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Sharebot Releases Improved SnowWhite2, Low-Cost SLS 3D Printer

In 2014, Italian 3D printer manufacturer Sharebot introduced its low-cost selective laser sintering (SLS) system, SnowWhite, at the TCT Show, two years prior to its market release. The company has since branched out in its 3D printer offerings, but is still improving its SLS system, releasing the SnowWhite2, an improved update to the original SnowWhite with some new features.

“SnowWhite was created to bring the advantages of sintering to small and medium-sized companies and laboratories, all in an economic, simple and effective way without sacrificing the professional quality of the result,” Sharebot states on its website. “The user can really “print in one click” because, once the profile of the material has been defined, the printing process is completely autonomous, requires no external intervention and the results are perfectly repeatable.”

The Sharebot SnowWhite2 features what Sharebot refers to as direct laser sintering (DLS) technology, infusing prints with thermal and mechanical resistance. Because of its CO₂ laser, multiple thermoplastic powders should work with this system, such as PA12 and TPU. It’s also possible to use special powders loaded with other material particles, like aluminum, carbon, or glass, to give prints a variety of mechanical, visual, and physical properties.

Textile sample 3D printed on SnowWhite2

One improvement that the SnowWhite2 features is an upgraded software interface, which includes custom print profiles and open parameters. The printer uses the Simplify3D slicer, and has Ethernet connectivity, which partners well with the Sharebox3D print notification system.

Another one of the major changes is improved temperature management of the print chamber. The SnowWhite2 printer can be integrated with a separate module, the SnowWhite2 Nitro, that uses oxygen presence sensors to regulate the flow of whichever inert gas is used, nitrogen or argon. This makes it possible to control the atmosphere inside the chamber, which Sharebot says means no more yellowing prints.

The company says that the Nitro module can be easily added for a modified print atmosphere at any time, and that it’s easy to set the 120 kg printer up. According to Sharebot, it takes less than ten minutes to start up the SnowWhite2, about the same amount of time to move from loading your material to printing out the first few layers.

The company states that the printer’s other features include ease of use, minimal maintenance and fast cleanup, durable prints with highly detailed surfaces, a heated build chamber, and a 50 micron Z-axis resolution. Sharebot also notes that, on average, the new SnowWhite2 consumes less than 1.5 kilowatts of electrical per hour, includes an advanced laser control system with emissivity settings, and that all the unused powder is recycled and “can be directly reused in subsequent processing.”

Assembly sample 3D printed on SnowWhite2

Additional SnowWhite2 3D printer specs are:

100 x 100 x 100 mm print volume
100 micron XY resolution
0.2 mm spot dimension
35 mm/h Z-axis speed
scan speed up to 3500 mm/s

With the SnowWhite 2, we are now seeing the second generation in low-cost SLS machines, as Sinterit has already released the Lisa 2 and Sintratec the S2. The goal with these systems is to bring sophisticated SLS technology down to a price point that smaller businesses and labs can afford. However, as these machines advance, one has to wonder how their costs will increase. Just as Sharebot has created its Nitro module for improved prints, Sinterit has launched a series of accessories that will likely bring up the total overall cost of operation. They may still be able to keep prices below high-end production systems, as Sinterit has demonstrated that it is still focused on reducing costs as much as possible with its accessories.

Sharebot is now taking pre-orders for the new SnowWhite2 3D printer, with delivery beginning October 1st, 2020. Also, there is currently a special discount for pre-orders of the printer until September 30; contact the company’s marketing department for more information.

(Images courtesy of Sharebot)

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Investigating Properties of Virgin, Sieved, and Waste 316L Metallic Powder for SLM 3D Printing

We often see metal 3D printing used to make steel parts, so plenty of research is being done regarding the material properties. Researchers from VSB – Technical University of Ostrava in the Czech Republic published a paper, “Research of 316L Metallic Powder for Use in SLM 3D Printing,” about investigating Renishaw’s AISI 316L powder for use in Selective Laser Melting (SLM) technology.

“Understanding the SLM process is extremely challenging, not only because of the large number of thermal, mechanical and chemical phenomena that take place here, but also in terms of metallurgy. The presence of three states (solid, liquid, gaseous) complicates the ability to analyze and formulate a model formula for proper simulation and prediction of part performance when printed,” they explained. “Since the SLM process operates on a powder basis, this process is more complicated by another factor compared to the use of other bulk material. The properties of the used printing powder define to a large extent the quality of the finished part.”

Because the material can impact an SLM 3D printed part’s final properties, powder research should be done ahead of time for best results. Particle size, shape, flowability, morphology, and size distribution are key factors in making a homogeneous powder layer, and using gas atomization to produce spherical particles helps achieve high packing density; this can also be improved with small particles.

The researchers investigated three phases of metallic powder present in the SLM process – virgin powder (manufacturer-supplied), test powder that had been sieved 30 times, and waste powder “that had settled in the sieve and was no longer being processed and disposed of.” They used a non-magnetic austenitic stainless steel, alloyed with elements like nickel and chromium and containing a low percentage of carbon.

