3D Printing Webinar and Virtual Event Roundup, July 19, 2020

A variety of topics will be covered in this week’s webinar and virtual event roundup, including additive manufacturing in aerospace, CAMWorks, product management, post-processing, and more. Read on to learn more about, and register for, these online opportunities.

AM in Aerospace Virtual Panel

On Tuesday, July 21st, Women in 3D Printing (Wi3DP) will host the third event, “Additive Manufacturing for Aerospace”, in its virtual panel series. Sponsored by AlphaSTAR and Link3D, the panel will focus on how AM is used in the aerospace industry. Moderated by AM-Cubed founder Kristin Mulherin, the speakers are Anna Tomzynska, Director and Additive Manufacturing Chief Engineer for Boeing; Deb Whitis, GE Aviation Chief Engineer; and Eliana Fu, Senior Engineer, Additive Technologies, at Relativity Space.

Pre-registration will begin at 11 am EST, with a welcome speech at 11:25. The hour-long panel will begin at 11:30, with plenty of time for live Q&A, and there will be a virtual networking reception at 12:30. Register for the virtual panel here.

3DEO Webinar – Why I Switched From CNC Machining

Also on July 21st, metal 3D printing company 3DEO is hosting a live webinar, entitled “Why I Switched From CNC Machining: An Engineer’s Perspective on Transitioning to Metal 3D Printing.” The webinar, which starts at 1 pm EST, will feature 3DEO Applications Engineer Julien Cohen, who will explain the major differences between metal 3D printing and CNC machining. The following topics will be covered:

  • Compare CNC machining and 3DEO’s proprietary metal 3D printing process

  • Understand the value metal 3D printing offers engineers in design and flexibility

  • Learn about the pros and cons of each process and when metal 3D printing makes sense

  • Discover three real-world case studies of 3DEO winning versus CNC machining

  • See 3DEO’s process for going from first articles to production

You can register for the webinar on 3DEO’s website.

Free CAMWorks Webinar Series

To make sure professionals in the CAM industry have easy access to educational and training materials during the COVID-19 crisis, a free CAMWorks webinar series has been launched. Each session will give attendees the opportunity to increase their CAM skills, learning about more advanced features that can help maintain business operations. SOLIDWORKS CAM and CAMWorks: Getting Started” is on Tuesday, July 21st, at 10:30 am EST, and will be a training session on using the integrated CNC programming system SOLIDWORKS CAM Standard. It will also provide an introduction to the Technology Database (TechDB), which can automate the CNC programming process. “SOLIDWORKS CAM for Designers: A Path to Better Designs” will also take place on July 21st, at 2 pm EST, and will focus on how to use SOLIDWORKS CAM to reduce cost, improve design, and make it easier to manufacture parts.

You’ll need to attend the “Getting Started” webinar before attending “SOLIDWORKS CAM and CAMWorks: Getting Started with the TechDB” on Thursday, July 23rd at 10:30 am EST. This is a more in-depth training session for using the TechDB included in SOLIDWORKS CAM and CAMWorks. The final webinar in the series is “The Future of Manufacturing in the COVID Era,” also held on July 23rd, at 2 pm EST. This session will help attendees learn how to automate part programming to stay productive and competitive during and after the pandemic.

Protolabs Webinar: HP’s Multi Jet Fusion

On Wednesday, July 22nd, at 2 pm EST, Protolabs will be hosting a webinar with HP, called “Tips and Tricks to Leverage Multi Jet Fusion in your Product Development Cycle.” One of the company’s Applications Engineers, Joe Cretella, and Brent Ewald, HP’s Solution Architect, will discuss design tips that result in good MJF parts, how to implement the technology, and where MJF fits within additive and subtractive manufacturing.

This webinar will help attendees understand how the HP Multi Jet Fusion technology 3D printing process can be leveraged in various stages of the product development lifecycle. The experts at HP and Protolabs have teamed up to give you key insights into Multi Jet Fusion materials, processing capabilities, and part quality. Whether the attendee is new to additive manufacturing or evaluating Multi Jet Fusion for their production project, this presentation will help identify when the technology provides the most value and what to consider when manufacturing Multi Jet Fusion parts.”

Register for the webinar here.

Dassault Systèmes on Project Management Solutions

At 10 am EST on Thursday, July 23rd, Dassault Systèmes will hold a live webinar,”Discover How to Deliver Projects on Time and Under Budget, a Real-time Online Experience,” all about collaborating with integrated project management solutions connected to 3D engineering data in order to drive project success. Dassault speakers Maximilian Behre, the Online Industry Business Consultant Director, and 3DS Industry Process Consultants Siddharth Sharma and Alessandro Tolio, will discuss project management challenges, shortening the design cycle through the 3DEXPERIENCE platform, provide a demonstration of Project Management on the cloud, and answer questions.

