industrial 3d printing Archives - Page 2 of 9 - Perfect 3D Printing Filament

Improving Foundry Production of Metal Sand Molds via 3D Printing

Saptarshee Mitra has recently published a doctoral thesis, ‘Experimental and numerical characterization of functional properties of sand molds produced by additive manufacturing (3D printing by jet binding) in a fast foundry.’ Delving into hybrid casting and improved methods for creating metal molds, Mitra analyzes varied printing parameters and their effects on mechanical properties.

Centered around improving production in foundries, the author investigates ways to create molds in a completely automated manner, taking advantage of some of the most classic benefits in 3D printing—from greater affordability and faster production time, to better quality in prototypes and parts.

“Besides, the absence of tooling costs makes this process particularly economical, and much complex geometry that cannot be manufactured using traditional sand casting can be reconsidered,” states Mitra. 3D printers are generally faster, easier to use and cheaper than other add-on technologies. It is also possible to make foundry sand molds of extremely small dimensions and very thin parts. Modern foundry industries gradually use this Hybrid Casting technology because they provide ease of sand molding with good surface finish.”

The goal of Mitra’s thesis is to create molds for metal casting with greater stiffness and permeability—ultimately, for use in both the aerospace and automotive industries—applications we have seen significantly impacted by AM processes from car parts to rocket engines, to the qualification of important end-use parts.

(a) Ancient Greece; bronze statue casting circa 450BC, (b) Iron works in early Europe: cast-iron cannons from England circa 1543 [4]

“Sand casting is the most widely used metal casting process in manufacturing, and almost all casting metals can casted in sand molds,” explained Mitra. “Sand castings can range in size from very small to extremely large. Some notable examples of items manufactured in modern industry by sand casting processes are engine blocks, machine tool bases, cylinder heads, pump housings, and valves.”

Metal casting requires:

Proper design
Suitable choice in material
Production of patterns for molds and cores
Selection of the casting process
Post-processing
Quality control

“Three-dimensional printing (3DP) of sand molds using binder jetting technology overcomes challenges faced in the traditional production method, e.g., limitations in terms of part complexity and size, production time and cost (which depends on the quantity and the part complexity, optimization in part design/design freedom for any castable alloys,” states Mitra.

Schematic representation of particle binder bonding and resin

Powder binder jetting process

A series of chemically bonded 3D printed samples were examined. While binder amounts were evaluated by Loss on ignition (LOI) experiments, mechanical strength was measured via standard 3-point bending tests. Permeability was measured by the air flow rate through the ‘samples at a given pressure.’

Mitra learned that molds could be stored extensively at room temperature, but permeability of samples did decrease as temperature was raised.

Printing recipe on ExOne 3D printer

3D printed 3PB test bars and permeability specimens

The author also noted that strength of the molds was ‘profoundly influenced’ by binder content, with increased amounts consequently increased mechanical strength.

“X-ray µ-CT images were used to compute the porosity, pore size, throat size and the permeability of the 3D printed specimens for different binder contents and grain sizes, using analytical and numerical methods,” concluded Mitra. “The permeability predicted in the steady-state was compared with experimental and analytical measurements for layered silica grain arrangement. A major advantage of using X-ray CT characterization is the nondestructive nature of the tests. The computed permeability can be used as input to numerical simulations of metal casting allowing the prediction of macroscopic defects.”

“The present findings represent a step forward towards improved prediction of mass transport properties of the 3DP sand molds. However, further characterization of permeability of such additively processed sand mold should be performed with varying average grain diameter, to check the convergence of the present model. Also, samples printed with other printing process parameters should be studied.”

Steps involved, (a) 3D printing of sand mold, (b) melting iron, (c) casting process
and (d) eroded molded with the respective positioning of thermocouples.

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.

[Source / Images: ‘Experimental and numerical characterization of functional properties of sand molds produced by additive manufacturing (3D printing by jet binding) in a fast foundry’]

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Researchers 3D Printing for Contaminant Removal with 3D Printed Zeolite Monoliths

International researchers explore methods for removing contaminants in their recently published ‘Nuclear wastewater decontamination by 3D-Printed hierarchical zeolite monoliths.’ Focusing on the radioactive cationic species, ¹³⁷Cs⁺ and ⁹⁰Sr²⁺, this study brings greater exposure to the need for selective removal of radionuclides.