Scanning electron microscopy (SEM) was used to investigate the powder morphology, which “affects the application of metal powder by laser in terms of fluidity and packing density.” First, the shape of the powder particles was measured and evaluated, and then a visual quality evaluation was completed to look at the spherical quality and satellite (shape irregularity) content. The team found that many particles had satellites, but that this number increased in over-sized powder.

Fig. 1. SEM image of virgin powder 316L, magnification x180

“The measurement of virgin powder (Fig. 1) reveals that the production of powder by gas atomization is not perfect and the shape of some particles is not perfectly spherical,” the researchers wrote. “It is also possible to observe satellites (small particles glued to larger ones, Fig. 2), which are again a defect of the production method.”

Fig. 2. Satellite illustration, magnification x900

They found that the particle shape was “not always isometric,” and that cylindrical, elongated, and irregular shapes appeared alongside spherical particles in over-sized powders.

“Another interesting phenomenon was manifested in the sieved powder, where particles with a smoother and more spherical surface were observed than the original particles. This is most likely due to the melting and solidification process that is specific to AM,” they noted.

Fig. 3. Morphological defects – a) particle fusion; b) gas impurities; c) agglomeration – sintered particle;
d) dendritic particle structure; e) spherical particle; f) particles with a satellite

An optical method was used to measure powder porosity. The 316L powder was embedded in a resin, and was “1 mm layer abraded” post-curing before the particles were cut in half and polished with diamond paste. The images captured via microscope were loaded into analysis software, which determined that the total density of the powder was 99.785%.

“In general, pores must be closed from 3/4 of their circumference to be considered pores,” the team explained. “Particles that do not comply with this rule are automatically considered irregular particles.”

Fig. 4. An example of open pores that correspond to the rule (L), and pores that do not conform (R)

The researchers also measured the size of all individual pores and recorded which ones began at 5 µm, though they noted that due to potential image resolution issues, “pore sizes of about 5-8 μm should be taken with some uncertainty.”

Fig. 5. Pore size measurement of 316L metallic powder

A histogram showed that, in the metallic powder particles, the “15 µm pore size was most present,” and that the largest was 30 µm.

Table 3. Measured values of porosity of powder particles

Finally, they used an optical method to measure and examine grain size distribution of the virgin and sifted powder. Using 200x magnification, measurements were taken at five random locations, each of which had roughly 200 particles on which they performed static analysis. The results were processed with statistical software, which created cumulative curves to indicate how many particles were smaller or larger than a certain size.

“Of these, the quantiles d10, d50 and d90 were obtained, which express the cut-off limit within which the size falls to 10, 50, 90 % of the measured particles,” they wrote.

The average particle size only increases a little by repeatedly sieving the metallic powder, but because of irregular particles, agglomerated or molten particles larger than 45 μm, they fall through the mesh. Results show that <10 µm particles are reduced, while larger particles are increased, in the sift powder. But, the team notes that the powder is still usable.

“The sift powder showed an increase in particle volume and surface area while circularity decreased, indicating that virgin powder generally has a higher sphericity,” the team explained.

They found defects like agglomeration, gas impurities, and particulate fusions at all three stages, but since the powder is still usable, they concluded that SLM is both an economic and ecological technology. The researchers listed several measures to take in order to “achieve the best possible consolidation,” such as high purity, fine surface, low internal porosity, tight particle distribution, and as few surface pores and satellites as possible.

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3DPOD Episode 16: 3D Printing Trends for 2020, with Xometry’s Greg Paulsen

Today Xometry’s Greg Paulsen is back and we geek out some more on 3D printing. We look at some anticipated trends in 3D printing for the next few years this time. Software is an integral part of the 3D printing experience and of getting the right parts made. Will we see more monitoring and control software in 3D printing? What new processes are we excited about? Are there new technologies coming to market at all? Which of these technologies excite us? What will the hurdles be and will they find adoption? Are there any materials that will make us all happy? Give the podcast a listen and tell us what you think! 6

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3D Printing News Briefs: October 18, 2019

The stories we’re sharing in today’s 3D Printing News Briefs run the gamut from materials to new printers. Altair has launched its new industrial design solution, and Remet opened a metal 3D printing lab in Poland. Innofil3D is sharing lots of material news, and Equispheres has released the test results for a unique 3D printing powder. Finally, Hackaday published a micro 3D printer project.

Altair Launches New Industrial Design and Rendering Solution

The “Geko Ring Collection,” jewelry by Luca Palmini, designed and rendered with Inspire Studio. Image courtesy of Luca Palmini.

