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Headmade Materials Receives €1.9 Million in Funding for “Cold Metal Fusion” 3D Printing Process

Based in Wuerzburg, Germany, Headmade Materials not only offers patented sinter-based cold metal fusion (CMF) technology to its customers, but also encourages them to consider new ways to design and manufacture with 3D printing technology—while still falling back on conventional methods as needed. Its innovative and low-cost printing processes for metal have earned the company the attention of users seeking support in design, part manufacturing, and process integration, as the well as the recent reward of €1.9 million in funding from the Industrial Technologies Fund of btov Partners.

The hefty sum will be put toward “scaling up” its technology, according to a recent press release sent to 3DPrint.com. The company will also be developing customer and marketing services further. As a spinoff of Würzburg-based polymer research institute SKZ, the Headmade Materials team has been working on its cold metal fusion technology for five years. As it partners with btov, it is expected that research and development will progress more rapidly.

“We see the Cold Metal Fusion technology as a very viable approach for serial production due to the high cost efficiency of the process. The combination of mechanical part properties known from metal powder injection molding (MIM) process and considerable process advantages, such as reduced safety requirements due to easier powder handling and higher green part stability, is also significant here,” says Robert Gallenberger, partner of the btov Industrial Technologies Fund.

Cold metal fusion technology began at the hands of founders Christian Fischer and Christian Staudigel in 2015 while both were still employed at a research institute. Sharing an interest in machine building, their goal was to bring serial production to 3D printing—eliminating limitations, lack of affordability, and creating better designs for a range of applications.

The process is different from other 3D printing techniques as it combines metal sintering with SLS printing (usually reserved for manufacturing of 3D printing plastics). The key is in the plastic binder mixed into metal powder, allowing for more versatile use; for example, with cold metal fusion, metal parts can be printed on laser sintering systems meant for plastics like the EOS Formiga P110 or the Sintratec S2. The components are then placed in a debinder and then furnace for final sintering.

Headmade Materials claims that other benefits of CMF include the ability to use a greater range of “mature machine technology,” requiring no build plates or support structures. Users can count on savings in time and money, with increased productivity. Feedstock left un-used can easily be reused, and because of superior green part strength, both automated depowdering solutions and rough production environments are acceptable. Perhaps more importantly, because the process can be performed using existing SLS machines, owners of those systems can begin making metal parts without investing in new metal 3D printers, even the new generation of bound metal printing processes, like those from Desktop Metal.

“When it comes to the economical series production of complex metal parts, there is no way around 3D printing with the cold metal fusion technology,” says the Headmade Materials team in their white paper, “Cold Metal Fusion / Metal SLS Technology.”

Image from “Cold Metal Fusion / Metal SLS Technology,” illustrating the CMF process.

The Headmade Materials team plans to 3D print series with up to 100,000 parts per year. Currently, it offers its sinter-based 3D printing processes to customers, using optimized feedstocks and services whether in helping with design and production, in-house production, or ready-to-use final parts.

Overall, 3D printing with metal continues to increase in popularity for industrial users, from taking advantage of micro-gravity and 3D printing in space with the potential for large structures, to experimenting with new materials, and even furthering electronics with liquid alloys.

[Source: EU-Startups / Images: Headmade Materials]

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The State of 3D Printing at Continental Automotive

Other organizations like NASA have also been using 3D printing technology for prototypes and functional parts—long before the rest of the world had an inkling about the impacts that would be made decades later in nearly every major industrial application. The Continental Automotive division serves as a good example of the long evolution of 3D printing and additive manufacturing within industries like automotive.

Selective Laser Melting (SLM) is used to print steel and aluminum. (Image credit: Claus Dick)

With a market cap of roughly $18.5 billion, Continental is a German multinational auto parts maker that manufactures such products as electronics; safety, powertrain and chassis parts; brake systems, tires, and more. Its customers run the gamut of car, truck and bus companies, including Volkswagen, Ford, Volvo, BMW, Toyota, Honda, Porsche and others.

As with every automaker, the firm has been using AM for design and prototyping purposes for some time, but it is now taking the technology to the next level. Just last year, the German-headquartered company opened the competence center for additive design (ADaM) at its Karben site. Five different 3D printing techniques are currently being used at ADaM:

Selective laser melting (SLM)
Selective laser sintering (SLS)
Stereolithography (SLA)
Digital light processing (DLP)
Fused deposition modeling (FDM)

“Practically at every location there are at least smaller additive systems, but this abundance and variety of systems is only available in Karben,” said Frauke Berger, site manager at Continental Automotive, in a recent interview.

Site manager Frauke Berger presents a printed component made of plastic. (Image credit: Claus Dick)

As the automotive and engineering divisions of the company, founded in 1871, work together closely, they are able to put the advantages of 3D printing into action using both plastic and metal materials.

For Continental, this means enjoying savings on the bottom line, more efficient manufacturing processes, ease in designing and making changes without waiting on a third party, and, most importantly for many industrial users, the ability to fabricate more complex geometries previously impossible with traditional techniques.

“A major advantage of additive manufacturing is that parts can be designed differently, and projects are therefore approached in a constructively different way,” said Berger.

