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Wi3DP: Experts Discuss Challenges and Trends in 3D Printing Sustainability

A virtual panel discussion and networking event by Women in 3D Printing (Wi3DP) gathered three industry experts and leaders to share their insights and experiences on sustainability trends in additive manufacturing (AM) and how they will impact the industry’s choice of materials, energy usage, and waste.

Hosted by AM-Cubed President and Founder, Kristin Mulherin, and supported by AM service company Link3D, the live event featured Ellen Jackowski, HP’s Chief Sustainability and Social Impact Officer; Sherry Handel, the newly appointed Executive Director of the Additive Manufacturer Green Trade Association (AMGTA); and Cindy Deekitwong, Global Head of Marketing and Strategy for 3D Printing at Henkel Adhesive Technologies. The group touched on several hotly debated topics, like the lack of research on the environmental benefits and challenges of AM and how to generate a fully circular economy for the industry, underlying the importance of finding ways to enhance the already visible benefits of the technology.

Mulherin asked the experts to discuss how sustainability initiatives can respond to many of the challenges facing 3D printing. For Jackowski, companies need to start making more sustainable decisions that will help move the industry forward in a responsible manner. Adding that everyone in the industry, no matter what role they play, need to have what she likes to call “sustainability contact lenses,” meaning that, even if the job description does not involve sustainability, they need to figure out a way to make decisions that will have an impact on the carbon footprint, the community, or the health and safety of a manufactured product.

“We certainly don’t want to start seeing 3D printed parts bobbing around in the ocean like we see so many other things these days. We all need to continue to drive the energy efficiency of this business,” suggested Jackowski. “For example, when you plug those 3D printers in, they suck up a lot of energy, and that is certainly an area for innovation. So, I would say that whatever part of the 3D printing industry you are in, think about your impact on sustainability. It is also crucial to understand the implications of the materials we use, where we source them from, and how our customers use them in the most sustainable manner.”

Ellen Jackowski visiting an FSC-certified forest to see responsible forest management in action. (Image courtesy of HP)

The other panelists agreed that sustainable impact is about collaborative efforts, and having everyone involved in reinventing the company for sustainable impact. Deekitwong highlighted that the technology itself lends to more efficient designs that create less waste and eco-friendly supply chains, but she believes the industry should enhance sustainability efforts by reducing fuel consumption, working with suppliers to find biorenewable materials and collaborate with ecosystem partners and consumers to recycle end-of-life parts. Deekitwong shared how Henkel’s recycling initiatives led the company to collaborate with TerraCycle to upcycle garbage from used 3D printed parts, resins, and packaging.

For Handel, who is focused on promoting the inherently positive environmental benefits of AM within key industries and the public at large, the existing research does not provide enough good metrics in data. This is why AMGTA is commissioning academic research through life-cycle assessment (LCA), to quantify and provide data and metrics on what it takes to produce a particular part via both traditional and additive manufacturing processes. Eventually, this will help the industry better understand what the eco-footprint is, and reveal some areas that will make the industry even more sustainable in the future.

Handel then centered on one of AMGTA’s core projects that will help create a more circular economy by empowering companies to develop a global set of standards to properly and cost-effectively recycle powder condensate, a vaporized metal powder that collects on the chamber walls and in the filter unit during a build process.

“The powder condensate cannot be reused and is considered a hazardous waste by the US Environmental Protection Agency (EPA). It usually ends up in a landfill, so we want to find a way to repurpose it, recycle it, and publish a a set of standards in early 2021 that we can share with our member companies and industry to help mitigate this challenge,” indicated Handel.

Then, Mulherin shared an overview of the importance of avoiding greenwashing, an unsubstantiated claim to deceive consumers into believing that a company is environmentally friendly. For both Deekitwong and Jackowski, this point is crucial, especially since both Henkel and HP have over 50,000 employees, and need to convey the message to everyone that the company’s reputation could be destroyed with one wrong move. Jackowski further described how it could be easy for employees to make a judgment call that could lean toward greenwashing, but said HP is “very aware of the boundaries of greenwashing.”

Cindy Deekitwong. (Image courtesy of Henkel Adhesive Technologies)

Both companies have seemingly strong objectives in place. For Henkel, reducing carbon footprint in operations means a 65% reduction by 2025, 75% by 2030, and becoming “climate positive” in 2040. While HP’s awareness of its responsibility around creating a circular economy led to policies to use fully recyclable materials in 3D printers.

“Our eye is looking at how we set up this industry, and as we’ve transitioned, we have seen increased adoption during the pandemic because of the flexibility and speed that 3D printing offers. But I think there are a lot of opportunities to continue to innovate and, as we stand up this industry, as we all transform from traditional manufacturing to 3D, we need to think about it holistically and doing it right from the beginning,” said Jackowski.

Sherry Handel, Executive Director of the Additive Manufacturer Green Trade Association. (Image courtesy of AMGTA)

A clear challenge for Handel is the lack of awareness of environmental management system certifications. AMGTA encourages member companies to get ISO 14001 certified, an international standard that helps set the framework for a company to benchmark where they are and help them improve environmental criteria over time, like energy use. But Handel said that “not everyone is going to be able to flip on a dime and hit the easy button to get things accomplished and starting somewhere is better than nothing,” which is why AMGTA suggests third party certifications, like the Green Business Bureau, taking companies on a pathway towards more environmentally sustainable practices.

