Fortify, a Digital Composite Manufacturing (DCM) firm in Boston, and Royal DSM, a Dutch multinational chemical company, have partnered up to develop industrial-grade composite materials for 3D printing end-use parts and structural components. The companies will develop the materials using Fortify’s DCM platform, which is powered by Fluxprint technology where magnets are integrated into DLP […]
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In use since at least the 4th century AD, dichroic glass displays different colors depending on how it’s being viewed. Now, Dutch scientists have produced the effect in a material that can be used to create 3D-printed objects – and it’s not just a novelty, as it could have practical applications.
A team of researchers at Wageningen University started with regular polyvinyl alcohol (PVA), which is a widely-available polymer commonly used as a 3D printing medium. To this they added gold nanoparticles of varying sizes – not much of the gold was needed, as it ended up constituting only 0.07 percent of the resulting composite material’s weight.
The giants are coming. DSM, SABIC, BASF, DOWDuPont, Eastman, Mitsubishi, Covestro, Evonik, Arkema, Perstorp, Clariant and Solvay have all joined the 3D printing industry. All these companies are making serious investments in creating materials and applications for 3D Printing. Their heft, polymer expertise and existing client base should all help our industry grow. They all have high hopes for our fast-growing industry but these giants range from $2 billion to $65 billion in revenue. Is there enough room in our $12 billion industry for this heard of elephants? Will act like accelerants to our industry, making 3D printing better? Are they here for the long run? What will they do?
3DPrint.com asked Brian Alexander of Solvay what the €12.4 billion Belgian chemicals company is up to in 3D printing. Solvay has not made a brash entrance at all but is slowly but surely making its polymers available to the 3D printing market. Solvay is selling directly via its own e-commerce site and is focussing on high-performance materials such as PPSU and PEEK. Brian leads the Business Incubation Platform Additive Manufacturing at Solvay Specialty Polymers and is in charge of bringing Solvay to the 3D printing market.
PPSU is a good candidate material for 3D printing, what do you think it will be used for?
PPSU delivers the highest performance of amorphous materials for chemical resistance, toughness and thermal stability. The high heat resistance and excellent hydrolytic stability of Radel PPSU make it an excellent choice for hot water fittings and medical devices requiring repeated steam sterilization such as dental and surgical instruments, but also for aircraft cabin interior parts, that need to withstand cleaning agents and to comply with extremely stringent fire, smoke, and toxicity standards.
Where do you see your Fluoropolymers portfolio being deployed in manufacturing?
With exceptional purity and chemical resistance, our fluoropolymers are typically used in the chemical processing industry, automotive and oil & gas. We already see demands from these sectors for 3D-printable fluoropolymers that will enable more sophisticated shapes and tailor-made, small-series production.
What are your plans for PEKK?
We are working on a PEKK powder for selective laser sintering (SLS) that enables for superior 3D-printed parts. It is currently available for sampling. We are also studying the use of PEKK with other printing technologies.
We have recently launched a AM-ready filament based on our KetaSpire PEEK, which has a unique reputation in the market as one of the highest performing polymers out there. We believe that Fused Filament Fabrication is the best technology for such a material, but the industry is evolving quickly, which is why we also work on adapting this material to other printing technologies.
When do I use PEKK and when do I use PEEK?
Both a similar materials, but PEKK has higher thermo-mechanical properties, while PEEK has a higher chemical resistance.
High-performance polyamides would seem to be a future area with significant competition with DSM, BASF and other gearing up in the space. Will you join with your PPA’s?
Solvay Specialty Polymers’ ambition is to leverage its full portfolio of high-performance polymers. At the same time, we work flexibly and pragmatically on new product developments, based on customer demand and technology readiness. PPA’s are currently not in our focus.
Do you believe in Swiss army knife polymers that can be used for a wide array of applications? Or very specific materials?
With over 35 different high-performance polymers in our portfolio, which is the broadest in the market, we firmly believe that there is no “one size fits all” polymer. What you need is a range of AM ready materials able to cover most industry applications. We have that.
Will you be selling resin for 3D Printing direct, through distributors?
We started selling our polymers directly through our eCommerce platform which offers a new experience to both existing Solvay customers and new customers. The great advantage of this site is that behind, you have access to Solvay’s unique materials expertise and application know-how. But we are also working “offline” with our strategic customers and building a network of partners capable of printing our materials to develop new applications and help our customers find the best solution for their needs.
