Posted on

RIZE Introduces Adaptive 2XC Desktop 3D Printer for Offices, Schools, and Homes

In 2016, Massachusetts-based 3D printing company RIZE Inc. released its first industrial-grade desktop 3D printer, the Rize One, renowned for its safety, low emissions, and elimination of post-processing. Then, in 2018, the company introduced the first industrial desktop AM solution for manufacturing full-color functional parts, the XRIZE system, which I was lucky enough to test out at RAPID 2019. Today, it’s announcing a new kind of desktop 3D printer, the professional RIZE 2XC, an adaptive system that was developed collaboratively with South Korean 3D printer manufacturer Sindoh.

I spoke with RIZE CEO Andy Kalambi ahead of the release, who told me that even during the ongoing COVID-19 pandemic, the company has been “very productive.”

“It’s been an interesting time, but rewarding,” Kalambi said.

He said that the RIZE team speaks every morning during a check-in meeting, to make sure everyone is doing okay and see if anyone needs help with a project. Even during lockdowns across the US, the company has been busy, 3D printing personalized face shields that were distributed to hundreds of essential and healthcare works in the Boston area and working on the new 2XC.

“Entirely during COVID times, we developed this new printer with Sindoh,” he told me.

The RIZE 2XC was engineered from home offices, and, according to a RIZE press release, is a testament “to the safety principles embodied in RIZE’s solutions – principles that are especially relevant today as organizations reinvent workflows for a return to office locations.” The business supply chain needs to be even more flexible now due to COVID, and RIZE says its new printer can help. The 2XC can be used at home – no need to worry about germs spreading from lack of social distancing – and in offices and classrooms, with no fear of releasing harmful airborne volatile organic compounds (VOCs).

“The newer, higher performance, safe materials from next-gen FFF players such as RIZE are helping to drive a transformation in the 3D printing sector that are particularly relevant now as the world emerges from a pandemic. The durability and safety advantage that’s possible from next-generation 3D printing systems merits the attention of any engineering or design team that wants to give their users the best, and safest, tools,” Tim Greene, research director, 3D printing, for IDC said in the release.

The adaptive printer is the first deliverable to come from the RIZIUM Alliance, which is a new collaboration between RIZE and industry partners, like Sindoh, to drive safer, more sustainable 3D printing. The RIZE 2XC was made with a redesigned Sindoh dual-extrusion 3D printer, which can run engineering-grade RIZIUM materials that are moisture-resistant, recyclable, and zero emission.

RIZIUM One material

“We based our material on safety – it’s engineered for safety, durability, and strength,” Kalambi told me. “They’re medical grade, and especially in today’s context, things like sanitizing and being able to wash it with alcohol or acetone is important. Materials science is our differentiating factor.”

Kalambi told me that the ‘C’ in the company’s new 2XC printer stands for ‘composite,’ since RIZE takes a “material-led approach.”

“What we have done now is taken our material portfolio and partnered with industrial players, so we can offer it to a broader market of users.”

Sindoh is applying the innovative RIZIUM materials, engineered for user health, so that customers in various sectors on its platform can use a safe, sustainable material at a lower price.

“With Sindoh, we’re working with the same materials,” Kalambi explained. “We have done lots of engineering efforts with them to get the printer ready for our materials, worked on nozzles and the drive train and the slicer, all of that, and made the printer far more robust. It’s a printer that is a joint product. It’s a new hybrid platform, releasing a set of products with Sindoh that’s based on our polymers and materials science.”

The two independent extruders on the RIZE 2XC are designed for composite filaments and hardened materials. One extruder runs RIZIUM polymers and composites, which can be washed with just soap and water, while the other runs the unique RIZIUM Support, created by RIZE specifically for filament-based extrusion 3D printers. All in all, RIZE says that its new printer offers a safe way to fabricate durable, strong, functional components, without any unnecessary post-processing.

“The RIZE 2XC is especially well-suited for a variety of Industrial and Academic applications,” Ricco Busk, Director at RIZE partner CADSYS, stated. “Given the high demand for having 3D Composite Parts, we are able to, almost immediately, sign up a customer for the RIZE 2XC to use in their innovative plastic molding applications, such as robotic grippers. Combining RIZE’s material advantage in the high quality, easy to use 2XC 3D platform opens doors to new markets for 3D printing that need precision parts made safely and sustainably.”

