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3D Printing News Briefs: October 27, 2018

We’re starting off with some news about products being displayed at the upcoming formnext in today’s 3D Printing News Briefs, and then moving on to business and research news. Clariant and Xaar have both revealed what they will be showcasing at formnext 2018 in Munich next month. Aurora Metals has announced a new partnership, while Lockheed Martin is the first organization to have an additive manufacturing facility certified to UL 3400 for AM hazards. Finally, America Makes has announced its next Directed Project Opportunity.

Clariant Presenting Industrial 3D Printing Materials at formnext

This year’s formnext is coming up in just a few short weeks, and companies all over the world are announcing what products they’ll be bringing with them to the show. Specialty chemicals company Clariant will be showcasing its 3D printing materials and solutions for intelligent industrial manufacturing at the event this year, including featured materials like polyamides for small lot production, customer-tailored colorant and additive guidance, and high impact strength materials that offer electrostatic discharge protection for manufacturing aids.

“OEMs require that 3D printing materials perform at the same level as their injection molded counterparts. This was the significant factor in achieving the acceptance to allow product production with our materials and will continue to be,” said Joanna Marguier, Senior Manager of R&D for Clariant’s 3D printing business. “From the inception of our 3D printing business, Clariant has focused on providing superior 3D printing materials that achieve the customer’s requirements for their specific application. We work closely with them to tailor solutions to meet their needs.”

Marguier will also be outlining the company’s success with flame retardants in a technical presentation at formnext on November 15. formnext runs November 13-16, and you can visit the Clariant team at booth 3.1-H40 in Hall 3.1 at the Messe Frankfurt.

Xaar Showcasing Latest Inkjet Printhead Technology at formnext

Speaking of formnext, digital inkjet technology Xaar will be exhibiting the latest in inkjet printhead technology at the show. Visitors can learn how the company’s award-winning High Laydown (HL) technology, which allows for the jetting of 3D fluids with high viscosity (at least 55cP), coupled with its partnerships with other industry leaders, can help its customers get ahead in volume 3D printing. Xaar will also be displaying samples that were produced with high viscosity photoresins from BASF 3D Printing Solutions

“The formnext show is a major global event for the 3D Printing sector and we are excited to be exhibiting our complete printhead portfolio and HL Technology for volume 3D production. We pride ourselves on providing ongoing support to all our customers’ projects – from early fluid evaluation through to commercialisation. That’s why we are welcoming manufacturers and integrators to visit the Xaar stand and discover how our printhead technology can help them introduce new printers quickly and cost-effectively, thereby delivering a true competitive edge and real value to 3D end- users,” said Simon Kirk, Senior Product Manager at Xaar.

You can visit Xaar at formnext at booth A78 in Hall 3.1

Aurora Labs Partnering with Fortescue Metals Group

Aurora Labs’ managing director David Budge. [Image: Ross Swanborough]

Australian metal 3D printing Aurora Labs has signed a preliminary non-binding term sheet agreement with fellow Australian company Fortescue Metals Group. The agreement comprises an Industry Partner Program, and Aurora Labs will work with Fortescue to demonstrate the potential for application of its Rapid Manufacturing Technology (RMT) in the mining industry. The terms of the agreement are for an initial 12 months and may be extended by mutual agreement, and Aurora believes that the venture could even progress further to developing technology together in order to lower operation and production costs in the mining industry.

“We’re very excited to sign a preliminary agreement with Fortescue, and pursue the opportunity to apply Aurora’s Rapid Manufacturing Technology to the mining sector,” said David Budge, Aurora Labs’ Managing Director. “Fortescue are an ideal industry partner for us and they are at the forefront of technological advancements in the mining sector.”

Lockheed Martin Certified UL 3400

Top global safety science company UL has announced that it has certified the first additive manufacturing facility to UL 3400, a set of safety guidelines published last year that address the hazards associated with AM facilities. UL issued this prestigious certification to Lockheed Martin, and its 6,775-square-foot Additive Design and Manufacturing Center in Sunnyvale, California. UL 3400, also called the Outline of Investigation for Additive Manufacturing Facility Safety Management, considers the three layers of safety: material, equipment, and the facility itself, and references applicable standards from OSHA, ASTM International, the National Fire Protection Association, and others. UL and its 3400 guideline cover the potential hazards and risk mitigation measures that are required for these facilities to function safely.

“Employers, employees, local regulators as well as insurance companies who have to underwrite additive manufacturing facilities, were not fully aware of the inherent material and technology risks. Safety is designed rather than built. Not a single standard or statutory guideline was available that specifically focused on additive manufacturing. Other standards and guidelines were developed for conventional manufacturing processes,” explained Balu V. Nair, UL’s Additive Manufacturing Lead Development Engineer and an important player in developing UL 3400. “We decided to address this industry need by developing a set of guidelines with exclusive focus on additive manufacturing.”

