Here‘s what happened in the Additive Manufacturing industry last week. Read about 3D printing from metal to plastic, from industry to small businesses, from production to bleeding-edge innovations.
As we move through the month of February, the 3D printing industry has already gotten off to an impressive start. This past week, additive manufacturing has continued on its momentous path, leading to yet another fresh slate of news stories, announcements, and technological innovations.
In this week’s 3D printing digest: Markforged receives an investment from a U.S. intelligence-backed VC, GE Research gains access to the world’s top supercomputer, Formlabs partners with the dental materials company BEGO, and more!
Renowned for its metal and composite 3D printing technology, the Massachusetts-based additive manufacturing startup Markforged has had little trouble getting investors and manufacturers lined up at the door. Past financing rounds have included the likes of Microsoft Ventures and Porsche SE.
But this past week, Markforged received its most interesting and top-secret investment yet, pulling in a strategic investment from In-Q-Tel, Inc., a non-profit investor that identifies and accelerates technologies in support of U.S. intelligence agencies like the CIA.
This investment will likely lead to certain intelligence organizations adopting the Markforged Metal X 3D printer, which is able to print metal parts from materials like copper, tool steel, and superalloys. This groundbreaking system employs a technology called Atomic Diffusion Additive Manufacturing (ADAM), using an FDM-like process that builds up metal parts layer by layer.
Markforged has also been praised for its industrial composite 3D printing systems like the Mark Two, which can produce parts made from continuous carbon fiber, Kevlar, and more.
The Metal X and Mark Two have already been adopted in government and defense sectors across the United States. For example, the U.S. military already has hundreds of machines operating in three different contents to support combat operations, using the 3D printer for machinery repair, tool creation, and field operations.
“Markforged stands out as a leading innovator in additive manufacturing,” said Clayton Williams, Technical Staff, Field Technologies at IQT. “We’re excited to begin this partnership with them to further our mission to support our government partners.”
In other news, GE Research was awarded access to the Summit Supercomputer at the Oak Ridge National Laboratory (ORNL). One of the world’s top supercomputers, GE researchers plan to use in order to optimize the efficiency of jet engines and power generation equipment.
The access comes in lieu of the U.S. Department of Energy choosing the GE project as one of the 47 winners of the Innovative and Novel Computational Impact on Theory and Experiment (INCITE) program. The competitive program awards various science and engineering projects with access to some of the world’s most powerful supercomputers.
This competitive and peer-reviewed program grants time for advanced science and engineering projects to harness the power of some of the nation’s most powerful supercomputers. Through the INCITE program, GE Research’s computational fluid dynamics division is receiving 590,000 node-hours to use on the Summit Supercomputer.
The team intends to improve jet engine and power generation design by using newly-advanced Large Eddy Simulations (LES) to examine how complex flow characteristics impact gas turbine performance. This time will also be used to focus on finding new ways to incorporate 3D printed components that will make these engine systems more efficient and improve performance.
“We’re able to conduct experiments at unprecedented levels of speed, depth and specificity that allow us to perceive previously unobservable phenomena in how complex industrial systems operate,” said Michal Osusky, the project’s leader from GE Research’s Thermosciences group. “Through these studies, we hope to innovate new designs that enable us to propel the state of the art in turbomachinery efficiency and performance.”
In this new project focused on jet engine and power generation design, the GE Research team will analyze a number of factors, including flow mixing, boundary layer transition, separated flows, multiscale flow structures and coupling between high pressure turbine components. In the past, researchers from GE have leveraged the power of the Summit Supercomputer to improve cycle power plant efficiency, wind energy output, jet engine performance, and more.
Following the release of the Form 3B dental 3D printer and launch of its very own Dental Business Unit, the Massachusetts 3D printing unicorn Formlabs has continued its crusade into the dental industry. This week, Formlabs announced a partnership with BEGO, a German manufacturer of prosthodontics and dental implants.
Through the new collaboration, the two companies intended to bring both temporary and permanent 3D printed crowns and bridges to the dental market. Formlabs will be able to offer dental customers to BEGO’s wide range of dental materials, providing them with the ability to 3D print crowns for patients right on the spot.
Founded back in 1890, BEGO has been developing 3D printing materials for over 20 years. Utilizing these resins, dental professionals using the Formlabs 3B or Form 2 will be able to 3D print temporary crowns and bridges as well as permanent single crows, inlays, onlays, and veneers.
“Directly printing temporary crowns and bridges are one of the most sought after applications from Formlabs customers,” explained Dávid Lakatos, Chief Product Officer at Formlabs. “By partnering with BEGO and leveraging their 130 years of dental experience, we will be able to not only address this need, but take it a step further by offering materials for permanent crowns.”
By enabling customers to 3D print dental restorations within Formlabs’ digital workflow, this partnership will lead to reduced production costs, faster turnaround time, and improved patient care. The 3D printing materials developed by BEGO offer unique benefits such as low discoloration and aging rates, low plaque accumulation, and high comfort because of minimal temperature sensitivity.
Both Formlabs and BEGO will be presenting their joint dental 3D printing collaboration at LMT Lab Day this weekend in Chicago, Illinois.
With the ability to 3D print custom circuit boards in just a matter of hours, the Israeli 3D printing company Nano Dimensions has raised a lot of eager eyebrows with its DragonFly Pro 3D Printer.
This week, Nano Dimension revealed that it would be further expanding its operations into the United States, announcing the opening of a new headquarters in South Florida. Located in the city of Boca Raton, the new office will help the company support its growing customer base in the U.S.
The headquarters will serve as Nano Dimension’s main center for sales, customer support, logistics, and training. It will also function as a demonstration center to showcase the technology to prospective American customers.
Last month, co-founder and former CEO Amit Dror was replaced by Yoav Stern. The new headquarters in South Florida demonstrates Stern’s intention to scale the growth of the company and expand into new markets.
With the opening of this office, Nano Dimension will also employ additional team members to accelerate the production of High Performance Electronic Devices (Hi-PEDs), which signifies a positive turnaround following news that the company cut 20% of its workforce back in 2019.
“From here the company will launch our AME Service Bureau,” said Stern. “There we shall convert digital electronic CAD/CAM files into sophisticated Hi-PEDs, ready to be installed in electronic assemblies and connected to electrical power.”
Nano Dimension’s new headquarters in Boca Raton, Florida will officially open on March 19, 2020. The company already has two other main offices located in Israel and Hong Kong.
While Stratasys has offered customers access to full-color PolyJet 3D printing technology for quite some time, the additive manufacturing pioneer is now focused on making this incredible industrial-grade technology more affordable. This past week, at 3DEXPERIENCE World in Nashville, Tennesee, the company unveiled its new J826 3D printer, which is approximately half the cost of other J8-series machines.
Offering a build volume of 255 x 255 x 200mm build volume, the J826 3D printer utilizes the same PolyJet materials as other 3D printers in its class. This machine is compatible with a full range of textures, VeroUltraClear transparency, and PANTONE-Validated color1, providing a wide array of realistic colors to improve the prototyping stage and overall design process.
Engineered to provide designers and enterprises with the ability to speed up the design cycle and produce highly realistic prototypes. Of course, the real selling point here is the reduced price tag, lowering the entry point for professionals that want to incorporate full-color 3D printing into their production workflow. According to Stratasys, the J826 is ideal for customers with mid-volume modeling requirements, especially for those working in the fields of consumer goods, electronics, automotive, and educational institutions.
Aside from the full-color capabilities and lower cost, the J826 3D printer has some other perks too, such as full GrabCAD Print software support and multiple print modes that makes it easy for users to set the speed and quality of the printing process. Overall, the Stratasys J826 enables same-day printing and simple post-processing while ensuring the same high resolution and impeccable detail expected from other J8-series 3D printers that cost double the price.
“We believe that exceptional resolution, full color, multiple materials, and high productivity should not be the province of the few,” said Shamir Shoham, Vice President, PolyJet Business Unit at Stratasys. “That’s why we extended the power of our world-class J8-series 3D printers to the new J826 – addressing the needs of mid-volume enterprise shops and educational institutions at a lower price.”
The J826 3D printer is already being leveraged by the UK-based medical company BiologIC Technologies, which is developing advanced medical instrumentation. Its first flagship product architecture will be fully 3D printed using the J826, enabling them to produce an ultra-realistic prototype and personalize medicine once the product is manufactured. On top of that, BiologIC Technologies Co-Founder Nick Rollings, stated in a press release that the newly acquired 3D printer saved the company both time and costs.
Most recent headlines involving the 3D printing unicorn Formlabs have centered around the startup’s expansion into the dental market with the specialized Form 3B 3D printer. But this past week, the Massachusetts-based SLA technology pioneer returned its attention to the Form 2 and Form 3 with the release of Tough 1500 Resin.
Resilient and highly durable, Tough 1500 Resin is capable of producing parts that bend and spring back quickly under cyclic loading. This material is ideal for functional prototypes, jigs and fixtures, as well as connectors that will need to return to shape after bending, such as springs, hinges, snap fits, and more.
Formlabs claims that its new resin is the most resilient of the entire Tough and Durable Resin line. In fact, it’s engineered to replicate the strength and stiffness of polypropylene, a thermoplastic material commonly used in several consumer packaged goods products. Striking a balance between elongation and modulus, the “1500” in Tough 1500 Resin stands of the tensile modulus of this material.
Tough 1500 Resin is already being used by Unplugged Performances, a company specializing in performance upgrades for Tesla vehicles, such as customized car bumpers. Using a Formlabs 3D printer, Unplugged Performance is 3D printing new sensor mounts in batches of 30, greatly reducing the time it took to remove sensor mounts from the bumper.
Prior to the incorporation of this new resin, it took the company around 45 minutes to remove each sensor, increasing its throughput from one car per 1.5 days to three cars per day. Because Tough 1500 Resin offers the ability to clip mounts onto various sensors in a secure way. Plus, leveraging the grey color of the new resin, Unplugged Performance has been able to create customized visible parts that blend with the interior of the car.
We’ve all taken an Uber or used another rideshare app to get around at one point or another, and perhaps in the future, you’ll be getting dropped off at a 3D printed hotel! This week, it was revealed that Travis Kalanick, the co-founder of Uber, was investing in a 3D printed hotel concept called Habitas.
Along with other investors, such as Tinder co-founder Justin Mateen and Indian ad-tech billionaire Div Turakhia, the hospitality startup has raised $20 million to expand its concept into Asia, Africa, and the Middle East. The influx of tech money demonstrates some excitement for this sustainable and high-tech hotel, which co-founder Oliver Ripley calls the “Club Med for our generation.”
Founded back in 2014, Habitas was conceived at the renowned arts festival Burning Man. The startup will leverage an unspecified 3D printing technology to build hotels, which has already manifested in Tulum, Mexico.
Habitas is capable of constructing modular hotels like Legos in just six to nine months, much faster than traditional hotels, which take between four to five years to build. The startup plans to open a Namibian hotel this month, as well as eight locations by the end of 2020.
Rooms at the hotel cost between $200 to $400 per night. In the future, the company may expand its concept to tackle issues like social housing. All in all, Habitas aims to offer more than a place to rest your head, but instead takes a note from Burning Man and allow human beings to connect with one another.
Back in 2017, the Massachusetts-based startup Markforged released its groundbreaking 3D printer: the Markforged Metal X. Using a technology coined as Atomic Diffusion Additive Manufacturing (ADAM), the process builds up metal parts layer-by-layer, embedding a metal powder rod inside of plastic filament. Markforged already offers a wide assortment of materials, including aluminum, different grades of stainless steel, and nickel.
