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EOS adds eight new metal powders and processes to AM material portfolio

EOS, the global leader in LB-PBF systems, has expanded its offering of AM materials with the release of eight new metal powders and processes for use with its M 290, M 300-4, and M 400-4 3D printing systems. The new material set consists of one PREMIUM and seven CORE products, characterized by their Technology Readiness […]

3D Printing Webinar and Virtual Event Roundup, June 28, 2020

This week is packed full with 3D printing webinars and virtual events, with four taking place Tuesday, and two each on Wednesday and Thursday. We’ll tell you all about them below!

Digital Manufacturing Investor Day

First up, software provider Dyndrite will be hosting its first ever Digital Manufacturing Investor Day on Tuesday, June 30th, featuring both pre-recorded and live content. Investors and venture capital companies have been invited to hear lightning presentations by hardware and software startups from all around the world, and several industry investment firms will also give panel presentations. The advisors for the inaugural Digital Manufacturing Investor Day are Gradient Ventures, HP Tech Ventures, and The House Fund.

“This virtual event is an initiative to help link startups in the digital manufacturing space to investors in the industry. As supply chains have been recently disrupted and workforces have to remain distanced, so new digital manufacturing technology becomes even more critical as manufacturers figure out how to tackle these challenges.”

Additive Manufacturing for Aircraft Interiors

Also on June 30th, a webinar about 3D printed aerospace applications will take place from 9-10 am EDT. “Additive Manufacturing for Aircraft Interiors – doing the trick for the In-Service Market” will discuss the use of polymer 3D printed parts for future aircraft cabins, how the technology can save money and time, possible new business opportunities for Maintenance Repair and Overhaul Providers (MROs), and what issues still remain, such as certification, investments, and availability of the right raw materials. Stephan Keil, Director Industrialisation for AM Global, will moderate the discussion between panelists Markus Glasser, Senior Vice President EMEA, EOS; Vinu Vijayan, Global Business Development Manager – Aerospace, EOS; Frederic Becel, Design Manager, CVE, Innovation Leader Aircraft Modification Division, Air France; and Karl Bock, Principal Design Engineer, Aircraft Modification Team, P21J Design Organisation, Lufthansa Technik.

“A wide spreading of AM manufacturing also has the potential to significantly change the supply chain setup of the Aero industry, impacting small and large suppliers, as distributed manufacturing moves closer to becoming a reality. Furthermore, new business models for spare parts and part design data may emerge, along with new services, which brings a need to tackle challenges around IP and regulation.”

nScrypt’s Cutting Edge of Digital Manufacturing Webinar

nScrypt is also holding a webinar on the 30th, titled “Pushing the Envelope of Digital Manufacturing.” The first part of the Cutting Edge Digital Manufacturing webinar series will take place at 1 pm ET on the 30th, and the second part will occur at the same time on July 7th. Panelists Mark Mirotznik, PhD, University of Delaware; Jing Wang, PhD, University of South Florida and Oregon State University; Devin MacKenzie, PhD, University of Washington, and Raymond C. Rumpf, PhD, University of Texas at El Paso, will discuss the future of direct digital manufacturing, covering topics like metamaterial use, permeating electronics in structures for control, sensing, and smart features, and going from a CAD file to a final, multimaterial electronic product in one build.

“JOIN YET ANOTHER DISTINGUISHED PANEL for part ONE of an in-depth discussion on the future of direct digital manufacturing by some of the premiere additive manufacturing universities in the country. The projects these universities are working on are solving problems with traditional antennas and printed circuit boards (PCBs).

ACCIONA’s Concrete 3D Printing Webinar

The last June 30th webinar will be held by ACCIONA, called “Let’s Talk Concrete 3D Printing.” It will take a multidisciplinary approach when discussing the technology’s use in the value chain, “where Innovation, Academia, Design, Manufacturing and Industry join together for a broad analysis of the technology.