America Makes Announces Next Directed Project Opportunity

This week, America Makes announced its next Directed Project Opportunity, available for its members for AM applied (R&D) projects for Advanced Tools for Rapid Qualification (ATRQ). The goal is to promote and accelerate the development and deployment of cost effective, energy-efficient 3D printing technologies in  order to meet defense and/or commercial needs. Approximately $3.9 million should be made available to fund multiple awards, with at least $1.95 million in matching funds from the winning project teams. The technical requirements of the ATRQ Directed Project Opportunity relate to the America Makes Technology Roadmap, as well as the Integrated DoD AM Roadmap.

“For our partners at the DoD, the anticipated outcomes of the America Makes ATRQ Directed Project Opportunity are of the utmost importance. The DoD’s need for rapid qualification and certification of AM processes and materials is great,” said Rob Gorham, the Executive Director of America Makes. “These projects will be instrumental in resolving the current deterrents that are hindering the wider adoption and deployment of AM technologies within the DoD and its supply chain.”

Technical topics for the ATRQ Directed Project Opportunity are Surrogate Damage Generation for LPBF Defects, Degradation of Polymer Parts Deployed in Harsh Environments, and Corrosion Mechanisms of LPBF Materials. All Project Concept forms are due no later than 5 pm EST on Wednesday, November 28, 2018. To see all of the technical project requirements, as well as other information about the Directed Project Opportunity like non-disclosure agreements, eligibility, and the proposal process, check out the America Makes website.

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Customers Customizing Their Own 3D Printed Razor Handles with Gillette’s New Razor Maker Platform

Everywhere you look, there’s customization and personalization in the products we use daily – we consumers definitely like the items we use to reflect our preferences and personal tastes. And in today’s world of advanced manufacturing, it’s easier than ever to connect everyday products with personalized experiences to form bonds with customers…and get us to buy things, of course. Now, razor manufacturer Gillette is turning to 3D printing again, this time to pilot its new Razor Maker concept and open up consumer personalization with 3D printed razor handles.

The new platform is a great example of direct-to-consumer, end-use 3D printed parts, as Razor Maker is giving consumers the power to create and order their own customized razor handles. Fabricated on Form 2 3D printers, there are 48 different designs to choose from, with more coming later, along with a variety of colors; there’s even an option to add custom text to your razor handle.

Donato Diez, global brand manager for Gillette and Razor Maker co-founder, said, “Our partnership with Formlabs, and the power of their 3D printers, enable consumers to have a say on how their razors should look. We are excited to work with our Boston neighbors to pilot this breakthrough concept of customization.

“For Gillette, piloting Razor Maker represents a crucial step in our customization journey where new technology and new business models must come together in order to deliver products that are as unique as our consumers.”

Gillette’s Razor Maker concept brings design freedom to the final product in a new business model that could change how companies work across the whole product lifecycle. This is more than just a 3D printed razor handle, my friends – it’s a look at the future of mass-customized products.

Evan Smith, global product manager for Razor Maker, said, “We know consumers today are looking for brands that innovate in ways that let them express themselves – and that’s exactly what this pilot is all about.”

Razor Maker had to totally rethink its approach to manufacturing in order to deliver such customization. So back to the 3D printed razor handle itself – the first process steps are totally digital. First, the customer customizes their own unique handle through the platform’s website. Next, the final design is converted into a 3D file by Razor Maker.

Then, multiple design files are sent to a Form 2 3D printer to be printed at the same time in one batch. Once the handles are done printing, they’re washed, post-cured, coated, and assembled, before they’re shipped right to the customer’s door in 2-3 weeks.

“The Razor Maker concept allows us to create a new design, print and test it, and then the next day that design becomes a new handle available on the website. That was never possible before,” said Rob Johnson, a design engineer and Razor Maker co-founder.

The designers of some of the original Razor Maker handles were inspired by many of the geometries and shapes often seen in architecture, nature, and even technology, but would be tough to reproduce through conventional methods of manufacturing.

“It allows us to think about form in a way that was never possible before. In a traditional sense, we could only do one or two razor designs a year, whereas now we can have an idea, create it in 3D, print it, look at it, adjust it, and say that’s it,” said Rory McGarry, industrial design lead at Razor Maker.

Easy customization like this is one of the hallmarks of 3D printing, which Gillette previously only used for prototyping purposes. No tooling is required, there’s no up-front investment in molds, and the costs of having to produce several complex design iterations to find the optimal one are gone. It’s easy to scale custom manufacturing by just adding more 3D printers, and the lack of design constraints makes it easy for consumers to make razors that are entirely personalized – good news in a market where we see a lot of mass-produced stuff for sale.

Johnson said, “Combining our best shaving technology with the power and flexibility of 3D printing opens up a whole new world of product design possibilities.”