Global technology company Altair has launched Inspire Studio, its new 3D design and rendering solution, to help architects, designers, and digital artists create, evaluate, and visualize designs. The solution builds on the functions of Altair Evolve, and includes 3D rendering and animation software Inspire Render, which helps users rapidly generate photorealistic product renderings and animations. Both Inspire Studio and Inspire Render run on MacOS and Windows, and help designers open up their creativity to go beyond traditional CAID tools. The solutions will be introduced next month during a one-day launch event in Italy, and you can also get a free ticket to formnext 2019, where you can learn more about Inspire Studio and Inspire Render at Altair’s booth E11, hall 11.1.

“We are very pleased with these two new solutions for the global industrial design community. Inspire Studio builds on our previous industrial design tool, Evolve, while going beyond Evolve’s capabilities. Inspire Studio will enhance designers’ creativity by letting them drive their designs. It offers an intuitive user interface and a powerful construction history, allowing them to quickly create and explore multiple iterations of their design. Relying on the same modern user experience with powerful interactive, full progressive and raytracing rendering engine, Inspire Render will help designers quickly run photorealistic renderings and walkthrough animations on GPUs and CPUs,” said James Dagg, CTO at Altair.

3D Design and Rendering Software | Altair Inspire Studio

Remet Opens Modern Metal 3D Printing Laboratory

Polish steel structures manufacturer for the oil and gs mining industry, Remet, has launched a metal 3D printing laboratory equipped with a range of high quality machines and devices. The first of these is the DMP Flex 350 by 3D Systems, followed by 3D Systems’ Figure 4, the office-friendly metallic powder atomizer ATO Lab, and plenty of other specialized research equipment. Remet completed the project together with 3D Lab, a top Polish industrial 3D printer distributor and manufacturer of the ATO Lab.

The ATO Lab metal atomizer, which enables testing and fabrication of many powdered metal alloys, was the starting point for this unique laboratory. A new branch of the enterprise, called Remet Metal Labs, is where the company will work on comprehensive additive manufacturing and industrial applications projects. Its goal is to create highly flexible conditions for creating prototypes in the powder production field, and automotive, aviation, and space industry customers are invited to work with Remet to take advantage of the lab. 3D Lab and Remet will present their solutions together at formnext in Frankfurt next month.

Innofil3D Materials and Design Rules Video

This week, Innofil3D, and its parent company BASF, have a lot of news to share. First up, Ultrafuse BVOH, its water-soluble support filament, is now available for purchase, along with its new Ultrafuse 316L metal filament. Designed for easy FFF 3D printing, this is the company’s first metal material – 80% stainless steel with a 20% polymer content.

For users interested in 3D printing their Innofil3D PRO1 filament on a Raise3D printer, you can now join the Raise3D Open Filament Program to take advantage of optimized settings and print profiles. This new program is a collaboration between Raise3D and filament manufacturers, like Innofil3D, to find the top-performing materials for its 3D printers. Finally, Innofil3D has released its second video tutorial for design rules and principles of FFF 3D printing. Check out the video below, and be sure to visit BASF at its large K-Fair exhibit in Hall 5, C21/D21.

Equispheres Releases Test Results for Unique AM Powder

Materials science technology company Equispheres has released the results from its first powder testing phase, completed by a facility that certifies AM materials for applications in aerospace and defense. The results have confirmed that the powder has exceeded expectations, allowing for a 20-30% increase in mechanical performance and a 50% increase in production speeds. In light of this news, Equispheres is launching new equity financing in order to, as the company wrote in a press release, “grow and unlock the vast potential of Additive Manufacturing.”

“The unique properties of our powder, including the high sphericity, narrow particle size distribution and low surface area results in significantly increased packing density. This allows an increase of powder layer thickness by a factor of 2 which significantly increases build speed. Most importantly, this boost to build speed does not come with a mechanical performance penalty. Instead, the uniform nature of our powder ensures that parts are produced with reliable and consistent mechanical properties. The minimal variance in our performance results provides design engineers the statistical confidence to produce stronger, lighter parts,” said Equispheres’ CTO, Dr Martin Conlon.

Hackaday Project: Micro Deltesian 3D Printer

A new Hackaday project by architect Ekaggrat Singh Kalsi was just published – a micro Deltesian 3D printer, which he says offers a quality that’s on par with any Cartesian 3D printer. The printer has a solid aluminum frame, with a standard slider Y axis and a Delta mechanism for the XZ axis. A 3.5″ LCD touchscreen, with a built-in SD card, is fast and easy enough for his young daughter to use, which was his ultimate goal. With an 80 x 100 x 85 mm build volume and a print bed held in place with magnets, the biggest challenge in making the minuscule 3D printer easy to use was the filament loading; Singh Kalsi used a lever-based latch mechanism for this.

“the micro deltesian was born out of the curiosity of building the convoluted deltesian mechanism,” he explained. “Later on it evolved into the idea of building a 3d printer simple enough to be used by my daughter. The deltesian mechanism seem very wierd when i first saw it but eventually i thought maybe i should give it a try and hence this printer was born.”