How about SLS powder?
SLS powder is much more specialised especially for higher performance polymers and requires a higher initial investment for the printer. We are currently working closely with some key customers to enter this market.
Are you focusing on FDM, SLS, SLA?
We are focussing mainly on FDM and SLS, but we monitor the market constantly for new technologies.
What future applications are you most excited by?
“The most exciting aspect of Additive Manufacturing, is not being limited to current applications and design. The most exciting applications are still in the minds of the designers and engineers, and it is our goal to help them find the right solution to meet the needs for their applications, whatever the industry.”
What does Solvay want to do in 3D printing?
Our objective is to become a globally leading supplier of customized high performance AM solutions.
What are some polymers that you have that we in 3D printing are not familiar with yet?
So far we have focused on a handful of materials from our portfolio, so we still have a wealth of possibilities to explore, both with aromatic polymers and fluoropolymers, including fluoro-elastomers.
We see some companies moving aggressively into 3D printing, Solvay seems comparatively cautious?
There is indeed a lot of communication around the topic, which some even consider to be a hype. We are working on creating the right foundations and expertise, both internally and externally, to grow our 3D printing capabilities for the long run.
Is there a particular industry that you are focussing on?
We started with PEEK and PPSU because they are polymers which are recognised and used extensively in Healthcare and Aerospace. Both industries have ambitious targets for the adoption of 3D printing in customised or small-series production, so they are obvious initial targets for our offering.
What kinds of companies are you interested in partnering with?
We believe in an open ecosystem approach that allows to combine the best solutions for a given customer or application. Those solutions will not always be the same. This is why we are ready to partner with a large range of players, from leading printer manufacturers – large and small – to specialist software companies such as e-Xstream, we want to work with the best companies to take 3D printing together to the next level. We have even launched an AM Cup, an open innovation competition to tap into the ideas and creativity of some of the brightest students in AM and accelerate our product development cycle – and we were stunned the results, which were excellent.
Why should I as an end user work with Solvay PEEK rather than someone else’s PEEK?
We have worked hard to develop a PEEK filament with superior performance and are already working on NexGen materials. We are also combining our strength with those of our partners in the printer, processing, and design space to allow our end users to print the best possible 3D parts.
PEEK is very difficult to print. Are you doing things to correct this? Or do you think that the industry will solve this with printers?
Materials, hardware & software all need to be optimised to get the best 3D printed part performance. We are working to take PEEK to the next level for demanding AM applications.
Just generally why should people work with you rather than another firm?
Solvay is an innovation powerhouse since 1863. We believe in the power of science and what science can deliver for society. We demonstrate this every day by pushing the limits of high performance polymers to solve some of the planet’s trickiest material challenges, and we do so striving for sustainable solutions. More specifically, we also have the broadest range of high performance materials and work with over 3,000 customers across all industries. This gives us unique capabilities to develop the best possible AM-ready material solutions.
What kinds of end-use customers are you looking for?
Obviously, we want to serve our over 3,000 existing customers with our AM offering. But we also believe in the democratisation of manufacturing thanks to AM. Tomorrow, anyone among the 10s of millions of designers, engineers, or makers across the planet could need a spool of Solvay filament for his or her project. Our eCommerce platform is there to also reach out to all these potential end users.
Melt processable fluoro TPE’s are very interesting materials – could these become 3D printing materials?
“We have our entire portfolio to play with, and we will develop it flexibly and pragmatically. too soon to say.”
Xioneer impressed me with its multiple material bays that let one pre-dry filament inside the printer. In this way, one could condition the filament on the machine itself and prepare it for 3D printing. With hygroscopic filaments such as PLA performance is significantly retarded and the material becomes brittle making it difficult to print. Polyamide materials (PA, Nylon) are even worse and suck up water like a starving man in the desert. These filaments may in a day or two to exposure to ambient air become less than performance ready. Polyamides such as PA 6 and PA 12 are industry standards and are great performance polymers for a lot of applications. By drying on the machine itself Xioneer shows us that they’re thinking about performance in an intelligent way. The machine has slick software and the parts on display were impressive as well. The company has cartridges for materials exchangeable nozzles for fine, bold and abrasive materials. A patented heating system and a full scan to ensure build platform calibration are other interesting features. Enough of a reason to interview CEO Andrei Neboian about the company and their printer.