In addition to its new Razor Maker platform, Gillette is also working with Formlabs to possibly automate its 3D printing production processes. The company is one of the first testers of Form Cell, its relatively new automated production system.

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

[Source/Images: Formlabs]

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3D Printing News Briefs: October 13, 2018

We’ve got business and education news galore in today’s 3D Printing News Briefs. First, Voodoo Manufacturing has launched its new Shopify app, and BeAM Machines is partnering with Empa, while Sculpteo is working with a property developer to provide 3D printed apartment models. VSHAPER has signed an agreement with educational publisher Grupa MAC, and the United Arab Emirates is introducing 3D printing into over 200 of its primary schools. The US Navy will be testing the first 3D printed ship component, and Lufthansa Technik has established a new Additive Manufacturing Center. Finally, maker Thomas Sanladerer shared on YouTube about his recent visit to the Prusa headquarters.

Voodoo Manufacturing Launches Shopify App

This spring, high-volume 3D printing factory Voodoo Manufacturing began its full-stack manufacturing and fulfillment service for 3D printing entrepreneurs, which allows users to outsource work like quality control and assembly for their products through its easy shopfront integrations with online marketplaces like Shopify. Now, the company has launched its own Shopify app, which will allow online sellers to create and customize 3D printed products and sell them on their own Shopify stores. Once the app is installed, users can make their first product in less than 5 minutes, which is then automatically added to their store, ready for purchase.

“We wanted to make it ridiculously easy for ecommerce stores to diversify their product offering with 3D printed products. By applying 3D printing to the print-on-demand business model, we are opening up an infinite range of product categories for Shopify merchants,” said Max Friefeld, the Founder and CEO of Voodoo Manufacturing. “The Voodoo app provides a new source of high quality, customizable, on-demand products, that don’t require any 3D design experience.”

Before the official launch this week, Voodoo piloted the service with a group of beta users, including It’s The Island Life by graphic designer and Guam native Lucy Hutcheson. She is already successfully selling six different products made with the help of the new Voodoo app.

BeAM Machines Partnering with Empa

BeAM, recently acquired by AddUp, has signed a research and development agreement with Empa, the Swiss Federal Laboratories for Materials Science and Technology. Together, the two will develop novel applications for BeAM’s powder-based Directed Energy Deposition (DED) technology, which uses focused thermal energy to fuse materials by melting them while they’re deposited. This makes parts manufacturing much faster. The partnership has come on the heels of Empa’s acquisition of a BeAM DED 3D printer, which is located at its Laboratory for Advanced Materials Processing in Thun and is used to integrate and test out innovative components.

Patrik Hoffmann, who leads the laboratory, said, “We are very excited to collaborate with BeAM’s engineers to push the boundaries of this innovative additive manufacturing technology and to develop a whole new range of applications for Swiss industries and beyond.”

Sculpteo 3D Printing Apartment Models

Together with Sculpteo, French property developer Valoptim is working to improve customer experience by providing clients with miniaturized 3D printed models of their future apartments when they sign their contracts, so they can better visualize and prepare for moving into their new home. These small, exact replicas give new owners an immersive experience, which is a definite value add. In addition, production of the 3D printed models is local, and can be done fast.

“Sculpteo uses the best machines and 3D printing processes on the market today. At first, we had the ambition to test the feasibility of 3D printing in the real estate sector. This innovative process has proven to be extremely interesting: the realistic rendering, with high-end finishes, allowed our clients to discover a miniaturized version of their future apartment enabling them to realistically imagine themselves living in it,” said Edouard Pellerin, CEO of Valoptim. “This innovation contributes to our business dynamic: constantly improving the customer experience.”

VSHAPER and Grupa Mac Sign Agreement

Polish 3D printer manufacturer Verashape has signed an agreement with Grupa MAC, the country’s top educational publisher, in front of Poland’s education curators at the recent Future of Education Congress. Per the agreement, Grupa MAC will use a network of educational consultants to distribute the VSHAPER GO 3D printers to kindergartens and other schools in the country. Grupa MAC recognizes that 3D printers are a good way to quickly present the effects of students’ learning, and the VSHAPER GO is the perfect choice, as it is easy to use and comes with an intuitive interface of SOFTSHAPER software.

“Classes with students are a perfect environment for the use of 3D Printing. Creating a pyramid model for history lessons, the structure of a flower or a human body for biology lessons are just a few examples, and their list is limited only by the imagination of students and teachers,” said Patryk Tomczyk, a member of the Grupa MAC Management Board. “We are happy that thanks to our cooperation with VERASHAPE, 3D Printers have a chance to reach schools through our network of educational consultants.”

3D Printing to be Introduced in UAE Primary Schools

Speaking of 3D printing in education, the Ministry of Education (MoE) for the UAE has announced that in early 2019, a country-wide introduction of 3D printing into over 200 primary schools will commence. As part of this new technology roll out, Dubai education consultancy company Ibtikar is partnering with Makers Empire, an Australian education technology company, to deliver a program that implements 3D printing and design. Makers Empire will supply 3D software, curriculum, teacher resources, training, and support to Ibtikar, which will in turn train MoE teachers to deliver the program.