Speakers will be Alaa K. Ashmawy, PhD, P.E. Dean and Professor for the School of Engineering at the American University in Dubai; Sualp Ozel, Senior Product Manager at Autodesk; Fahmi Al Shawwa, the CEO of Immensa Additive Manufacturing; Carlos Egea, Manager 3D Printing, Skill Center at ACCIONA; and Luis Clemente, COO 3D Printing at ACCIONA. The webinar will take place at 8:30 am EST, and attendees can join here.

3D Systems Webinar Featuring VAULT

On Wednesday, July 1st, at 10:30 am EST, 3D Systems will be holding a live webinar, “Advanced Your Engineering and Equip Sales to Win Business with SLA,” featuring VAULT, which manufactures enclosures for tablets in the point-of-sale industry. The company integrated 3D Systems’ SLA technology into its process, and the 45-minute webinar will explain how SLA can be used at every stage of business. VAULT will share customer reactions to quality and service, in addition to the training and on-boarding process, and explain how companies can win new business by providing access to high-quality 3D printed parts.

“Gaining a new client is all about gaining their confidence. No matter how refined your sales pitch, nothing wins trust or business faster than immediately following through on your promises.

“Join our live web event featuring VAULT’s VP of Engineering, Quentin Forbes, to find out how in-house 3D printing with 3D Systems’ stereolithography is helping the company build its reputation and client base.”

Webinar for New Metal 3D Printing Material

Also on July 1st, metallurgist expert Aubert & Duval will join Alloyed, formerly known as OxMet Technologies, in hosting a free webinar about ABD-900AM, a new nickel superalloy for metal additive manufacturing. When tested with laser powder bed fusion (LPBF) technology, the high-strength material offered improved manufacturability, as well as high creep and oxidation resistance, compared to common AM alloys. It also features ~99.9% density and is highly crack resistant. Adeline Riou, Global Sales Manager at Aubert & Duval, and Will Dick-Cleland, Additive Manufacturing Engineer at Alloyed, will give an overview of the material’s properties, along with several interesting case studies, during the 30-minute webinar.

“Designed for use at high temperatures up to 900°C / 1650°F, ABD®-900AM has been tailored for AM by Alloyed not just for high mechanical properties, but also for excellent printability. Compared with Ni718, ABD®‑900AM provides a minimum of 30% improvement in yield stress at temperatures >800°C and a creep temperature capability improvement by up to 150 o C – similar to alloy 939 and alloy 738.”

The webinar will begin at 11 am EST, and you can register here.

Stratasys Aerospace Webinar Series Continued

Stratasys will continue its new aerospace webinar series this Thursday, July 2nd, with “Value Proposition of AM to Airlines.” During this hour-long webinar, Chuan Ching Tan, General Manager, Additive Flight Solutions (AFS), will speak about several related topics, including when and where additive manufacturing can make its business case to airlines, use cases – especially regarding aircraft interiors – by AFS to airlines, and other issues to get past in order to speed adoption of the technology.

You’ll have to wake up early if you’re in my time zone – the webinar will take place at 4 am EDT. Register here.

VO Webinar: Coming of Age for Additive Manufacturing

Recently, Viaccess-Orca (VO), a global provider of advanced data solutions and digital content protection, joined the collaborative 3MF Consortium as a Founding Member. Now, it’s presenting a free 45-minute webinar with HP and Autodesk, also active members of the 3MF Consortium, about “Additive Manufacturing’s coming of age: the essential role of data security and standards.” The webinar, also held on July 2nd, will focus on the importance of data security and standards as the closed AM ecosystem moves to a more open future. Dr. Phil Reeves, Managing Director of Reeves Insight Ltd, will facilitate the discussion between speakers Scott White, Distinguished Technologist, 3D Software and Data, HP, Inc.; Martin Weismann, Principal Software Engineer for Autodesk; and Alain Nochimowski, Executive Vice President of Innovation at VO.

