DESIGN WORLD 2019 ADDITIVE MANUFACTURING HANDBOOK

September 2019

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2019

Additive Manufacturing Handbook

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E d i t o r i a l

Additive technology

expands in multiple directions Welcome to the second annual edition of the Additive Manufacturing Handbook. This dynamic industry continues to find new ways to make parts faster, and some of these new methods are included within this issue. But one of the bigger stories on additive this year is the growth of service providers. This industry continues to develop new ways to make objects faster, but which one do you choose for your needs? An excellent approach is to work with service providers. Not only do they typically have all the additive technologies you need, they also have “seen it all,” and can offer excellent advice and guidance so that you get the part you want.

Another big story involves the funding developers of additive technology are getting. For example, Carbon announced it raised more than $260 million in growth funding a few months ago. This latest round brought its total fundraising to more than $680 million.

Markforged in Massachusetts announced earlier in the year that it closed an $82 million Series D round of funding led by Summit Partners with participation from existing strategic and financial partners.

And Essentium, Inc., a provider and innovator of 3D printing solutions for industrial additive manufacturing, closed $22.2 million in Series A funding.

Service providers are growing through funding as well. One example is Fast Radius in Chicago with its recent announcement of $48 million in a Series B funding round led by UPS, with strong insider participation from Drive Capital.

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

Among these pages you’ll find information that describes how many of the additive technologies work. You’ll also read stories on applications, both popular and unique. In addition, you’ll read what various industries leaders have to say about this technology and how they plan to make additive technology more useful for manufacturing.

Given the dynamism of the industry, changes will continue to come.

And we will continue to keep you informed of those changes.

Leslie Langnau | Managing Editor llangnau@wtwhmedia.com

On Twitter @ DW_3Dprinting

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Contents 9

2019 • designworldonline.com

•

04 _3D SYSTEMS

28 _MARKFORGED

Engine manufacturer validates designs with SLS 3D printing

Advancing the use of desktop metal 3D printing

08 _BIGREP

32 _NANO DIMENSIONS

When size matters

How 3D printing can produce a functional RF circuit

10 _CARBON

How additive manufacturing addresses automotive manufacturing challenges 14 _DESKTOP METAL

Post processing options for metal additive parts 18 _EOS

Shaping the future of manufacturing

34 _RENISHAW

Take the stress out of metal additive parts

Company Profiles 50-54

38 _RIZE

3D printing jigs and fixtures with zero post processing 40 _STRATASYS

Building a better 3D printer

20 _FORMLABS

46 _ULTIMAKER

Low force stereolithography delivers better surface finish

Streamlining manufacturing with 3D printing

22 _GE ADDITIVE

Additive manufacturing delivers the scaffolding for growth 24 _HP ADDITIVE

3D printed anatomical models make surgeries easier and faster

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User stories

Engine manufacturer

validates designs with SLS 3D printing A version of this V-twin intake manifold success-

fully underwent 2000 hours of testing on wide-open throttle.

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The Rapid Prototyping Center at Briggs & Stratton has been using Selective Laser Sintering (SLS) 3D printing since 2015 when it acquired a 3D Systems’ SLS printer. Prior to bringing SLS in-house, the products manufacturer used machining, external services, and other in-house printing technologies to meet its prototyping needs. Buying an SLS printer introduced new levels of throughput, durability, and accuracy, as well as cost savings to Briggs & Stratton’s prototyping capabilities.

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The SLS prototyping applications include prototyping blower housings and fuel injector systems, cyclonic air cleaning systems, mufflers and intake manifolds, just to name a few. In addition to proof-of-concept prototyping for nearly all parts, Briggs & Stratton designers include certain SLS parts on engine fitups for early insights into design performance, assembly, and interferences.

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The company’s designers unanimously agree that the greatest advantage of the SLS technology is speed. “The quicker we can get a design in our hands, the sooner we can take next steps,” says Matt Martinek, New Product Development, Briggs & Stratton. “We SLS print just about every part we come up with a new design for.”

The ability to stack parts within the build enables higher throughput, making it possible to build more parts at once and keep up with the continual demand for parts.

Michael Dorna, manager of Briggs & Stratton’s Rapid Prototyping Center, estimates that 30-40% of SLS part orders are tested for function. “With SLS, we get the benefit of tough, durable parts that can also be detailed,” says Dorna.

Citing an extreme application example, Dorna says he received a part request for an SLS printed and epoxy-sealed intake manifold: “The next thing I knew I had an order for six more,” he says. “I found out these SLS parts are used to qualify the design, which means they’re being run on an air-cooled engine for 2000 hours at wide open throttle. That’s a brutal environment, and these parts are holding up.”

Briggs & Stratton currently uses DuraForm® ProX® PA across all of its prototyping applications. DuraForm ProX PA is a durable polyamide 12 nylon material with resolution and mechanical properties for complex parts with thin walls or snap fit requirements. Many of the parts that are functionally prototyped using SLS are ultimately injection molded

¾-scale V-twin that turns with the crank handle; printed as an assembly with only the pushrods printed separately.

in an ABS plastic or glass-filled nylon, however designer Brian Holzman also reports great success using SLS to prototype sheet metal parts. “A lot of the sheet metal parts are 0.8 - 1 mm thick, and the DuraForm material does an awesome job on those,” he says. “It’s durable and flexible, so it’s conducive to thin parts.”

Mechanical designer Jonathan Tyznik works in Briggs & Stratton’s Research & Development group and estimates that depending on where he is in development he requests an average of 1 - 2 to 12 - 15 SLS parts a week. Designer Casey Groh says: “I’ve easily requested a hundred parts or more for the current project I’m working on.”

According to Bob Johnson, a Briggs & Stratton designer for more than 30 years, a coat of spray paint is all it takes to give the SLS parts a close resemblance to their final molded counterparts, and the SLS parts perform similarly as well.

To ensure confidence in final production materials, Briggs & Stratton does not exclusively rely on SLS parts for final pre-production testing, but Johnson says using SLS for certain testing, such as performance and airflow, allows the company to accelerate its validation process.

3D Systems | www.3dsystems.com

This SLS printed cam tensioner lever

spent 500 hours inside a running engine.

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User stories COMPANY

MACHINE NAME

BUILD ENVELOPE (MM; W X D X H)

BUILD MATERIALS

LAYER THICKNESS

BUILD SPEED

3D SYSTEMS

FABPRO 1000 ENTRY-LEVEL INDUSTRIAL 3D PRINTER

125 X 70 X 120 MM (5 X 2.75 X 4.7 IN. )

FABPRO TOUGH BLK, PROTO GRY, JEWELCAST GRN, ELASTIC BLK AND SELECTED NEXTDENT DENTAL MATERIALS - UV CURABLE PLASTICS

0.03 TO 0.1 MM

UP TO 21 MM/HR VERTICAL BUILD SPEED

FIGURE 4 STANDALONE 3D PRINTER

124.8 X 70.2 X 196 MM (5 X 2.75 X 7.72 IN.)

FIGURE 4 TOUGH-GRY 10, TOUGH-GRY 15, FLEX-BLK 10, ELAST-BLK 10, JCAST-GRN 10 - UV CURABLE PLASTICS

0.02 TO 0.1 MM

UP TO 104 MM/HR VERTICAL BUILD SPEED

FIGURE 4 MODULAR 3D PRINTER

124.8 X 70.2 X 346 MM (5 X 2.75 X 13.6 IN.)

FIGURE 4 TOUGH-GRY 10, TOUGH-GRY 15, FLEX-BLK 10, ELAST-BLK 10 - UV CURABLE PLASTICS

0.02 MM MIN.

UP TO 104 MM/HR VERTICAL BUILD SPEED

FIGURE 4 PRODUCTION 3D PRINTER

124.8 X 70.2 X 346 MM (5 X 2.75 X 13.6 IN.)

30+ UV CURABLE MATERIALS

0.02 MM MIN.

UP TO 104 MM/HR VERTICAL BUILD SPEED

NEXTDENT 5100 DENTAL 3D PRINTER

124.8 X 70.2 X 196 MM (5 X 2.75 X 7.72 IN.)

BROAD SELECTION OF NEXTDENT DENTAL MATERIALS - UV CURABLE PLASTICS

0.03 MM MIN.

PROJET CJP 260PLUS COLOR 3D PRINTER

236 X 185 X 127 MM (9.3 X 7.3 X 5 IN.)

VISIJET PXL - CMY COLOURS

0.1 MM

20MM/HR MAX. VERTICAL BUILD SPEED

PROJET CJP 360 3D PRINTER

203 X 254 X 203 MM (8 X 10 X 8 IN.)

VISIJET PXL - WHITE (MONOCHROME)

0.1 MM

20MM/HR MAX. VERTICAL BUILD SPEED

PROJET CJP 460PLUS COLOR 3D PRINTER

203 X 254 X 203 MM (8 X 10 X 8 IN.)

VISIJET PXL - CMY COLOURS

0.1 MM

23MM/HR MAX. VERTICAL BUILD SPEED

PROJET CJP 660PRO COLOR 3D PRINTER

254 X 381 X 203 MM (10 X 15 X 8 IN.)

VISIJET PXL - FULL CMYK COLOURS

0.1MM

28MM/HR MAX. VERTICAL BUILD SPEED

PROJET CJP 860PRO COLOR 3D PRINTER

508 X 381 X 229 MM (20 X 15 X 9 IN.)

VISIJET PXL - FULL CMYK COLOURS

0.1 MM

5-15MM/HR MAX. VERTICAL BUILD SPEED

PROJET MJP 2500 PLASTIC 3D PRINTER

295 X 211 X 142 MM (11.6 X 8.3 X 5.6 IN.)

VISIJET M2R-WT, M2R-BK RIGID PLASTICS, VISIJET PROFLEX M2G-DUR ENGINEERING PLASTIC; MELT AWAY SUPPORT

32μ

PROJET MJP 2500 PLUS PLASTIC 3D PRINTER

295 X 211 X 142 MM (11.6 X 8.3 X 5.6 IN.)

VISIJET PROFLEX M2G-DUR, ARMOR M2GCL ENGINEERING PLASTICS VISIJET M2R-WT, M2R-BK, M2R-CL, M2RGRY, M2R-TN RIGID PLASTICS VISIJET M2 EBK, M2 ENT ELASTOMERIC MATERIALS MELT AWAY SUPPORT

32μ

PROJET MJP 2500W REALWAX 3D PRINTER

294 X 211 X 144 MM (11.6 X 8.3 X 5.6 IN.)

VISIJET M2 CAST - WAX MATERIAL

16μ

PROJET MJP 2500 IC REALWAX 3D PRINTER

294 X 211 X 144 MM (11.6 X 8.3 X 5.6 IN.)

VISIJET M2 ICAST - WAX MATERIAL

42μ

PROJET MJP 3600 PLASTIC 3D PRINTER

UP TO 298 X 185 X 203 MM (11.7 X 7.3 X 8 IN.)