Kalambi told me that the RIZE 2XC has plenty of great features, such as a heated build plate, a camera for monitoring prints, and automatic bed leveling. Because the company’s Augmented Polymer Deposition (APD) platform has not been added, the system does not print in color, but he said that it does have “a much bigger build volume” in comparison to other desktop printers.

“It’s great for home and office use, as those industries wanted a good printer within a certain price point,” Kalambi explained. “Lots of 3D printing is being done in schools and offices, which is why we partnered with Sindoh…they have lots of knowledge in the education field. That industry had a requirement for a low-cost printer, and RIZE wanted to be able to offer a more affordable option.”

Kalambi also said that the RIZE 2XC is great for 3D printing industrial parts.

According to the RIZE release, this new printer is the first that has brought “safe, sustainable 3D printing” to the industry’s compact sub-$5k market, which can help organizations struggling to get back on their feet in a post-pandemic world get a leg up over the competition.

“Sindoh’s cooperative R&D effort with RIZE showed us that we chose the right partner indeed – a partner as committed to innovation in materials and technologies as we are. We’re delighted to expand our reach into more segments of the market through the cooperative solutions we are creating with RIZE,” said BB Lee, CEO, 3D Printing Division at Sindoh Co., Ltd.

The RIZE 2XC will be available from RIZE’s network of channel partners starting June 30th, for an introductory price of $3,995 in the US market and €3,995 in Europe. In the meantime, I’ll be keeping my ear to the ground, because Kalambi said RIZE will have some more exciting news to share with us in mid-July.

The post RIZE Introduces Adaptive 2XC Desktop 3D Printer for Offices, Schools, and Homes appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

MITRE and Lithoz Advance Marine Transducers with 3D Printing

A variety of transducers have been created via 3D printing, often driven by piezoelectric vibration and other features for innovations like cancer-measuring devices, parts for photo-acoustic systems, and 3D printing process monitoring. Now, an industry partnership between MITRE, MSI Transducers Corp., and Lithoz-America has been established to create a 3D-printed model for further development of transducers in specific applications.

Transducers are used in many different applications today, meant to serve as efficient converters of one element or measurement like light or pressure into an electrical signal. These devices are similar to sensors except that instead of reacting to a change in the environment, transducers are responsible for translating energy from one type to another. Used in many industries—from automotive to energy to medical—they may also be used in marine applications as aquatic transducers.

The three partners came together (through MITRE’s Bridging Innovation program) as there was a need for printing of piezoelectric material on MITRE’s end. As MITRE lacked the equipment or expertise to complete upcoming and specific development for underwater aquatic transducers, the partnership will yield knowledge from MSI in terms of piezoelectric material processing, as well as packaging, and testing of the products. Lithoz brings forth AM hardware, along with material development expertise for 3D printing piezoelectric materials and geometries.

Dealing with an underwater environment can be challenging in any case, and previously it has often only been possible to power transducers with batteries, employing systems that are not as efficient or sensitive as needed. With the use of piezocomposites, however, there is a much better transfer of energy.

From the MSI website, including image: “MSI has designed transducers to withstand the most severe environments normally encountered in industrial applications, including temperatures ranging from -40°C to >150°C and pressures up to 25,000psi (170MPa). Frequencies can range from 25kHz to over 1MHz. In addition, MSI can produce large line and area arrays or roller transducer arrays for scanning large areas of industrial materials at high speed.”

While so far, there have been commercial restraints for the creation of such structures, the partners plan to use additive manufacturing processes for greater flexibility in production. In fact, here they will be using one of the greatest benefits of 3D printing as they are able to branch out and manufacture improved prototypes and products.

With the ambition to create “novel-shaped transducers with augmented properties,” the team expects to evolve far beyond the limitations of the technology typically used in the past; for example, they expect to increase sensitivity with materials through 3D printing, creating necessary structures that can be designed easily as well as changed on demand and then re-printed quickly.

Working as a group, they are able to cut out waiting periods usually required as other parties must go back and reproduce items that have been changed due to design flaws or lack of desired functionality. Overall, greater affordability, faster turnaround in production, and higher performance can be achieved—along with printing components and devices that are lighter in weight but stronger in many cases.

3D printers at Lithoz (Image: Lithoz)

And while they are still seeking a ‘benchmark material,’ in 2019 the partners successfully designed, printed, and tested their first round of samples. They report that material and piezoelectric evaluations showed better quality than with traditional methods and consider such results to be a ‘major project milestone.’ This year they will begin to focus on designing and testing new and complex shapes and structures for improved performance in aquatic environments. The partners are also reporting on their research and success to Navy sponsors.