Learning objectives of the webinar will include why data standards are so important for the growth and deployment of the technology in the Industry 4.0 supply chain, how 3D CAD and AM hardware vendors can embrace both interoperability and data standards to benefit customers, what the 3D printing industry can learn about analytics, traceability, and data security from more mature industries, and the consortium’s newly released Secure Content specification. At the end, there will be a Question and Answer session, facilitated by Laura Griffiths, Deputy Group Editor at TCT. The webinar will take place at 10 am EST; register here.

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the comments below.

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US Air Force uses Senvol software to develop multi-laser 3D printing applications

The US Air Force is using Senvol’s data-driven machine learning software for additive manufacturing (AM), to enable the production of large-scale aerospace parts using multi-laser 3D printing technology. Utilizing an EOS powder bed fusion (LPBF) 3D printer, the program is focused on developing baseline mechanical properties and design allowables, to optimize the production of end-use […]

3D Printing Webinar and Virtual Event Roundup, June 23, 2020

We’ve got three upcoming webinars to tell you about in this week’s roundup, with two taking place at the same time on June 24th. The first one is focused on metal 3D printing, while the second is about how to use the technology to unlock massive value, specifically in the food and beverage manufacturing sector. Finally, Stratasys is holding the first of two webinars about aerospace 3D printing on June 25th.

BIG 3D Metal Printing Webinar

This Wednesday, June 24th, at 11 am EDT, EOS North America and Additive Manufacturing Customized Machines (AMCM) are hosting the free “BIG 3D Metal Printing” webinar, focusing on how technology advancements in additive manufacturing are driving applications in commercial space hardware. In this one-hour course, attendees will learn why metal 3D printing is more accessible, what DMLS technology is, what materials can be leveraged, and how customized 3D printing is continuing to advance. The speakers – Martin Bullemer, Managing Director of AMCM; Dr. Ankit Saharan, Manager of Research and Applications Development at EOS North America; and Graham Warwick, Aviation Week’s Executive Editor for Technology – will discuss what metal 3D printing is truly capable of creating.

“The challenges of fast development and innovation have lessened because of industrial metal 3D printing (additive manufacturing, or AM). Whether propulsion, structural, or integrated componentry, AM is accelerating the latest space race.

“Now, AM is moving quickly to meet even greater requirements—such as fully 3D printed combustion chambers with high-performance features, lighter weight structural components, or even fully 3D printed satellites. The latest advancement? Fully printed 3D components up to one (1) meter tall.”

3D Printing for Food and Beverage Manufacturers

Ultimaker is also holding a free webinar at 11 am EDT this Wednesday, titled “3D printing for food and beverage manufacturers.” If you don’t want to miss either one, you also have the option of attending the first broadcast session of this webinar at 5 am EDT. Even if you’re not in the food and beverage industry, this 50-minute webinar could still be useful, as the company “will be revealing some of the best ideas and strategies that we use to help our biggest customers unlock massive value with 3D printing.”

Ultimaker’s Director of Community Development, Matt Griffin, and Application Engineer, Jeremy Evers, will discuss which AM applications in this industry are currently working, and how to use the technology to achieve excellent results, such as reduced costs, increased line uptime, and optimized efficiency. During the webinar, they will give examples of industry-proven applications that have saved Ultimaker customers a lot of money, provide two sample criteria that the company’s application engineers use to determine which applications can achieve the largest ROI, discuss the future of 3D printing in the food and beverage industry in a post-coronavirus market, and more. Additionally, attendees will have the chance to participate in a live Q&A afterwards. Register here.

Stratasys Aerospace Webinar Series

This Thursday, June 25th, at 10 am EDT, Stratasys will be hosting the first in its new aerospace webinar series, titled “Challenges Of Manufacturing Aircraft Production Parts.” Niccolò Giannelli, Aerospace Application and Account Manager EMEA for Stratasys, will speak during this hour-long webinar about how certifying 3D printed aircraft parts for installation is easier with the company’s Aircraft Interiors Solution (AIS).