“Whether you are managing big programs that involve hundreds of people or are leading a smaller project, an easy to use integrated project management solution will help you to seamlessly collaborate across all disciplines with any stakeholder. Connect the dots between Marketing, Engineering to Manufacturing and customer services.”

Register here.

KEX Knowledge Exchange on Post-Processing

Finally, former Fraunhofer IPT spinoff KEX Knowledge Exchange AG is holding its second webinar on its KEX.net web platform, “Online Seminar Post-Processing for Additive Manufacturing,” on Thursday, July 23rd. Lea Eilert, the project and technology manager for the ACAM Aachen Center for Additive Manufacturing, will teach attendees about typical heat treatment for AM materials, the necessity of post-processing for 3D printed components, and various post-machining and surface finishing methods.

Register for the webinar here. In addition, Eilert will also present the third KEX webinar on August 6th, entitled “Market, Costs & Innovation.”

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! 

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Hybrid 3D Printing Profile: DMG Mori

DMG Mori is one of the largest machine builders worldwide, generating about $3 billion in revenue each from its Japanese and German divisions. Though its position in the 3D printing industry is comparatively limited, it is growing, which is why we thought we’d take a look at DMG Mori its role in additive manufacturing (AM).

A 1960’s era Mori Seiki MH 1500 lathe. Image courtesy of HASUDAI MACHINERY CO.,LTD.

DMG Mori began as textile manufacturing equipment maker Mori Seiki Co. in 1948, which ultimately led to the production of machine tools by 1958, from which it has not since diverted.  Early machines included manually controlled lathes before the introduction of numerically controlled lathes, then vertical and horizontal machining centers. These various machine tools continued to improve up to the present day.

An important component of DMG Mori’s current operations is its German division, DMG Mori AG, which first became a partner of the Japanese company in 2009. The largest manufacturer of cutting machine tools in Germany, DMG Mori AG was founded as GILDEMEISTER by Friedrich Gildemeister in 1870 and, by 1910, was a mass manufacturer of turret lathes, multi-spindle automatic lathes, milling machines, and vertical and horizontal milling machines.

While new automation features and orders from a quickly industrializing Soviet Union allowed the German company to succeed during the depression of the 1920s, the two World Wars saw Gildemeister nearly shut down by Allied forces twice. After World War Two, the company began to boom as the German economy recovered, with Gildemeister ultimately releasing numerically controlled machine tools in the 70s. From the 60s through the 90s, the company made important acquisitions. By the time of the 1995 acquisition of Deckel Maho AG, it was an established European powerhouse in manufacturing machine tools.

As Mori Seiki’s partnership Gildemeister, deepened and the Japanese company increased its ownership shares in the German manufacturer, it changed its name to Deckel Maho Gildemeister (DMG) Mori in 2013. By 2016, the Japanese and German divisions were officially integrated into a single conglomerate.

It wasn’t until 2015 that DMG Mori entered the AM market with its first hybrid manufacturing system, the LASERTEC 65 3D, which incorporated a directed energy deposition (DED) head into a five-axis milling machine. The system features a 2.5-kW diode laser for DED at rates of up to 1 kg/h. Since then, the company continued to release hybrid machines. In 2016, the LASERTEC 4300 3D was added to its portfolio, which included DED, 5-axis milling and turning functionality. Its most recent hybrid system is the LASERTEC 125 3D Hybrid, unveiled at Formnext in 2019.

The new LASERTEC 125 3D hybrid from DMG Mori.

In 2017, DMG Mori acquired a majority stake in early metal powder bed fusion (PBF) company Realizer and released its first PBF 3D printer, the LASERTEC 30 SLM, to the market. This was followed up by the LASERTEC 12 SLM, which is smaller and designed specifically for thin-walled components.

Printed metal parts typically require heat treatment, which hardens the metal, before other post-processing operations can be performed, meaning that hybrid machines can’t necessarily move directly from printing to machining without heat treatment in between. However, the newest LASERTEC 125 3D hybrid can deposit material with a hardness of up to 63 HRC, DMG Mori suggests allows users to skip the heat treatment step when harder metals are used.

DMG Mori bills all of these systems as part of a larger collection of four process chains. While the hybrid systems are able to perform all of the additive and subtractive functions necessary for 3D printing, the SLM machines and the LASERTEC 65 3D (a pure DED system) can be complemented with CNC machines offered by the company. Workpieces 3D printed with these systems can be finished to proper tolerances and surface quality on a milling machine or previously milled base plats and bases can be have objects printed onto them without the need for support structures.

Now that the Japanese conglomerate is firmly settled in the additive space, it has begun offering AM consulting services. This includes verifying the printability of parts, redesigning parts for AM, engineering new components and product categories, simulation and topology optimization, 3D printing of prototypes and small series, courses and training, and consultations dedicated to overall strategy.

