey DeGrange, CCO, Impossible Objects. “We consider our technology capable of printing large parts, but there are also 3D printers available today printing houses, shipping vessels, and more.”

Giorgio Olivieri, applications manager, Meltio, says each manufacturer generally refers to internal benchmarks when talking about builds. For example, at Meltio, larger is anything that exceeds the build envelope of its Meltio M450 unit—or 145x168x390 mm.

Mignatti suggests large format 3D printers refer to industrial-sized printers with a build volume of 400x400 mm or more.

“I would consider anything above 400 mm to be ‘larger’ in size for PBF machines for metal. Typical starter printers are in the range of 300 mm build plate size,” advises Rao.

Bouwmeester considers anything with a build volume of 0.2 cubic meters and up as a large printer. “Traditionalsized printers typically have dimensions up to 20 centimeters (cm) and resulting volumes are significantly less,” he states.

“The definition of a larger 3D printer varies based on industry requirements and specific applications,” agrees Teipel. However, a typical measurement for larger printers may include a build volume exceeding 200x200 mm in any

4. At Meltio, larger is anything that exceeds the build envelope of its Meltio M450 unit—or 145x168x390 mm. 5. Photocentric’s Liquid Crystal Titan is a good solution for customers that regularly want to print a certain volume of large items.

axis. This contrasts with more traditional-sized printers, which often have smallerbuildvolumes."

Siebertpointsoutthatwith3Dprinters,youcanprintupto2000xl000xl000 mm."Howeverthisdependsonthetechnology and material. In comparison, traditional industrial 3D printers' build envelopesare typicallyaboutthesizeof amicrowave."

Build size is tied to the type of 3D printingtechnology.Forexample, 3DCeram offers stereolithographytechnology (SLA)withUVlasers."Whatsetsourapproachapartistheutilizationoftop-down printing,whichgrantsusthefreedomto achieve large printingplatformswithout sizelimitations,"offersKareenMalsallez, marketingmanager,3DCeram.

"Unlike other technologies such as digital light processing, which is restrictedbythesizeoftheprintingplatform due to its inherent limitations, our top-down SLA method enables us to overcome these constraints. This means we can offer customers the advantage of printing larger parts without compromising on size or scale," notesMalsallez.

Similarly, Zarezadeh shares the uniquefeatureofliquidcrystaldisplaybased 3D printersisthattheycurethe wholebuildareasimultaneously. "This means customers can fit and print as manypartsaspossibleontheplatform, and they print at the same time. Mass manufacturing for Photocentric certainly starts in the thousands of single items, but we see the sweet spot as being achieved in the tens and even hundredsofthousandsofeachpart. In practicealotofpartsarethesamesize, inprintingterms."

While specific terminology and measurementsofbuildsizesmayvarywithin theindustry,Logtenbergsayslargersizes aregenerallydefinedbybuildvolumesexceeding15to20cm."However,atCEAD, wecategorizelargersizesasanindustrial-sized 3D printer. In the AM industry,

industriallarge-scale3D printing istypically referred to when the print volume isaroundonecubicmeter. Itispossible to print both smaller and larger parts, depending on the part design and the specificsystembeingused. Asageneral guideline, we consider a minimum part sizeof40cmineitherthexorydirection (width or depth), but we always assess thefeasibilityofeachprintindividually."

Sincethereisnostandard measurement, it's difficult to compareandcontrastpricing.

"Largeformat3Dprinters are significantly more expensive than desktop or even professional level printers. Factors to consider in the cost not only include the size, but the cost of the materials and the need for dedicated staffto operate and maintain,"commentsMignatti.

Olivieri says most manufacturersscaleprice withsize,asinsometechnologies an increase in sizemeansanincreasein complexity and number

of critical components-such as laser sourcesandrelatedequipment.

Rao adds that price does not scale linearly with build plate size. "The reason for this is that the challenges with larger platforms, such as consistent gas flow across the bed, laser coverage acrossthebuildplates,andlaserredundancyaren'teasytoscalewithsize."

Teipeladmitsthatthepriceofalarger sized 3D printermayvarydependingon

factors such as build volume, technology, and additional features. "Generally, larger sized printers tend to have a higher price point due to increased material and equipment costs. However, the return on investment is justified by the ability to produce larger parts, often at high temperature and faster printing speeds, and streamline manufacturing processes."

While the investment in a large printer is typically bigger, Bouwmeester stresses that productivity also significantly increases. "The cost per unit volume produced over time is probably the most significant parameter when someone considers a larger printer."

''After the initial investment, large format printers eliminate the time and cost associated with outsourcing large format prints or using traditional manufacturing methods. Outsourcing a large format print greatly increases both the costs of the project and timeline to complete. The ability to print in one large print has decreased costs associated with the manual labor required for

printing smaller parts and constructing them together to create the final product," explains McNulty.