“Through this rollout of 3D technology, our students will learn to reframe needs as actionable statements and to create solutions to real-world problems,” said HE Eng. Abdul Rahman of the United Arab Emirates Ministry of Education. “In doing so, our students will develop an important growth mindset, the skills they need to make their world better and the essential ability to persist when encountering setbacks.”

US Navy Approves Test of First 3D Printed Shipboard Part

USS Harry S. Truman

The US military has long explored the use of 3D printing to lower costs and increase the availability of spare parts. Huntington Ingalls Industries, the largest military shipbuilder in the US, has also been piloting new technologies, like 3D printing, as part of its digital transformation. In collaboration with the US Navy, the company’s Newport News Shipbuilding division has worked to speed the adoption of 3D printed metal components for nuclear-powered warships. This has led to an exciting announcement by the Naval Sea Systems Command (NAVSEA): a metal drain strainer orifice (DSO) prototype has officially been approved as the first 3D printed metal part to be installed on a US Navy ship. The assembly is a component for the steam system, which allows for drainage and removal of water from a steam line while in use. The 3D printed DSO prototype will be installed on the USS Harry S. Truman in 2019 for evaluation and tests. After one year, the assembly will be removed for inspection and analysis.

“This install marks a significant advancement in the Navy’s ability to make parts on demand and combine NAVSEA’s strategic goal of on-time delivery of ships and submarines while maintaining a culture of affordability. By targeting CVN 75 [USS Harry S. Truman], this allows us to get test results faster, so-if successful-we can identify additional uses of additive manufacturing for the fleet,” said Rear Adm. Lorin Selby, NAVSEA Chief Engineer and Deputy Commander for Ship Design, Integration, and Naval Engineering.

Lufthansa Technik Opens New Additive Manufacturing Center

Lufthansa Technik, a leading provider of maintenance, repair and overhaul (MRO) for civil aircraft, has established a new Additive Manufacturing Center. The goal of the new AM Center is to bundle and expand the company’s experience and competence with the technology, which can be used to make individual parts more quickly and with more design freedom. As the world of aircraft is always aware of weight, making more lightweight parts is an excellent benefit of 3D printing.

“The new AM Center will serve as a collaborative hub where the experience and skills that Lufthansa Technik has gained in additive manufacturing can be bundled and further expanded,” said Dr. Aenne Koester, the head of the new AM Center. “The aim is to increase the degree of maturity of the technologies and to develop products that are suitable for production.”

Tom’s 3D Visits Prusa Headquarters 

Maker Thomas Sanladerer, who runs his own YouTube channel, recently had the chance to tour the Prusa Research headquarters in Prague. Not only did he get the opportunity to see how the company makes its popular MK3 and and MK2.5, but Sanladerer was also able to see early models of the company’s recently announced SL1 resin 3D printer, as well as the Prusament filament production line.

“I always find factory tours like this super interesting because it’s the only chance you really get of seeing behind the scenes of what might really just be a website, or you know, a marketing video or whatever,” Sanladerer said in his video.

Sanladerer took the tour of the Prusa factory right after Maker Faire Prague, which the company itself organized and sponsored. To see behind the scenes of Prusa for yourself, check out the rest of the video below:

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

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Renishaw Partnering with Altair to Bring Metal 3D Printing to Industrial End Users

UK-based Renishaw, one of the world’s top metrology and spectroscopy companies, is also well-known for its advanced metal 3D printers. The company works to make the technology more mainstream, and is now partnering up with enterprise engineering software provider Altair for a new series of projects with the end goal of bringing metal 3D printing to industrial end users for the purposes of serial production.

“Working closely with Renishaw benefits the development and application of our software to optimize designs for functionality as well as for printability, accuracy and suitability for its designated purpose,” said David Coates, Altair’s Senior Program Manager. “This collaboration helps ensure AM part development, print cycles and scrap rates are minimized for our customers.”

This isn’t the first time that Altair, headquartered in Michigan and serving 5,000 customers across broad industry segments, has collaborated with Renishaw over the years. The two companies – one focused on hardware and the other on software – have partnered up on several various projects, including a pivoting bell crank for a race car’s suspension system, a spider bracket for architectural glass panels, and a unique, customizable bicycle frame.

Now, Renishaw is able to leverage all of the software products that Altair has to offer, including its HyperWorks suite with Altair OptiStruct and Altair Inspire.

“Altair is a world leader in simulation-driven design. Research combining their software with our latest systems will give them practical insights that will lead to innovative improvements in their products,” said Stephen Anderson, the AM Business Development Manager of Renishaw Inc.