This past week, Markforged unveiled a new material for its metal 3D printing system: Markforged Copper. Made with more than 99.8% copper, this material offers incredible thermal and electric conductivity, as well as high ductility. In fact, it provides nearly double the amount of electric conductivity than the aluminum material.
Markforged has developed this material for customers who typically avoid copper because of the difficult processing challenges that come with this material. Surprisingly enough, Markforged Copper is as easy to print with as any other metal materials engineered for the Metal X.
With Markforged Copper, customers will be able to produce parts that require a high degree of thermal or electrical conductivity, including heat sinks, welding shanks, and bus bars.
This groundbreaking material will eliminate the need for brazed or welded assemblies, effectively reducing production costs and improving part consistency. The manufacturer also states that Metal X users will be able to experiment with copper parts that have complex internal cooling channels.
All in all, Markforged Copper aims to satisfy low-volume production lines looking to manufacture complex copper parts without the overhead costs of tooling. It’s also well-suited for functional prototypes that can be tested before sending off designs for production.
When MakerBot rolled out the industrial-grade MakerBot Method 3D printer back in 2019, it signified a notable shift from consumer to professional 3D printing. But the well-established 3D printer manufacturer hasn’t forgotten how it earned its stripes, through its unrivaled leadership in the educational setting.
This week, MakerBot launched SKETCH Classroom, a 3D printing ecosystem tailored for specific classroom environments. The new program utilizes MakerBot 3D printers and a full-fledged educational solution, providing students with better access to 3D printing tools and resources. Aiming to help teachers better prepare their students for the job market, MakerBot intends to make 3D printing training a key part of the educational curriculum, particularly by improving the 3D printer-to-student ratio and overall workflow.
That’s where MakerBot SKETCH Classroom comes in. At the center of this educational package is the new MakerBot Sketch 3D printer, a new machine specifically designed for the classroom setting. But it isn’t just the hardware that is engineered for students and teachers, SKETCH offers a workflow solution to ensure that all students have easy and efficient access to the 3D printer. This includes printer management software that provides out-of-the-box access to print design, preparation, and management.
“With SKETCH, we are changing the way 3D printing is used in schools and advancing the possibilities of learning to boost student innovation. We believe that SKETCH Classroom is the best 3D printing setup for the classroom, with an ideal student-to-printer ratio, making 3D printing more accessible to students, and setting educators up for 3D printing success,” said Nadav Goshen, CEO, MakerBot.
For teachers, the selling point for MakerBot SKETCH is the ease of use and tinker-free setup, giving them more time to educate students with their 3D printing curriculum. The built-in filter and enclosed chamber also make the 3D printer exceptionally safe for the classroom setting. According to MakerBot, its team has tested the SKETCH 3D printer for over 46,000 hours to ensure system reliability and print quality testing.
Features like full integration of SKETCH into the MakerBot Cloud are expected in the coming months. The SKETCH Classroom 3D printer and ecosystem will make its way in classrooms in North America starting this month and will be available in other regions shortly thereafter.
As models will strut the runway at London Fashion Week starting next week, the female-led additive manufacturing organization Women in 3D Printing will kick-off the week-long extravaganza by co-hosting an event called FUTURE FASHION TEXTILE TECHNOLOGY.
Working alongside the London-based 3D printing and architectural firm Hobs 3D, the co-working space The Trampery, and The Stratford Hotel London, the FUTURE FASHION TEXTILE TECHNOLOGY will highlight the ever-evolving intersection between 3D printing technology and fashion. The day-long event, which takes place on Tuesday, February 11, at The Stratford Hotel London, will focus exclusively on 3D printed fashion, including a pop-up exhibition and a panel discussion.
Designers presenting at the event include Ganit Goldstein, Annie Foo, Mingjing Lin, Petit Pli, Lucy Wheeler, and Mark Bloomfield. Visitors can take a gander through the exhibitions during the day, while the panel will take place in the evening. Additionally, Hobs 3D will be demonstrating how technologies like 3D printing are being used in fashion design. Kadine Hames, Hobs3D creative director and a chair of Women in 3D Printing UK, will be at the event.
Another exhibitor at the FUTURE FASHION TEXTILE TECHNOLOGY will be HOT:SECOND, a concept store that trades physical garments for digital experiences. This unique storefront will be showcasing its virtual reality digital tailoring solution.
At the panel, which will discuss the duality and interdependence of technology and fashion, speakers will include Karinna Nobbs, the founder of HOT:SECOND, designer Ganit Goldstein, designer Martina Spetlova, and David Leigh, the CEO and strategy director of SWIM XYZ. It will be chaired by Patrick Scally, House Manager of The Trampery, Fish Island Village.
Over the last few months, we’ve seen a few shake-ups on the executive level of several additive manufacturing companies, from Stratasys to Voxel8. This week, the established 3D printing veteran 3D Systems announced that president and CEO Vyomesh (VJ) Joshi had notified the Board of Directors that he would be retiring.
Joshi will remain in his executive role until a new CEO is appointed. From there, the 65-year-old will transition to a strategic advisor for the company. 3D Systems is working with the executive search firm Spencer Stuart to find a successor. After joining 3D Systems as CEO back in April 2016, Joshi helped the company achieve financial stability, bolster product quality, and expand the portfolio of 3D printing hardware, materials, software, and services.
“A lot of personal reflection and discussion with the Board have gone into my decision. The deciding factor was our full confidence that 3D Systems is ready for the next level. “We are poised for growth and we have built a great team, a strong culture and a powerful portfolio. I am honored to have led 3D Systems through such a pivotal stage and position the company for profitable growth in its next chapter.”
The executive announcement comes as the company planned to discuss its 2019 fourth quarter financial results over a conference call with shareholders in the coming weeks. During that quarter, 3D Systems anticipates revenue ranging between $163 million to $165 million.
One of the most glaring issues surrounding the National Football League and American Football at large is player safety. The sports equipment manufacturer Ridell is using 3D scanning and 3D printing to improve helmet safety, and now, the NFL has awarded three students from the Duke Engineering school in support of their 3D printing startup.
What started as undergraduate students producing a customized 3D printed collarbone brace for an injured Duke football player (and current New York Giants quarterback Daniel Jones), the successful result led the three students to form Protect3D.
During the NFL’s 1st and Future Innovations challenge, which was held in Miami during the festivities surrounding Super Bowl LIV, Protect3D was awarded a $50,000 grand prize and two tickers to the big game. The competition asked groups to present innovative solutions for player health, safety, and performance. Protect3D presented its business model and technology, showcasing how 3D scanning and 3D printing was used to create customized protective devices optimized for each individual athlete’s comfort.
The team of undergraduate students was mentored by Ken Gall, associate dean for entrepreneurship at Duke Engineering. They also received guidance and support from the Due Innovation CoLab, which offered access to 3D printers, as well as the Pratt Student Shop, which lent the students a 3D scanner to conduct the scan of Daniel Jones. Protect3D has been operating out of a startup incubator called the Breakthrough Research Initiative to Develop Global Entrepreneurs (BRiDGE).
Courtesy of a grant, two of the students were able to focus on Protect3D full-time after they graduated, while the other continued to work on the startup while enrolled at Duke. After a full pilot program with North Carolina State’s football team, Protect3D has created 61 3D printed protective devices for nearly 30 athletes.
They’ve also streamlined the process by creating an app that allows trainers to use an iPad and 3D sensor attachment to scan the athlete’s body in 30 seconds. Once the scan is complete, the startup creates a digital prototype and 3D prints the custom medical device to fit the athlete’s body. The ultimate goal is to be able to deliver personalized protective devices to football players across the country in just two to three days.
“We hope this event helps spring our business forward so we are able to support NFL and college football teams across the country this coming season,” said Kevin Gehsmann, co-founder of Protect3D. “Most of the money will be used to expand our manufacturing facility in Durham to prepare to scale up to meet that challenge.”
Additive manufacturing history was made this past week, as a Boeing aircraft equipped with 3D printed engine parts took flight for the very first time. Said to be the world’s largest twin-engine jetliner and passenger plane, the Boeing 777X took off from Paine Field in Everett, Washington last weekend.
The Boeing 777X aircraft has two GE9X engines that are composed of over 300 3D printed parts, resulting in seven main components. Each engine measures out to 134 inches in diameter and features 16 carbon fiber composite fan blades. By using additive manufacturing technology from GE, engineers were able to manufacture parts with complex geometries.
Originally produced at Avio Aero in Cameri, Italy and GE’s Additive Technology Center (ATC) in West Chester, Ohio, GE Aviation has been developing the 3D printed engine since 2013. Prior to the flight of the Boeing 777X, GE Aviation conducted 72 test flights of the engine, completing more than 4,100 hours of ground and air testing.
GE Aviation is currently finishing certification testing for the 3D printed engine, which is expected to be done sometime this year. Engineers from GE have manufactured eight GE9X engines and two spares for the Boeing 777X test program.
“Today’s massive milestone is a testament to the outstanding work and dedication of both companies,” said David Joyce, president and CEO of GE Aviation. “We are proud to be the power under the wings of the 777X and provide this state-of-the-art aircraft with GE’s advanced technology.”
The wheels on Ford vehicles are now safe from theft, all thanks to fully customized 3D printed locking nuts. Working with the German additive manufacturing leader EOS, engineers from Ford have designed locking nuts for wheels that are 3D printed from acid and corrosion-resistant stainless steel.
This isn’t just any old car security system that uses a special adapter or key, the 3D printed locking wheel nuts are completely one-of-a-kind, designed according to the contours of the sound of the driver’s voice.
To design the security mechanism, the engineers record the driver’s voice for a few seconds as they utter a unique phrase, and this soundwave is converted into a physical pattern using special software. From there, the pattern is turned integrated into a circle and used as the design for the locking nut’s indentation and key.
The nut and key are then 3D printed as a single part, separated, and processed to make them ready for use. In the design, there are also spaced ribs and deep indentations inside of the nut that prevents a potential thief from being able to clone or copy the pattern. Thieves often try to copy the pattern of a lock nut by creating a wax imprint, but the specialized pattern in the 3D printed nut causes the wax to break apart when it’s removed.
Aside from using the soundwave of the driver’s voice, the engineers can also implement a logo, initials, or another personalized pattern into the design. All in all, this project marks an impressive innovation as automotive manufacturers continue to thwart thieves and improve car security systems, while also showcasing how Ford engineers can use 3D printing technology to come up with novel solutions.
“It’s one of the worst experiences for a driver, to find their car up on blocks with all four wheels gone. Some alloy wheels can cost thousands to replace, but these unique rim nuts will stop thieves in their tracks,” Raphael Koch, research engineer, Advanced Materials and Processes, Ford of Europe. “Making wheels more secure and offering more product personalization are further proof that 3D printing is a game-changer for car production.”
One of the most prestigious names in the world of fine-art museums, the Smithsonian Institution has 19 museums spread out across the United States. This past week, the Smithsonian Exhibits’ (SIE) studios, which is a part of the Smithsonian Institution, announced that it has added a Mimaki 3DUJ-553 full-color 3D printer into its facility in Landover, Maryland.
The Japanese-made 3D printer, which utilizes UV curing inkjet to print with full-color ink, is capable of producing over 10 million different colors and has a 508 × 508 × 305 mm build volume.
SIE works with various museums and offices that are a part of the Smithsonian Institute to plan, develop, and design museum exhibits, as well as models for research and public programs. With the Mimaki 3DUJ-553, the studio is planning to 3D print models from Smithsonian collections that can be used for hands-on educational activities. The 3D printer will also be used to produce tactile display elements for blind visitors, such as raised-line maps.
“We are pleased to be a part of the Smithsonian Institution’s efforts to engage and inspire audiences through the increase and diffusion of knowledge,” said Josh Hope, Sr. Manager, 3D Printing & Engineering Projects at Mimaki USA. “This printer will enable the Smithsonian to use new technologies to produce exhibits in new ways, particularly for creating models and tactile elements that help bring exhibits to life for all visitors.”