VISIJET M3-X, BLACK, CRYSTAL, PROPLAST, NAVY, TECHPLAST, PROCAST - UV CURABLE PLASTICS

16μ TO 32μ

PROJET MJP 3600 MAX PLASTIC 3D PRINTER

UP TO 298 X 185 X 203 MM (11.7 X 7.3 X 8 IN.)

VISIJET M3-X, BLACK, CRYSTAL, PROPLAST, NAVY, TECHPLAST, PROCAST - UV CURABLE PLASTICS

16μ TO 32μ

PROJET MJP 3600W REALWAX 3D PRINTER

UP TO 298 X 183 X 203 MM (11.7 X 7.3 X 8 IN.)

VISIJET M3 CAST, M3 HI-CAST - WAX MATERIAL

16μ TO 32μ

PROJET MJP 3600W MAX REALWAX 3D PRINTER

UP TO 298 X 183 X 203 MM (11.7 X 7.3 X 8 IN.)

VISIJET M3 CAST, M3 HI-CAST - WAX MATERIAL

16μ TO 32μ

PROJET MJP 3600 DENTAL 3D PRINTER

284 X 185 X 203 MM (11 X 7 8 IN.)

VISIJET M3 DENTCAST, PEARLSTONE, STONEPLAST - DENTAL UV CURABLE PLASTICS

29μ TO 32μ

PROJET MJP 5600 MULTIMATERIAL 3D PRINTER

518 X 381 X 300 MM (20.4 X 15 X 11.8 IN.)

VISIJET CR-CL 200, CR-WT 200, CR-BK; CEBK, CE-NT COMPOSITE MULTI-MATERIAL PRINTING

13μ TO 16μ

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MACHINE NAME (MM; W X D X H)

BUILD ENVELOPE

BUILD MATERIALS THICKNESS

LAYER

BUILD SPEED

PROJET 6000 HD SLA 3D PRINTER

UP TO 250 X 250 X 250 MM (9.8 X 9.8 X 9.8 IN.)

ACCURA 25, XTREME, XTREME WHITE 200, ABS BLACK, CLEARVUE, 48HTR, PHOENIX, SAPPHIRE, E-STONE™

0.025 TO 0.125 MM

PROJET 7000 HD SLA 3D PRINTER

UP TO 380 X 380 X 250 MM (14.9 X 14.9 X 9.8 IN.)

ACCURA 25, XTREME, XTREME WHITE 200, ABS BLACK, CLEARVUE, 48HTR, PHOENIX, SAPPHIRE, E-STONE™

0.050 TO 0.125 MM

PROX 800 SLA 3D PRINTER

UP TO 650 X 750 X 550 MM (25.6 X 29.5 X 21.6 IN. )

ACCURA PLASTICS AND COMPOSITES (WIDEST RANGE, SIMULATING ABS, PP AND PC, HIGH TEMP., FOR CASTING PATTERNS AND OTHER SPECIALTY MATERIALS)

0.05 TO 0.15 MM

PROX 950 SLA 3D PRINTER

1500 X 750 X 550 MM (59 X 29.5 X 21.6 IN.)

ACCURA PLASTICS AND COMPOSITES (WIDEST RANGE, SIMULATING ABS, PP AND PC, HIGH TEMP., FOR CASTING PATTERNS AND OTHER SPECIALTY MATERIALS)

0.05 TO 0.15 MM

PROX SLS 6100 3D PRINTER

381 X 330 X 460 MM (15 X 13 X 18 IN.)

DURAFORM PROX PLASTICS AND COMPOSITES (POWDERS)

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 (15 X 13 X 18 IN.)

DURAFORM PLASTICS, ELASTOMERS AND COMPOSITES, CASTFORM PS (POWDERS)

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 (21.6 X 21.6 X 18 IN.)

DURAFORM PLASTICS AND COMPOSITES (POWDERS)

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 (21.6 X 21.6 X 29.5 IN.)

DURAFORM PLASTICS AND COMPOSITES (POWDERS)

0.08 TO 0.15 MM

3.0 L/HR VOLUME BUILD RATE

DMP FLEX 100 PRECISION METAL PRINTER

100 X 100 X 80 MM* (3.9 X 3.9 X 3.1 IN.)

READY-TO-RUN LASERFORM COCR (B), COCR (C), 17-4 (B), 316L (B) METAL ALLOYS WITH EXTENSIVELY DEVELOPED PRINT PARAMETERS. CUSTOM MATERIAL PARAMETER DEVELOPMENT AVAILABLE WITH OPTIONAL SOFTWARE PACKAGE.

10 μM - 100 μM. PRESET: 30 μM

PROX DMP 200 PRECISION METAL PRINTER

140 X 140 X 100 MM* (5.5 X 5.5 X 3.9 IN.)

READY-TO-RUN LASERFORM COCR (B), 17-4 (B), MARAGING STEEL (B), 316L (B), NI625 (B) AND ALSI12 (B) WITH EXTENSIVELY DEVELOPED PRINT PARAMETERS. CUSTOM MATERIAL PARAMETER DEVELOPMENT AVAILABLE WITH OPTIONAL SOFTWARE PACKAGE.

10 μM - 100 μM. PRESET: 30 μM

DMP FLEX 350 AND DMP FACTORY 350

275 X 275 X 380 MM* (10.8 X 10.8 X 14.9 IN.)

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), ALSI10MG (A), ALSI7MG0.6 (A) AND MARAGING STEEL (A). CUSTOM MATERIAL PARAMETER DEVELOPMENT AVAILABLE WITH OPTIONAL SOFTWARE PACKAGE.

10μM - 100μM PRESET: 30 AND 60 μM

DMP FACTORY 500 SOLUTION

500 X 500 X 500 MM (19.6 X 19.6 X 19.6 IN.)

LASERFORM MATERIALS

ADJUSTABLE, MIN. 2 μM, MAX.200 μM, TYP. 30-60-90 μM

* MAXIMUM AVAILABLE PART SIZE USING STANDARD BUILD PLATE

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Additive technology

The PRO additive manufacturing system.

When size matters How big can you build and how fast can you build are frequent questions from users of additive manufacturing.

BigRep, a global leader in large-scale 3D printing, offers answers through its Metering Extruder Technology (MXT) and its new PRO and EDGE additive systems.

The PRO and EDGE are next-generation 3D printers that help engineers and designers create functional prototypes, composite tooling, and end-use parts in small-number serial production capacity. Both printers can print with highperformance materials for applications in industries such as automotive, aerospace, consumer goods, manufacturing and more.

Metering Extruder Technology establishes a clear separation between filament feeding and melting and

8

molten extrusion. This technology takes full advantage of the printing materials BigRep, in partnership with BASF, develops.

The PRO and EDGE systems have two MXT modular extrusion heads that manage and synchronize the extrusion and printing operations.

This means that: The PRO has printing speeds of >600 millimeters per second (mm/s), using the 0.6 mm nozzle. The EDGE surpasses that with speeds of 1,000 mm/s with the 0.6 mm nozzle.

Demonstrated filament throughput rates are 5x the maximum extrusion rate and 3x the average extrusion rate.

¡ ¡

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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

The PRO handles large-scale industrial parts with a build envelope of one cubic meter and a large, temperature-controlled spool chamber for continuous printing with high-performance materials like ASA/ ABS, nylon and more. The insulated, enclosed metal frame ensures an optimal even temperature control.

The heated print bed is mounted with polyimide foil for better adhesion during the printing process, and an integrated inductive sensor semiautomatically levels the bed.

The EDGE has a print bed measuring 1500 x 800 x 600 mm (59 X 31.5 X 23.6 in.) for end-use parts and functional prototypes. The heated build chamber provides a controlled, high-temperature environment of up to 200° C in the chamber and 220° C in the print bed. The EDGE also has automatic, upward-moving doors and an easy-to-use graphical interface on a large screen for full control over all print settings.

Extrusion technology has largely been unchanged for a quartercentury. But BigRep in partnership with Bosch Rexroth incorporated a state-of-art CNC control system and drives, making the PRO and EDGE systems IoT-ready with full connectivity and data.

Build Speed

up to 140 mm/s at layer height 0.1 mm

Metering Extruder Technology

establishes a clear separation between filament feeding and melting and molten extrusion.

BigRep | www.BigRep.com/nextgen

The Edge additive manufacturing system.

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User stories

Howadditive manufacturing

addresses automotive manufacturing challenges

Ford Motor Company recently developed a dedicated additive manufacturing research program to explore the potential of additive, not just for the rapid development of functional prototypes but also to manufacture final parts that will eventually hit the road. “If we can shave months off of production time and get a new model onto the market earlier, we can save millions,” said Ellen Lee, team leader in

Initially Ford was working with a pre-release version of Carbon’s first device to evaluate its ability to produce commercial-quality polymeric parts by unlocking mechanical properties unattainable with other 3D printing technology.

additive manufacturing research at Ford.