Another factor to consider is that in production environments, cost of labor involved in changing and cleaning printers is a significant contributor to the total product expense. "Larger printers allow more parts to be produced at once and hence reduce the labor cost," adds Bouwmeester.

Material costs are also a factor. "When it comes to large or small parts, we see no major difference in price. Material costs per part are still too high compared to injection molding, so as adoption increases, we anticipate lower costs," suggests DeGrange.

Bigger Builds

There is increased demand for larger build sizes amongst 3D printer manufacturers. This is largely driven by the need for bigger components, but also higher volumes.

"BecauseAMhassurpassedtherealm of mere prototyping, manufacturers are

now seriously considering 3D printing as a true production tool. It should be noted that we, as manufacturers, have worked diligently and made significant progress, particularly in making production costs more compelling. Industrial professionals are well aware of the advantages of producing through 3D printing, and as they witness the expansion of printing platforms, they naturally consider the production of large parts," shares Malsallez. "They make a simple calculation regarding their investment and choose tools that offer them the most possibilities, allowing the production of both large parts and large series of small parts. They also benefit in terms of maintenance costs, as it is more cost effective to have a high-capacity machine than numerous small machines."

While there is no standard definition that classifies a 3D printer as larger, the trend is clear and predicted to continue.

For more on larger build sizes in AM, check out industrialprintmagazine.com for a web-exclusive series. /PM

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SAFETY IN MATERIALS

by Melissa Donovan

Filaments, powders, and resins are all integral to the creation of three-dimensional (3D) builds. As further advancements in these materials occur, their defined feature sets become integral to meet the demands of the industries using the technology. In particular, there is increased interest in flame retardant (FR) resins and powders. Most notably, aerospace; transportation—automotive, trains, boats; electronics; and even the medical field require FR materials.

“The demand for FR resins has drastically increased among industries looking to leverage in-house additive manufacturing (AM) for all steps of the production process. Many industries commonly integrate some type of 3D printing into prototyping workflows, but often have to move to traditional manufacturing methods while still in the development stage in order to comply with regulatory requirements for flammability. With FR resin, large businesses can not only improve their development timelines, but also use a common material across teams, from design to maintenance and repair operations, as well as manufacturing fixtures,” proposes Elena Austras, product marketing manager, Formlabs.

3D printing on its own offers a host of benefits, from cost efficiency and durability to faster design production. Hason Rolland, SVP of materials, Carbon, says, “adding flame retardancy to the list ensures that manufacturing, electrical, healthcare, and aerospace specialists, among others, are provided with the safest equipment and products possible.”

Keeping it Beneficial

With demand for FR resins and powders deriving from a number of industries and applications, many are poised to benefit.

“For the applications in transportation or consumer goods FR materials are necessary

for safety reasons. The associated certifications are required to enable products to be sellable or to pass transportation safety regulations. This is part of the natural progression of applications moving from functional prototyping into more end-use applications, which come with increasing requirements. This is a good indication that we are progressing into more challenging areas,” notes Aric Yackly, product manager, P3, Stratasys.

According to Steven Kubiak, process engineering manager, Jabil Inc., “anywhere the benefits of additive intersect with an FR need will benefit. FR powders will benefit the same way general powders will benefit.”

“With FR resin, users easily and quickly create stiff, creep resistant, and functional plastic parts that perform well long term in high temperature environments without turning to injected molding. FR resin is ideal for producing airplane, automobile, and railway interior parts; protective and internal consumer electronics components; and custom jigs, fixtures, and replacement parts for industrial environments or ignition sources,” shares Austras.

Nirup Nagabandi, VP of materials and process engineering,

Essentium

1. Formlabs’ Flame Retardant par ts open up new opportunities for 3D printing in the transportation, aviation, manufacturing, electronics, and aerospace industries.

FR resins and powders serve as a game changer by significantly reducing the risk of fire incidents and enhancing overall safety measures.

— Nirup Nagabandi, VP of materials and process engineering, Essentium

FR Resins and Powders

Inc., notes how “FR resins and powders serve as a game changer by significantly reducing the risk of fire incidents and enhancing overall safety measures.”

The 3D Process

3D printing processes like fused deposition modeling (FDM), digital light processing (DLP), stereolithography (SLA), and masked stereolithography (LCD) all use FR materials.

“Theoretically, a new process could be designed for these materials. That being said, FR resins/powders are perfectly capable of being processed with common, commercially available 3D printing processes today,” suggests Sylvia Monsheimer, head of industrial 3D printing, Evonik.

In Yackly’s experience, FR materials are developed for both thermoplastic and photopolymer thermosets and are becoming available on an increasing range of systems, with FDM and DLP as the leading technologies.

“All printing processes produce parts in FR material, but the amount and type of additive or modifier to the polymer will depend on the process,” explains Kubiak.

Photocentric Inc. started testing its FR resin on some UV DLP and LCDbased systems to fully validate it.