The SIE has already utilized the Mimaki 3DUJ-553 printer for its first project, 3D printing full-color, highly detailed models of viruses. Created for the “Outbreak: Epidemics in a Connected World” exhibition on display at the Smithsonian’s National Museum of Natural History in Washington, DC, the 3D printed models were made for hands-on engagement for visitors.
For example, in the photo above, you can see a 3D printed model of the influenza virus model in an opened position. In this incredibly detailed 3D model, the clear part of the model contains eight purple capsids and eight yellow RNA strands.
After entering the 3D printing industry back in 2016 with filaments and powders, the German chemical producer Henkel is expanding further into the additive manufacturing realm. This past week, Henkel partnered with the Vancouver-based NewPro3D, a 3D printing company specializing in digital light processing (DLP), to use its technology to serve the medical industry.
After recently joining Henkel’s Open Materials Platform, NewPro3D is working with the chemical producer to 3D print patient-specific anatomical models, custom prosthetics, and other medical devices.
Combining Henkel’s 3D printing resin and NewPro3D’s Intelligent Liquid Interface (ILI) ultra-fast technology to produce patient-specific models from hard and soft materials. The ILI DLP process utilizes a transparent wettable membrane that enables faster movement between cured layers.
The collaboration has already yielded some life-saving results. Henkel and NewPro3D have produced an anatomical model of an infant’s skull, which was used by surgeons to prepare for surgery on a child with a misaligned anterior mandible. The surgical team was able to develop a treatment plan and identify where to situate a device to lengthen the mandible.
“Our goal with additive manufacturing is to drive production at scale. While that’s a potential game-changer in all the markets we serve, perhaps nowhere is it more important than in the medical industry, where lives are literally at stake,” explained Sean Dsvila, Head of 3D Printing Materials at Henkel. “It’s very gratifying for our team to play a small role in improving the outcome for those in need.”
Originally announced in October 2018, the 3D printing wing of the tech titan HP and Nanyang Technological University (NTU) revealed plans to construct a new facility in Singapore. This week, the collaborators celebrated the grand opening of HP-NTU Digital Manufacturing Corporate Lab by showcasing projects that will lead to the development of new digital manufacturing technologies.
Researchers from the facility unveiled intelligent design software tools capable of automating advanced customization and supply chain models, reducing time to market and the overall carbon footprint. This software will enable engineers to customize and optimize the mechanical properties of materials. Through automation, designers can combine certain material properties to find the ideal strength, flexibility, and weight for their products or components.
Another project launched at the Corporate Lab is focused on optimization end-to-end supply chain operations. By incorporating advanced business models and analytics to supply chains, researchers plan to reduce the time manufacturers need to identify which parts are suitable for 3D printing as well as the impact of the carbon footprint.
Finally, the HP-NTU Digital Manufacturing Corporate Lab also announced the SkillsFuture development program, which aims to train Singaporean workers in the fields of additive manufacturing and digital design. At the opening, there were six 3D printing courses launched. Over time, the HP-NTU Digital Manufacturing Corporate Lab plans to train approximately 120 working professionals every year. The facility itself is already made up of a team of more than 60 scientists, engineers, and researchers focused on digital manufacturing.
“Our joint work in 3D printing, AI, machine learning, security and sustainability will produce disruptive technologies that define the future of manufacturing,” said Shane Wall, Chief Technology Officer and Head of HP Labs, HP Inc. “Working together, we can create the workforce of the future and ensure the 4th Industrial Revolution is also a sustainable revolution.”
A true trio of additive manufacturing pioneers, GE, Oak Ridge National Laboratory (ORNL), and the Xerox-owned company PARC have recently received a $1.3 million grant to reduce the timeline for designing and validating 3D printed components for energy systems.
Awarded through ARPA-E’s DIFFERENTIATE program, the partnership will aim to make 3D printing more efficient for a vast array of power generation products, including wind and gas turbines. The team will utilize ORNL’s Summit, known as the world’s most powerful supercomputer, in order to develop AI and machine learning technologies that will help create and validate millions of design iterations at a much faster speed than currently possible.
Researchers from GE, ORNL, and PARC will attempt to reduce the overall timeline for turbomachinery product design in half, making 3D printing faster than traditional manufacturing methods like casting. traditionally, components for products like jet engines and turbines must go through a gauntlet of experts to ensure that the structural, thermal, and fluid properties are properly accounted for. This part validation process could last two to five years.
“One of the keys to enabling the widespread use and benefits of 3D printing is the reduction of the time it takes to create and validate defect-free 3D component designs,” said Brent Brunell, leader of GE Research’s Additive. “Using multi-physics enabled tools and AI, we think we can beat the timeline for some traditional manufacturing processes by automating the entire process.”
While optimizations have already been made to validate structural characteristics, the team is working to automate the same process for thermal and fluid properties. In addition to using the Summit supercomputer, the team will also leverage ORNL’s High Flux Isotope Reactor to analyze 3D printed parts and generate data needed to train and evaluate AI-based models.
All in all, the grant will enable GE, ORNL, and PARC to develop systems that could lead to multi-functional and high-performance 3D printed components that are free of defects, capable of handling high temperatures and stresses, and can also be validated in a much shorter span of time.
While not exactly a direct development in the professional sector of additive manufacturing, a new project showcased by researchers from the University of Seville and the University of Nottingham could have a major impact on the pharmaceutical industry in the near future. This past week, a joint team successfully 3D printed stabilized gold nanoparticles for biocompatible and biodegradable systems.
Utilizing inkjet 3D printing, the research team 3D printed an image of the University of Seville’s logo using the gold nanoparticle material. While gold inks already exist for inkjet 3D printing systems, these materials are highly unstable and difficult to print with.
The research team developed polymers with a comb structure to create tiny gold nanoparticles with a high degree of stability. The polymers were created using a natural sugar called arabinose, making the material biocompatible, biodegradable, and also completely free from polluting residues that are found in oil-derived polymers.
The gold nanoparticles were derived from three chemically functionalized polymers that were extremely small and proved to be stable for at least six months after being 3D printed. After testing out each ink, the best formulation was used to print the logo of the University of Seville.
According to the research team, this development could potentially be used for various applications in the pharmaceutical industry, including the creation of biocompatible and patient-specific biosensors made from nanoparticle gold, which have proven effective in detecting carcinogenic cells and tumor biomarkers.
Back in 2017, the tech giant HP unveiled FitStation, a 3D printing platform that leverages the groundbreaking Multi Jet Fusion technology to produce custom-fitted footwear. This week, Superfeet, a leading producer of insoles for active people, obtained a license from New Balance to use HP’s FitStation to produce the footwear company’s insoles.
The new line of insoles, which will be sold under the brand New Balance Stride 3D insoles, includes three designs from the Superfeet line: Casual, Running, and Sport. Using Multi Jet Fusion 3D printers, HP and Superfeet will produce customized 3D printed insoles based on the biometric data of the customers.
The FitStation platform utilizes 3D scanning and gait analysis technology to create individualized footwear designs, which are 3D printed using flexible materials like TPU. New Balance custom insoles will have 3D printed caps integrated into the design, which will be assembled into the final insole at the Flowbuilt Manufacturing facility in Washington state.
This isn’t the first time HP and Superfeet have worked together. Back in 2017, the two companies worked with Brooks Running Company to create tailored sneakers via the FitStation platform. The new line of custom insoles is already available online, in New Balance stores, and in select retailers. In 2020, Superfeet plans to expand its New Balance insole offerings in North America and certain parts of Asia.
“Together with partners like Superfeet we are helping the world’s leading footwear companies take full advantage of digital manufacturing, create innovative designs, improve workflows, and deliver individualized products,” said Philipp Jung, General Manager & Global Head of Vertical Industries & End-to-End Applications, 3D Printing & Digital Manufacturing, HP Inc.
From smart wearables to 3D printed hair, there’s no shortage of innovation coming out of the MIT Media Lab. This week, Associate Professor Neri Oxman and a group of graduate students unveiled a new 3D printing technique capable of producing objects that can control living organisms.
Developed alongside researchers from Harvard University’s Wyss Institute and Dana-Farber Cancer Institute, the method is able to integrate living cells into 3D printed materials, using selectively placed chemicals to activate cells. According to MIT, this technology could be used to 3D print biomedical tools that contain living cells to produce therapeutic compounds like painkillers and topical treatments.
At the moment, the team is just in the early stages of experimentation. Thus far, they have integrated chemicals that act as signals to activate predictable responses in biologically engineered microbes that have been spray-coated onto the 3D printed object. These microbes emit specific colors as a reaction to the chemical signals.
With the success of their proof-of-concept experiment, the team claims that these colored patterns showcase the ability to integrate living cells into the surface of 3D printed objects.
To accomplish this, the research team utilized multi-material inkjet 3D printing technology, utilizing combinations of resins and chemicals to create the materials. In one case, they found that a resin typically used to 3D print support structures was able to absorb and retain the incorporated chemical signals used to control the behavior of living organisms. The living layer, which is made up of a hydrogel infused with biologically engineered bacteria, is added onto the surface of the object after the fact.
Additionally, the inkjet 3D printing platform allowed the researchers to control material properties in certain areas of the structures, making some parts more stiff, flexible, absorbent, or liquid-repellant. This capability could be especially helpful for the production of biomedical devices that require varying degrees of strength and softness. In the test case, the MIT Media Lab used genetically modified E. coli bacteria, but other organisms could also be used.
“There are exciting practical applications with this approach, since designers are now able to control and pattern the growth of living systems through a computational algorithm,” Oxman says. “Combining computational design, additive manufacturing, and synthetic biology, the HLM platform points toward the far-reaching impact these technologies may have across seemingly disparate fields, ‘enlivening’ design and the object space.”
The additive manufacturing behemoth 3D Systems is getting into the bioprinting game through a partnership with CollPlant, a regenerative medicine company focused on 3D bioprinting of tissues and organs. This week, the two companies signed a joint agreement to develop tissue and scaffold bioprinting processes that can be leveraged by third-party collaborators.
Already a pioneer in the medical 3D printing realm, 3D Systems will utilize a proprietary recombinant human collagen (rhCollagen) BioInk technology developed by CollPlant, which is already used to bioprint tissues and organs. Together, 3D Systems and CollPlant will aim to create groundbreaking 3D bioprinters and BioInks to produce scaffolds and tissues for regenerative medicine applications.
Through the agreement, both companies will have access to 3D Systems’ 3D printing technology, as well as CollPlant’s existing BioInks and new rhCollagen-based materials created via the partnership. For instance, the photo above features a soft tissue implant with vascularization channels produced with an SLA bioprinter from 3D Systems using CollPalnt’s BioInk material.
“We believe 3D printing to be a key technology for regenerative medicine, and this collaboration is one of many we are entering to play an integral role in this exciting field,” Chuck Hull, co-founder and CTO, 3D Systems. “Combining our innovative 3D printing technologies with CollPlant’s rhCollagen based BioInks has the potential to make a significant impact in bioprinting and regenerative medicine.”
Smart International, the global brand licensee for the KODAK Portrait 3D Printer, has launched its new Materials Partnership Program that will provide customers with an array of professional-grade 3D printing materials. New material profiles for BASF, Clariant, and DSM will make it easier for industrial customers to successfully 3D print functional parts with the KODAK Portrait 3D Printer.
Each of the materials produced by the three partners has been rigorously tested and calibrated by Smart International to find the optimal printing temperature, flow values, and print bed temperature. Using this data, highly accurate printing profiles were developed specifically for the KODAK Portrait. These profiles can already be accessed on the Smart3D website or the KODAK 3D Cloud.