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Company Machine Name

Carbon

M2 Printer

Build Size

Build Materials

Layer Thickness

Build Speed

Layer-less

Variable

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

Carbon Rigid Polyurethane Carbon Elastomeric Polyurethane Carbon Dental Production Carbon Cyanate Ester Carbon Flexible Polyurethane Carbon Medical Polyurethane Carbon Epoxy Carbon Silicone Urethane Dentca Dentures for Carbon Printers Dreve FotoDent Indirect Bonding Tray for Carbon Printers Dreve FotoDent Impression Tray for Carbon Printers Dreve FotoDent Gingiva for Carbon Printers WhipMix Surgical Guide for Carbon Printers Keystone KeySplint Soft™ Clear for Carbon Printers

To date, key challenges have stood in the way of 3D printing/additive manufacturing becoming a manufacturing tool for the automaker. The first issue is a fundamental one — conventional 3D printing technologies make parts layer-by-layer, slowly crafting one layer at a time, creating parts that aren’t nearly as robust as those stamped or injection molded. While the slow speed of this process is a drawback, the bigger problem is that the parts produced are not isotropic and not durable enough to be used in production vehicles.

In addition, most parts used in vehicles must withstand temperature extremes from the hottest desert to the coldest Arctic environments and still maintain their integrity. With only a handful of stock materials available for 3D printers, meeting the automaker’s unique demands has not always been possible.

In 2014, Carbon demonstrated Continuous Liquid Interface Production technology (CLIP) to Ford’s additive manufacturing group. “It was exciting to see the resulting mechanical properties. There were a lot of things we saw in the technology that would address the main challenges, and we decided to investigate,” Lee said.

The team was eager to join Carbon’s early access program and begin using one of the devices. Ford was working with a pre-release version of Carbon’s first device to evaluate its ability to produce commercial-quality polymeric parts by unlocking mechanical properties unattainable with other 3D printing technology.

Ford has already used the CLIP-based device

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Most parts used in vehicles must withstand temperature extremes from the hottest desert to the coldest Arctic environments and still maintain their integrity. With only a handful of stock materials available for 3D printers, meeting the automaker’s unique demands has not always been possible.

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cmy pms

Your partner for innovative manufacturing

black

reverse

Power your additive manufacturing with multi-laser productivity As manufacturers ourselves, we understand the challenges you face. For 45 years, Renishaw has been creating breakthrough innovations that solve manufacturing problems and move productivity to new heights. Renishaw multi-laser AM systems open the door to a new world, bringing more applications within reach of AM technology.

Hydraulic block manifold additively manufactured using four 500W lasers on the RenAM 500Q

RenAM 500Q has four efficiently applied high power lasers that reduce cost per part, while advanced sensors and systems ensure unparalleled processing conditions to deliver consistent class leading performance, build after build.

Allow us to be your partner for innovative manufacturing by combining high productivity AM with our unparalleled breadth of process control technologies for CNC machining processes.

www.renishaw.com/multi-laser

Renishaw, Inc. 1001 Wesemann Drive, West Dundee IL, 60118 T 847-286-9953 F 847-286-9974 E usa@renishaw.com

www.renishaw.com

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User stories

to grow elastomer grommets for the Focus Electric and test them against those made by traditional 3D printing methods. The soft but sturdy grommets protect wiring on the inside of the door from damage when the door opens and closes. The Ford team used CLIP to produce the grommets in less than a third of the time and with material properties much closer to the final properties desired for the part. In a similar project, several alternative designs were evaluated for a damping bumper part on the Ford Transit Connect. The game-changing manufacturing time of the CLIP process allowed engineers to make design iterations more quickly than with traditional methods.

Most recently, Ford needed to address a major engineering issue that arose after placing a V8 engine into a new vehicle body design. The vehicle’s design created an unreachable oil filler cap because the engine sat lower and farther back under the hood. The product engineering team realized

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the opportunity to address the issue using Carbon’s CLIP based device. The team was able to rapidly design, prototype and manufacture an oil connector using rigid polyurethane and elastomer materials to access the oil fill tube without needing major redesigns to several components of the vehicle.

When it comes to realizing Ford’s ambitions to use additive manufacturing as a manufacturing technology, nothing is more important than having the right materials. Thanks to Carbon’s commitment to polymer chemistry and the advantages CLIP technology has to support a broad range of materials, Ford has been able to expand its own materials research efforts.

To date, the team has tested several materials, including resins reinforced with nano-sized particles and is eager to further investigate resin modifications for improved mechanical properties and consider the creation of thermally and electrically conductive materials for www.designworldonline.com

Ford uses Carbon’s CLIP-based additive technology to grow elastomer

grommets for the Focus Electric. The soft but sturdy grommets protect wiring on the inside of the door from damage when the door opens and closes.

future vehicle applications.

“Carbon’s CLIP technology is allowing our engineers to shorten their design iteration time and reach a final-part more quickly, which is exciting because it means higher quality and more cost effective products for our customers,” explained Lee. Carbon | www.carbon3D.com

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Additive technology

Post processing options for metal additive parts In 2019, much attention is on the best ways to post process additively made parts. Nearly all additively made metal parts need secondary finishing as these parts tend to have rough surfaces. The layer-by-layer build process can deliver variations in average roughness (RA) throughout a part. The surface of the part will vary between top, bottom, and the sides. And if there are internal channels, they can be difficult to finish.

The technique chosen to finish additive parts depends on the part’s application. A part for prototype use, for example, may need less post processing than one for a presentation to customers. In another example, a prototype part may be needed to examine tolerances.

Desktop Metal recently tested centrifugal disc, centrifugal barrel, and media blasting techniques on metal parts printed with the Studio System for surface finish. In general, these finishing methods are viewed as aggressive because they deliver frequent abrasive contact to part surfaces, but they offer the advantage of finishing many parts quickly.

Even though additive and 3D printing technologies continually make strides at improving build speed, that is not the total picture. Include in your timing estimates how much additional time will be needed to properly finish a part, especially with parts made from metals.

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Company

Machine Name

Build Size

Build Materials

Desktop Metal

Production System

13 x 13 x 13 in.

(330 x 330 x 330 cm)

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

Studio System + Printer

11.4 x 7.4 x 7.4 (28.9 x 18.9 x 19.5 cm)

17-4PH, 316L, AISI 4140, H13, Copper, Inconel 625

Layer Thickness

Build Speed

50 um

8200 cm3/hr

std resolution = 100-220 um

Max build rate = 16 cm3/hr

high resolution = 50 um

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Additive technology

The surface of the part will vary between top, bottom, and the sides. And if there are

internal channels, they can be difficult to finish.

Centrifugal disc machines consist of a large drum with stationary sides and a rotating disc at the bottom of the drum. The rotating disc moves parts and media upward for efficient de-burring and finishing. A variety of abrasive media can be used.

Polishing media can be mixed with a special liquid compound for tumblefinishing of the parts.

The amount of time parts spend in these machines can be important as it can affect part definition, especially at part edges.

Centrifugal barrel finishing is considered the fastest method of mass finishing. The machine consists of a horizontal main shaft with a circular drive plate that connects to this shaft and rotates in one direction. Octagonal barrels with media, water, liquid compound, and the printed parts rotate in the opposite direction. These actions create a centrifugal force that increases gravitational pull by 15 to 20 times.

In general, this machine is suitable for parts needing longer run-times for finishing.

Media blasting is a good choice when parts have undergone other post-processing methods (such as

16

machining, grinding, or sanding) as it can give parts an overall consistent finish. It uses compressed air to blast a loose, abrasive media through a nozzle to the surface of a part.

Several types of media are available in multiple shapes and sizes to give parts the desired surface quality and reflectivity, such as aluminum oxide, stainless shot, and glass bead. For example, round particles can deliver high reflectivity; angular particles give more of a matte finish.

Different types of media blasting equipment include suction, wetblast, and direct-pressure. Direct pressure is the most aggressive of this selection. Typically, only one part is blasted at a time.

Additions tips to keep in mind: Mass finishing works equally on all sides and edges of the part, but it affects flat surfaces, curved surfaces, and edges differently.

•

There is a difference between • surface smoothness and shine.

The average roughness (RA) measures the smoothness of a part and can be measured with a profilometer.

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Typical batch size differs • based on the type and size of

the equipment. Estimated cost-per-part should be calculated before selecting a finishing method.

The desired surface finish may • impact design specifications,

so it is important to consider the finishing method prior to fabrication. To maintain required tolerances, parts may need to be “over-built” or “masked” in some areas to allow for removal of material during post-processing.

There is no one-size-fits-all • solution for metal finishing. For

some applications, visible printing lines are acceptable and minimal post processing is needed. Different finishing techniques are better suited for applications that require a smooth or bright finish (<60 RA) versus those where a rougher surface finish is acceptable.

Desktop Metal Inc. www.desktopmetal.com

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"Making the Additive Manufacturing Promise Real"

www.thermwood.com 800-533-6901

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9/13/19 8:18 AM

Additive Insights

Shaping the future of manufacturing

With an installed base of nearly 3,500 industrial 3D printing systems, the German family-owned enterprise EOS is a leading supplier of systems for additive manufacturing (AM). When founding the company on April 24, 1989, Dr. Hans J. Langer had a clear vision: produce three-dimensional objects directly from CAD data using laser technology for what was at the time a new rapid prototyping market.

While the early phase of the enterprise was dominated by stereolithography technology, EOS turned to laser sintering in 1997. The powder-bed based process is well suited to today’s rapidly growing market of series applications in terms of quality and reproducibility and the speed and cost of part production.

EOS offered AM systems for processing both polymers and metals, as well as the materials, processes, and software tailored to suit these systems. To support companies in the use of AM technology, EOS founded its consulting unit Additive Minds in 2015. With more than 300 successful customer projects, EOS has a number of experts for AM consulting.

Shaping the future of manufacturing The potential applications for 3D printing are practically unlimited as it is capable of producing flexible, light, and stable parts that only use as much raw material as needed to manufacture the product. EOS technology and know-how are used in a variety of industries and areas of life: such as fuelsaving components in the aviation sector, spare parts on demand for buses and trains, or prostheses individually created to suit each patient.

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The increasing use of AM in serial production scenarios is accompanied by the necessity to integrate this technology in existing production environments. The goal is to achieve flexible production that optimally combines industrial 3D printing and conventional manufacturing technologies in a digital factory.

