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Nervous System Works with Rice University Researchers 3D Printing Vascular Networks

Nervous System has been heavily engaged in experimenting with 3D and 4D printing of textiles in the past years, and all their research is paying off now as they find themselves engaged in the realm of tissue engineering. The Somerville, MA company is known for their generative design process, combining both programming and art within most of their serious projects, drawing bioengineers from Rice University to turn to them for added expertise.

Assistant professor Jordan Miller invited the Nervous System team to join his researchers on an incredible journey to fabricate examples of possible vascular networks via bioprinting—harnessing their knowledge of software and materials to find a way to create soft hydrogels. Kind of not a phantom but more a path towards ideas that can lead to concepts that may let us build true vascularized structures at one point. As Miller explains, in their research they were able to create large tissue blocks easily, but as so many scientists engaged in bioprinting today have discovered before them, it is extremely challenging to keep cells alive. Viability becomes the goal, and as that becomes more comprehensively mastered overall in bioprinting, it may finally unlock the door to true fabrication of organs that can be transplanted into the human body.

Open-source technology, mainly centered around 3D printing has offered huge opportunity for the bioengineers from Rice University to make progress in their work—and that was what drew them to Nervous System in the first place. Jordan became ‘captivated’ with the structures they were creating, specifically in their Growing Objects series, which was featured as an exhibit at the Simons Center for Geometry and Physics in Stonybrook, NY in August and September of 2014. In speaking with Nervous System, his proposal involved what they describe as an ‘epic task,’ to create simulated synthetic tissue and human organs.

Rendering showing lung-mimicking structures generated within different volumes

“The idea of taking our generative systems which are inspired by nature and using them to actually make living things was a dream come true,” states the Nervous System team in their case study.

Elsewhere the research did,

“…show that natural and synthetic food dyes can be used as photoabsorbers that enable stereolithographic production of hydrogels containing intricate and functional vascular architectures. Using this approach, they demonstrate functional vascular topologies for studies of fluid mixers, valves, intervascular transport, nutrient delivery, and host engraftment.”

As Miller and his expanding team continued to work on developing the necessary tools for bioengineering, part of their research resulted in a new 3D printing workflow called SLATE (stereolithography apparatus for tissue engineering). Their proprietary hardware can bioprint cells encased in soft gels that act just like vascular networks. Nervous System accompanied them (going back as far as 2016) in this bioprinting evolution by designing the materials for the networks—but with their background in programming, the contribution went far beyond designed materials and included customized software for creating ‘entangled vessel networks.’ These networks can be connected to both inlets and outlets for oxygen and blood flow, as they use specific algorithms to ‘grow’ the branching airways.

“Air is pumped into the network and it pools at the bulbous air sacs which crown each tip of the network,” states Nervous System in their case study. “These sacs are rhythmically inflated and deflated by breathing action, so called tidal ventilation because the air flow in human lungs is reminiscent of the flows of the ocean tides.

“Next we grow dual networks of blood vessels that entwine around the airway. One to bring deoxygenated blood in, the other to carry oxygen-loaded blood away. The two networks join at the tips of the airway in a fine mesh of blood vessels which ensheathes the bulbous air sacs. These vessels are only 300 microns wide!”

This project, bringing together scientists and art designers, was featured in the American Association for the Advancement of Science (AAAS) in ‘Multivascular networks and functional intravascular topologies within biocompatible hydrogels,’ authored by Bagrat Grigoryan, Samantha J. Paulsen, Daniel C. Corbett, Daniel W. Sazer, Chelsea L. Fortin, and Alexander J. Zaita.

The recently published article goes into great detail about SLATE 3D printing, indicating that this hardware is capable of rapid bioprinting, and offering possible sustainability to human cells—along with maintaining functionality of stem cells and necessary differentiation.

The project was created by Jordan Miller at Rice University and Kelly Stevens at the University of Washington, and included 13 additional collaborators from Rice, University of Washington, Duke University, and Rowan University.

Nervous System is undeniably one of the most fascinating companies producing 3D printed innovations today. Their versatility has led them to create everything from 4D textiles and 3D printed stretched fabrics to their famed Kinematics Petal Dress. With their latest project delving into 3D printed tissue, the stakes become higher—and their impact on the world much greater. Find out more here.

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The Miller Lab fabricated and tested the architectures we generated showing that they can withstand more than 10,000 ventilation cycles while being perfused with human red blood cells. Study of the printed gels shows that the architecture we designed promotes red blood cells mixing and bidirectional flow which is hypothesized to occur in the human lung.

[Source / Images: Nervous System]

3D Printing News Briefs: April 21, 2019

We’re beginning with an aerospace 3D printing story in 3D Printing News Briefs today, then moving on to news about some upcoming industry events and finishing with a little business. Launcher tested its 3D printed rocket engine on an important date in history. DuPont will be introducing new semi-crystalline 3D printing products at RAPID + TCT, and Nanofabrica has offered to 3D print micro parts at no cost for interested companies attending the annual euspen conference. Ira Green Inc. used Rize technology to transform its production process, GOM is now part of the Zeiss Group, and the Ivaldi Group received its ISO 9001:2015 certification.

Launcher Tests 3D Printed Rocket Engine

New York startup Launcher, which uses EOS technology to create 3D printed components for metal rocket engines, has completed many firing tests with these parts over the last year and a half. Recently, on the anniversary of the date the first human left Earth to go into space, the startup announced the results of the latest test.

Launcher’s founder and CEO Max Haot posted on his LinkedIn account that the E-1 copper bi-metal rocket engine, which was 3D printed on the EOS M290, broke the startup’s combustion pressure record at 625 psi, mr 2.5. It will be interesting to see how the engine performs on its next test.