Each material producer has joined the program with a wide variety of materials. Here’s a quick overview of each one:
“Partnering with top filament companies like BASF, Clariant and DSM gives the customer the opportunity to choose the material that best fits their project, and gives them confidence to use these high-quality 3rd party materials with the KODAK Portrait 3D Printer,” said Roberto Gawianski, CEO, Smart International. “We are pleased to be able to assist in the development and evolution of 3D printing filaments, and will continue to support progress in this area.”
We often talk about 3D printing on land or in outer space, but the maritime industry is also benefiting from this technology. This past week, the offshore rig design specialist Keppel Offshore & Marine (Keppel O&M) received certification from Lloyd’s Register that enables them to produce offshore-grade steel with Laser Aided Additive Manufacturing (LAAM) technology.
With this newly acquired certification, Keppel O&M can speed up offshore production using LAAM 3D printing system, which is a high energy laser beam-based technology developed by the Nanyang Technological University Singapore (NTU Singapore) and the A*STAR Singapore Institute of Manufacturing Technology (SIMTech). Not only can the LAAM process 3D print entire parts from metal, but it’s also capable of fixing or modifying existing components.
This technique will enable the offshore rig design specialist to 3D print components for offshore products in a faster and more cost-effective way. It can also help Keppel O&M reduce its carbon footprint and thwart potential resource constraints.
The LAAM technology underwent stringent mechanical testing and an audit in order to receive certification. Over 50 sample parts made from 3D printed offshore-grade steel were tested based on material yield, tensile strength, elongation, fatigue, and toughness. Ultimately, the parts surpassed ASTM A131 standards.
“This certification is the first step for us to produce high-value components essential to the offshore and marine structures,” said Aziz Merchant, Executive Director of Keppel Marine & Deepwater Technology. “Additive manufacturing or 3D printing as it is more commonly known will speed up production times which in turn can help bring projects to completion much quicker.”
Already established as a manufacturing leader for custom, high-volume silicone prototypes and parts, the Massachusetts-based Albright Silicone has recently announced that it would bring its silicone material to the 3D printing stage. The silicone molder company has integrated 3D printing capabilities into its portfolio by developing a special 3D silicone molding process for rapid prototyping.
The offering is tailored towards customers that need small-volume production of parts but are not prepared to invest in metal tooling. Instead, they can benefit from a silicone molder with 3D printed tooling.
Albright Silicone will offer customers several ways to benefit from different 3D printing options, including molding with commercial grades of Liquid Silicone Rubber (LSR) between 10 and 80 Shore A durometer, color matching, mold components with complex shapes and undercuts, small-volume part production, and more.
With its new 3D printing options in place, the company is now capable of producing an assortment of rigid and high-temperature thermoplastic components for an assembly or overmolding substrate component in the 3D printing casting process or LSR product molding, slitting, and assembly processes.
“This capability of 3D printing and molding LSR is a helpful solution to customers’ problems when trying to develop and prove a concept before investing in metal tooling,” said Mr. Matt Bont, Product Manager at Albright Silicone.
This past week, over 4,500 companies gathered at the Las Vegas Convention Center for CES 2020, the world’s largest consumer tech conference and trade show. Each year, organizers recognize a wide range of remarkable products in the field of consumer electronics with the coveted CES 2020 Innovation Awards.
While there was only a single product honored in the 3D printing category last year – a 3D printed titanium hearing aid – there was a total of four additive manufacturing marvels named at the 2020 edition of the CES 2020 Innovation Awards.
Created by the Korean beauty company Amorepacific and Lincsolution, a 3D printing system producer, this 3D printer is capable of printing a custom hydrogel mask that fits specific facial features and skin conditions.
The system uses a smartphone app to capture the dimensions of the customer’s face, including the eyes, nose, mouth, forehead, cheeks, and chin, to create a bespoke mask. Each mask takes less than five minutes to 3D print and is lined with hydrogel formulas with various skincare effects that are implanted for certain areas of the face.
At the CES 2020 Innovation Awards, the 3D printing system was recognized for its compatibility with breakthrough materials like silicon and liquid hydrogel. It was mentioned for providing excellent temperature control and its ability to maintain hygienic and effective use of the hydrogel for skincare products.
After working on the prototype system over the last few years, these 3D printed masks will be available as a part of IOPE’s Tailored Solution in April 2020.
Back in May 2019, the Snapmaker 2.0 raised over $7 million from 7,388 backers on Kickstarter, a record-breaking haul on the crowdfunding platform. This past week, the new Snapmaker 3D printer was honored with a CES Innovation Award, yet another milestone for the young-and-upcoming 3D printer manufacturer.
Building off the multi-faceted design of the original model, the new and improved Snapmaker 2.0 has garnered attention for offering 3D printing, laser engraving, and CNC carving all in one machine. The modular design makes it easy to swap out the different modes and harness the power of various technologies.
The Snapmaker 2.0 has a sturdy frame made of aerospace-grade aluminum and an intuitive touchscreen. There are three different models available, the largest (A350) offering a build area of 320 x 350 x 330 mm. This all-in-one 3D printer has set itself apart as a module machine of every maker’s dream – and CES has clearly recognized this achievement.
“We were proud to see that not only was the Snapmaker 2.0 the most funded technology project on Kickstarter, but we are honored with the CES 2020 Innovation Award now,” said Daniel Chen, CEO, Snapmaker. “We are excited to show the Snapmaker 2.0 at CES, expanding the reach of the Snapmaker 2.0 even further.”
Another honoree lauded at the CES 2020 Innovation Awards was the ULTRA Supercharged 3D printer, manufactured by the French company Volumic. This professional-grade FDM 3D printer is said to offer print speeds that are “three times faster” than other machines.
According to Volumic, the ULTRA Supercharged 3D printer is compatible with more than 50 types of 3D printing materials, from flexibles like TPU to high-strength plastics like PEKK. This boastful claim is backed up by the dual drive print head that can reach up to 420 °C and a heated bed that maxes out at 170 °C.
Another unique aspect of the ULTRA Supercharged 3D printer is the assortment of safety features, such as the full enclosure, ABEK filet, and password protected that prevents unwanted access to the machine. This 3D printer also has a modest 300 x 200 x 300 mm build volume and 7-inch touchscreen display.
Starting at 5980 Euros, the Ultra Supercharged 3D printer has been recognized by CES in the 3D Printing and Sustainability and Eco-design categories.
Lastly, another 3D printer honored in the CES 2020 Innovation Awards was the da Vinci Color 5D 3D printer from XYZprinting.
Officially introduced during the Las Vegas trade show, this 3D printer is much more than your average FDM machine. It’s a multi-faceted full-color 3D printer that’s also capable of laser engraving and 2D printing onto inkjet paper.
The 5D has better CMYK inks and a new color-absorbing PLA filament, which reportedly makes for three times better color saturation than the previous da Vinci model. XYZprinting has also integrated a quick-release extruder that makes it easy to swap out new nozzles or the laser engraver module.
“The da Vinci Color 5D can be used by a wide range of people, but will be particularly useful to small businesses and designers, thanks to its high-quality printing and ease of use,” said Fernando Hernandez, EMEA MD of XYZprinting. “The 2D printing and laser engraver features make the da Vinci Color 5D a world first, and the most complete and user-friendly desktop 3D printing unit developed.”
In a couple of weeks, leaders and innovators from across the globe will gather at the mountainous Swiss town of Davos for the World Economic Forum Annual Meeting.
This past week, the World Economic Forum published a white paper entitled “3D Printing: A Guide for Decision-Makers,” indicating that the technology will be on the docket during the upcoming conference. The report aims to address potential policy changes that will affect 3D printing and offer guidance to governments, businesses, and other stakeholders to adjust to potential shifts in international trade agreements.
The white paper is primarily focused on how a digital border tax would impact 3D printing files transferred across borders. Currently, 3D printing files are not subject to customs duties, but this could change if duties for electronic transmissions are eventually implemented. Outside of 3D printing files, a digital border tax would also include streaming content, e-books, online courses, and more.
In 1998, the World Trade Organization (WTO) put a moratorium on these electronic transmissions, which has since been extended until June 2020. The World Economic Forum discusses several arguments both in favor and against electronic duties. While this tax will likely stymie digital and offline trade, it could also increase customs revenue.
Moreover, the World Economic Forum also states that holding off on the digital tax could also encourage more innovation and collaboration between the international additive manufacturing industry. It could also help level the playing field for 3D printing companies in different parts of the world.
The organization also touches on how to define the value of 3D printing files, whether these files should be considered goods or services, the possibility of using a VAT or sales tax instead of customs duties, and more. You can read more about the discussion on the World Economic Forum website.
Regularly making headlines for developing novel additive manufacturing materials and solutions, Massachusetts Institute of Technology (MIT) is once again walking the walk – in rubbery 3D printed shoes!
MIT’s Self-Assembly Lab is collaborating with Native Shoes, a Vancouver-based footwear company, and Emily Carr University, to develop Liquid Printed Natives. Using a breakthrough 3D printing technique, the flexible shoes are produced from a liquid rubber material that resembles black patent leather.
Native Shoes has reimagined its two most popular footwear styles: the Audrey flats and the Croc-like Jefferson. The 3D printing technique employs a clear water-based gel bath, where the liquid rubber material is dispersed into the liquid medium. The model remains suspended in the gel bath, allowing the 3D printed shoes to be produced in a single piece.
This liquid 3D printing method enables the production of completely customizable shoes with no support structures required. Native Shoes is currently developing technology so that customers can scan their feet through a smartphone app or in-store. From there, the captured data can be sent directly to the liquid 3D printing program. That way, the footwear company doesn’t have to worry about inventory and overstocking products.
The flexible and rubbery material used to produce the shoes is partially made of recycled ethylene vinyl acetate (EVA). In fact, the shoes can feasibly be made from 50% EVA, making this method much more sustainable than traditional methods like injection molding. Each pair of shoes take about two hours to emerge from the liquid bath.
While there’s no release date on these shoes, the company is currently testing them out and plan to make further improvements to the material.
Aside from the collection of honorees at CES 2020, a unique electric vehicle with 3D printed parts almost whizzed right by us. On the trade show floor, the automotive manufacturer Rinspeed showcased its latest concept vehicle: the MetroSnap.
Over 30 of the components included in this electric and modular vehicle were 3D printed using FDM and PolyJet technologies from the additive manufacturing titan Stratasys. Both the interior and exterior of the MetroSnap featured 3D printed parts, such as the interior consoles, plug socket fixtures, air vents, display frames, and even the license plates.
The vehicle itself follows a unique design concept found in Rinspeed’s previous concepts. The chassis and body are completely separated, so the body can be swapped out to serve different purposes, whether that be transporting goods or people.
Rinspeed believes its MetroSnap concept could be especially useful for parcel delivery. For instance, it could be used to drop off entire parcel stations (the body) in a neighborhood while the chassis leaves to run other tasks. Another interesting aspect of this electric vehicle is that batteries are divided between the body and chassis, so the vehicle can be charged while the body is being loaded with cargo or cleaned.
There’s no telling whether this concept will be whipping through your neighborhood anytime soon, but it certainly generated some electricity in Las Vegas this past week.
At the start of 2020, the 3D printing veteran Stratasys will have a fresh face at the very top of the leadership chain, as the company recently announced the appointment of Yoav Zeif (pictured above) as its new CEO.
Starting the position on February 18, 2020, Zeif will utilize his experience in global operations and leadership to steer Stratasys into its next phase of growth. Until then, interim CEO Elchanan Jaglom will continue to run the company and will maintain his role as chairman once the new CEO begins his tenure.