Previously, the Continental team was able to create a more durable brake caliper:

“Usually such patterns come from sand casting. It takes about 14 weeks. The printed part was finished in less than a week,” explained Stefan Kammann, head of the Additive Design and Manufacturing business segment. “In principle, all weldable metals such as aluminum, stainless steel and tool steel, titanium or, to a limited extent, copper can be printed.”

Plastics are usually printed at Continental via selective laser sintering (SLS), as the team finds it to be the fastest route, as well as the most similar to ‘series technology.’ Materials such as PA12, as well as PA6, are often employed, along with polypropylene for parts like brake fluid containers.

As 3D printing and AM processes have continued to make impacts around the world and progress due to user’s needs, that growth has been seen at Continental, too, as software, hardware, and materials have been further refined. Orders for parts that may have previously involved up to 40 hours of production time now may take as little as 60 minutes.

“In the past we knocked the supports off the lattice platform with a hammer and chisel and had to be careful not to tear out any piece of the model, the material was so firm,” says Kammann. “The process is extremely precise, and we achieve good surfaces with it.”

With Selective Laser Sintering (SLS), support structures are no longer required. (Image credit: Continental)

DLP printing also allows for the option of 3D printing several parts at once, along with using a selection of materials, like ABS, PLA, TPU, and other plastics.

“For this purpose, a filament, i.e. a rolled plastic, is pressed through a hot nozzle and applied in sausages in a manner comparable to a CNC-controlled hot glue gun,” said Kammann. “You need an infrastructure and other technologies to process, combine, and instill the parts properly.”

Next year, the Continental team is planning to complete a large order for a manufacturer in need of 9,500 parts—all of which will be 3D printed.

Stefan Kammann explains how the rolled plastic is pressed through a hot nozzle. (Image credit: Claus Dick)

Industrial users continue to enjoy the positive impacts of 3D printing and AM processes in a wide variety of other applications too such as aerospace, dental and medical, construction, and far more.

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The Continental Competence Center for Additive Design and Manufacturing (Adam) in Karben houses various systems for 3D printing. (Image credit: Claus Dick)

[Source / Images: Automotive IT]

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Dental Students Compare Conventional and 3D Printed Surgical Training Models

There are few things I hate more than going to the dentist. That’s why I’m always glad to hear stories of dental students using 3D printed training models to learn on – if they have to work in my mouth, then I want them to know what they’re doing. A group of researchers from University Hospital Münster in Germany published a paper on this topic, relaying the results of their work using real patient data to create 3D printed surgical training models for root tip resection. Then, they compared them against a commercial typodont model, which is a common simulation model used at university dental clinics with replaceable gingiva masks and teeth that often “show idealized eugnathic situations, which are rarely encountered in everyday practice.”

“Furthermore, the ready-made standard models do not usually depict special pathological or anatomic situations,” they wrote.

A root tip resection, or apicoectomy, removes inflammation around the tip of the tooth’s root. The researchers explained that the typodont model at their university features teeth “in direct contact with the hard plastic that simulates the jawbone,” and simulates the inflammation (apical granuloma) with wax, though it’s missing a sensitive periodontal ligament.

“The teeth used are idealized stereotypes. Anatomical variations, such as extremely long or even curved roots, cannot be simulated with these industrially produced models. Therefore, we have developed a method to create more realistic, individualized training models,” the researchers explain.

The model they created is of a real patient’s upper jaw with three anterior root apices, periodontal ligament, and the apical granuloma, along with a gingival mask.

“We also present an evaluation of the model by dental students and compare it with their evaluation of the conventional typodont model,” the team wrote. “Our intention was to evaluate whether dental students accept the 3D-printed surgical training model just as well as the popular typodont model.”

L-R: Modified plaster cast, modified plaster cast with wax layer.

They used CAD/CAM technology to design the training model, which allowed them to add the simulated inflamed tissue, and took a conventional impression of the area in question in order to make a plaster cast. The gingiva was modeled with a 1 mm thick layer of wax, and an industrial 3D scanner was used to attain the shape of the modified cast with and without the wax gingival mask.

L-R: Scanned surface of the plaster cast without wax layer and meshes of the three teeth aligned to the upper jaw.

The cone beam computed tomography (CBCT) data of another patient was used to create 3D models/meshes of teeth 11, 12, and 21 in Materialise Mimics, and the 3D reconstruction was modified using Rhinoceros 5. To make a model of the periodontal ligament, which the typodont model doesn’t include, they deleted the upper parts of the teeth mesh and thickened the rest by 0.25 mm in Geomagic Wrap.

L-R: Meshes of the roots (rear faces of mesh in blue-green), extruded root surfaces representing periodontal ligament.

They constructed a 6 mm sphere around the root apex of tooth 11 to simulate an apical granuloma.

“The material used to represent the periodontal ligament and the apical granuloma is softer than the material used for the other parts of the model. This allows a more realistic representation than in the typodont model,” they explained.

Meshes of the granuloma on tooth 11 and the periodontal ligament on teeth 11, 12 and 21, 3D printed in soft support material (red).

The 3D printed model also includes a silicone gingival mask so students can practice the surgical incision. A 3D printed matrix technique was used to fabricate the mask directly onto the model, and the model was 3D printed out of liquid photopolymer on an Objet Eden 260V PolyJet 3D printer. The undercut areas and the cavities in the model that simulated apical granuloma and periodontal ligament were filled with a soft support material. It took roughly six hours to 3D print 12 models in a single build.