Because DMG Mori has developed laser PBF, DED and hybrid machines, it would appear to be an important contender in the AM space. Perhaps, in the near future, we’ll see the company release a hybrid PBF system, like Matsuura offers, or laser-based machining, like Trumpf. As impressive as hybrid 3D printing technology appears to be from the outside, we will have to see more success stories coming from industry before we can truly assess its place in the larger AM and manufacturing markets.

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3D Systems: Augmenting Your Workflow with Traditional and Additive Manufacturing

Combining Old and New Technology

Remember the days when people thought that we would all end up with our own home desktop 3D printers to make anything our hearts desired and would never have to leave the house to buy consumer goods again? While I’m not saying this future isn’t still in the cards (imagine never having to get in another shopping cart lane battle at the store!), most people have realized this might be just wishful thinking and are focusing on other uses for additive manufacturing – such as combining the technology with traditional forms of manufacturing.

Just because you’re interested in 3D printing doesn’t mean you have to completely forget about all of the existing manufacturing technologies – you can complement your workflow, learn something new, and add that skill to your wheelhouse. And try as you might, it’s not always economically feasible or the right choice for your business to switch completely over to 3D printing. So one more time for the people in the back – by combining conventional manufacturing with 3D printing, companies can truly augment and speed up their workflows.

3D Systems knows a little something about this, as the company offers both additive and subtractive manufacturing capabilities through its On Demand manufacturing services.

“Our online 3D printing portal was designed by engineers for engineers,” the 3D Systems On Demand webpage states. “Our goal is to make the process of ordering 3D printed parts and prototypes the easiest in the industry.”

This is what sets 3D Systems apart from other service bureaus in the market. In fact, the company just released an eBook, titled “The Benefits of Traditional and Additive Manufacturing from a Single Source,” that’s all about combining 3D printing with other types of manufacturing it offers, such as CNC machining, investment casting, injection molding, urethane casting, sheet metal, die casting, etc. The campaign for 3D Systems’ new eBook recently went live, and the book itself discusses different ways to combine additive and traditional manufacturing for the optimal effect, in addition to using your project budget in the most efficient way, speeding up time to market, and the best ways to fulfill design goals.

3D Systems On Demand service bureau offers traditional injection molding for low-volume projects, and most commercially available thermoplastics from production-grade tooling are available. Nearly 20 different materials are available, with ten finish options, including Light Texture, Mirror, and Color-Matching. A urethane casting service is also available for rapid prototyping purposes, with a wide array of materials and three different finishes offered.

“One of the greatest benefits of the Cast Urethane process is the ability to over-mold existing parts or hardware with a second material,” the website states.

Learn more about the traditional Capabilities such as Cast Urethane in the new eBook. 

While you can visit many vendors to receive external prototyping and production services, there aren’t too many like 3D Systems that offer a full range of options in both traditional and additive methods. For example, less than a year ago, the company released its ProJet® MJP 2500 IC RealWax™ 3D printer, which lets existing investment casting operators switch to additive manufacturing for their patterns, using 3D Systems’ MJP 3D printing technology. In addition, its VisiJet® M2 ICast (MJP) material is wax, which means it will work within the existing foundry without requiring any updates or changes to furnaces or temperatures.

Four years ago, 3D Systems also highlighted its digital molding technology for the first time. This is a scalable 3D printing process – backed by the company’s configurable Figure 4® technology – that lets you do tool-less production, and is a good alternative for low-volume plastic part production.

3D Systems’ Figure 4®

Confederate Motors, which has been designing and manufacturing bespoke motorcycles in small batches for over two decades, has been collaborating with 3D Systems On Demand since 2014 in an effort to convert 140 different designs into prototypes and production parts for its P51 Combat Fighter. 3D Systems provides a one-stop shop for Confederate Motors’ motorcycle parts, including everything from the intake manifold and swing arm parts to the front and back fenders and the key to start up the motorcycle.

“With the exception of some engine components, wiring, wheels, tires and lighting, 3D Systems makes every part of the Fighter. We save a tremendous amount of time and hassle by being able to consolidate part production with one primary vendor. Parts go together better coming from the same vendor, and we can be assured that the part finish of everything will match,” said Jordan Cornille, a designer at Confederate Motors.

“We like to move quickly in our decision-making processes and design quickly in order to offer our customers as many solutions as possible within a certain time frame. We don’t produce thousands of copies of each model, and 3D Systems allows us to change designs frequently without committing to thousands of dollars worth of tooling.”