Toward the end of the conversation, Mulherin suggested that organizations need to recognize that sustainability efforts will generate revenues, instead of simply costing the companies money. In fact, Jackowski indicated that customers are taking notice of a company’s sustainability initiatives, detailing how HP saw $1.6 billion in new sales in 2019 due to the company’s actions in sustainability, a 70% increase year over year.

“We are seeing a shift, an awakening of general consciousness in consumer behavior and purchase patterns surrounding sustainability, and we only expect it to get stronger. That provides financial motivation for everyone in this space to continue to accelerate what we are doing. Whatever part of the value chain you are in, you are going to start feeling it more: the pressure to go sustainable,” said Jackowski, who also emphasized HP’s continued commitment to sustainability since founders David Packard and Bill Hewlett created the company in 1939. “As it has evolved over the years, sustainability has gone from being founder-led to across the DNA of the company.”

The virtual event gathered a wide array of participants worldwide, most of them working in the AM industry and eager to learn about sustainable practices thriving in 3D printing. As with previous panels, this Women in 3D Printing event facilitated a networking experience both before and after the speakers virtually took the floor, with crowded tables and a lot of simultaneous chats about the importance of environmentally sound practices in additive.

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Industrial 3D Printing for High-Performance Parts

One of the most exciting aspects of exploring our platform at Shapeways is learning more about how users on all levels are innovating today, and how you might be able to expand your own concepts and designs further through 3D printing. There are a variety of different, affordable services and products offered; however, one of the most important facets that must always be considered — from Shapeways to the entire 3D printing space worldwide — is materials. You can modify printers and write new software all day long, but without a good selection of feedstocks to choose from, quality results are nearly impossible.

BASF (known as a worldwide leader in development and production of chemicals) began partnering with Shapeways this year in providing new materials through their BASF 3D Printing Solutions subsidiary. Our new Powered by Shapeways platform enables users to choose from BASF’s Forward AM materials, expanding accessibility and options for high-performance parts.

The new material portfolio includes Ultrasint TPU01, Ultrasint PP, Ultracur3D RG 35, and HP High Reusability PP.

Ultrasint TPU01

Ultrasint industrial grade powders are meant for 3D printing complex geometries that are accurate, strong, and durable. This thermoplastic polyurethane material is suitable for 3D printing functional end-use components, and is recommended if you require excellence in quality and flexibility for parts, along with the following features:

High level of detail
Good surface quality
Recyclability (Ultrasint TPU01 offers up to 80% reusability ratio)
Airtight parts (down to 1mm wall thickness)
UV resistance
Hydrolysis resistance

Approved for contact with skin, TPU01 is popular in automotive applications due to the open lattice structure encouraging both heating and cooling for interior parts like headrests or seats. Materials can be customized for individuals, and especially in areas typically experiencing heavier loads. Many of the best advantages of 3D printing technology can be used with TPU01 in particular, to include exponentially less time spent in development, production, and assembly time — along with elimination of tooling requirements and cost. Texture can be customized in terms of hardness/softness, and a variety of accompanying finishing options are offered too.

Another unique
benefit of TPU01 is that it can be used to 3D print protective gear for
the automotive industry; for instance, a protective glove was created for
workers at Jaguar Land Rover, offering support to prevent injuries due to
repetitive tasks. This type of gear is strong, yet lightweight and can be
completely customized for the wearer, including special modifications for the
job requirements of the individual. Again, this design is possible due to the
flexible lattice structure of the material. While it is flexible, hardness can
also be customized during the design process.

3D printing is employed in many footwear applications these days, and by users of widely varying experience and resource levels—from leading sports shoe companies to designers fabricating elegant flats or heels at their studios or from home workshops. Midsoles typically represent the 3D printed portion of shoes, with TPU01 allowing for consumer-specific customizations for greater comfort — designed around the wearer’s step, gait, pressure, and support — whether for sports, running, or other needs. Shoes can be made quickly, affordably, and on-demand.

TPU01 can also
be used to 3D print midsoles that are eco-friendly, requiring less material, as
well as offering improved aesthetics and performance. Personalized touches can
be applied afterward with a variety of different finishes and color choices.

Download the material data sheet from this page.

Ultrasint PP nat 01

A polypropylene material suitable for rapid prototyping as well as large-volume production of smaller parts, Ultrasint PP is a popular and affordable plastic with good market recognition. This material yields parts with excellent quality, balanced mechanical properties, and liquid, hydrolysis, and chemical resistance.

Ultrasint PP is
meant for production of smaller components like fluid reservoirs,
interior and exterior automotive parts, air ducts and piping, clips, covers,
hinges, and more. Parts like sensor covers can be made for critical aerospace
applications also, with prototypes fabricated from the same material and
process as the functional part. Live-hinge and snap-fit “barb” fittings can be 3D
printed too, with options for color and surface.

Download the material data sheet from this page.

Ultracur RG 35

Ultracur RG 35 is a highly reactive photopolymer suitable for a variety of parts used for multiple purposes, to include:

Connectors
Snappers
End-use components

Recommended for parts that require rigidity, Ultracur RG 35
offers excellent resolution in printing, low shrinkage, accuracy, and both
speed and ease in production.

Download the material data sheet from this page.

HP High Reusability PP

A material specialized for use in HP’s production-grade Multi Jet Fusion 3D printers, HP High Reusability PP is suitable for making parts that are chemically resistant like piping and fluid systems, as well as automotive parts for the interior, exterior, and under the hood.