While Zeif is new to the world of additive manufacturing, he has an extensive resume and expertise is in sales, product, R&D, and manufacturing operations. Stratasys is hoping that the new CEO will leverage this experience to help bolster the company’s success in the industrial additive manufacturing market.
Most recently, Zeif served as a partner at McKinsey & Company’s New York office. Prior to that, he worked at Netafilm, which is the world’s largest micro-irrigation company, where he held the titles of President of the Americas, Head of Product Offering and Chief Commercial Officer. He was also the Senior Vice President of Products and Marketing at the crop production company Makhteshim, now named Adama Ltd.
“Stratasys pioneered and continues to power the additive manufacturing landscape, enabling companies across virtually all industries to build and improve their businesses through 3D printing technology,” commented Zeif.
“In particular, thanks to its outstanding innovations and application engineering, it is clear that Stratasys is poised not only to reshape product development and prototyping but also to transform supply chains and manufacturing through efficiency and personalization. I am excited to be joining the company and its talented and dedicated teams around the world at such a pivotal time.”
Stratasys wasn’t the only additive manufacturing company to shake up its executive structure. Voxel8, the Massachusetts-based multi-material 3D printing company, has appointed Dr. Friedrich von Gottberg as its new President and CEO.
With a Ph.D. and MS from MIT, Dr. von Gottberg accumulated leadership experience as Senior Vice President of the chemicals company Cabot Corporation. From April to December 2019, he also served as Entrepreneur in Residence at Harvard University. He will replace former CEO and co-founder Travis Busbee, who will take up the role of Chief Technology Officer and focus on R&D.
“I’m excited to join Voxel8, and look forward to working with Travis and the rest of the team as the company positions itself for the next stage of growth,” said Dr. von Gottberg.
This past week, the 3D printing wing of the global tech giant HP announced that it was strengthening its partnership with Oakley, the popular sportswear sunglasses brand. The two trailblazing companies will utilize HP’s Multi Jet Fusion 3D printing technology to improve Oakley’s product design process and prototyping.
Acquired by the eyewear giant Luxottica in 2007, Oakley has been a leader in the performance sunglasses space for over 40 years. Although the company has employed 3D printing technology in its product design process for decades, HP’s Jet Fusion 580 system will allow Oakley to further transform and streamline the production process.
With this groundbreaking 3D printing technology, designers will be able to speed up design iterations and produce prototypes in less than 24 hours. Not only with HP’s system make the product development process quicker, but it will also enable Oakley to produce detailed, full-color prototypes for its eyewear products.
Using HP’s 3D High Reusability CB PA 12 material, Oakley will produce functional prototypes that can be properly tested, and will also be able to make use of the Multi Jet Fusion machine’s system to create several prototypes at once.
“World-class athletes around the globe depend on Oakley to compete at the highest level,” said Nicolas Garfias, Head of Design at Oakley. “With HP’s breakthrough 3D printing technology, we will not only accelerate our design to production timeline, but we will also re-conceptualize the way our products are made, pushing the boundaries of sports performance to new heights.”
Not many additive manufacturing companies have managed to achieve the speedy success of the Silicon Valley-based startup Carbon, which has managed to score partnerships with big-name companies like Adidas and Riddell. Carbon also started working with the Italian luxury sports car manufacturer Lamborghini back in February, and now that collaboration is shifting into a higher gear.
Carbon and Lamborghini have recently fortified its partnership, working to produce 3D printed use-end parts for the Sián FKP 37, which is Lamborghini’s first hybrid production car. The luxury car manufacturer will use Carbon’s 3D printing technology to manufacture central and lateral dashboard air vents for the new vehicle.
Combining Carbon’s Digital Light Synthesis platform and Lamborghini’s high-end craftsmanship, the 3D printed air vents in the Sián FKP 37 are designed to provide comfort and elevate the driving experience with a look that reflects the need for speed. By 3D printing these air vents, Lamborghini was able to reduce its part lead time by 12 weeks, while also eliminating expensive tooling steps that came with traditional manufacturing processes.
“With the Carbon Digital Manufacturing Platform, we were able to go from an initial concept to showing the final part on a show car in only three weeks, passing through many different design iterations to get the best result. Just three months later, we were able to move into production,” said Maurizio Reggiani, Chief Technical Officer at Automobili Lamborghini.
The air vents were 3D printed with Carbon EPX 82 material, which was used to meet stringent standards. It passed several tests regarding Interiors Flammability, Volatile Organic Compounds, Thermal Cycling, and Heat Aging. Earlier this year, Lamborghini used Carbon 3D printing to create a textured Fuel Cap and a clip component for an air duct in its Urus SUV.
Now, with the 3D printed air vents being integrated into the Sián FKP 37, the two companies have reached yet another milestone together.
Finally, we have a couple of major updates regarding 3D bioprinting in…that’s right…outer space.
Firstly, the US-based 3D-printing-in-microgravity company Made in Space is teaming up with the Swedish startup CELLINK to create a 3D bioprinter for use in outer space. Leveraging its expertise of 3D printing in zero-gravity environments, Made in Space will use the bioprinting company’s technological prowess to identify opportunities for bioprinting both on Earth and on the International Space Station (ISS).
Using the microgravity environment, the two companies hope to gain insights that could provide benefits on planet Earth, namely when it comes to drug screening and cancer research. As for bioprinting on the ISS, it could potentially be used to reduce health and safety risks for crews on long-duration spaceflight missions. Bioprinting could also enable astronauts to someday develop skin and bone patches to help heal wounds in space.
“CELLINK supports space programs in the United States with our deep commitment to cutting-edge innovation, extensive portfolio of technologies and world-class team of scientists and engineers,” said CELLINK co-founder and CEO Erik Gatenholm. “We are excited to partner with Made In Space to refine bioprinting technologies that can support and enhance future missions in spaceflight and space exploration.”
Despite the exciting news from Made in Space and CELLINK, there appear to be some bioprinting endeavors already taking place aboard the ISS. After experimenting inside of the ISS, Russian scientists from 3D Bioprinting Solutions, also known as 3dbio, successfully 3D printed bone tissue by growing fragments in zero-gravity conditions.
Made from calcium phosphate ceramics, these tissue samples were populated with living cells, proving that the technology could be used to create bone implants for astronauts on long-distance missions in outer space. The samples are currently being studied back on Earth.
The scientists hope that, in the future, these bioprinted tissues can be transplanted to astronauts if they are injured, fall ill, or if their bone structure degenerates in micro-gravity. After sending cellular materials to the ISS back in August, the Organ.Aut magnetic bioprinter was used to produce tissue structures in micro-gravity.
Because it’s stationed in a zero-gravity environment, this unique 3D printer uses magnetic levitation to produce objects volumetrically instead of a layer-by-layer fashion. The Russian astronauts aboard the ISS were able to produce a spheroid-shaped fragment of bone tissue, which were able to form stable chemical bonds with one another. Then, live osteogenic cells were distributed evenly on the surface of the fragments, leading to the creation of the engineered tissue structure.
Next summer, the world’s greatest athletes will gather in Tokyo for the 2020 Olympics to compete for gold medals and national pride. But for those of us who prefer 3D printing innovation over pole-vaulting, the U.S. Air Force is kicking off an event that will probably better suit your interests.
The Air Force’s Rapid Sustainment Office (RSO) has announced the launch of the Advanced Manufacturing Olympics, a weekend-long event focusing specifically on additive manufacturing innovation. It will take place next year in Salt Lake City, Utah, from July 7 to 10. A number of additive manufacturing companies, defense contractors, tech startups, and university groups will be invited to partake in several different design challenges.
Outside of the competition, the Advanced Manufacturing Olympics will also feature keynote speakers, breakout sessions, networking opportunities, and more. On the event’s website, the RSO states that “approximately 60% of the Air Force supply chain comes from a single source,” and this event is being hosted in an attempt to prove the viability of 3D printing technology, while also bringing more innovations into the fold.
At the Advanced Manufacturing Olympics, participants will compete in various competitions. One challenge will be to replicate parts that meet the stringent regulations at the Air Force without using design specifications. There will also be a “supply chain marathon” where contestants will try to figure out the logistics of delivering a 3D printed part to a specified location.
All in all, the U.S. Department of Defense, specifically the Air Force, has made it a clear mission to integrate 3D printing technology into military production. Last week, the Ohio-based national accelerator for additive manufacturing America Makes signed a seven-year Cooperative Agreement (CA) with the Air Force Research Laboratory (AFRL) that included a total funding value of up to $322 million. Furthermore, we’ve already seen the Air Force install 3D printed parts on their fighter aircrafts, and with the Advanced Manufacturing Olympics on the horizon, we only expect the military branch’s affiliation with 3D printing to continue soaring.
Speaking of the Air Force, another aerospace-centric organization that has seen its use of 3D printing “lift-off” in recent years is NASA. Whether we’re talking about 3D printing spacecraft parts in low-Earth orbit or producing structures on Mars, NASA continues to drive innovation on the additive manufacturing front –working with an assorted universe of partners to bring this technology into space.
This past week, Fabrisonic, a specialist in solid-state metal 3D printing, and Luna Innovations showcased its groundbreaking collaborative Ultrasonic Additive Manufacturing (UAM) through its partnership with NASA. Employed by NASA to gather data from cryogenic fuel pipes for rocket test stands, the UAM process was used to 3D print sensors into the wall of the rocket fuel pipe.
Fabrisonics’ UAM process is capable of embedding sensors, fibers, and wires into a metallic substrate. It’s been used to insert microphones, thermocouples, and ultrasonic inspection sensors into solid metal components. In his case, the sensors, which were provided by Luna Innovations, were embedded in order to provide NASA with precise and accurate readings of thermal and pressure gradients, enabling NASA to monitor how the engine is behaving.
Prior to embedding the 3D printed sensor into the pipe, NASA tried to gather data by mounting sensors on the outside of the part, but the external placement made it an ineffective way to gather data. And so, the UAM process was used to place the sensors directly inside of the wall of the fuel pipe.
Believe it or not, only a small portion of the pipe was actually 3D printed by Fabrisonic. The project started with a pipe structure and use CNC milling to carve out a “small grove” for the embedded sensors. Once the fiberoptic sensors were embedded, the UAM process 3D printed metal over the groove until the outer diameter of the pipe was restored. With the ability to embed sensors directly into metal parts, Fabrisonic believes its technology offers several advantages, allowing customers to place sensors exactly where they need to go, which in turn helps sensors function for a longer time in more challenging environments.
In other news, the additive manufacturing veteran Stratasys is continuing to expand its customer base throughout the world – this time in the Oceania region. This week, Stratasys AP, the subsidiary company of Stratasys, announced the appointment of TCL Hoffman and TCL Hunt as the latest authorized channel partners.
Aiming to expand its market outreach in both Australia and New Zealand, the new partners will leverage their long-built understanding of local manufacturing and customer needs to increase the presence of Stratasys technology in the region. Both TCL Hofmann and TCL Hunt will sell the complete suite of additive manufacturing solutions, including Stratasys 3D printers, engineering-grade materials, 3D printing software, as well as post-sale service.
“3D printing has changed the ways that many things are created and as an innovator and partner of our customers, Stratasys continues to push the boundaries to ensure needs are matched with the most fitted solution, whether our customer requires 3D printed replica of a patient’s heart for pre-surgical analysis, or a customized masking jig in shop floor,” said Ben Darling, Senior Territory Manager of Stratasys Australia and New Zealand Region.
Joining Stratasys’ reseller network, the new partners will serve the manufacturing sector and other businesses looking to integrate Industry 4.0 or smart manufacturing into their production workflow. TCL Hofmann, based in Australia, and TCL Hunt, which services New Zealand, are a known supplier of raw materials, products, and machinery for a wide range of industries. With the Stratasys becoming a part of the portfolio, more companies in the Oceania region will have access to industrial-grade additive manufacturing solutions.
