Global chemical production company BASF’s 3D printing arm Forward AM, has reached an agreement to strengthen its partnership with 3D printing process and hardware provider Prismlab. The deal, signed at Prismlab’s Shanghai base, will see some of its 3D printing photopolymer products integrated into Forward AM’s Ultracur3D photopolymer portfolio. Closer cooperation with Prismlab not only […]
3D printing industry news sliced: EOS, ExOne, Materialise, Essentium, Relativity Space, PrintLab, 3D Printz, and more
In this edition of Sliced, the 3D Printing Industry news digest, we cover the latest business developments, partnerships, and acquisitions across our industry. Today’s edition features updates on the 3D printing industries reaction to COVID-19, the latest software news, space launch agreements, industry partnerships and of course, the King of Belgium. Read on for the […]
Scientists use plasma technology to overcome FDM “weak spot”
Researchers at Texas A&M University, in collaboration with scientists at Texas-based 3D printer manufacturer Essentium, have developed a method to more effectively weld adjacent layers together in a 3D printed part. The group of researchers explain that a “weak spot” of 3D printing lies in the imperfect bonding between the individual printed layers that make […]
PLA: The Effects of Annealing & Autoclaving on Mechanical Behavior of Desktop FDM Parts
Researchers from the University of California delve into a very important area of 3D printing for the medical field, experimenting with how sterilization processes affect materials. They released their findings in the recently published ‘Identifying a commercially-available 3D printing process that minimizes model distortion after annealing and autoclaving and the effect of steam sterilization on mechanical strength.’
3D printed models are currently changing the face of medicine in terms of patient-specific treatment, allowing for better diagnosis, education for patients and their families (and medical students), along with acting as pre-planning tools and surgical guides.
In relation to FDM 3D printing in medicine, the authors refer back to previous studies concluding that PLA was weakened by sterilization yet strengthened in annealing, explaining that the next viable step would be to find a 3D printing material that can withstand heat treatment and steam sterilization.
The team fabricated four 30 mm cubes as samples for the study, each featuring different infill—designed in Tinkercad and then 3D printed on a LulzBot Mini 3D printer.
Manufacturer temperature (°C) recommendations for FDM 3D printing materials
Samples were printed all at once, using 0.38 mm layer height and a 0.5 mm printhead nozzle. Materials tested included:
- ColorFabb Woodfill
- Dragons Metallic PLA in All That Glitters Gold
- Essentium PLA in Gray
- Maker Series PLA in Food Safe FDA OK Clear
- Maker Series PLA in White HOT White
- Proto-Pasta HTPLA in White
- Raptor Series PLA in HD Vivid Blue
a) Infill geometries clockwise beginning from top-left: tetrahedral, triangles, grid, zig-zag and b) 3D printed cubes
Each sample was bathed in hot water, with the annealing treatment performed via an 800 W Strata Home sous vide circulating precision cooker.
“The cubes were removed from the hot water-bath and allowed to cool to room temperature without interference. The X, Y, and Z dimensions of the cubes were measured again to quantify deformation and calculate percent changes, a positive percent change indicating expansion and a negative percent change indicating shrinkage,” explained the researchers.
“In order to quantify distortion in either direction, we took the absolute value of these percentages. Subjective observations were noted such as spherical ‘balloon-like’ expansion. We also analyzed whether certain materials consistently expanded or contracted in every axes.”
Samples were then placed in autoclave sterilization pouches and deposited into a Tuttnauer 2540 M autoclave for 45 minutes at 134 °C and a pressure of 375 PSI. Afterward, the samples were cooled to room temperature and then examined for any signs of deformation.
a) Standard Army-Navy retractor and b) strength-optimized Army-Navy retractor designs in inches created in AutoDesk Fusion 360 obtained from Chen et al. c Retractor orientation on the build plate to eliminate need for support material
a) Standard retractors warping after hot water-bath annealing and b) after autoclaving. c) Strength-optimized retractor without intervention (right) and warping after hot water-bath annealing (left)
The material exhibiting the least amount of deformation was Essentium PLA Gray. The highest deformation was noted in Maker Series PLA White HOT White.