Watch the video below to see just how easily his daughter uses the micro Deltesian 3D printer:

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

The post 3D Printing News Briefs: October 18, 2019 appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

3D Printing News Briefs: August 11, 2019

We’re starting off this 3D Printing News Briefs edition with some good news from Xometry – this week, it announced the availability of Carbon DLS technology as one of its process options. Moving on, Markforged published a case study and Aeromet announced new properties for its A20X powder. Finally, HP has launched a design competition.

Xometry Offering Carbon DLS Technology

Just this week, custom on-demand manufacturing network Xometry announced that it will be offering Digital Light Synthesis (DLS) technology by Carbon as one of its available 3D printing process options, in addition to SLS, SLA, FDM, DMLS, PolyJet, and HP’s Multi Jet Fusion. Through its Instant Quoting Engine, Xometry customers can get quotes, design feedback, and lead times for production-grade parts 3D printed with Carbon’s DLS. You can learn more about how to get the most out of this technology, and the Xometry platform, during a live webinar on Wednesday, August 14, from 12 – 1 pm; each attended will be entered to win a pair of Adidas Futurecraft 4D shoes with 3D printed soles by Carbon.

“We are very excited to add Carbon’s cutting-edge DLS technology to Xometry’s capabilities. Our additive customers have been asking us for it due to its reputation for speed and quality,” stated Bill Cronin, Xometry’s Chief Revenue Officer.

Aeromet Announces New Properties for A20X Alloy

announcement covering new record-breaking properties achieved by the A20X alloy after a research project involving Rolls-Royce, Renishaw and Aeromet.

A20X cements its status as a leading aluminium powder for additive manufacturing after breaking the critical 500 MPa UTS mark.

6th August 2019: A20X, the aluminium alloy developed and patented by UK foundry specialist Aeromet International, has cemented its status one of the strongest aluminium additive manufacturing powders commercially available after surpassing the key 500 MPa UTS mark.

As part of a recent research project involving aero-engine giant Rolls-Royce and additive manufacturing equipment specialist Renishaw, heat-treated parts produced using A20X Powder have achieved an Ultimate Tensile Strength (UTS) of 511 MPa, a Yield Strength of 440 MPa and Elongation of 13% – putting the powder at the forefront of high-strength aluminium additive manufacturing.

Crucially, parts additively manufactured with A20X Powder maintain high-strength and fatigue properties even at elevated temperatures, outperforming other leading aluminium powders.

Mike Bond, Director of Advanced Material Technology at Aeromet, commented: “Since bringing the A20X alloy to market for additive manufacturing 5 years ago we have seen significant adoption for high-strength, design-critical applications. By working with Rolls-Royce, Renishaw and PSI we have optimised processing parameters that led to record-breaking results, opening up new design possibilities for aerospace and advanced engineering applications”.

The HighSAP project, backed by the UK’s National Aerospace Technology Exploitation Programme (NATEP), was led by Aeromet and involved Rolls-Royce, Renishaw and atomisation experts PSI. A20X Powder for additive manufacturing is derived from the MMPDS-approved A20X Casting alloy, the world’s strongest aluminium casting alloy, which is in use by a global network of leading aerospace casting suppliers.

Aeromet announces new properties for A20X powder
Case study: Dunlop uses Markforged technology to save thousands
HP launches 3D Print Design Competition

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Aerosint and InfraTrac Extending Chemical Tagging in Parts 3D Printed with Powder Bed Fusion

I can’t think of a single person who likes getting the automated reminder that it’s time to change their password, which includes the many instructions on what does and doesn’t make a good one – capital letters, numbers, spaces vs. no spaces, no repeats, etc. etc. But it’s a necessary evil if we want to keep our data safe, which is why many companies, and even apps, have made these reminders standard procedure. So why aren’t we doing the same when it comes to our 3D printed products?

There are plenty of options to make our prints secure and easy to authenticate, such as QR codes, watermarks, serial numbers, RFID tags, and even holograms. But while marking parts is standard for some, it’s not mainstream yet, and as 3D printing continues to scale, security will become more important, not less.

That’s why Belgian company Aerosint, which developed a selective powder deposition system to replace the single-material recoater in laser powder bed fusion (LPBF) processes, has teamed up with Maryland-based InfraTrac to extend chemical security into multi-powder deposition 3D printing through covert part tagging.

According to an Aerosint press release, “…the ability for anyone to create end-use parts enables bad actors as well as helpful new outsourcing players. Some of the people 3D-printing aircraft and auto parts are not going to be licensed, careful, high-quality suppliers, and new approaches to protection will be required.

“In this new model, a digital file conveys the ability to create a product. Software protections and digital rights management are necessary to protect the intellectual property in that file. However, none of those digital protections are going to keep us safe from 3D-printed counterfeit parts and products: once the print is complete, its digital safeguards lose their power. Anti-counterfeiting for additive manufacturing needs to be integral to the final printed product.”