According to Dr. Adrian Keppler, CEO of EOS: “The establishment of complete digital production platforms is a major goal that we aim to achieve in the coming years.

It’s not just about providing the right 3D printing solutions, but about evaluating, planning, setting-up, and optimizing AM production cells to leverage all the advantages and possibilities of digitalization.”

The EOS ecosystem Established and expanded over many years by Dr. Langer, the EOS Ecosystem is a multi-layered network of EOS investments, the company DESIGN WORLD

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COMPANY

MACHINE NAME

BUILD VOLUME (MM)

BUILD MATERIALS

LAYER THICKNESS

BUILD SPEED

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 P 396

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)

EOS P 500

500 X 330 400 MM (19.7 X 13 X 15.7 IN.)

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)

40 MM/H (1.6 IN. / H); 6.6L/H MAX

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 P 800

700 MM X 380 MM X 560 MM (27.6 X 15 X 22.05 IN)

EOS PEEK HP 3 AMONG OTHERS

TYPICALLY 0.12 MM (0.005 IN)

7 MM/H (0.3 IN/H)

EOS P 810

700 MM X 380 MM X 380 MM (27.6 X 15 X 15 IN)

HT-23 FROM ADVANCED LASER MATERIALS (ALM)

120 µM

UP TO 10 MM/H (0.4 IN/H); UP TO 2,7L/H

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 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 - 30µM DEPENDING ON MATERIAL

NA

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

EOS M 300-4

300 MM X 300 MM X 400 MM (11.8 X 11.8 X 15.8 IN)

METALS

EOS M 400

400 MM X 400 MM X 400* MM (15.8 X 15.8 X 15.8 IN)

MARAGING STEEL, COBALT CHROME, TITANIUM, NICKEL ALLOY, ALUMINIUM

30 - 90µM DEPENDING ON MATERIAL

SCANNING SPEED: UP TO 7.0 M/S (23 FT/S)

EOS M 400-4

400 MM X 400 MM X 400* MM (15.8 X 15.8 X 15.8 IN)

MARAGING STEEL, TITANIUM, NICKEL ALLOY, ALUMINIUM, STAINLESS STEEL

30 - 60µM DEPENDING ON MATERIAL

SCANNING SPEED: UP TO 7.0 M/S (23 FT/S)

PRECIOUS M 080

Ø 80 MM X 95 MM (HIGH, INCLUDING BUILDING PLATTFORM)

METALS

LESS THAN 30 UM

SCANNING SPEED: UP TO 7.0 M/S (23 FT/S)

AM Ventures, and external partners that support promising start-ups. The cooperation between the various companies combines expertise to enable the implementation of customer-specific manufacturing solutions along the entire value chain – from the initial idea to design and engineering, production, post-processing, and ultimately the finished part. For example, one field of application with potential is the aerospace industry to

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SCANNIN SPEED: UP TO 7.0 M/S (23 FT/S)

enable further innovation in rocket engines.

Even after 30 years, EOS remains true to its mission statement: Shaping the future of manufacturing.

EOS | www.eos.info

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Additive technology

Low Force Stereolithography

delivers better surface finish Thanks to investments made during the recent 3D printing hype cycle, vendors have

introduced new ways to extrude and cure photopolymer resins. For example, Formlabs recently introduced Low Force Stereolithography (LFS).

LFS is a variation on stereolithography. Like traditional stereolithography, it uses a vat of photo-reactive resin and an illumination source to cure the resin into three-dimensional objects. However, there are a few key differences: The printer uses a parabolic mirror to create a perpendicular laser spot. This feature ensures uniformity across the build platform.

A feature called the flexible tank keeps the need for part supports minimal. The flexible tank reduces the peel forces needed during printing.

The Light Processing Unit (LPU) includes a custom enclosed optics engine to build parts with consistency and accuracy. The laser beam in the LPU passes through a spatial filter to catch stray light. A galvanometer positions the laser beam in the Y direction. The unit includes a fold mirror and a parabolic mirror to ensure the laser beam is always perpendicular to the print plane. Fine details are possible through the linear path the laser takes.

• • •

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The Light Processing Unit contains a galvanometer that controls the direction of the laser, as the entire LPU unit moves across the build area. The Form 3 contains 1 LPU unit where the Form 3L contains 2.

Company

Machine Name

Build Size

Build Materials

Layer Thickness

Build Speed

FORMLABS

FORM 2

14.5 × 14.5 × 17.5 CM 5.7 × 5.7 × 6.9 IN

PHOTOPOLYMER RESIN

25-300 MICRONS .001-.012 IN

DEPENDENT ON GEOMETRY, IN GENERAL 1-3 CM/HR ALONG THE Z AXIS WHEN PRINTING AT 100 MICRONS

FUSE 1

16.5 X 16.5 X 32 CM, 6.5 X 6.5 X 12.6 IN

NYLON POWDER

199 MICRONS .008 IN

10 MM/HR

FORM CELL

UP TO 10 FORM 2 3D PRINTERS OR FORM WASH UNITS HOUSED TOGETHER WITH ROBOTIC GANTRY ARM

PHOTOPOLYMER RESINS

25-300 MICRONS .001-.012 IN

DEPENDENT ON SETUP

FORM 3

14.5 × 14.5 × 18.5 CM 5.7 × 5.7 × 7.3 IN

PHOTOPOLYMER RESINS

25-300 MICRONS .001-.012 IN

DEPENDENT ON GEOMETRY AND MATERIAL, BUILD SPEED WILL BE AVAILABLE AS MATERIAL SETTINGS SHIP

Low Force Stereolithography (LFS) is an advanced form of SLA printing that uses a flexible tank and linear illumination to turn liquid resin into flawless parts.

The laser has a spot size of 85 microns and an increase in power at the print plane of 25%. Stereolithography uses a layer-by-layer process to build objects. As in all layer-bylayer processes, surface finish is affected by a layer’s alignment with the previous layer. With the flexible tank, the bond formed between the printed part and the tank is gently broken to prepare for the next layer. For example, an inverted stereolithography 3D printer tends to exert a large force on the layers of the part, resulting in a step appearance on the surface.

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LFS reduces the stresses from this force by gently peeling the layer away as the build platform pulls the part up. Thus, build objects need only minimal support.

The print speed is adaptable.ABG Formlabs | www.formlabs.com

www.designworldonline.com

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User Stories

Additive manufacturing

delivers the scaffolding for growth A key application of additive manufacturing is in the development of spinal implants. A team at Nexxt Spine are pioneers in the design and development of spinal fusion implants that incorporate interconnected microlattice architectures with the goal of promoting osteoconduction, osteointegration, and boney fusion. They found that additive technology not only adds value to their products, it is helping their company grow as well.

“Additive is booming,” says Alaedeen Abu-Mulaweh, director of engineering at Nexxt Spine a medical device company focused on designing, manufacturing and distributing innovative spinal implant solutions. The company designs and manufactures 100% of its implants exclusively from its facility in Noblesville, Indiana. Abu-Mulaweh began his additive journey two years ago.

Established in 2009 and initially producing speciality spinal screws, rods, and plates using conventional subtractive manufacturing techniques, Nexxt Spine’s first

investment in metal additive technology was the acquisition of a Concept Laser Mlab 100R in 2017.

“We used the first Mlab primarily for R&D purposes, but we soon realised that further investment in additive technology could add value not only to our overall growth strategy, but also at a clinical application level with the ability to develop implants with intricate micro-geometries that could maximize healing.

We have made a seamless jump from R&D to serial production and in doing so have significantly accelerated the time from concept

The Nexxt Matrixx system is a collection of porous titanium spinal fusion implants that interweave highly differentiated surface texturing technology with novel 3D printed cellular scaffolding.

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to commercialization,” Alaedeen continues.

The investment in Concept Laser Mlab machines allowed the Nexxt Spine team to take ownership of the entire design, production and distribution process in-house, eliminating the need for contract manufacturers, thereby accelerating development and commercialization.

Focus on core science One of Nexxt Spine’s flagship products, launched in 2017 is its Nexxt Matrixx System - a collection of porous titanium spinal fusion implants that interweave highly differentiated surface texturing technology with novel 3D-printed cellular scaffolding.

However, while other medical manufacturers have used additive DESIGN WORLD

9/17/19 2:18 PM

Company

Machine Name

Build Size (mm)

Build Materials

Layer Thickness

Build Speed

MLAB CUSING

50 X 50 X 80 MM (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

NA

1-5 CM3/H (DEPENDING ON MATERIAL)

MLAB CUSING R

70 X 70 X 80 MM (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

NA

1-5 CM3/H (DEPENDING ON MATERIAL)

MLAB CUSING 200R 70 X 70 X 80 MM (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*

NA

1-5 CM3/H (DEPENDING ON MATERIAL)

GE ADDITIVE CONCEPT LASER

50 X 50 X 80 MM3 (X,Y,Z); 2 X 2 X 3.12 IN. M1 CUSING

250 X 250 X 250 MM (X,Y,Z); 9.84 X 9.84 X 9.84 IN.

CL 20ES, CL 50WS, CL 91RW, CL NA 92PH, CL 100NB, CL 101NB REMANIUM STAR CL

2-15 CM3/H (DEPENDING ON MATERIAL / LASER POWDER)

M2 CUSING

250 X 250 X 280 MM (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

NA

2-20 CM3/H (DEPENDING ON MATERIAL)

M2 CUSING MULTILASER

250 X 250 X 280 MM (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

NA

2-35 CM3/H (DEPENDING ON MATERIAL / LASER POWDER)

M LINE FACTORY

400 X 400 X UP TO 425 MM (X,Y,Z); 15.75 X 15.75 X 16.73 IN.

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

NA

NOT STATED

X LINE 2000R

800 X 400 X 500 MM (X,Y,Z); 31.5 X 15.75 X 19.68 IN.

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

NA

UP TO 120 CM3/H (DEPENDING ON MATERIAL / GEOMETRY)

manufacturing to develop devices that directly mimic bone’s trabecular Some medical manufacturers use additive manufacturing to develop devices geometry, Nexxt Spine chose to deviate that directly mimic bone’s trabecular geometry, Nexxt Spine chose to deviate from the status quo and instead blend from this and instead blend cellular porosity, inspired by natural bone biology, cellular porosity, inspired by natural with core engineering fundamentals to develop structurally sound devices, bone biology, with core engineering optimized for fusion. fundamentals to develop structurally sound devices, optimized for fusion.