Some of the topics to be discussed in this first webinar include the value of both Stratasys’ AM solution and additive manufacturing for aircraft production parts, what comes in the Stratasys AIS package, and the improved performance of airline companies after they’ve implemented the Stratasys Aircraft Interiors Solution. Register here. The next webinar in this series will be held on June 30th.

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IMTS conference canceled for the first time since WWII, Formnext organizers provide updated safety precautions

The 2020 edition of the International Manufacturing Technology Show has been canceled due to the ongoing Covid-19 pandemic. Having monitored the impact of the coronavirus on the 3D printing industry, IMTS planners decided that the health and safety of its exhibitors and audience remain its top priority, and canceled the event. IMTS Network, a live-streaming […]

Braskem launches 3D printing materials portfolio

Brazilian petrochemical company Braskem, will add polyolefin-based filament, powder, and pellets for 3D printing, to its material portfolio. Polypropylene (PP) is a recyclable thermoplastic that displays high impact strength and durability, making it suitable for 3D printing applications such as creating functional prototypes and models. “We are excited about the capabilities our polypropylene has over […]

Cooksongold AM, ITA, and EOS use 3D printing to advance glass fiber production

Precious metal specialists Cooksongold AM and Sempsa JP – both part of the Heimerle + Meule Group – have successfully 3D printed the tip plates of a bushing (which is used to extrude glass fibers) using precious metals. The work is intended to develop and innovate glass fiber production in the future and was done […]

BigRep launches ABS & ASA materials for large format 3D Printing

German-based large-format 3D printer manufacturer BigRep has added Acrylonitrile Styrene Acrylate (ASA) and Acrylonitrile Butadiene Styrene (ABS) to its material portfolio. The filaments are designed for use in the automotive industry, but also have applications in end-use sports and outdoors consumer products. The newly-added materials are suitable for use with BigRep’s STUDIO G2 and PRO […]

3D Printing and COVID-19, May 12, 2020 Update: Limbitless Solutions, Dunlee, 3DPRINTUK

Companies, organizations and individuals continue to attempt to lend support to the COVID-19 pandemic supply effort. We will be providing regular updates about these initiatives where necessary in an attempt to ensure that the 3D printing community is aware of what is being done, what can be done and what shouldn’t be done to provide coronavirus aid.

Albert Chi, a trauma surgeon from Oregon Health and Science University (OHSU), and the team at Limbitless Solutions, a 3D printed prosthetics company, are creating a ventilator that does not require electricity. Instead of using electronics, the device relies on airflow from an oxygen tank. The design is made up of 3D printed parts, low-cost, off-the-shelf components and can be made with less than $10 in materials, according to its makers. This makes it possible to not only manufacture the product nearly anywhere in the world, but use it in places without electricity.

Using printers at its lab at the University of Central Florida, Limbitless was able to make 10 iterations of Chi’s designs for the device, which were then sent to his lab at OHSU for testing. After seven days of continuous functioning, the team found that there were no issues, leading Chi to file for emergency approval by the U.S. Food and Drug Administration.

The 3D printed ventilator device being tested. Image courtesy of OHSU/Kristyna Wentz-Graff.

Because CT scanning is a crucial technology for examining the respiratory issues caused by severe cases of COVID-19. To deal with the increased use of the technology during this time, Dunlee is ramping up production of anti-scatter grids for CT systems with 3D printing. The grids are used to absorb unwanted scatter radiation, in turn improving the quality of CT scans. Its Cone Beam CT line, for instance, is able to improve the signal-to-noise ration by 1.7 times, according to the company. Working with EOS, the company is obtaining new printers and using its existing machines to print pure tungsten grids 24 hours a day.

3D printed, tungsten anti-scatter grid from Dunlee. Image courtesy of Dunlee.

3DPRINTUK is helping to provide facial shields to workers at the National Health Institute. Pointing out that some of the existing shield designs are meant for material extrusion systems, the British 3D printing service bureau has optimized a model for large batch printing using selective laser sintering machines.