Harkening back to the disasters that occurred at Chernobyl in 1986 and the Fukushima Daiichi plant in 2011, the research team reminds us of the intense need to handle nuclear waste properly. The two radionuclides, ¹³⁷Cs and ⁹⁰Sr, are the ‘most likely to contaminate water bodies’ – with ¹³⁷Cs being a large part of the Fukushima cleanup; however, aluminosilicate zeolites play a huge part in treatment—and removal of contaminants.

“Nuclear waste treatment can be demanding, in some cases the radionuclides must be removed from highly radioactive solutions that are also extremely acidic or caustic, where natural zeolites suffer due to their nature as aluminosilicates,” explain the authors. “Various synthetic materials such as titano-, zircono-silicates or metal oxides have been developed and proved more useful in these cases.”

Stating that they have created a ‘breakthrough solution,’ the authors present a method for 3D printing ion exchanger monoliths. Pointing out that the technology has been used in numerous applications to fabricate nanotubes, nanoparticles, and a variety of piezoelectric products, 3D printing is also used in dry applications regarding gas absorption, separation, and more.

“To date, no 3D-printed zeolite monoliths have been produced specifically for ion exchange of aqueous media where they would need to be both insoluble and stable with regards shape retention over time when exposed to water,” stated the researchers.

Digital light processing (DLP) was used in this work, allowing for the required customization and control over issues like porosity. The research team mixed photopolymerizable monomers with zeolite powder, taking advantage of the ability to modify the binder’s properties in terms of:

Stretchability
Temperature responsivity
Hydrophobicity

(a) Schematic overview of the printing process; first dispersion of the zeolite was formed within the polymerizable monomers and porogenic solvent, then the formulation was 3D-printed by the DLP method. (b and c) The printed zeolite-embedded monolithic structures.

Two cylindrical zeolite samples were printed, in the form of synthetic chabazite and commercial zeolite 4A. It was critical for the 3D printed zeolite to allow the solution to flow through the column, with the polymeric matrix providing access for the cations.

(a) TGA curve of 3D-CHA. (b and c) Comparison between the PXRD of zeolite powders and the zeolite embedded printed structures (b) 3D-CHA and pure chabazite powder; (c) 3D-4A and pure zeolite 4A powder. The patterns of the printed systems have been offset for clarity. (d–f) N2 adsorption isotherms of (d) 3D-CHA; (e) the pure chabazite powder; (f) the printed polymer.

With the ultimate goal being the ability to remove Cs or Sr, the team tested the samples for ion exchange (using SEM-EDX, Infinite Focus Microscopy (IFM), XRD and X-ray Fluorescence (XRF) spectroscopy).

SEM images of Cs-exchanged 3D-printed monolith (a) an overview (b) side view (c) top view of the rod taken from the grid.

Overall, the monoliths exhibited ‘good mechanical stability, and the researchers confirmed that DLP 3D printing offered the required control necessary—also allowing them to create the proper degree of porosity and good internal matrix structure.

IFM images of 3D-printed monolith (a) before and (b) after Cs ion exchange and their profile measurements.

SEM image, EDX results and elemental mapping of Cs-exchanged 3D-CHA.

“In the case of nuclear waste treatment, in addition to the above-mentioned advantages, the printed columns enable simple and safe handling of the contaminated ion exchanger and may significantly reduce the risks and difficulties that rise when dealing with radioactive contaminated powders,” concluded the researchers. “We have not tested the radiological stability of the polymer matrix, but as the radioactive cations are trapped within the inorganic zeolite particles, we would not expect any release of these into the environment even with polymer degradation.”

“The polymer should also not significantly interfere with the thermal conversion of the spent exchangers into ceramic or vitreous wasteforms as it would be readily oxidized during the process without release of any radionuclides.”

(a) Schematic diagram of an ion exchange column, (b) photograph of a packed column.

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.

[Source / Images: ‘Nuclear wastewater decontamination by 3D-Printed hierarchical zeolite monoliths’]

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Cornet: Research Network in Lower Austria Explores Expanding 3D Printing Applications

Ecoplus Plastics and Mechatronics Cluster in Lower Austria has just completed their ‘AM 4 Industry’ Cornet project, outlining their findings regarding 3D printing—with the recently published work serving as the culmination of a large group of research partners and fifty-one companies (from Austria, Germany, and Belgium) working together on ‘industrial AM concepts’ for two years.