DuPont to Introduce New Semi-Crystalline Materials

At next month’s RAPID + TCT in Detroit, DuPont Transportation & Advanced Polymers (T&AP), a DowDuPont Specialty Products Division business, will be launching an expansion to its 3D printing portfolio: advanced, high-performance semi-crystalline materials, which will give customers more manufacturing agility and open new opportunities to lower costs while increasing production.

Jennifer L. Thompson, Ph.D., R&D programs manager for DuPont T&AP, will be presenting a technical paper about the materials during the event as part of the Material Development and Characterization session. During her presentation at 10:15 am on May 23rd, Thompson will discuss alternative 3D printing methods, like pellet extrusion modeling, in addition to highlighting new engineering materials and talking about tailored material testing programs. Thompson and other DuPont employees will be at DuPont T&AP’s booth #552 at RAPID to answer questions about the company’s 3D printing materials.

Nanofabrica Offers Free 3D Printing Services for euspen Attendees

Last month, Israeli 3D printing startup Nanofabrica announced the commercial launch of its micro resolution 3D printing platform. In order to show off the system’s abilities to potential customers, Nanofabrica has made an enticing offer to attendees at next month’s euspen conference and exhibition in Spain: the startup will print parts for interested companies at no charge. Then, the parts printed on the new micro AM platform will be presented to them at the event, which focuses on the latest technological developments that are growing innovation at the micron and sub-micron levels.

“It’s quite simple really. We believe that the best way to prove what our AM system can do, how high the resolution and accuracy of the parts we make are, is to manufacture parts for attendees,” Jon Donner, the CEO of Nanofabrica explained. “Registered attendees are welcome to send us their files, and we will examine and print them. That is how confident we are that you will be amazed by the capabilities of our system, and this we feel will mean that we can forge meaningful relationships with manufacturers that will endure into the future.”

Rize 3D Printing Transformed Company’s Production Process

Rhode Island-based IRA Green Inc. (IGI), a full-service manufacturer and distributor of unique uniform items earned and worn by military personnel around the world, recently turned to RIZE and its 3D printing capabilities in order to manufacture small fixtures for its tool shop. The company’s products are in high demand, but lead times were growing longer due to bottlenecks and 8 hours of work for each $300 fixture. Precision is also important for these parts, which is why IGI decided to turn to the RIZE ONE hybrid 3D printer. According to a new case study, IGI’s design team uses the printer every day to manufacture accurate fixtures in just 50 minutes for $2.00 a part. Using the RIZE ONE, which has the unique capability of adding ink markings to parts for verification, the company has been able to standardize its nails and molds, which helped lead to an ROI in less than five months.

IGI’s Manufacturing Manager, Bill Yehle said, “Implementing RIZE 3D printing as part of a strategic process shift has completely transformed our production process.

“We have realized an 80% time savings in setup and changeover alone using RIZE and virtually eliminated errors.”

ZEISS Group Acquires GOM

In an effort to expand its industrial metrology and quality assurance portfolio, the ZEISS Group, a technology enterprise operating in the optics and optoelectronics fields, has acquired GOM, which provides hardware and software for automated 3D coordinate measuring technology. By combining GOM’s optical 3D measuring technology with its own products, ZEISS could expand market access, and create new opportunities, for its Industrial Quality & Research segment. Once the transaction is complete, which should happen soon, GOM will become part of this ZEISS segment, while the legal form of its companies in Germany and elsewhere will stay the same. The financial details of the transaction will not be discussed publicly.

“Our growth strategy expressly mentions the targeted acquisition of highly innovative solutions, technologies and companies, which can reach their full potential as part of the ZEISS Group. By acquiring GOM and thereby expanding our solutions portfolio, we are bolstering the leading position of our Industrial Quality & Research segment and will be able to offer even better solutions for our customers. This is entirely in keeping with our corporate strategy, which is focused on our customers’ success,” said Dr. Michael Kaschke, President & CEO of ZEISS.

Ivaldi Group Awarded ISO 9001:2015 Certification

California startup Ivaldi Group, which uses 3D printing and metal fabrication solutions to provide in-port parts on-demand services for the maritime, mining, offshore, and construction industries has become ISO 9001:2015 certified in less than ten months. This standard, which is certifies quality managements systems that focus on customer satisfaction, continuous improvement, and active involvement of employees and management in a process-based approach, is the first step in the certification process that’s required to certify specific products. This proves Ivaldi’s commitment to constantly improving itself.

“Certifying our quality management system has helped us to structure our processes to create a solid foundation. This will allow us to improve efficiency, productivity, and traceability,” said Anna D’Alessio, Quality Management Specialist of Ivaldi Group. “Global quality management systems are important to align processes and optimize operations across facilities. This certification proves our commitment to meet requirements of stakeholders affected by our work.”

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Researcher Presents Case Study on Partially 3D Printed Lace-Like Dress

Lace isn’t just for wedding dresses or your grandmother’s doilies anymore, especially not when 3D printing is involved. Researcher Lushan Sun recently presented her case study about a 3D printed garment, titled “Instilled: 3D Printing Elastic Lace,” at the International Textile and Apparel Association (ITAA) Annual Conference Proceedings.

“The purpose of this design study is to explore the elastic performance in the various 3D printed structures using flexible FDM filament (nylon) in ready to wear apparel,” Sun wrote in her paper. “The goal is also to explore visual illusion in surface design through digital textile printing. Research through design (RTD) methodology was applied in this case study, and data were collected through reflexive journal documentation, video recording of the virtual design process.”