Silicone gingival mask.

“Dental students, about one year before their final examinations, acted as test persons and evaluated the simulation models on a visual analogue scale (VAS) with four questions (Q1–Q4),” the researchers wrote.

35 students evaluated the typodont model, while 33 students used the 3D printed simulation model. Participants watched a video of the root tip resection exercise, and then completed the procedure once. They were given a questionnaire about the simulation model and the difficulty of the exercise, rated on a visual analogue scale (VAS). There was also an optional free-text section if a participant wanted to express their opinion in their own words.

Surgical incision guidance on the 3D printed model in the phantom.

Osteotomy of the root tip.

Presentation of the root tip. Note: torn gingiva mask.

Resected root tip with demarcation to the bone.

Suture exercise on the gingiva mask.

54.5% of the Group 2 participants said in the free-text section that the gingiva mask in the 3D printed model tore during the procedure, while 20% in Group 1 said that it detached from the typodont model.

Questionnaire results; white dots denote the mean values.

“Shapiro–Wilk normality tests revealed that, with the exception of Q4, normality cannot be assumed,” they explained. “Wilcoxon rank sum tests were therefore carried out to identify differences in the assessments of the two model types. The alternative hypothesis for each test was “The rating for the typodont model is higher than that for the 3D printed”. As the p-values presented in Table 1 reveal, the alternative hypothesis has to be rejected in all cases.”

Table 1.

The researchers determined that their 3D printed training models were “not inferior to the industrially manufactured typodont models,” and that the approach is very flexible – the models can be easily redesigned and adapted for different learning scenarios, and it’s much faster to fix them when necessary. While the 3D printers weren’t cheap, the material costs for a 3D printed single-use model were only about €10, compared to €300 for the multi-use hypodont model.

“A shortcoming of our study is that the exercises were performed by students without surgical experience. As a result, there is a lack of professional evaluation of the models in terms of how well they reflect the reality. Thus, we were not able to check an important quality aspect of the models,” the researchers noted.

“Future studies with experienced surgeons could provide more information about the realism of the 3D-printed models.”

Other issues include the missing color difference between anatomical structures or cortical and cancellous bone structures, and the gingiva mask needs improvement, either through alternative technologies or materials.

“Individual 3D-printed surgical training models based on real patient data offer a realistic alternative to industrially manufactured typodont models. However, there is still room for improvement with respect to the gingiva mask for learning surgical incision and flap formation,” they concluded.

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Protolabs Expands European Presence with Larger German 3D Printing Operations

Digital manufacturing bureau Protolabs is investing USD$12.87m (£10.5m) into a new German production facility. The funds will expand the company’s 3D printing capacity in Germany by 50 percent, complementing its existing additive manufacturing (AM), CNC machining, sheet metal and injection molding capabilities.

The COVID-19 pandemic has shut down large swaths production and shipping globally, in turn highlighting the ability of on-demand manufacturing to provide parts locally. Perhaps spurred by this turn of events, the U.S.-based service bureau is opening a new 5,000 square-meter production facility in Putzbrunn, Germany. Construction begins on the site as general public restrictions and distancing measures are eased in the city, with the initial shell scheduled for completion by the end of December and machinery to be installed beginning in May 2021.

Groundbreaking ceremony for Protolabs’ new German 3D printing facility: (l-r) Michael Meier (Protolabs), Edwin Klostermeier (Mayor of Putzbrunn) and Daniel Cohn (Protolabs). Image courtesy of Protolabs.

This equipment will include up to 25 more 3D printers, along with a 5-axis mill for finishing 3D-printed parts, as well as systems for finishing, coloring and painting. By increasing the 3D printing capacity of its German location by 50 percent, the company will be able to augment its European 3D printing services. According to Protolabs, the company can currently produce over 50 3D printed parts in one to seven days, over 200 CNC parts in one to three days, and over 10,000 injection molded parts in one to fifteen days.

Multi Jet Fusion 3D printing at Protolabs. (Image courtesy of Protolabs.)

The project comes on the heels of a USD$6.13m (£5m) extension being finalized at Protolabs’ European Headquarters in Telford in the U.K. The Telford location represented the Minnesota company’s entry into the European continent when it was established in 2005. This was followed, in 2009, by the opening of a location in Japan. In addition to these and several offices in the U.S., Protolabs now has positions in Sweden, Italy and France.

This latest site in Putzbrunn, outside of Munich, will house all of its current departments from its existing Feldkirchen office. The production facility will support the company’s U.K. activity and will include the ability to produce medical devices certified under ISO 13485.

The metal AM service bureau segment is expected to reach $9.4 billion in revenues by 2025, according to the recent “The Market for Metal Additive Manufacturing Services: 2020-2029” report from SmarTech Analysis. The company’s recent “Polymer Additive Manufacturing Markets and Applications 2020-2029” report has additive polymer parts from service bureaus reaching $7.8 billion by the same year.

SmarTech believes metal 3D printing service bureaus in particular can solve the short-term disruptions associated with the pandemic and then aid in production re-shoring to prevent future disruptions. To reflect the changes in the metal AM service bureau segment from the pandemic, the company will be providing updated forecasting in June 2020.