“Titanium – porous or otherwise - is physically incapable of biological remodeling, so using additive to mimic the structural randomness of bone doesn’t make a whole lot of sense. Nexxt Matrixx was designed with functionality to fulfil our vision of actively facilitating the body’s natural power of cellular healing,” continues Alaedeen.

“We are seeing ongoing adoption of additive manufacturing in the orthopaedic industry and an exciting shift from research and development to serial excited for what the future holds for production,” says Stephan Zeidler, senior to serial additive manufacturing production, Nexxt Spine is wellus,” comments Alaedeen. global and key accounts director for the placed to service and scale, as medical sector at GE Additive. needed, to meet the growth in GE Additive | www.ge.com/additive demand for spinal fusion device.

Additive opens up new frontiers

“Like I said, additive is With design, manufacturing and distriabsolutely booming. We are butions functions in-house, and the shift

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User stories

3D printed anatomical models

make surgeries easier and faster

At Rady Children’s Hospital in San Diego, CA, 3D printed heart models serve to educate patients and their families regarding the complicated anatomy of the heart and also provide surgeons with the opportunity to inspect the patient’s specific anatomy, develop a surgical plan, and even test the plan in advance of the actual surgery to ensure accuracy and limit the chances for complications.

Such models helped Leanne Wilbert with her son’s condition.

“We found out that our son had a heart condition called transposition of the great arteries, where the two main arteries are switched,” she said. “We knew pretty far in advance that he was going to need open-heart surgery.”

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Surgeons can practice an upcoming surgery with full color models of organs, like this heart of a young girl with a complex heart defect. The heart was printed using HP’s Jet Fusion 300 / 500 3D printer.

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The 3DI Lab at Rady Children’s Hospital in San Diego, CA, uses an HP Jet Fusion 580 Color 3D printer to help surgeons plan operations and help explain those operations to patients.

Company Machine Name HP

Build Volume in mm

Build Materials

Layer Thickness

Build Speed

HP Jet Fusion 3D 4210/4200/3200 Printing Solutions

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

HP 3D High Reusability PA 11 HP 3D High Reusability PA 12 HP 3D High Reusability PA 12 GB Vestosint 3D Z2773 PA 12

0.08 mm (0.003 in)

4115 cm³/hr (251 in³/hr)

HP Jet Fusion 5200 Series 3D Printing Solution

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

HP 3D High Reusability PA 11 0.08 mm (0.003 in) HP 3D High Reusability PA 12 Girbau DY130 Dyeing Solution9

5058 cm³/hr (309 in³/hr)

HP Jet Fusion 540/340 3D Printer

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

CB PA 12 material

0.08 mm (0.003 inches)

1,817 cm3/hr (111 in3/hr)

HP Jet Fusion 580/380 Color

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

CB PA 12 material

0.08 mm (0.003 inches)

1,817 cm3/hr (111 in3/hr)

HP Metal Jet

430 x 320 x 200 mm (16.9 x 12.6 x 7.9 in)

316L stainless steel MIM powder

1200 x 1200 dpi addressability in a layer 50 to 100 microns thick

NA

But obtaining 3D printed models could be a challenge for the physicians. For several years, the orthopedics department and the cardiology unit either 3D printed anatomical models using FDM printers or outsourced the models.

Outsourcing had its drawbacks; projects could take at least two weeks to complete and often could only be delivered during business hours. The costs of outsourced 3D models were also a burden for the hospital: A small FDM model could cost between $600 and $700 USD, and larger models could cost in excess of $1,200 USD. Due to the lengthy production schedule, Rady Children’s was only able to complete about one to two outsourced projects per month.

Ultimately, these departments needed to bring more 3D printing technology in-house to reduce

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turnaround time and enable new innovations in the medical domain.

The decision to bring 3D printing technology in-house came about when Justin Ryan, Ph.D., joined Rady Children’s to start the hospital’s new 3D Innovations (3DI) Lab (which was launched in July 2018). He developed an interest in HP Multi Jet Fusion technology when the medical staff learned about its ability to produce delicate and resilient structures, which had

“3D printed heart models educate patients and their families on the anatomy of the heart, and allow surgeons to inspect that anatomy before surgery and limit complications.” www.designworldonline.com

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User stories

“The HP MultiJet Fusion delivers accuracy, the potential for color, good mechanical properties, and consistency. You can just have one of these elements and sacrifice other ones, especially for a hospital where consistency and accuacy are critical.”

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been a challenge with the hospital’s former binder jetting technology.

Therefore, the 3DI Lab made sure to include the HP Jet Fusion 580 Color 3D printer in its new facility.

“The HP Multi Jet Fusion captures the anatomy very well,” says Dr. Ryan. “The spatial resolution and mechanical properties are great, especially compared to competing technologies.”

For Wilbert’s son, the surgical team obtained an image of his heart from a computerized tomography (CT) scan, and after creating a computerized 3D version of the heart, they printed it to scale using HP Multi Jet Fusion technology and HP 3D High Reusability CB PA 12 material.

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With the 3D anatomical heart model in hand, the surgeon was able to practice surgery and try different approaches. In closely inspecting the 3D part, the surgeon was even able to identify a second ventricular septal defect (VSD), also known as a hole in the heart.

“We knew [our son] had one [VSD], but once we had that imaging, we were able to see that there was another small one,” Wilbert says.

“[The surgical team] knew in advance exactly what they were going to be facing and exactly what they needed to do to make sure that it was done smoothly without any complications,” Wilbert added.

“We feel that this should be in every single hospital; everyone should have the opportunity to have it done.”

Benefits to hospitals Depending on the ultimate goal, computerized 3D models may require further refinement. For example, anatomical models for surgical planning may need to be color-coded or virtually cut to reveal deeper structures, while parts of educational models may need to be simplified or exemplified to display different types of anatomy or pathology.

Notes Dr. Ryan, “Since they know very intimately what the anatomy looks like, they perform the surgery with greater confidence and under less time, which has incredible implications: If you can reduce surgical time, you in fact reduce anesthesia time and bypass time, which has a direct correlation on the reduction of complications— especially stroke events.”

“With some of the other technologies, we would print duplicate models knowing that one might not make it—one or two might break,” says Dr. Ryan. “We

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haven’t had to do that with HP. This is really due to the ideal mechanical properties.”

With in-house production capabilities, instead of waiting 4 days or more for an anatomical model, the doctors now can produce a model for a critical patient and have it ready to review the following day, or even the same day. With HP MJF as an integrated point-of-care process, Rady Children’s has noticed savings in both time and expenses compared with outsourcing.

“Operating room time has a correlation to cost,” says Dr. Ryan.

Mayo Clinic reports that one minute of their OR time is between 80 and 150 USD, so if you can save a few minutes of operating time by having a model better educate a surgical team, that’s going be a great way to save on resources.”

In addition, the HP Multi Jet Fusion delivers accuracy, the potential for color, good mechanical properties, and consistency: “You can’t just have one of those elements and sacrifice other ones,” he says, “especially for a hospital where consistency and accuracy are critical.”

With HP Multi Jet Fusion, “I have better peace of mind than with our other current technologies. It’s been great in terms of its consistency, and that’s something that I come to expect from the HP name.”

HP | www8.hp.com

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Additive Insights

Advancing the use of

desktop metal 3D printing Desktop metal 3D printing is still a rare technology, but that doesnâ&#x20AC;&#x2122;t stop one of the leading vendors in this market from developing products that improve this technology. Jon Reilly, VP of Product, Markforged, gives us a closer look at these developments.

Q: You recently announced an

AI powered software for

additive processes. How do

you see AI affecting this

and other areas of Additive Manufacturing?

A: Traditionally, manufacturing machines have gone through the same motion of making parts with no awareness of the actual part they are making - without intervention they will happily make thousands of out of spec parts. With the help of sensors and AI, a machine can compare the part it makes to the CAD intent.

Engineers at a Canadian integrated energy services company were tasked with creating an automated handling machine to load large glass reinforcement tape pads, which weigh between 115 and 230 lb. The goal was to reduce changeover time and increase plant throughput. The pad handling machine consists of 53 unique 3D printed parts.

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Company

Machine Name

Build Size

Build Materials

Layer Thickness Build Speed

Desktop Series

Onyx One

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

Chopped carbon only

100 micron

Desktop Series

Onyx Pro

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

Continuous fiberglass

100 micron

Desktop Series

Mark Two

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

All continuous fibers

100 micron

NA

Industrial Series

X3

330 x 270 x 200 mm (12.99 x 10.6 x 7.87 in.)

Chopped carbon

50 micron

NA

Industrial Series

X5

330 x 270 x 200 mm (12.99 x 10.6 x 7.87 in.)

Continuous fiberglass

50 micron

NA

Industrial Series

X7

330 x 270 x 200 mm (12.99 x 10.6 x 7.87 in.)

All continuous fibers

50 micron

NA

Metal X

250 x 220 x 200 mm (9.8 x 8.6 x 7.8 in.)

Aluminum, inconel, titanium, stainless steel, tool steel

50 micron

NA

Markforged

NA

Several of the 3D printed parts for the pad handling machine were reinforced with Kevlar, HSHT fiberglass, and carbon fiber.

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Additive Insights

Mechanical designers used their Markforged composite printer to fabricate tools and fixtures for a pick and place machine.

Metal 3D printing on the desktop is still a rare technology, but that doesnâ&#x20AC;&#x2122;t stop one of the leading vendors in this market from developing products that improve this technology.

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Blacksmith - the first adaptive manufacturing AI - allows any production system that has controls to self-adjust and get closer to a perfect part. We are starting with Additive Manufacturing, but Adaptive Manufacturing naturally extends to a variety of existing manufacturing processes. Take CNC for example, by inspecting the actual part produced and automatically modifying the tool path for the next part, we can tighten tolerances and eliminate process drift - all of which improves yields and reduces out of spec parts.