Parts can be tested for the presence of site-specific chemical taggants using a small, handheld spectrometer like those in the Spectral Engines NIROne series (left). In the right panel, an ULTEM sample (lit orange) containing an InfraTrac taggant is assayed. Penny for scale. [Image: Aerosint]

InfraTrac has an award-winning method for anti-counterfeiting in 3D printed parts – it adds a taggant (compatible chemical marker) during printing in a small, covert, subsurface spot. With instant field detection, the company’s tagging model provides chemical security to 3D printed parts. But until now, this was only limited to one material, making it unavailable for powder bed 3D printing, which is an important process for scalable industrial applications. But by teaming up with Aerosint, InfraTrac can now extend its model even further.

“Complexity is the enemy of security: difficult procedures invite work-arounds,” the Aerosint press release states. “That’s what makes us reuse passwords even when we know we shouldn’t. Security procedures that align with existing processes are most likely to be adopted, and less likely to be circumvented. Applying taggant or codes should be part of the standard print or manufacturing workflow, not an add-on. Detection should take seconds, with inexpensive, portable, off-the-shelf equipment.”

LPBF 3D printing, like SLM and SLS, use selective fusion of powdered material spread in layers across a build surface, but neither of these two popular methods can place multiple powders within a layer at specific locations. With control at the voxel level, it’s possible to precisely put two or more powdered materials in one layer…and this is exactly the kind of selective powder deposition system that Aerosint is working on.

In its new collaboration with InfraTrac, Aerosint is 3D printing simple demonstrator parts from both polymer and metal, which include fingerprinting sites that are based on InfraTrac’s powder formulation. These components, printed on either an SLM or SLS system that is equipped with the special recoater, have embedded materials at specific sites that can be traced by InfraTrac; then, the parts will be tested and verified. Because InfraTrac can make its taggant materials appear identical to the bulk material of the 3D printed part, it’s just about impossible to counterfeit them.

[Image: InfraTrac]

Thanks to the partnership between Aerosint and InfraTrac, users in industries that require the strictest quality control can confidently ensure simple, scalable sourcing authenticity of their parts.

What do you think? Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

Interview With SmarTech’s Scott Dunham on the Additive Manufacturing Metal Powders Research

For the past five years, Scott Dunham has been preparing the Additive Manufacturing with Metal Powders Report for SmarTech. SmarTech, part-owned by 3DPrint.com, is the only analysis and research firm that is focused on the Additive Manufacturing and 3D Printing market. With the release of the new Additive Manufacturing with Metal Powders Report, we thought we’d delve into the report to share some of Scott’s findings and methodologies.

The report focuses on Powder Bed Fusion, Directed Energy Deposition, and Binder Jetting metals. It goes into the major players in each segment and catalogs mayor market events over the past year. Another section looks at standards formation, M&A activity as well as investments and things such as VC activity. It catalogs leading companies in metal printing and looks at the overall competitive landscape. It delves deeper at industrial use of metal 3D printing and looks at key trends in the industry. Through interviews and surveys, industry participants help identify key trends in the industry.

Things such as customer openness, competency, and spare parts are some of the elements the report looks at more in-depth. Things such as the industrialization of Powder Bed Fusion, increases in machine costs, process parameters, and market share are shared. For Directed Energy Deposition things such as the repair market, adding other AM processes to DED business units and segmentation are looked at. The growth in the binder jetting part of the market is revealed. Trends and drivers in metal powders are cataloged as well. Sales channels for powder, demand for custom alloys, and long term supply are discussed. The overall market growth in 2018 is shared, as are the differences across regions and new developments.

Scott says that the primary audience for this report is “business unit or business line managers of companies in metal powders or machine OEMs, or those companies that wish to enter the market. Consultancy firms, analysts, financial analysts, and business development people also make up a strong contingent of customers. One surprisingly large group of customers is researchers at research institutes and universities.”

Different customers have different motivations for buying the report. With prices starting at $5000 a copy it often requires a degree of interest or investment in 3D printing metals to consider it.

“Researchers and academics, for example, will use it to identify problems that do not yet have solutions or where adequate solutions have not yet been commercialized. For startups, it is used by the whole team to validate business cases and plans. For large teams at industrials or other multinationals, the entire product team would get a license to accompany their evaluation of the market. A business unit leader elsewhere may be very interested in drivers, market outlook, and developments. Consultants will use the report to get up to speed on 3D printing in relevant client engagements. OEMs and powder companies like to be abreast of the latest developments but also use it to benchmark themselves, measure unit performance, establish performance goals, and goal setting.”

Scott considers the Fifth Additive Manufacturing Metal Powders report to be a “full resource on metal additive manufacturing.”

“As per all of the powder based technologies, we provide a guide and detailed analysis based on dozens of interviews and many more surveys of market participants. Why should you trust us? We were the first to offer a market research report focused on powder processes. Over the five years, we’ve refined it, learned and sifted through a lot of data to make it more accurate and usable for customers. At SmarTech, we only do Additive Manufacturing; for us, this is not a part-time thing, but a complete focus for us as a business. This lets us build up and sharpen our knowledge. The effect is that our reports gain in useful information and in depth. The specific expertise and research we do let us make a more solid report than other firms that may have the same people cover IoT, the cloud, or other subjects. Additive Manufacturing is a fast growing, very competitive industry that deserves full time committed analysts, not tourists.”