A metal powder bed fusion room at Protolabs. Image courtesy of Protolabs.

Protolabs can definitely see the direction that the market is headed. In 2016, the company began integrating multiple metal powder bed fusion systems from Concept Laser (now GE Additive) into a new 77,000 sq. ft. facility. By 2018, it was one of the first partners in the GE Manufacturing Partner Network and more recently installed over 25 GE Additive Concept Laser Mlab and M2 machines in one of its production facilities. As for polymers, Protolabs has also been an early adopter of HP’s Multi Jet Fusion technology, which is becoming continuously important for AM service bureaus.

The company is not alone in the segment, however, even when matched against other digital manufacturing providers and service networks that also do not focus solely on AM. While it may still be larger than startups like 3D Hubs and Xometry, it contends with Stratasys Direct Manufacturing and 3D Systems on Demand, who also provide a multitude of manufacturing options. This also doesn’t include the pureplay service bureaus or those owned by much bigger conglomerates. Sculpteo, for instance, is now owned by BASF, the largest chemical company in the world and Siemens owns selective laser melting experts Material Solutions.

Protolabs, then, is in an increasingly competitive industry and, with the benefits of distributed production becoming more and more evident, we can safely say that that industry is only going to increase in its competitiveness.

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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)

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SLM Solutions Webinar: “We Want to Give our Customers the Freedom to Innovate”

A new webinar series by 3D metal printer manufacturer SLM Solutions showcases its system’s ability to empower customers to grow in the ever-evolving additive manufacturing (AM) marketplace. For many 3D printing companies, webinars are turning into a fundamental tool to create awareness about new developments and to identify customer needs. For the German-based top metal 3D printing supplier, this new series of webinars can draw in users in search of cost-efficient, fast, and reliable Selective Laser Melting (SLM, DMLS, Powder Bed Fusion) 3D printers for part production, which is the core development at SLM Solutions.

During the hour-long educational talk through the advantages of true open architecture in AM, the Director of Industrialization Strategy for SLM Solutions Americas, Thomas Haymond, explores the company’s goal: building a system that grows with the user. By opening up the system’s architecture, SLM Solutions wants to prove that customers will never outgrow the machines and instead be able to adapt their businesses, reduce their learning curve, and innovate from day one.

Defined by Haymond as a system that allows for full user access, where there are no closed doors, and essentially everything about the system and its inherent variables is fully discoverable, open-architecture systems are unquestionably important to the company. So, what are the key elements? Haymond defined four:

Powder variety
Open process parameters
Freedom to control variables
Customized development

Certainly, many metal 3D printing manufacturers offer open access to certain aspects of their systems, however, SLM Solutions claims that its product is different and unique because there are no additional requirements associated with it.

“The initial variable of powder variability is an open architecture element we recognize and we will support you with. Empowering the user to understand this intricate knowledge expedites their evolution and turns them into power users of additive manufacturing technology,” asserted Haymond. “By providing the ability to utilize an unlimited variety of raw materials, opening the doors on all of our parameter configurations, and educating the customer on how to transform all facets of built strategy parameters, we are enabling them to apply the SLM technology in whatever direction they choose.”

Achieving a successful build is heavily dependant on the powder being used, which according to Haymond, is arguably one of the most important system-level variables. In fact, he considers that the first key element of an open architecture system is the ability to vary the raw material, emphasizing the importance of powder quality and variety. That is why SLM Solutions offers a wide assortment of materials, from the traditional to the rather exotic more advanced AM powders, as well as a few new aluminum alloys which they have yet to release.

“So, why is powder critical to success? Powder specifications are critical to succesfull builds. We understand that there is a need for material diversity as this industry is constantly growing and establishing new applications. In the old additive manufacturing world, it was about processing properties and performance; but in the metal additive manufacturing world, powder drives processing, drives properties and ultimately drives performance, something we call P⁴.”

One of the big perks of SLM Solutions systems is that they work with external powders. Haymond described that there are no fees, penalties, or stigma associated with sourcing raw materials for their SLM systems. However, he indicated that “while we do permit these external powder use we do so with a number of recommendations with respect to powder quality and powder specifications that are critical to building quality and success.”

When customers choose to source powder externally the company claims they will walk them through the three basic requirements, that is flowability, moisture content, and particle size distribution.

SLM Solutions manufacturing headquarters in Lübeck, Germany (Credit: SLM Solutions)

To encourage user development, SLM Solutions said they develop and provide parameters for each of its released materials. The open process parameters are the materials and parts in specific settings that can be varied and impact a user’s build quality. Haymond indicated that there is no need to actively edit any of these available parameter settings, but they are open in case a customer wishes to do alter them in pursuit of a specific development objective.

“When you purchase one of our systems, you are guaranteed to have access to all build strategies that we have released. Furthermore, the software that we have developed around parameter modification and material development is a very detailed sweep that allows our customers to explore the intricacies of the build strategies that we have released. It is designed to provide the user with as much functionality, information, sensor feedback, and flexibility that is really possible. Both SLM solutions software, that is the Build Processor and the Material Development Module (MDM), facilitate the variation of every available parameter in a very user-friendly fashion, as we strive to provide the most comprehensive software for our customers.”