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: The Mitre Corporation]

The post MITRE and Lithoz Advance Marine Transducers with 3D Printing appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

3D Printing News Briefs, June 10, 2020: 3D Systems, nTopology, Jellypipe

We’re discussing an upcoming event and some business news in today’s 3D Printing News Briefs. 3D Systems is holding a virtual trade show next month. nTopology and Yamaichi have signed an agreement, and a 3D printing platform has announced the onboarding of Europe’s largest purchasing and marketing association for industrial B2B.

3D Systems Holding Virtual Trade Show

On Wednesday, July 8, 2020, 3D Systems will be holding an exclusive virtual trade show centered on helping manufacturers keep their competitive advantage by using digital manufacturing solutions to fix supply chain dependencies, streamline supplier distribution, reduce supply interruptions, and lower risk. By integrating both additive and subtractive technologies into the environment, businesses can improve their productivity and agility, and offer customers new innovations. 3D Systems’ own Phil Schultz, Executive Vice President, Operations, and Radhika Krishnan, Executive Vice President and General Manager – Software, will give the keynote address for the event.

“Phil Schultz and Radhika Krishnan outline the essence of agile manufacturing, explaining in practical terms how to transform your environment to deliver a digital end-to-end manufacturing workflow that is fit for today and perfect for tomorrow.”

The event will kick off at 9:30 am EST and, in addition to the keynote, will include live webinar presentations and a virtual exhibit hall. Register here. If you’re unavailable to attend on the day of, the virtual trade show will be available on demand for the 30 days following the event.

nTopology and Yamaichi Sign MoU

Software startup nTopology has signed a Memorandum of Understanding (MoU) with Yamaichi Special Steel (YSS) to bring its next-generation nTop software platform to Japan. YSS is part of the automotive and heavy industry manufacturing supply chain in Japan, and its additive division promotes 3D printing and DfAM in the aerospace, automotive, and medical industries. The two have set up a reseller and service agreement, where YSS will bring nTop to its Japanese customers, providing support and training to users. Then, the Cognitive Additive solution of YSS will be connected to the nTop platform, to help users predict cost and printability.

To kick off the partnership, the YSS Additive Manufacturing team used topology optimization to redesign a brake caliper. As the part is used in a high temperature and fatigue environment, YSS designed a TPMS-based heat exchanger for the caliper, and also added an oil circuit and shielding surfaces. The brake caliper was 3D printed out of aluminum alloy AlSi10 using laser powder bed fusion (L-PBF) technology.

Jellypipe Onboards PVH Future LAB and E/D/E

German 3D printing platform Jellypipe uses its Jellypipe Eco-system to help companies take their 3D business to the next level, and features a comprehensive marketplace and the largest 3D printing factory in the D-A-CH region. Now, it’s announced the onboarding of PVH Future LAB, an innovation platform for technology-driven business models, and Einkaufsbüro Deutscher Eisenhändler GmbH (E/D/E), which drives PVH and is the largest purchasing and marketing association for industrial B2B in Europe. Both will now connect to the Jellypipe Eco-system.

“With Jellypipe’s 3D ecosystem – the connection with 3D specialists and our partners is a most important step in the digital automation and supply of 3D printed parts,” said Thilo Brocksch and Frederik Diergarten, both General Managers at PVH FUTURE LAB GmbH. “We can now offer our customers a new and wide process range for 3D printed products.”

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

The post 3D Printing News Briefs, June 10, 2020: 3D Systems, nTopology, Jellypipe appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

Axial3D & Fast Radius Offer DICOM-to-Print Anatomical Model 3D Printing Service for Surgical Planning

We’re still in the midst of the COVID-19 pandemic, but it seems like there’s at least a small light at the end of the tunnel as businesses and services begin to open their doors once again. This is also a pretty important time for hospitals right now, since they are starting to perform surgical procedures again. Obviously, the crisis has created a pretty big surgery backlog, which is why Fast Radius and Axial3D are teaming up to create better 3D-printed anatomical models for surgical planning.

When it comes to surgery, using 3D printing in the pre-planning process has been proven time and again to be of tremendous value, as it can help save on costs, as well as decrease the amount of time a patient is on the operating table. It can help make the process more efficient, and the surgeon more confident, especially when dealing with complex cases.