Quantifying absolute deformation in 30 mm cubes across 3D printing materials after annealing
“After hot water-bath annealing for 30 mm cubes, the infill that deformed the least was ‘grid,’ and the infill pattern that deformed the most was ‘zig-zag.’ After both annealing then autoclaving for 30 mm cubes, the material that deformed the least was Essentium PLA Gray. The material that deformed the most was Maker Series PLA White HOT White. After both annealing then autoclaving for 30 mm cubes, the infill pattern that deformed the least was ‘grid,’ and the infill pattern that deformed the most was ‘tetrahedral.’”
Quantifying absolute deformation in 30 mm cubes across 3D printing materials after annealing then autoclaving
Quantifying absolute deformation in 30 mm cubes across infill geometries after annealing then autoclaving
Maker Series PLA White HOT White was the only material noted to expand in every axis—despite the infill geometry or intervention. Every other material showed variances due to infill. Expansion after annealing usually seemed to suggest ‘direction of distortion’ after autoclaving.
“We acknowledge that dimensional changes and strength limitations may not be a challenge at a lower autoclave cycle, which would require further testing. We have also yet to understand the mechanical behavior of the 3D printed models in this study when they are subjected to multiple cycles of autoclaving and whether they will continue to undergo dimensional change. However, regardless of whether 3D printed PLA surgical instruments are determined to be single or multi-use, these instruments may still be valuable in fields such as aerospace medicine where space limitations exist, or in resource-limited situations where additional instruments are needed,” stated the researchers.
“This study is intended as a pre-clinical evaluation of the mechanical behavior of FDM 3D printing materials following hot water-bath annealing treatment and autoclave sterilization. For FDM 3D printed Army-Navy retractors, further sterilization and biocompatibility validation will be necessary for it to be applied clinically.”
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[Source / Images: ‘Identifying a commercially-available 3D printing process that minimizes model distortion after annealing and autoclaving and the effect of steam sterilization on mechanical strength’]
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3D Printing and COVID-19, April 4, 2020 Update
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.
Essentium, Inc. is now using its technology to 3D print reusable protective face masks to fulfill supply needs in its hometown of Pflugerville, Texas. The mask frame is made from thermoplastic urethane branded as Essentium TPU74D and is meant to be easy to clean and used in conjunction with single-use filtration media. It is meant for general, non-medical use during the COVID-19 outbreak based on FDA Emergency Use Authorization and is hosted on the National Institute of Health repository.
Essentium’s 3D-printed face mask for police and fire department staff. Image courtesy of Essenitum.
In response to an order from the city’s Pflugerville Community Development Corp, the company has so far delivered 30 units for the city’s police and fire department. By next week, it hopes to provide a total of 500 masks and thinks that it can ramp up production to 5,000 pieces weekly.
Meanwhile, Shapeways is producing face fields that are being used by medical crews. So far, the 3D printing bureau has made 1,100 face shields. The company is requesting $20 donations to make the shields, but will contribute its own funds to make every fifth shield produced.
Siemens already announced that it would be opening up its additive manufacturing network at no cost to designers and suppliers to produce supplies for the COVID-19 outbreak. The German giant has now provided a progress report on its efforts, including the fact that it is working with manufacturers to adapt and speed up production of pharmaceuticals and protective gear. In particular, it has ramped up its manufacturing of blood-gas monitoring, portable X-ray, ultrasound and CT systems. It has also increased its deployment of virtual training and remotely managed imaging systems.
Protective eyewear designed and printed by BEGO. Image courtesy of BEGO.
Others participating in complementing the supply efforts include BEGO, a digital dentistry specialist that relies on 3D printing and CAD/CAM to produce utensils for the prevention of infection. The company has opened up design files for modular face shield frames, breathing brackets and other parts, while also offering its production services in Bremen, Germany to medical facilities to fabricate any parts that may be necessary. For instance, BEGO Implant Systems has 3D printed protective eyewear and donated it to the Association of Statutory Health Insurance Dentists for distribution among local hospitals and clinics.
Smaller firms are continuing to provide their own services to produce face shields, including Brooklyn-based 3D printing company Makelab. The shield itself is made out of plastic dividers and presentation covers to attach to 3D-printed brackets. On the flipside, Solvay, which has extensive resources as a large chemical company, is working with Boeing to create face shields made from its own transparent thermoplastic films.