Download the material data sheet from this page.

Here at Shapeways, we have always offered a rich foundation for providing a wide range of materials suitable for industrial use. And while there are certainly no rules within the 3D printing realm about using (as well as continually developing) and experimenting with materials, our partnership with BASF has yielded a treasure trove of quality materials for the automotive industry, as well as for critical applications used in aerospace, architecture, and medicine. Recently, our team has also focused on offering 3D printing for robotics and drone applications.

Whether you are a busy designer or an engineer hoping to have a prototype or functional part 3D printed quickly, you will find an inspiring range of materials available at Shapeways. Without having to invest in industrial printers or materials on your own, you can benefit from our long-term experience and investment in proprietary, advanced technology.

The post Industrial 3D Printing for High-Performance Parts appeared first on Shapeways Blog.

SmarTech’s Metal 3D Printing Powders Report Sees Stalled Growth to $3.7B in 2020

SmarTech Analysis has published the sixth edition of its report dedicated to metal 3D printing powders, “Additive Manufacturing with Metal Powders 2020”, which takes into account the economic challenges and opportunities associated with metal additive manufacturing (AM) in the face of the COVID-19 pandemic. Using what the market research firm calls “a robust market tracking and forecasting dataset” that is provided with the report, SmarTech explores current dynamics in metal AM, both focusing on short-term trends and long-term projections.

The company predicts fewer purchases of metal 3D printing hardware, due to the economic downturn, may be partially offset by opportunities in material and production services resulting from new interest in 3D printing, leading to single-digit growth in these segments. In turn, SmarTech anticipates single-digit growth in metal AM revenue even after the economic issues faced by 3D printing companies. This growth is dependent on firms conducting new market strategies founded on this new interest in overcoming supply chain issues faced during the pandemic, according to SmarTech.

SLM Solutions facility in Lübeck, Germany. (Image courtesy of SLM Solutions)

As we have seen, the pandemic has impacted every company in the industry, from 3D Systems and Stratasys to GE and Boeing, but that some firms have been able to weather the storm to some extent. SLM Solutions, for instance, has curiously posted a 90 percent increase in revenue growth over the first half of 2020 compared to last year through an order backlog from 2019 and a careful review of these orders.

SmarTech notes that nearly every firm in 3D printing used AM in a positive manner during the pandemic, either to produce critical components for medical care or to enable the development of new medical products for future events. As a result, 3D printing has come to the forefront of manufacturing once more. At the same time, the market research company points out that the fact that metal AM is heavily tied to powder bed fusion has “raised the collective bar for performance and capability of the technologies, exposing holes in the broader manufacturing landscape in terms of necessary expertise in additive.”

Source: SmarTech Analysis

Despite the economic depression that has resulted from the impacts of the virus, new investments were made into metal AM in 2019 and early 2020. While growth has slowed, there have been new business ventures, with SmarTech pointing out that, so far during this time, the emphasis of these projects has been on production services rather than hardware.

An example of this is further investment by one of the world’s largest traders of goods and services, Sumimoto Corporation, in metal 3D printing service provider Sintavia. Despite the pandemic, Sumimoto is pouring more funds into the Florida-based AM company to scale its production for flight-critical parts.

Sintavia is the only company in the world with Nadcap approvals for laser additive manufacturing, electron beam additive manufacturing, and in-house heat treatment. (Image courtesy of Business Wire)

In addition to the new SmarTech report, the report’s author and Vice President of Research for Smartech, Scott Dunham, has recently written a 3DPrint.com PRO article providing some insight into the short-term dynamics of the metal 3D printing powders market. In that article, he notes that metal powders grew significantly in 2019 at a rate of 37 percent, compared to 2018. In the first three months of 2019 alone, as much powder was sold and shipped as in all of 2014 combined. This is driven in part, according to Dunham, by a small group of “AM power users”, such as Stryker, Siemens, and GE, who are using metal 3D printing for series production of important parts.

In other words, though the pandemic is generally slowing economic growth overall, the benefits of 3D printing when successfully implemented are continuing to make their way into general manufacturing. While growth may slow to single digits in the near-term, the long-term outlook for metal AM is bright.

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BASF and Photocentric Launch Materials for Visible Light 3D Printing

BASF’s 3D printing unit, Forward AM, has advanced its partnership with Photocentric to develop and launch a materials portfolio specifically tailored for the LCD-screen based daylight 3D printers from Photocentric. The partnership combines the latest materials and 3D printing technology, improves the quality and efficiency in 3D printing components, and aims to further enable the industrialization of the additive manufacturing industry.

“From the very beginning of our cooperation, together we have aimed to extend the possibilities of advanced photopolymer solutions to address the enormous spectrum of applications opened up by the outstanding performance of this Additive Manufacturing technology. We believe the combination of the expertise gained through decades of BASF research into 3D printing materials, our unique material portfolio, and Photocentric’s remarkable printer technology, genuinely has potential to enable cost competitive parts printing and thus make mass-manufacturing of functional end-use parts a reality,” explains François Minec, Managing Director BASF 3D Printing Solutions.

“The new chemistries we have harnessed for our product offering enable us to meet our customers’ very high mechanical performance demands and realize their mass scale applications. At the same time we are intentionally offering industry-disruptive prices on formulated bulk resin to the market: Jointly we want to move the Additive Manufacturing business towards higher productivity and lower prices per printed part,” adds Dr. Piotr Bazula, Global Product and New Business Development Manager Liquid Formulation Solutions, BASF 3D Printing Solutions.