Altair applies simulation, optimization, and machine learning throughout a product’s lifecycle to transform design and decision-making processes. Using its broad portfolio of patented simulation software allows companies, like Renishaw, to confidently generate reliable, high quality designs that can achieve correct 3D printed parts the first time.

On the flip side, Altair is now using Renishaw’s wide range of metal 3D printers to manufacture products based off their customers’ specific concepts.

“With Renishaw’s help, we are learning about how to best generate and simulate products for multiple laser systems and are actively thinking about laser assignment strategies within our simulation models,” said Coates.

The two companies are now offering joint workshops, training events, and seminars to their customers. These collaborative events demonstrate nearly the entirety of the metal 3D printing process – all the way from powder to finished build – with special emphasis on both machine productivity and throughput.

Customers attending these joint events can also engage in 3D design projects with Altair, in order to develop designs that are well-suited for printability on Renishaw’s metal 3D printer range. In addition, any customers that want to design and test the manufacturing of their metal 3D printed parts at one of Renishaw’s Solutions Centers can instead use Altair’s expertise and software.

Anderson explained, “Together with Altair, we are collaborating on customer-focused productivity projects, particularly in the automotive sector, which will lead to significant improvement in part volumes and lower costs per part.”

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

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BigRep and Bosch Rexroth Partnering Up to Combine 3D Printing with CNC Control Systems and Drives

German large-format 3D printing company BigRep, which became the newest member of the Direct Manufacturing Research Center (DMRC) an industrial research network in June, is on a mission to reshape the face of manufacturing with its large, serial production 3D printers. Founded four years ago in Berlin, with offices in Boston and Singapore, the company is committed to creating complete solutions in industrial sectors like automotive and aerospace.

Now, BigRep has announced an important development partnership with its strategic partner Bosch Rexroth, which supplies drive and control technologies. Together, the two companies will introduce a new dimension of industrial 3D printing, and set it up as an Industry 4.0 application in industrial production.

“This partnership demonstrates that Bosch Rexroth is constantly developing sustainable technologies and new factory automation solutions for the Factory of the Future,” said Thomas Fechner, Director of the Business Unit New Business at Bosch Rexroth.

As a result of this new development partnership, BigRep’s large-scale 3D printers, like the BigRep ONE and the Studio, will be equipped for the first time with excellent CNC control systems and drives by Bosch Rexroth. This will make BigRep’s 3D printers systems that are IoT-ready.

BigRep ONE 3D Printer

“Across industries, customers are looking for reliable, controllable and efficient 3D printers in order to manufacture top quality parts. As BigRep is the first to integrate CNC-grade control systems in 3D printers, we will re-define Additive Manufacturing,” said BigRep CEO Dr. Stephan Beyer. “The Rexroth controls are also an excellent platform for providing our 3D printers with full connectivity for existing production and automation systems. This will establish 3D printing as a key industry 4.0 application.”

Previously, Bosch Rexroth had predicted that in the future, industrial 3D printers will be faster and more reliable, which will make them far more suitable for use in mass production. Over the years, additive manufacturing has been busily setting itself up as an ideal manufacturing technology for the Factory of the Future, with major reported impacts on small serial production and prototyping.

Bosch Rexroth is also committed to 3D printing – it does offer AM components and solutions, after all. But in addition, the drive and control technologies specialist is using the technology, as stated in a BigRep press release, to “enable the fast and cost-efficient creation of models, patterns, prototypes, tools and end products.”

By following the lead that’s been set by BigRep and Bosch Rexroth in their partnership to combine large-scale, industrial 3D printing with drive and control technology experts, the additive manufacturing industry will be able to realize more cost-efficient and rapid creation of models, prototypes, tools, end-use products, and patterns.

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

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3D Printing News Briefs: September 29, 2018

We’ve got some 3D printing event news to share with you in today’s 3D Printing News Briefs, along with some business news and a story about a cool 3D printed container. At the TCT Show this week, Additive Industries announced a partnership with Laser Lines, and DEVELOP3D Magazine will soon celebrate product design and metal 3D printing at a live event. CRP Technology has created an updated 3D printed fairing for the Energica Ego Corsa superbike, and employees at the GE Additive Customer Experience Center in Munich made a 3D printed beer krug just in time for Oktoberest.

Additive Industries Partnering with Laser Lines

L-R: Mark Beard, General Manager UK, Additive Industries; Mark Tyrtania, Sales Director, Laser Lines; Daan Kersten, CEO, Additive Industries; and Phil Craxford, Sales Manager, Laser Lines

At the opening of the TCT Show, which took place in Birmingham earlier this week, Additive Industries announced a new partnership with Laser Lines Ltd. in order to speed up its 3D printing presence in the UK and Ireland. Laser Lines is a UK supplier of 3D printers, 3D scanning equipment, lasers, and related accessories, and will work together with Additive Industries to help grow the maturing market in the UK and Ireland for industrial 3D printers. Laser Lines will support Additive Industries in its work to further develop the industrial market for various applications in the aerospace, automotive, machine building, and medical sectors.