In other news, EvoBus GmbH, a subsidiary of the German automotive corporation Daimler, is using Selective Laser Sintering (SLS) technology to produce end-use interior parts for its line of buses. The bus manufacturer has announced that it has installed the Sintratec S2 3D printer at its manufacturing facility in Neu-Ulm.
By bringing this SLS 3D printer into the production workflow, EvoBus and Daimler plan to achieve faster turnaround times, lower logistical costs, and a reduction in waste. Prior to the addition of the S2, the manufacturer was depending on external service providers to handle the production of spare parts.
Created by the Swiss 3D printer manufacturer Sintratec, the S2 will be used for small-to-medium-sized production and training purposes. In 2020, Daimler Buses is planning to launch its first service bases, which will act as hubs where 3D printed spare parts and small components can be quickly produced.
Daimler will also use the S2 3D printer to focus on 3D printing material advancements, using the S2’s easy material change system to improve the development process. This workbench-sized 3D printer features semi-automated processes for laser sintering, de-powdering, material preparation, and surface treatment, making the entire SLS 3D printing process easier to manage.
“With 3D printing the Daimler bus division can respond quickly, flexibly, economically and environmentally friendly to urgent customer needs,” said Ralf Anderhofstadt, Head of Center of Competence Additive Manufacturing at Daimler Buses. “The advantages of additive technologies, especially with regards to spare parts, are evident.”
Following its well-established success in the domain of SLA 3D printing, the Massachusetts-based company Formlabs has recently focused in on the medical industry. Shortly after releasing the Form 3 3D printer, Formlabs unveiled the application-specific version of its new machine designed for dental professionals: the Form 3B.
This week, the 3D printing unicorn announced it was entering a new collaboration with GE Healthcare that will enable clinicians to make patient-specific 3D printed models directly from imaging data. By improving access and reducing costs of these anatomical models, this partnership will allow medical professionals in North America and Europe to visually communicate and coordinate with each other and their patients.
Both Formlabs and GE Healthcare are bringing innovative products to the table. Radiologists and biomedical engineers will be able to leverage the Formlabs 3D printing ecosystem, including the new Form 3B, as well as a treasure trove of proprietary resins that offer medically beneficial properties. On the other hand, GE Healthcare will utilize its own Advantage Workstation (AW) advanced visualization tools, which are specifically tailored toward medical professionals.
Through this collaboration, radiologists will be able to use AW’s workflow to produce models of normal and pathological anatomy using automation techniques, reducing the time it takes to create STL and OBJ files from hours to minutes. From there, utilizing Formlabs 3D printers and PreForm print preparation software, medical professionals will be able to serve various surgical specialties with a single workflow while also saving time and money.
“Formlabs is proud to collaborate with GE Healthcare, a true pioneer and leader in medical imaging, as both organizations share an aim to support the practice of medicine and the pursuit of precision health,” said Gaurav Manchanda, Director of Healthcare at Formlabs. “This collaboration represents an important milestone for the medical 3D printing community and will hopefully serve as a catalyst for its growth. Our clinical customers should be able to serve more patients, more efficiently, with trusted, reliable, and intuitive technologies.”
America Makes, the Ohio-based national accelerator for additive manufacturing, announced a major partnership with the Air Force Research Laboratory (AFRL) this past week, striking a new seven-year Cooperative Agreement (CA) with a total funding value of up to $322 million, which will be shared between the government and America Makes.
This Cost-Reimbursement/Cost Share agreement will enable America Makes to continue advancing the adoption of additive manufacturing, and will focus on the areas of materials, design, education, and community in additive manufacturing. Through this new CA, America Makes will bolster its public-private model and will establish a more robust manufacturing base to provide additive manufacturing solutions to the defense industry.
The new agreement between America Makes and the AFRL will also provide support to the Office of the Secretary of Defense(OSD)’s Manufacturing Technology (ManTech) program. This program directly sponsors America Makes and specifically focuses on the manufacturing needs of the defense industry. The institute will help improve manufacturing technology for the OSD’s Research & Engineering’s priorities, which include hypersonics, cyber, and AI/machine learning.
According to America Makes Executive Director John Wilczynsk, the new CA “signifies a high level of confidence by AFRL in America Makes,” and will expand its already established collaborations and improve R&D projects involving additive manufacturing.
“For America Makes, this new CA with AFRL marks a monumental milestone,” said Wilczynski. “We have worked tirelessly together with the America Makes membership community during the last seven years and two previous Cooperative Agreements with AFRL to execute our mission of advancing the adoption of additive manufacturing.”
This week in 3D printing was also marked by a number of companies announcing plans to construct additive manufacturing facilities throughout the world.
To start, the German industrial giant thyssenkrupp is investing several million euros into a new metal additive manufacturing center in Israel. The company’s Marine Division will work with the Israeli Impact Labs in a joint venture called Metal Point. This metal 3D printing center will work directly with companies in Israel to produce customized metal parts.
Aiming to increase productivity across the country’s manufacturing sector, Metal Point will be supported by the Ministry of Economy, the Israeli Institute of Metals at the Technion-Israel Institute of Technology, the Manufacturers Association of Israel, among other agencies.
In the United Kingdom, the global manufacturer Gardner Aerospace acquired the additive manufacturing service provider FDM Digital Solutions and announced the creation of the Gardner Technology Centre. Through the acquisition of FDM Digital Solutions, the new business model will be integrated into the Gardner Technology Centre, which will focus primarily on advanced technology, innovative solutions, and R&D initiatives.
Already capable of producing metal parts and sub-assemblies, Gardner Aerospace is planning to bring FDM’s additive layer manufacturing into the fold, allowing them to expand its offerings to customers. Prior to the acquisition, FDM Digital Solutions had already proven value in serving customers in the automotive, medical, motorsport, F1 and aerospace industries.
“Gardner Aerospace is breaking new ground in terms of technology,” said Dominic Cartwright, Chief Executive Officer at Gardner Aerospace. “The acquisition of FDM and the creation of our new Technology Centre business unit provides us with the perfect opportunity to expand our technical knowledge, R&D capability and product offering, and aligns us with our customers’ growing expectations on innovative solutions, continuous improvement and cost competitiveness.”
Finally, the medical training center AdventHealth Nicholson Center announced the launch of its Prototype Lab, which will serve as an innovative space for health care professionals to use state-of-the-art CAD and 3D printing technology to develop ideas for medical devices.
The center will utilize a full-fledged development process to take medical products from concept to working prototype. In the Prototype Lab, engineers will first take initial concepts and complete a preliminary art and patent search. From there, CAD modeling will be used to design the prototype before its send to the in-house Objet350 Connex3 Polyjet 3D printer by Stratasys.
Following the evaluation of the 3D printed prototype, the creator of the device can test it out on tissue in the same location, and can even have the product validated if it’s ready to be reviewed by the Food and Drug Administration (FDA). The Prototype Lab can also help with personalized medicine. Engineers can 3D print patient-specific anatomical models using imaging data from CT or MRI scans. These models can be used for patient consultation, surgical planning, and reference during the procedure.
“Our expert team can help bring an idea from ‘napkin sketch’ to reality, and our 3D printing capabilities allow inventors to hold an actual version of their device in their hands for evaluation,” said Jodi Fails, B.S., Biomedical Engineer and Prototype Lab lead at AdventHealth Nicholson Center. “Most product developers assist with creation but have to look externally for lab testing. However, with Nicholson Center’s Prototype Lab, we have the unique ability to take inventions straight from the printer to the lab for immediate testing on high-quality tissue.”
This week, a couple of industrial pioneers announced new simulation solutions to optimize industrial-level design. After rolling out a bunch of major announcements at Formnext 2019, the global tech giant Siemens signed an agreement to acquire MultiMechanics, Inc., a simulation software developer.
As a part of the acquisition, Siemens will incorporate MultiMech finite element software into Siemens Digital Industries Software and offered to customers. The MultiMech software is used to simulate functions and predict failures in advanced materials.
Through this integration, companies working with Siemens will be able to rapidly predict material properties and behavior, including failure at the microstructural level, all with impeccable speed and accuracy. For instance, customers can use MultiMech software to create a digital twin of materials engineered with part design and performance engineering in tact.
“Customers will have the ability to fully exploit the potential of advanced materials to optimize weight and performance in an efficient way that is not possible with classical, test-based, approaches,” said Jan Leuridan, Senior Vice President, Simulation & Test Solutions, Siemens Digital Industries Software.
In other news, the global tech company Altair also launched its new manufacturing simulation solution, called Inspire Print3D. Designed exclusively for additive manufacturing, the new software aims to provide an accurate toolset to design and simulate the 3D printing process for selective laser melting (SLM).
With Inspire Print3D, designers and engineers will be able to generate 3D models that are optimized to meet stringent performance requirements, and can also simulate performance to quickly modify critical process variables before sending the designs off for manufacturing.
Features of this software include part build simulation, cooling, cutting, and springback, as well as optimized part orientation, defect detection, and minimal support structure generation. Put simply, Inspire Print3D will allow engineers to make the most of SLM 3D printing, offering advanced simulation that will ultimately reduce the time and costs that go into post-processing and trial-and-error.
“With Inspire Print3D, companies can now reduce development and manufacturing costs by minimizing part supports and reducing material usage, print times, and post-processing,” said James Dagg, Altair chief technology officer, design and simulation solutions.
This past week, on social media, the Greek machine shop Extreme Tuners showed off 3D printed carbon composite connector rods that were made for use in the Mitsubishi Lancer Evolution.
According to a recent post on the shop’s Facebook page, which revealed the new 3D printed parts, the rods weigh just 77 grams, which is 10 times lighter than steel and 6.5 times lighter than aluminum. The tensile strength of this 3D printed rod is over 2600mpa, and is designed to handle over 15,000 rpm and 3000 horsepower.
For certain parts, such as pistons and rods, Extreme Tuners went on to state that it would be replacing CNC machining with 3D printed ceramics and titanium. In order to ensure high strength and lightweight properties, these parts are being designed using topology optimization.
3D printed rods and pistons are currently being tested in the Extreme Tuners facility, but all signs point to these parts as being suitable for functional use. All in all, the machine shop has demonstrated how 3D printing technology can be used beyond basic prototyping and implemented as end-use parts for automotive and aerospace applications.
Developed by the Warsaw University of Technology, researchers have recently created an atomizer capable of turning any metal scrap or part into material for metal powder bed fusion technologies. This solution, called the rePowder system, is being commercialized by the Polish company Amazement.
No matter what form the initial feed material comes in, the rePowder system is able to churn out high-quality powder. This feed can range from previously produced alloys to failed prints. This system can complete the entire powder production cycle, providing a closed-loop system that goes straight to the DMLS printer.
According to Łukasz Żrodowski, the inventor of the rePowder device and CEO of the Amazemet, the device will first be used to develop new 3D printed alloys by three groups within the university faculty, including a Biomaterials Group, a Group researching Aerospace Materials, and a Structural and Functional Materials Division.
While experimenting with DMLS 3D printing systems, the researchers realized that a system like the rePowder would be much more effective than having to wait weeks and pay thousands for a limited selection of materials. All in all, the Warsaw University of Technology research team is hoping to address the current lack of metal powder materials on the market by producing new materials on the rePowder system.
As the Oakland Raiders plan to move from the Bay Area to Las Vegas, the NFL team will be greeted by an 85-foot-tall 3D printed memorial to their former owner Al Davis. As reported by the Las Vegas Review-Journal last week, the interior of the new Allegiant Stadium will boast an 85-foot-tall Al Davis Memorial Torch.