3D Systems used plenty of CNC machining to make the parts for the P51 Combat Fighter motorcycle; according to the 3D Systems On Demand site, this subtractive technology “is the best choice for rapid prototyping of high-quality metal and plastic parts” that need an extremely high degree of dimensional accuracy. The service bureau offers a variety of different materials and finishes for CNC machining and promises a standard delivery time of 1-2 weeks, based on the order.

As noted in its new eBook, the company also offers integrated additive and traditional manufacturing approaches, which is perfect for projects that need to combine the ability to manufacture complex shapes at a faster rate of speed with high precision. Room Temperature Vulcanization (RTV) is just one of these integrated processes – it uses 3D printed masters and silicone molds to produce high-quality parts in low to mid-volume batches, without having to rely on expensive hard tooling. The benefits of RTV include a large material selection, a shorter lead time, and the ability to over-mold existing hardware and parts with an additional material.

“When the 3D Systems On Demand service bureau was established several years ago, the company expanded its expertise and resources through strategic acquisitions, not only for 3D printing and additive manufacturing, but for traditional approaches as well,” the eBook states. “3D Systems On Demand now has a worldwide network of facilities to locally service companies that need a stable, reliable, well-resourced and uniquely experienced partner.”

To learn more about the wide variety of additive and traditional manufacturing processes that 3D Systems offers through its On Demand service bureau, check out the company’s new eBook, or contact us for more details.

[Images: 3D Systems]

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3D Printing and the Circular Economy Part 6: CNC Machining

Desktop Metal CNC

CNC machining is a manufacturing process in which pre-programmed computer software dictates the movement of factory tools and machinery. The process can be used to control a range of complex machinery, from grinders and lathes to mills and routers. With CNC machining, three-dimensional cutting tasks can be accomplished in a single set of prompts. CNC refers to computer numerical control. Today we will be comparing CNC methods to 3D Printing and additive manufacturing in terms of their places within a circular economy. 

Transportation waste is not as large of a concern when it comes to CNC machining. It is important to have one’s material ready before they are to place the material within a CNC center. The layout of one’s factory or fabrication environment is more critical towards this type of waste. Similar thoughts can be arrived at in terms of additive manufacturing. Based on the types of material used for a CNC machine, it is slightly difficult to transport larger amounts of the metals used for these machines. 

Inventory waste is mostly oriented towards what material you are using for the CNC process. Typically we are using metal materials. The type of materials typically used consist of brass, copper alloys, aluminum, steel, stainless steel, titanium, and plastics. The type of material is very important because of production needs. CNC machining is a subtractive process. Hence, the various materials will cause different shearings as well as carving residue and debris that will be produced during a cutting out of a piece. 

Image result for cnc machine debris

CNC Waste

Waiting time in terms of CNC machining depends on the feed rate. Feeds specifically refers to the feed rate the tool advances through the material while speed refers to the surface speed that the cutting edge of the tool is moving and is needed to calculate the spindle RPM. Feed is generally measured in Inches Per Minute (IPM) in the US and speed is measured in Surface Feet per Minute. Feed speed as well as material density causes the amount of wait time to differ per manufactured part. Part geometry also has a role to play here as well as hardness. A CNC typically is faster than a 3D printer device, but this is again dependent on material and geometry. 

Over-processing is not as much of a concern for both of these methods of manufacturing. CNC machining and 3D printing are both great at building quick prototypes of designs. Over-processing can become problematic in CNC when one wants to make very polished cuts of a material to have sharper edges and rounded surfaces. There may be an element of over-processing there that leads to time wasted. 

Post processing is a big issue when it comes to 3D printers. Post processing issues are not as apparent with CNC parts. They typically are ready for deployment after they have been produced with excellent surface finishes. 

Image result for cnc waste

CNC Carvings

Recyclability is apparent with various CNC waste materials post production. It is important to be constantly aware of the different products used. In order to recycle, it necessitates the separation of materials. This requires bins oriented towards specific materials labelled clearly near a CNC machine. Without this, most of the scrap will be left unattended and mix together to a point of difficult separation. 

Overall the differences between CNC machines and 3D print are considerable. The sheer amount of waste material produced by a typical CNC is way more than a 3D printer. There are efficiency trade offs that are associated with 3D printers in terms of speed and material transportation. In the future advances to additive manufacturing will shrink the gap in terms of creating products in a more sustainable and additive manner versus a subtractive fashion.

The post 3D Printing and the Circular Economy Part 6: CNC Machining appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

3D Printing and CNC Machining Platform Weerg Announces New Headquarters

There are many 3D printing platforms available online, but not as many that offer both 3D printing and CNC machining. One site that does is the new platform Weerg, which offers both additive and subtractive manufacturing services to customers. All a client needs to do is upload their 3D file to the site, and Weerg will provide an instant quote and then 3D print or CNC machine it and deliver it within five days. The company is based in Marghera, Italy, near Venice, but delivers worldwide, and will soon be relocating to a new facility in Gardigiano.