Improving yields translates directly into lower part cost and reduced scrap and waste.

Blacksmith is better for the environment, and will help bring down the cost of a lot of products.

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Q: What are some of the

challenges of growing metal additive manufacturing?

Is it acceptance, education, something else?

A: The number one challenge is education. When you introduce a breakthrough, new way to make parts, it’s naturally going to take a while for everyone to understand the process and how it can be leveraged to improve their business.

With the Metal X system, it’s more affordable and easier than ever to rapidly prototype metal parts, build tooling and fixtures for digital manufacturing lines, and replace low volume after-market service parts. We have created Markforged University to help companies overcome the education barrier and adopt additive manufacturing at scale.

Q: What are some of the design

challenges in working with metal and composite materials for users?

A: Like any manufacturing technique - engineers need to design for the process. Being able to go through and identify what sections of a part require specific properties, what environment the part needs to perform in, and how the part needs to behave under a load are all critical to identifying the best additive solution for the application.

When you’re designing a part for composites, continuous strands of fibers are essential to 3D printing a strong part. To take full advantage of the strength of the fibers, you need to think about how your design can leverage the strength of the continuous fibers to increase the strength of your part. Likewise,

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metal 3D printing is a three-step process that involves printing, washing, and sintering. Taking full advantage of the process requires an understanding of what each step can do to your part. A part that’s very tall and skinny, for example, could collapse in a furnace if not supported well. Adding tapers or flanges to your design will improve its inherent stability in the furnace and create a more successful part.

Q: Tell me a bit about your flame

retardant Onyx material?

Some of its properties, best applications, and so on.

A: Onyx FR (Flame Retardant) is a V0 rated carbon fiber filled Nylon. We introduced it to meet an incredibly common request from our automotive, aerospace, and defense customers. In many of their applications you need an engineering grade material that self-extinguishes when exposed to flame. Like all of our plastics, Onyx FR can be reinforced with continuous strands of carbon fiber - unlocking flame-retardant 3D printed parts that are as strong as aluminum at half the weight.

Markforged www.markforged.com

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Additive technology

How 3D printing can

produce a functional RF circuit

Can a 3D printer be used to make functional radio frequency (RF) circuits?

That’s the question Harris Corporation, a leading technology innovator of electronic products that connect, inform and protect, set out to answer.

Working with Nano Dimension, a developer of 3D printers designed to include electronics, the two companies began a study on the advantages of using additive manufacturing to develop RF circuits for wireless systems as part of a joint project with the Israel Innovation Authority and Space Florida Foundation, a partnership promoting research development and the commercialization of aerospace and technology projects.

The project included designing, simulating, and testing a 3D printed RF amplifier and comparing it with the performance of an amplifier developed with conventional manufacturing techniques, using FR4 substrate material as a baseline.

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Creating an RF circuit for conveying information such as data, video and voice across long distances is typically a long, complex multi-stage process when using conventional manufacturing methods. Consequently, achieving optimum performance is an iterative process: create a design, produce the RF circuit, test its performance, improve the design, and repeat the process until an optimum design is reached. In practice, optimizing performance in this manner can be expensive and lead times are long.

Harris engineers chose the Nano Dimension’s DragonFly Pro system and were able to 3D print functional RF circuits. A 101 mm x 38 mm (4 in. x 1.5 in.) x 3 mm thick circuit was 3D printed in 10 hours. Nano Dimension’s silver nanoparticle conductive and dielectric inks were used to create the functional electronic parts in a single print and then components were manually soldered to the PCB.

To assess the quality of the 3D printed RF circuit versus one

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manufactured with traditional methods, Harris used amplifier measurements that tested for small signal gain, input return loss, and output return loss.

The resulting data showed similar RF performance between the 3D printed and the baseline amplifiers, demonstrating the viability of 3D printing technology to produce a functional RF circuit with performance comparable to those developed using conventional manufacturing techniques.

• There was no noticeable difference in the input or output return loss response over the frequency range from 10 MHz to 6 GHz. • No noticeable difference was detected in the gain of the 3D printed circuit and the conventionally manufactured amplifier. The gain difference between the 3-D printed circuit and the conventionally manufactured circuit was less than 1 dB up to 4.7 GHz and less than 1.3 dB up to 6 GHz.

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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.

With the DragonFly Pro, circuits and systems that have rigid packaging integrated with flexible circuits can be produced in a single print without the need for cables and connectors.

The performance of the 3D printed RF circuits was comparable

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with the traditionally manufactured circuits. An added bonus was the ability to use in-house 3D printing to make RF amplifiers. This ability drastically reduced the cost and time required per iteration so that RF amplifier manufacturers can iterate several versions in

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less time than with traditional methods. Other advantages of 3D printed electronics include the ability to save time by evaluating several design variations at one time, and fabricate complex electronic systems that cannot be manufactured by conventional means.

“The ability to manufacture RF systems in-house offers an exciting new means for rapid and affordable prototyping and volume manufacturing,” said Dr. Arthur Paolella, Senior Scientist, Space and Intelligence Systems, Harris Corporation. “The results of the study provide substantial motivation to develop this technology further.”

Nano Dimension www.nano-di.com

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Additive technology

Takemetal the stress out of additive parts Even though additive manufacturing (AM) gives designers more freedom to design geometrically complex objects, there are some limitations. One of which is cost. While a designer can create anything from his/her imagination, it may not be manufacturable. Or, the part may require additional processing steps to ensure specific mechanical features.

The laser powder-bed fusion additive process, for example, can bring residual stresses to parts made with this technology. Residual stress occurs because of the rapid heating and cooling of the laser as it sinters each layer in the build process.

Remember, powder bed fusion is a layer-by-layer build process. Thus, as the laser moves over a fresh sweep of powder, it melts that layer fusing it to the layer it melted

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While a designer can create anything from his/her imagination, it may not be manufacturable. Or, the part may require additional processing steps to ensure specific mechanical features.

COMPANY

RENISHAW

MACHINE NAME

BUILD VOLUME (MM)

BUILD MATERIALS

RENAM 500M METAL ADDITIVE MANUFACTURING SYSTEM

250 X 250 X 350 MM

AISI10MG, IN625, IN718, TI6AI4V

AM 400 METAL ADDITIVE MANUFACTURING SYSTEM

250 X 250 X 300 MM

AISI10MG, COCR, IN625, IN718, STAINLESS STEEL 316L, TI6AI4V

THE RENAM 500Q

250 X 250 X 300 MM

Residual stress occurs because of the rapid heating and cooling of the laser as it sinters layers on top of one another in the build process. Just as quickly as the laser heats the top layer, the hot metal begins to cool and solidify. As that top layer cools, it contracts. Because this layer is constrained by the already built solid layers below it, the contraction sets up shear forces between the solidified layers, which introduces residual stresses.

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Additive technology

One way to reduce residual stress is to include a hatching pattern within the part.

Here are several hatch patterns recommended by Renishaw.

Even though additive manufacturing (AM) gives designers more freedom to design geometrically complex objects, there are some limitations. One of which is cost.

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previously. The laser in effect creates weld pools which adhere the layers together. This process happens in microseconds. But, just as quickly as the laser heats up the top layer, the hot metal begins to cool and solidify. As that top layer cools, it contracts. Because this layer is constrained by the already built solid layers below it, the contraction sets up shear forces between the solidified layers, which introduces residual stresses.

Each layer can have residual stresses, which can eventually build to the point of distorting the part. This distortion can take the form of layers curling up at the edges or layers pulling away from supports. In extreme cases, the stress may exceed the strength of the material and part design, leading to cracking, or the part can be brittle and crumble and break easily. In other cases, the residual stress could distort the build plate.

Parts with large cross-sections tend to experience these effects the most because the long weld tracks give shear forces more distance to act.

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Tips to reduce residual stress One way to reduce residual stress is to include a hatching pattern within the part. In hatching, the laser is moved back and forth in a pattern that varies the length of the scan vectors. The following are hatch patterns recommended by Renishaw.

•

• The Meander Hatching Patten

creates a 67° rotation after each layer. It offers a high build rate and is suitable for small and thin features.

part, so factor that in if tolerances are important.

Thus, in summary: Design out residual stresses where possible Avoid large areas of uninterrupted melt Be careful about changes in cross-sections Use thicker build plates where stress is likely to be high Select an appropriate scan strategy

• • • • •

Renishaw | www.renishaw.com

• The Stripe Hatching Pattern

creates a homogenous distribution of residual stresses.

This pattern suits large parts.

• The Chessboard Hatching Patten

divides each layer into 5 by 5 mm islands and uses a 67° rotation of the whole pattern and each island after each layer. It too creates a homogenous distribution of residual stresses. It is also suitable for large parts.

While a designer can create anything from his/her imagination, it may not be manufacturable. Or, the part may require additional processing steps to ensure specific mechanical features.

• The orientation of scan vectors

can be rotated from one layer to the next so that stresses are not all aligned in the same plane.

A rotation of 67 degrees is typically used between each layer to ensure that it is many layers before the scanning direction is exactly repeated.

• Another technique is to heat the

build plate to reduce residual stresses. Often, vendors will recommend that a part be placed in a furnace or in some heat treatment to reduce the effect of residual stress. Such treatments will tend to shrink the final dimensions of a

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User stories

3D printing jigs and fixtures with zero post processing

When it comes to the production of jigs, fixtures, and other manufacturing tooling, 3D printing is proving to be a reliable, capable, and affordable choice over more traditional methods.

For HMS Industries Inc., in Blairsville, PA, a manufacturer of custom metal stamping and industrial tooling, 3D printing solved their search for a fast and affordable way to produce strong jigs and fixtures that secured parts during production for consistent manufacturing. HMS provides highquality manufacturing services, including product and prototype development, EDM, tool design, tool and die manufacturing, as well as high-volume stampings and CNC machining, to manufacturers across all industries.

Consulting with Cimquest Inc., a Rize Authorized Reseller, HMS chose to use the Rize One 3D printer from Rize Inc., a Boston based, next-generation additive manufacturing company. HMS cited Rize’s zero-post-processing, isotropic part strength as two of the reasons for the purchase.