According to Las Vegas Stadium Co. Chief Operating Officer Don Webb, the memorial will be the largest 3D printed object in the world, emerging through a giant hole that encompasses two levels of the stadium.
In the Las Vegas Review-Journal article, Webb said that the torch was 3D printed in order to achieve the complex geometry of the design.
“It’s complex geometry, it’s not a cylinder, it’s a swooping kind of thing. It’s a sculpture,” he explained. “In order to have that so it’s absolutely perfect you just can’t manipulate materials by hand without having some imperfections. So that’s why it’s being 3D printed.”
The frame of the torch is currently in place, while the final pieces are still being 3D printed in Kansas City. With a carbon fiber and aluminum structure, the torch will be a premier hangout spot for fans, surrounded by a circular bar.
As for the stadium itself, construction will cost around $2 billion and will be able to hold approximately 65,000 fans at any given game.
The Massachusetts-based company Desktop Metal had several announcements at Formnext 2019, including the release 4140 chromoly steel material for its flagship desktop-sized Studio System. But the most exciting news to come from the metal 3D printing pioneer during the trade show was the creation of a new metal binder jetting system: the Shop System.
Aiming to satisfy the market for mid-volume production, Desktop Metal is calling its latest 3D printer “the world’s first metal binder jetting system designed for machine shops.” There will be four different versions of the Shop System (4L, 8L, 12L, 16L), each of which will have different dimensions. The 4L, for example, has a build volume of 350 x 220 x 50 mm, while the 16L has a build volume of 350 x 220 x 200 mm.
While the Studio System was made for low-volume production and the Production System targeted mass production, the Shop System fits right in between the two, designed for shop owners looking for the middle ground in terms of production runs.
Starting at $150,000, the Shop System is surprisingly affordable for a 3D printing system of its caliber. The binder jetting technology enables this machine to pump out parts at ten times the speed of other metal production techniques. According to Desktop Metal, the Shop System can complete a batch of complex parts every 6-12 hours, which makes it possible to print hundreds of near-net-shape metal parts in a single day.
This high-speed production is possible due in part to the built-in support structure that the powder bed provides, as well as removable sintering setters. The Shop System reportedly produces parts with remarkable print resolution, around 33% higher resolution compared to other binder jetting systems.
According to Desktop Metal, this new system is the “highest resolution single-pass binder jetting printing system on the market”, providing a spot size of 16 microns per drop, 1600 native single pass DPI, and the ability to distribute up to 670 million drops per second.
“The Shop System offers users the same fully-dense metal parts at an affordable price that works in harmony with machining on the shop floor,” said Jonah Myerberg, co-founder and CTO of Desktop Metal. “What’s more, the system enables owners to both save and make money by eliminating tooling costs, lowering lead times, and bringing in new business because of an improved part-cost equation.”
During the first day of Formnext, GE Additive pulled the curtain to reveal two new metal 3D printing systems: the Arcam EBM Spectra L and Concept Laser M2 Series 5. Aiming to meet the evolving demands of industrial partners, the new machines show enhancements in both build volume and production capabilities. Both systems were on display in GE Additive’s booth at Formnext.
Already available to GE Additive customers, the Arcam EBM Spectra L offers double the build volume of the EBM Spectra H, while also providing a larger print area and more speed than the Q20plus. Equipped with a 4.5kW, the new EBM machine is currently compatible with grade 5 Ti6AI4V and grade 23 Ti6AI4V, and will work with pure copper sometime next year.
According to GE Additive, the Arcam EBM Spectra L platform can be used with newly unveiled Arcam EBM PRS 30, an automated powder retrieval system that makes powder handing both safer and more efficient. This system was developed with the aerospace industry in mind, providing a high degree of reliability, repeatability, and automation.
To complement the EBM portfolio, GE Additive also showcased the Arcam EBM Build Performance Analyzer, a suite of machine health data analytics that will be released throughout the next year.
The Concept Laser M2 Series 5, which is scheduled to be released early in 2020, was developed in collaboration with the GE Aviation. Utilizing a dual laser system, the latest Concept Laser system has a build volume of 350 x 245 x 245 mm and faster production speed.
According to GE Additive, this metal 3D printing system also aims to reduce surface roughness, provide greater consistency from build to build, and also contains hardware enhancements like an improved gas flow system and optical cooling with more than ten internal sensors.
The German additive manufacturing mogul EOS rolled up to Formnext 2019 with a brand-new 3D printing process called Fine Detail Resolution (FDR) technology. Demonstrated live during the trade show, the CO laser solution processes polymers in a way that creates delicate yet robust parts. According to EOS, FDR technology is able to produce intricate details and wall thicknesses as low as 0.22 mm.
“The new technology will combine the best of two worlds: the detailed resolution of stereolithography (SLA) with the durability and quality of selective laser sintering (SLS),” said Dr. Tim Rüttermann, Senior Vice President, Polymer Division, EOS.
At the heart of this technology is a 50-watt CO laser that is capable of producing an ultra-fine laser beam with a focus diameter that is half the size of what most SLS 3D printers are equipped with. While this increased precision can tackle complex details, it does come at a slight cost, as the exposure parameters can lead to superfine surfaces.
According to EOS, this super high-resolution technology is suitable for a wide range of applications, such as the production of filter units and fluid channels, plugs, electronic components, as well as consumer products like eyeglasses. Currently, the new process has been tested with a renewable PA 1101 material, which offers high impact resistance and elongation at break.
Customers can leverage the FDR technology through a variety of EOS configurations, including the EOS P 500 3D printer. Compared to EOS LaserProFusion, which was unveiled at last year’s Formnext, the new technique is positioned on the other end of the spectrum, giving users the ability to choose the technology the best suits their needs. While FDR technology is ideal for manufacturing delicate components, EOS LaserProFusion is better-suited for those seeking maximum productivity with dedicated application materials.
There were plenty of other noteworthy product releases and partnerships announced during Formnext 2019. While it’d be impossible to cover everything that happened in this digest, we’ll try to provide a quick recap of the other happenings to come out of Frankfurt this past week.
One of the most thrilling displays on the trade show floor was LOCI, a 3D printed “pod car” created by the German 3D printer manufacturer BigRep. Using large-scale FDM 3D printers and BigRep Part DNA technology, this autonomous electric car has NFC chips embedded into the 3D printed parts.
By embedded NFC chips into 3D printed components, BigRep wanted to demonstrate how engineers could use this technology to scan and identify unique parts using a mobile device. Designed by BigRep’s in-house consultant NOWLAB, LOCI is intended to serve as a “last mile transportation solution” for urban environments, such as airports and train stations.
“LOCI is more than a vehicle, it’s the evolution of personalized mobility,” said NOWLAB co-founder and BigRep CIO Daniel Buening. “LOCI is an affordable solution for urban transportation, harnessing the agility of AM while also demonstrating the cost-efficient advantages of 3D printing for sustainable AM such as manufacturing personalized products on-site and on-demand.”
Speaking of transportation, the additive manufacturing veteran Stratasys announced its new Rail Industry Solution at Formnext 2019. The new service aims to help passenger trains become more reliable and reduce costs by allowing operators to 3D print spare parts on-demand.
The Rail Industry Solution will make use of Stratasys Fortus 3D printers, along with ULTEM 9085 resin and Antero 800NA material, both of which have passed the European Union’s Rail Standard, EN45545-2. Rail operators will be able to quickly produce unique spare parts that meet stringent government certification requirements, reducing lead times and production costs.
A number of customers and partners are already utilizing the Rail Industry Solution, including Angel Trains, Bombardier Transportation, Chiltern Railways, DB ESG, and Siemens Mobility.
In other news, the Massachusetts-based 3D printing pioneer Markforged announced Turbo Print for its X7 Carbon Fiber 3D printer. This new feature effectively doubles the system’s print speed without jeopardizing surface quality. By increasing the print speed of the Markforged X7 3D printer, customers will gain the ability to quickly replace parts, increase production volume, and ultimately receive a greater return on investment.
There was a whole lot more happening at Formnext, but these were some of the most impactful tidbits from throughout the week. Stay tuned for our next 3D Printing Industry Digest to find out what else is taking place on the industrial 3D printing stage.
Announced ahead of Formnext 2019, the global tech giant HP is continuing its triumphant journey through the additive manufacturing landscape with a new “pay-per-build” HP 3D as a Service (3DaaS) Base subscription service. Aiming to improve customer experience with its groundbreaking Multi Jet Fusion technology, HP will provide customers with automatic replenishment of HP 3D Supplies, tracking of billing and usage, as well as remote and on-site support services for its HP Jet Fusion 5200, 4200, and 500 series printers.
“The journey to digital manufacturing requires much more than just technology. Customers want integrated solutions coupled with convenient capital models providing the predictability, transparency, and flexibility to quickly scale their businesses,” said Ramon Pastor, interim President of 3D Printing and Digital Manufacturing, HP Inc.
HP is also expanding its Service (3DaaS) Plus subscription to include the HP Jet Fusion 340, merging together hardware, supplies, and services for customers that want to bring rapid prototyping and final part production in-house. Outside of the new subscription offerings, HP is also flaunting a treasure trove of new partnerships and expansions at Formnext 2019.
Showcasing new applications for Multi Jet Fusion and its Metal Jet 3D printing technology, HP will be demonstrating use cases that stem from partnerships with Siemens and Volkswagen. In collaboration with Siemens, the company will show off two production-ready automotive parts for EDAG and Adient, one of which is an active coolant distributor for electric vehicles as well as a seat headrest.
In addition to the new subscription service and partnerships, HP has also expanded its Digital Manufacturing Network by bringing new service providers on board, including Prototal in Europe and Solize in Japan. Finally, Lubrizol is rolling out ESTANE 3D TPU M95-A, a powder-based TPU material for the HP Jet Fusion 4200, giving customers the ability to print more flexible and elastic parts.
The Massachusetts-based 3D printer manufacturer Formlabs also swooped in with several exciting announcements this week, not the least being the launch of Formlabs Dental, a new sector that will focus on providing a complete ecosystem to orthodontic professionals. Enlisting industry professionals into its growing ranks, the new business unit will comprise of a dental service plan that helps educate and aide customers.
In tandem with the new Formlabs Dental program, Formlabs also unveiled the Form 3B, a variation of the Form 3 that is specifically designed for orthodontic applications, sporting a clinical white color scheme and said to deliver “crisp and consistent dental parts.” The company is planning to roll out a large swath of dental materials, including four new hues of dental resins. In the meantime, a team of around 50 materials scientists will continue to develop new materials and profiles, all of which are to be verified by dental professionals.
“Our new Form 3B printer is uniquely tailored to seamlessly digitize, streamline and expedite workflow so dentists and technicians can focus on providing patients with the outcomes they expect and deserve,” said Max Lobovsky, CEO and Founder of co-Formlabs.
Formlabs also shared that the Form 3B will benefit from the company’s Materials Partner Program, effectively allowing dental practices to utilize third party materials. But that’s not all the SLA 3D printing pioneers announced this week.
In other news, Formlabs also acquired Spectra, a photopolymer materials provider that has been the company’s primary material supplier since 2012. Following the acquisition, which includes a one million dollar investment in R&D, the newly acquired materials supplier will start developing biocompatible polymers, which could indicate a further focus on bioprinting applications.
This past week also yielded some big news regarding advancements in the material realm of additive manufacturing. For starters, the 3D printing service bureau Shapeways struck a partnership with the coveted material provider Henkel to expand Loctite materials to be more compatible with large-scale 3D printing. The collaborative project, dubbed “Loctite powered by Shapeways,” will give Shapeways customers access to materials under the Loctite brand.