“With the recently announced expansion to the UK with a dedicated Process & Application Development Centre, we already acknowledge that the UK & Ireland is an important market that provides great opportunities for industrial companies to enter into industrial metal additive manufacturing,” said Daan Kersten, the CEO of Additive Industries. “With Laser Lines Ltd we add an experienced partner to our fast growing worldwide network that will work with us to identify and manage these opportunities that will contribute to our execution of our accelerated growth.”

DEVELOP3D Magazine Holding Live Event

Each year, DEVELOP3D, a monthly print and digital design journal, holds a live US event all about product design. This year’s DEVELOP3D Live event will be held this coming Tuesday, October 2nd, from 8 am – 6:30 pm at Boston University.

“We have some really fascinating folks coming to celebrate product design in the 21st Century,” Martyn Day from X3D Media, which runs DEVELOP3D, told 3DPrint.com. “We are especially pleased to have Ti Chang from Crave, Tatjana Dzambazova from new metals 3D printing company Velo3D and Olympian, Jon Owen from Team USA Luge.

“Our day is split with MainStage presentations from designers and the industry, together with a track dedicated to Additive Manufacturing, with all the latest in metals 3D printing.”

Tickets are just $50, and include full access to the conference and all 30 exhibitors, plus refreshments, lunch, and drinks at a social mixer. There will be 20 speakers presenting in two separate streams, and topics include CAD, topology optimization, 3D printing, virtual reality, and product development.

3D Printed Fairing for Ego Corsa

Together, Italy-based CRP Group and its subsidiary Energica have been using 3D printing and Windform materials to develop components for electric motorcycles and superbikes for a few years now. In April, the Ego Corsa electric motorcycle completed its third demo lap, and at the last series of road tests before the first edition of the FIM Enel MotoE World Cup, the 2019 2019 Ego Corsa prototype hit the track with a new 3D printed fairing, manufacturing by CRP Technology with its laser sintering technology and Windform XT 2.0 Carbon-fiber reinforced composite material. The 3D printed fairing update has improved the Ego Corsa’s aerodynamics.

“We have had the fairing available in short time. Thanks to the professional 3D printing and CRP Technology’s Windform composite materials, it is possible to modify motorcycle components – even large ones – from one race to the next ones, in order to test different solutions directly on the track,” said the Energica technical staff.

“This fairing is not only more aerodynamic, but it also has a smaller frontal and lateral section. These improvements led to achieve increase in terms of performance and they led to achieve greater manageability in fast corners.

“The Windform XT 2.0 has once again proved to be a high performance composite material. We are very happy how the 3D printed new fairing behaved during the tests.”

GE Additive 3D Prints Metal Beer Stein

Even though the month of October doesn’t start for another few days, Oktoberfest itself officially kicked off last Saturday in Germany. In order to celebrate the occasion, the AddWorks team at the GE Additive Customer Experience Center in Munich, which opened last winter, decided to take another look at the traditional glass beer krug; what we’d call a pitcher or stein in the US.

The unfortunate thing about glass is that it breaks. Obviously, if you’ve enjoyed too much beer at an event like Oktoberfest, the likelihood of breaking your glass drink container goes way up. So AddWorks decided to create a new prototype beer krug, but instead of using glass, they 3D printed it using a combination of stainless steel and titanium…and the result is pretty impressive.

Take a look at the video below, which stars the head of the Munich CEC (Matthew Beaumont), to see the whole process:

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US Army Research Lab Scientists Creating Atomic-Level 3D Reconstructions of Specimens

The US Army Research Laboratory (ARL) is responsible for plenty of innovative 3D printing research over the years, such as 3D printing drones and working with recycled 3D printing material. Now, material scientists from the ARL have their sights set on something much smaller that could have a very large impact – analyzing atomic-level metal and ceramic specimens.

Dr. Chad Hornbuckle, a materials scientist with the ARL’s Weapons and Materials Research Directorate, specializes in microstructural characterization using electron microscopes and atom probe tomography (APT), and is working on the atomic-level research. He said that the unique atom probe being used in this research not only sets the standard for accuracy in chemistry, but is also necessary to understanding the interior structure of materials themselves.

“The atom probe gives us a 3-D reconstruction at the atomic level. When you see the reconstruction that’s made up of millions of dots, the dots are actually individual atoms,” Dr. Hornbuckle explained.

“It’s basically the only machine in the world that can do this at the atomic level. There are machines, like transmission electron microscopes, or TEMs, that do chemical analysis, but it is not as accurate as this.”

Dr. Chad Hornbuckle, a materials scientist with the ARL, specializes in atom probe tomography, which analyzes ceramics or metal 1,000 times smaller than a human hair.

