PostProcess Technologies granted U.S. patent for automated support removal technology

PostProcess Technologies, a manufacturer of post-printing systems for 3D printed parts, has been granted a U.S. patent for its Submersed Vortex Cavitation (SVC) technology. Issued on August 11, but originally filed in June of 2016, the patent is now one of more than 50 that PostProcess holds, including ones for hardware, software, and proprietary chemicals. […]

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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Stratasys receives largest ever F900 3D printer order from AM craft

3D printer manufacturer Stratasys has received its largest-ever to date orders after aerospace firm AM Craft purchased four of its F900 3D printers. AM Craft’s order adds to its existing portfolio of four Fortus F450mc 3D printers and will boost production capacity. Following the company’s recent investment, AM Craft is now one of the largest […]

Renishaw reports profit in FY 2020 despite revenue decline caused by COVID-19

British engineering firm and metal 3D printer manufacturer Renishaw has reported a pre-tax profit of £48.6 million in its full-year (FY) financials despite the impact of the COVID-19 pandemic on its revenue.  Renishaw, which reports its FY results from June 30 2019 to June 30 2020, generated £510.2 million in revenue for the 2020 financial […]

Voodoo Manufacturing shuts down permanently amid pandemic

3D printing service provider Voodoo Manufacturing has closed down for good. In an explanatory message on its main page, the New York-based startup cites the COVID-19 pandemic as the root cause, stating that a lack of clear end in sight meant the company “couldn’t make it to the other side”. Combating COVID Founded in 2015, […]

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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Arevo Announces New Aqua 2 Carbon Fiber 3D Printer, $25M in Series B Funding

Due to its stiffness, high strength-to-weight ratio, and the fact that it demonstrates anisotropic properties, carbon fiber has been used as a less expensive replacement material for metals such as titanium for decades, and has many applications in industrial sectors like aerospace and automotive. As you may know, Silicon Valley technology startup Arevo has long focused on continuous carbon fiber composites printing. Back in 2015, the company, which counts the CIA’s venture capital arm In-Q-Tel as an investor, developed a laser-based method for 3D printing carbon fiber with a multi-axis robotic arm. This technology, paired with quality design software, allows Arevo, and its customers, to automate the design and printing of large, complex, continuous CFRP composite parts.

“High speed automation removes human errors in traditional composites manufacturing,” the Arevo site states. “Our patented technology uses lasers to manufacture high quality composite parts at scale.”

Now, the California company is announcing its newest innovation: the Aqua 2 3D printing system. Arevo states in a press release that the new Aqua 2 is the first high-speed 3D printer in the world for large continuous carbon fiber composite structures. Additionally, it said that the Aqua 2 printer is of higher quality, can achieve rapid, on-demand fabrication of custom composite parts up to one cubic meter in size, and can also print four times faster than the 3D printer that came before it.

But its new Aqua 2 3D printer isn’t the only good news Arevo is sharing—the company also announced that it has closed its Series B financing round after raising an additional $25 million, bringing the total amount raised to $60 million.

Leaders of this round were GGV Capital and Defy Partners, and additional support came from Alabaster, previous investor Khosla Ventures, and more.

“We are excited to have Defy and GGVC on board to bring not only capital but a vast amount of strategic experience,” Arevo’s co-founder and chairman Hemant Bheda stated. “The strong interests in the company despite tough market conditions really reaffirm our vision.”

Aqua 2 Printer Head

Additionally, Defy has appointed serial entrepreneur and investor Brian Shin to join the board of directors at the startup, which also includes Bheda, Khosla’s Bruce Armstrong, and Arevo’s CEO Sonny Vu.

“Arevo is a compelling opportunity for us as it combines our three main investment foci: consumer internet, enterprise, and smart tech. We see fantastic potential in this market, and have backed Sonny before at Misfit,” said Hans Tung, a Managing Partner at GGVC. “Arevo is led by an experienced team with solid technological foundation and 3D printing manufacturing know-how at scale – to offer breakthrough products at competitive prices.”

Arevo has been historically well-funded over the years, and recently launched a crowdfunding campaign on Indiegogo to sell its first direct-to-consumer products: the Superstrata bicycle and e-bike. The startup has used its technology to create bicycle frames before, but claims that its Superstrata products will be the first real custom 3D printed unibody carbon fiber bikes. This campaign has been so popular that within three minutes of launching, the goal of $100,000 had already been reached, and now it’s close to raising $4 million.

“Arevo’s new platform enables fabrication of high strength, low weight carbon fiber parts, currently not possible with today’s standard techniques. We are thrilled to be working with the team to help scale up this incredibly impactful technology,” said Trae Vassallo, founding partner at Defy.

Carbon fiber-reinforced thermoplastic bracket

(Source/Images: Arevo)

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SLM Solutions announces 90 percent revenue growth during H1 2020

German metal 3D printer manufacturer SLM Solutions Group AG has reported a 90 percent increase in revenue over the first half of 2020.  For the three months ending June 30, 2020, SLM recorded revenue of €31.1 million compared to the €16.3 million generated in H1 2019. SLM’s revenue has shown continued growth during 2020, and […]

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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Challenges Face Metal 3D Printing Powder Suppliers in 2020

Most AM companies which report public information noted during their Q1 releases that they expected Q2 to be much more heavily impacted by COVID-19. They weren’t wrong. Shutdowns and uncertainties didn’t actually hit Western firms until March. But it’s no secret that the metal additive manufacturing industry was already in the midst of tougher times throughout 2019 — we’ve written about it pretty extensively at SmarTech.

  • Most of the ongoing metal AM slump story involved hardware. Metal powder sales have remained excellent. Total shipments of powders for the year in 2019 grew an estimated 37 percent compared to 2018, to an estimated 2,650 tons shipped to AM users. SmarTech estimates that in the first quarter of 2019 alone -just three months -there was as much powder sold and shipped to users as there was in all of 2014 combined; about 550 tons!
  • Sales of powders have been driven by the relatively small community of AM power users which have reached serial production on certain components especially in aerospace, medical, and oil and gas. These successes include Stryker’s Tritanium product line, GE’s continued scale up of additive parts in its LEAP engines and gas turbines, Siemens gas turbine burners, and more. It has also been driven by several service providers.
  • Successful implementations of AM continue to drive powder sales. While signs of some commoditization of mainstream additive powders have begun to emerge, SmarTech believes that the AM powder market will be temporarily thrust to the forefront over the next year.
  • The metal additive material market is witnessing new dynamics never before seen in additive manufacturing. In 2020, diversity in materials for additive manufacturing has made significant strides compared to just five years ago. Though significant steps still are needed in this area, development of processing parameters for new additive metal powders can be a lengthy endeavor. For example, while there have historically been just four metals comprising the nickel and cobalt additive materials segment (a number which persisted for several years), today there are at least double that many alloys now offered by more than one large AM material supplier between these two major metals. Cobalt Alloy 188 and 509, as well as Nickel Alloy 230 and Inconel 738 are now widely available, to name a few.

In this PRO we show how the additive materials business has done well through the down turn, but may be about to hit its own little recession due to product maturity.  Nonetheless, no supplier of metal additive manufacturing powder should worry too much. The long-term prospects for AM materials are encouraging.

(Feature image courtesy of Equispheres.)

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