“We chose a building that could respond to our sudden needs for business expansion and therefore space dedicated to production systems,” said Weerg’s Matteo Rigamonti. “It is a former knitwear factory of about 27,000 square meters, which we will occupy initially 5,000 square meters, in addition to other 3,000 square meters already optioned. A choice that allows us to envisage future expansions of the machine park without requiring further transfers.”

Interior of an empty warehouse

 

Weerg offers CNC machining services with 5-axis continuous Hermle milling machines and Mazak Integrex multitasking lathes, as well as Hitachi tools and Hypermill Open Mind CAM software. In terms of 3D printing, the company utilizes the HP Jet Fusion 3D 4200. Weerg possesses six of the Jet Fusion 3D printers, the largest installation in southern Europe. When the new facility is opened, the latest installations of Hermle machines will be carried out, consisting of two batteries of five Hermle machines each, fully automated with anthropomorphic robots.

Weerg prides itself on the simplicity of its site and processes. The production process is almost fully automated, facilitated by unique evaluation and management software that was developed by the company’s R&D department. The software directs the machinery, which was selected according to parameters of efficiency, productivity, quality and automation.

“One of our mottos is ‘Set and forget’: clearly we address our customers to whom we want to offer a purchasing experience that is absolutely new in the world of mechanics: the estimate in a few seconds and the certainty of the delivery date, which can be chosen from 3 to 10 days,” continued Rigamonti. “But not only that, because this slogan also tells the story of our organization, where all the steps are managed through advanced software that drastically reduces manual intervention by operators and therefore procedures relegated to craftsmanship that does not belong to us.”

Weerg has the Trusted Shops certification, a stamp of quality for e-commerce in Europe. The company intends to conquer the markets throughout the continent, expanding outward from its Venetian origins. Its customers come from a wide range of industries: automotive, boats, mechanics, aerospace, and a variety of industrial automation sectors. Every day the site sees more than 15,000 requests for quotes, which are processed within seconds thanks to the company’s software.

Currently Weerg does not offer design services, just production, but that may follow as the company expands. Weerg’s materials selection is growing, and it promises competitive prices thanks to the efficient, modern equipment and round-the-clock production it utilizes.

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts below. 

[Images courtesy of Weerg]

 

 

Fabrisonic’s Whitepaper on Metal 3D Printed Heat Exchangers for NASA JPL

Founded in 2011, Ohio-based Fabrisonic uses its hybrid metal 3D printing process, called Ultrasonic Additive Manufacturing (UAM), to merge layers of metal foil together in a solid-state thanks to high frequency ultrasonic vibrations. Fabrisonic mounts its patented hybrid 3D printing process on traditional CNC equipment – first, an object is built up with 3D printing, and then smoothed down with CNC machining by milling to the required size and surface. No melting is required, as Fabrisonic’s 6′ x 6′ x 3′ UAM 3D printer can “scrub” metal foil and build it up into the final net shape, and then machines down whatever else is needed at the end of the process.

Last year, Fabrisonic’s president and CEO Mark Norfolk told 3DPrint.com at RAPID 2017 that about 30% of the company’s business was in heat exchangers, as the manufacturing process is a lot smoother thanks to its low-temperature metal 3D printing technology – no higher than 250°F. UAM makes it possible to join metal alloys that are notoriously difficult to weld, such as 1000, 2000, 6000, and 7000 series copper, aluminum, stainless steel, and exotic refractory metals…all of which are used in the heat management systems at NASA’s Jet Propulsion Laboratory (JPL).

[Image: Sarah Saunders]

Justin Wenning, a production engineer at Fabrisonic I spoke with at RAPID 2018 this spring, recently published a whitepaper, titled “Space-grade 3D Metal Printed Heat Exchangers,” that takes a deep dive into the work he’s been doing with Fabrisonic’s 3D printed metal heat exchangers for aerospace applications. The company participated in a two-year program at JPL, and 3D printed a new class of metal heat exchanger that passed JPL’s intense testing.

“For every interplanetary mission that JPL oversees, numerous critical heat exchanger devices are required to regulate the sensitive, on-board electronic systems from temperature extremes experienced in space. These devices can be small (3 in. x 3 in.) or large (3 ft. x 3 ft.),” Wenning wrote in his whitepaper.

For many years, NASA glued bent metal tubes along, and fastened them to, the exterior of a space vehicle’s structure, which weigh a lot and do not perform well thermally. These devices were also assembled and quality-checked by hand, so production could take up to nine months. At the end of its partnership with NASA JPL, Fabrisonic showed that 3D printing can be used to improve upon all of these issues.