3D printed anatomical heart model. (Image credit: Materialise)

By using 3D technologies in surgical planning, clinicians can enjoy a higher standard of medical imaging, which enables them to have more insight into the unique anatomical details of different patients. Before they’re anywhere close to the operating room, the surgeons can hold 3D-printed anatomical models in their own two hands and take a much closer look at what they’ll be dealing with. Not only does this allow them to better define, and even practice, surgeries ahead of time, but patients can also handle the models in order to gain a better understanding of what’s going on in their bodies.

“The partnership between Fast Radius and Axial3D comes at a critical time for healthcare institutions. We are now able to support surgeons and hospitals in the US minimize the impact of COVID 19 as they endeavor to return elective surgery capacity,” explained Roger Johnston, the CEO at Axial3D.

Belfast-based healthcare technology firm Axial3D is focused on the global adoption of 3D printing in the healthcare industry, and its patient-specific 3D-printed medical models are award-winning. By partnering with Chicago-headquartered digital manufacturing solutions provider Fast Radius, clinicians all across North America will be able to make much more precise surgical plans than what 2D imaging can offer, according to the partners.

(Image credit: Axial3D)

Together, the two companies have developed what they consider a high-volume, high-quality DICOM-to-print service that will allow hospitals and surgeons in Canada, Mexico, and the United States to fabricate patient-specific 3D anatomical models, at high speeds, with an accuracy of micro-millimeters. They’ll use patient 2D scans to create the models, and once they’re 3D printed, they will be shipped to the hospitals within a minimum of 48 hours. How’s that for service?

“Our mission at Fast Radius is to help companies make new things possible that advance the human condition. Partnering with Axial3D to make these surgical models will have a great impact on patient care. It’s work we’re proud to do,” said Lou Rassey, the CEO at Fast Radius.

What do you think? Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

The post Axial3D & Fast Radius Offer DICOM-to-Print Anatomical Model 3D Printing Service for Surgical Planning appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

3D Printing News Briefs May 31, 2020: M. Holland, Nexa3D, Formlabs

We’re sharing materials and business news with you in today’s 3D Printing News Briefs. First up, M. Holland is distributing Braskem polypropylene filament, and Nexa3D has launched a new high-performance polymer material, in addition to partnering with 3DZ. Finally, Formlabs is expanding its APAC management teams.

M. Holland Distributing Braskem’s Polypropylene

Thermoplastic resins distributor M. Holland Company is partnering with Braskem to exclusively distribute the petrochemical company’s new high-performance 3D printing polypropylene (PP) filament, enhancing its own material offerings in order to better support clients with applications development and prototype creation. Polypropylene typically has high failure rates with 3D printing, so M. Holland’s AM engineers tested out Braskem’s PP material first, and found that it generates clean surfaces, great layer adhesion, and better surface performance in support material. It features a proprietary formula, which allows users to achieve low warpage, consistent extrusion, and high stability, in addition to less stringing and more repeatable outcomes.

“The 3D printing market has seen increased adoption of additive manufacturing technologies and applications due to machinery commoditization and expanded material offerings. Our partnership to distribute Braskem’s 3D printing polypropylene products will enable injection molders to finally use genuinely 3D printable and easy-to-use polypropylene, opening up a world of applications,” said Haleyanne Freedman, Market Manager, 3D Printing at M. Holland.

Nexa3D Launches High-Performance xCE-Black Polymer

Belt pulleys 3D printed on NXE400 with xCE-Black

This week, stereolithography 3D printer manufacturer Nexa3D launched its new high-performance polymer material, xCE-Black, which is meant for high-speed printing of injection molding tools, heavy duty parts, and end-use plastic components, such as belt pulleys. Extensive testing by the company found that the single cure polymer exhibits long-term environmental stability and great isotropic properties, which makes it perfect for electronics, industrial, and automotive applications. xCE-BLack also has excellent thermal stability and higher flexural strength.

Brent Zollinger, Customer Success Lead at Nexa3D, stated, “When I needed to produce thousands of belt pulleys in our flexible factory overnight, I selected our new xCE-Black material for the job because of its high flexural strength and long-term stability. Within the first 2.5 hours into the project, I was able to print 2,000 pulleys in a single build or 13 parts every minute. That’s really fast and extremely practical for serial production of industrial parts.”

Nexa3D Announces Reseller Partnership with 3DZ

More news today from Nexa3D, as the company is entering the southern European 3D printing market thanks to a new reseller partnership with 3DZ Group, the largest AM value-added reseller in that region and an authorized dealer of 3D printers and scanners for some of the industry’s biggest names, including Artec 3D, Formlabs, HP, Markforged, Materialise, and 3D Systems. 3DZ has offered AM services and consultancy to the industry for several years, and will be able to help grow Nexa3D’s global reseller network so the company can increase the distribution of its flagship NXE400 3D printer.