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Previously, HMS built jigs and fixtures from aluminum, costing as much as $1,000 each. This required a specially trained team member to be taken off another job to produce the part.

With their Rize One 3D printer, HMS employees design and print parts on demand in one day, freeing up a team member and saving up to two days per fixture vs. producing aluminum fixtures, and only costing approximately $40.00 per part.

Moreover, Rize’s safe and sustainable biocompatible materials and process, without any VOCs or postprocessing, enables the HMS team to operate Rize One in their tool shop without the need for any special ventilation, storage or disposal equipment.

HMS also uses Rize’s 3D printed marking capability to indicate, right on the part, the location where the part

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A benefit of Rize’s 3D printers is the ability to mark and indicate, right on the fixture, the location where a part should be placed and part numbers for identification.

Company

Machine Name

Build Size

Build Materials

Layer Thickness

Build Speed

Rize

Rize One

300 x 200 x 150 mm (12 x 8 x 6 in.)

Rizium One thermoplastic

0.25 mm

No info available

Even if painted brown, 3D printed placement fixtures save up to two days per fixture versus producing aluminum fixtures.

should be placed and part numbers for identification.

Noting that a digital model cannot tell the whole story, the HMS team also prints complex parts to assist in the quoting process before machining the parts. This avoids the additional time and high cost of potentially having to re-machine the parts and increases customer satisfaction.

“Our first 3D printer, my team was able to learn how to use Rize One and be up and running in less than twenty minutes,” said Barry Aikins, Vice President at HMS Industries, Inc.

Said Andy Kalambi, President and CEO of Rize, “We purpose built Rize One with an appliance user experience to bring simplicity, safety and speed to industrial 3D printing and HMS Industries, a first time 3D printing user, has demonstrated its value beyond doubt.”

Rize | www.rize3d.com

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Additive Insights

Building a better

3D printer

Additive manufacturing continues to be a dynamic industry. Scott Sevcik, VP of Manufacturing Solutions, Stratasys takes a look into what developments you can expect in the near future.

Q What can users of extrusion-based 3D printers expect in terms of

future developments, especially in regards to speed and accuracy?

A You’ll see significant advances in speed and accuracy coming from many different sources. There’s a lot of inefficiency in non-print time and extrusion today, and that will be eliminated through architectural changes, software changes, changes to the tool pathing algorithms among other developments.

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Boom Supersonic is building the world’s fastest supersonic aircraft for commercial travel. They signed a 7-year agreement with Stratasys to leverage the full range of printers for prototypes and end-use parts.

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Company

Technology

Stratasys

material extrusion

Printer

Build Envelope (mm)

Model Material Options

F120

10 x 10 x 10 in.

ABS, ASA, SR30 and others

Layer thickness (mm) 0.013 in.

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, PCISO, PC, PC-ABS, FDM Nylon 12

Down to 0.127

FORTUS 380mc Carbon Fiber

355 x 305 x 305 mm (14 x 12 x 12 in.)

FDM Nylon 12CF Carbon Fiber and ASA

from 0.330 mm to 0.254 mm, depending on material

FORTUS 450mc

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

ABS-M30, ABS-M30i, ABS-ESD7, ASA, PCISO, 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, PCISO, 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.)

MODEL: Rigid Opaque: VeroWhitePlus, VeroGrayTM, VeroBlueTM, VeroBlackTM, VeroBlackPlusTM, Simulated Polyproylene: RigurTM, Durus, High Temperature

28 microns , 16 microns for VeroClear Material

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 jetting: 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)

Stratasys

Stratasys Polyjet

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Additive Insights

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Polyjet Dental Systems

Metal 3D printing

SL

OBJET30 ORTHODESK

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

MODEL: VeroDentPlus - Clear Bio-compatible - 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 Bio-compatible - VeroGlaze

Layer thickness 16 microns

OBJET EDEN-260VS DENTAL ADVANTAGE

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

MODEL: VeroDentPlus - Clear Bio-compatible - VeroGlaze

16 microns - accuracy 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 gum-like 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

20 x 20 x 23 in.

Various resins

1000 ips

LPM (Layered Powder Metallurgy)

V650 Flex

The Stratasys production-level manufacturing floor machine

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You’ll also see advances that decouple the throughput and accuracy trade-offs with material extrusion. Right now, you either print really slow for feature resolution or you print really fast and do post machining. What’s needed is the ability to localize where you need accuracy without affecting throughput on the whole part, especially with the demand from big parts that are accurate and detailed.

So, in the next few years you’ll see systems that address the challenge of being big, being accurate and not having to wait a week for your parts to be done.

The next generation will architecturally enable us to do more with the software. Right now, throughout the industry, the architectures are fairly rigid and I think you’ll see more dynamic, more configurable systems to enable us to do more to break that throughput and accuracy trade off.

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This new elastomer material is being used across manufacturing environments as some of the most durable, flexible 3D Printed material for production parts. It is actively being used at such customers as Polaris in Minnesota.

Q

Are you able, at this point, to give any kind of a guesstimate of the percentage improvement capital equipment venue allows in speed and accuracy? us to address a broader range of applications for those capital A From a speed standpoint you’re equipment customers as well. going to see 200%, 300%, 500% improvement; 2X to 5X is what we’ll Q What is the development state see over the next few years.

of the metal additive

manufacturing system Stratasys has been Q Recently Stratasys announced

a stereolithography system.

working on?

What was the reasoning

behind that?

A We started talking last year about Layered Powder Metallurgy, A Outside the industry, a lot or LPM, which is a new metals of people think 3D printing is technology unlike any of the all one technology and all the existing metal printers that are technologies are interchangeable. out there today. We continue to The reality is that each of the progress well on the metal projects nearly dozen additive technologies that have been announced. But has applications which are better there’s no new announcements to or worse, either technically or share at this time. We believe our economically. As we’ve built our Layered Powder Metallurgy will be service business at Stratasys a compelling technology for more Direct Manufacturing, we got a economical printed metal parts out strong appreciation for where each for production applications, in the additive technology fits, and we near future. learned that stereolithography is very complimentary to our FDM and Q What are some of the PolyJet technologies. For example,

challenges you see with shifting you want a multi-color multi-textured additive technology into faster design model? You’re going to use

manufacturing production?

PolyJet. You want an investment casting pattern, then you’re A There are many challenges going to use stereolithography. facing additive manufacturing Adding stereolithography to our production. Speed and economics

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“In the next few years, you’ll see additive systems that address the challenge of being big, accurate, and of not having to wait a week for your parts to be done.”

September 2019

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Additive Insights

are always the first to be raised, but there are other stakes. We focused heavily on repeatability over the last few years. Manufacturers need to trust that they are going to get the part they expect every time.

That’s absolutely fundamental to manufacturing. We’ve demonstrated with FDM levels of repeatability that are unprecedented, and in some cases are better than traditional technologies. And that ability to demonstrate repeatability, the ability for our customers to trust the part quality, that’s now leading to the development of standards. So, we have a published qualification with the National Institute of Aviation Research that is moving through the Society of Automotive Engineers.

It will be called an AMS7100, which is a standard for FDM Additive Manufacturing that’s based on our ability to hit those very high levels repeatedly. Standards, of course, make adoption easier within the supply chain. So, reaching high levels of repeatability is fundamental for any technology to be accepted for adoption.

There are other things, of course. Tools are vital, so we’ve been working with providers of simulation tools like MSC, Siemens, the Source Systems and CAD tool as well to ensure that engineers have all the tools they are used to using with traditional technologies.

If you can’t simulate an additive part accurately, you’re going to over design that part or you’re going to be forced to design and test more. So those same tools that engineers are using for traditional technologies, until those are accurate and useful for additive technologies, there will continue to be a bias to use the traditional technologies that designers are used to.

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Q What are some of the

challenges with additive in industries like aerospace?

A Aerospace is, I would say, out in the lead with regard to most other industries in terms of adopting additive. They were the first to really pull FDM in particular into tooling. So, there have been thousands of tools produced by aerospace companies to support aircraft production and spacecraft production. And now, as we have focused on repeatability, we work on material properties. Some of those same early adopters for tooling have been the ones pushing the boundaries for production.

We see Lockheed Martin and NASA building the alliance phase leveraging our technology and the Antero material that we provide for that. Airbus and Launch Alliance go back several years in terms of using our technology to put parts on launch vehicles and the A350. And we’re seeing that accelerate now with more companies outside of these big-name industry leaders.

We’re seeing the supply chain start to follow suit so we know many Tier 1 aircraft interiors manufacturers that are qualifying the technology and delivering parts to the OEMs or to the airlines. We just recently saw Diehl Aerospace and the curtain headers that they’ve printed for installation on A350s. This is growing as we’ve focused on their needs of repeatability in parallel with their needs for simulation tools.

Stratasys | www.stratasys.com

September 2019 www.designworldonline.com

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User stories

Streamlining

manufacturing with 3D printing At the Ford pilot plant in Cologne, Germany, each new vehicle design has a trial manufacturing run before it goes into mass production. The pilot plant is a small-scale manufacturing line where engineers can experiment with design and manufacturing processes before full production. Lars Bognar, Research Engineer at Fordâ&#x20AC;&#x2122;s Research & Advanced Engineering team in Aachen, has been working on optimizing the workflow to create jigs, tools, and fixtures for the manufacturing process.

Most car designs require custom tooling specific to one task and one car model.

Creating the tools externally takes time and is expensive. To get tools faster, the engineering and manufacturing teams at Ford decided to see what 3D printing could offer.

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The Ford pilot plant in Cologne, Germany, is a small-scale manufacturing line where engineers can experiment with design and manufacturing processes before full production of new vehicle designs.

Company

Machine Name

Build Volume (mm)

Materials

Layer Resolution

Build Speed

Ultimaker

ULTIMAKER 2+

223 x 223 x 205 mm (8.7 x8.7 x 8 in.)

