DESIGN WORLD 2018 ADDITIVE MANUFACTURING HANDBOOK

September 2018

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2018

Additive Manufacturing Handbook

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Our People Know Our People Know how to scale from plastic prototyping to production with Figure 4 TM

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E d i t o r i a l

From prototyping to manufacturing, 3DP/AM is building a new world

Welcome to the inaugural Design World Additive Manufacturing Handbook.

Additive manufacturing is a dynamic industry. I’ve watched it grow from an initial seven ways to build a part layer-by-layer, primarily for prototyping, to the many more options we have today that seek a place on the manufacturing floor.

According to the Wohlers Report 2018, the number of metal additive systems sold grew nearly 80%! In 2017, 135 companies produce and sell additive systems; this is up from 97 companies in 2016. And more ways to build parts a layer at a time are on the way.

Additive technology offers great promise for designers and manufacturers alike, but with more systems, more ways to build in layers, more materials, this industry is still a bit on the bleeding edge. One of the inhibitors to greater adoption is information as users struggle to learn enough to make the most of this technology.

3D printing/additive manufacturing seems simple—load a CAD file, hit print, and watch a part grow before your eyes. But there are nuances to learn. New ways of thinking to adopt.

This handbook will help sort through all the developments and changes.

Among these pages you will find information that describes how many of the additive technologies work. You’ll also read stories on applications, both popular and unique. In addition, we’ve spoken to many of the additive industry’s leaders to look ahead at what vendors need to do to make additive more useful for manufacturing and what benefits of additive are being overlooked.

Given the dynamism of the additive industry, changes will continue to come. So stay tuned for the 2019 edition of the handbook.

Leslie Langnau | Managing Editor llangnau@wtwhmedia.com

On Twitter @ DW_3Dprinting

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EDITORIAL

VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Managing Editor Leslie Langnau llangnau@wtwhmedia.com @dw_3dprinting Executive Editor Leland Teschler lteschler@wtwhmedia.com @dw_leeteschler Senior Editor Miles Budimir mbudimir@wtwhmedia.com @dw_motion Senior Editor Lisa Eitel leitel@wtwhmedia.com @dw_lisaeitel Senior Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora CREATIVE SERVICES

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Contents 9

2018 • designworldonline.com

•

04 _3DP PLATFORM

32 _LULZBOT

Tips on working with thin walls

Views on the role of desktop 3D printing in industry

06 _3D SYSTEMS

A look at the future of 3D printing 10 _ARCAM

How electron beam melting works 12 _BIGREP

3D printing’s shift to additive manufacturing

14 _CARBON

34 _MARKFORGED

How a desktop 3D printer can print metal 36 _NANO DIMENSIONS

How Nano Dimensions sees the future of 3D printing 38 _RENISHAW

How the Carbon process works

Can medical device regulation work with additive manufacturing?

18 _CONCEPT LASER

40 _STRATASYS

Sintering metal to build parts

Why use 3D printing for sacrificial cores? For innovation

22 _DESKTOP METAL

How destop metal 3D printing works

44 _ULTIMAKER

24 _EOS

Volkswagen maximizes productions with 3D printed tools, jigs, and fixtures

More applications on the horizon for additive manufacturing

Company Profiles 48-54

28 _HP

How HP Multi Jet Fusion printer builds parts 30 _XJET

An innovation jetting technology delivers metal parts with fine details

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Application Notes

3DP Platform specializes in extrusion based 3D printers with large build platforms.

Tips on working with thin walls Many 3D printed designs require some sort of support during the build process. For extruded designs, the material that supports the design is either a soluble or easily removable material or the same materials as the printed part, just printed densely enough to provide support but easy to remove.

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Often when printing supports, the outside perimeters and the infill settings are insufficient, creating a weak, thin part. Or, the support structures are too dense without enough separation for easy removal.

A common challenge is thin wall parts. To properly support walls, consider the actual wall thickness of the model when setting perimeters.

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Failed print: The model walls were thin and the part required

Fixed print: With strong outside walls and little

substantial support structures. The process settings made the walls fragile and the supports did not break cleanly from the part.

Using separation layers in the support process settings can eliminate damage often caused by support structure removal. Additionally, adding one or two dense support layers can increase the quality of the surface finish of the printed part.

Corrective action typically involves making a few thin wall adjustments. Such as increase the number of outside perimeters to match the intended wall width, or increase the infill percentage to create a more solid thin part.

sign of scarring where the break-away support structures were removed.

To correct for the structure, designers can use two dense support layers, with 55% density, or use one upper and one lower separation layer to aid in the removal of support structures.

A number of additive vendors offer software that will aid in suggesting the best support options. For example, Gap Fill settings within Simplify3D provide assistance when dealing with thin wall models.

3D Platform | www.3dplatform.com

Company

Machine Name

Build Size

Build Materials

Layer Thickness

Build Speed

3D Platform

100 Series Work Table

1.0 m x 1.0 m x 0.5 m

various plastics

70 microns

80 g/hr - 160 g/hr

200 Series Workbench Classic

1.0 m x 1.0 m x 0.5 m

various plastics

70 microns

80 g/hr - 160 g/hr

300 Series Workbench Pro

1.0 m x 1.0 m x 0.7 m

various plastics

70 microns

0.16 kg/hr - 1.35 kg/hr

400 Series workbench Xtreme

1.0 m x 1.5 m x 0.7 m

various plastics

70 microns

0.16 kg/hr - 1.35 kg/hr

WorkCenter 500

1.4 m x 2.8 m x 700 m

various plastics

70 microns

1.35 kg/hr to 7.5 kg/hr

Excel Series - 1m

1.2 m x 100 m x 1.2 m

various plastics

70 microns

1.35 kg/hr to 55+ kg/hr

Excel Series - 2m

2 m x 100 m x 1.2 m

various plastics

70 microns

1.35 kg/hr to 55+ kg/hr

Excel Series - 3m

3 m x 100 m x 1.2 m

various plastics

70 microns

1.35 kg/hr to 80+ kg/hr

Excel Series - 4m

4 m x 100 m x 1.2 m

various plastics

70 microns

1.35 kg/hr to 80+ kg/hr

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Additive Insights

A look at the

future of 3D printing 3D printing is a dynamic industry, with new technologies and techniques

emerging all the time. Here’s what Menno Ellis, senior vice president, Strategy & Vertical Markets, 3D Systems says about coming developments.

The Figure 4 platform delivers part accuracy

and repeatability with Six Sigma repeatability across all materials. The light-based UV curing process builds parts in minutes.

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1 What is the most underrated or least printer technologies to deliver more recognized capability of 3D printing/additive accurate parts in less time at lower cost, the AM spotlight has shifted to manufacturing? making end-use parts. Both the AM industry – as well as the Media - are For many years, the additive manufacturing (AM) enamored with this next wave where industry has focused on prototyping. What additive manufacturing selectively began as quick, relatively simple prototypes displaces subtractive and formative evolved into aesthetically pleasing (i.e., color, manufacturing approaches in a improved surface finish and texture) and variety of industries; like dominoes functional items such as springs, hinges, and getting knocked over one at a time. moving parts. With the advent of more durable What’s gotten lost in the excitement plastics and metals as well as advances in

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which by the way is a relatively slow movement in light of the traditional manufacturing efficiencies that have been steadily honed since the dawn of the industrial revolution – are the millions upon millions of “invisible” parts that are 3D printed daily as sacrificial tools and thus never see the light of day. Examples of this include: ● The hundreds of thousands of dental models printed daily to produce invisible dental aligners or help dentists build crowns, implants, and other devices for their patients ● Wax rings, pendants and other jewelry items that are printed before being cast into precious metals ● Resin or wax printed patterns used for casting engine components and other metal parts across a wide range of industries ● 3D printed clips, jigs, and fixtures used in factories all over the world to enable automated production of a variety of products.

These are all single-use items, and the production volumes are staggering. However, since nobody thinks about them when holding an

end product in their hands - they are the forgotten killer application of this industry.

2 What is the most significant development in 3DP/AM materials in the last few years?

By far, the most significant materials development in additive manufacturing is biocompatibility and associated regulatory approvals for placing 3D printed parts on and in the human body. Among the most important materials for producing implants are cobalt chromium and titanium. Enabling manufacturers to 3D print these materials allows them to make both “standard” parts for mass consumption that are uniquely suited for 3D printing due to their complex geometries, as well as developing custom parts for each individual patient based on their specific needs. Significant advances have also been made with plastic materials to develop custom parts for each patient. The majority of hearing aids are produced with 3D printing. Additionally, through additive manufacturing companies can produce shortterm use items such as surgical

guides for facilitating medical and dental procedures, as well as longterm appliances like dental crowns and dentures. As revolutionary as this sounds, all these items are available today. Looking towards the future I believe the next frontier in biocompatible printing will be tissue and organ printing.