Evolution of UAM 3D printed heat exchanger with NASA JPL. Samples began small to
evaluate benchmark burst and helium leak performance in 2014. The team then began focusing on technology scale-up and system integration. The culmination is a full-size, functioning heat exchanger.

The UAM system does not use any controlled atmospheres, so the part size and design range greatly. NASA JPL first started working with Fabrisonic in 2014, thanks to a JPL Spontaneous R&TD grant, to look into small, simple UAM heat exchangers, before moving up to larger structures in 2015 through NASA’s SBIR/STTR program. The result was a full-size, functioning heat exchanger prototype for the Mars 2020 rover mission that was fabricated in far less time, with a 30% lighter mass.

The 3D printed heat exchangers that Fabrisonic creates involve building pumped-fluid loop tubing right into the structure for additional efficiency and robustness, as the company’s UAM process can also be used to mix and match materials, like copper and aluminum.

UAM starts with a metal substrate, and material is then added to and removed from the structure to make the device’s internal passageways. To help with material deposition, a proprietary water-soluble support structure is added, before adding strength and features, respectively, with optional heat-treating and final CNC machining. Fabrisonic then added SS tubing, which helps with fitting attachments, to the aluminum structure with friction welding for NASA JPL’s development parts.

NASA JPL also needed to raise its technology readiness level (TRL) from 3 to near 6. During the program, Fabrisonic and its EWI affiliate 3D printed and tested dozens of different heat exchangers, in order to develop a final prototype for ground-based qualification standards based off of NASA JPL’s existing heat exchangers.

UAM process steps for fabricating NASA JPL heat exchangers.

The NASA JPL TRL 6 qualification included several tests, including proof pressure testing to 330 PSI, two-day controlled thermal cycling from -184°F to 248°F in an environmental chamber, and vibration testing on an electrodynamic shaker, which simulated a common day rocket launch (1-10 G) in all orientations while attached to a dummy mass at the same time for imitating a normal hosted electronics package. Other tests included:

  • Burst testing greater that 2500 PSI with a 0.030-in. wall thickness
  • Helium leak testing to less than 1×10-8 cc/s GHe between thermal and vibration testing
  • Full 3D CT scans of each specimen before and after mechanical testing, in order to evaluate void density and any accumulated testing damage

JPL project with copper embedded. [Image: Sarah Saunders]

Each of the three UAM 3D printed heat exchanger components passed the qualifications, which raised the technology to its goal of near TRL 6. To corroborate the results, NASA JPL scientists completed more helium leak and burst testing, along with thermal shock testing on certain devices; this involved submerging certain heat exchangers in liquid nitrogen (-320°F) to test their bi-metallic friction welded stainless steel aluminum joints. According to the whitepaper, the joints were “robust and helium leak tight” post-submersion.

Fabrisonic’s new class of 3D printed metal heat exchanger, developed under NASA JPL, has uses in other commercial production applications, which the company is currently exploring.

“For instance, the lack of melting in UAM enables the integration of multiple metals into one build since high temperature chemistry is avoided,” Wenning wrote. “Thus, copper may be integrated as a heat spreader in critical locations improving thermal performance with a small weight penalty.”

Because of its low temperatures, UAM can also be used to embed sensors into solid metal. In 3D printed heat exchangers, sensors could help monitor system health and improve control by being integrated in important locations.

Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts below.

[Images: Fabrisonic unless otherwise noted]

3D Hubs Releases Second Edition of Digital Manufacturing Trends Report

Last quarter, 3D Hubs published its first Trends report to include Digital Manufacturing trends. The popular and long-running report still includes all of the latest information about 3D printing, but now also includes more insights on other digital manufacturing technologies, such as injection molding and CNC machining.

Today, 3D Hubs has released the second edition of this newly revamped report. The Digital Manufacturing Trends report for Q3/2018 is exclusively available for free download here.

“Spring has brought about a change to the data, with the end of the financial year and students ordering,” George Fisher-Willson, 3D Hubs’ Communications Manager, told 3DPrint.com.

Highest Rated Industrial Printers

In the Highest Rated Industrial Printers category, SLS still reigns supreme, accounting for six of the top ten 3D printer models, though one should note that only 3D printers with over 30 reviews per quarter are included in the breakdown. The top four are virtually unchanged from last quarter, with the Formiga P 100 still in first with a quality rating of 5. The iSLA-650 Pro was knocked down one slot to sixth place by the sPro 140, which received the same 4.93 rating as the EOSINT P 760 above it.

Most Used Industrial Printers

The HP Jet Fusion 3D 4200 is holding steady at first place in the Most Used Industrial Printers category…and with a record 30% more output, with an increase from 5,087 to over 6,550 prints.

“At #1 the HP machine created 6,551 prints, nearly triple that of #2 place Formiga P 110 which achieved a respectable 2,244,” 3D Hubs’ Digital Manufacturing Trends report states.