By nesting the parts, the company is able to print 260 brackets for face shields in a single print in 27 hours on an EOS Formiga P110 system. The bracket is made from PA2200/Nylon 12, features a closed-peak design for greater protection, and can be flat packed in an A4 envelope, according to the company. Managing Director of 3DPRINTUK Nick Allen said:

“That is 6 minutes per shield, which is a game changer. The design that we created clips together in 10 seconds, uses silicone straps for adjustment, can take an acetate sheet with 3 holes, is lightweight at only 42 g, and is sterilisable with IPA, autoclave, or ethylene oxide (Et0). All in all, we believe that this is the most efficient visor design to produce via 3D printing available today.”

Because 3DPRINTUK is currently using its own fleet of printers to produce ventilator parts with the UK cabinet and manufacturers, the company partnered with the Arts University Bournemouth, who used its own P110 machine and laser cutting capabilities to produce 5,000 face shields. The partners are inviting other SLS systems owners to aid in production capacity, as well.

One employee of Thomson Reuters has been producing face shields at the company’s office in Costa Rica, making over 100 such devices for healthcare workers and raising money within the office to buy filament. Given the fundraising effort, it’s worth noting that the multinational media conglomerate has a net income of $4 billion. The company’s chairman, David Kenneth Roy Thomson, is the Lord Baron of Fleet in the U.K. and, as of 2019, was the wealthiest person in Canada with a net worth of $37.8 billion.

Global military members are also producing medical devices. A fighter pilot for the Italian Air Force is 3D printing valves for ventilators at local Italian hospitals, including 50 “Charlotte Valves” and 50 “Dave Valves”. Soldiers from the 20th Chemical, Biological, Radiological, Nuclear, Explosives Command, which has a unique role given the nature of the pandemic, are using their 3D printing capabilities to produce NIH-approved face shield designs for local healthcare workers and beyond. The 10 volunteer soldiers, who met in an Explosive Ordnance Disposal (EOD) Facebook group, aim to make more than 13,500 face shields to send to 28 states and one U.S. territory.

ExOne has posted its Q1 20202 earnings in the midst of the pandemic and has reported total revenue of $13.4 million, a 40 percent increase over Q1 2019. The company also says that it has a record backlog of $33.8 million, with CEO John Hartner tying this strong to new product introductions and the number of orders backlogged from the end of 2019. Like SLM Solutions, which reported a similar pattern of increased revenues and orders from the previous year, Hartner says that the impact of the virus could be felt in March:

“Despite initial effects of COVID-19 on our business, our execution performance was solid. Globally, our facilities continued to operate in support of our customers in critical industries and essential businesses, subject to social distancing and other procedures to keep our employees safe.” He continued, “However, conditions clearly changed in March. We previously anticipated that growth would continue during 2020, but the COVID-19 pandemic has impacted shipping, travel and installation schedules, as well as the timing of customer capital investments. The uncertainty of our outlook caused by this situation prompted us to reduce our cost structure as we manage through these historic times.”

As the pandemic continues to grip the world, we will continue to provide regular updates about what the 3D printing community is doing in response. As always, it is important to keep safety in mind, remain critical about the potential marketing and financial interests behind seemingly good humanitarian efforts from businesses, and to do no harm.

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POLYLINE Project: Developing Digital Production Line for 3D Printing Spare & Series Automotive Parts

Because 3D printing can ensure complex structures and geometry, mass production of individualized products seems closer than ever. But, since standards are somewhat lacking across process chains, and automated levels of handling and transport processes are low, it’s only possible to achieve horizontal and vertical AM integration in production lines on a limited basis. Additional obstacles include limited monitoring and a lack of transparency across the process chain, due to a non-continuous digital data chain at lots of interfaces. But the potential benefits of integrating AM into assembly and series production lines in the automotive industry are great, which is why the POLYLINE project was launched.