What is Xioneer?
The company was founded in 2012 and has around 20 employees working at our headquarters in Vienna, Austria. Our main investor is the German company Fischer, well known for the Fischertechnik sets and its products for the construction industry.
What does your company hope to achieve?
We want to help companies to achieve more with 3D-printing. We do that by caring for every detail and by constant innovation and merging that into great 3D-printing systems. Our FFF-systems are flexible, reliable and accessible and provide great value to the customer – letting them do more with 3D-printing than before.
What makes your systems different than other 3D printers?
It’s the combination of technical innovations and smaller improvements in details that make our products stand out. Our systems are more flexible (e.g. with the different swappable nozzle-units), easier to use (e.g. automatic material management and automated calibration), and provide the benefits of high-end AM systems (e.g. material drying, heated build environment, water-cooled nozzles).
Who are your target customers?
We target various industries such as automotive, aerospace, medical and tooling manufacturers who want to create functional parts from industrial materials quickly and efficiently.
For what types of parts and applications is your system ideally suited?
Our swappable nozzle-units and materials cover a wide range of applications. Ranging from large fixtures and mounts printed within record time from PC or ABS, to carbon-fiber reinforced jigs, or small intricate parts with thin walls printed with flexible Nylon or TPU.
What makes the Xioneer desktop better than other desktop systems?
Over 6 patented technologies are used in our desktop system as well as in our industrial system. These provide state-of-the-art topographic calibration system for the nozzles and for the build-surface as well as the unique material feeding system which is the easiest to use on the market.
What kind of motion system is on it?
A derivative of the Core-XY system adopted to the needs of 3D-printing by our engineers.
How accurate is it?
The positional accuracy is within the range of 5 micrometers or lower.
What is Gecko Peel and what does it do?
GeckoPeel is our support material which is flexible and easy to remove from the surface of the model. It makes support removal much safer and quicker and other materials.
How does your automatic calibration work?
It scans the entire surface of the build table and compensates any unevenness automatically during the print. Unavoidable deformations caused by e.g. the high temperature of the print surface and the build chamber are compensated automatically. This allows using the entire build-surface and saves costly setup time.
You have “plug and play” proprietary filament but can I also use my own?
We provide a range of materials which we have tested internally. But we also understand that different customers and industries have their specific material needs. Therefore, we offer an on-demand service to certify customer materials through our internal material testing process.
How much is the X1?
List price for the Starter Set is under 15000€
And the X1s?
List price for the Starter Set is under 25000€
It seems to have a lot of spool holders in it?
These are the additional pre-dry units to prepare more material cartridges for printing. This saves time in busy environments where you need additional spools of material ready for your next print-job immediately.
PA CF is really being adopted much more widely, how come?
It’s a great material which combines the strength of Nylon with the stiffness that the fiber-reinforcement gives to your parts.
So why do you have four different nozzles and what do they do?
Our quick-changeable nozzles offer you more flexibility to do things beyond a standard filament printer can do. The nozzle-unit BOLD lets you print parts in lower resolution much quicker than any other nozzle: large bulky parts are made in just a few hours instead of days! The nozzle-unit HARD is made of a wear resistant ceramic material which allows printing fiber-reinforced materials such as PA-CF. The nozzle-unit FINE lets you create intricate parts in the level of detail which is usually expected from high-resolution 3D-printing technologies. The nozzle unit STANDARD is our all-rounder covering all other print-jobs. The additional benefit of our patented twin-head system is the ability to combine different nozzles within a single job: print the inside of your part with a BOLD nozzle, while preserving the high quality of the outer shell with the STANDARD nozzle – this will save you hours!
What is your modelPlus material?
It’s a modelling material with similar mechanical properties to ABS, and a great surface finish. It’s highly recommended for printing visual prototypes.
Why should I buy one of your machines and not one from another company?
The Xioneer X1s provides the latest technology for producing functional parts from a variety of industrial plastics. It’s a high value product with a quick return on investment, and a money-back guarantee. On top of that, we provide application support to our customers to get the best out of their X1s.