“Food-contact applications are definitely a place where 3D printing will take a bigger piece of the cake, it’s only the tip of the iceberg for us with surface treatment. It’s a market that will grow a lot in the coming years, so there’s a big potential there.” That’s how Mads Østergaard, Team Manager at The […]
FELIXprinters Launches Its First Bioprinter the FELIX BIOprinter
If we could visualize the future of medicine, drug testing, and artificial tissue and organ development, we would most certainly find bioprinters in the spotlight. Part of the vanguard vision of many companies and researchers alike is that the machines will become a familiar resource used in every bioengineering lab, university and even school around the globe. But building up to that momentum might take many years, even decades, yet this is becoming one of the most interesting times for the field, with a widening array of companies boosting bioprinting technology commercially, we can’t help but get excited when we hear about recent advances and newly launched machines.Taking advantage of years of knowledge in 3D printing, Dutch manufacturer FELIXprinters announced today their latest venture, the commercial launch of a new bioprinter known as the FELIX BIOprinter. The company partnered with TRAINING4CRM and the Technical University of Denmark (DTU) to design a machine that works for all types of bioprinting research, equipped with strong motors that can extrude a wide range of material types and viscosities. According to the product site, the BIOprinter dispenses a wide range of viscous materials up to a viscosity of 64,000 Centipoise, with the ability to extrude materials and bioinks that range in consistency from liquids to pastes.
“The BIOprinter has been designed to be the ultimate bio research instrument in a cost-effective package, and has been developed alongside the brightest minds in the bioprinting sector,” suggested Wilgo Feliksdal, co-founder of FELIXprinters. “Uniquely, the BIOprinter combines dual sterilizable printheads which have a modular design for easy changeovers, and separate heads are available to print different bioinks at the same time. This integrates different material properties into a single scaffold structure.”
The new BIOprinter (Image: FELIXprinters)
Based on the existing and established FELIX products, the BIOprinter was developed on the chassis of the FELIXprinters product line. According to the company, the new printer is characterized by key features that are specifically designed for medical, scientific and research applications, including syringe cooling, print bed cooling and heating, a dual-head system, easy syringe positioning (ergonomic access to the machine innards supports researchers in their work), and automatic bed leveling.
It is also equipped with a touchscreen that has a user-friendly interface and embedded print server that allows remote print file monitoring, use in a multi-user environment, and print-file management. A nozzle probing system enables automated bed leveling and calibration of the nozzles, plus a camera module that allows users to monitor prints remotely from their smartphone or computer complete the features of this machine. FELIX indicates that the BIOprinter also retracts with a highly precise motor for better dosage or materials and more accurate material flow versus alternative air pressure systems.
“The BIOprinter consists of an adaptable and flexible ecosystem to ensure that it can meet a wide range of researchers’ needs without generating unnecessary costs. One major advantage is the source control system which enables the user to use standard slicing software and make changes themselves if needed. Also, syringes are not restricted to expensive brand-specific or in-house produced products that essentially drive up operating costs. The machine instead has been designed to use a standard 5ml syringe, and standardized Petri dishes and culture plates, so there are no limitations on auxiliary parts and materials,” continued Feliksdal.
A big plus is that the machine uses familiar slicing software Simplify 3D, to allow fully in-control and customizable user experience. The BIOprinter is also WIFI and LAN enabled, comes with a one-year warranty, and lifetime customer support.
FELIXprinters officials claim that their new machine has been designed to be easily upgradeable, which means that its lifecycle can be extended without compromising quality, reliability, and productivity. While users can benefit from the fact that print heads are easy to sterilize, which eliminates the likelihood of contamination.
First introduced at Formnext‘s event in Frankfurt, Germany, last November, the machine is now commercially available with pre-orders already being processed. It was showcased alongside the company’s Tec 4, Pro 3 Touch, and Pro L and XL machines, which are used throughout an array of industry sectors for challenging AM production applications, and under the umbrella of their theme: “Going Dutch”, which displayed moving windmills, mini-clogs, and iconic colored tulips all created in FELIXprinter’s machines. It’s all part of the company’s Dutch heritage, which they are extremely proud of.