Begun in November of 2016, this ongoing research was funded with 2.1 million euros, and is comprised of the following organizations:

Research Institute for Rationalization (FIR) of the RWTH Aachen University
Research Subsidiary of FH Wiener Neustadt
Fraunhofer Institute for Casting, Composite and Processing Technology
Institute for Polymer Injection Molding and Process Automation of the Johannes Kepler University Linz
Chair of Polymer Processing of the University of Leoben
RHP-Technology GmbH
Belgian Collective Center for the technological industry – Sirris

Noting that 3D printing and additive manufacturing processes are becoming increasingly more popular around the world by users on every level, the researchers found that it is having impacts on industrial production, and often allows designers and engineers to create parts and prototypes made up of complex geometries—ones that may not have been possible with conventional techniques. New mechanical properties and functionality may be added to components also.

It is no secret that while 3D printing offers a host of advantages and the ability to offer infinite new designs and innovations, many companies are still not ready to completely embrace additive technologies, breaking free from traditional methods.

For those already using AM processes, some may be reaping the rewards by enjoying profitable results, while others have trouble in attempting to learn and use the technology. The researchers pointed out that users must understand the following:

Processes
Materials
Finishing
Quality assurance
Cost-benefit ratios

Industrial applications also require:

Definition of quality characteristics
Development of methods for design and construction
Reliable monitoring of production processes
Suitable guidelines for reworking
Appropriate cost-benefit model

Cooperation between all entities on the research project was ‘intensive’ and it has now been deemed ‘successfully completed.’ Results were so extensive that they were separated into five different publications for practice and research.

The five publications include: a catalog of errors for laser beam melting, a practical design methodology for additive manufacturing, a fundamental study of processes, a tool for quality optimization and cost analyses and an application-oriented example for getting started with OpenFoam and chtMultiRegion.

Residual stresses become apparent during separation from the building plate (post-process), as discussed in Project report – AM 4 Industry – LBM Additive Manufacturing Defect Catalogue

Concerns over tool accessibility during machining, which reduces the achievable geometric complexity – as discussed in ‘Design for Additive Manufacturing A feasable methodology’

“Thanks to the expertise and the committed and open-minded cooperation of the partners involved, we were able to develop several methodologies and guidelines that will prove to be extremely relevant for the industry,” said ecoplus project manager Benjamin Losert.

Find out more about the Cornet research here.

3D printing continues to offer benefits to a long list of fields today, allowing medical professionals to make huge strides with medical devices and implants, aerospace engineers to expand functionality and design of rockets, and so much more. 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.

[Sources: Additive Manufacturing Association Austria; Images: AM 4 Industry ]

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3D Printing News Briefs: February 21, 2020

In today’s 3D Printing News Briefs, we’re talking about new products and materials, an industry event, 3D printed electronics, and education. 3Doodler announced a new product, and Essentium will be showcasing two new materials at RAPID + TCT. The 4th annual AM Cluster of Ohio conference is coming up in July, and nScrypt is microdispensing 50um dots for 3D printed electronics. Finally, Penn State University is investing in Roboze technology.

3Doodler Introduces New 3D Build & Play

At the New York Toy Fair, February 22-25 at Manhattan’s Jacob Javits Center, 3Doodler will be showcasing its latest device – the 3D Build & Play, perfect for preschoolers and kindergartners to use. The pen was designed for users as young as four years old, and introduces growing children to 3D printing technology in a way that promotes cognitive and fine motor skills development, hands-on learning, story telling, and three-dimensional thinking. The 3D Build & Play is kid-safe, extruding low-heat, BPA-free, non-toxic, biodegradable plastic, and comes with a story-based Activity Guide so parents and kids can create together. Currently available for pre-order, 3D Build & Play will have an MSRP of $29.99, and major retailers, like Amazon, are also expected to carry the product in Q2 2020. Visit 3Doodler in Booth #2771 at the New York Toy Fair to learn more.

“3D Build & Play brings the creative fun of our Start pen without the learning curve for the youngest users. The system we have developed, that lets kids crank and create in 3D, is a major benefit for parents looking to improve their children’s basic motor skills. The included molds make it easy to create 3D objects by simply filling and popping them out. There’s nothing on the market today that makes 3D creation this simple or fast for young creators,” said 3Doodler’s CEO Daniel Cowen.

Essentium’s New Materials for High-Temperature Applications

At RAPID + TCT 2020 in Anaheim this spring, 3D printing solutions provider Essentium will introduce new ULTEM AM9085F and ABS materials for high-temperature industrial AM applications. These high-performance materials, which will be showcased on the company’s High Speed Extrusion platform at the event, provide high strength and have excellent resistance to heat and chemicals at high temperatures, so they can be used for applications in the aerospace, automotive, industrial, and medical industries.