3 Do you see any new applications for 3DP/AM on the horizon?

The advances in the medical/life sciences space represent a major evolution that will continue to unfold and change the lives of many in front of our very eyes. In addition, continued evolution of printer-material combinations (such as, concrete, glass, food) captures our imagination as early advances provide a glimpse of what is possible. Imagine contact lenses, glasses, hearing aids, or prosthetic devices being created while you wait during a single visit to a licensed practitioner. On the commercial side, we are seeing early stage advancements in the printing of circuit boards and other electricity conducting devices that will revolutionize the way companies build electronics. Finally, the advances we

Company

Machine Name

Build Envelope

Build Materials

Layer Thickness

Build Speed

3D Systems

ProJet CJP 260Plus Professional 3D Printer

236 X 185 X 127 MM

VisiJet PXL - CMY colours

.1 mm

20mm/hr max. vertical build speed

ProJet CJP 360 Professioal 3D Printer

203 X 254 X 203 MM

VisiJet PXL - White (monochrome)

.1 mm

20mm/hr max. vertical build speed

ProJet CJP 460Plus Professional 3D Printer

203 X 254 X 203 MM

VisiJet PXL - CMY colours

.1 mm

23mm/hr max. vertical build speed

ProJet CJP 660Pro Professional 3D Printer

254 X 381 X 203 MM

VisiJet PXL - Full CMYK colours

.1 mm

28mm/hr max. vertical build speed

ProJet CJP 860Pro Professional 3D Printer

508 X 381 X 229 MM

VisiJet PXL - Full CMYK colours

.1 mm

5-15mm/hr max. vertical build speed

ProJet MJP 2500 Professional 3D Printer

295 X 211 X 142 MM

VisiJet M2R-WT, M2R-BK rigid plastics, VisiJet ProFlex M2G-DUR engineering plastic; melt away support

32μ

N/A

ProJet MJP 2500 Plus Professional 3D Printer

295 X 211 X 142 MM

VisiJet M2R rigid plastics, VisiJet M2R-TN dental material, VisiJet M2 elastomeric materials, VisiJet M2G engineering plastics; melt away support

32μ

N/A

ProJet MJP 2500W Professional 3D Printer

295 X 211 X 142 MM

VisiJet M2 CAST wax material

16μ

N/A

Continued on page 8

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Additive Insights Continued from page 7 Company

Machine Name

Build Envelope

Build Materials

Layer Thickness

Build Speed

3D Systems

ProJet MJP 3600 Professional 3D Printer

UP TO 298 X 185 X 203 MM

VisiJet M3-X, Black, Crystal, Proplast, Navy, Techplast, Procast - UV Curable Plastics; melt away support

16μ to 32μ

N/A

ProJet MJP 3600 Max Professional 3D Printer

UP TO 298 X 185 X 203 MM

VisiJet M3-X, Black, Crystal, Proplast, Navy, Techplast, Procast - UV Curable Plastics; melt away support

16μ to 32μ

N/A

ProJet MJP 3600W Professional 3D Printer

UP TO 298 X 185 X 203 MM

VisiJet M3 CAST, M3 Hi-Cast - Wax material

16μ to 32μ

N/A

ProJet MJP 3600W Max Professional 3D Printer

UP TO 298 X 183 X 203

VisiJet M3 CAST, M3 Hi-Cast - Wax material

16μ to 32μ

N/A

ProJet MJP 3600 Dental Professional 3D Printer

284 X 185 X 203 MM

VisiJet M3 Dentcast, PearlStone, Stoneplast - Dental UV curable plastics; melt-away support

29μ to 32μ

N/A

ProJet MJP 5600 Professional 3D Printer

518 X 381 X 300 MM

VisiJet UV curable rigid plastics and elastomeric materials, multi-material composites; melt-away support

13μ to 16μ

N/A

ProJet 6000 HD Professional 3D Printers

UP TO 250 X 250 X 250 MM

VisiJet SL UV curable plastics

0.025 to 0.125 mm

N/A

ProJet 7000 HD Professional 3D Printers

UP TO 380 X 380 X 250 MM

VisiJet SL UV curable plastics

0.050 to 0.125 mm

N/A

ProX 800 SLA Production 3D Printer

UP TO 650 X 750 X 550 MM

Accura plastics and composites (widest range, simulating ABS, PP and PC, high temp., for casting patterns and other speciality materials)

0.05 to 0.15 mm

N/A

ProX 950 SLA Production 3D Printer

1500 X 750 X 550 MM

Accura plastics and composites (widest range, simulating ABS, PP and PC, high temp., for casting patterns and other speciality materials)

0.05 to 0.15 mm

N/A

ProX SLS 500 SLS Production 3D Printer

381 X 330 X 460 MM

DuraForm ProX polyamides, reinforced plastics and flame retardant

0.08 to 0.15 mm

2.7 l/hr volume build rate

sPro 60 HD-HS SLS Production 3D Printer

381 X 330 X 460 MM

DuraForm polyamides, reinforced plastics, flame retardant, elastomeric and polystyrene

0.08 to 0.15 mm

1.8 l/hr volume build rate

sPro 140 SLS Production 3D Printer

550 X 550 X 460 MM

DuraForm polyamides and reinforced plastics

0.08 to 0.15 mm

3.0 l/hr volume build rate

sPro 230 SLS Production 3D Printer

550 X 550 X 750 MM

DuraForm polyamides and reinforced plastics

0.08 to 0.15 mm

3.0 l/hr volume build rate

ProX DMP 100 Precision Metal Printer

100 X 100 X 100 MM

Ready-to-run LaserForm CoCr (B), 17-4 (B) metal alloys with extensively developed print parameters. Custom material parameter development available with optional software package.

10 μm - 100 μm.

Preset: 40 μm

ProX DMP 200 Precision Metal Printer

140 X 140 X 125 MM

Ready-to-run LaserForm CoCr (B), 17-4 (B), Maraging Steel (B) and AlSi12 (B) with extensively developed print parameters. Custom material parameter development available with optional software package.

10 μm - 100 μm.

Preset: 40 μm

ProX DMP 300 Precision Metal Printer

250 X 250 X 330 MM

Ready-to-run LaserForm CoCr (B), 17-4 (B), Maraging Steel (B) and AlSi12 (B) with extensively developed print parameters. Custom material parameter development available with optional software package.

10 μm - 100 μm.

Preset: 40 μm

ProX DMP 320 Precision Metal Printer

275 X 275 X 420 MM

Wide choice of ready-to-run metal alloys with extensively developed print parameters, including LaserForm Ti Gr. 1 (A), Gr.5 (A) and Gr.23 (A), CoCrF75 (A), 316L (A), Ni718 (A) and AlSi10Mg (A).

Custom material parameter development available with optional software package.

10 μm - 100 μm.

Preset: 30 and 60 μm

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3D Printing

UlteM® pei w/ 3M™ adhesive pre-applied

“While it is exciting to watch and anticipate advanced R&D efforts, it is equally important for the industry to continue proving that early stage/prototype successes can be scaled and applied in production environments. ” are seeing in so-called 4D printing where a 3D printed part continues to evolve after it has been printed defies previously held beliefs about the laws of physics.

While it is exciting to watch and anticipate the advanced R&D efforts unfolding before us, it is equally important for the industry to continue proving that early stage/prototype successes can be scaled and applied in large production environments. For example, the aforementioned dental scenario comes to mind, as well as early adoption we are seeing in the automotive industry for low volume specialty vehicles, which will ultimately pave the way for massproduced cars and light trucks.

Thinking more broadly, we should also consider advances that drive greater adoption of existing 3DP/AM applications in true high volume production environments.

For example, with increasingly fast printers and the development of multi-printer appliances, automation of pre-and post-processing is gaining growing importance, and is right now in a bit of a catch-up mode vis-à-vis print speeds. We are seeing both printer OEM’s and third parties develop solutions that automate key aspects of the process, including print job loading, curing, washing & drying, support removal, and process monitoring.

Moreover, advances in scanning technologies, remote monitoring,

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“The ultimate 3D printing surface”

machine learning, and AI are enabling more predictable and reliable print production, as well as preventive maintenance and service to maximize machine uptime.

Advances in these areas will drive another wave of adoption among manufacturers for whom 3D printing advancements by themselves are not enough, and demand endto-end solutions to disrupt their traditional manufacturing workflows.

CUSTOM CUT FOR ANY PRINTER

PEI PROS:

• • • •

3D Systems | www.3dsystems.com

www.designworldonline.com

• • •

Perfect for ABS & PLA Filament Ideal for heated print plates Easy Applicable: Backed with adhesive liner for remove and stick application.

High Temp- 3M™ 200MP Acrylic Adhesive Adhesive can be laminated to either side of film: Gloss or Matte Dimensions u p to: 47” wide Custom sizes available

Other materials: Optically Clear FEP Film made with Teflon® fluoropolymers Kapton® Film Polyester Tape Aluminum Foil Tape

(800) 461-4161 www.cshyde.com Resources@cshyde.com

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How Technology Works

How Electron Beam Melting Works

Electron Beam Melting is one of the several technologies used to build parts layer-by-layer. Specific to Arcam, a GE Additive division, it uses an electron beam to melt each layer of the desired part, delivering fully dense metal components.

The electron beam is managed by electromagnetic coils which deliver extremely fast and accurate beam control that allows several melt pools to be maintained simultaneously. Arcam refers to this as Arcam MultiBeam.

As with most laser-based additive technologies, the EBM process takes place in vacuum at high temperature. This process results in stress relieved components with material properties better than cast and comparable to wrought material.

The Arcam EBM Spectra H is the newest maching from the company. It is built to handle high

heat and crack prone materials.

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The vacuum system provides a base pressure of 1×10-5 mbar or better throughout the entire build cycle.

During the actual melting process a partial pressure of He is introduced to 2×10-3 mbar. This clean and controlled build environment is important to maintain the chemical specification of the built material.

For each layer in the build the electron beam heats the entire powder bed to an optimal ambient temperature, specific for the material used. The parts produced with the EBM process are free from residual stresses and have a microstructure free from martensitic structures.

Arcam’s Multibeam technology allows several melt pools to be maintained simultaneously. This melting strategy is made possible by state-of-the-art deflection electronics enabling optimization of surface finish, precision and build speed simultaneously.

Company

Machine Name

Build Size

Build Materials

Arcam

ARCAM Q10plus

200 x 200 x 180 (W/D/H); 7.87 x 7.87 x 7 in.

Titanium Ti6AI4V Titanium Ti6AI4V ELI Titanium Grade 2 Cobalt Chrome

ARCAM Q20plus

350 x 380 (Ø/H)

Titanium Ti6AI4V Titanium Ti6AI4V ELI Titanium Grade 2

ARCAM A2X

200 x 200 x 380 (W/D/H); 7.87 x 7,87 x 15 in.

Titanium Ti6AI4V Titanium Ti6AI4V ELI Titanium Grade 2 Inconel 718

Spectra H

200 x 200 x 380 (W/D/H); 7.87 x 7,87 x 15 in.

crack-prone alloys like Titanium Aluminide, nickel alloy 718

Electron Beam melting takes place in a vacuum.

Arcam | www.arcam.com

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Additive Insights

3D printing’s shift

to additive manufacturing Frank Marangell, president of USA at BigRep GmbH gave us his thoughts on the state of the additive manufacturing industry.