The two companies had been collaborating on optimizing photopolymer resins and printer parameters, and the next step has been to go to market together with a range of high performance photopolymers: ‘Ultracur3D Powered by Photocentric’. For BASF, this is another specialized application for its Ultracur range of materials, which can be applied to DLP, LCD and SLA based 3D printing technologies.

“Photocentric is deepening its partnership with BASF to facilitate the custom mass manufacture of components in a wide variety of industries. Together we have created a unique combination of software, hardware and chemistry that removes obstacles to using Additive Manufacturing in mass production. Working with Forward AM, we have developed a portfolio of products that delivers the required functional properties perfectly, enables high-resolution mass manufacture, and thereby adds real customer value,” says Paul Holt, Managing Director, Photocentric Ltd.

“This extended range of high performance materials now allows our customers to take full advantage of the large build volume, speed and reliability of Photocentric printers, to move towards the cost-effective, large-scale production of end-use parts,” comments Sally Tipping, Sales Director, Photocentric Ltd.

Image Courtesy of Photocentric

Ultracur3D EPD 1006 Powered by Photocentric will be the first in an initial set of ten products specifically developed for LCD daylight technology, and the partnership will look to expand offerings within the portfolio progressively.

BASF Ultracur material used in the LC Magna. Image Courtesy of Photocentric.

Photocentric, founded in 2002 and headquartered in the UK, has disrupted the vat photopolymerization 3D printing market with its Liquid Crystal 3D printers and material solutions that rely on LCD-screens (using visible or low light spectrum) to cure special photopolymers to print high quality parts, that significantly improve the speed and cost efficiency of 3D printing production, particularly in digital dentistry.

Video courtesy of Photocentric

The polymer market is set to generate $11.7 billion in 2020, as per SmarTech’s “Polymer Additive Manufacturing Markets and Applications: 2020-2029” report, and BASF, a leading polyurethane manufacturer and the world’s largest chemical company (by revenue), has been expanding its presence in the 3D printing industry, to include specialized materials providers, hardware and software providers, as well as service bureaus.

In 2019, BASF had introduced its new 3D printing brand ‘ForwardAM’ and, since then, has engaged in a number of partnerships, investments and acquisitions in the 3D printing ecosystem to expand its presence and offerings in the industrial AM market. The company acquired Sculpteo, partnered with Shapeways to combine the product creation platform’s proprietary technology with the range of additive materials from ForwardAM via a co-branded website; teamed with HP to develop materials for the Multi-Jet Fusion 3D printing platform, with Impossible Objects in its composite sheet layering technology, and with Origin and ECCO for footwear production; invested in Materialise for materials and software; invested in and partnered with PrismLab in the Asian market, with Essentium for Ultrafuse filaments for high-speed extrusion printing, as well as with Owens Corning for glass-fiber reinforced filament materials.

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RIZE Announces RIZIUM Glass Fiber 3D Printing for Large Color Parts

This morning Massachusetts-based Rize, Inc. announced the release of its RIZIUM Glass Fiber (GF) composite. Founded in 2014 by CTO Eugene Giller (formerly of ZCorp), the 3D printer manufacturer also specializes in materials for applications like life sciences, communications, and branding. Now, the World Economic Forum (WEF) 2020 Technology Pioneer continues its commitment to color 3D printing with a new composite for large, full-color parts, offering the strength to support complex structures—while preventing issues like warping.

On a mission to redefine 3D printing, the company stated in a recent press release that they hope to continue to provide users with the ability to expand their work further with this new material. Sustainability for their users with next-generation technology has always been a focus for the Rize development team too, as they have developed proprietary materials over the years. RIZIUM Glass Fiber is compatible with all of their 3D printers (as well as printers from RIZIUM Alliance partners).

The new GF material was founded on Rize’s cyclic olefin-based matrix, offering the following features:

Low emissions during production
Extremely low moisture absorption
High chemical resistance
Strength, durability, and stability

RIZIUM GF has been “rigorously tested” and proven prior to its release, and is compatible with Rize Augmented Polymer Deposition (APD), combining inks with polymers to make new materials. Rize states that users will also be able to look forward to 3D printing “large build volumes” for many different applications.

RIZE RIZIUM Glass Fiber tooling

“Until now full color 3D printing applications could only deliver weak approximations of the original, and users often avoided large parts or complex geometries because they could warp or crack,” said Andy Kalambi, CEO of Rize. “We’re delighted to help drive a renaissance in industrial manufacturing with better 3D printing materials and technology.

RIZE RIZIUM Glass Fiber hip assembly

This release also marks the fourth time that RIZE has received UL GREENGUARD Certification, based on the ANSI/CAN/UL 2904 Standard Method for Testing and Assessing Particle and Chemical Emissions from 3D Printers. Issues with emissions, toxicity, and safety are an ongoing concern in 3D printing and industrial AM processes, prompting research into the possibility of whether we are unknowingly poisoning ourselves, causing health hazards, as well as seeking out new solutions for users printing at home.

With the UL GREENGUARD Certification, the new materials are verified as safe for use in enclosed spaces, to include areas like schools, hospitals, and offices.

“We like the print reliability that RIZIUM Glass Fiber delivers to the Rize product line. Azoth can be confident in the quality and strength of RIZIUM GF parts. Being able to transform 3D rendered models into accurate full color parts is something our customers love,” said Ronnie Sherrer, application engineer at Azoth, an Ann Arbor based provider of technology and additive manufacturing to large manufacturers.