To develop the BIOprinter, which is handmade in the Netherlands, the company received funding from the European Union Horizon 2020 Programme, a funding program for research and innovation with nearly €80 billion of funding available over a seven-year period (from 2014 to 2020). While 13 research institutions participated in the development, including the University of Gothenburg, Universidad Autonoma de Madrid, Tufts University, Lund University and more.
New 3D bioprinters and bioinks bring so many opportunities to researchers with unique needs. And exploring new possibilities to work with different biomaterials and machines in the field of biofabrication helps them make new discoveries that can benefit everyone. For now, we will have to wait and see what FELIX BIOprinter users will create!
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Sustainability in additive manufacturing?
2019 has been the year of environmental sustainability, with global protests and increased political and social focus. The additive manufacturing industry isn’t an exception; sustainability is on the agenda. But how?
We are entering a new era for additive manufacturing now. One in which the increase in adoption for production applications requires the industry to mature and demonstrate the reliability, repeatability and quality of more established manufacturing techniques. This was clear during the recent Formnext 2019, where there was a significant message coming from most OEM’s, which was more focused on delivering on previous promises made of their technology. During the recent Formnext 2019, newly appointed CEO of EOS, Marie Langer, was asked about her priorities for the coming years, she discussed a focus on delivering repeatable and transferable processes, usability, quality and reliability. However, there was another significant topic that came up during that press event, and as the week progressed, it was a topic widely discussed on the Formnext floors. The topic was sustainability in additive manufacturing.
The topic was discussed in press conferences, in panel discussions, at networking events, and in one-on-one conversations.
For Marie Langer sustainability is a critical subject and one the whole industry should be championing. This was echoed by Brian Neff, CEO of Sintavia, who also commented on the opportunity and advantage AM has, as a more sustainable production technology than traditional subtractive manufacturing technologies. Langer spoke about developing more sustainable materials that could be recycled and re-used. Brian highlighted that for metal AM, there is far less material waste and that through distributed manufacturing, shipping could be reduced and therefore the overall carbon footprint of producing a part could be lowered.
The topic of sustainability was also taken up by Rush LaSelle, Senior Director, Additive Manufacturing, at Jabil Additive, as he was on a panel on Formnext TV. LaSelle described the benefits of distributed manufacturing from the perspective of sustainability. Moreover, senior leaders in companies like Carpenter Additive, HP, and DSM, made it clear, that sustainability is on the agenda. Camille Caron, HP’s Director of Education and Sustainability for their 3D printing business has recently written an article about this topic.
It seems clear that AM has the opportunity to lead the global manufacturing market as a sustainable production technology. The benefits offered through reduced material waste, supply chain innovations that reduce the needs for shipping parts thousands of miles, the use of recycled plastics and metals in materials, as well as the development of new recyclable materials, can all position AM as the most sustainable production solution for companies. It comes at a time where large companies are all under pressure to reduce carbon footprint and do more to protect and preserve the environment. Therefore this opportunity is one that could further support the acceleration of the AM industry as a whole. However, while this topic was widely talked about at a senior level, there is still very little being done to actually drive sustainability initiatives. Part of that problem likely lies with the question “Who is responsible?”. How many AM organisations, be they machine OEM’s, Materials Companies etc. have a Head of Sustainability, or at least an internal champion to take ownership? This is something Alexander Daniels Global are going to explore more and early in 2020 plan to prepare a report looking directly at what the major companies are doing to further this very important cause.
By Nick Pearce, Director of Alexander Daniels Global
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3D Printing News Briefs: November 25, 2019
We’re finishing the week out with some more formnext news for 3D Printing News Briefs: Poly-Shape presented a metal 3D printed Francis Turbine at the event. Moving on, Etihad Engineering opened a 3D printing lab for aircraft parts with EOS and BigRep, and Y Soft launched an online collection of 3D lessons for educators.