With regards to specific trends Scott points out a “few soft last quarters” that are due to many factors, but one is the increasing complexity of implementations while others is a gulf between what is promised and what is achievable.

“The promise and hype of binder jetting has also given some customers some pause with powder bed fusion implementations. The landscape can be very confusing for new market entrants, and some decisions are tough to make and require technical expertise and understanding that new entrants often don’t have.”

He goes on to say, “the market is strengthening this quarter, and we are seeing a rapid rate of change in the industry.” Interested? Download the SmarTech Additive Manufacturing with Metal Powders report here.

3DPrint.com is part owner of SmarTech.

ColorPod DualBox is an Add-on That Turns Desktop 3D Printers Into Color Powder 3D Printers

[Photo: Hackaday]

As 3D printing arrived on the scene, surprising artists and designers with a certain level of self-sustainability in creation never experienced before, the hunger for more, more, more in terms of options became almost immediate—and mainly with a desire for more color. There have been forays into 3D printing with color and full-color 3D printers, but for the most part there has still been a wait while manufacturers have been busy developing a wide range of hardware, software, and alternative materials (in a basic array of monotones and colors) that can take on everything from construction to saving lives via tissue engineering. So far, color has generally taken a backseat while the important work was getting figured out.

We learned about the ColorPod though a few years ago, as a device for several RepRap Cartesian style 3D printer variants that allows for 3D printing in full color. In development by Aad van der Geest for years now, the device has evolved into a customized, streamlined workaround for having it all while 3D printing, and you can take matters further into your own resourceful hands by making your own parts for the DualBox add-on too—turning your FDM 3D printer into a full-color powder machine.

The bottom pulls itself up with threads that are wound around the axis of a geared stepper motor. (Photo: Hackaday)

Today, the versatile ColorPod works with most 3D printers, supports .stl and .obj 3D model files, and is accompanied by supporting software. Objects are 3D printed in full color as the unit dispenses colored droplets on powder in the DualBox add-on, comprised of two compact units: the feeder box, which moves up; and the model box, which moves down. Powder is dispersed from one box to the other in thin layers with a spinning roller, and cross sections are fabricated with ink and water on the powder.

Parts that come in the Colorpod dualbox add on set for $499 (Photo: Tindie)

Professional powder from gecko-3d.com is recommended by the developer for better accuracy in printing. 3D models can be printed up to 110 X 70 X 50 mm. For $499, you can buy the set to make your own DualBox, with components to include:

500 gr gecko 3d powder
1 HP45 cartridge filled with clear fluid
2 plexiglass box cutout set
1 plexiglass bridge part
2 geared stepper motor
4 bottom axis support
4 box fixing plate
10 nylon M3 screws 5mm
1 servo modified for continuous rotation
1 resistor 100k on connector
1 resistor 820E on connector
1 dyneema thread 1200 mm
1 screw terminal
1 geeetech sync cable
1 endswitch conversion cable
1 5V regulator with cable
1 rubber band
2 ball bearing with outside diameter 16mm
1 stainless steel tube 210X20X2 mm
1 supply cable male
1 supply cable female
1 fuse holder with 2A fuse
2 M3 threaded rod 80mm
1 M4 threaded rod 96mm
1 metal spring
2 M2 screw 20mm
2 M2 screw 12mm
4 M2 nut
4 M2 washer

Other parts must be 3D printed to complete the set.

Build the basic container using sticky tape. Numbers are engraved on the outside of the container. Later you can make the final unit with super glue. (Photo: vouwbad)

With the advent of 3D printing, users were thrilled with the capability to design a 3D object and then be able to produce it on their own too, whether in a home workshop, professional, or industrial setting. While choices for post-processing and finishing could include intricate painting and detailing, quickly, the ability to print in more complex ways evolved with multi-materials and multi-components, full-color printers by HP and Mcor, and more. Innovations such as the ColorPod give users even more options for producing spectacular prototypes, parts, and artistic works.

What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

(Photo: vouwbad]

[Source: Aad van der Geest]

3D Printing News Briefs: October 20, 2018

We’re starting with some information about a couple of upcoming shows in today’s 3D Printing News Briefs, followed by some business and aerospace news. Sinterit is bringing its newly launched material to formnext, while Materialise has announced what products it will be presenting. Registration is now open for AMUG’s 2019 Education and Training Conference. Moving on, Sciaky sold its EBAM and EB Welding System to an aerospace parts manufacturer, while final assembly has been planned for the Airbus Racer, which features a 3D printed conformal heat exchanger. The Idaho Virtualization Lab is a leader when it comes to 3D printing dinosaurs, and the recently released movie First Man used 3D printed models during filming.