Formlabs’ FR resin is compatible with SLA printers. “For many industries, maintenance and repair parts have to

be ordered to ensure the product remains compliant. SLA 3D printing was not traditionally a viable option, despite its low cost per part and efficiency. With FR resin, SLA 3D printing can finally be deployed as an on demand repair part manufacturing solution,” shares Austras.

According to the company, Essentium Duratem can be used with any open eco-system high-temperature 3D printing machine, including the Essentium High-Speed Extrusion 180 HT and HSE 280i HT 3D printing platforms.

Carbon EPX 86FR works best on Carbon DLS printers, such as the M2, M3, M3 Max, and L1.

Get Certified

Standards are in place to certify whether a resin or powder is FR.

Certification depends on the industry and application. For example, FR materials used in consumer electronics are certified by the Underwriters Laboratories (UL), whereas FR grades for aerospace applications require testing to a different burn standard and are certified in conjunction with the aircraft manufacturer in question and the FAA, shares Kubiak.

UL 94 is a plastics flammability standard released by the UL. “One common standard for assessing plastics flammability is UL 94. There are varying degrees of FR that get assessed by the orientation of the part in the flame, the thickness it will pass the test at, burn rate, and whether or not it will drip flammable plastic drops or not,” explains Yackly.

Another standard to comply with is the FAR 25.853(a) regulation. Carbon

EPX 86FR achieves a 12 second burn compliance for a thickness of one millimeter. It is also accredited for UL 94 rating at a two millimeter thickness.

Formlabs’ FR resin is halogen-free, UL 94 and FAR 25.853(a) certified with favorable flame, smoke, and toxicity (FST) ratings. FR resin produces 3D printed parts that meet necessary certification requirements for enduring hazardous environments, according to the company.

“Our FR materials undergo rigorous testing and certification processes to ensure their FR properties. Essentium’s certificate of conformance provides individual spool traceability through the ISO and AS9100 quality process. Essentium is working with customers, including the U.S. Air Force, to certify materials for uniform, repeatable, and reliable part production. These certifications validate the flame retardancy of our materials, providing confidence to our customers in their safety performance,” explains Nagabandi.

Pricing Structure

FR resins and powders cost more. However, the applications that deem flame retardancy as a critical feature make it so the purpose outweighs the cost.

Development can be challenging, which increases pricing. “The development cost of the material itself needs to be recaptured, and assuring FR performance out of printed parts is a challenging technical problem,” explains Kubiak.

Manufacturing a FR resin or powder can be more complicated, which effects cost. “Various additives must be integrated into the material, requiring additional process steps,” says Kubiak.

“Typically FR materials carry a premium over standard materials due to the additional cost of additives as well as the development cost to create and process 3D printable materials that have the right mix of temperature, mechanical, and FR performance,” agrees Yackly.

Continued quality control, to ensure the customer that the additive will perform as

2. & 3. Formlabs’ Flame Retardant Resin is self-extinguishing once the flame source is removed. 4. At Stratasys some of its more advanced FR/FST materials are Loctite 3D 3955 FST.

expected-in this case with FR properities,alsoenhancesthecostoftheseresins and powders,according toMonsheimer.

The investment incurred to test and certify an FR material also means the enduserpaysmore,accordingto Kubiak.

Despite the high costs for FR materials, a representative from Photocentric notes thatthe pricing is nodifferentthan other engineering grades of materials. Further noting the desire "to make AM accessible and applicable to all."

Also, when comparing AM to traditional manufacturing process like injection molding, FR materials are less expensive. "FR resin unlocks design freedom to create isotropic and highly detailed parts with an excellent surface finish that have the look and feel of injection molded parts but at much lower cost. It also helps to accelerate time to market without the design constraints and high costs of its injection molding or casting counterparts," notes Austras.

"The investment in FR materials is justified by the significant risk reduction and enhanced safety they offer, which outweighs the incremental cost," notes Nagabandi.

FR Future

It is because of the higher costs and need for certification that Kubiak believes all resins and powders will not be FR in the future.

the basic horizontal burn tests, but as far as the more stringent FR requirements products will be targeted to an application. In the future I expect many more materials to be aligned to increasingly specific applications with their own set ofrequirements."

''While certain industries rely on FR resins to meet strict production regulations, not all AM printing processes and materials require or are conducive to the same characteristics held by this type of resin;' addsAustras.

Keeping in mind that demand for FR materials may grow; Nagabandi suggests "a widerrangeofresinsand powders may have FR propertiesin the future:'

"The next generation of resins and powders will build upon recent software models and I expect that flame resistance will remain a top priority for developers," adds Rolland.

Product Roundup

Carbon EPX 86FR is a photopolymer resin that offers a combination of FR, functional toughness, high strength, and long-term stability. It features dual cure chemistry, utilizing a print and bake process.

Evonik offers INFINAM R TPC, an elastomeric copolyester that exhibits excellent flexibility, durability, and resistance to abrasion, chemicals, and UVradiation-in addition to being FR.

range of applications, from aerospace parts to maintenance uses such as replacing clamping blocks and switch covers.It is also ideal forrailwaycomponents,including ventilators and covers.