The large-format UnionTech Lite 600, up from 201 to 1,665 prints, most often used to create automotive molds and tooling, moves from its tenth place ranking last quarter to third this time around, knocking the sPro 230 down to fourth. The Objet30 Prime is also up a few places this time to round out the top five, though its number of prints only increased by 227.

Highest Rated Desktop Printers

In terms of Highest Rated Desktop Printers, only 3D printers with over 140 reviews in the quarter are included in the statistics for this quarter, which have the Zortrax M200 moving up from fifth place last quarter with a rating of 4.81 to first place this time around with a barely increased rate of 4.87.

The LulzBot Taz 5 makes a surprise entrance, and its 4.86 rating puts it at #2 on the list. Those reviews must have all been extremely positive, as #3 on the list, the Original Prusa i3 MK2, has the exact same rating with a total of 658 reviews. The Creality CR-10 is up from the tenth position to #4, and the Original Prusa i3 MK3 is up to #5 this quarter, with 349 reviews netting it a 4.83 rating.

The report notes, “The machines also took a large share of the reviews showing their popularity with service providers across the world.”

Most Used Desktop Printers

The battle rages on between the Form 2 and the Original Prusa i3 MK2 in the Most Used Desktop Printers category, with the Form 2 increasing its number of prints from 14,211 to 14,516 to jump back up to first. This gap may continue to grow, as Formlabs has released two new resins over the last few months. The FlashForge Creator Pro and the Original Prusa i3 MK2S both remain, respectively, in the #3 and 4 slots, though the latter has dropped its number of prints just a smidge, and the Prusa i3 MK3 has made the list this quarter, with a total of 6,345 prints.

According to the report, “Of the total 71,869 prints produced in the top 10, the Prusa machines have manufactured over 25,000 of the [sic], an impressive figure.”

Most Used Technologies

Not much change this quarter for the Most Used Technologies, as FDM 3D printing continues its first place ranking…even going up one percentage point while SLS dropped one.

“For the first time since the report began Metal Sintering double its share going to 2%, this could be potentially due to businesses putting in their high-end orders before the end of the financial year,” the report stated. “It could also be down the fact that Metal 3D printing is seeing further adoption by large multinationals as its ability to create complex geometries in metal cannot be beaten by traditional technologies.”

Most Used Materials

Last quarter, the Most Used Materials category adopted the generic term “Standard,” to denote that suppliers are listing materials to include all variants. Since then, the top ten has changed a little bit.

“Standard PLA has distanced itself further from ABS, at #1 with 33%, growing 3% since Q2’s report. ABS, although it maintains its #2 spot with 14%, has seen its number go the opposite way with a decrease of 3%,” the report explained. “This movement could be down to more new materials entering the market that challenge ABS’s position, which is relatively hard to print and not safe for non-ventilated spaces due to its fumes.”

Standard Resin is now in the #3 spot with 9% usage, while SLS Nylon appears for the first time at #4 with 8% usage. Standard PETG is hanging on to the #5 spot, though its reported usage has increased from 4% to 6%. Onyx, the proprietary material from Markforged that contains chopped Carbon Fiber, has entered the list for the first time at #9.

FDM Color Distribution

As for FDM Color Distribution, black is still in the #1 spot, with an increase of 5% of the market share – according to the report, nearly half of all of the 3D printed parts made on 3D Hubs are black. However, only the colors of submitted prints are reviewed for this report, so who’s to say that gray, up to #3 this quarter, isn’t used more often and those people just don’t submit their work?

Additionally, the spread of colors has dropped quite a bit, with Other down to 11% from 24%, which “is in line with the standardization of colors on 3D Hubs” explained last quarter. Transparent also makes it to the list for the first time, which 3D Hubs speculates could be due to the rising popularity of SLA and DLP 3D printing.

Top Print Cities

“The student peak in line with the end of the financial year has impacted the Top Print Cities and Top Print Countries,” Fisher-Wilson tells us. “Both the USA/UK and New York/London grew substantially, as the high concentration of universities in these cities bumped up their market share.”

Loughborough University, which 3D Hubs is familiar with, has also cracked the top ten for the first time in terms of Top Print Cities with its #9 placement. Following New York and London in the top two places, Amsterdam, Los Angeles, and San Francisco round out the rest of the top five.

The US and the UK continue to hold the top two spots for 3D printing usage in the Top Print Countries list, but the Netherlands has come up to knock Canada out of third place down to fifth, while Germany sits in fourth.

The report says, “India moves into the Top 10 for the first time, sharing the same percentage as Italy with 1.4% at #10. With the increases for the top two, countries like France have seen a substantial drop in market share moving from 3.4% to 2.5%. The trend continues that countries with a heavy population of students have seen market share increase.”