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Q: What do you think is the most underrated, or least recognized, capability of 3D printing / additive manufacturing?

Q: What do you think is the most significant development in additive materials over the last couple of years?

A huge opportunity for growth is in manufacturing tooling.

Even so, only a fraction of manufacturers are using additive manufacturing to help them make better parts through jigs and fixtures, special custom trays, or even safety guides.

But it’s not just the ability to make useful tooling. We are seeing how additive manufacturing is facilitating creative ideas from the manufacturing engineer. It’s amazing how much they can use additive to improve their process.

The use of additive manufacturing for tooling, even items larger than 12 in., is under the radar because it’s not sexy.

We’re seeing more movement in materials that meet applications specific needs. Customers need to solve some particular application. So, if it’s in automotive it might be ASA, which is a better UV resistant than ABS, or PA6, and maybe it’s PA6 with carbon fill, or glass fill. So, materials are not as generic anymore as they used to be. They’re getting very application specific.

The ability to print PA6 is going to be critical in the future. Right now no one is doing it; it’s more challenging than PA12, or PA11. But automotive

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Company

Machine Name

Build Size

Build Materials

Layer Thickness

BigRep

BigRep ONE

1005 x 1005x 1005 (mm); 39.56 x 39.56 x 39.56 in.

BigRep PLA, BigRep ProHT, BigRep PETG other filaments on request.

0.4 - 0.8 mm standard extruder; 0.15 to 1.4 mm power extruder

500 mm x 1000 mm x 500 mm

BigRep PLA, BigRep PRO HT, BigRep PRO HS, BigRep PETG

0.1 to 0.4 mm

BigRepSTUDIO

companies need PA6 if they’re going to make a real end use part. If automotive is going to shift specialty car parts from injection molding and into additive, then they’re going to want to make it in the same material they make their injection molding, probably, which is PA6. And that’s why companies that are forward thinking are working on PA6.

As more people get out of prototyping and turn to manufacturing with additive technology, application specific materials are replacing the materials that up until now have been good enough. In my Object days, we had our ABS life material, the green material from Object, and it was good enough to test whether you wanted to go to tooling and make this real end use part. But as we shift to additive manufacturing, material properties can’t be prototype quality anymore, they have to be manufacturing quality, and the same with machines.

Materials and additive machine development are tied together.

The developments in materials are interrelated to the developments in additive machines.

Q: What kind of new applications are you seeing on the horizon?

The amazing thing coming out right now is the shift in manufacturing to additive systems. You see it from the recent acquisitions made by some notable companies like GE, BASF, Ford and others.

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Build Speed

up to 140 mm/s at layer height 0.1 mm

In manufacturing, a machine needs to deliver reliability, repeatability, print ability, usability, and all the abilities. And you also need connectivity. You need to be able to have both in situ monitoring of the system, and you need to be able to have data that gets into the manufacturing environments, and you need to be automated, and you need to come out in a serial way, not in a batch way. A few additive companies in this industry are attacking that, particularly those in metal additive manufacturing.

BigRep | www.bigrep.com

The amazing thing coming out right now is the shift in manufacturing to additive systems. You see it from the recent acquisitions made by some notable companies like GE, BASF, Ford and others.

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How Technology Works

How the Carbon process works Carbon developed a modification to vat photopolymerization, also known as stereolithography, which speeds up the build process considerably. The founders, who are chemists, use a form of digital

The Carbon SpeedCell is a

system of connected manufacturing units that enable repeatable production of end-use parts.

light processing to create parts that rival those made by conventional injection molding.

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Company

Machine Name

Build Size

Build Materials

Layer Thickness

Carbon

M1 printer

141 x 79 x 326 mm (5.6 x 3.1 x 12.8 in.)

Carbon custom materials

75 um pixels

M2 Printer

189 x 118 x 326 mm (7.4 x 4.6 x 12.8 in.)

Carbon custom materials

75 um pixels

In typical UV stereolithography approaches, a build tray dips into a vat of photo-reactive resin where a UV light cures a layer. Then the tray dips into the resin again and another layer is cured onto the previous layer, and so on.

Carbon founders figured out how to eliminate the dips, shaving a lot of build time off the entire process. Depending on the part, the speed improvement is 100 fold or more.

To skip the dips, the printer injects oxygen at a key point in the build, which inhibits the resin from curing too quickly, enabling the next layer to adhere to the previous layer without demarcations or the stair-step effect common in other 3D printing technologies. Plus, without layers, the risk of fractures along the build layers is reduced or eliminated entirely, so parts are inherently strong. The controlled curing, part of the Continuous Liquid Interface Production (CLIP) process, also makes it seem as if the part is “growing” out of the printer. As with any additive process, you can make any geometry you like.

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Carbon has developed a range of elastomer materials that exhibit unique properties from soft rubber to hardnesses that compete with carbon-based materials.

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How Technology Works

Software controls the oxygen injection process and monitors and manages the build zone as light and oxygen mix.

This oxygen injection process is controlled through software, which is another key part of Carbon’s development. The oxygen is injected into a hardware part called the Window, located at the bottom of the build interface.

The software monitors and manages this build zone where light, oxygen and other factors are tracked. The software calculates all the parameters needed to ensure a proper build.

Post processing involves a solvent wash to eliminate residual resin or some supports. The next

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step is the part is baked to install specific mechanical properties. The resultant parts can be machined and cut. Some material combinations will behave like real rubbers.

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From Powder to Performance.

ZEISS 3D ManuFACT

// INNOVATION MADE BY ZEISS

ZEISS 3D ManuFACT Improving Yield in Additive Manufacturing 3D printing processes – additive manufacturing – are becoming increasingly a part of the industrial production chain.

Medical technology, aerospace, and automotive industries are leading the way in innovation and implementation.

ZEISS 3D ManuFACT is a holistic inspection solution, each step having significant impact on overall yield.

Find out more at www.zeiss.com/metrology/solutions/additive-manufacturing

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How Technology Works

Sintering metal to build parts

In Concept Laser’s metal laser melting process, branded as LaserCUSING, a high-energy fiber laser fuses commercial materials that are in powder form. The one-component metal powder is completely fused. This process results in finished components with almost ideal material properties.

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Company

Machine Name

Build Size

Build Materials

Concept Laser

Mlab cusing

50 x 50 x 80 mm3 (x,y,z); 2 x 2 x 3.12 in.

CL 20ES, CL 80CU, CL 92PH, remanium star CL, Yellow gold, Rose gold*, Red gold*, Platinum, Silver alloy

1-5 cm3/h (depending on material)

Mlab cusing R

70 x 70 x 80 mm3 (x,y,z); 2.75 x 2.75 x 3.12 in.; 90 x 90 x 80 mm3 (x,y,z); 3.5 by 3.5 x 3.12 in.

CL 20ES, CL 31AL, CL 4ITI ELI, CL 42TI, CL 80CU, CL 92PH, remanium star CL, rematitan CL, Yellow gold, Rose gold*, Red gold*, Platinum, Silver alloy

1-5 cm3/h (depending on material)

Mlab cusing 200R

70 x 70 x 80 mm3 (x,y,z); 2.75 x 2.75 x 3.12 in.;

CL 20ES*, CL 31AL*, CL 4ITI ELI*, CL 42TI*, CL 80CU*, CL 92PH*, remanium star CL, rematitan CL*

1-5 cm3/h (depending on material)

50 x 50 x 80 mm3 (x,y,z); ; 2 x 2 x 3.12 in.

Build Speed

M1 cusing

250 x 250 x 250 (x,y,z); 9.84 x 9.84 x 9.84 in.

CL 20ES, CL 50WS, CL 91RW, CL 92PH, CL 100NB, CL 101NB remanium star CL

2-15 cm3/h (depending on material / laser powder)

M2 cusing

250 x 250 x 280 (x,y,z); 9.84 x 9.84 x 11 in.

CL 20ES, CL 31AL, CL 4ITI ELI, CL 42TI, CL 50WS, CL 91RW, CL 92PH, CL 100NB, CL 101NB, CL 110CoCr* remanium star CL, rematitan CL

2-20 cm3/h (depending on material)

M2 cusing Multilaser

250 x 250 x 280 (x,y,z); ; 9.84 x 9.84 x 11 in.

CL 20ES, CL 31AL, CL 4ITI ELI, CL 42TI, CL 50WS, CL 91RW, CL 92PH, CL 100NB, CL 101NB, CL 110CoCr* remanium star CL, rematitan CL

2-35 cm3/h (depending on material / laser powder)

M LINE FACTORY PRD / PCG

400 x 400 x up to 425 (x,y,z); 15.75 x 15.75 x 16.73 in.

CL 20ES*, CL 31AL*, CL 4ITI ELI*

not stated

X LINE 2000R

800 x 400 x 500 (x,y,z); 31.5 x 15.75 x 19.68 in.

CL 20ES*, CL 32AL, CL 4ITI ELI, CL 100NB

up to 120 cm3/h (depending on material / geometry)

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Layer Thickness

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How Technology Works

The laser uses a mirror-deflecting unit (scanner) to direct the laser beam to fuse the powder when building the part. The build bed is lowered, a new layer of powder is applied over the previous later, and melted with the laser. In this way, the component is built layer by layer. Layer thicknesses range from 15 – 500 μm.

This process delivers stochastic control of the slice segments (also referred to as “islands”), which are processed successively.

Thus, the process ensures a significant reduction in stress when manufacturing large components.

LaserCUSING produces almost no waste. Metal powder that has not been melted can be fully reused without any material being lost for further processes. Furthermore, the

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laser process is almost emission-free.

Thanks to the high level of efficiency of the laser systems, the energy is efficiently converted into working capacity.

It can be used to fabricate mold inserts with close-contour cooling and direct components for the jewelry, medical, dental, automotive and aerospace sectors. This applies to both prototypes and batch parts. *The term “LaserCUSING” was coined from the C in Concept Laser and the word FUSING.

Concept Laser | www.conceptlaserinc.com

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How Technology Works

How desktop metal

3D printing works

The Desktop Metal Studio printer is one of the first 3D printers that enables users to work with metal materials without special facility and installation requirements. Working with metal in 3D printing often requires considerable safety systems because of the combustibility of most metals. Desktop Metal created a solution that eliminates this issue.