At RAPID + TCT 2023, Formlabs introduced its Flame Retardant Resin, which is its first UL 94 certified resin and first self-extinguishing material. Formlabs is looking forward to expanding its portfolio of FR certified-resins to broaden printing capabilities for the many industries that rely on durable components that can withstand high temperature environments.

Jabil's FR additive polymer currently is the PC 1500 FR, which is an FR polycarbonate filament. Made from UL V-0 YellowCardcertifiedrawmaterials,Jabil's PC 1500FRcanbeprintedondirectdrive and bowden tube 3D printers. This material, with its FR properties, is used in the aerospace and automotive industries.

Photocentric was planning to announce a newFRmaterialat presstime.

Similar to what occurred in the injection molded plastics world, Yackly also doesn't see all resins and powders being FR nor passing all FR tests. "Many 3D

Essentium Duratem,one ofthe company's newest materials, can withstand temperatures of 150° C and is resistant to FST and passed FAR 25.853 FST printing materials today already pass testing. The material is suitable for a

COMPANIES MENTIONED

Seepage12formoreinformation.

AtStratasyssomeofitsmoreadvanced FR/FST materials are Loctite 3D 3955 FST, KimyaPC-FR, AddigyPA6/66-GF20 FR LS,andUltem 9085 resin.

FR Materials

The introduction of FR resins and powders in 3D printing means users who relied oninjectionmolding for manyoftheir buildsnolongerhavetoimplementthatas part of the process. In turn, more industries are introduced to the advantages of AM. Meeting requirements like flame retardancy for specificapplications is a sign that AM ismaturing as an industry. /PM

Stacy Hoge, marketing communications manager, Phoseon Technology, points out that UV LED curing presents a stable process that increases the strength, durability, and chemical

resistance of 3D/AM printed parts on a commercial scale. “Reliable UV LED curing equipment benefits the 3D printing industry by providing fast, consistent, and reliable curing every time.”

UV curing in AM offers high reaction rate; small footprint—especially UV LED; low emissions as formulations are 100 percent reactive; unique

performance properties like toughness; process flexibility and consistency; higher first time quality as the product can be handled immediately after forming; as well as less waste,” according to Colin Bergs, technical sales engineer, AMS Spectral UV, a Baldwin Company.

UV curing proves its merits in many ways. “Primarily, the materials that are UVcurable bring to the table superior mechanical properties. They span an impressive spectrum, offering everything from extreme flexibility to lasting durability, effectively imitating materials as diverse as rubber and glass,” explains Mikhaylichenko.

This type of versatility opens the door to additional applications, ranging from the creation of prototypes to the production of parts meant for end use.

Another attribute of UV curing is its exceptional speed and efficiency. “In an industry where each tick of the clock represents potential profits, the rapid curing times offered by UV light significantly expedite production timelines and cut down on costs,” notes Mikhaylichenko.

Along with speed, Mikhaylichenko says UV curing also ensures precision and sustainability. “It facilitates layerby-layer curing, providing the ability to

1. Uvitron continuously works to maximize the potential of UV light systems, as it designs new generations of UV post-curing systems that elevate the quality of products obtained from AM processes and more.

create complex geometries, intricate details, and internal features that are difficult to achieve with conventional manufacturing techniques. Moreover, UV curing contributes to the ‘green’ revolution in AM. By utilizing just the right amount of material, it minimizes waste, and the materials it employs are frequently more eco-friendly compared to those used in other manufacturing methods.”

UV Curing Process in AM

UV curing in AM generally begins with a digital design of the object, which is usually created with 3D modeling software. “This design is then sliced into very thin layers by a specialized software program, preparing it for the AM process,” explains Mikhaylichenko.

Depending on the specific AM method used, steps typically include a layerby-layer construction, UV curing, and post processing.

The process starts in a UV-curable resin tank and the 3D printer constructs the object layer by layer. This is followed by UV curing. “The key role of UV curing in this process is to harden or cure the UV-reactive resin. When exposed to UV light, the resin undergoes a chemical reaction known as photopolymerization,” explains Mikhaylichenko.

Following the completion of the printing process, Mikhaylichenko says it’s often necessary for the printed object to undergo further treatments. “This might include steps such as cleaning of uncured material residue, an additional UV curing stage to improve hardening and reduce surface tack, and occasionally some finalizing procedures to ensure the object’s surface is sleek and immaculate.”

Bergs adds that each layer of 3D printed material is cured with UV light absorbed by photoinitiators (PIs), which are formulated to match the required peak wavelength to cure the product instantly. “The outcome is a product that

is ready to use and does not require a secondary cure.”

“AM processes that require a long printing cycle or use heat-sensitive materials benefit the most from UV LED curing,” comments Hoge.