The materials from which they are made, Radel PPSU and Udel PSU, can be sterilized for medical use. Additionally, Solvay is working on 3D printing parts for ventilators, CAPRs, PAPRs, and surgical and N95 mask parts, as well as lubricants for oxygen machines. It is also making sanitizing gels. Boeing is moving some of its manufacturing operations to make face shields at its sites in Missouri, California, Arizona, Alabama and Pennsylvania. It plans to use its cargo aircraft to transport supplies to healthcare facilities.
Given all of the efforts by companies large and small, along with helpful Makers and hobbyists, it will be interesting to determine to the extent to which their work has aided in preventing the spread of the virus, if it is finally contained. How this analysis can be achieved is difficult to know, but it is something that we will surely be considering.
The post 3D Printing and COVID-19, April 4, 2020 Update appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.
Essentium and LEHVOSS develop PEEK and HTN materials for FFF 3D printing
Essentium Inc., the Texas-based 3D printer manufacturer behind High Speed Extrusion (HSE) technology, has announced a partnership with chemical and mineral materials specialist LEHVOSS Group to develop high-performance materials for additive manufacturing. The materials, comprising a line of PEEK and High-Temperature Nylon (HTN), were created specifically for production-level extrusion-based 3D printing processes. They are designed […]
3D Printing News Briefs: February 21, 2020
In today’s 3D Printing News Briefs, we’re talking about new products and materials, an industry event, 3D printed electronics, and education. 3Doodler announced a new product, and Essentium will be showcasing two new materials at RAPID + TCT. The 4th annual AM Cluster of Ohio conference is coming up in July, and nScrypt is microdispensing 50um dots for 3D printed electronics. Finally, Penn State University is investing in Roboze technology.
3Doodler Introduces New 3D Build & Play
At the New York Toy Fair, February 22-25 at Manhattan’s Jacob Javits Center, 3Doodler will be showcasing its latest device – the 3D Build & Play, perfect for preschoolers and kindergartners to use. The pen was designed for users as young as four years old, and introduces growing children to 3D printing technology in a way that promotes cognitive and fine motor skills development, hands-on learning, story telling, and three-dimensional thinking. The 3D Build & Play is kid-safe, extruding low-heat, BPA-free, non-toxic, biodegradable plastic, and comes with a story-based Activity Guide so parents and kids can create together. Currently available for pre-order, 3D Build & Play will have an MSRP of $29.99, and major retailers, like Amazon, are also expected to carry the product in Q2 2020. Visit 3Doodler in Booth #2771 at the New York Toy Fair to learn more.
“3D Build & Play brings the creative fun of our Start pen without the learning curve for the youngest users. The system we have developed, that lets kids crank and create in 3D, is a major benefit for parents looking to improve their children’s basic motor skills. The included molds make it easy to create 3D objects by simply filling and popping them out. There’s nothing on the market today that makes 3D creation this simple or fast for young creators,” said 3Doodler’s CEO Daniel Cowen.
Essentium’s New Materials for High-Temperature Applications
At RAPID + TCT 2020 in Anaheim this spring, 3D printing solutions provider Essentium will introduce new ULTEM AM9085F and ABS materials for high-temperature industrial AM applications. These high-performance materials, which will be showcased on the company’s High Speed Extrusion platform at the event, provide high strength and have excellent resistance to heat and chemicals at high temperatures, so they can be used for applications in the aerospace, automotive, industrial, and medical industries.
According to a survey commissioned by Essentium, 51% of executives believe that the high cost of materials is a major obstacle when it comes to adopting 3D printing for large-scale production purposes. The new ULTEM AM9085F and ABS materials were created to give manufacturers a more cost-effective solution when compared to expensive closed-system materials. Learn more at Essentium’s Booth #3400 at RAPID + TCT in Anaheim, CA, April 20-23, 2020.
4th Annual Additive Manufacturing Cluster of Ohio Conference
The Additive Manufacturing Cluster of Ohio, powered by organizations such as America Makes and the Youngstown Business Incubator, has announced that its 4th annual conference will take place this summer in Cleveland. Cluster members work together to create a supply chain of interconnected institutions and businesses to advance regional growth in 3D printing. This conference, to be held on Thursday, July 30, at the Embassy Suites by Hilton Cleveland Rockside, will be the first cluster event of 2020, and will give Ohio manufacturers of multiple business models and sizes perspectives on available opportunities for adopting 3D printing into their process chain over the next five years.