Poly-Shape’s 3D Printed Francis Turbine
At formnext 2019 last week, French company Poly-Shape presented something rather unique: a 72 kg Francis Turbine made with its Directed Energy Deposition-powder (DED-P) metal 3D printing technology. Turbine components are often used in the aerospace and energy industries, and DED-P printing can be used to fabricate the raw part, with its complex geometry, in less than 3 days; in fact, the Francis Turbine was printed in just 55 hours.
“The DED-P process is operated within a 5-axis CNC machine thanks to a material depositing system,” a Poly-Shape press release stated.
“By minimizing the needed allowance (typically < 1,5 mm), the part machining is reduced to finishing operation. In case of hard to access areas, the DED and the machining production can be sequenced such as the tool accessibility would be released.”
Etihad’s 3D Printing Lab for Aircraft Parts
Bernhard Randerath, VP Design, Engineering & Innovation, Etihad Engineering; Abdul Khaliq Saeed, CEO, Etihad Engineering; Markus Glasser, SVP EOS; H.E. Ernst Peter Fischer, German Ambassador to the UAE; Marie Langer, CEO EOS; Tony Douglas, Group CEO Etihad Aviation Group; Martin Black, CEO BigRep.
Etihad Engineering, a division of the Etihad Aviation Group, partnered with EOS and BigRep to open a 3D printing lab. It’s one of the first airline MROs in the Middle East that’s received approval from the European Aviation Safety Agency (EASA) for designing, producing, and certifying cabin parts made with powder bed fusion technology, two years after receiving approval for filament 3D printing. The laboratory is located at the Etihad Engineering facility, adjacent to Abu Dhabi International Airport, and houses two industrial 3D printers – the EOS P 396 and the BigRep ONE. It was opened officially in a ceremony last week, and in recognition of the relationships between Etihad, EOS, and BigRep, was attended by His Excellency Ernst Peter Fischer, German Ambassador to the UAE.
“The launch of the new facility is in line with Etihad Engineering’s position as a leading global player in aircraft engineering as well as a pioneer in innovation and technology,” said Bernhard Randerath, VP Design, Engineering and Innovation for Etihad Engineering. “We are extremely proud to collaborate with EOS and BigRep to expand our capability and support the UAE’s strategy to increase production technology and cement its position as a global aerospace hub.”
Y Soft Launches be3D Academy for Educators
The Y Soft Corporation has launched its be3D Academy, available as part of its YSoft be3D eDee 3D printing solution for education. There are many benefits to using classroom 3D printing as a tool for learning, and adoption in schools is growing fast, but developing lesson plans that incorporate the technology can be difficult, due to lack of knowledge or access. The company’s new online collection of teacher-tested 3D lesson plans in STEAM subjects make it easy for educators to teach in 3D. The be3D Academy lesson plans provide tools like student worksheets, presentations, video tutorials, and 3D model files, all of which can be made on the YSoft be3D eDee printer with its certified filaments.
“3D printing is particularly valuable in the classroom to convey complex subjects. When students can touch and adjust physical objects they have created, understanding increases. Comprehension of STEAM subjects can be difficult, and be3D Academy’s lessons make concepts interesting and fun. be3D Academy lesson plans range from creating castles to understanding geometric shapes and volumes to creating a Da Vinci bridge as a science learning project,” said Elke Heiss, the Y Soft Chief Marketing Officer.
The be3D Academy is open to all educators looking to add 3D printing to their classrooms.