According to a survey commissioned by Essentium, 51% of executives believe that the high cost of materials is a major obstacle when it comes to adopting 3D printing for large-scale production purposes. The new ULTEM AM9085F and ABS materials were created to give manufacturers a more cost-effective solution when compared to expensive closed-system materials. Learn more at Essentium’s Booth #3400 at RAPID + TCT in Anaheim, CA, April 20-23, 2020.

4th Annual Additive Manufacturing Cluster of Ohio Conference

The Additive Manufacturing Cluster of Ohio, powered by organizations such as America Makes and the Youngstown Business Incubator, has announced that its 4th annual conference will take place this summer in Cleveland. Cluster members work together to create a supply chain of interconnected institutions and businesses to advance regional growth in 3D printing. This conference, to be held on Thursday, July 30, at the Embassy Suites by Hilton Cleveland Rockside, will be the first cluster event of 2020, and will give Ohio manufacturers of multiple business models and sizes perspectives on available opportunities for adopting 3D printing into their process chain over the next five years.

The website states, “The program will look at similarities and differences across several selected manufacturer types and will identify strategies ranging from low to high risk. Attendees will leave with actionable strategies and information about regional resources to help them remain competitive in the evolving manufacturing landscape.”

nScrypt Working with 3D Printed Electronics

Orlando company nScrypt is working with precision microdispensing, an additive method of dispensing pastes, inks, and other fluid materials, to create adhesive dots with volumetric control, in the 50 micron range, for 3D printed electronics and flexible hybrid electronics (FHE). Microdispensing gets much closer to the substrate surface when compared to methods like jetting, and the closer the nozzle is to the surface, the finer the features of the 3D printed parts. The team used the nScrypt SmartPump, a silicone adhesive, a conical pen tip, and Heraeus SAC305-8XM8-D Type IX solder paste, and tested the consistency and repeatability of ~50µm Type IX solder and adhesive dots.

These tests showed a consistent average dot diameter of 51.24 microns, with a 6.42 micron (13%) standard deviation. These results support the fabrication of 3D printed electronics through the use of direct digital manufacturing (DDM), which allows printing to both planar substrates and the non-planar world of Printed Circuit Structures, which prints the housing or structure of an electronic device as well as placing the electronics conformally. In the future, the team plans to conduct a larger solder and adhesive dot study, in order to test required downtime, long-term reliability, and the frequency of clogging.

Penn State University Invests in Roboze Technology

Penn State, a 3D printing leader through its Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D), has invested in a new FFF solution in order to expand its AM capabilities. The ROBOZE One+400 Xtreme 3D printer, which was designed to create high performing, functional finished parts in advanced composite materials, will help the university increase its development of high performance plastics for 3D printing, and will be housed in the Department of Chemical Engineering. Students will be able to test out new polymers on the system, and develop new formulations to provide 3D printed parts with multi-functionality. These parts will be used to advance research in applications like chemical reactors.

“ROBOZE One+400 Xtreme will be used to examine novel polymers to help to fundamentally understand the 3D printing process and as a tool to enable custom equipment more cost effectively than can be obtained with machining metals while also allowing for designs not possible with traditional manufacture. The ROBOZE One+400 Xtreme will allow Penn State to leverage its expertise in materials science, engineering and characterization to enable new solutions to problems through additive manufacturing,” said Professor Bryan D. Vogt from the Department of Chemical Engineering.

“The ability to use custom filaments and control the print processing was a critical factor in selecting ROBOZE. The flexibility allowed by ROBOZE along with its excellent printing capabilities is well aligned with the discovery-oriented research mission of the university to expand knowledge and its application. Moverover, our prior 3D printer had issues printing high temperature engineering plastics like PEEK with severe deformation of the structure generally observed. After challenges with printing PEEK with standard belt driven systems, the novel direct drive approach with the ROBOZE was an added bonus.”

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GKN Aerospace to Open Latest Additive Industries Process and Application Centre Close to Bristol, UK

GKN Aerospace is just one aspect of the powerhouse of manufacturing activity emanating from GKN—a company rich in history—with origins founded as far back as the 1700s. Overall, GKN presents a huge emphasis on 3D printing and additive manufacturing processes that only continues to grow within all of their main divisions featuring aerospace, automotive, powder metallurgy, and wheels and structures. With main headquarters in the UK, GKN Aerospace continues the overall forward momentum as CTO Russ Dunn opens the latest Additive Industries Process and Application Centre close to Bristol.