[Image: Danit Peleg]

Many designers are experimenting with the use of 3D printing in customized apparel design, in order to solve aesthetic issues as well as creating a unique design that’s also functional. While some designers, like Continuum Fashion with its N12 bikini, use SLS technology to create articulating structures for clothing, others, such as Israeli fashion designer Danit Peleg, use FDM and more flexible materials to make pieces that are actually comfortable to wear.

This second was the route that Sun took for the study, which focused on the “inspiration of visual illusion.” Sun integrated organic forms, which fused together to look like lace, in the prototype garment, which featured a delicate torso and skirt portion, completed with a flared silk skirt with an uneven hemline. The torso part of the dress, which blends two digital design applications, was lined with silk habotai – one of the most basic plain weaves of silk fabric – and did not require an additional closure in the form of a zipper.

“The torso was developed in silk charmeuse and consists of a stylized neckline and waistline. The back consists of two layers, a stylized cowl neckline and a 3D printed portion (nylon in FDM). The silks are draped over the elastic 3D printed lace to juxtapose the loosely fitted and the form-fitted silhouettes,” Sun wrote.

“Overall, the organic engineered print and 3D printed lace patterns in the front and back help to provide a unique focal point from different angles of the garment.”

There were four important phases in the development of the dress. First, Sun explored and sampled the chosen engineered textile prints in order to work out the appearance and color schemes, using Adobe to generate graphics for rendering and manipulation. Draping techniques were then used to develop flat patterns for the flowing piece.

The third step consisted of using direct 3D modeling techniques in Rhino to fully reflect the style of the dress’s organic shapes.

Sun explained, “The units were repeated to form the various groupings that were sampled for different elastic performance.”

The shapes in the lace-like, 3D printed part of the garment, which is fitted to the waist, upper hip, and shoulder, were customized to the shape of the flat pattern, in addition to being engineered to different scales so they would fit both the elastic and aesthetic needs of the dress. Finally, Sun used commercial Rit dye to give the 3D printed part of the garment the same ombre transitioning color scheme that the textile portions had.

“The resulting garment prototype takes the advantage of engineered elastic performance of the 3D printed lace in form fitting,” Sun concluded.

“This case study also suggested some challenges exist in developing a resilient and flexible structure that is both comfortable and durable in wearing. Future research should consider alternative 3D printed structures through difference 3D modeling techniques. Additionally, alternative complexity can be considered in the structure with different FDM materials.”

I can honestly say, without a doubt, that this is one of my favorite 3D printed pieces of clothing. I would definitely wear this dress out and about, as it looks comfortable enough to spend a decent amount of time in…pair it with some 3D printed high heels and I’m out the door!

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Creatz3D Case Study Shows How 3D Printing Improved Design of Multi-Axis Suction EOAT Robot

3D printing solutions provider Creatz3D, which operates in Singapore and Vietnam, was founded in 2012 and works to bring awareness to the fact that 3D printing adoption needs to be accelerated in order for manufacturers to remain competitive in today’s landscape. The company works with educational and government facilities, in addition to commercial companies, to drive this acceleration, and recently completed a 3D printing case study with Universal Robots (UR) that led to major time and cost savings.

The Danish company, which makes user-friendly industrial robots and has offices in the US, Latin America, Europe, and Asia, implemented the technology for its Multi-Axis Suction End-of-Arm Tooling (EOAT), which can be used in multiple industries to pick up multiple parts through independent vacuum channels.

As the current workforce starts to age out, and their expertise and experience go with them, it’s more important than ever to adopt new design paradigms in the manufacturing world, such as 3D printing and automation. While in the past robots may have been considered too dangerous to use on the factory floor, thanks to the advancements introduced by Industry 4.0, smaller collaborative robots, or cobots, can safely work next to humans in manufacturing settings. In fact, using 3D printing to make cobots means they can be more lightweight, which also makes them more efficient.

In warehouse settings, EOATs make sure that proper material “pick and place” flow is occurring, but standard, conventionally manufactured machines have some major limitations, such as hard to machine internal channels, reduced payload due to heavy tooling, and safety concerns due to sharp sheet metal edges.

The case study states, “CNC produced EOAT were restricted in design due to the constraints of traditional manufacturing and are unable to meet requirements. UR thus wanted to explore the opportunity of producing a lightweight EOAT that was able to pick multiple parts at a quicker pace. In addition, each end of the vacuum was to have their independent channels to accommodate different pick and place patterns.”

UR was looking for an alternative means of producing EOATs that would help make them more lightweight and easier to program. A customized machine could pick up multiple uniquely shaped parts at a faster rate of speed, which would definitely help improve productivity. Creatz3D is a Stratasys reseller, and UR decided to use its Fortus 450mc FDM 3D printer to fabricate more durable, precise parts out of polycarbonate (PC) material, which was chosen for its excellent sealing and mechanical properties. PC offers more flexibility and strength than other thermoplastics, like ABS, and is also lightweight enough that robot arms can move quickly.

By turning to 3D printing like UR did, manufacturers can make on-demand design iterations to parts, while requiring less lead time to complete low volume production runs. The technology offers more freedom in design when making customizable products, and parts can be made much more quickly and cost-efficiently as well.

In fact, by using 3D printing, UR was able to achieve time and cost savings, respectively, of 94.6% and 76%, and even lowered the number of components for assembly. The work was completed in less than five days, as opposed to taking weeks to finish. But that’s not all: UR also mounted a 3D printed modular bracket to the EOAT that could be used in the future to hold cameras and sensors to detect abnormalities during the machine’s pick and place operations.

However, after receiving some post-trial run feedback, the team realized that a change needed to be made to the bracket, and were able to quickly fix the problem.