“It is full speed ahead for us at Nexa3D as we continue to expand our global reseller network, and we’re honored to partner with a company with the vision, reach and proven performance of 3DZ. Manufacturers are adapting processes to become much more agile in their design and resilient in their supply chain in the face of changing circumstances. We believe that our products are at the heart of enabling customers to make that adjustment by converting current 3D printing speeds from dialup internet to broadband-like productivity,” said Avi Reichental, the Executive Chairman and CEO of Nexa3D. “We’re very excited to build together with 3DZ the future of design agility and supply chain resiliency for the benefit of our mutual customers.”

Formlabs Expanding APAC Management Teams

L-R: Jiadong Sun, Yoshinori Hasebe

This week, Formlabs announced that it is expanding its management team for the Asia-Pacific (APAC) region by appointing two new hires, in order to continue growing its global operations and scale its growth in these markets. Jiadong Sun, with broad experience leading global sales and marketing at top tech companies across several industries, will be joining the team as the China General Manager, while Yoshinori Hasebe, who brings over 20 years of management experience at multinational companies to the table, will serve as the Japan General Manager. Together, they will help guide the company’s business strategy in these new markets, so that Formlabs users in the APAC region can continue to localize manufacturing and reduce costs and lead times with 3D printing and rapid iteration.

“As Formlabs continues to expand our global operations, Jiadong and Yoshinori will provide strategic guidance as we expand and scale in the important APAC region. These appointments will enable Formlabs to remain at the forefront of 3D printing as needs for additive manufacturing in major industries, including healthcare, continue to grow,” said Luke Winston, Chief Business Officer of Formlabs.

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

The post 3D Printing News Briefs May 31, 2020: M. Holland, Nexa3D, Formlabs appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

3D Printing News Briefs, May 18, 2020: Fraunhofer, Formnext, Visagio & DiManEx, BCN3D Technologies

In today’s 3D Printing News Briefs, Fraunhofer will soon discuss adoption of Industry 4.0-related technologies in a webinar, and we’ve learned that Formnext 2020 is still planned for this November. Moving on, Visagio and DiManEx have announced a partnership. Finally, BCN3D’s technology was used to make an interesting event installation.

Fraunhofer’s Industry 4.0 Webinar

Tomorrow, May 19th, the Fraunhofer Project Center (FPC) at the University of Twente will be holding a free webinar called “The Road to Digitalisation” that explains some of the challenges in adopting technologies related to Industry 4.0, such as 3D printing, as well as the solutions. Industry 4.0 is about optimization, and can offer companies many benefits, such as increased revenue, better quality, and reduced cycle times and costs. But, it can be a tough journey to start, and companies looking to start could use some help.

“Industry 4.0 is all about optimization; from managing big data to efficiency in the production line. All this aims at enabling businesses to make quicker, smarter decisions while minimizing costs. This webinar sets out to explain the challenges and to offer solutions in the adoption of I4.0 related technologies.”

The webinar, featuring Join Biba Visnjicki, Managing Director of FPC, and Thomas Vollmer, Head of Production Quality Dept. from Fraunhofer IPT, will last 60 minutes; register for free here.

Formnext 2020 Still a Go in Frankfurt

As many places in the world are cautiously reopening after recent mass shutdowns due to the COVID-19 pandemic, we need to look to the future. In that vein, Mesago Messe Frankfurt GmbH is still planning to hold the AM industry’s biggest event, formnext 2020, this November 10-13. Recently, the Federal Government and the Federal States of Germany ruled that trade shows are no longer under the ‘major events’ category for health risks, but the health of all the employees, exhibitors, and visitors are still considered the highest priority if the event does indeed take place this fall. That’s why the exhibition organizer is working around the clock to develop an updated health concept, such as introducing contact tracing and decreasing visitor density, along with a supplementary digital/virtual program.

“We remain convinced of the unique value and advantages of a physical exhibition. And although digital interaction will never be able to replace face-to-face contact, it does offer more scope than previously thought possible only a few weeks ago,” stated Sascha F. Wenzler, Vice President of Formnext, Mesago Messe Frankfurt GmbH.

“Ultimately, even in these challenging times, we want to organize a trade show that is as responsive as possible to the current situation and the needs of participants and the market.”