Haymond suggested that this access essentially allows users to understand the logic behind the systems’ parameter structure, and learn how to create similar constructs for themselves in pursuit of their growth with SLM Solutions machines, and within the AM industry itself.

“Additionally, through providing this unparalleled level of access we are enabling significant cost and time savings for the development of new materials or the development of new exposure strategies for established materials.”

SLM Solutions machines (Credit: SLM Solutions)

There is no real limit to the number of combinations for a given material family. And SLM Solutions makes it unnecessary to edit the variables because the parameters they claim to provide for any given material are deemed to produce ideal mechanical and physical properties for a wide range of geometries. Yet, like in the previous two elements of open-architecture systems, the company believes that having the freedom to control variables will enhance the user’s experience, allowing them to innovate and grow with the system and technology.

All the variables are modified with the Build Processor. Haymond explained that they “found many of our customers begin their path to custom development with the use of a new material not currently offered with an optimized parameter set.” So SLM has developed a unique tool within the built processor software, the MDM, which facilitates the automatic varying of individual parameters and will also automatically assign the matrix of parameters across the given build platform. Haymond proposes that users who have experienced a new material development will appreciate that they will no longer have to laboriously and tediously create each individual parameter set and type it in by hand and then assign it to the parts. Instead, the MDM software eliminates all this time consuming and error-prone activities.

“Essentially the MDM allows the user the ability to perform a systematic analysis of the part parameter variation. It is an incredibly useful tool, mostly focused around the editing of the basic parameters. The software is designed to utilize the user-specific rules to create matrices of every parameter setting. So once customers decide which parameters they wish to study and establish their relative boundary conditions the rule editor can be utilized to build the matrix.”

One of the primary tenants of open architecture philosophy means altering and modifying all parameter variables, which will eventually lead to customized development. That’s the goal for SLM Solutions: providing capability of complete customization gives the user freedom.

SLM Solutions machines at work (Credit: SLM Solutions)

As the AM world develops, SLM Solutions asserted that they will continue to develop and release material and process parameter combinations. Even more so, Haymond stated that the “needs of our customers can sometimes outpace our efforts, and rather than forcing our customers to wait for us we choose to empower them to continually strive for the rise of metal AM, using our machines as their vessels.”

“Essentially, it all boils down to providing the capability that the user needs to customize the development. We feel that we want to provide an open architecture to allow customers to grow because this is such a new industry with so much potential, and we are still in the infancy of its development, furthermore, without the flexibility of open architecture, you’ll be forever catching up to market trends. Instead, we want to empower our customers to be the trendsetters.”

High-quality SLM additive manufacturing machines have high costs, especially if parts aren’t optimized or designed for the process. SLM Solutions’ approach to creating true open architecture manufacturing systems expects to offer customers full access to every aspect of the system and its inherent variables, enabling them to optimize their systems. As discussed in the webinar, providing accessibility to control variables and parameters can take the users to new levels.

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For a Personalized Look, Try a 3D Printed Pompillon Bow Tie

There’s something fantastically dapper about a bow tie, and a 3D printed version definitely takes this fashionable look the extra mile. Ties and bow ties, along with ascots and scarves, were born from the cravat, and can quickly elevate an outfit. But using 3D printing to make these fashion-forward accessories means that you can easily play with the shape and texture of the tie for a more unique aesthetic.

Pompillon, a clothing brand based in Italy and Germany, was founded in 2017, based on an idea from bow tie collector and aerospace engineer Luca Pompa, also the founder of the brand. That idea, of course, was to use 3D printing to make more creative, customizable bow ties. The name Pompillon is a playful merger between the surname Pompa and ‘papillon,’ which the website explains is “the French name of the beloved bow tie.”

“The vast assortment of colors of bow ties and combinable ribbons wants to encourage everyone’s imagination to the maximum, to personalize his style with a small accessory with attention to every detail,” the Pompillon Facebook page states. “Moreover, the various editions will allow collecting them in all its lines.”

3D printed Pompillon bow ties merge classic shapes with creativity, experimentation, and technology; add in attention to detail and a wide range of ribbons and tie colors, and the sky is the limit when it comes to personalizing your style. The Pompillon tie takes the typical bow tie silhouette, reduces it down to the most essential lines, and reinterprets the accessory with 3D printing.

The brand uses another Italian original to fabricate its bow ties – Sharebot 3D printers. Pompillon bow ties are 3D printed using a hexagon infill shape. Several of these six-sided polygons, all with sides of equal length, are joined together to make the bow tie and optimize “structural packing to the maximum.”

3D printed Pompillon bow ties are perfect for classic, everyday style, and for more formal occasions as well. The brand’s ideal clientele are those who appreciate a personalized and colorful look, as they enjoy dressing in a refined way, without being boring.

The bow ties are 3D printed out of plant-based, biodegradable PLA material from renewable resources, which keeps them lightweight. In the future, Pompillon will make special editions of its bow ties out of carbon fiber, marble powder, and even wood.

Pompillon has two versions of its bow tie – the filled Gentlemen and the open Rebel. When you combine the two, it makes the Unique model. The brand also offers a Gala Edition bow tie, which appear to only come in black and white for more sophisticated evenings, à la James Bond. These 3D printed bow ties are completely customizable with a variety of colors, clips, and ribbon, so you have a lot of choices to play around with in making your own unique accessory.