“From the initial concept design which unfortunately posed a safety risk with the possibility that fingers could get stuck during operations, our engineers leveraged on the design freedom of 3D printing for a more effective solution with bent fingers,” the case study explains. “The use of FDM technology also allowed for the insertion of embedded inserts to the air supply connector and suction cup, which improved the overall durability of the EOAT tool and ability to pick up objects of varied sizes.”

Because UR had more design freedom thanks to its use of FDM 3D printing, the company was able to come up with a better solution than the original mounted design.

To see the revamped EAOT in action, watch the video from the case study on the Creatz3D website.

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[Images provided by Creatz3D]

CRP Technology Used SLS 3D Printing and Windform XT 2.0 to Make Aircraft Model for Wind Tunnel Testing

The new AW609 wind tunnel model designed for Leonardo HD by Metaltech S.r.l. and 3D printed by CRP Technology

CRP Technology, part of the larger CRP Group, is well-known for its 3D printing applications in the automotive sector, but lest we forget that it is also accomplished in aerospace 3D printing, the company has come out with a new case study about its work creating a new 3D printed wind tunnel model (1:8.5 scale) of the Leonardo TiltRotor AW609 for the Leonardo Helicopter Division (Leonardo HD, formerly known as AgustaWestland).

According to the case study, CRP Technology was able to “highlight the perfect union” between its advanced SLS 3D printing technology and high-performance, composite Windform materials – particularly its Windform XT 2.0, a polyamide-based carbon fiber reinforced composite. Metaltech S.r.l. designed the model.

The goals of Leonardo HD’s project included:

design and manufacture an internal main structure out of aluminum alloy that can easily have new geometries added
complete the work in a very short timetable, but with an extremely high level of commonality and reliability
make components out of materials with high mechanical and aerodynamic characteristics

3D printed aircraft propeller spinners

These goals are why Leonardo HD was referred to CRP Technology – it would be able to meet these goals while 3D printing the external parts for the wind tunnel model, which was designed, manufactured, and assembled in order to complete a series of dedicated low-speed wind tunnel tests. Some of the parts that were 3D printed for the wind tunnel model include nose and cockpit components, fairings, external fuel tanks, rear fuselage, wings, and nacelles.

The level of detail that went into these 3D printed parts “is crucial to the applied loads to be sustainable,” as the wind’s aerodynamic loads in the tunnel are high. So load resistance was one of the more important project aspects, along with maintaining good dimensional tolerances, under load, of large components.

“It is important to remember that the performance of these components affects the final performance of the entire project, especially because the external fairings have to transfer the aerodynamic loads generated by the fuselage to the internal frame,” CRP Technology wrote in the case study.

3D printed tail fairing

The tests needed to cover the standard range of flight attitudes at Leonardo HD’s Michigan wind tunnel facility, in addition to Politecnico di Milano, and varying external geometries were changed during testing, so that technicians would be able to gain a better understanding of “aerodynamic phenomena.”

Today, the CAD-CAM approach is used to design models for wind tunnel testing, before an internal structural frame of aluminum and steel is milled and assembled. Then, 3D printing is used to obtain all external geometries. Because Leonardo HD used CRP Technology’s advanced 3D printing and Windform XT 2.0 material the project was completed much more quickly, with “excellent results and with high-performing mechanical and aerodynamic properties.”

CRP analyzed the dimensional designs that Leonardo HD had sent in order to make the best composite material recommendation: its Windform XT 2.0, with high heat deflection, increased tensile strength and modulus, superior stiffness, and excellent detail reproduction.

“The choice of the Windform XT 2.0 composite material was not casual, all the goals required by Leonardo HD were considered, such as the importance of a short realization time, good mechanical performances and also good dimensional characteristics,” CRP Technology wrote in the case study.

It was necessary to 3D print the single parts separately, as “some components were dimensionally superior to the construction volume of the 3D printing machines,” but CRP Technology was able to complete the project with no time delays. The company used CAD to evaluate the working volume’s functional measures in order to determine which parts to split, and to figure out how to maximize contact surface where structural adhesive would be added to the model.

3D printed aircraft nose and cockpit

It only took four days to 3D print the various parts of the components.

The case study noted, “Different confidential efficiencies, which are an integral part of CRP Technology’s specific know-how, allowed the reduction of the delivery lead time and allowed CRP to minimize the normal tolerances of this technology, and eradicate any potential problem of deformation or out of tolerance.”

The completed model underwent surface finishing, before it was assembled by Metaltech S.r.l. and mounted directly onto a rig assembly, so any small imperfections resulting from single components being put together could be optimized. Thanks to CRP Technology, this step was finished very quickly, and Leonardo HD was able to efficiently flatten the model’s surface and treat it with a special liquid to both prepare for painting and make the model waterproof.

Leonardo HD needed to review the behavior of the aircraft, and so completed a high-speed wind tunnel test campaign, which encompassed speeds Mach 0.2-Mach 0.6, on a new 1:6 scale model at NASA Ames Unitary Plan 11′ x 11′ transonic wind tunnel. The company called on CRP USA, based in North Carolina, to speed up the process, using its partner company’s SLS 3D printing and Windform XT 2.0 composite material to make the external fuselage and some additional components.

3D printed model installed in the 11’x 11’ test section at NASA Ames

While the architecture of the new 3D printed model, which spanned nearly 2 meters, is similar to the original AW609 version, some improvements were made so remote controls could be used for the wing flaperons and elevator surfaces. Additionally, by using four different 6-component strain gauge balances, all the loads were able to act on the complete model, the nacelle, the tail surfaces, and the wing alone.