Most Used CNC Materials

In Most Used CNC Materials, affordable Aluminum 6061 is still hanging on to the lead, with over half of all 3D Hubs’ orders using the materials, though its usage has decreased a few percentage points. However, as Fisher-Wilson tells us, there was a shake-up in the category as previously predicted, with 19 new materials added this quarter.

“Stainless Steel 304 at #2 lost nearly half of its market share (11.6% to 6.8%) with Delrin at #3 and Mild Steel 1018 at #4 debuting with 5% each,” Fisher-Wilson told 3DPrint.com.

Aluminum 7075, with 4.8% usage, is #5 in this category.

There’s now more variety in Most Used Finishes at 3D Hubs, as it’s introduced some new materials, though the percentage of respondents leaving their parts as machined is down a bit from 77.6% to 70.8%. Bead blasting, at 7.5% in the #2, is still far behind, though the number three finish, anodized color, has increased its usage by nearly double.

What do you think of these results? Discuss this new trend report, and other 3D printing topics, at 3DPrintBoard.com, or share your thoughts in the Facebook comments below.

3D Printing Combines with Other Technologies for Latest Energica Ego Component

Following the progress of the CRP Group and its subsidiary Energica over the past few years has been exciting, as the companies work together to develop 3D printed electric superbikes such as the Eva, Ego, and Ego Corsa. The Ego made its public debut at CES at the beginning of 2016, and has wowed the public not only with its performance but with the advanced manufacturing that went into its creation: 3D printing, using Selective Laser Sintering and CRP’s Windform family of materials, and CNC machining.

The Energica Ego continues to undergo development, and recently Energica engineers along with CRP staff worked together to focus on the motor housing, a complex, important component of electric motorcycles. From the beginning, the team worked to redesign the part in order to accommodate the rotor, stator, and speed reducer. The propulsion unit to be supported is flexible and compact enough that the Energica motor housing can be adapted to any vehicle, and the reducer is composed of a straight-cut gear train that adds strength along with simplicity of design. The structure holds the shaft and pinion and final drive to the wheel with a standard motorcycle chain.

To redesign the motor housing, the team had several requirements. The electric motor was heavy and needed to be balanced out by a lightweight housing, and because the motor generated high torque it required high resistance. The gears needed to be the correct size, and the materials and heat treatments would need to be carefully chosen.

The first step was creating a functional prototype, which was done by CRP Technology. It was manufactured using SLS technology and Windform LX 2.0, a composite polyamide-based material reinforced with a new-generation glass fiber now replaced by Windform LX 3.0. The prototype allowed the technicians to validate the 3D CAD drawing and helped Energica mechanics to work on the motorcycle’s development. It was mounted directly on the motorcycle, allowing for a full check of potential issues related to the assembly of each part.

“Being able to touch the 3D printed prototype of the motor housing was very important for us, as we are the ones who manage fit and assembly,” stated the Energica technicians. “For example, we have been able to study first-hand if the component can be assembled and disassembled easily; if all the parts can be reached; if it is possible to use standard wrenches … We must put ourselves in the shoes of those who will handle the motorcycle on the market: customers, dealers and mechanics of authorized workshops.

“Designing and creating a motorcycle is a team effort between designers, technicians and engineers. We deal with technological/engineering, design, functionality issues; the final aim is to match the work of the three sectors. The prototypes created in Windform 3D printing allow you to study the various elements, and to improve them where required by shortening development time and reducing costs.

“Through the combination of LS technology and Windform composite materials, it is possible to ensure the ongoing study of the components. The prototypes made in Windform are 100% functional, we can mount them on the motorcycle and test them on the road and on the track. We do not waste time which, at this stage, is very precious.”

The next step, after the validation of the CAD file, involved the creation of an aluminum prototype. The requirements included performance, light weight, and resistance to temperature. Using aluminum alloys 6082 and 7075, CRP Meccanica CNC machined the part with its 5-axis production systems. The central part, which was the largest, originally had a pass-through window to allow the motor to be positioned inside. Each side was a half shell, and one of the two halves held the gearing housing, sealed in with a cover. The other half housed the pinion and oil pan.


“This phase has been completed in a short time,” the technicians stated. “CRP supported us very much, and we did not have any problem with the component, both during the bench tests and the assembly on the motorcycle: the tolerances required were very complicated and tight, as the project included two rows of bearings (those on the motor, plus the outer ones to support the output shaft). Later, we were able to validate the road-going prototype.”

The next phase involved the realization of models for pre-series. The component was manufactured using traditional sand casting, with the same alloy used in the metal prototyping phase. The production of the part was truly a team effort – between Energica and CRP, and between three different technologies that worked together to produce a strong, lightweight and high-performing component.

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[Images: CRP Group]