Mikhaylichenko points out that for SLA, UV curing systems create objects by focusing a UV laser onto a vat of photopolymer resin. As the laser traces a pre-defined design, the photopolymer hardens, building the object layer by layer. “Post-processing UV curing systems play a crucial role in solidifying these intricate designs and adding a polished finish,” he shares.

When it comes to DLP, it follows a similar path to SLA, but with a digital projector screen to expose the entire layer of resin at once, rather than a UV laser tracing the design. “This simultaneous exposure and curing by UV light expedites the process, and postprocessing UV curing systems are instrumental in enhancing the speed and efficiency of this method,” notes Mikhaylichenko.

MJP jets photopolymer materials onto a build platform, which are immediately cured by UV light to solidify them. This method is renowned for its high resolution, precision, and ability to print in multiple materials and colors simultaneously. “UV curing systems here in

the post-processing stage ensure that high standards of precision are maintained while offering a tack-free and smooth finish to the printed objects,” adds Mikhaylichenko.

Material jetting is a popular technology used for 3D printing, which can be UV cured. “PolyJet belongs to the family of material jetting AM processes. The PolyJet 3D printer sprays photo-sensitive resin material layer by layer onto the print tray until the parts are completed. Each layer of material is cured with UV light while being sprayed and can be taken out and used immediately without secondary curing. It can realize the combination of color and multi-materials in a single printing to produce a prototype close to the real product. It is also used to print quick molds and verify product designs. Full color, multi-material 3D printers can mix six materials at the same time to achieve 500,000 colors,

different textures, transparency, and softness. Products are widely used in medicine, education, and engineering models,” shares Hoge.

Each of these processes benefit from UV curing, not only because of the high resolution, fine detail, and smooth surface finish that can be achieved, but

also due to the variety of materials utilized and the rapid production times possible, according to Mikhaylichenko.

With a reliable UV LED light source, Hoge says customers can run a stable process for a long time, with some printing cycles reaching over 48 hours. The UV LED printing process offers the highest efficiency, printing accuracy, and most yield to fulfill the end customer’s stringent requirements. LED technology allows users to cure heat-sensitive materials offering new revenue opportunities for printers.

“The final outcome of this process is a 3D object created from a digital design, exhibiting high resolution and detail. The object can be as strong and durable as the UV-curable material allows,” shares Mikhaylichenko. “This gives UV curing a significant advantage over other 3D printing technologies as it can produce parts that are not just prototypes but are also strong enough for end-use applications in various industries.”

Material Considerations

The use of UV curing in AM is recognized for resin-based processes.

Bergs points out that formulations that can be UV cured must be specifically created to do so. “There is a specific chemical class of PIs that absorb UV energy and then transform to a compound that is highly reactive to start the polymerization process.”

Therefore, Bergs explains that UV curing in AM works very well with resins, which aid in enhancing the material properties. “Through the use of UV curing, AM processes are quicker with higher quality product as a final result.”

For the most part, Hoge says LED cured AM materials are acrylate-based, which is the same as what is seen in inks, adhesives, and coatings—i.e. monomers, oligomers, and PIs. “It is likely that some

2. Uvitron's IntelliRay 600 is used in many types of 3D printing processes.

3D printers are using other atypical chemistries with LED high UVA wavelength energy to cure,” she notes.

In addition to photopolymer, other substances are tailored to respond to UV light. UV-curable inks, coatings, and adhesives are common examples that are employed across various industries. “These substances contain PIs—compounds that react to UV light to trigger hardening or curing. In the realm of AM, efforts are underway to widen the array of UV-curable materials, beyond just photopolymer resins,” says Mikhaylichenko.

UV and UV LED Trends in AM

Experts expect an increase in use of UV curing within certain AM technologies.

Hoge specifically sees growth with UV LED curing technology because it offers a consistent, reliable process that runs on a wide range of heat-sensitive materials for a long period of time.

Bergs predicts growth will come as companies try to move away from conventional UV, which is not as energy efficient as UV LED. “As more formulators make products with LED UV curing capability the market use will increase significantly. LED UV is the future for sustainable curing in almost every industry that uses UV in their processes.”

A primary driving force is the continuous advancement in UV curing and AM technologies. “The constant innovation we are observing in UV light sources, photopolymers, and 3D printing hardware and software ensures a bright future for this sector. As these technologies mature, they create an effective synergy, further enhancing the efficiency and capabilities of UV-cured AM,” comments Mikhaylichenko.

Another compelling factor is the increasing adoption of AM across an array of industries. “Whether it’s aerospace or healthcare, automotive or consumer goods, companies leverage AM for rapid prototyping, customization,

and in some areas such as the dental industry, even large-scale production. As more sectors uncover the unique benefits of UV-cured 3D printing— namely, high resolution, superb mechanical properties, and rapid production times—we see continued growth in the demand for UV curing within AM,” states Mikhaylichenko.