The model was constructed in such a way as to be mounted in the transonic wind tunnel on a single strut straight sting support system.

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[Images: Leonardo HD]

Betatype Reducing Build Time and Cost for Manufacturing 3D Printed Orthopaedic Implants

Spinal cage production build

Founded in 2012, London-based Betatype works to increase the productivity and efficiency of metal 3D printing, so that it can be used as a viable production technology. The company has worked with the aviation, automotive, and consumer products industries, and is now moving on to the medical field in its latest case study.

Metal 3D printing, and laser powder bed fusion (PBF) in particular, can be very advantageous when it comes to fabricating orthopaedic implants. Betatype has found time and again that this particular process can majorly increase productivity, as it is able to manufacture strong, complex structures that are durable enough to endure in the human body and can simulate the porous, mesh-like properties of bone, without wasting materials or time. Medical device manufacturers are able to achieve cost-effective serial production of everything from lumbar cages to acetublar cups using PBF, as the technology can be used to make safer, more porous implants of multiple shapes and sizes.

Obviously, orthopaedic implants have a certain level of design complexity, which can result in high volumes of data being generated that then slow down build processors. But Betatype’s innovative data processing platform Engine, which can manage and control multi-scale design, is able to get past this problem thanks to its supercomputing power, and rapidly create scan data for laser PBF 3D printing.

Engine can produce optimized build data, and has what essentially boils down to limitless scalability for generating builds. Recently, Betatype successfully created serial production build data for a company, to the tune of over 50 GB worth of build files. Its Engine platform can scale up to 640 virtual CPUs with 4.88 terabytes of RAM in just a few hours, saving companies time and money.

Macro of CAD of spinal cage. L-R: traditional mesh format, and ARCH or LTCX format.

Betatype uses its Engine technology to help its orthopaedic clients achieve lower costs on serial production of implants by lowering process time, optimizing high build data volume, and maximizing machine usage. Engine applies specialist algorithms for converting complex geometry, which lets the implant designers work in file formats, like nTopology’s LTCX data or Betatype’s ARCH format, that are up to 96% more lightweight than STL files; for instance, a spinal cage model that weighed 235 MB as an STL file was only 8MB as an LTCX file.

By combining Engine’s build data generation with these more lightweight representations, Betatype can help designers shorten and simplify the orthopaedic implant manufacturing process, so it’s more cost-effective and flexible, without having to deal with any mesh data.

Single stack of posterior lumbar cages, supported via sacrificial beam elements.

In terms of cost per part for serial production, it’s also very important to properly utilize a 3D printer’s total build volume. Betatype designs lattice node matched supports, which allows it stack implant parts on top of one another – an effective use of build volume that results in the production of many complex implants in one print. In addition, standard media blasting can be used to remove the supports, which is another time-saving feature in that it totally eliminates the need for any kind of manual post processing work.

Betatype’s technology is also able to directly optimize laser firing times, and lower delay times, without having to use multiple lasers. This can decrease build time by as much as 40%, and the more parts you 3D print in a single build, without sacrificing time, the more cost-effective those parts are, which is why equipment amortization can majorly effect the cost of orthopaedic implants 3D printed with laser PBF technology.

It’s possible to break build time down into three separate components, which can be addressed in order to speed up the process:

dosing (applying powder to the machine bed)
fusion (applying energy to the powder bed)
motion (movement between fusion)

In another project, Betatype used its technology portfolio to lower the build time for an orthopaedic manufacturer’s implants to 15.4 hours, down from 25.8 hours. Betatype can optimize its laser scan paths in order to decrease how much movement time and firing is necessary to 3D print complex lattice structures, and galvo-driven path optimization can be used to ensure that only prerequisite delays are applied to the process, lowering delay times from 13 hours to just 3.

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[Images provided by Betatype]

3D Printing News Briefs: November 3, 2018

In this month’s first edition of 3D Printing News Briefs, we’re starting again with news about formnext, before moving on to other business news, a medical story, and a case study. Mimaki will be bringing over 10 million colors to formnext, and M. Holland has signed a distribution agreement with 3DXTECH. Some exciting medical news out of South Korea – the country’s first chest transplant using 3D printing has been successfully completed. Finally, LulzBot published a case study about its work to help produce a haunting stop-motion animation short film.

Mimaki Showcasing Over 10 Million Colors at formnext

At formnext in Frankfurt later this month, Mimaki will be bringing its advanced, full-color 3D printing technology, under the theme of ‘Shape the Future in Colour.’ Its 3DUJ-553 3D printer, which offers consistent results in over 10 million colors, will be running live during the event so visitors can see the super fine, photorealistic detail it offers. In addition, through a collaborative project with Materialise, Mimaki’s 3D printed models are currently available under the name Multicolor+ through i.materialise. These models, 3D printed in UV-cured photopolymer resins with inkjet printing heads, have a strength that’s higher than other color 3D printing technologies and can be handled directly off the 500 x 500 x 300 mm build plate of the 3DUJ-553.

“Materialise is currently trialling Mimaki’s full-colour 3D printing technology. The material, Multicolor+, allows us to create smooth surfaces with vibrant colours that enhance the value of a finished object. Multicolor+ offers more vivid and intense colours and enables stronger, sturdier materials with a minimum wall thickness of 1mm. It also allows for printing interlocking parts. As a result, Multicolor+ is ideal for printing decorative parts such as figurines, avatars and architectural models,” said Miranda Bastijns, Materialise Director Manufacturing Online.

Come see Mimaki’s full-color 3D printing capabilities for yourself at booth D26 in Hall 3.1 at formnext, November 13-16.