Visagio and DiManEx Partnering to Improve AM Supply Chains

(Image: DiManEx)

Management consultancy Visagio Ltd and DiManEx BV are partnering to strengthen end-to-end 3D printing usage in supply chains. Companies are looking to conquer supply base disruptions, and by pairing Visagio’s supply chain services with DiManEx’s end-to-end 3D printing platform, they can do so by digitizing their inventory and 3D printing parts on demand, which can delivered all over the world. The collaboration is a representation of how both companies address market needs, especially in these challenging times as COVID-19 disrupts the global supply and demand process.

“Companies are increasingly looking for ways to optimize their supply chains and mitigate risks, such as those brought about by pandemics or geo-political tensions. Our platform embeds 3D printing in supply chains easily, realising the concept of ‘Digital Inventory at your Fingertips, Ordered at a Click of a Button’. Coupled with Visagio’s industry and management expertise, this is a winning combination for supply chain optimization,” said Tibor van Melsem Kocsis, the Founder and CEO of DiManEx.

3D Printed Cisco Live 2020 Installation

Thanks to 3D printing, it was possible to quickly iterate not only the main design, but also all the smaller parts of the internal mechanisms.

Speaking of collaborations, Barcelona data interpretation firm and design studio Domestic Data Streamers pairs data and arts with storytelling to develop “participatory projects” for community building and education. Its workshop has long used 3D printers from BCN3D Technologies, and recently turned to the technology again to create an installation for the Cisco Live 2020 event. The studio wanted to give attendees “a better experience” by displaying the event schedule on an interactive Recommendation Wall of clickable screens; once clicked, the animated image turned into a QR code, which visitors could scan for more information. The screens had to be custom-made, and so Domestic Data Streamers turned to its in-house printer farm, and the BCN3D Epsilon 3D printer. They used PETG to print over 40 of the main covers in just four weeks, which equaled major cost savings.

“The printers work very well, we count on a very high success ratio, and the support from the team is always quick and helpful,” said Pol Trias, the Head of Design at Domestic Data Streamers.

“It gave us great agility when it comes to functionally and aesthetically validating the designs at a very low cost…our processes were more efficient and much faster thanks to our BCN3D Epsilon.

“This could not have happened without 3D printing. For a project like this one, where you want high-quality results in a short time and within a limited budget, there is no better option than 3D printing.”

You can learn more about the project here, or check out the video below.

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

The post 3D Printing News Briefs, May 18, 2020: Fraunhofer, Formnext, Visagio & DiManEx, BCN3D Technologies appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

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)

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

The post POLYLINE Project: Developing Digital Production Line for 3D Printing Spare & Series Automotive Parts appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

AMT & Leering Hengelo: PostProDP Range of Automated Depowdering Systems for 3D Printing

In 2017, UK-based Additive Manufacturing Technologies Ltd (AMT) first introduced its automated AM post-processing solution, PostPro3D, to the industry, and officially released the system a year later. Following up with the smaller PostPro3D Mini and the medical-grade PostPro3D Pro, the growing company is now partnering with blasting equipment producer Leering Hengelo to launch two new automated depowdering systems for 3D printing – the PostProDP and the PostProDP Pro.

AMT’s safe, sustainable, and fully automated post-processing solutions allow for industrial production of 3D printed parts at scale. The patent-pending PostPro3D technology is based on the company’s proprietary BLAST process (Boundary Layer Automated Smoothing Technology), and helps decrease manufacturing and operation costs and lead time. This is a big deal, since up to 60% of the manufacturing costs for 3D printed parts come from lengthy manual post-processing and depowdering methods.

The new PostProDP range was designed especially for the 3D printing industry, and is AM material-agnostic, so it works with all powder-based 3D printing, such as EOS, HP, and 3D Systems, and several thermoplastic polymers, like elastomeric materials and polyamides. The two depowdering machines are CE and ATEX certified, ensuring what AMT refers to as “a standalone high throughput industrial de-powdering solution.”

“AMT’s vision is to develop fully automated safe and sustainable post-processing solutions to enable the industrial production of additively manufactured parts at scale. We first achieved this with the successful commercialization of the PostPro3D vapor smoothing system. De-powdering is the next key bottleneck in the post processing chain, and PostProDP goes a long way to mitigate many of the current issues with cleaning AM parts,” stated AMT’s CEO Joseph Crabtree in a press release. “We are delighted to be partnering with industry experts Leering on this industry critical mission.”