The secret is the use of metal rods combined with a binder material. The binder ensures safe handling of the metal material. The rods are fed into the Studio printer, which then extrudes them for the layer-by-layer build process.

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The next step is for the part to go through an office-friendly sintering furnace with a peak temperature of 1400 C. This process burns the binder out of the built object and sinters it to the required density, typically 96 to 99.7%.

The last step is post processing where users can apply optional

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finishing methods such as machining or bead blasting for critical tolerances and finishes. Supports are removed by hand.

The Studio System produces near-net-shape metal parts, with features like closed-cell infill for lightweight strength, and with the resolution and accuracy needed for DESIGN WORLD

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Support materials easily snap off the metal 3D printed part.

Company

Machine Name

Build Size

Build Materials

Layer Thickness

Build Speed

Desktop Metal

Studio System Printer

12 x 8 x 8 in.

(30 x 20 x 20 cm)

Alloys, including stainless steel, copper, and tool steels, 17-4PH, 316L, Inconel 625, H13, AISI 4140

50 um

16 cm3/hr

Production System

330 x 330 x 330 mm (12.99 x 12.99 x 12.99 in.)

Alloys, including stainless steel, copper, and tool steels, 17-4PH, 316L, Inconel 625, H13, AISI 4140

<50 um

8200 cm3/hr

3D printed parts go through an officefriendly sintering furnace that burns the binder out of the built object and sinters it to the required density, typically 96 to 99.7%.

Rods that are a combination of metal powder and binder provide a safe way to 3D print metals.

The Studio System 3D printer extrudes rods to build parts in a layer-by-layer process.

functional prototyping. Software constructs print and sinter plans for every build and material— automatically generating supports and control parameters needed in printing through sintering.

Cloud-connected, the furnace has temperature profiles tuned to every build and material. It uniformly heats parts to just below their

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melting point, removing binder and fusing metal particles to form fully dense parts without the residual stresses introduced in laser-based systems.

The printer works with typical existing MIM (Metal Injection Molding) materials, ranging from steels and aluminum to superalloys and titanium. www.designworldonline.com

Desktop Metal www.desktopmetal.com

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Additive Insights

More applications

on the horizon

for additive manufacturing

EOS has been involved in additive manufacturing for many years. We asked Dr. Ankit Saharan and Dr. Gregory Hayes at EOS to explore the next phase of development in additive manufacturing.

Q: What is the least recognized capability of 3DP/AM? We all know about how 3D printing upends the traditional manufacturing world including new designs, green technology, reduced carbon footprint, new modes of manufacturing, and so on. With all these new avenues of development we still have to understand that in principle the underlying backbone for all these innovations is a result of transformation. When considering the underrated capability of 3D printing, two topics

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are immediately apparent: transformation of human capital, and transformation of supply chain logistics.

Traditional engineers, manufacturing managers, and business developers need to undergo a mindset change and start â&#x20AC;&#x153;thinking additive.â&#x20AC;?

The 3D printing community is still a tight knit one, where everyone knows everyone. We have exciting applications like patient specific implants, heat exchangers, lighter aircraft parts, more efficient engines. Imagine as the

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capability transcends to more people, especially students coming out of universities, the explosion in applications is inevitable. With AI now a topic, and how it could make certain professions irrelevant, 3D printing gives people a chance to make themselves count, attain a higher level of skill limited only by their creativity.

With respect to supply chain logistics; traditional cost models, spare part logistics, and supply change management need to undergo an additive transformation. Consider the production of a typical aerospace component. Part design and qualification, raw material supply and stock, product lifetime, spare part logistics, and product cost are all known. With the introduction of additive technology, raw material is

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Additive Insights Company

Machine Name

Build Volume (mm)

Build Materials

Layer Thickness

Build Speed

Software

EOS

FORMIGA P 110

200 x 250 x 330 mm (7.9 x 9.8 x 13 in)

Polyamide 12 (standard, glass bead filled, flame retardant, aluminium filled, dental), Polyamide 11, Polystyrene

0.06 mm, 0.1 mm, 0.12 mm (0.0024 in, 0.0039 in, 0.0047 in)

up to 20 mm/h (0.79 in/h)

EOS RP Tools

FORMIGA P

340 x 340 x 600 mm (13.4 x 13.4 x 23.6)

Polyamide 12 (standard, PrimePart, glass bead filled, flame retardant, black, aluminum filled, carbon fiber reinforced), Polyamide 11, Polystyrene, TPE

0.06 mm (0.00236 in), 0.10 mm (0.00394 in), 0.12 mm (0.00472 in), 0.15 mm (0.00591 in), 0.18 mm (0.00709 in)

up to 48 mm/h (1.9 in/h)

PSW 3.8, EOSAME, EOS ParameterEditor, EOS RP Tools, EOSTATE Everywhere

EOS P 770

700 x 380 x 580 mm (27.6 x 15 x 22.9 in)

Polyamide 12 (standard, PrimePart, glass bead filled, fire retardant, aluminium filled), Polyamide 11, Polystyrene

0.06 MM (0.00236 IN), 0.10 MM (0.00394 IN), 0.12 MM (0.00472 IN), 0.15 MM (0.00591 IN), 0.18 MM (0.00709 IN)

up to 32 mm/h** (1.3 in/h); up to 10.5 l/h

EOS ParameterEditor, EOSAME, EOS RP Tools, EOSTATE Everywhere, PSW 3.8

EOSINT P 800

700 x 380 x 560 mm (27.6 x 15 x 22.05 in)

Polyaryletherketone

typically 0.12 mm (0.005 in)

7 mm/h (0.3 in/h)

EOS RP Tools; EOSTATE; Magics RP (Materialise)

EOS M 100

Ø 100 x 95 mm (Ø 3.9 in x 3.7 in) height, incl. build platform

Cobalt Chrome, Stainless Steel, Titanium

20 - 30 µm depending on material

NA

EOSPRINT, EOS RP Tools, Cambridge or Magics RP and other modules

EOS M 290

250 x 250 x 325 mm (9.85 x 9.85 x 12.8 in)

Maraging Steel, Cobalt Chrome, Titanium, Nickel Alloy, Aluminium, Stainless Steel

20 - 60 µm depending on material

NA

EOSTATE Everywhere, EOSPRINT incl. EOS ParameterEditor

EOS M 400

400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in), inlcuding build plate

Maraging Steel, Cobalt Chrome, Titanium, Nickel Alloy, Aluminium

30 - 90 µm depending on material

NA

EOSPRINT; EOS ParameterEditor; EOSTATE Everywhere; EOSTATE PowderBed; Materialise Magics Metal Package and modules

EOS M 400-4

400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in), including build plate

Maraging Steel, Titanium, Nickel Alloy, Aluminium, Stainless Steel

30 - 60 µm depending on material

NA

EOS RP TOOLS; EOSPRINT; EOS PARAMETEREDITOR; EOSTATE EVERYWHERE; EOSTATE POWDERBED; MATERIALISE MAGICS RP AND MODULES

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now in universal powder form, spare parts are manufactured on demand, and part design is no longer confined to subtractive technologies. Of course, qualification of components must still be carefully considered. With further ideas of distributed manufacturing (optimizing capacity), the decreased need for physical labor jobs, and the use of data to create digital twin models of components, the cost models for specific parts need to be reconsidered. Overall, the impact of additive technology on design and engineering thinking, and reorganization of the supply chain results in beneficial cost and production models, ultimately leading to better components and a better product for end use customers.

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Q: What is the most significant develop in 3DP/AM materials in the last few years?

Materials unlock applications for additive technologies. In the current additive metals world, traditionally conventional alloy chemistries like 316L, 15-5PH stainless steels, Ti64 and other superalloys were developed. Now that powder bed additive technology has gained some maturity there is a realization that new alloy chemistries are needed to take advantage of the cooling rates of this process. Hence we see an explosion of new AM specific materials in the industry

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today where these new alloys not only match the traditional alloys but in some cases surpass performance giving design engineers more space to create and make not only new generative designs but also achieve performance from these applications which was not possible before. This is especially true in case of Aluminum and we see a bright future for other alloy classes as well like high carbon steels, gamma and gamma prime super alloys.

Q: Do you see any new applications for 3DP/AM on the horizon?

We have all come to know many different applications from additive technology ranging from conformal cooling in tooling to brackets and hinges in aerospace to combustion chambers in engine technology to patient specific implants in the medical world. However, one of the upcoming applications that can potentially disrupt many industries is heat exchangers. With new options in the aluminum class of materials in addition to some in the copper family, never before designed heat exchangers are now being tested and showing unparalleled performance. This can impact many

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industries ranging from aerospace to automotive to electronics. The latter being the key where the volumes truly would test the limit of this technology in terms of it’s viability as a mass production tool in todays’ world and make everyone more aware of the impact of 3D printing technology in their daily lives.

EOS | www.eos.info

“With respect to human capital; traditional engineers, manufacturing managers, and business developers need to undergo a mindset change and start “thinking additive.”

www.designworldonline.com

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How Technology Works

How the HP Multi Jet Fusion printer builds parts Foundationally, HPâ&#x20AC;&#x2122;s 3D printing technology is based on its thermal inkjet technology that was invented 30 years ago.

In a sense, it is similar to ink cartridges on a carriage that scan across a build bed depositing droplets of material at very fast speeds. HP claims to be able to increase the deposition speed up to 10 times faster than other technologies.

The HP process is essentially a chemical sintering process that uses heat to fuse or compact the powder into a solid shape, without liquefying the powder. Chemical agents control the heat process.