You can visit the brand’s online shop page to see what’s available. Two of the looks I really like are the Pompillon Dark Rebel, which is a red ribbon and black bow tie combination for just €24.90, and the Pompillon Unique White Snow & Blue Ocean, also at a price of €24.90. A 3D printed Gala Edition bow tie will set you back just €26.90, and several of the Pompillon Gentlemen ties, including my favorite in the limited edition Nature Green color, only cost €19.90.

They even look good on dogs!

“Have fun using them in bulk or combined with our other Pompillon. Make it unique and customizable for every look and mood,” the shop page says.

“Take a picture wearing it and post it on social media. If you send it to info@pompillon.it, it will be published and advertised on our social networks! plus you will have the chance to win a free one…be Lucky!”

Would you wear a 3D printed Pompillon bow tie? Let us know! Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

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3D Printer Manufacturer Xioneer Systems Acquired by BellandTechnology (VXL)

As BellandTechnology AG acquires Xioneer Systems, excellence in 3D printing materials and hardware continue to meet–and improve–via global expansion. Headquartered in Bayreuth, Germany and founded in 2008, BellandTechnology today is branded under VXL, and is known as a consumables manufacturer—mainly through development and production of acrylic-based thermoplastic polymers.

With the addition of Vienna, Austria-headquartered Xioneer Systems GmBH in December, BellandTechnology receives 100 percent of their shares, as well as their impressive expertise in manufacturing FFF 3D printers.

Xioneer was founded in 2012 and worked with a team of around 20 employees last time we interviewed them regarding their six patented technologies and features surrounding their 3D printers and materials. They are known for their initial Xioneer Desktop 3D printer, and the 2016 FormNext Start-up Challenge Award as they were recognized for their 3D printing innovation.

“By merging our companies, we combine the 3D printing know-how of Xioneer with the materials know-how of BellandTechnology. And this places us in a unique competitive position: a position to tackle 3D printing challenges in a new way, to deliver new solutions. All that with one goal in mind: to promote the FFF technology in both the consumer and the industrial additive manufacturing markets,” explains Dr. Andrei Neboian, founder and CEO of Xioneer.

“To achieve this, we decided to focus on the entire FFF industry and change our product course accordingly. Therefore, we will expand our service portfolio and we plan to offer innovative add-on systems, components, and accessories for any FFF 3D printer on the market.”

Xioneer currently also serves customers engaged in aerospace, automotive, medical and tooling, and engineering applications—supported by the Xioneer Industrial 3D printer, beginning in 2018. Their pioneering efforts in the production of hardware will complement BellandTechnology’s unique position in the 3D printing industry as they continue to make and market high-performance thermoplastics featuring ‘controlled solubility.’ This applies to both water or aqueous alkali solutions and can be critical in areas like electronics, and mechanical or medical engineering too. Typical products produced via these polymers include:

Solids
Adhesives
Foams
Films
Fibers
Semi-finished products

BellandTechnology thermoplastics, offering notably higher thermal stability, are also used in 3D printing complex parts.

“We are excited about the future with Xioneer on board. In the coming years we will serve the FFF 3D printer market with software solutions, hardware components, and innovative concepts for 3D printing consumables – all perfectly matched together,” said Thomas Demmer, the CEO of BellandTechnology AG.

“These products will be cost-efficient, professional, and user friendly. As a 3D printing materials company, we are open to work with all 3D printer manufacturers. And we believe that this openness, together with the willingness to deliver great products to manufacturers and end-users, will help us push the FFF market forward.”

What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

The Xioneer Desktop Professional 3D Printer

[Source / Images: Xioneer Technologies]

The post 3D Printer Manufacturer Xioneer Systems Acquired by BellandTechnology (VXL) appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Industrie 4.0: Mein Har(t)z Brennt Part 1

“Turning and turning in the widening gyre

The falcon cannot hear the falconer;

Things fall apart; the centre cannot hold;

Mere anarchy is loosed upon the world,

The blood-dimmed tide is loosed, and everywhere

The ceremony of innocence is drowned;

The best lack all conviction, while the worst are full of passionate intensity.”

WB Yeats.

15 years after the Hartz reforms made Germany a tougher and more resilient place in which to work and live, decades-long semi-austerity has left the motor of the European economy coughing and sputtering in anticipation of a global Trumpcession. Amidst worldwide turbulence and upheaval, a baby boomer generation sets to retire, leaving the reins of Mittelstand companies in the hands of a TV generation trying to raise an internet generation. This could not have happened at a foggier time. China, the workshop of the world, is asserting itself and decidedly moving upmarket in many niches. Manufacturing excellence is not something that small German family firms put on awards on the wall, manufacturing excellence is the dream that one of the richest and most powerful countries in the world wants to attain. A million new immigrants have exposed long glossed over German societal fractures such as extreme right terror, nationalist violent groups of all stripes, a radicalized Antifa, new Germans not entirely absorbed and oops the ossi wessi divide or areas of economic backwardness didn’t disappear with the Trabant. Cooperation, social adhesion, catholicism, and identity; they are all ebbing or under siege. Even though roads seem in perennial repair; underinvestment in infrastructure has left the country looking less than spiffy.