Dutch company Leering makes blasting equipment, such as blast cabinets, abrasives, and mobile blastrooms and blastunits, for the metal and plastics processing industry.

“Leering are experts in surface finishing with 80 years of experience in machine design and production for surface treatment. We export our machines, branded Normfinish, worldwide,” said André Gaalman, the CEO of Leering. “The partnership with AMT will allow us to strengthen each other’s positions in additive manufacturing and offer our joint customers globally the best solution for their post-processing needs. We’re excited to offer our customers each other’s solutions and bring a next generation of post-processing solutions to the market.”

The unique plug and play PostProDP systems come with a PLC controller that’s pre-loaded with recipes for common material combinations, and include a removable, adjustable tumble basket inside for optimized part cleaning. The basket also helps decrease the amount of fine particulate powder leakage after processing, and ionizing nozzles ensure that the parts are totally powder-free after blasting.

The range complements AMT’s current range of PostPro3D vapor smoothing systems, and the overall design configuration of the PostProDP machines make the user experience safer and more efficient. Both the PostProDP and PostProDP Pro take just ten minutes to remove the powder without damaging your 3D printed parts, and can be run with multiple medias, including steel balls. The compact PostProDP features two large entrance doors with safety sensors, splash glass, and automatic filter cleaning cartridge filters, while the PostProDP Pro has a removable nozzle holder and the option for manual blasting through a side door. Both come with a 12-month warranty.

The PostProDP range has been tested with customers across the US and Europe, and are now available to order from AMT.

The post AMT & Leering Hengelo: PostProDP Range of Automated Depowdering Systems for 3D Printing appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

Titomic Signs Agreement with Airbus to Make 3D Printed Metal Demonstrator Parts

Global aerospace leader Airbus develops, creates, and delivers innovative solutions in the commercial aircraft, defense, helicopter, space, and security sectors, and has long been a champion of using additive manufacturing to do so. Airbus installed its first 3D printer back in 2012, and used its first metal 3D printed part – a titanium bracket – in one of its commercial jetliners just two years later. Now, over 1,000 3D printed parts are used in its A350 XWB aircraft.

In order to deliver 3D printed aerospace solutions, the European aircraft manufacturing giant has partnered up with many big names in the industry, from Local Motors and Materialise to Premium AEROTEC and GE Aviation, and just today announced a new collaboration. Australian large-scale, industrial AM company Titomic has just reached a major agreement with Airbus, which will use the Melbourne company’s patented Titomic Kinetic Fusion (TKF) technology to demonstrate high-performance metal parts.

“We are pleased to partner with Airbus for this initial aerospace part made with Titomic Kinetic Fusion® (TKF), the world’s largest and fastest industrial-scale metal additive manufacturing process,” stated Titomic CEO Jeff Lang in a press release. “The TKF process ideally suited to produce near-net shape metal parts for the aerospace industry using our patented process of fusing dissimilar metals that cannot be produced with either traditional fabrication methods or metal-based 3D printers.”

TKF is the result of a Commonwealth Scientific and Industrial Research Organisation (CSIRO) study, when Australia’s government was looking to capitalize on its titanium resources. Titomic’s proprietary TKF technology platform uses a process similar to cold spray, and has no limits in terms of build shape and size. A 6-axis robot arm sprays titanium powder particles, at supersonic speeds, onto a scaffold in order to build up complex parts layer by layer.

Thanks to its unique AM technology, Titomic can provide its customers with production run capabilities, which helps rapidly create excellent products, with decreased material waste, that have lower production inputs.

“3D printing, of which TFK is the leading technology, has the potential to be a game changer post the global COVID-19 pandemic supply chain disruption as aircraft manufacturers look to reduce production costs, increase performance, improve supply chain flexibility and reduce inventory costs, and TKF, co-developed with the CSIRO, can be an integral part of this change,” said Lang.

“Regulations force aerospace manufacturers to provide spare parts for long periods after the sale of an aircraft, so it’s not rocket science to assume they will be early adopters of 3D printing solutions for spare-part management.”

The Titomic Kinetic Fusion process involves a 6-axis robot arm spraying titanium powder particles onto a scaffold at supersonic speeds.

TKF technology could be crucially important for aircraft manufacturers, like Airbus, as the field of aviation is one of the largest customers of titanium alloy products. That’s why Titomic has invested in further developing AM so it can meet the material, process, and design qualification system that’s required by the European Aviation Safety Agency (EASA) and the US Federal Aviation Administration (FAA). The company will work to develop TKF 3D printing material properties and parts process parameters for Airbus.