Other customers include NASA, PSMI, Wichita State University, the U.S. Army and Festo. Rize has also continued to evolve in the manufacturing of new hardware over the past few years from the introduction of their initial RIZE One industrial desktop 3D printer to the XRIZE 3D printer, and the adaptive desktop RIZE 2XC 3D printer.

[Source / Images: Rize, Inc.]

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3D Printing Financials: ExOne 27% Revenue Drop, Employee Layoffs and Government Contract in Q2 2020

Pioneer and global leader in binder jet 3D printing technology ExOne has posted a year-on-year revenue fall of 27% for their second-quarter earnings report. Company officials said challenging market conditions and future uncertainties as a result of the COVID-19 pandemic continue to put a strain on ExOne, particularly the disruptions to domestic and international shipping and the negative macroeconomic effects. In response to the global crisis, the company took several cost-saving actions, including a mix of employee terminations, furloughs, and pay rate reductions in an effort to save close to $2 million for the April through June quarter. Nonetheless, it is optimistic that a record backlog, increased liquidity, a contract with the U.S. Department of Defense, and a growing interest in 3D printing from companies worldwide will increase revenues in the future.

Heavily disarrayed supply chains brought chaos as lockdown impositions around the world meant factories were shut down and transportation was disrupted. As the year’s second-quarter earnings season took off, we have witnessed countless companies inform revenue declines mainly due to the impacts of the pandemic and various curtailment measures. In the statement released on August 6, 2020, ExOne said the revenue for this period totaled $11.1 million, down from $15.3 million in Q2 2019, claiming its revenue decline resulted from a 47% decrease in earnings from 3D printing machines driven by lower volumes (eight units sold in the current quarter versus 13 in the prior-year period) and an unfavorable mix of machines sold. This decrease was partially offset by a 3% increase in revenue attributable to 3D printed and other products, materials, and services driven by funded research and development contracts.

ExOne Q2 2020 revenue summary. (Image courtesy of ExOne)

Following the report’s release, ExOne’s stock was trading at $9.90, a 1.44% increase compared to the previous day. On March 11, 2020, when COVID-19 reached pandemic status, according to the World Health Organization (WHO), company stock was trading at $5.16 and since then, its shares have increased by 95% and are now at $10.07.

ExOne’s CEO, John Hartner, said on an earnings call that the results showcase how ExOne business has truly differentiated within the 3D market and that during the second quarter they made contingent progress towards a more predictable revenue model delivering recurring revenues of $6.2 million, a year-on-year increase of 3%. Hartner explained that this is largely due to the growth in the company’s install base, funded R&D, and other engineering development services. He also particularly highlighted the continued growth of an already strong backlog to $38.2 million, a new record level that, he expects, will continue to support revenue predictability for some time. As well as a stable gross margin of 27.8% and a total liquidity increase to $29.7 million from $26.8 million on March 31, 2020.

“The fundamentals that support our business remain highly favorable, it may even be enhanced by the current market conditions. ExOne is part of a ten billion dollar 3D printing industry that is growing at double-digit rates and remains relatively young […],” explained the CEO. “We believe our binder jetting technology is in a sweet spot, as manufacturers look for smart and sustainable supply chain solutions that link into a new industry 4.0 dynamic.”

Record backlog for ExOne during Q2 2020. (Image courtesy of ExOne)

Although Hartner revealed that the operating results continue to be impacted by a prolonged downturn in the global manufacturing sector, which has in turn influenced the capital expenditures of its customers, he remains confident that Pennsylvania-headquartered ExOne can better the situation. Mainly through the combination of its encouraging backlog, robust front-of-sales funnel, traction in new contracts, recurring revenue stream, and accelerated market adoption of binder jetting technology to provide the basis for operating stability for the remainder of 2020 and into 2021.

Despite machine unit sales in Q2 being at 57% of Q1 2020, investments still remain focused on the further development of binder jetting technology, including the X1 160PRO metal 3D printing system, which is poised to move metal 3D printing into high volume production. The team of engineers behind its fabrication continues to receive many inbound requests and is already producing the first machine for its customers, remaining on target with the original release plans, and expecting first shipments by the end of 2020.

Machine unit sales for ExOne during Q2 2020. (Image courtesy of ExOne)

A focus on government R&D and adoption projects has provided diversified strength during the capital spending downturn for ExOne. The company revealed a significant contract with the U.S. Department of Defense to develop a field-deployable binder jet 3D printer. The recently awarded $1.6 million contract is part of ExOne’s program development contracts with the U.S. government and companies that want to ramp up the engineering work associated with getting a production 3D print cell and workflow off the ground.

On this point, Hartner suggested that part of the growth in these contracts, which are recognized as recurring revenue, is leading towards future production machine sales. Beyond government awards, ExOne also has engaged several global manufacturers in the automotive, medical, and consumer goods industry on production program developments. Further revealing that at least one of these companies is planning to use the printers to modernize and decentralize the supply chain in key locations around the world.