So far, other Additive Industries centres have been opened in Eindhoven, Los Angeles, and Singapore. Each facility offers its ‘own specialism’ related to AM processes. The UK & Ireland Process and Application Centre is situated at Filton Aerospace Park, famously known as the site of the Concorde’s development and production in the 60s and 70s. Other important aerospace activities are currently taking place there, as well as engineering and manufacturing, with industry leaders like Airbus, Rolls-Royce, and GKN working nearby.

The site, now completely renovated and ‘in line with all the highest standards,’ has been used for numerous aerospace projects in the past, as well as lightning strike tests. The Additive Industries facility at this site will allow for a focus on both the production of new materials as well as continued process development.

On March 12th, Russ Dunn, CTO of GKN Aerospace, Dr Mark Beard, Additive Industries’ Global Director Process & Application Development and General Manager of the Centre, and Daan Kersten, CEO of Additive Industries, will oversee the official opening ceremony of the facility.

The opening ceremony and event will run from 11:00 am to 5:00 pm. There will be a full schedule, featuring presentations and announcements. During the afternoon, those attending can expect the following:

Presentation about GKN Global Technology Center (also in Filton) – by Paul Perera, VP Technology at GKN Aerospace.
Discussion on the additive manufacturing vision for Airbus, and perspective on the growing AM ‘ecosystem’ in Filton – by Dave Best, Head of Business and Strategy for Airbus.
Presentation on APWorks and their choices for advancing in industrialization, working with the Additive Industries Competence Centre in Filton; accompanied by a case study that includes GKN and ANSYS – by Jon Meyer, CPO for APWorks.

Both GKN and Additive Industries continue to be a powerful—and advancing—presence within the AM field, around the world. GKN has collaborated with other companies like GE Additive and Porsche, and recently they purchased Forecast3D. Additive Industries has also been in the 3D printing news headlines as they partnered with APWorks, Volkswagen, the Switzerland-based Sauber F1 Team, and more.

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.

[Source / Images: Additive Industries]

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BigRep Exhibits at 3DEXPERIENCE World 2020; Launches PARTLAB at Boston Headquarters

The BigRep team will soon be attending and exhibiting at the 3DEXPERIENCE World 2020 show (hosted by Dassault Systèmes) in Nashville from February 9-12, along with opening a new office in North America as they launch their 3D PARTLAB in Boston on February 10th.

The German-based BigRep is a leader in additive manufacturing technology and offers solutions to users engaged in large-format digital fabrication around the world (with existing offices in New York and Singapore too). The soon-to-open Boston office will be available to new and existing users, allowing them to enjoy a bigger facility with a showroom featuring the BigRep ‘fleet’ of large-format AM systems such as the STUDIO G2s, ONEs, and PROs.

“Addressing a growing demand in the market for flexible AM printing services, BigRep 3D PARTLAB will set a new standard in customer services for both existing and new industrial clients looking for innovative AM solutions from proven professionals,” says Frank Marangell, BigRep CBO and President of BigRep America.

“PARTLAB will support both our partners and customers who are over capacity and assist other companies in need of large-format parts printed by industry experts.”

The Boston office will offer AM demos and consulting, but more importantly, clients can look forward to customized ordering not just for useful prototypes but also functional 3D printed parts, to include molds and more. BigRep offers a wide range of engineering-grade materials, and the new PARTLAB will offer enormous potential to its customers in the US—along with comprehensive new services for industrial users throughout North America.

BigRep, founded in 2014, is known for its medium-format 3D printers. As they offer industrial users—and partners such as Bosch Rexroth, Etihad Airways and Deutsche Bahn—the ability to print on the large scale, they continue on their goal to transform manufacturing with greater speed, reliability, and efficiency.

At 3D EXPERIENCE World 2020, visitors will have the opportunity to mix with peers, 3D designers, innovators, engineers, and other business owners and leaders involved in ‘powering an industry renaissance.’

With over 350 sessions offered at the show, everyone involved can learn a lot, as well as connect with hundreds of other technology partners. The BigRep team will be there at booth 308, presenting one of their industrial AM systems, along with samples of 3D printed parts. Find out more about BigRep here, and 3DEXPERIENCE World 2020 here.

BigRep continues to maintain an international presence within the 3D printing and AM realm, and this is only expected to expand further with their latest move into Boston also. Over the years their team has contributed to important additive manufacturing research, along with showcasing ongoing new technology, and working with other industrial partners.

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.

[Source/Images: BigRep]

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Ti6A14V Titanium Alloy: Testing DMLS 3D Printed Samples Under Static Load

As 3D printing with metal continues to expand for industrial users around the world, so does the study of materials like powders, unique alloys, and a range of composites. In this study, outlining their findings in the recently published ‘Strength analysis of Ti6A14V titanium alloy produced by the use of additive manufacturing method under static load conditions,’ researchers focus on the uses of titanium alloy Ti6Al4V and comprehensive analysis of mechanical properties after printing via direct metal laser sintering (DMLS).