Because experiments require consistency, it’s extremely important to maintain a high level of accuracy during research like this.

Dr. Hornbuckle said, “You might have one effect one time, but if the chemistry changes, you get a completely different effect the next time. If you can’t control the chemistry, you can’t control the properties.”

If you thought working at the nanoscale level was small, consider this: the atomic-level specimens being analyzed in this research are roughly 1,000 times smaller than the end of a strand of human hair. Researchers have to create very sharp tips to get the samples ready for analysis, which are used to mill, or sandblast, the materials away using gallium and either a focused ion beam microscope or a dual beam scanning electron microscope. Then they are inserted into the atom probe.

The interior of the probe is a super cold vacuum. Atom samples are ionized with a laser, or a voltage pulse, within the probe’s tip, which causes them to field evaporate from the surface. Then, the evaporated ions are analyzed and identified, which results in a 3D model with a near-atomic spatial resolution.

Atom probe

Dr. Hornbuckle himself developed the probe during his time as a graduate student at the University of Alabama. Army scientists and other researchers now ask him for his help in characterizing samples, and use APT technology to determine which atoms are located where in a material.

Dr. Denise Yin, a postdoctoral fellow at ARL, said, “I can give you one specific example of how it’s helped our research. We were electrodepositing copper in a magnetic field and we found a chemical phase using the atom probe that didn’t otherwise show up in conventional electrodeposition.

“Electrodeposition is a process that creates a thin metal coating.

We were having problems identifying this phase using other methods, but the atom probe told us exactly what it was and how it was distributed.”

Dr. Yin said that the atom probe has “impressive” capabilities:

“You can see the atoms show up in real time. Again, it’s at the nanometer scale, so it’s much finer than all the other characterization techniques. The atom probe told us quite easily that the unknown phase was two different types of a copper hydride phase, and that’s not something that we could have detected using those other methods.”

[Image: ARL]

Only a limited number of these atom probes exist, and the one used by the ARL is one of just several in the US. So you can imagine that many universities hope to use it to analyze their own samples. As part of its Open Campus business model, the lab looks for formal agreements.

ARL Director Dr. Philip Perconti explained, “Open Campus means sharing world-class ARL facilities and research opportunities for our partners. A thriving Open Campus program increases opportunities for technology advancement and the transfer of research knowledge.”

Dr. Hornbuckle said that a partnership with Lehigh University yielded some “important results.”

Army scientists explore materials at the nano-level with the goal of finding stronger or more heat-resistant properties to support the Army of the future.

“One university that we collaborate with is Lehigh University. At first, this collaboration was more of a mutual exchange of expertise, where I analyzed some of their samples in the atom probe and they used their aberration-corrected transmission electron microscope to analyze some of our copper-tantalum sample,” said Dr. Hornbuckle. “We now have a cooperative agreement with them to continue this collaboration.

“I actually ran a nickel-tungsten alloy that was electrodeposited for them and identified and quantified the presence of low atomic number elements such as oxygen and sodium. This resulted in one research journal article with several more in preparation.”

The ARL is also collaborating with Texas A&M University on atomic-level analysis.

“This collaboration initiated due to the Open Campus initiative. I have analyzed a few nickel-titanium alloys that had been 3-D printed. They noticed some nanoscale precipitates within the 3-D printed materials, but were unable to identify them with their TEM,” Dr. Hornbuckle said. “I am trying to determine the chemistry of the phase using the atom probe, which should help to identify it.”

The University of Alabama is another of the ARL’s partners, and this collaboration led to several published research journal articles.

“They have a different version of the atom probe. They have run some our alloys in their version and ours to compare the differences noted in the same material. This material is actually being scaled up through a number of processes that are relevant to the Arm,” Dr. Hornbuckle explained.

In addition to creating important and meaningful connections, these various partnerships also provide the Army with access to equipment not found at the ARL. Then, the knowledge that Army researchers learn through this joint research can be applied to current problems the Army is facing, as well as to developing future relevant materials.

Dr. Hornbuckle said, “When you see things no other human has ever seen before, it’s very cool to think that I’m helping to push the envelope of new modern materials science, which then obviously is used for the Army. Every time we run a new material we think about how we can help the Soldier with this new discovery.”

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[Images: US Army photos by David McNally]

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Aconity3D to Set Up North American Base of Operations for 3D Printing at UTEP

Bottom, L-R: Diana Natalicio, UTEP President; Yves Hagedorn, Aconity3D, managing director; Florian Sondermann, AconityUS, managing director. Top, L-R: Ryan Wicker, PhD, Keck Center director; Zia Uddin, student researcher; Alfonso Fernandez, powder bed manager; Francisco Medina, director of technology and engagement; Mireya Flores, Keck Center manager; Philip Morton, applications manager. [Image: UTEP Communications]

The University of Texas at El Paso (UTEP) has long been a 3D printing advocate, and a lot of this important work takes place at the university’s W.M. Keck Center for 3D Innovation, which is also the first satellite center for America Makes. Now, UTEP has made an agreement with Germany-based Aconity3D GmbH, which develops laser powder bed fusion 3D printers, to be its base of operations in North America.