The X1 160PRO from ExOne. (Image courtesy of ExOne)

Claiming to be the only binder jet 3D printing provider with a comprehensive portfolio of solutions for the direct printing of metals and ceramics in addition to sand molds and cores, ExOne expects to have a key competitive advantage by offering customers manufacturing flexibility through its more than 20 material printing capability. Last November, the company unveiled its tenth metal printer, the X1 160PRO, in what 3DPrint.com considered “a solid move towards a more production-oriented 3D printing industry.” Moreover, in two months, it expects to surround the new production 3D printers with a complete and intelligent workflow to enhance the user experience, from applications to monitor the 3D printers to entirely new 3D printing networks. Part of this has already been announced as the company revealed an entirely new Scout App to monitor industrial 3D printers and launched a new Sand 3D Printing Network, powered by more than 40 industrial binder jetting systems. Hartner suggested these are the first steps in broader long term plans to include new automation and software tools that are currently in development.

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Bioprinting Biocompatible Hydrogels from Cellulose Inks

Researchers from Italy and Sweden add to the ongoing trend for improving bioprinting techniques and materials. Upon developing bio-based photocurable materials for 3D printing and bioprinting with hydrogels, the authors released the details of their study in ‘DLP 3D Printing Meets Lignocellulosic Biopolymers: Carboxymethyl Cellulose Inks for 3D Biocompatible Hydrogels.’

Modified carboxymethyl cellulose was at the center of this experiment for bioprinting with digital light processing (DLP). While more commonly used as a filler, cellulose has been used in other inks. Beginning the research with the study of lignocellulosic biopolymers, the authors explained that they present a range of options for printing with DLP, while carboxymethyl cellulose (CMC) is often used in food, paint, and detergents. For this reason, it is a sustainable material with particular utility in bioprinting.

Approved by the FDA, and deemed biocompatible, CMC is water-soluble, versatile, and considered “an ideal candidate for the preparation of novel photocurable resins for DLP.” These types of formulations can also imitate cell microenvironments because of their similar makeup to glycosaminoglycan found within the extracellular matrix.

“Due to its versatility, its advantageous properties, water-solubility, and susceptibility to further functionalization, we also expected CMC would be an ideal candidate for the preparation of novel photocurable resins for DLP,” explained the authors. “However, the use of light-assisted printing techniques requires reactive photocrosslinkable functional groups, which means CMC needs functionalization to produce ink formulation for the production of 3D photocured hydrogels.”

“CMC was therefore methacrylated and its photorheology and DLP printability was investigated in two formulations, namely, M-CMC/Dulbecco’s Modified Eagle Medium (DMEM) and M-CMC/water, in presence of a fixed amount of lithium phenyl-2,4,6-trimethylbenzoylphosphinate (LAP) photoinitiator.”

(A) Scheme for the methacrylation of carboxymethyl cellulose (CMC). The presented product only presents one of the possible reaction products. (B) FTIR and (C) 1H NMR spectra for methacrylated CMC (M-CMC, red) and neat CMC (CMC, black).

During evaluation, the authors also investigated compatibility for hydrogels, with M-CMC solubilized in a culture medium (DMEM). Rheological properties (storage modulus, G′, and loss modulus, G″) were evaluated during UV curing for CMC/DMEM/LAP and M-CMC/water/LAP:

“Although the formulation M-CMC/DMEM/LAP showed a slight delay with respect to the onset of the curing process, the DMEM medium still allowed sufficient light penetration for the photocuring process in view of 3D printing,” said the researchers.

Both the CMC/DMEM/LAP and M-CMC/water/LAP formulations proved to be stable after 90 s of UV irradiation. Hydrogels were created from both formulations, and deemed “extremely promising” in comparison with other DLP biocompatible materials.

(A) Photorheology of methacrylated carboxymethyl cellulose (M-CMC) 20 mg/mL (2 wt% lithium phenyl-2,4,6-trimethylbenzoylphosphinate (LAP)) solubilized in water (black) or in culture medium (pink). (B) Gel point. Film thickness 300 m. (C) Frequency sweep. Strain rate 1% and oscillation frequency from 0.01 to 10 Hz.

The researchers created a variety of 3D printed samples, to include cylinders, parallelepipeds, and other complex structures—all stemming from the M-CMC/DMEM/LAP and M-CMC/water/LAP formulations. On further evaluation, the hydrogels were stable, flexible, and the photocrosslink reaction was completed. Although dyes can be helpful in limiting light diffusion, there is also the risk of cytotoxicity, leading the authors to avoid such use in this study.

3D printed M-CMC hydrogels. (A) Simple cylinders and parallelepipeds (solvent: water). (B) The hydrogel exhibited good flexibility and handleability. (C) SEM analysis performed on the freeze-dried hydrogel. (D–F) 3D objects printed from water (D) and from culture medium solution (E,F).

Crosslinking and reactivity were further evaluated, along with compression tests, assessment of swelling ability, and cytotoxicity testing to investigate lack of cell death due to release of LAP photoinitiator or unreacted polymer chains. Ultimately, the team of researchers reported that there were no signs of cytotoxicity, and overall, their work was successful with cells exhibiting viability similar to control samples.

3D-printed M-CMC hydrogels. (A) Simple cylinders and parallelepipeds (solvent: water). (B) The hydrogel exhibited good flexibility and handleability. (C) SEM analysis performed on the freeze-dried hydrogel. (D–F) 3D objects printed from water (D) and from culture medium solution (E,F).