The partnership will benefit Henkel by providing their materials to a broader global audience, while Shapeways customers will have access to Loctite’s production-grade resins for large-scale manufacturing technology provided by the 3D printing service bureau. The multi-step program will allow Shapeways users to order demo parts made from Loctite materials.
“Combining Shapeways’ technology and production expertise with our materials know-how and industry access enables a powerful combination for the large-scale 3D printing of customized Loctite parts,” said Philipp Loosen, Head of 3D Printing at Henkel. “Based on the partnership, we will launch a digital platform leveraging novel opportunities to its global customers for Loctite solutions in 3D printing through Shapeways’ existing platform integration.”
There has also been some innovation on the metal 3D printing material front. The California-based material provider HRL Additive has recently developed incredibly high-strength aluminum 3D printing powder. First used by NASA’s Marshall Space Flight Center back in September, the company is now scaling and commercializing its 7A77 powder, which is reported to be the strongest 3D printable aluminum available to date.
HRL intends to target the automotive and aerospace industries with its new aluminum powder, as it hopes to be applicable for large-scale, high-performance applications in these fields. The material producer has reportedly started working nTopology, a 3D design software company focused on generative design, and the manufacturing service provider Morf3D to showcase the aluminum powder’s potential for heat transfer and flow applications.
“We are a new aluminum supplier and are offering a new product, 7A77 powders. We believe the current demand for aluminum powders for additive manufacturing is high and will only grow as high strength alloys like ours become available,” said Michele Durant, spokesman for HRL Laboratories.
While we’ve covered some major announcements from big industry names like HP and Formlabs, there’s also a boatload of exciting news coming from smaller, perhaps lesser-known companies on the additive manufacturing circuit. At Formnext 2019, new innovative 3D printers will be in abundance across the trade show’s expansive floor. Here are some of the most notable 3D printers that were unveiled this past week, some of which will be on display in Hamburg this coming week.
The Polish 3D printer manufacturer 3DGence is broadening its product offerings to touch on the professional 3D printing market, unveiling its new Industry F420 3D printer at Formnext 2019. This FDM machine offers an impressive 380 x 380 x 420 mm build volume and a print speed that reportedly reaches up to 400 mm/s. What separates the Industry F420 from other 3DGence printers is its ability to print with high-performance materials such as PEEK and ULTEM.
Another unique aspect of the F420 is its quick-change modular system, allowing users to seamlessly switch between three modules with pre-defined profiles for different engineering-grade materials. Furthermore, this industrial-grade machine from 3DGence is also equipped with an advanced air filtration system that filters out styrene, VOC, PM 2.5 and PM 10.
This past week, the Swedish startup WeMatter launched its new Gravity 2020, a new SLS 3D printer that intends to provide engineers with the ability to produce durable parts at a lower cost. Boasting a surprisingly sizable 300 x 300 x 300 mm build volume, the Gravity eases many of the complexities that accompany SLS 3D printing, offering an integrated powder handling system, as well as pneumatic mechanisms that assist in transporting, dosing, and evacuating powder materials in a closed system.
Users are able to monitor and control the Gravity 2020 through cloud connectivity, which utilizes built-in sensors, cameras, and electronics to keep the printing process under supervision. At the moment, this SLS 3D printer will come with a PA11 powder material, but WeMatter is reportedly in the process of developing new materials for its system.
Known for its large-format desktop 3D printers, the Barcelona-based BCN3D Technologies is also shifting toward more professional pastures with the release of its new Epsilon 3D printer. This dual-extrusion FDM machine has a 420 x 300 x 400 mm build volume along with a fully-enclosed, heated build chamber. Featuring its independent dual extrusion (IDEX) system, which comprises of two extruders that work independently of one another, the Epsilon offers duplication and mirror modes to improve production volume.
Priced just under the $8,000 mark, the Epsilon is a professional system made for designers and engineers, evident by BCN3D’s recent negotiations to integrate its new 3D printer into the production workflow of automotive manufacturers like BMW, Nissan, and Renault. In addition to unveiling the BCN3D Epsilon, the company also announced partnerships with BASF and Mitsubishi Chemical (MCPP) to develop new application-specific material for the new professional-grade 3D printer.
Known for disrupting the metal additive manufacturing space with the Studio System and Production System, the Massachusetts-based startup Desktop Metal has found immense success with its affordable metal 3D printers. Late last week, the company expanded its scope (and heating up its battle with competitor Markforged) by unveiling the Desktop Metal Fiber. Using a process dubbed as micro automated fiber placement (μAFP), the Desktop Metal Fiber 3D printer is capable of printing high-strength and incredibly stiff parts with industrial-grade continuous fiber composite materials.
According to a press release shared by Desktop Metal, the new 3D printing platform produces parts that are two times stronger than steel and one-fifth of the weight. By miniaturizing a technology commonly found in million-dollar machines and combining it with FDM 3D printing, the company will offer its Fiber 3D printing platform in two forms. Equipped with a robotic tool changer architecture, the Desktop Metal Fiber line can store up to four tools, including additional FDM print heads for different materials, as well as planned enhancements such as automated in-process inspection.
“For the first time, Fiber printers combine the material properties of high-performance AFP continuous fiber materials with the affordability and speed of a desktop 3D printer,” said Ric Fulop, CEO and co-founder of Desktop Metal.
Starting at $5,495 per year, Fiber HT is designed to produce parts with continuous composites that have less than 1% porosity and up to 60% continuous fiber loading with industrial-grade matrixes, such as PEEK and PEKK. This platform is capable of producing flame retardant parts that can withstand high temperatures up to 250 degrees Celsius.
The other 3D printer, called Fiber LT, is a cheaper option that starts at $3,495. This machine utilizes continuous fiber 3D printing to manufacture high strength and non-marring parts with less than 5% porosity using PA6 thermoplastics. Both platforms offer a 310 x 240 x 270mm build volume and are engineered to be used in print farm configurations of 6 or 10 3D printers.
A partnership struck back in 2018 between Volkswagen and HP’s 3D printing wing has borne fruitful progress, as the German automotive company recently reached a milestone using the HP Metal Jet system, a metal 3D printer touted for its ability to manufacture high volumes of production-grade metal parts.
After announcing a three-phase strategic roadmap leading to the functional production of automotive parts, Volkswagen has reached an important milestone in the first stage of this plan, producing over 10,000 miniature ID.3 models ahead of the electric vehicle’s long-awaited launch event. The Volkswagen ID.3 is the company’s first fully-electric production car offering a CO2-neutral footprint.
“What better way to showcase the innovation of Volkswagen than to use our own technologies in the marketing campaign for the premiere ID.3 launch,” said Dr. Goede. “We are extremely pleased with the technical features and the speed, quality and low cost per part that HP Metal Jet has provided. The surface quality and feature resolution enabled great attention to detail and made it possible to add a special touch to this important company milestone.”
This is just the first accomplishment of the collaboration, which also includes GKN Powder Metallurgy, as Volkswagen eventually plans to use the HP Metal Jet system to 3D print structural parts for the next generation of vehicles. Aiming to increase in-part size and technical requirements, the automotive manufacturer hopes to produce between 50,000 to 100,000 soccer-size parts per year.
The HP Metal Jet could be utilized to produce higher performance functional parts with critical structural requirements, including custom gearshift knobs and mirror mounts. Volkswagen also intends to use the metal 3D printing system for other applications in the near future, including the production of lightweight metal parts that still meet stringent safety requirements.
With the esteemed additive manufacturing trade show Formnext on the horizon, a number of 3D printing companies are starting to roll out innovative products. While most of the attention is usually placed on 3D printers, this week’s spotlight is focused on new advanced materials.
For instance, the Italian 3D printer manufacturer Roboze has unveiled a new amorphous thermoplastic polyimide filament called EXTEM AMHH811F for its professional-grade ARGO 3D printer. Based on an industrial-grade resin made by the global chemical producer SABIC, this industrial-grade filament is said to be flame-retardant and highly resistant to heat, capable of deflecting up to 230 degrees Celsius.
Earning UL Blue Card recognition with V0-075 certification, this material is on par with metal parts produced with traditional manufacturing techniques, such as injection molding. According to Roboze, this thermoplastic polyimide filament can be used for electronics, consumer goods, as well as parts for aeronautics and aerospace applications.
Making its grand debut at Formnext 2019, the company 6K, previous known as Amastan Technologies, will showcase new metal additive manufacturing powders made from sustainable sources. Employing a combination of what 6K calls a UniMelt system and Alloy Reclamation technology, the company is able to produce metal powders from certified chemistry machined millings, turnings, and other recycled feedstock sources.
Finally, Kanthal, which is a heating technology brand under Sandvik, is rolling out a new 3D printing service that will focus on 3D printing custom thermal components using Kanthal AM100. This material is an advanced heat-resistant ferritic iron-chromium-aluminum alloy (FeCrAl) that offers a high degree of strength and exceptional form stability at high temperatures.
According to the company, Kanthal AM100 creates a highly protective aluminum oxide layer, providing protection in high-temperature furnace environments where oxidizing, sulphidizing, and carburizing takes place. The industrial-grade material is reportedly best-suited for the production of heating elements, burner nozzles, protective shells fittings, and more.
Widely recognized for its industrial-grade binder jetting technology, ExOne recently unveiled its new X1 160Pro, a high-volume metal binder jetting machine that is said to be the largest on the market. Boasting a whopping 800 x 500 x 400mm build volume and 10,000 cm3/hour build speed, the new ExOne system is capable of producing pure metal parts from a single alloy.
The ExOne X1 160Pro will launch with six different materials, including a variety of stainless steel and Inconel powders. Ceramic materials will also be available for the new binder jetting system. This machine will employ the company’s exclusive Triple Advanced Compaction Technology (ACT) system, which works by dispensing, spreading, and compacting ultra-fine powders to produce dense parts with a high degree of repeatability.
“Our technology roadmap has been leading us to this machine for more than two decades,” said John Hartner, ExOne CEO. “At the same time, the X1 160PRO was also designed in response to growing demand from automotive, defense and aerospace customers. We’re incredibly proud of what this model means for the future of metal 3D printing and sustainable production of large metal parts without design limitations.”
At Formnext 2019, visitors can also stop by the booth belonging to the Vienna-based 3D printer manufacturer Incus GmbH, previous known as Lithoz GmbH. The company has recently announced the Incus Hammer Series machine, an industrial-grade metal 3D printer that uses photopolymerization to produce intricate metal parts, such as drill heads and heatsinks.
By using metal feedstock, the Incus Hammer Series eliminates the need for using protective gas atmospheres and is compatible with precious metals, iron-based alloys, and more. This 3D printing system is capable of producing finely detailed structures with high-quality surface quality in a cost-effective and speedy manner. The Incus Hammer Series will be on display at Formnext 2019.
Finally, the metal 3D printing company Velo3D, known for its Sapphire metal 3D printers, has hooked its first customer for its Assure Quality Assurance and Control System, and oh boy it’s a big one. The new metal 3D printing quality assurance system will be adopted by Stratasys Direct Manufacturing, a subsidiary of the additive manufacturing titan Stratasys.
Assure was designed to provide evidence of part quality for Sapphire metal 3D printers using real-time, multi-sensor, physics-based detection algorithms. The software is capable of detecting flaws or miscues and addressing the issue to ensure that these anomalies are not repeated. As a result, customers like Stratasys Direct Manufacturing will be able to prevent variation and obtain extensive documentation to increase the speed and quality of high-volume production.
“Assure is a revolutionary quality-control system, an inherent part of the VELO3D end-to-end manufacturing solution for serial production,” says Benny Buller, founder and CEO of VELO3D. “Assure is part of our vision to provide an integrated solution to produce parts by additive manufacturing with successful outcomes.”
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