Further, he says the emphasis on sustainability in the manufacturing industry also contributes to this upward trend. UV-cured AM presents a “greener” alternative to traditional manufacturing methods, minimizing waste through efficient material usage and reducing the carbon footprint by consuming less energy. As the shift towards environmentally friendly manufacturing solutions gains momentum with more countries introducing expanding environmental regulations, UV-cured AM is likely to generate increasing attention.

Mikhaylichenko believes the recent COVID-19 pandemic with its supply chain issues underscored the value of AM in fulfilling urgent, large-scale requirements, such as the production of medical equipment and personal protective gear. “This realization may result in more industries incorporating AM as a dependable contingency strategy, thereby broadening the scope for UV curing applications.”

Advantages to AM

UV and UV LED curing bring certain benefits to AM, including faster print speeds, increased durability, consistent curing over time, and reduced environmental impact compared to traditional methods, lists Hoge.

Mikhaylichenko says in its work specializing in the post-processing stage of AM, Uvitron found UV curing systems to be instrumental in enhancing the quality and efficiency of the final product. A few key advantages he’s observed include speed and efficiency, exceptional detail, versatility and robustness, and sustainability.

In terms of speed, UV curing systems rapidly solidify each layer of the product, thereby significantly reducing production times. This increase in speed allows companies to expedite their production cycles, enhancing overall productivity and reducing the time-to-market of their products, according to Mikhaylichenko.

When it comes to detail, Mikhaylichenko feels that the advantage of UV curing systems lies in their capacity to yield high-detail results. "They allow for the creation ofintricatedesigns and complex geometries, whichmightbedifficult or even impossible to achieve with other manufacturing methods."

Versatility comes with the ability of UV curing systems to be employed with a wide and continuously expanding array of UV-curable materials. It enables the creation of easily customized products with varying properties, rendering UV curing relevant across a range ofindustries, according to Mikhaylichenko.

And for sustainability, UV curing systems contribute to a more environmentally conscious manufacturing process. They efficiently utilize materials, curing only what's necessary, and typically

consume less energy than other techniques. "This aspect can help reduce the overall environmental impact ofthe manufacturing process," says Mikhaylichenko.

Future of UV and AM

The future is bright for 3D printing and AM, and UV is along for the ride.

''As more research and development is done to push the performance of UVcured resins, the future will offer the ability to print on a wider range of materials and substrates enabling new applications," predicts Hoge.

Mikhaylichenko anticipates several developments that will influence its specializationinthepost-processingstageof AM. "Firstly, we foresee a wider range of UV-curable materials. Today, photopolymer resins are primarily used, but ongoingresearchaimstobringUV-curableceramics,composites,andevenmetalsinto the fold. This progression would expand the scope of UV-cured AM, paving the way for more diverse end products and broaderindustrialapplications."

Mikhaylichenko also foreseesimprovementsinUVlight sources, which are crucial for postcuring. Forinstance,LED

3. Phoseon air-cooled UV LED curing light sources offer a high performance, consistent, and reliable solution for AM processes. 4. AMS Spectral UV offers many custom solutions for customers' specific needs and is supported in the field by a great service department to complement quality systems. AMS Spectral UV products are manufactured in River Falls, WI.

technology advancements offer lower energy consumption and extended operational life, promising to significantly improve UV curing efficiency. "More precisecontrol over wavelengthandintensity couldalsounlockanewlevelofcuringprecisionandexpandmaterialoptions:'

The fusion of UV curing with other emerging technologies is another exciting prospect. "Integrating artificial intelligence and machine learning, for example, could optimize the curing process, reducingerrorsandenhancingefficiency. Pairing UV curing with 3D scanning technologies may also facilitate real-time monitoringandqualitycontrolduringthe AMprocess;' commentsMikhaylichenko.

Lastly, the exploration of functional UV-curable materials holds immense potential. "The incorporation of additives or nanoparticles into UV-curable formulations could introduce specific properties like conductivity, thermal resistance, or antimicrobial characteristics. Such advancements would open new opportunities for producing electronic components, heat-resistant parts, or even biomedical devices through UV curing," shares Mikhaylichenko.

"With more industries utilizing this technology there will be an even larger demand for UV curing," advises Bergs.

Expanding UV

UV-curablematerialsareutilizedinresinbased processes, most commonly SLA, DLP,andMJP.TheuseofUV andUV curingisexpectedtoexpandintothefuture.

"Inoureffortstodriveinnovationinthe AM industry, we arefocused on exploring andexpandingthe possibilitiesofUVcuring;' says Mikhaylichenko. "Integrating these technologies is keytoreachingnew avenuesforfastprototypingandmasscustomizationacross various sectors such as automotive, aerospace, healthcare, and consumer goods. As we move ahead, our commitment is to deliver reliable and efficient UV curing systems that fuel the futureofAM." /PM

AutomatedSoftwareSolutionsTieitTogether

by Melissa Donovan

utomated software helps converters and packaging plants pivot to moreefficientproduction L...a�7'...-" workflows. It's incredibly helpful in digital printenvironments due to the fact that manytimes this technology is used to produce product with multiple SKUs or versions. Utilizing software to organize this data is far more cost effective than manual processes.