[Source / Images: ‘DLP 3D Printing Meets Lignocellulosic Biopolymers: Carboxymethyl Cellulose Inks for 3D Biocompatible Hydrogels’]

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BASF Acquires Industrial XSTRAND 3D Printing Filaments from Owens Corning

Last fall, Germany-headquartered BASF 3D Printing Solutions (B3DPS), a 100% subsidiary of BASF New Business GmbH, introduced its new corporate brand presence, Forward AM, to the 3D printing industry during formnext 2019. B3DPS provides service solutions and a wide variety of materials for the additive manufacturing (AM) value chain under this brand, which is ultimately working to propel industrial scalability in the additive manufacturing industry.

The materials that Forward AM currently offers include Ultrasint powders for powder bed fusion (PBF) printing, several Ultrafuse filaments ranging from standard and flexible to support and metal, and Ultracur3D photopolymers. Now, Forward AM is expanding its AM materials portfolio with the announcement that it has acquired the high-performance XSTRAND Business Line from global building and industrial glass fiber-reinforced composites leader Owens Corning.

“Through the acquisition of the Owens Corning XSTRAND business, we are able to serve our customers with new and innovative filaments for 3D printing,” stated François Minec, the Managing Director for BASF 3D Printing Solutions, in a press release sent to 3DPrint.com. “By adding these high-performing materials, Forward AM now offers one of the broadest product ranges in the entire Additive Manufacturing industry, with expert solutions tailored to all industrial customer needs.”

The acquisition was effective as of August 6th, 2020, with a scope that “does not envisage the transfer of any personnel” but does include transferring the brand itself, and all of its important intellectual property (IP), to BASF’s Forward AM brand.

The XSTRAND line of materials is made up of three separate, 30% glass fiber-reinforced filaments that Owens Corning developed: a polyamide, a polypropylene, and a polycarbonate. They are:

XSTRAND GF30-PA6, featuring extreme durability and a large operational temperature range
XSTRAND GF30-PP, with superior strength, chemical and UV resistance, and low moisture absorption
XSTRAND GF30-PC, with high heat deflection temperature and dimensional stability

Parts and components that are 3D printed using glass fiber-reinforced filaments like the XSTRAND line have high strength and ridigity, and it also enables easy printing and handling as well, so they can be used for very demanding industrial AM applications, such as industrial tooling and fixtures, transportation, automotive, electronics and small appliances, and engineering.

The XSTRAND filaments have excellent mechanical properties, due to the integrated glass fiber which reinforce them. Because of this, Forward AM says the materials are able to perform better than the standard polymer filaments you find on the market.

“BASF’s capability will enable the further acceleration of XSTRAND products and support future growth of the composites industry. Owens Corning will continue its collaboration with BASF as we transition XSTRAND® to them,” said Dr. Christopher Skinner, the Vice President of Strategic Marketing, Composites, for Owens Corning.

One of the XSTRAND filaments: GF30-PA6 filament for 3D printing is a reinforced material specifically designed to be compatible with any standard Fused Filament Fabrication (FFF) 3D printer. (Image courtesy of Owens Corning)

By acquiring this advanced AM material line, Forward AM will continue to grow its portfolio, further solidifying its place in the 3D printing industry as a top materials and service provider.

(Source: Forward AM / Images: Owens Corning)

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BASF Forward AM Materials: Ultrasint & Ultracur3d Comparison Guide

Shapeways is pleased to have partnered with BASF to bring you access to four Forward AM materials: Ultrasint® PP nat 01, Ultracur3D® RG 35, Ultrasint® TPU01 and HP High Reusability PP enabled by BASF. These durable and versatile materials facilitate a high level of design complexity and accuracy, producing functional, resistant prototypes and end parts with first-rate surface quality. Common applications for these materials include automotive, industrial, aerospace and consumer goods.

Here are some details on each of these four material
options, and a comparison guide to help with your material selection process.

Ultrasint®
PP nat 01

Polypropylene (PP) is one of the most commonly used plastics materials printed using Selective Laser Sintering (SLS) technology. Highly flexible and durable, it has a low moisture absorption rate and is resistant to most acids and bases, which makes it a great choice for parts with water contact. Ultrasint® PP nat 01 suits a range of applications from healthcare and orthopedic products to electronic and automotive parts and allows for post-processing such as thermoforming and sealing. It is a sturdy material that is well suited to industrial parts and production.

IDEAL APPLICATIONS:

Pipes and Ducts

Water Manifolds and Reservoirs

Economic and Functional Prototypes

Multi-Purpose Industrial Goods

Durable Jigs and Fixtures

Ultracur3D®
RG 35

This rigid, medium viscosity photopolymer is great for printing high-performance, functional and multi-purpose parts using Stereolithography (SLA), Digital Light Processing (DLP), or Liquid Crystal Display (LCD) machines. Parts produced with Ultracur3D® RG 35 are able to maintain extreme accuracy. It is a solid, tough material and is recommended for functional parts such as air ducts, electrical sockets and connectors.

IDEAL APPLICATIONS:

Snapper

Air Ducts

Electrical Sockets

Thermoforming Molds

Connectors

Jigs and Fixtures

Ultrasint®
TPU01

Ultrasint® TPU01 is a multi-use thermoplastic
polyurethane that typically comes in white and printed using Multi Jet Fusion
technology. It is a highly flexible material with excellent shock absorption,
making it ideal for footwear and other elastomeric parts. It is capable of producing
a high level of structural detail and intricacy and is UV and hydrolysis
resistant. It has excellent surface quality, high process stability and
throughput and its flexibility opens it to a myriad of uses that include
sporting goods and protection as well as interior automotive components and
orthopedic models.