It seems that if you move your government to Berlin, Berlin will look nicer while the country looks more like Berlin. Underinvestment in education has meant that in this area the nation lags European peers as well. Germany does invest cohesively in innovation but seems set to perennially lag behind the US and China on that front. Lack of VC capital, when compared to the US, means that there are far fewer startups, especially far fewer larger successful ones. Erstwhile staid institutions such as Deutsche Bank seem wobbly or indeed have been quite adept at carrying on as a giant hedge fund/Russian Money transfer scheme while masquerading as a boring financial institution. The Volkswagen scandal still weighs heavily on a collective culture of excellence and quality.

Over 100 years ago the German government had a goal for itself in the collective stumble to slaughter that was the First World War. The government’s goal was the: establishment of a Germany dominated customs union. 104 years on, two observations can be made:

Germans are persistent
Be careful what you wish for

Many people would have given up after the First World War, not the Germans. Many people would then have given up after the Second World War, not the Germans. They kept on going and finally after 100 years got their Germany dominated customs union. But, now what? A nation-state born out of a conflagration the German Federal Republic now has over 70 years of prosperity, growth, stability, and peace behind it. After turbulence and destruction, there was rubble and this was turned into a path to future riches and safety that would have seemed a feverish dream to those clambering through bomb crater hewn Allee’s. Germany is one of the most successful countries that the world has ever seen, but what is its place in a world that is seeing the demise of the nation-state and the rise of ultra-nationalism simultaneously?

Nihilism, apathy, and extremism grow as we enter the age of China and the caudillo. Civil society is for textbooks and what will the terrorists do once we’ve run out of acronyms for them? It is becoming increasingly clear that those left-wingers that shouted while standing on boxes for workers’ rights have essentially won, only to suddenly lose. All of their dreams from worker safety to pay, to vacations, to affordable housing have been granted. Meanwhile, the right has gotten its law and order with crime being reduced to next to nothing and violent crime being something you’re likelier to find on vacation than at home. Centrists have gotten their civil society a little bit of everything a la carte dream while länder press and public have power. Businesses are easy to start and are well regulated while labor unions have been so successful as to be useless. Essentially Germany has done such a good job of keeping its promises and attaining its dreams that it has no more hopes and dreams with which to feed a future thirst for that thing that is Germany.

Extremism is on the rise because they do manage to break through a cluttered media landscape with simple ideas and now it is Baader Meinhof Phenomena that dominate the things that we think about. Technocratic policies alienated many because they simply were too complex for a large segment of the populace to understand. Embarrassed to ask, they become disenfranchised by the multisyllabic integrated policies and their fine-tuning. Alienated, they feel as if they were patronized by ‘adults in the room.’ Everyone, however, can join a discussion about what kind of headdress the supermarket check out girl should be allowed to wear. A resurgence is populism is therefore not because of the anti-immigrant, xenophobic, isolationist nature of these policies or indeed their objectives. Populism has grown due to the fact that it is simple to understand, talk about and spread in a confusing world. Populism is popular now because it is a series of hale spears designed to pierce the heart of modern democracy itself. Tossed by tossers who are nihilists themselves but do believe in their own call to power the populist policies are popular because they are simple, fit into a soundbite and are easy to talk about. As per Mr. Yeats, therefore, we can see ourselves in a place where indeed, the center is not holding and the good roam listlessly while the sheep are stirred by the truthful seeming simple burn that is hate.

How to counter this as a member of society which through policy and concerted effort has tried to create and maintain an equitable country for all? We must come up with new dreams as vibrant scary and hopeful as the ones of the past. From the land of Herder new ideas are emerging, in fact, that could, in fact, herd us all to a hopeful optimistic future where harmony reigns supreme. Having accomplished the rise of the human Germany now turns to the rise of the robot.

Images: Lisa, Trine, Cynthia, Stefan.

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Interview With Kevin Neugebauer of myprintoo on 3D Printing in Germany

German 3D Printing reseller and store myprintoo is a popular Hamburg based destination site for buying 3D printers and supplies. As with the other 3D printing retailers and resellers that we’ve interviewed for this series myprintoo is shifting its focus more towards the enterprise. They sell Materialise Magics, Artec Studio as software and also have consulting services. The company also offers professional level printers from third wave 3D printing companies such as Xact Metal, 3ntr, and Ansioprint. With Formlabs equipment, 3D scanners, Ultimaker and Sinterit the firm focuses on the higher end of the desktop market as well as entry-level manufacturing solutions. This cauldron of activity is currently a very profitable but also a very competitive space in 3D printing. We interviewed Kevin Neugebauer to find out more about his firm and the 3D printing market in Germany.

What is myprintoo?

myprintoo is a specialist in 3D printing technology. Our 3D printing retail store ranked number three amongst the ten most popular 3D printing online stores 2018 (according to 3druck.com).

What makes us different from most of the online shops selling 3D printing products? We offer not only products from the top 3D printing manufacturers, but we also provide all-round services for 3D printing technology. If only buying a 3D printer was as easy as buying a regular 2D printer! Here you need to know precisely what you will use it for. Will it improve your everyday life, and will it save resources? Will you be able to operate it?