Sinterit Launches New PA11 Powder

Military glass case 3D printed with PA11 Onyx

Desktop SLS 3D printing company Sinterit has launched a new material – PA11 Onyx – which it will be bringing to formnext next month, along with its Lisa and Lisa 2 Pro 3D printers. According to Sinterit, this is first powder that’s ready for use in desktop SLS 3D printers, and it delivers excellent thermal, chemical, and abrasive resistance, along with better flexibility and impact resistance. PA11 Onyx is a high performance, lightweight, polyamide-11 bioplastic produced from plant-based renewable resources. In addition, the material also has high elongation at break, which means that durable finished products, like a military glass case and custom casings, can be opened and closed thousands of times without getting damaged.

“Our clients use a lot of electronic devices, like Raspberry Pi, that need a proper, individually made housing that can endure in unfriendly conditions. They are looking for durable materials but also require some elasticity and high-temperature resistance,” said Sinterit Co-Founder Konrad Glowacki. “PA11 Onyx delivers that.”

Come visit Sinterit at booth G41 in Hall 3.1 at formnext, November 13-16, to see its 3D printers and newly launched powders, which also include Flexa Black and Flexa Grey TPU materials.

Materialise Announces formnext Product Introductions

Materialise Magics 23

Speaking of formnext, 3D printing leader Materialise will also be attending the event in Frankfurt, and has just revealed what new product introductions it will be displaying at its booth C48 in Hall 3. Some of the highlights include new plastic and metal materials, like Inconel, Polypropylene, and Taurus, automotive applications, and the Materialise Magics 3D Print Suite; this last includes a new Simulation Module, the E-Stage for Metal 1.1 automatic support structure generation upgrade, and Magics 23, the latest software release.

Additionally, there will also be presentations from Materialise partners and the company’s own experts, like Lieve Boeykens, the Market Innovation Manager for Materialise Software. Boeykens will be presenting on the TCT Stage about “Reducing Costs and Speeding Up the Validation of AM Parts” on November 15 at 4 pm. Visit the Materialise formnext site for updates.

AMUG Conference Registration Open

The Additive Manufacturing Users Group (AMUG) just announced that online registration is now open for its 2019 Education & Training Conference, which is now in its 31st year and will be held in Chicago from March 31-April 4. The conference is open to owners and operators of industrial 3D printing technologies for professional purposes, and welcomes designers, educators, engineers, plant managers, supervisors, technicians, and more to share application developments, best practices, and challenges in 3D printing. The program has been adjusted to include more hands-on experiences and training, and will include workshops, technical sessions, and even a new Training Lab. There will also be networking receptions, catered meals, the two-night AMUGexpo, a Technical Competition, and the fifth annual Innovators Showcase, featuring special guest Professor Gideon Levy, consultant for Technology Turn Around.

“As the AM community evolves, so will AMUG,” said Paul Bates, the President of AMUG. “We are excited to present the new program with the goal of continuing to act on our mission of educating and advancing the uses and applications of additive manufacturing technologies.”

Sciaky Sells EBAM and EB Welding System to Asian Aerospace Parts Manufacturer

VX-110 EBAM System

Metal 3D printing solutions provider Sciaky, Inc. has announced that an unnamed but prominent aerospace parts manufacturer in Southeast Asia has purchased its dual-purpose hybrid Electron Beam Additive Manufacturing (EBAM) and EB Welding System. The machine will be customized with special controls that allow it to quickly and easily switch from 3D printing to welding. The system will be used by the manufacturer, remaining anonymous for competitive purposes, to 3D print metal structures and weld dissimilar materials and refractory alloys for said structures, as well as for other aerospace parts. Delivery is scheduled for the second quarter of 2019.

“Sciaky is excited to work with this innovative company. This strategic vision will allow this manufacturer to reduce operating costs by combining two industry-leading technologies into a single turnkey solution,” said Scott Phillips, President and CEO of Sciaky, Inc. “No other metal 3D printing supplier can offer this kind of game-changing capability.”

Airbus Plans Final Assembly for Racer

Scale model of the Airbus Racer on display at Helitech International 2018. The manufacturer is aiming for a first flight of the demonstrator in 2020. [Image: Thierry Dubois]

Together with partners of its Racer demonstration program, Airbus Helicopters explained that it definitely expects to meet performance targets, and complete the first flight of the compound helicopter on time in 2020. The 7-8 metric ton aircraft, in addition to a targeted cruise speed of 220 knots and 25% lower costs per nautical mile compared to conventional helicopters, will also feature several advanced components, including a three-meter long lateral drive shaft. Avio Aero was called in to 3D print a round, conformal heat exchanger for each later gear box, which will help achieve reduced drag.

The preliminary design review was passed last July, with final assembly targeted to begin in the fourth quarter of 2019. The flight-test program will likely be 200 flight hours, with the second part focusing on demonstrating that the Racer will be able to handle missions like search-and-rescue and emergency medical services. The program itself is part of the EU’s Clean Sky 2 joint technology initiative to help advance aviation’s environmental performance.