IDEAL APPLICATIONS:

Sporting Goods

Footwear

End Use Automotive Parts

Lattice Structures for Custom Performance

HP High Reusability PP enabled by BASF

HP 3D HR PP is a highly versatile and durable
polypropylene material. It is chemically resistant and has a low water
absorption rate, which makes it a great choice for piping, fluid systems and
containers. It is the HP 3D material that costs the least and is very easy to
process, which increases productivity and reduces waste. Because it is both cost-effective
and functional, the material is well suited for prototypes as well as end parts.
It is a highly flexible material that is weldable to other PP parts, expanding
its range of applications from the automotive industry to the consumer goods
sector.

IDEAL APPLICATIONS:

Piping and Fluid Systems

Containers

Interior and Exterior Automotive Parts

Material Properties: Ultrasint® PP nat 01, Ultracur3D® RG 35, Ultrasint® TPU01 and HP High Reusability PP

Take a side-by-side look at each of these
materials’ properties below:

	Tensile Strength X	Tensile Strength Z	Heat Deflection Temp (0.45 MPa)	Tensile Modulus X	Tensile Modulus Z	Elongation at Break X	Elongation at Break Z
Ultrasint® PP nat 01	28 MPa	28 MPa	102 °C	1400 MPa	1400 MPa	30 %	10 %
Ultracur3D® RG 35	49 MPa	49 MPa	84 °C	1990 MPa	1990 MPa	4 %
Ultrasint® TPU01	9 MPa	7 MPa		75 MPa	85 MPa	220 %	120 %
HP High Reusability PP	30 MPa	30 MPa	100 °C	1600 MPa	1600 MPa	20 %	18 %

Ready to give these materials a try? Upload your model here to get an instant quote.

The post BASF Forward AM Materials: Ultrasint & Ultracur3d Comparison Guide appeared first on Shapeways Blog.

Programmable Filament: Multicolor & Multimaterial 3D Printing with No Hardware Upgrades

Most of us still get excited about the opportunity to cast aside single-color fused filament fabrication (FFF) and explore the potential of multi-colored, multi-material printing, typically reserved for higher end binder jet and inkjet technologies. While historically a more challenging and complex technology, multi-color printing often allows the user more opportunities with add-on hardware.

As always, accessibility and affordability are what really allow new hardware, software, and materials to catch on. With this in mind, a research team from the Computer Science and Engineering Department at Texas A&M University (working also with researchers from Japan) has developed an interactive system for 3D printing with multiple colors and multiple materials using a single printhead—and without any hardware updates necessary.

Programmable Filament works with existing 3D printers, splicing multiple filament segments into a single thread. The process begins by simply printing a new strand of filament made up of varying existing strands of filaments. This new multicolored, multi-material wire of filament can then be used to print a multicolored, multi-material object. The technique is meant to work with less expensive FDM single-nozzle 3D printers, and is “built upon computational analysis and experiments,” as outlined in “Programmable Filament: Printed Filaments for Multi-material 3D Printing.”

Programmable Filament is a novel 3D printing technique that enables users to 3D print an object with multiple materials using an FDM printer without any hardware modification. (From left to right) First, users generate a filament that contains multiple materials, to feed into the extruder, then 3D print an object in full color.

While many may find this reminiscent of the Palette technology with open-source software released by Mosaic Manufacturing in 2018, here the researchers explained that they were inspired by DasMia, an Instructables user innovating with a thin, wire-like filament:

“… we expand on the concept to fabricate a programmable filament connecting several segments of various materials into a single filament based on the user’s specifications (referred to as printed filament). We demonstrate that the printed filament can be used in the same way as a conventional filament, i.e., extruded through a standard nozzle, requiring no hardware modification.”

While DasMia focused on producing a pretty awesome-looking rainbow filament and Mosaic offers a variety of ways for users to innovate after upgrading their systems and relying on Canvas Hub for support, Programmable Filament is meant to streamline previous challenges found in dual printing, cutting down on shifting and mixing of colors and materials between segments. Their goal is also to present more options to users, overriding some of the limiting factors of previous technology and methods. This also reverses more common but less effective techniques focusing on post-processing with brushing and painting. With pre-processing of filament, the printer does the work in the fabrication of multi-faceted items.

Printing procedure of a filament: (a) Printing starts with one color, (b) it pauses upon completion of printing all segments, allowing the user to change the material. (c-d) The 3D printer prints the remaining segments avoiding collision with prior segments, (e) then prints stitches to join adjacent segments.

Upon splicing together segments to create one filament, a long spiral is produced. The authors claim that this can be used just like standard 3D printing filaments. As a programmable filament, however, the material can be fine-tuned for required characteristics like thickness, roundness, and more. Users are able to manipulate the printing path accordingly, establishing how much material is needed for printing segments, as well as the length of the spiral.

An exemplary printed filament and object printed using it: The layers of (a) and (b) are printed in the same segment length (200 mm), but appear with different layer counts.

While this process offers new opportunity for users, the implications for the future of filaments is vast in terms of the ability to produce on-demand materials that can be programmed and customized in extreme detail.

“In this future filament supply-chain, the customer and manufacturer can also closely work together, empowering the potential for manufacturers to become aware of the emerging needs in producing new materials for mass manufacturing,” explained the researchers.

This work has been accepted for the ACM UIST 20 conference, held from October 20-23, 2020. Find out more about the HCI (human-computer interaction) virtual event here.

[Source / Images: “Programmable Filament: Printed Filaments for Multi-material 3D Printing”]

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