The website states, “The program will look at similarities and differences across several selected manufacturer types and will identify strategies ranging from low to high risk. Attendees will leave with actionable strategies and information about regional resources to help them remain competitive in the evolving manufacturing landscape.”
nScrypt Working with 3D Printed Electronics
Orlando company nScrypt is working with precision microdispensing, an additive method of dispensing pastes, inks, and other fluid materials, to create adhesive dots with volumetric control, in the 50 micron range, for 3D printed electronics and flexible hybrid electronics (FHE). Microdispensing gets much closer to the substrate surface when compared to methods like jetting, and the closer the nozzle is to the surface, the finer the features of the 3D printed parts. The team used the nScrypt SmartPump, a silicone adhesive, a conical pen tip, and Heraeus SAC305-8XM8-D Type IX solder paste, and tested the consistency and repeatability of ~50µm Type IX solder and adhesive dots.
These tests showed a consistent average dot diameter of 51.24 microns, with a 6.42 micron (13%) standard deviation. These results support the fabrication of 3D printed electronics through the use of direct digital manufacturing (DDM), which allows printing to both planar substrates and the non-planar world of Printed Circuit Structures, which prints the housing or structure of an electronic device as well as placing the electronics conformally. In the future, the team plans to conduct a larger solder and adhesive dot study, in order to test required downtime, long-term reliability, and the frequency of clogging.
Penn State University Invests in Roboze Technology
Penn State, a 3D printing leader through its Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D), has invested in a new FFF solution in order to expand its AM capabilities. The ROBOZE One+400 Xtreme 3D printer, which was designed to create high performing, functional finished parts in advanced composite materials, will help the university increase its development of high performance plastics for 3D printing, and will be housed in the Department of Chemical Engineering. Students will be able to test out new polymers on the system, and develop new formulations to provide 3D printed parts with multi-functionality. These parts will be used to advance research in applications like chemical reactors.
“ROBOZE One+400 Xtreme will be used to examine novel polymers to help to fundamentally understand the 3D printing process and as a tool to enable custom equipment more cost effectively than can be obtained with machining metals while also allowing for designs not possible with traditional manufacture. The ROBOZE One+400 Xtreme will allow Penn State to leverage its expertise in materials science, engineering and characterization to enable new solutions to problems through additive manufacturing,” said Professor Bryan D. Vogt from the Department of Chemical Engineering.
“The ability to use custom filaments and control the print processing was a critical factor in selecting ROBOZE. The flexibility allowed by ROBOZE along with its excellent printing capabilities is well aligned with the discovery-oriented research mission of the university to expand knowledge and its application. Moverover, our prior 3D printer had issues printing high temperature engineering plastics like PEEK with severe deformation of the structure generally observed. After challenges with printing PEEK with standard belt driven systems, the novel direct drive approach with the ROBOZE was an added bonus.”
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The post 3D Printing News Briefs: February 21, 2020 appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.
3D Printing Industry News SLICED: Rize, 3D Systems, Essentium, Protect3d, Xioneer Systems
In this edition of Sliced, the 3D Printing Industry news digest, we cover the latest partnerships, acquisitions, medical developments and creative applications from across our industry. Additionally, you’ll find out how 3D printing helped to miniaturize the tallest statue in the world; the novel technique used by law enforcers to help keep the Super Bowl […]
3D Printing Industry News Sliced: Essentium, Tommy Hilfiger, Prodways, Arkema, Smart International
In this week’s edition of Sliced, the 3D Printing Industry news digest, concrete 3D printing is looked as at a solution for rebuilding a village; fashion brands are integrating 3D printing for a “sizeless” solution, and generative design is used for architectural planning. We also cover news from Essentium, Ricoh, Smart International, Arkema, Prodways, Endurance Lasers and […]
80 additive manufacturing experts predict the 3D printing trends to watch in 2020
Predicting the future is impossible. But that doesn’t stop us at 3D Printing Industry from inviting CEOs, CTOs and other AM experts to give us 3D printing predictions for 2020. If you want to stay up to date with the latest 3D printing news, subscribe to our free 3D Printing Industry newsletter. You’ll be among […]