Corrugated is a large piece of the packaging segment. With this in mind, we asked various software vendors to share how solutions help automate print environments by connecting disparate systems.

Above:EngView Packaging Suite is a professionalsoftwarefor structuraldesignandpreproductionofboxesanddisplays.

Conversion to Efficiency

Software creates efficiencies in production. Today's solutions targeting converters and packaging plants-specifically those handling corrugated-touch all parts of production workflow.

"The world has changed immensely since the pandemic, with automation and remote solutions now more soughtafter than ever," shares Peter Barke, WEBcll{ product manager, Arden Software. Workflow solutions that enable automation of "the project management of your packaging production across the globe and streamline workflow in the packaging supply chain" are vital.

Digital print is not the first and only technology used to print corrugated packaging. With the adoption of digital print, software solutions have by association become increasingly necessary due to the mixing and matching of past and present systems.

"The proven fact is that the adoption of digital print is unfortunately resulting in a more specialized and 'siloed' production workflow with fewer seamless connections. These types of environments must have a very fluid front end.

And while most software has the goal of facilitating fast, smooth output, assets such as digital presses and finishing devices do not communicate with each other that efficiently. Many printers refer to these as production 'bottlenecks' that often require time consuming as well as costly manual intervention," explains Marc Raad, president, Significans Automation.

To address bottlenecks the separate solutions must be linked. "We're familiar with the many intricacies of these software systems and know how to tailor them to the unique workflow needs of any individual print operation. Unless these components are customized, the individual software for each of your printing or finishing devices won't communicate in harmony to minimize the dysfunction that comes with the adoption of a digital press and other equipment. In a nutshell, we clean up the workflow software 'mishmash' for our clients," shares Raad.

"The ideal scenario is using one and the same software through the whole process or an integrated solution to feed the digital machines," adds Tsvetelina Nacheva, marketing manager, EngView Systems.

Beyond validating components that work well between a mix of print

technologies, "a good production workflow helps printers deal with the many morebut smaller quantitydigital jobs that are received," explains Mike Agness, EVP, Americas, HYBRID Software. Agness defines a "good" system as one that works entirely in PDF, connects to enterprise resource planning (ERP) systems to receive job details, collaborates with supply chain partners and customers, and is quick enough to keep up with high-speed printers.

A management information system (MIS) is also key, as it "provides packaging industry manufacturers with a comprehensive overview of all the information they need to make decisions ranging from daily minutiae to top-level strategy," explainsJack]. Lafler, VP, sales and technical services, HiFlow Solutions.

"Instead of the guesswork and time wasted trying to pinpoint a problem, an MIS provides real-time management of business and production processesfrom customer service and sales, to prepress and scheduling, production, warehouse, machines, personnel, and business analytics," shares Lafler.

The best part of an automated solution is the data, with Lafler admitting in terms of an MIS, it might be the most important feature. "Taking the entirety of the data collected and presenting it in a way that managers can use to improve and speed up workflows. Open a dashboard and in a few clicks get the information and analysis you need. Create reports to share with stakeholders that illustrate exactly where you stand, as well as weak areas that require improvement."

1.& 2. HiFlow's built-in Imposition module gives estimators the tools to lay outjobs in an optimum way to quickly get quotes out to sales.

Open Communication

To mitigate the challenges of older and newer devices and systems communicating with one and other, working with current software solutions that

enable an open form of communication is key.

Lafler admits that today's software is designed to integrate easily. "There are various kinds of integration with machines.

To thoroughly con- 2 nect machines with

software, smart sensors need to be installed, especially in legacy machines. Once this is done, the machines transmit a large range of data to the management software through its manufacturing execution systems. Ideally, plants should connect IoT, SCADA, and PLCs to their software system so all information on processes can be collected and analyzed."

''A good workflow is flexible and works with traditional printing, a digital press, or both. It connects to MIS/ ERP systems, color management, other workflow tools, and the digital front end (DFE)-basically any task you would ever need," explains Agness.

One important part of the corrugated printingequationwhenplatemakingisinvolved is whether the workflow communicates well with the mounting system. "When itcomestotraditionalprintingitis important to know whether the converter has in-house platemaking capabilities. Corrugated plates are the most complicated to work with. Besides the tedious, large size of the plates, there are other considerations. For example, how do you make a plate for a 126-inch press, when the largest plate is only 80 inches wide? Theanswerismountingthe platesontoa carrier, butthatis not a simpleprocess. A

good workflow works with the mounting system," suggests Agness.

As a software systems integrator, Significans Automation operates as a neutral third party. "We always look to evaluate and objectively select the bestin-class software solutions to bring 100 percent connectivity to any printing or packaging operation. We find 'open' solutions designed to 'future proof any business, providing long-term value and agility. We look at every aspect of the business and perform an initial assessment. Ideally, we like to use the resources that the shop already has, but we may suggest bringing in additional software systems if needed," explains Raad.