We consult with our customers and find suitable solutions for their 3D printing applications together. We also discuss further possible applications of the 3D printing technologies, so that their investment pays off in the future as well. If our customers have any technical questions, we gladly support them in the German and English.

Additionally, we offer webinars and product training in Hamburg or on-site, to show the customers how to work successfully with the hardware and software and which procedure is best suited for their application. We also work closely with educational establishments by providing them with information and professional guidance on 3D printing.

The core myprintoo team; Kevin is seated.

What markets do you focus on?

We focus on the B2B markets – mostly in the German-speaking area. For some of our products we have exclusive rights to the DACH region, for some – additionally, to the Benelux Union.

What kind of customers do you have?

Our customers come from different branches and industries: mechanical engineering, automotive, aerospace, R&D departments, universities, laboratories, medical establishments. They all have different demands and applications and require different approaches.

These are

a) customers who are new to 3D printing,

b) customers who got familiar with 3D printing some time ago, are developing their applications and need more professional 3D printers,

c) advanced users who require professional solutions for their specific needs.

How is your product portfolio structured?

According to our customer’s types, we differentiate our products as follows:

Products that are well suited for beginners – these are the desktop 3D printers Ultimaker and Formlabs.

To those who need a professional solution in FDM we offer our two 3ntr 3D printers – A2 and A4 – they score with an open system for a high variety of materials. Three nozzles allows the printing of parts with a combination of two different colors and/or properties while at the same time printing utilizing support material – necessary for complex geometries. These machines are ideal for prototyping, product development, printing of spare parts and demonstration objects, for example for medical institutions.

To customers who want to print with titanium, aluminum, stainless steel & bronze we offer our two 3D metal printers – Xact Metal XM200C and XM200S. Both are perfectly suited for taking the first steps in the metal 3D printing. Their compact design and best price-performance value makes them attractive for mechanical engineering and automotive, while affordable for universities and R&D centers at the same time.

To Aerospace & Automotive customers, who need to 3D print extremely light but, simultaneously, strong parts with high mechanical load capacity, we offer the Anisoprint Composer series A4 to A2. It’s a 3D printer capable of printing with high-strength composite materials, using special reinforcing carbon fiber along with the common plastics, which gives the parts superior mechanical properties. Universities and research centers profit from experimenting with continuous carbon fiber as well.

Why should I work with you?

For almost 5 years we have been delivering not only professional 3D printing technology, but also knowledge essential for the 3D printing. Our team has been gathering experience in different branches like 3D printing, chemistry, architecture, design, IT and sales so that our solutions are tailor-made to meet the needs of our customers.

We support our customers during their first steps in 3D printing and enable the transfer from desktop to professional 3D printers. We see ourselves not only as consultants who help finding the best solutions, but also as project partners who are interested in successful results.

I keep thinking that maintenance and service will be key to reseller profits in the future?

Of course, being supported when having technical questions, a customer can start 3D printing immediately. To prevent long repairs and downtimes we offer additional annual maintenance contracts for our brands 3ntr, Xact Metal & Ultimaker. Our technicians inspect the purchased 3D printer on site or at our service desk in Hamburg and replace spare parts when necessary. We also give expert advice reliably and quickly on the phone and via e-mail.

What is the market like in Germany?

3D printing is gaining more and more popularity in Germany. We all hear: “3D printing is revolutionizing the industry!” What is really happening is that the top companies mostly in the automotive and aerospace industries are purchasing the high-end products of the well-known 3D printing brands.However, there are many small and medium-sized enterprises who want to be involved in 3D printing as well, but cannot afford the high-end 3D printers. Meanwhile, the low-cost, high-performance professional 3D printers already exist and guarantee successful introduction into 3D printing. Our goal is to inspire the smaller companies, to let them know that 3D printing is getting affordable and that they could, if not revolutionize the industry, at least optimize their own production site.

What are the stumbling blocks in 3D printing?

The biggest problem is that it’s not that easy to recognize the applications and the added value of the 3D printing.
People keep printing conventional parts, sometimes not knowing what parts are best suited for the 3D printing. However, modifying the design of the parts can help evolve the manufacturing process and save resources.
In-house knowledge in 3D printing technology is limited.

What advice would you give me if I was a company new to 3D printing?

First, find a reliable team of experts in 3D printing technology, like myprintoo. Tell them your applications, ideas and even doubts. Believe me there’s a solution for every implementation.

Buy a 3D printer together with a webinar or a product training – that’s how you ensure a smooth software installation, impeccable hardware operation and the fastest ROI.

Research what parts are best suited for 3D printing or the ways you can optimize the parts to get more value out of 3D printing.

Keep in touch with us – that’s how we can evaluate, whether you are getting the best out of the 3D printing technology. Additionally, we offer upgrade programs for customers who want to trade their old machine in for a new professional 3D printer.

How do you see our industry evolve?

I imagine fully automated production lines with non-stop manufacturing processes involving 3D printers not only printing prototypes and spare parts, but totally new end products with modified designs, properties and customized tailor-made solutions.

I believe in the near future any respected educational establishment should have a 3D printing lab to prepare the new open-minded experienced professionals who will continue revolutionizing our industry.