M. Holland Signs New Distribution Agreement

This spring, international thermoplastic resins distributor M. Holland signed its first 3D printing product distribution agreement with Owens Corning to sell the company’s XSTRAND product line. Now, the company has announced that it signed its second distribution agreement, this time with Michigan-based manufacturer and supplier of high-performance 3D printing materials and parts 3DXTECH. This agreement will provide M. Holland’s industrial manufacturing clients with access to a larger team of commercial and technical support resources, in addition to adding over 24 materials, like carbon fiber and fire-retardant materials, to the company’s current 3D printing product portfolio.

“At M. Holland, our mission is to give our industrial clients agnostic advice about how to integrate 3D printing into their operations to create value. The 3DXTECH product line gives us a full portfolio of high quality, engineering-grade materials, which we can marry with objective recommendations about methods and machinery to deliver the optimal solutions to our clients,” said Haleyanne Freedman, M. Holland’s global 3D printing and additive manufacturing engineering specialist.

South Korea Completes First Local Chest Transplant Using 3D Printing

3D printed sternum model

A 55-year-old man, who chooses to remain anonymous, has just received the first chest transplant using 3D printing in the country of South Korea. Following Spain, Italy, the US, Britain, and China, this makes it the sixth nation in the world to complete this amazing medical innovation. The patient had a malignant tumor in his thorax, and while he’d had four other surgeries and anti-cancer drugs in the past, these conventional methods did not ultimately work, and the cancer returned to his body.

“All of a sudden, the patient once again was feeling pain, and the lump on his chest became clearly visible. This meant the cancer had grown resistant,” explained Professor Park Byung-Joon with Chung-Ang University Hospital. ” We felt the new treatment was necessary and so we had to perform surgery urgently.”

He knew that 3D printing could help customize treatments for patients. Together with the rest of his team, Professor Park created a 3D printed breastbone for the patient that would have been nearly impossible to create with other methods of manufacturing. The hope is that this 3D printed chest transplant will help spur additional innovation in South Korea.

To learn more, watch the video below:

LulzBot Helps Produce Stop-Motion Animation

Dale Hayward and Sylvie Trouvé of Montreal-based See Creature Animation, together with the National Film Board of Canada, have been working together for the past three years to produce the short film Bone Mother, a stop-motion animation version of the Slavic folklore tale of the witch Baba Yaga. For the first time, See Creature decided to use 3D printing, and chose the LulzBot Mini as the affordable, reliable machine they needed to create nearly the entire film with 3D printing. Then, the team decided to add three more to the studio, due to how much 3D printing was required – over 1,500 unique faces were needed, and See Creature used woodfill PLA by colorFabb, with a light infill, to make them. Adjustments were also made to reduce print precision, as one character needed plenty of wrinkles.

“Our main character, Baba Yaga is an ancient witch and naturally she should have wrinkles. So instead of sculpting them into the computer model, we found that if we print the face lying down, the layers look like a topographical map and the print naturally accentuated the curves of her face, creating a lot of the wrinkles for us,” Hayward explained. “We loved the look and it fit her character so much that we actually lowered the resolution to get even more stepping.”

“Where technology has forced traditional hand-drawn animation to adapt or fade away, stop-motion has always ridden the tech wave, so much so that there has become a renaissance of stop-motion films over the last decade. This is attributed to technologies like 3D printing…. they have opened the doors to greater creative possibilities at a lower budget.”

Bone Mother, which clocks in at less than nine minutes, recently premiered in Toronto. See it for yourself below:

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Luxury Watchmaker Collaborates with Betatype to Design and 3D Print Titanium Watch Strap

London metal 3D printing company Betatype, which was founded in 2012, provides functional 3D printed components to customers in a variety of industries, including aerospace, industrial motor sports, and consumer. Recently, the company was involved in the design and development of an innovative watch strap for luxury watch manufacturer Uniform Wares. The two collaborated to make a unique, woven strap out of 3D printed T5 titanium alloy, which is a complement to the newly launched PreciDrive M-Line watch collection.

“While we are always taking prompts from heritage and traditional processes in the watch and other industries, we also like to push things forward,” Michael Carr, the Creative Director at Uniform Wares, said in a Betatype case study about the technical side of this collaboration.

Uniform Wares set out to build a brand that embodies character and distinction through intelligent design, which resulted in a new breed of premium contemporary timepieces. In the company’s drive to continually embrace innovative technology and new materials, it began working with Betatype.

Previously, Uniform Wares had used more conventional manufacturing methods to make a mesh bracelet. But Betatype helped the company 3D print the ‘woven’ mesh bracelets in any texture or grain, which used less material and made the process simpler.

“We used a huge, cumbersome machine to weave steel cable into the mesh pattern, which we then had to cut to size and weld working parts onto it,” Carr explained.

“We were already using 3D printing to develop plastic – and some metal – prototypes, so when Betatype explained that they could help us to achieve more accurate and intricate designs [with 3D printing as the production method], we were interested.

“The idea that Betatype was using a new technology that would mean less waste and new materials was hugely appealing. We also liked that they were London-based and could produce the bracelets locally.”

The resulting 3D printed watch strap, made of 4,000 interlocking links, is made using laser powder bed fusion (LPBF) technology and is strong, yet lightweight it almost feels like fabric. Because the links are asymmetric, each side of the strap has a differing bend radius, which makes it easy to fit over the the wearer’s hand but flexible enough to secure around their wrist.

The 3D printed watch strap, weighing in at 10.5 grams, so has a new kind of directional clasp design, which has integrated microscopic teeth inside that interlock with the weave itself. This design element, which could only be economically achieved with 3D printing, makes it possible to make very fine adjustments, while still ensuring a secure hold and easy removal.