Features to Look For

Features likeERP, customerrelationship management (CRM), and preflighting are essential to digital printing workflow that involves corrugated packaging. Others may be added to address a converter or packaging provider's specific needs.

''Automation takes place in all aspects of the corrugated workflow from receiving materials to supply management to inventory location management. Automation is the key to lowering costs and minimizing manual processes that cost labor time," shares Lafler.

Important features to note, according toAgness, are "connectivitytoan MISso that job specifications are automatically sent to the production workflow system, as well as connectivity to production planning, corrugators, and inspection."

Estimating and scheduling should be addressed. "Estimating is a huge time saver for packaging companies. There are several ways management software does that. One is to ensure access to a central, accurate database, soanestimator only has to click to find past customers and quote, and not rummage around paper files. Secondly, an estimator has real time access to available tools, real time inventory, and supplier and vendor connections. Estimators can also access a built-in imposition module to produce quotes quickly, bypassing the CAD department where quotes can get bottlenecked," shares Lafler.

Regarding scheduling, "once a quote becomes a job, smart algorithms schedule that job according to material availability, staffing, and machine availability. Instead of hours, it takes minutes, and jobs can then be scheduled according to ideal capacity of the plant and easily moved as managers analyze more solutions well suited for their plant floor," adds Lafler.

Automation on the inventory side of things should also be considered. “Automation in warehouse is also key to optimizing the corrugated manufacturing environment. Barcode management can bring inventory up to real-time status and warehouse modules such as product inventory and inventory of materials store this information for easy access,” notes Lafler.

“Beyond the typical tasks you’d find in a commercial workflow like preflighting, color management, and editing, software solutions should also have options to create three-dimensional (3D) views for proofing, move finishing files for the cutters, and have variable data capabilities for serial numbers, for instance,” continues Agness.

Proofing and approving artwork can be accelerated with automated solutions. “Our customers tell us that approving artwork files is a complex, timely process that involves multiple stakeholders—often using different applications to view and review packaging and label artwork files, which can lead to quality issues and delays. A solution that enables users to seamlessly connect prepress tools to an interactive sharing platform enables all stakeholders to easily upload, share, annotate, and approve packaging and label artwork, all in hyper-realistic 3D,” shares Jan De Roeck, director of marketing, industry relations and strategy, Esko.

Even web-to-print-type portals is something seen in these environments today. “The customer can see the final design in 3D, get a price quote from

the printing house, and order it online. Such platforms help the salespeople handle more project inquiries because the projects contain the correct structures, material, and the 3D visualization with folding animation of the panels,” explains Nacheva.

In terms of corrugated work, automated solutions must be flexible. For example, “have the layout capabilities to take approved one-ups—like pizza boxes—and place them economically on a sheet using step and repeat. Or handle work if it is preprint—printing a top sheet that will be adhered to the corrugated, or post print—printing directly on corrugated,” recommends Agness.

Nathan Armata, director of workflow development, Significans Automation, suggests it is good practice to start the process by understanding a client’s desired level of automation. “For instance, what needs to be assessed is the application requirements, environment, culture, and resources. Then leverage existing foundational software that will connect critical aspects of a print shop, establishing an automated production environment. The plan is executed by combining and deploying a range of workflow software. This includes everything from web to print, ERP, CRM, DFEs, and preflighting— whatever is required to maximize productivity and the investment.”

The Dreaded ROI

Return on investment (ROI) on software can be difficult to calculate, which is why many hesitate on investing. In

truth, it’s all about combined ROI and frankly, what is saved from utilizing an efficient system.

“It really depends upon the number of jobs, the original investment of required software, and other factors. However, as a rule, from our experience the payback can be as quick as three months or as long as a couple of years,” admits Agness.

Armata says at minimum, results have ranged in the thousands of dollars from removing multiple costly steps in production to deploying a new workflow in minutes. “Our clients have seen an almost immediate capacity boost, such as processing hundreds of jobs a day instead of ten and even less while drastically minimizing costly human errors. Plus, with the proven efficiencies of artificial intelligence, we can boost that shop’s efficiency anywhere from 20 to 70 percent and even more, contributing to long-term growth.”

“Typically, ROI is achieved quickly—sometimes within a few months of implementation. However, this can depend on factors that are relative to the how much the company has participated and invested in the process of training and how committed management is to utilizing all of the automation features of the software,” suggests Lafler.

Software Adoption

Gaining efficiencies in a production plant is something that can be done anywhere, anytime—with a little help. Whether it’s a neutral vertical integrator that comes in and makes all of your systems communicate harmoniously with each other, or a vendor with a solution that can fix the one piece of the puzzle that is missing. In corrugated work arenas, automated software solutions are essential in the push to adopt digital technologies in house.

Our recent webinar addresses this topic. Visit industrialprintmagazine.com to view the archived broadcast. IPM