This agreement, the future delivery of the 3D printed demonstrator parts to Airbus, and a technology review process of said parts, all validate the certification process that Titomic’s government-funded IMCRC research project, with partners RMIT and CSIRO, is currently undergoing.

Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below. 

The post Titomic Signs Agreement with Airbus to Make 3D Printed Metal Demonstrator Parts appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Posted on

Additive Industries & ArcelorMittal Using MetalFAB1 3D Printer to Make Spare Steel Parts

One of the world’s leading steel and mining companies, ArcelorMittal, is partnering with Dutch company Additive Industries to investigate the use of metal 3D printing to make large spare parts for the steel industry. Additive manufacturing is used to fabricate spare parts for plenty of applications and industries, including maritime, railways, the military, consumer appliances, automotive, and many more. It makes a lot of practical business sense, as 3D printing spare parts offers companies, like ArcelorMittal, flexibility, a reduced production cycle, and on-demand manufacturing; if this happens onsite, it can even save on shipping costs.

3D printed spare parts used in ArcelorMittal facilities: (A) Example of part consolidation application with 316L original part on the left and 3D printed part on the right; (B) example of functional large parts with internal lattice structure made with 316L above 500 mm; and (C) lightweight (hollow) functional spare parts made with Maraging Steel with ArcelorMittal’s optimized parameters.

By collaborating with Additive Industries on metal 3D printing over the last few years, and using the technology to build on-demand spare parts, ArcelorMittal has improved its quality and process performance – allowing the company to print large, complex components that are ready to use.

“Additive Manufacturing is an exponential technology, moving very fast. Our collaboration with Additive Industries is a clear demonstration of our ability to remain at the cutting-edge of this technology: we started by printing small specimens and have now progressed to large size and complex parts,” said Jose López Fresno, Head of the Additive Manufacturing department, ArcelorMittal Global R&D in Avilés, Spain.

Operations in the steelmaking industry require components, and spare parts, that must hold up under difficult conditions. In the beginning of the ArcelorMittal and Additive Industries collaboration, they had to figure out how best to achieve the necessary requirements for component size and quality. But over the last two years of working together, the two have achieved an up to fourfold increase in component size, in addition to improving their reliability and quality. This means that the steel company has been able to increase the amount of applications for its 3D printed spare parts from small size part consolidation to jobs that need complex, functional, large, and strong parts.

MetalFab1 on the day of installation in ArcelorMittal R&D facilities in Avilés.

Now, the two are looking at what metal 3D printing can do for the steel industry with the MetalFAB1 by Additive Industries, which is one of the market’s largest 4-laser metal AM systems.

“Innovation and market leader ArcelorMittal have helped us to stress-test our MetalFAB1 system for critical spare-part production,” stated Daan A.J. Kersten, Co-Founder and CEO Additive Industries. “This enabled us to expand our experience to the steel industry from our main application markets in aerospace and automotive. It has become clear that metal 3D printing is a serious alternative for a large variety of cast parts.”

First introduced back in 2015, the unique MetalFAB1 printer has a 420 x 420 x 400 mm build volume, which makes it possible to fabricate large steel spare parts for the mining and steelmaking industries. But at the same time, it also ensures high productivity because it automated the manual steps of regular powder bed fusion 3D printers; this, in turn, equals the lowest cost per 3D printed part.

The modular MetalFAB1 has multiple build chambers, up to four 500W lasers, and can be configured for up to 11 different modules for more productivity or post-processing automation. It’s also well-designed for safety, which is perfect for ArcelorMittal and its focus on operator safety. In addition, 3D printing spare parts can help reduce waste – meeting another of the company’s objectives in terms of environmental safety.

“We are proud to work together with ArcelorMittal, jointly driving the business case for 3D-printed parts in the steel industry,” said Harry Kleijnen, Key Account Manager for Additive Industries. “ArcelorMittal’s typical applications have enabled us to further adapt the MetalFAB1 system to print high density, high volume parts. We are looking forward to expanding the range of applications and materials in this intense and strong collaboration.”

Since the first MetalFAB1 3D printer was installed at ArcelorMittal’s R&D facilities, the company has already used several of the 3D printed spare parts. To see the assembly and installation of the MetalFAB1 at ArcelorMittal, check out Additive Industries’ video here.

Discuss this story and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

(Source/Images: Additive Industries)

The post Additive Industries & ArcelorMittal Using MetalFAB1 3D Printer to Make Spare Steel Parts appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.