For many applications, the benefits of 3D printing and additive manufacturing processes overshadow more conventional methods for the creation of devices like dental implants, rocket engine components, car parts, and more. While greater affordability is key, so is the ability for many users to create parts that may never have been possible before—or even more notable, perhaps, is the option to scan older parts that have become obsolete and re-create them via 3D printing (especially helpful in applications like automotive and for the military).

Medical devices such as implants are often made from alloy due to the following advantages:

High mechanical properties
Low density
Corrosion resistance
Biocompatibility

Test sample dimensions.

Heat treatment is common with the use of metals, as it improves mechanical properties. Methods such as hot isostatic pressing (HIP) are often used; however, in this study, the researchers use DMLS additive manufacturing to create the samples to be tested for viable mechanical properties.

Physical form of research samples: (a) turned from a drawn bar, (b) manufactured by the additive method DMLS.

The team created samples in the form of annealed drawn bars (12mm in diameter) as well as a set created via DMLS on an EOS M280W machine, and annealed afterward.

“The printing process was characterized by the following parameters: laser power 200 W, minimum layer thickness 30 μm, scanning speed up to 7 m / s. The sample print direction was consistent with the Z axis,” explained the researchers.

The applying scheme one layer of the sample by the DMLS method.

Strength of the first samples was found to be lower in comparison, while hardness related different values:

“The difference in results is related to the method of sample preparation by the additive technology and the external load it has been subjected to,” stated the researchers.

“Slight changes in the hardness value in the x-plane of unloaded samples indicate similar mechanical properties of the material produced by the DMLS method.”

Samples for hardness tests: (a, b) samples from a drawn bar, (c, d) samples made using the DMLS method before tensile tests, (e, f) samples made using the DMLS method after tensile tests.

The team of researchers also noted that in this case, variances in hardness (between x-y and x-z) could be due to 3D printing of material grains, combined with deformations caused by the axial load.

Testing of sample DMLS macrostructures demonstrated obvious changes related to tensile load, indicating that it may also again be due to 3D printing—as well as set parameters and direction of material layers. The researchers compared macrostructures both before and after tensile loading, realizing that plastic deformations then occurred, and were plainly visible caused by the load line.

Because titanium is used in a host of 3D printing and AM processes today, this material is an ongoing source of study from use with composites, to medical devices like sternum or hip implants, printing with glass, and more.

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.

Macrostructure of the Ti6Al4V material resulting from the DMLS additive manufacturing method taken from: (a) samples along the Z axis, (b) sample gripping part, (c) distribution of force lines in the sample during tensile force; I – the area of significant changes in the material structure resulting from the tensile force action, II – transitional area, III – area with limited impact of tensile force.

Schematic presentation of two-phase microstructure formation of two-phase α + β titanium alloy plastically deformable in the phase transition temperature range α + β → β as a function of deformation degree ε.

[Source / Images: ‘Strength analysis of Ti6A14V titanium alloy produced by the use of additive manufacturing method under static load conditions’]

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Transistor-Based Localized-Microwave-Heating May Lead to New Metal 3D Printing Technology

In the recently published ‘Incremental solidification (toward 3D-printing) of metal powders by transistor-based microwave applicator,’ authors Amir Shelef and Eli Jerby explore the potential of a new device for metal printing, using a compact scheme in a nitrogen-shielding environment.

While techniques such as selective laser-melting (SLM) and electron-beam melting (EBM) are popular for use in 3D metal printing, inert gases such as nitrogen and argon are used to prevent oxidation. Microwave energy is being used for heating of ceramic, as well as in post-processing for 3D printing, metal-powder sintering, joining, and casting and production processes too.

“The intentional localized-microwave-heating (LMH) instability, utilized in other processes such as microwave drilling and basalt melting, was also proposed and investigated for AM purposes,” stated the researchers. “It was found that LMH may heat up a small batch of metal powder by inducing eddy currents in it, till melting. The microwave irradiation is then stopped, and the batch is solidified (while cooling down) and consolidates with its substrate. In those pioneering studies, a ∼1-kW magnetron generator was employed in a waveguide structure.”

“The feasibility of the LMH-AM technique is demonstrated by incremental constructions of simple elements, such as pillars, in the aspect of batch solidification and joining. On this basis, LMH-AM of more complicated structures in various orientations could be conceived.”