There are four phases to the 3D printing process. The first phase consists of spreading a layer of material over the build

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Company Machine Name HP

HP MultiJet Fusion 3D 4200 Printer

Build Volume in mm

Build Materials

Layer Thickness

380 x 284 x 380 mm (15 x 11.2 x 15 in)

HP 3D High Reusability PA 12 0.08 mm (0.003 in) VESTOSINT® 3D Z2773 PA 11, Certified for HP Jet Fusion 3D Printers

Build Speed 4115 cm3/hr (251 in3/hr)

For the latest info on new materials please visit: www. hp.com/go/3dmaterials Jet Fusion 3D 4210

380 x 284 x 380 mm (15 x 11.2 x 15 in)

0.08 mm (0.003 in)

4115 cm3/hr (251 in3/hr)

Jet Fusion 3D 3200

380 x 284 x 380 mm (15 x 11.2 x 15 in)

0.08 mm (0.003 in)

2800 cm3/hr (170 in3/hr

Jet Fusion 500 series

7.5 x 13.1 x 9.8 inches (190 mm x 332 mm x 248 mm)

color

0.08 mm (0.003 in)

NA

Jet Fusion 300 Series

7.5 x 10 x 9.8 inches (190 mm x 254 mm x 248 mm)

color

0.08 mm (0.003 in)

NA

area. Then, in one continuous pass, thermal-ink print heads deposit “agents” on top of the material.

The agents are special materials that fuse the build material and detail it, controlling part quality and accuracy. One agent absorbs the heat needed to sinter the plastic powder. The other agent stops the heat absorption process to ensure sharp part details. It takes about a light second to cure the exposed area.

In the next step, the build material and agents are exposed to an infrared energy. The fusing agent absorbs the energy, melting the material, and the detailing agent creates a thermal fence that prevents the thermal energy from absorbing in unwanted areas of the build. In a sense, the detailing agent acts like masking tape.

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It’s preventing the thermal flow of the material in specific areas. At the last step, you have a final fuse part that’s ready for de-powdering or de-caking.

HP Inc. | www.hp.com

Fusing-Coating Area Wide Pass

Once a layer of material is spread over the build area, thermal-ink print heads deposit special materials on top of the build material. These agents control part quality and accuracy.

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How Technology Works

An innovation jetting technology delivers metal parts with fine details XJet developed a unique way to build metal or ceramic parts layer by layer.

The

developers call it NanoParticle Jetting (NPJ) technology. Itâ&#x20AC;&#x2122;s a type of inkjet approach where nanoparticles of irregularly shaped (stochastic) metal in a liquid suspension are deposited onto a build surface. Thousands of nozzles jet millions of ultrafine drops of these liquid suspensions of both the build and the support material.

The drops create an ultrathin layer, enabling this technology to deliver superfine details, smooth surfaces and high accuracy. Manufacturers can create finished parts of almost any geometry, including those with tiny holes, thin walls, challenging arches and sharp edges.

Support materials are removed simply without harming the part, greatly reducing the need for timeconsuming and delicate post-processing.

These materials are safe to use because the liquid suspensions are delivered in sealed cartridges.

XJet | www.xjet.com

Nanoparticles of build

or support material are suspended in a liquid.

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Company

Machine Name

Build Size

Build Materials

Layer Thickness

Build Speed

XJet

Carmel 700

500 x 140 x 200 mm (19.7 x 5.5 x 7.9 inches)

ceramic (zirconia)

10-15 microns

1-1.5mm height per hour for a full tray

Carmel 1400

500 x 280 x 200 mm (19.7 x 11 x 7.9 inches)

metal and ceramic

3-8 microns in metal and 10-15 microns in zirconia

1-1.5mm height per hour for a full tray

Both build and support

nanoparticles are jetted from thousands of nozzles onto the build surface in ultrafine layers.

Material particles are shredded to create smaller, irregularly shaped particles for the NPJ process.

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ny me

Additive Insights

Views on the role of desktop 3D printing in industry

ture

ally rt

bility and 155 3D

few

was

r eir

r en

Desktop 3D printers continue to play a key role in the additive industry. In many cases, not only do these printers handle prototypes, they also handle low-volume production.

Aleph Objects Inc. is one of main developers of desktop style 3D printers. We recently asked a spokesperson from Aleph to comment on the future of this technology.

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Q: What is the most under rated or least

recognized capability of 3DP/AM? Low-volume/bridge manufacturing is an under-rated capability. 3D printing enables manufacturing startups that previously would have either been financially unfeasible due to needed capital. With desktop 3D printers, it’s possible to start at extremely low volumes and scale up to meet demand, all the while turning a profit. Our company wouldn’t exist today if we didn’t have that in-house capability ourselves.

We’ve been able to iterate quickly without

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Company

Machine Name

Build Volume

Build Materials

Layer Thickness

Build Speed

LULZBOT

LULZBOT TAZ 6

280 X 280 250MM

OPEN FILAMENT FORMAT: ABS,

SOFTWARE

30 - 200MM/S

NYLON, POLYCARBONATE, AND MORE

CONFIGURABLE

OPEN FILAMENT FORMAT: ABS, NYLON, POLYCARBONATE,

SOFTWARE CONFIGURABLE

LULZBOT MINI

152 X 152 X 158MM

30 - 275MM/S

AND MORE

considering tooling costs and we’ve scaled the printer cluster as needed to meet demand. We currently run 155 LulzBot printers 24/7, and have printed more than 2-million production quality 3D printer parts since 2011.

Q: What is the most significant development in

3DP/AM materials in the last few years?

Not a single development, but we think the involvement of major chemical companies in filament development is a big deal. Until recently, most filament was made from polymers intended for other manufacturing processes. As a result, most were less than perfect for 3D printing due to shrinkage, off-gassing, poor lay bonding, and so on. Now Eastman, Dow, BASF, and others are applying their portfolios of polymers to 3D printing and it’s expanding the range of what’s possible on the desktop.

Q: Do you see any new applications for

3DP/AM on the horizon?

Not sure whether it’s technically new, but we’re definitely keeping an eye on bioprinting. We’ve worked with researchers who are using modified LulzBot 3D printers, to do truly groundbreaking bioprinting work. The simplicity of their processes was eye opening, relatively affordable printers running Free and Open Source software enabling things not possible with expensive proprietary tool chains.

“Desktop 3D printers continue to play a key role in the additive industry. In many cases, not only do these printers handle prototypes, they also handle low-volume production.”

Lulzbot | www.lulzbot.com

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How Technology Works

How a desktop

3D printer can print metal

Markforged uses a process it names Atomic Diffusion Additive Manufacturing (ADAM) for printing metal materials.

Metal powder is combined with a plastic binder to make the material safe to handle. The material is extruded to form the part shape layer-by-layer. Then the part is sintered in a furnace to burn off the binder and solidify the powder into the final fully dense metal part. The sintering step burns off the plastic binder and causes the metal powder to diffuse together

into 99.7% dense metal. Thermally sintering parts is well established in the Metal Injection Molding (MIM) industry to create end-use parts for medical, aerospace, and consumer applications.

Markforged offers two basic types of material. One is the metal powder bound with a plastic binder.

The other is carbon fiber reinforced where 60% of the metal powder is

substituted with micro strands of carbon fiber bound in plastic.

Other materials include wellknown metal injection molding materials such as 17-4 Stainless Steel, and in the near future Tool Steels, Titanium, Aluminum, and Inconel.

Markforged | www.markforged.com

Material for this metal desktop printer consists of

metal powder combined with a plastic binder for safe handling.

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Company

Machine Name

Build Size

Build Materials

Layer Thickness Build Speed

Markforged

Onyx One

320 x 132 x 154 mm (12.6 x 5.2 x 6 in)

Onyx thermoplastic

100 micron

dependent on geometry

Onyx Pro

320 x 132 x 154 mm (12.6 x 5.2 x 6 in)

Onyx thermoplastic, Fiberglass

100 micron

dependent on geometry and fiber reinforcement

Mark Two

320 x 132 x 154 mm (12.6 x 5.2 x 6 in)

Onyx thermoplastic, Carbon fiber, Fiberglass, Kevlar, HSHT Fiberglass

100 micron

dependent on geometry and fiber reinforcement

X3

330 x 270 x 200 mm (13 x 10.6 x 7.9 in)

Onyx thermoplastic

50 micron

dependent on geometry

X5

330 x 270 x 200 mm (13 x 10.6 x 7.9 in)

Onyx thermoplastic, Fiberglass

50 micron

dependent on geometry and fiber reinforcement

X7

330 x 270 x 200 mm (13 x 10.6 x 7.9 in)

Onyx thermoplastic, Carbon fiber, Fiberglass, Kevlar, HSHT Fiberglass

50 micron

dependent on geometry and fiber reinforcement

Metal X

300 x 220 x 180 mm (11.8 x 8.7 x 7.1 in)

17-4 PH Stainless Steel with more to come

50 micron

dependent on geometry

Another material available with this printer consists of carbon fiber bound with metal powder.

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Additive Insights

How Nano Dimensions

sees the future of 3D printing Desktop 3D printing is gaining ground with engineers, especially as it shows capability to combine technologies into one part, such as mechanical and electrical. Hereâ&#x20AC;&#x2122;s how Nano Dimensions views the future of 3D printing.

Q: What is the most underrated or least recognized capability of 3DP/AM?

Q: What is the most significant development in 3DP/AM materials in the last few years?

A: Most people understand 3D printing, but may not be fully aware of how itâ&#x20AC;&#x2122;s evolved over the last decade. Among the newest and most underrated capabilities of additive manufacturing is the ability to print with multiple materials -- combining metals, plastics and ceramics, for instance, in a single print job. Multi-material printing, and the ability to 3D print complex, functional electronics, means the possibilities for what can be printed in the future are practically limitless, from R&D to customized manufacturing.

A: In the last decade, weâ&#x20AC;&#x2122;ve seen additive manufacturing move from hobbyist machines printing single-material, static objects to professional printers capable of printing everything from working prosthetic body parts to fully functioning electronic components for quick product development. One of the most exciting developments has been the use of conductive and dielectric inks to build working components such as circuit boards, antennas, sensors, passive components or other items in a single print job.

Q: Do you see any new applications for 3DP/AM on the horizon?

A: With the combination of 3D printed electronics and multimaterial print capabilities, additive

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manufacturing is going to change dramatically over the coming years, from prototyping towards real production manufacturing. We will see greater demand for 3D printed elements, such as sensors, antennas, embedded components, circuit boards and more. But we also see this technology acting as a major disruptor for Industry 4.0 and the Internet of Things because companies will have options for designing and 3D printing their own electronic parts for competitive advantage, creating new designs and form factors never before possible. They also will be able, for instance, to conduct smallbatch component making in-house using specialty printers, or 3D print electronic elements to replace broken or damaged items in their local or edge networks.