Idaho Virtualization Lab is 3D Printed Dinosaur Leader

The Idaho Virtualization Laboratory (IVL), a research unit housed in the Idaho Museum of Natural History on the Idaho State University campus, has long been a leader in using 3D printing to digitize and replicate fossils and skeletons. Museum director Leif Tapanila said that IVL’s 3D printing program has been ongoing for the last 15 years, and while other labs in the country are more driven by research, the IVL is operated a little more uniquely – it’s possibly the only program in the US that goes to such great extent to 3D print fossils.

Jesse Pruitt, lab manager of the Idaho Virtualization Lab, said, “Everybody does a little bit of this and a little bit of that, but no one really does [everything we offer].

“We do our own internal research, we digitize our collections and we also do other people’s research as well.

“It’s not something you see at a smaller university. For this to exist at the level that it exists here is pretty remarkable in my mind.”

The IVL is also one of the only programs to have a large online database of the 3D models it creates, and works to spread knowledge about its 3D printing processes to students and researchers.

3D Printed Models for First Man Movie

Lunar module miniature [Image: Universal Pictures]

While many movies swear by CGI to create special effects, there are some directors and production crews who still prefer to use old school miniatures and models. But old school meets new when 3D printing is used to make these models for practical effects. Oscar-winning director Damien Chazelle used some 3D printed miniature model rockets for his new movie First Man, which was just released a week ago and is all about Neil Armstrong and his legendary first walk on the moon. The movie’s miniature effects supervisor Ian Hunter, who won an Oscar for Visual Effects for Interstellar, was in charge of creating and filming the models, which included a one-thirtieth scale miniature for the giant Saturn V rocket and one-sixth scale miniatures of the Command/Service Module and Lunar Excursion Module.

“We had banks of 3D printers running day and night, running off pieces. We also used a lot of laser-cut pieces,” Hunter said about the Saturn V rocket miniature. “The tube-like shape of the rocket came from PVC piping, with the gantry made of acrylic tubing, along with many 3D printed and laser cut parts.”

The 3D printed model of the Saturn V rocket even made it into one of the trailers for the film, and the film itself.

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Researchers Study the Dynamics of Powder Spreading in 3D Printing

Many things affect the quality of a finished 3D printed part, and in powder-based 3D printing, the spreading of the powder is a key step in determining how well the part will come out. In a study entitled “Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing processes by high-speed x-ray imaging,” a group of researchers studies the particle-scale dynamics of the powder spreading by using in situ high-speed high-energy x-ray imaging.

The researchers developed an experimental method in which they used high-speed high-energy x-ray imaging to characterize the powder spreading process with high spatial and temporal resolution and study the particle scale spreading process in-situ. With this method, they revealed the evolution of the repose angle, the slope surface flow speed, and slope surface roughness during the powder spreading process.

“We observed and analyzed the evolution and flow of two different types of powder clusters on the slope surface, and closely examined the particles that formed such clusters,” the researchers state. “We analyzed the dynamic interaction of individual particles with their respective boundaries and calculated coefficients of friction between the powders and boundaries.”

They developed a powder spreading system to simulate the spreading process under additive manufacturing configurations. The system consisted of a spreading structure (wiper and confinement walls) and a powder bed container. The wiper was made from an aluminum blade that was perpendicular to the powder bed substrate. Confinement walls, designed to keep the powder inside the spreading system, were made from high-density graphite and attached to either side of the blade.

“Powders are spread by an aluminum wiper (blade) at a spreading speed of 11.5 mm/s on an aluminum substrate,” the researchers explain. “As the powder is spread, an x-ray beam passes through the powder bed, and the x-ray signal is recorded by a detection system. The exposure time is 500 ns. A camera is set to record at a speed of 10,000 frames per second and an analysis of the images is done using the Image9.”

They used two different diameters of 316 L stainless steel powder. Eight samples were extracted and analyzed for each type of powder; the samples were carefully spread over a glass substrate and then images were obtained using an optical microscope.

Several conclusions were reached by the experiment:

The average powder size is an important parameter that affects powder flow dynamics during the spreading process. The powder with a larger average diameter showed a higher average dynamic repose angle, as well as a higher average surface flow speed, than the powder with a smaller average diameter.
Powder clusters affect powder spreading behavior. The powder clusters could not easily flow through the slope surface.
Interactions of powders with boundaries were characterized and the coefficients of friction were calculated. The calculated kinetic coefficients of friction were 0.25 for particles moving over an aluminum substrate, and 0.18 for particles moving over a high density graphite surface.

“The particle-scale powder spreading dynamics revealed are important for understanding powder spreading behavior in the powder-bed-based additive manufacturing process,” the researchers conclude. “This is critical for the development and validation of more accurate models for predicting powder spreading behavior.”

Authors of the paper include Luis I. Escano, Niranjan D. Parab, Lianghua Xiong, Qilin Guo, Cang Zhao, Kamel Fezzaa, Wes Everhart, Tao Sun and Lianyi Chen.

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