A conceptual scheme of the proposed LMH-AM process: A powder batch is incrementally added as a building block to the structure made of previously solidified batches. The LMH effect melts the additional powder batch. After the microwave is turned off, the melt cools down and solidifies as an extension of the constructed structure.

For this study, the authors tested their solid-state microwave application in an LMH-AM process, while also evaluating its true feasibility for other applications too.

The transistor-based LMH-AM experimental setup, demonstrating a rod construction – (a) The LMH applicator in a microwave cavity with a movable electrode. The directed microwave power melts the powder batch. After the microwave is turned off, the melt solidifies on top of the previously constructed structure (demonstrated by a rod in this case), and is merged with it as an additional building block. The nitrogen flow prevents plasma ejection, and protects the LMH-AM product from oxidation. The powder batch is supplied on demand. Two options for the powder-batch support during LMH are illustrated; one employs a mechanical support (Opt. I), and the other applies a static magnetic field in a contact-less manner for ferromagnetic powders (Opt. II). (b) A block diagram of the experimental setup. The microwave system is based on a solid-state (LDMOS-FET) power amplifier. The peripheral equipment provides the controls for the LMH-AM process, and its diagnostics.

The LMH-AM applicator is made up of a coaxial waveguide (with movable inner electrode) and a conductive electrode tip for ‘intensifying the LMH effect’ as it increases the electric field in the presence of powder. The solid-state microwave source is founded on a field-effect transistor (FET), of laterally diffused metal-oxide semiconductor (LDMOS), with an amplifier integrated into the RF-PowderTool system made up of an internal signal generator and power-amplifier module. Nitrogen serves as the shielding gas for preventing parasitic plasma effects, along with allowing the LMH-AM process to operate at lower microwave levels.

During experimentation for this study, the researchers placed powder manually, with the AM process performed in a series of steps, as follows:

Ceramic bead was filled with the powder batch
LMH was applied in a nitrogen environment
A hotspot was created
The batch was melted due to the thermal runaway
Microwave power was turned off
Ceramic bead was manually removed
New powder batch was added on top of the previously solidified batch

“The LMH-AM operation at relatively low-power level (∼200 W) generated by a commercially-available solid-state amplifier was enabled here by the nitrogen environment, which eliminates the plasma produced in air-atmosphere,” concluded the researchers. “The effective microwave-energy density (absorbed in the powder batch) is therefore comparable to (and even higher than) the one demonstrated with previous magnetron-based experiments.”

“In future, operating at higher microwave frequencies may further improve also the spatial resolution (due to the shorter wavelengths) hence the narrower hotspots would enable more delicate structures.”

An incremental solidification by the solid-state LMH-AM applicator, demonstrated by a construction of a bronze rod (∼20-mm long, ∼2 mm diameter). The images show the outcomes of 9 sequential steps.

Researchers around the world continue to experiment with better ways to use additive manufacturing processes, but especially with metal. This means studying the uses of a wide range of powders and alloys, solving issues like powder spreading, exploring new AM processes, improving management of materials, and more.

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.

(a) The reflected microwave power and the temperature evolution Vs. time, at the beginning of the process (the available microwave power is ∼180 W in this case). (b) The hotspot evolved, and the molten batch of powder appears inside the microwave cavity.

[Source / Images: ‘Incremental solidification (toward 3D-printing) of metal powders by transistor-based microwave applicator’]

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Xometry Acquires Shift, Continues Western European Expansion of 3D Printing Services

Xometry, a Maryland-based company offering a network of manufacturing choices to its customers, has now announced the acquisition of Shift, based in Munich, Germany.

(Photo: Xometry)

Already involved in a partner network of over 1,000 European manufacturers for CNC machining and sheet metal, it is easy to see how the somewhat similar company—and Europe’s largest on-demand manufacturing marketplace—will help leverage Xometry’s current plans to continue expanding throughout Western Europe.

“Global expansion is a key step for us,” said Xometry CEO Randy Altschuler. “Many of our customers, like BMW and Bosch, have a global presence and we can serve more of their needs with a global network. Our AI-driven algorithms and intelligent sourcing platform give us a competitive advantage as we expand across new geographies and manufacturing technologies.”

Shift, now to become Xometry Europe, will figure in predominantly as all involved accelerate 3D printing services, increasing their combined network to include 4,000 manufacturers, and the opportunity to conduct business in 12 additional countries.

“We are thrilled to join the Xometry team,” said Albert Belousov, Shift co-founder and Managing Director of Xometry Europe. “Our customers and suppliers will benefit from us joining forces with Xometry.”