With 10.7 Mio. Euro in funding by the German Federal Ministry of Education and Research (BMBF), this “lighthouse project” is bringing together 15 industrial, science, and research partners from across Germany with the shared goal of creating a digital production line for 3D printed spare and series automotive parts.

The three-year project officially began at a kick-off meeting of the consortium partners this spring at the Krailling headquarters of industrial 3D printing provider EOS, which is leading the project. The other 14 partners are:

BMBF is funding POLYLINE as part of the “Photonics Research Germany – Light with a Future” program in order to set up AM as a solid alternative for series production. The resulting next-generation digital production line will 3D print plastic automotive parts in an aim to complement more traditional production techniques, like casting and machining, with high-throughput systems.

The project is looking to disrupt the digital and physical production line system, and is using an interesting approach to do so that, according to a press release, “takes a holistic view and implements all required processes.” To succeed, all of the quality criteria and central characteristic values from the CAD model to the printed part need to be recorded and documented, and individual production sub-processes, like the selective laser sintering, cooling, and post-processing, will be automated and added to the production line. For the first time, all technological elements of the SLS production chain will be linked as a result.

Schematic representation of a laser sintering production line

Per the application partner’s requirements, the production line will be realized with “a high degree of maturity,” and uses cases for POLYLINE will include large amounts of both serial and customized components.

Each partner will add its own contribution to the POLYLINE project. Beginning with the leader, the EOS P 500 system will have real-time monitoring and automated loading of exchange frames added to its features; the printer will also be embedded in an automatic powder handling system. Premium automotive manufacturer the BMW Group, already familiar with 3D printing, has a massive production network of 31 plants in 15 countries, and is creating a catalog of requirements for the project to make sure that the new line will meet automotive industry standards. Additionally, the demonstrator line will be set up near its Additive Manufacturing Campus, and cause-and-effect relationships will be jointly researched.

Iterations of a BMW Roof Bracket made with 3D printing. (Image: BMW Group)

Industrial process automation specialist Grenzebach will be responsible for material flow and transport between AM processes, as well as helping to develop automated hardware and software interfaces for these processes. 3YOURMIND is setting up a data-driven operating model, which will include “qualified digital parts inventories, orders processing, jobs and post-processing planning and execution, material management, and quality control,” while software solutions developer Additive Marking is focusing on quality management optimization and resource efficiency.

Post-processing specialist DyeMansion will develop a process for certified, UV-stable automotive colors, create Industry 4.0-ready solutions for cleaning and mechanical surface treatment with its PolyShot Surfacing (PSS) process, and contribute its Print-to-Product platform’s MES connectivity. Bernd Olschner GmbH will offer its customer-specific industrial cleaning solutions, Optris will make fast pyrometers and special thermal imaging cameras adapted for plastic SLS 3D printing, and air filter systems manufacturer Krumm-tec will work to upgrade the manual object unpacking process.

(Image: DyeMansion)

Along with other project partners, Paderborn University is “working on the horizontal process chain for the integration of additive manufacturing in a line process,” while the Fraunhofer Institute for Casting, Composite and Processing-Technology IGCV is developing a concept for POLYLINE production planning and control, which will be tested in a simulation study for scalability. The Fraunhofer Institute for Material Flow and Logistics IML will work on “the physical concatenation of process steps,” paying specific attention to flexibly linking the former manual upstream and downstream AM processes.

TU Dortmund University will help apply deep learning, and implicit geometric modeling, for data preparation and analysis, along with online monitoring and quality management, in order to achieve sustainable automation and efficiency for the project. The University of Augsburg’s Chair of Digital Manufacturing works to integrate AM processes into current production methods, and will apply its expertise in this area to the POLYLINE project, helping to develop strong vertical process chains. Finally, the University of Duisburg-Essen will focus on creating quality assurance for the material system, and its laser sintering process.

The consortium of the POLYLINE project (Image: EOS GmbH)

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

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