Nano Dimensions www.nano-di.com

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Company

Machine Name

Build Size

Build Materials

Nano Dimensions

DragonFly 2020

200 x 200 x 3 mm (7.87 x 7. 87 x 0.1 in.)

plastics, some metals

DragonFly 2020 Pro 3D Printer

Layer Thickness 0.03 mm

Build Speed 16 cm3/hr

Metals (conductive silver nano particle inks) and polymers (dielectric inks)

The DragonFly 2020 Pro 3D printer produces PCB prototypes for electronics applications.

“Among the newest and most underrated capabilities of additive manufacturing is the ability to print with multiple materials combining metals, plastics and others in a single print.”

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Application Notes

Can Medical Device Regulation

work with additive manufacturing?

The European Union’s (EU’s) Medical Device Regulation (MDR) was first introduced in 2017 and set in motion a three-year countdown to its full application in 2020. The MDR could drastically affect the way that medical devices are made in the EU, particularly those produced using additive manufacturing (AM).

The regulation suggests that any medical device mass produced by means of an industrial process no longer falls under the ‘custom-made’ exemption and therefore requires its own clinical evidence to authorize its sustainability. It also needs its own CE Mark to prove it has been tested and meets all relevant standards.

The problem is that there isn’t a clear definition of ‘mass-produced’ or ‘industrial manufacturing processes.’ Without these terms being defined, there

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is a risk that the regulations will cover additively manufactured patient specific implants (PSIs) when produced on an industrial scale, even though each one is unique.

Additive manufacturing is a core technology for rapidly producing custom metal parts, with complex geometry for the medical sector. The technology can produce components with variable surface finish to suit different surgical

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In medical device regulations, there isn’t a clear definition of mass-produced or industrial manufacturing process, which means regulations may cover additive parts from an industrial perspective rather than an individual, unique perspective.

Company

Machine Name

Build Volume (mm)

Build Materials

Build Speed

Renishaw

RenAM 500M metal additive manufacturing system

250 x 250 x 350 mm

AISi10Mg, In625, In718, Ti6AI4V

Up to 25 cm3/hr

AM 400 metal additive manufacturing system

250 x 250 x 300 mm

AiSi10Mg, CoCr, In625, In718, stainless steel 316L, Ti6AI4V

Up to 20 cm3/hr

5/01 Vario vacuum casting system

520 x 445 x 425 mm

Polyurethane resins, wax for investment casting masters, high viscosity resins

Up to 50 parts per mould

RenAM 500Q

250 x 250 x 300 mm

AM250

250 x 250 x 300 mm

procedures. It can also produce complex lattice structures more efficiently than traditional subtractive machining can.

Implants can be designed specifically to a patient’s magnetic resonance imaging (MRI) or computed tomography (CT) scans, resulting in one off, unique products, specific to an individual’s needs.

Patient specific additively manufactured implants are helping to improve treatment processes, decrease procedure revision numbers and reduce surgery times, which can also reduce costs for the NHS and provide better patient outcomes.

Despite the benefits AM offers so far, the new MDR may interfere with the use of additive manufacturing in the medical industry in future.

The MDR has been released, but the subsequent guidance documents could be influenced if enough manufacturers have an input.

Patient specific implants are

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150 cm3/hour deposition rate For dental and medical applications

already used in surgeries across the world.

An interpretation of the regulation as it currently stands may mean AM will not be able to help patients in the same way once the regulations come into full force.

For the technology to reach its potential, industry and healthcare need to work together to develop a body of evidence to demonstrate the efficacy and benefits of the technology.

NA

The only way to prevent the MDR from having a negative impact on additive manufacturing is to prove its worth, not just for hospitals and medical professionals, but also for patients that have the potential to receive a better outcome.

Renishaw | www.renishaw.com

An interpretation of the European Union’s Medical Device Regulation may mean that additively made implants or other medical designs may not be able to help patients once regulations come into full force.

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Application Notes

Why use 3D printing

for sacrificial cores?

For innovation.

Reducing design time and part weight have become the new design goals.

Todayâ&#x20AC;&#x2122;s students are learning them too. The student motorsport team Tecnun is using a Stratasys 3D printer to create complex end-use race parts. The students are able to reduce the time it takes to create these parts as well as their weight by 3D printing sacrificial cores to innovate composite part production.

Tecnun, the Formula student team from the University of Navarra in Spain, designs and manufactures its own Formula Student racecars that compete each year at the Formula Student International competition. Harnessing Stratasysâ&#x20AC;&#x2122; additive manufacturing technology through the its local reseller, Pixel Sistemas, Tecnun can produce extremely complex 3D printed molds for key race parts in a

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Company

Technology

Stratasys

Printer

Build Envelope (mm)

Model Material Options

Layer thickness (mm)

UPRINT SE PLUS

203 x 203 x 152 (8 x 8 x 6 in.)

ABSplus in 9 colours

0.245mm or 0.330

STRATASYS F170

254 x 254 x 254 (10 x 10 x 10 in.)

ABS-M30TM, ASA, PLA

Down to 0.127

STRATASYS F270

305 x 254 x 305 (12 x 10 x 12 in.)

ABS-M30TM, ASA, PLA

Down to 0.127

STRATASYS F370

356 x 254 x 356 (14 x 10 x 14)

ABS-M30, ASA, PC-ABS, PLA

Down to 0.127

FORTUS 380mc

356 x 305 x 305 (14 x 12 x 12 in.)

ABS-M30, ABS-M30i, ABS-ESD7, ASA, PC- Down to 0.127 ISO, PC, PC-ABS, FDM Nylon 12

FORTUS 450mc

406 x 356 x 406 (16 x 14 x 16 in.)

ABS-M30, ABS-M30i, ABS-ESD7, ASA, PC-ISO, PC, PC-ABS, FDM Nylon 12, FDM Nylon 12CF, ST-130, ULTEM 9085 resin, ULTEM 1010 resin

Down to 0.127

FORTUS 900mc

914 x 610 x 914 mm (36 x 24 x 36 in.)

ABS-M30, ABS-M30i, ABS-ESD7, ASA, PC-ISO, PC, PC-ABS, PPSF, FDM Nylon 12, FDM Nylon 6, ST-130, ULTEM 9085 resin, ULTEM 1010 resin

Down to 0.178

OBJET30 PRO

300 x 200 x 150 mm (11.8 x 7.9 x 5.9 in.)

28 microns , MODEL: Rigid Opaque: VeroWhitePlus, 16 microns for VeroGrayTM, VeroBlueTM, VeroBlackTM, VeroBlackPlusTM, Simulated Polyproylene: VeroClear Material RigurTM, Durus, High Temperature

OBJET30 PRIME

300 x 200 x 150 mm (11.8 x 7.9 x 5.9 in.)

MODEL: Rigid Opaque: VeroWhitePlus, VeroGray, VeroBlue, VeroBlack, VeroBlackPlus - Transparent: VeroClear and RGD720 - Simulated Polypropylene: Rigur, Durus - High Temperature - Rubberlike: TangoGrayTM and TangoBlackTM - Biocompatible

28 microns for TangoTM materials 16 microns for all other materials

OBJET EDEN260VS

255 x 252 x 200 mm (10 x 9.9 x 7.9 in.)

MODEL: Rigid Opague: VeroWhitePlus, VeroBlackPlus, VeroGray, VeroBlue - Rubber-like: TangoPlusTM, TangoBlackPlusTM, TangoBlack, TangoGray - Transparent: VeroClear and RGD720 - Simulated Polypropylene: Rigur and Durus - High Temperature - Biocompatible

Horizontal build layers as fine as 16 microns.

Accuracy 20-85 microns for freatures below 50mm; up to 200 microns for full model size

OBJET260/350/500 CONNEX 3

OBJET260: 260 x 260 x 200 mm (10.2 x 10.2 x 7.9 in.)

OBJET350: 350 x 3350 x 200 mm (13.8 x 13.8 x 7.9 in.)

OBJET500:500 x 400 x 200 mm (19.7 x 15.7 x 7.9 in.)

MODEL: Rigid Opaque: VeroWhitePlus,Vero PureWhite, VeroBlackPlus, VeroGray, and VeroBlue; VeroCyanTM, VeroMagentaTM, VeroYellowTM - Rubber-like: Agilus30, TangoPlus, Tango BlackPlus, TangoBlack, Tango Gray - Transparent: VeroClear and RGD720 - Simulated Polypropylene: Rigur and Durus - High Temperature - Biocompatible - DIGITAL: Vibrant blended colours in Rigid Opaque - Translucent colored tints -Rubber-like materials in a range of Shore A values - Digital ABS PlusTM for durability, including blends with rubber - Simulated polypropylene materials with improved heat resistance

Horizontal build layers as fine as 16 microns.

Accuracy up to 200 microns for full model size (rigid models only)

STRATASYS J750

490 x 390 x 200 mm (19.3 x 15.6 x 7.9 in.)

MODEL: VeroTM family of opaque materials including neutral shades and vibrant colors, TangoTM family of flexible materials, Transparent VeroClearTM and RGD720 DIGITAL: Unlimited number of composite materials including over 360,000 colors, Digital ABS and Digital ABS2TM in ivory and green, Rubber-like materials in a variety of Shore A values, Translucent color tints

Horizontal build layers as fine as 14 microns.

Accuracy up to 200 microns for full model size (rigid models only)

Material jettin: OBJET1000 PLUS

1000 x 800 x 500 mm (39.4 x 31.5 x 19.7 in.)

MODEL: Transparent rigid: VeroClear - Rubber-like: TangoPlus and TangoBlackPlus - Rigid Opaque: Vero family Simulated Polypropylene: Rigur DIGITAL: Transparent shades and patterns - Rigid Opaque shades - Rubber-like blends in a range of Shore A values - Simulated Polypropylene blends in rigid and flexible options Digital ABS Plus siulates ABS plastics by combining HT resistance and toughness Digital ABS matches these to provide enhanced dimensional stability in walls thinner than 1.2 mm - Rigur-based Digital Materials in a range of Shore A values and shades in rigid and flexible options

Horizontal build layers as fine as 16 microns.