“There are huge opportunities in enabling Xometry’s Instant Quote Engine and other product features in the European market,” said Alexander Belskiy, Shift co-founder and Head of Technology for Xometry Europe.

With an existing network of customers that includes leaders in European manufacturing, Shift (now Xometry Europe) will continue to maintain headquarters in Munich. Their leading investors, Cherry Ventures, will now back Xometry too:

“The custom manufacturing industry is a massive global market of over $100 billion. We’re excited for Shift to utilize Xometry’s industry-leading technology as well as leverage the global manufacturing expertise from other Xometry investors, including BMW i Ventures and Robert Bosch Venture Capital,” said Christian Meermann, Founding Partner, Cherry Ventures.

(Photo: Xometry)

Founded in 2013, Xometry has already raised $118 million, and doubled revenues each year. Their team has also grown from 100 to 300 employees.

“We’re eager to leverage Xometry’s technology to continue to scale our business in Europe. We look forward to providing our customers with additional manufacturing capabilities, including additive manufacturing and injection molding,” said Dmitry Kafidov, Shift co-founder and Managing Director of Xometry Europe.

Currently, Xometry works with a large customer base—from new businesses to well-established companies within the Fortune 100. With their ever-growing international network in place, Xometry can offer custom manufacturing with rapid lead times, as well as industrial supply materials, and capabilities to include the following:

3D printing
CNC machining
Sheet metal fabrication
Injection molding
Urethane casting

Along with the previously mentioned BMW and Bosch, other notable Xometry customers include Dell Technologies, GE, and even NASA. Xometry has remained a dynamic force within the 3D printing industry over the years, from other acquisitions to experiments with materials, and ongoing manufacturing solutions. 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.

[Source / Images & Video: Xometry]

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dp polar GmbH & ALTANA Unveiled AMpolar ® i2 3D Printer at Formnext

Formnext, held from November 19-22 in Frankfurt, yielded a wealth of information about new products in the 3D printing world. This included the latest from dp polar GmbH, with added support by ALTANA, a specialty chemicals group headquartered in Wesel, Germany, upon the unveiling of the AMpolar ^® i2 3D printer.

This new 3D printing system offers a continuously rotating platform, resulting in high-precision parts produced up to 20 times faster—and in higher volume—in comparison to technology where the printhead moves instead. The AMpolar ^® i2 features a build volume of 700 liters, which dp polar GmbH states is the largest build area for a 3D printer being used in the material jetting realm. The release of this printer will allow industrial users to move forward to the manufacturing of functional components rather than just rapid prototyping.

The AMpolar ^® i2 3D printer allows users to enjoy a varying range of materials simultaneously via multi-material jetting, uninterrupted—and is suitable for applications like electronics and assembly and ‘pick and place’ robotics.

“Our 3D production machine AMpolar® i2 currently has the largest build area and the largest installation space in the field of material jetting,” says Dr. Florian Löbermann, Managing Director of dp polar GmbH. “Combined with ALTANA’s know-how in material development, we are bringing a 3D printing solution to market that will give customers from a wide variety of sectors, including the automotive, aerospace, and medical technology industries, completely new possibilities for manufacturing their products.”

This also means that exponentially more users will be able to benefit from 3D printing and additive manufacturing. While savings is sometimes not realized immediately for those investing in expansive AM technology, hardware like the AMpolar ^® i2 3D printer means that 3D printed medical devices like orthotics and prostheses, for example, can be created much more affordably and rapidly—also leaving the door open for easier customization as new iterations of designs are quickly formed and printed.

3D printing offers new levels of comfort—especially important for children who may have suffered through arduous fittings when using conventional methods—only to find out that they had nearly outgrown devices once they were delivered.

A 3D printed device can be easily adjusted for a new size, color, or even a different style, and takes just a fraction of the time to make, as we have seen in previous stories outlining new improvements by US researchers, optimization with simulators, new design software, and much more.

While they are able to offer critical support in the development of this new 3D printer, ALTANA quite literally has a stake in this project as they acquired part of dp polar in 2017.

“The extremely close cooperation between mechanical engineering, machine development, and material development makes it possible to develop individual solutions for our customers and their specific requirements,” says Dr. Petra Severit, Chief Technology Officer of ALTANA AG. “In material development, we are focusing on our core competencies and at the same time expanding the application spectrum of our solutions in the highly innovative field of 3D printing.”

Discuss this article and other 3D printing topics at 3DPrintBoard.com.

[Source / Images: dp polar & ALTANA press release]

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