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Oerlikon at Formnext 2019: 3D printed rocket parts, post-processing, and digital factories
Oerlikon AM, the additive manufacturing branch of Swiss technology group Oerlikon, has announced a series of partnerships at this year’s Formnext show. The company has revealed that it will be providing metal 3D printed parts and qualification for United Launch Alliance (ULA), a U.S. rocket launch service provider. ULA will use the metal components to […]
Additive Manufacturing Technologies unveils integrated post-processing Digital Manufacturing System at Formnext 2019
UK-based post-processing specialist Additive Manufacturing Technologies (AMT) has launched its new Digital Manufacturing System (DMS) at Formnext 2019. Described as a comprehensive post-processing system, the DMS uses AMT’s proprietary technology to provide an automated and digital solution for the entire manufacturing workflow. Namely, the system was designed to address the manual stages between 3D printers […]
ExOne forms multiple partnerships to simplify sintering for metal binder jet 3D printing
Leading binder jet 3D printer manufacturer ExOne has announced two partnerships during Formnext 2019 aimed at developing the sintering stage of its metal binder jet 3D printing process. The company is collaborating with engineering simulation company ANSYS to develop software for predicting the sintering behavior of metal parts 3D printed via binder jetting. ExOne has […]
EOS debuts Fine Detail Resolution 3D printing at Formnext 2019
During this year’s Formnext show, leading German 3D printer manufacturer EOS is showcasing its Fine Detail Resolution (FDR) polymer-based 3D printing technology. The new process uses a CO laser to 3D print delicate yet robust polymer components with fine detail resolution surfaces and a minimum wall thickness of 0.22 mm. EOS states that it is […]
EnvisionTEC and Sartomer develop water-soluble resin for cDLM 3D printers
EnvisionTEC, a global 3D printer and materials manufacturer, and Sartomer, a subsidiary of French advanced materials company Arkema, have collaborated to develop a water-soluble resin known as E-Aquasol. Designed for use on EnvisionTEC’s proprietary Continuous Digital Light Manufacturing (cDLM) 3D printing platform, the resin incorporates Sartomer’s UV-curable resin technology. “We are excited to collaborate with […]
3D Printing News Briefs: November 20, 2019
We’re starting out with some formnext news in today’s 3D Printing News Briefs, as the show is currently taking place in Frankfurt this week. SCANLAB is introducing a new scan system control extension at the show. We also have some metal stories today – Desktop Metal has launched 4140 chromoly steel for its Studio System, while QuesTek Innovations and the German Aerospace Center are exploring the potential of a high-temperature aluminum alloy. Moving on, XJet’s Carmel 1400 AM system was installed at KU Leuven University. Finally, Additive Minds investigated EOS 3D printing without the use of supports.
SCANLAB Integrating Process Data into 3D Printing
Laser scanning solutions manufacturer SCANLAB GmbH is at formnext 2019 this week, and will be introducing a scan system control extension that uses a smart data-acquisition interface that reads external sensors. It’s a functioning model of an intelligent interface, and can integrate sensor data into scan system control – giving AM users the ability to inquire about, and evaluate, centralized process data.
Two tradeshow demonstrators were created that show how diverse the integrable sensor range is. The first incorporates a surface-temperature pyrometer into the scan head control, and the sensor system’s data merges with laser beam position data. In the second, an OCT (optical coherence tomography) sensor from Precitec is integrated to measure the powder bed’s surface topography. Visit SCANLAB at formnext this week at Booth B41, Hall 12.0.
Desktop Metal Launches 4140 Chromoly Steel for Studio System
Massachusetts-based company Desktop Metal is expanding its material portfolio by launching 4140 chromoly steel for industrial applications for its office-friendly Studio System. 4140 is a versatile material, with high tensile strength, abrasion and impact resistance, and toughness. DM Studio Systems users can now use this material to 3D print parts like connecting rods, couplings, pinions, press brake tools, and more for industries including automotive, agriculture, industry, and defense.
“As global demand for the Studio System grows, Desktop Metal is broadening its materials portfolio to include 4140 chromoly steel, enabling designers and engineers to print a broad variety of critical industrial applications, such as couplings, forks, pinions, pump shafts, sprockets, torsion bars, worm gears, connecting rods, and fasteners. Now, teams around the world will be able to leverage the Studio System to iterate quickly on 4140 prototypes and ultimately produce end-use, customer-ready parts faster and more cost-effectively,” said Desktop Metal’s CEO and Co-Founder Ric Fulop.