Accuracy up to 600 microns for full model size (for figid models only)

material extrusion

Stratasys

Stratasys

Polyjet

?

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Application Notes

continued from page 41

Stratasys

Polyjet Dental Systems

Stratasys

Carbon Fiber

OBJET30 ORTHODESK

300 x 200 x 150 mm (11.8 x 7.9 x 5.9 in.)

MODEL: VeroDentPlus - Clear Biocompatible - VeroGlaze

Horizontal build layers down to 28 microns

OBJET30 DENTAL PRIME

300 x 200 x 150 mm (11.8 x 7.9 x 5.9 in.)

MODEL: VeroDentPlus - Clear Biocompatible - VeroGlaze

Layer thickness 16 microns

OBJET EDEN260VS DENTAL ADVANTAGE

255 x 252 x 200 mm (10 x 9.9 x 7.9 in.)

MODEL: VeroDentPlus - Clear Bio-compat- 16 microns - accuracy ible - VeroGlaze 0.1mm

OBJET 260/500 DENTAL SELECTION

OBJET260: 255 x 252 x 200 mm (19.7 x 15.7 x 7.9 in.)

OBJET500: 500 x 400 x 200 mm (19.7 x 15.7 x 7.9 in.)

MODEL: VeroDent, VeroDentPlus, VeroGlaze, Clear Bio-compatible Additional materials include: VeroWhite, VeroMagenta, TangoPlus, TangoBlackPlus, Digital materials to reproduce gumlike textures and natural tooth shades

16 microns

J700 Dental

490 x 390 x 200 mm (19.3 x 15.6 x 7.9 in.)

Proprietary acrylate/dental photopolymers

55 microns

Mojo

127 x 127 x 127 mm (5 x 5 x 5 in.)

ABS

0.17 mm

FORTIS 380 MC

355 x 305 x 305 mm (14.0 x 12.0 x 12.0 in.)

FDM nylon 12CF, ASA, soluble support

± 0.127 mm or 0.0015 mm/mm, whichever is greater

FORTIS 450 MC

406 x 355 x 406 mm (16 x 14 x 16 in.)

FDM nylon 12CF, FDM Nylon 12, ABS-M30, ABS-M30I, ABS-ESD7, Anterro 800NA, ASA, PC, PC-ABS, PC-ISO, ULTEM 9085 resin, Ultem 1010 resin, ST-130

± 0.127 mm or 0.0015 mm/mm, whichever is greater

STRATASYS F90

914.4 x 609.6 x 914.4 mm (36 x 24 x 36 in.)

FDM nylon 12CF, FDM Nylon 12, ABS-M30, ABS-M30I, ABS-ESD7, ASA, PC, PC-ABS, PC-ISO, PPSF, ULTEM 9085 resin, Ultem 1010 resin, ST-130

± 0.069 mm or 0.0015 mm/mm, whichever is greater

matter of a few hours, compared to three weeks when using traditionally manufactured aluminum molds.

Using the time saved during production, the team can make further iterations to its designs and develop final carbon fiber parts that are 60% lighter than conventional

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production methods. The lighter weight helps increase the cars’ performances on the track.

As Javier Aperribay, Technical Director of Tecnun Motorsport, explains, crucial to success and one specific area in which Stratasys’ technology can be successfully deployed, is the design of the intake manifold – a component that ensures enough air reaches the engine cylinders.

“Manufacturing an intake manifold is complex as it comprises several important components critical to the air distribution along the four intake manifolds,” Aperribay says.

“We aim to create intake manifolds in carbon fiber composites, but we’re well aware that manufacturing such a part requires a mold to lay-up the composite materials and create the final part.”

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“CNC machining is used to produce the mold in aluminum, however this is typically an inflexible and costly process and on top of that, any subsequent design revisions applied to the mold delay projects and add extra costs,” he adds.

Invariably hamstrung by tight production schedules and budgetary constraints, Tecnun has in the past tested various other additive manufacturing technologies as faster and cheaper alternatives to produce the lay-up tool.

However, it found that the plastics were not strong enough and broke during the lay-up process.

Working with Pixel Sistemas using a Stratasys Fortus 450mc Production 3D Printer, Tecnun is successfully producing mold tools for parts like the intake manifold.

This is 3D printed in ST-130 sacrificial tooling material, before the carbon fiber composite material is wrapped around the mold. Once cured, the internal sacrificial core is washed away, leaving the final composite part.

“Using Stratasys FDM sacrificial tooling allows us to make the intake manifold from carbon fiber instead of heavier, less efficient materials,” says Aperribay. “The superior soluble characteristic of the ST-130 material enables a more complex shape of the intake manifold compared to aluminum molds, removing the need to assemble all the individual components. We can now 3D print molds for the intake manifold in just five hours, as opposed to the three weeks lead time associated with conventional aluminum molds.”

According to Aperribay, the team is also impressed with the performance of the 3D printed sacrificial core molds during the

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carbon fiber lay-up and curing processes.

“We find that the material performs in high temperatures of up to 121°C and, at certain temperatures, pressures of up to 620 kPa throughout curing,” he says. “Unlike the previous additive polymer materials, we tested, the mold doesn’t break, and the quality of the resulting carbon fiber composite intake is fantastic.

“Using this technology has facilitated the combustion reaction and has increased performances on the track,” says Aperribay. “Moving forward, there is very little doubt that FDM sacrificial tooling will play a crucial role in overcoming our ongoing engineering challenges.”

“Tecnun’s use of 3D printed sacrificial cores to reduce production times and increase part complexity - and their use of this time-saving for further design iterations to produce what are ultimately much lighter parts - mirrors the way some

of professional motorsport’s bestknown teams are also benefitting from our technology,” says Andy Middleton, President, EMEA, Stratasys. “For us, it is thrilling to see tomorrow’s engineers embrace this technology so successfully as the rise of additive manufacturing continues within the automotive sector.”

Stratasys | www.stratasys.com

“Using Stratasys FDM sacrificial tooling allows us to make the intake manifold from carbon fiber instead of heavier, less efficient materials.”

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Application Notes

Volkswagen

maximizes production with

3D printed tools, jigs, and fixtures Before working with Ultimaker, Volkswagen Autoeuropa used thirdparty suppliers to manufacture their tools. The process took several weeks, especially when multiple designs or assemblies were required. It also meant more paperwork, quotations, and the adoption of a trial-and-error approach, all of which were holding up the tool manufacturing process â&#x20AC;&#x201C; at additional cost.

In 2014, Volkswagen Autoeuropa engineers looked into 3D printers. Today, they have seven Ultimaker 3D printers in operation. Up to 93% of manufactured tools the engineers needed and were sent out for production are now created

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3D printing enabled engineers at Volkswagen Autoeuropa to test construction and assembly tools, reduce development times by 95%, and achieve an overall cost reduction of 91%.

Company

Machine Name

Build Volume (mm)

Materials

Build Speed

Ultimaker

ULTIMAKER 2+

223 x 223 x 205 mm

Open material system and Ultimaker optimised materials

0.25: up to 8 mm3/s 0.40: up to 16mm3/s

ULTIMAKER 2 EXTENDED+

223 x 223 x 305 mm

Open material system and Ultimaker optimised materials

0.40: up to 16mm3/s

ULTIMAKER 3

215 x 215 x 200 mm

Open material system and Ultimaker optimised materials

30 mm/s - 300 mm/s

ULTIMAKER 3 EXTENDED

215 x 215 x 300 mm

Open material system and Ultimaker optimised materials

“In 2014, Volkswagen Autoeuropa engineers looked into 3D printers.

Today, they have seven Ultimaker 3D printers in operation.”

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Application Notes

in-house. Within two years, their assembly tooling cost savings rose – from 70% to 95%.

Ultimaker enabled Volkswagen Autoeuropa to test solutions without having to contact suppliers, reducing the time taken by an average of eight weeks.

Volkswagen Autoeuropa can now avoid processes that waste the company’s time and money, which benefits the team and improves the final product. As Luis Pascoa, Pilot Plant Manager at Volkswagen Autoeuropa, said, “It’s a simple process – we just convert our idea to a 3D file, send to the 3D printer, postprocess the part, evaluate with functional testing, and finish by implementing the idea.”

Ultimaker enabled Volkswagen Autoeuropa to: l Make even complex concepts a reality l Develop ideas quickly and easily l 3D print concepts on the same day as design – shrinking the development process from months to days l Reduce costs by testing prototypes, rather than redesigning or altering an existing mold

satisfaction. Innovative 3D printed products of Volkswagen Autoeuropa are being used in several applications and are considered best practices in the Volkswagen group.

3D printing enabled them to test construction and assembly tools, reduce their development times by 95%, and avoid the bureaucratic process of dealing with suppliers.

By printing prototypes in-house, Volkswagen Autoeuropa achieved a 91% cost reduction (approximately €325,000 per year).

Ultimaker | www.ultimaker.com

The reduction in development time and cost to produce prototypes led to a higher ROI, a better quality product, and more customer

“Ultimaker enabled Volkswagen Autoeuropa to test solutions without having to contact suppliers, reducing the time taken by an average of eight weeks”

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XL

Flexibility to Address Fidelity and Speed

R

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400

1 m x 1.5 m x 0.7 m Build Volume Starting at $40,000 USD

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300

1 m x 1 m x 0.7 m Build Volume Starting at $31,000 USD

200

NEW HFE900

1 m x 1 m x 0.5 m Build Volume Starting at $24,000 USD

100

NEW HFE300

1 m x 1 m x 0.5 m Build Volume Starting at $15,000 USD

VOLCANO

3D Platform 6402 East Rockton Road Roscoe, Illinois 61073 USA +1.779.771.0000 â&#x20AC;¢ 3dplatform.com

3D Platform 9-18_Additive Mfg Hbk.indd 47

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Industry Baseline

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Request a FREE Sample kit at: http://bit.ly/3dp-samplekit 9/17/18 1:21 PM

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Vendors in the additive industry

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your biggest ideas a reality. As a global leader in manufacturing large format industrial strength 3D printers, our team is focused on driving advancements in technology to innovate, design, and build nextgeneration equipment for additive manufacturing at an affordable price.