Open material system and Ultimaker optimised materials

0.25 mm nozzle: 150 to 60 micron 0.4 mm nozzle: 200 to 20 micron 0.6 mm nozzle: 400 to 20 micron 0.8 mm nozzle: 600 to 20 micron

0.25 nozzle: up to 8 mm³/s 0.4 nozzle: up to 16 mm³/s 0.6 nozzle: up to 23 mm³/s 0.8 nozzle: up to 24 mm³/s

ULTIMAKER 2 EXTENDED+

223 x 223 x 305 mm 8.7 x 8.7 x 12 in. )

Open material system and Ultimaker optimised materials

0.25 mm nozzle: 150 to 60 micron 0.40 mm nozzle: 200 to 20 micron 0.60 mm nozzle: 400 to 20 micron 0.80 mm nozzle: 600 to 20 micron

0.25 nozzle: up to 8 mm³/s 0.40 nozzle: up to 16 mm³/s 0.60 nozzle: up to 23 mm³/s 0.80 nozzle: up to 24 mm³/s

ULTIMAKER 3

215 x 215 x 200 mm (8.5 x 8.5 x 7.8 in.)

Open material system and Ultimaker optimised materials

0.25 mm nozzle: 150 - 60 micron 0.4 mm nozzle: 200 - 20 micron 0.8 mm nozzle: 600 - 20 micron

< 24 mm³/s

ULTIMAKER 3 EXTENDED

215 x 215 x 300 mm (8.5 x 8.5 x 11.8 in.)

Open material system and Ultimaker optimised materials

0.4 mm nozzle: 20 - 200 micron

30 - 300 mm/s

ULTIMAKER S5

330 x 240 x 300 mm Open (13 x 9.4 x 11.8 in.) material system and Ultimaker optimised materials

0.25 mm nozzle: 150 to 60 micron < 24 mm³/s 0.40 mm nozzle: 200 to 20 micron 0.60 mm nozzle: 400 to 20 micron 0.80 mm nozzle: 600 to 20 micron

Many manufacturing plants implement 3D printing to optimize their manufacturing process.

DESIGN WORLD

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User stories

Initially, the Ford engineer team used selective laser sintering (SLS) technology, but it added to the post processing steps. The design team experimented with extrusion technology from Ultimaker. It delivered a fast, affordable solution with less hassle.

“By having a dedicated 3D workshop in the plant, Ford produces the right tool design before a new car goes into mass production. This ability gives engineers more time to iterate the designs of all the custom tools.”

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A dedicated additive manufacturing team was founded and they began a successful project using selective laser sintering (SLS) technology. The results were good, but the parts needed specific postprocessing. That’s why the team started using extrusion technology from Ultimaker. It delivered a fast, affordable solution with less hassle.

In addition, not only engineers but local workforces are able to use these 3D printers to create the tools they need.

Many manufacturing plants implement 3D printing to optimize their manufacturing process.

However, by having a dedicated 3D workshop in the pilot plant, Ford produces all the right tool design before a new car goes into mass production. This ability gives the engineers more time to iterate the designs of all the custom tools.

The engineers want to create tools that speed up the manufacturing time of the vehicles as well as offer ergonomic benefits for the workforce.

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9/17/19 2:00 PM

Now, Ford is placing Ultimaker 3D printers in factories all over Europe, notably in Spain, Italy, and Romania. The design team in Germany will supply the designs electronically, and the tools will be 3D printed and shipped back to Germany by the next day.

But Ford is also going a step further. Using Trinckle generative software Paramate, workers in these plants can generate jigs without much experience in 3D design. The team in Cologne will create components they can use for the tools such as handles and magnet holders. The engineer will load the design of the car, add handles, an open space where they need to add a part to the car, and the software will generate the jig.

This design can be sent directly to Ultimaker Cura and printed locally with their onsite Ultimaker S5 machines.

So far, this pilot project has been beneficial to Ford. Per custom tool, the company has saved a considerable amount of money compared to traditional manufacturing or outsourcing.

The Ford Focus, for example, is manufactured using more than 50 custom designed tools, jigs, and fixtures. Ford is also looking at spare parts for production machines from the manufacturing line. By printing these parts, they increased the uptime of the machines and the manufacturing line is no longer paused for long.

As for the ergonomic benefits, Ultimaker’s range of materials are strong enough to replace metal tools, cutting weight and making the job easier for assembly personnel.

Ford is expanding their 3D printing capabilities rapidly. While optimizing the workflow to create tools, jigs, and fixtures, they’re learning more about the possibilities of 3D printing. Lars is not only

DESIGN WORLD

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The Ford Focus is manufactured using more than 50 custom designed tools, jigs, and fixtures.

looking to create tools and fixtures, but also exploring possibilities to create spare parts and final parts using 3D printing. “We want to design for additive manufacturing and print production parts for production vehicles.”

Ultimaker | www.ultimaker.com

www.designworldonline.com

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2019

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

TM

TM

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

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2019

Vendors in the additive industry

HP Multi Jet Fusion 3D Printing Technology

HP Inc. creates technology that makes life better for everyone, everywhere.

Through our portfolio of personal systems, printers, and 3D printing solutions, we engineer experiences that amaze. More information about HP Inc. is available at www.hp.com/go/3DPrint.

Products: • HP Jet Fusion 5200 Series 3D Printer • HP Jet Fusion 4200 Series 3D Printer • HP Jet Fusion 500/300 Series 3D Printers • HP Metal Jet https://www8.hp.com/us/en/printers/3d-printers.html

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

hp.com/go/3DPrint

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Vendors in the additive industry

Mimaki USA

Mimaki is a global industry leader of wide-format inkjet printers, cutting plotters, 3D modeling machines, software, hardware and associated consumable items. The company engineers and manufactures a complete range of products that provide a total workflow solution for the sign graphics, textile & apparel, industrial products and 3D markets.

Mimaki USA Josh Hope 150 Satellite Blvd. NE, Ste. A Suwanee, GA 30024 Toll Free: 888-530-3988 www.Mimakiusa.com/3D

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2019

Vendors in the additive industry

Renishaw Renishaw is one of the world’s leading

engineering and scientific technology companies, with expertise in precision measurement and healthcare. We are also a leading manufacturer of advanced metal additive manufacturing systems and provider of custom tailored solutions. We offer a total solution for metal additive manufacturing, from systems, metal powders, ancillaries and software; all with expert advice and support. Our advanced metal additive manufacturing systems are designed and built by Renishaw to fulfil a range of industry applications where durability, customized parts and precision are key.

Also called 3D printing, AM is a process used to create three dimensional parts from a digital file. It usually involves building up, or solidifying, thin layers of material to create complete parts.

The technology enables the production of complex shapes which cannot be produced by ‘traditional’ techniques such as casting, forging and machining.

Additive manufacturing (AM) introduces new design possibilities for metal parts, including opportunities to combine multiple components in production, minimize material use and reduce tooling costs.

Our expertise in process development and experience in using the technology in our own manufacturing operations enable us to provide turn-key and optimized additive manufacturing solutions for a broad range of applications.

Renishaw, Inc. 1001 Wesemann Drive West Dundee, IL 60118 (847) 286-9953 usa@renishaw.com www.renishaw.com DESIGN WORLD

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Vendors in the additive industry

THERMWOOD Thermwood Corporation, located in Southern Indiana and established in 1969, manufactures both three & five axis CNC machining centers and Large Scale Additive Manufacturing (LSAM) systems. The LSAM can perform both the “additive” and “subtractive” functions on the same machine. This approach, called “near net shape”, uses carbon or glass fiber reinforced thermoplastic material to quickly create a part that is nearly, but not exactly, the final net shape. The “subtractive” function then machines the part to the exact final net shape.

Thermwood’s LSAM system can use a variety of materials from low temperature to high temperature applications and is used for the production of large to very large tools, molds, masters, patterns, plugs and fixtures. A variety of industries including aerospace, automotive, marine, foundry, thermoforming and more can use the LSAM system.

LSAM can print either horizontally or vertically, allowing for the printing of parts as long as the table.

Thermwood is a US based company with dealers and distributors worldwide. In addition to machine manufacturing and software development, Thermwood has a technical service organization that provides support, machine installation, training, retrofits, custom programming and production assistance.

Please visit www.thermwood.com, call 1-800-533-6901 or email info@thermwood.com for more information.

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Thermwood Corporation 904 Buffaloville Rd Dale, IN 47523 Toll-Free 800.533.6901 Telephone 812.937.4476 info@thermwood.com www.thermwood.com

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2019

Additive Manufacturing Handbook

Change Service Requested

1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114

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Additive Manufacturing Handbook www.makepartsfast.com Itâ&#x20AC;&#x2122;s not a web page, itâ&#x20AC;&#x2122;s an industry information site Stay current with the latest additive manufacturing technologies, resources, and news, visit makepartsfast.com and stay on Twitter, Facebook and Linkedin. The site is updated regularly with relevant technical information and other significant news to the additive manufacturing community.

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AD INDEX

SALES

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Company Profiles

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EVP Marshall Matheson

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cmy pms

Your partner for innovative manufacturing

black

reverse

Power your additive manufacturing with multi-laser productivity As manufacturers ourselves, we understand the challenges you face. For 45 years, Renishaw has been creating breakthrough innovations that solve manufacturing problems and move productivity to new heights. Renishaw multi-laser AM systems open the door to a new world, bringing more applications within reach of AM technology.

Hydraulic block manifold additively manufactured using four 500W lasers on the RenAM 500Q

RenAM 500Q has four efficiently applied high power lasers that reduce cost per part, while advanced sensors and systems ensure unparalleled processing conditions to deliver consistent class leading performance, build after build.

Allow us to be your partner for innovative manufacturing by combining high productivity AM with our unparalleled breadth of process control technologies for CNC machining processes.

www.renishaw.com/multi-laser

Renishaw, Inc. 1001 Wesemann Drive, West Dundee IL, 60118 T 847-286-9953 F 847-286-9974 E usa@renishaw.com

www.renishaw.com

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Unlock Manufacturing Possibilities

Whether you want to create prototypes or ďŹ nal parts, we can help you to produce lightweight parts with optimal mechanical properties, even at low volumes.

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