“Every element of the [watch] bracelet has been engineered exactly as it needs to work. The radius at which it curves, the flexibility and stiffness at each point – every link incorporates fine adjustments. It represents bespoke engineering at every point,” said Carr.

Betatype and Uniform Wares worked together to create a design for additive manufacturing (DfAM), which allowed them to blend 3D printing with the brand’s aesthetic requirements. By using Betatype’s optimized LPBF process to manufacture the T5 titanium strap, little to no waste was produced, as the method uses the least amount of material possible.

The company exerted greater geometric control over the 3D printing process by applying its unique multi-scale approach, which enabled the company to achieve the right feel, look, and strength for the watch strap design. Betatype can control, down to the micron, the laser’s scan path, exposure settings, and material microstructure for each individual link to get the best mechanical performance and fit.

In addition, Uniform Wares can now also streamline ordering and won’t need to request thousands of straps five months in advance.

Carr said, “We can now place an order for 60 pieces and they can have them ready in under a week; this is a real gamechanger for us.”

Fabrication and finishing for the T5 titanium strap is completed at Betatype’s East London design and manufacturing facility.

Uniform Wares and Betatype are already discussing additional collaborative projects for the future.

“We plan to incorporate what we’ve learned into other aspects of our products. Whatever we decide to do next, we’ll start with the design based on the knowledge of the additive process,” said Carr.

The 3D printed T5 titanium alloy watch strap will be available in a natural matte finish, with selected references from Uniform Wares’ new PreciDrive collection. It will cost £250 to purchase the strap on its own, while the M-Line watches with the titanium strap will be available for £500-£800, sold via the company’s website and select retailers, which include Nordstrom and Mr. Porter.

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PostProcess Technologies Uses Hybrid DECI Duo Solution to Achieve Excellent Surface Finish for 3D Printed Shrouded Impellers

Exacting Surface Finishing of Complex 3D Printed Metal Geometries.

PostProcess Technologies, which expanded its channel partner coverage in North America this spring, is well known for its software and post-printing solutions. With its automated Hybrid DECI Duo solution, PostProcess helps its customers achieve excellent surface finish standards and replicable results for complex metal parts.

Recently, PostProcess demonstrated in a new case study how well its technology can help other companies. The subject was Ingersoll Rand, a $14 billion global industrial manufacturing company that specializes in compressed air technologies. The company uses 3D printing for its shrouded impellers, which improve the performance of a compressor package more than open impellers because there is no clearance between the stationary inlet and the impeller, so no slip losses occur as a result of compression gas recirculating in the space.

The design for shrouded impellers, which rotate 60,000 RPM, has very tight tolerances in order to meet aerodynamic testing. In addition, the blades need excellent surface finishing, and it takes months to build using conventional forms of manufacturing. So Ingersoll’s engineering team, needing to commercialize its shrouded impeller design, turned to 3D printing because of its complete design freedom; the technology also makes it possible to build the part as monolithic, so no welding is required. But, in order for 3D printed parts to meet performance thresholds, they do require outstanding surface finishes.

Ingersoll 3D prints its shrouded impellers out of titanium and nickel alloy, but they unfortunately come off the print bed at an Ra (roughness average) value that doesn’t meet the engineering team’s specifications. The team has tried everything from manual sanding and grinding tools to chemical etching, but the results were inconsistent and did not have the necessary, repeatable quality needed to produce end parts within the required specifications.

The company needed to find a replicable process that would provide them with the necessary surface finish for its shrouded impeller’s complex geometry, in order to, as PostProcess wrote in its case study, “drive a measurable increase in efficiency for its advanced air compressors.”

So, Ingersoll turned to PostProcess in hopes that the company could work with complex metal part geometries, like organic shapes and internal channels, and help achieve repeatable results and excellent surface finish standards for its shrouded impellers.

Automated DECI Duo for Post-Print Support Removal & Surface Finishing.

PostProcess delivered a “transformative outcome” for Ingersoll’s 3D printed titanium and nickel alloy parts, thanks to its patent-pending, automated Hybrid DECI Duo solution. The Hybrid DECI Duo – a single, multi-functioning, data-driven system – promises fast cycle times for even the most complex of parts Designed to optimize production floor space, the system also includes noise reducing features for a low dBa, an LED lighted chamber, and a manual mode for hands-on part finishing when needed.

The system also uses PostProcess’ proprietary AUTOMAT3D software, in order to optimize energy and exclusive chemistry, which includes detergents and suspended solids so the geometries maintain their fine-feature details while still receiving the desired surface finish.

“We have chosen the DECI Duo because of its repeatability, minimal setup, processing times, and cost of ownership. Photochemical machining, extrude honing, and micro polishing or micro machining all yield very good results when applied correctly, however extensive tooling and equipment costs, setup times, and required DOE’s prior to applying the surface finishing method to obtain a repeatable process have made the DECI Duo a better option,” said Ioannis Hatziprokopiou, Mechanical Engineer, New Product Development, Ingersoll Rand Compression Technologies and Services.

“In addition, some of aforementioned finishing techniques unevenly remove material inside the flow path of the impeller, whereas the DECI Duo uniformly treats the entire surface of the flow path. The final geometry of the flow path must remain as unaltered as possible after post-processing of any kind.”

3D printed shrouded impellers were
implemented on the last 3 stages of this 6 stage 6R3MSGEP+4/30 engineered air booster machine.

The PostProcess solution established operating settings that were in line with Ingersoll’s standards using benchmark parts. Then, the DECI Duo was able to consistently finish metal parts that were able to successfully pass exacting aerodynamic tests.