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Vendors in the additive industry

3D Systems

3D Systems software delivers the power to take you from prototyping through to 3D production:

Geomagic® 3D scan and inspection software; GibbsCAM® CNC programming solutions; Cimatron® mold and die design; DICOM-to-print (D2P ) CT scan processing solutions, DfAM manufacturing software with 3D Sprint and 3DXpert to deliver perfect parts, every time.

TM

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333 Three D Systems Circle Rock Hill, SC 29730 United States of America Phone: 803.326.3900 Fax: 803.326.4069 http://www.3dsystems.com DESIGN WORLD

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Vendors in the additive industry

AGS Additive Manufacturing

AGS Additive Manufacturing is a third-

generation, veteran-owned manufacturing company based in Fort Worth, TX. Our unique combination of 3D printing technology in metal and CNC machining gives us a distinct advantage in producing parts and protypes that meet the stringent standards required for the aerospace, military, medical and robotics industries. For example, our engineers 3D printed a complex dust filter on behalf of Blazetech Corp for a NASA mission to Mars, a piece that is impossible to make any other way.

Our laser powder bed fusion 3D printer holds tight tolerances, saves assembly time and provides rapid prototyping at low cost. From CAD models or prints, we can create parts in steel, aluminum, titanium, cobalt chrome and inconel. Once a prototype is green-lighted for production, AGS has a full CNC-equipped, 40,000 sq. ft. machine shop with over 60 years of experience and 70 machines for large-scale production. As part of Goold Holdings, AGS has additional capabilities with our sister companies: Southwest Industrial Services Inc., AAA Canlines and AAA industrial Chromium Company.

50

Metal parts made perfect AGS Additive Manufacturing 2413 Whitmore St., Ft. Worth, TX 76107 817â&#x20AC;˘877â&#x20AC;˘3181 quote@ags-am.com ags-am.com

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BigRep BigRep develops the world’s largest serial production 3D printers, creating the industry benchmark for largescale printing with the aim to reshape manufacturing.

Its award-winning, German- engineered machines, the STUDIO and ONE, are establishing new standards in speed, reliability and efficiency. BigRep’s printers are the preferred choice of engineers, designers and manufacturers at companies around the world.

Through collaborations with its strategic partners - including Etihad Airways and Deutsche Bahn - and key investors - including BASF, Koehler, Klöckner and Körber - BigRep continues to develop complete solutions for integrated additive manufacturing systems, as well as a wide range of printing materials on an open-source basis.

Learn more at www.bigrep.com/engage

BigRep 400 W. Cummings Park, Suite 1675 Woburn, MA 01801 781 281 0569 americas@bigrep.com

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Vendors in the additive industry

CS Hyde Company

CS Hyde Company is your worldwide source for high performance tapes,

films, fabrics, and silicone. For over 20 years we have been serving almost every industry with performance materials for all types of applications. Our newest industry is additive manufacturing/3D Printing. We have created a product line solely dedicated to industrial/home 3D Printers. This category consists of 3D printing surfaces for FDM and SLA printers. Our custom cutting capabilities allow us to cut plastic tape and films to exact dimensions of a build plate or resin tray.

Common materials include ULTEM® PEI, and Optically Clear FEP tape and film.

Our PEI sheets have become one of the top printing surfaces on the market. FDM printers using PEI benefit from a surface with durability and a surface that will hold filament in place and remove cleanly when cooled. Our PEI sheets are also pre-laminated with high temperature 3MTM adhesive that securely bonds to the existing surface of the build plate. We can produce sheets up to 26” wide and offer a variety of thicknesses from .003” to .040”. Common sizes are posted on our online catalog for click and ship availability. If you have a custom size please e-mail resources@cshyde.com and receive a quote today.

CS Hyde Company Phone: 800.461.4161 resources@cshyde.com

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Vendors in the additive industry

HP Multi Jet Fusion 3D Printing Technology

Created in 2015 and based in Silicon Valley, HP Inc. combines the heart and energy of a

start-up with the scale and power of a Fortune 100 multinational corporation. Backed by nearly 50,000 employees and drawing from a 76-year legacy of engineered innovation, the company is focused on creating technology that makes life better for everyone, everywhere. Through our portfolio of printers, PCs, mobile devices, solutions, and services, we engineer experiences that amaze. HP Multi Jet Fusion 3D Printing technology is set to reinvent design and manufacturing, by unlocking the full potential of 3D printing. More information is available at hp.com/go/3DPrint.

HP 1501 Page Mill Road Palo Alto, California 94304-1100 Phone: 877.468.8369

hp.com/go/3DPrint

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ZEISS 3D ManuFACT The integrated holistic inspection process

D ManuFACT egrated holistic ion process ZEISS 3D ManuFACT

wder and terial aracterization M, CT X-ray, LM

ZEISS developed a unique holistic inspection process for 3D manufacturing, applying the concentrated competence of all ZEISS technologies: ZEISS developed a unique + holistic inspection process for 3D +manufacturing, applying the concentrated + Material Microscopy Computer Tomography 3D Scanning Technology competence of all ZEISS technologies: + Tactile & Optical Measuring Technology + Data Analysis & Statistical Tools.

The integrated holistic inspection process

Powder and Material Characterization SEM, CT In-Process X-ray, LM

+ Material Microscopy + Computer Tomography + 3D Scanning Technology + Tactile & Optical Measuring Technology + Data Analysis & Statistical Tools.

In-Process Metrology and Data Analysis

Metrology and Data Analysis

Post-Print Heat Treatment and Part Removal CMM, 3D scanning

Post-Print Heat Treatment and Part Removal CMM, 3D scanning

Defect and Inner Structure Inspection Defect and CT X-ray, LM

Inner Structure Inspection CT X-ray, LM

Post-Print Material Quality Inspection SEM,Post-Print CT X-ray, LM

Process Data Dimensional and Statistics Surface Quality and Analytics Inspection PiWeb, Analytics and CMM, CT X-ray, Dimensional and 3D scanning, LMSurface Quality Correlation tools

Process Data Statistics Material Quality and Analytics Inspection Inspection PiWeb, Analytics and CMM, CT X-ray, SEM, CT X-ray, LM www.zeiss.com/metrology/solutions/additive-manufacturing Correlation tools 3D scanning, LM

ZEISS ensures standards of quality wherever maximum

precision is a must: with multidimensional measurement machines, metrology software and microscope systems for science, research and material inspection. ZEISS plays its part in ensuring that even the tiniest structures and processes become visible.

Around 2,400 employees work for ZEISS Industrial Metrology at manufacturing sites in Germany, China, US and India. In the US, ZEISS has Metrology Centers in Boston, Charlotte, Chicago, Detroit, Irvine, Minneapolis and Nashville.

ZEISS Industrial Metrology metrology@zeiss.com zeiss.com/metrology 1.800.327.9735

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September 2018

www.designworldonline.com

2018

Additive Manufacturing Handbook

SEPTEMBER 2018 COV_ADDITIVE MFG HBK_Vs1.indd 1

9/12/18 1:30 PM

Additive Manufacturing Handbook Itâ&#x20AC;&#x2122;s not a web page, itâ&#x20AC;&#x2122;s an industry information site Stay current with the latest motion control tips, resources, and news, visit motioncontroltips.com and stay on Twitter, Google plus, Facebook and Linkedin. The site is updated regularly with relevant technical information and other significant news to the motion control design community.

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AD INDEX

SALES

Jami Brownlee

3D Platform .............................................................. 47 3D Systems .............................................................IFC AGS Additive Manufacturing............................... 21

jbrownlee@wtwhmedia.com 224-760-1055

Mike Caruso

mcaruso@wtwhmedia.com 469.855.7344

Garrett Cona

CS Hyde Company ................................................... 9

gcona@wtwhmedia.com 213.219.5663 @wtwh_gcona

HP 3D Printing ........................................................ BC

Bill Crowley

BigRep ...................................................................... IBC Zeiss Industrial Metrology.................................... 17

bcrowley@wtwhmedia.com 610-420-2433

Michael Ference

mference@wtwhmedia.com 408.769.1188 @mrference

Michelle Flando

Company Profiles

3D Platform ........................................................................ 48

mflando@wtwhmedia.com 440.670.4772 @mflando

3D Systems ....................................................................... 49

Mike Francesconi

AGS Additive Manufacturing........................................ 50 BigRep ................................................................................... 51 CS Hyde Company ........................................................... 52 HP 3D Printing ................................................................... 53 Zeiss Industrial Metrology............................................. 54

Jim Powers

jpowers@wtwhmedia.com 312.925.7793 @jpowers_media

Courtney Seel

cseel@wtwhmedia.com 440.523.1685 @wtwh_CSeel

LEADERSHIP TEAM

Publisher Mike Emich

memich@wtwhmedia.com 508.446.1823 @wtwh_memich

Managing Director Scott McCafferty

smccafferty@wtwhmedia.com 310.279.3844 @SMMcCafferty

EVP Marshall Matheson

mfrancesconi@wtwhmedia.com mmatheson@wtwhmedia.com 630.488.9029 805.895.3609 @mmatheson

David Geltman

dgeltman@wtwhmedia.com 516.510.6514 @wtwh_david

Neel Gleason

ngleason@wtwhmedia.com 312.882.9867 @wtwh_ngleason

om

rldonline.c

gnwo www.desi r 2018

Septembe

201e8

Check out the digital edition!

So much happens between issues of Design World that even another issue

Additiv ring Manufactu dbook

would not be enough to keep up. That’s why it makes sense to visit designworldonline.com and stay on Twitter, Google plus, Facebook

FOLLOW US ON

and Linkedin. It’s updated regularly with relevant technical information and other significant news to the design engineering community.

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AD INDEX - ADDITIVE MFG_9-18_Vs2.indd 56

DESIGN WORLD

9/17/18 2:38 PM

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