QuesTek’s 3D Printable Aluminum Alloy
Integrated Computational Materials Engineering (ICME) technologies leader QuesTek Innovations LLC and the German Aerospace Center (DLR) are working on a joint project to explore the potential of QuesTek’s new 3D printable high-temperature aluminum (Al) alloy. The material, able to perform at temperatures between 200-300°C in its as-built condition, is being developed by QuesTek under several US Navy-funded Small Business Innovation Research awards, and is believed to be the first powdered Al alloy to meet necessary requirements without any subsequent heat treatment. The DLR will be 3D printing demonstration components with the material, which can be used to fabricate more lightweight precision components like heat exchangers.
“The accelerated design and development of a printable aluminum alloy capable of meeting so many current needs is especially exciting, as it will enable concurrent design of material composition and component geometry,” stated Greg Olson, QuesTek Chief Science officer. “Based on our internal test results, we see broad application of this material in manufacturing components for aerospace, satellite, automotive and high-performance racing.
“We are particularly pleased to be collaborating with the DLR. Their unrivaled reputation, expertise and close relationship with industry needs will bring an important new scope to our efforts.”
XJet’s Carmel 1400 3D Printer Installed at KU Leuven University
Professor Shoufeng Yang, KU Leuven, shakes hands with Avi Cohen, VP of Healthcare and Education at XJet.
For the first time, a 3D printing system has been installed at a European academic institution. XJet recently delivered its Carmel 1400 AM system to the KU Leuven University in Belgium, where it will be used to for university research and to help develop regional 3D printing medical opportunities. The 3D printer, and its proprietary NanoParticle Jetting (NPJ) technology, will be put to good use at the European research center, as academics will used it to explore medical applications and AM educational and research purposes. XJet’s zirconia material will also be used to 3D print ceramic medical models.
“Since the Carmel was installed, we are already reaping the benefits. The XJet system offers the high levels of precision and exceptional detailing required, levels which were previously impossible or extremely time-consuming in post-processing. The use of soluble support materials, with no harmful powders, makes it a much easier process and opens up opportunities to innovate that simply did not exist before,” said Professor Shoufeng Yang, who is heading the AM research at KU Leuven. “It’s an amazing and fantastic technology for R&D in universities and for the manufacturing industry, and it’s very exciting to be a part of. I believe that this is the best ceramic additive manufacturing method which can be easily upgraded into future multi-materials additive manufacturing, which is a grand challenge in the AM industry.”
XJet is also attending formnext this week – you can find the company at stand #C01 in Hall 12.1.
3D Printing Without Supports
Image credit: EOS
Michael Wohlfart, DMLS Process Consultant for the EOS Additive Minds Process Consulting team, wrote an article on LinkedIn, titled “Building without support? Possibilities and limitations,” about the design aspect of printing without supports in metal powder bed fusion technology, which can reduce build time, material consumption, and cost. The three main reasons for supports are heat transfer, residual stress, and recoater forces, but there are workarounds for all three. In recoater forces, forces are acting on the part while spreading powder, and the recoater will wipe away parts not connected to the baseplate. Prop supports, such as cones and stacking parts, can be used to negate the need for a baseplate connection. Wolfhart discussed a few examples that were 3D printed on an EOS M290 out of titanium.
“Let’s move on to a more advanced design and even incorporate stacking,” Wohlfart wrote. “Since Christmas season is coming up, how about a Christmas tree designed with Siemens NX and pimped with nTopology? By turning it upside-down, the tree is self-supporting and the tree trunk can act as a shell for the next tree. You can see a small overlap of 0.1 mm in x-y-direction between the lattice and the solid parts in order to assure a good connection.”
To learn more, check out Wohlfart’s LinkedIn post.
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