Ingersoll came to PostProcess with a need for high quality and requirements in consistency and repeatability. But, it’s also achieved additional advantages from working with the company, such as cost savings and ease of operation.

In addition, the DECI Duo also produced an average of 70-80% reduction in Ra for parts run for 20 minutes or less.

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[Images: PostProcess Technologies]

Betatype Case Study Illustrates Cost and Time Savings of Using 3D Printing to Fabricate Automotive Components

When it comes to industrial 3D printing for automotive applications, London-based Betatype is building up considerable expertise. The 3D printing company was founded in 2012, and works with its customers to deliver functional, 3D printed components. Betatype built a data processing platform called Engine to help manage and control multi-scale design; the platform maximizes the ability of 3D printing to provide control in one process over material, shape, and structure.

Some of the benefits provided by 3D printing include high cost-per-part, productivity, and volume, especially when it comes to using metals. Betatype recently completed a case study that demonstrates how the advantages of metal 3D printing can be properly leveraged for applications in automotive parts production. It focuses on Betatype’s use of laser powder bed fusion (LPBF, also called Powder Bed Fusion, DMLS and SLM) 3D printing and optimization technology to, as the case study puts it, challenge “the current status quo” by producing 384 qualified metal parts in one build, which helped lower both lead time and cost per part.

“When it comes to automotive and other consumer-facing industries focused on producing high volumes of parts at low costs, the current generation of Additive Manufacturing (AM) processes is generally considered incapable of meeting these needs,” Betatype explained in its study.

“The key to making AM productive enough for wider adoption across these high-volume industries, however, lies in process economics – choosing the most effective manufacturing process for each part. Combining these principles with Betatype’s knowledge of the limits of additive – as well as how and when to push them – together with the company’s powerful optimisation technology, supports customers with the design and production of parts that not only perform better, but that are economically viable against existing mass production technologies.”

Production build of automotive LED heatsinks by Progressive Technology on an EOS M280.

You’ll often hear people in the 3D printing industry saying that one of the benefits of the technology is its ability to offer greater design freedom than what you’d find in more conventional manufacturing process. While this is true – 3D printing can be used to produce some pretty complex geometry – that doesn’t mean it’s without its own problems. It’s necessary to understand these constraints in order to find applications that can fit with the technology, and be used in high volume manufacturing as well.

Processes like die casting are capable of creating millions of components a year. 3D printing is valuable due to its capability of using the least amount of material to provide geometrically complex parts. Often 3D printing just doesn’t have the manufacturing volume or part cost to be an economical choice. But, this may not be the case for long.

According to the case study they looked at, “how it is possible to combine the innate geometric capabilities of AM with increased production volumes of cost-effective parts and improved performance” The team looked at “the Automotive industry’s switch to the use of LED headlights, which brings with it new challenges in thermal management.”

Most LED headlights need larger heatsinks, which are typically actively cooled. Betatype realized that the geometry of these metal parts would make them a good candidate for metal 3D printing, which is able to combine several manufacturing processes into just one production technique.

Betatype realized that LPBF would be ideal during the component’s initial design stage, and so was able to design the component with in-built support features. This made it possible to stack multiple headlight parts without requiring any additional supports; in addition, the company maintains that completed parts could be snapped apart by hand without any other post-processing required. This claim is something that we are highly skeptical about. No destressing or tumbling, shot peening, HIP or other processes usually result in parts that look different from the ones in the images given to us.

[Image: EOS]

Depending on part geometry it can be difficult to achieve full stacking with LPBF 3D printing. This is largely due to thermal stresses placed on parts and supports. Betatype designed the part in such a way as to decrease these stresses. This is what allowed Betatype to nest a series of heatsinks in order to maximize build volume and produce nearly 400 parts in one build envelope using an EOS M 280 3D printer owned by Progressive Technology.

“Through specific control parameters, the exposure of the part in each layer to a single toolpath where the laser effectively melted the part was reduced significantly, with minimal delays in between.”

13 x the productivity per system. Estimated Number of Parts per Machine per Year/Model built on build times provided by Progressive Technology for SLMF system (EOS M 280) and Renishaw AMPD for MLMF system (RenAM 500Q).

One of the large drivers in part cost is equipment amortization, and it’s important to lower build time in order to make parts more cost-effective. By using LPBF 3D printing and its own process IP and optimization algorithms, Betatype claims to have reduced cost-per-part from over $40 to less than $4, and lower the build time from one hour to less than five minutes per part – ten times faster than what a standard build processor is capable of performing. This would be a huge leap in capability for metal printing if these cost estimates stack up.

On single laser systems, like the EOS M 280 and Renishaw’s RenAM 500M, Betatype says that lowered the build time for all 384 parts from 444 hours to less than 30 hours; this number went down even further, to less than 19 hours, by using new multi-laser systems like the SLM Solutions 500 and the RenAM 500Q.

Up to 90% reduction in part cost. Estimated Cost per Part / Model built on build times provided by Progressive Technology for SLMF system (EOS M 280) and Renishaw AMPD for MLMF system (RenAM 500Q).

Betatype’s claims that their customer was able to achieve a productivity gain of 19 times the old figure per system in a year – going from 7,055 parts to a total of 135,168.

The case study concludes, “With an installation of 7 machines running this optimised process, volumes can approach 1 million parts per year — parts that are more functional and more cost-effective.”

It always good to show performance that is a step change ahead of what everyone thought possible. It is also significant that companies are making detailed case studies and verifiable claims as to output and yield. Betatype’s Case Study shows very promising numbers and we hope that productivity can indeed reach these heights with their technology.

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[Images provided by Betatype unless otherwise noted]