“We are pleased to establish a relationship with UTEP. This is an excellent example of how research universities can partner with private industry to advance the educational opportunities afforded to students and also attract economic development to the region,” said Yves Hagedorn, PhD, the Managing Director of Aconity3D. “We are confident that the combined expertise of the Keck Center and Aconity3D will yield innovative approaches to 3D printing and offer world-class research opportunities for students.”

Aconity3D was founded in 2014 as a small startup, though it now boasts over 50 employees, and makes 3D printers capable of manufacturing complex metal parts for medical implants, airplanes, and cars, among others. It was eager to set up camp at UTEP due to the Keck Center’s expertise and prominence in the industry, as well as its commitment to increase economic development.

“This exciting collaboration is very well aligned with UTEP’s access and excellence mission. UTEP is committed to providing our students with exceptional educational opportunities, many of which are advanced through the ground-breaking research underway on our campus,” said UTEP President Diana Natalicio. “This agreement with Aconity3D will enhance UTEP’s research environment, broaden the range of experiences available to our students in the Keck Center for 3D Innovation, and attract new business development that will enable UTEP graduates to remain in this region to pursue their career goals.”

This agreement will not only give Aconity3D a home in the US, but it will also attract high-end jobs for the community’s engineering students, increase UTEP’s production and service operations, and advance 3D printing through important research investigations with government agencies and industry.

“The Keck Center is a natural fit for Aconity3D as it is a recognized leader in additive manufacturing. This collaboration will enhance our technical knowledge base and expand our expertise,” said Theresa A. Maldonado, PhD, the dean of UTEP’s College of Engineering. “We can also work collaboratively toward our model to incubate startups and provide them a pool of highly qualified graduates.”

The company’s 3D printers have an open architecture system, which is different from most commercial approaches in that users can modify the parameters themselves in order to find the optimal way to 3D print a customer’s specified material. The equipment is great for research, as one needs plenty of knowledge about the technology in order to operate the 3D printers. This helps feed Aconity3D’s corporate philosophy of locating near high-tech research organizations – for instance, its German headquarters are near the Fraunhofer Institute for Laser Technology (Fraunhofer ILT). Aconity3D’s model of supporting the institute’s interns and students will continue at UTEP.

Aconity3D will begin its North American operations with only a CEO, but plans to hire up to three employees within a year. The hiring process will focus first on Keck Center graduates who have experience working with the company’s technology, as one of Aconity3D’s laser powder bed machines is already housed there.

“We have long worked on leveraging our expertise in 3D printing to build a new economy in El Paso around additive manufacturing. Our partnership with Aconity3D is a major milestone in that direction and is validation of all of our combined efforts,” said Ryan Wicker, PhD, the founder of the Keck Center. “The only way a company like Aconity3D would decide to come here is because of our technical strength in additive manufacturing, access to our graduating talent to meet their workforce needs, and the tremendous opportunities available for commercial success through collaborations with UTEP. We can apply this economic development model to build other businesses around their technologies, recruit other 3D printing businesses to our region and create new businesses from our own 3D printing technologies coming out of UTEP. As a research university, UTEP must be – and is excited to be – fully engaged in stimulating economic development for the benefit of our region.”

The long-term goal of this agreement is to set up a technical center and research space in the Keck Center, which will work with Aconity3D’s German headquarters to sell and service its 3D printers in North America. Its US base of operations will be located at UTEP’s University Towers Building.

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3D Printing News Briefs: July 20, 2018

We’re starting out with some construction news in today’s 3D Printing News Briefs, then following that with a little business, a little metal, and a little 3D design. Russian firm AMT-SPETSAVIA has updated two of its construction 3D printers, and the University of New Brunswick has chosen a Concept Laser 3D printer to use for its upcoming research. Mass Portal’s software team went through a reorganization, and attendees learned all about lightweight aluminum material at the recent AMAP forum. Finally, users of browser-based SelfCAD 3D software can access the MyMiniFactory design library…and share their own work there as well.

Spetsavia Completes Updates on Large Construction 3D Printers

Three years ago, Russian firm Spetsavia presented its home construction methods and 3D printers at the 3D Print Expo. Now, the group of machining and 3D printing companies collectively known as AMT-SPECAVIA has updated its range of construction 3D printers (Construction Objects Printing or COP) to introduce two new large-format models. The S-300, with a “working field” of 11.5 x 11 x 5.4 m, is able to print directly on the foundation of buildings up to two stories and 120 square meters, while the S-500 features an 11.5 x 11 x 15 m field and can 3D print buildings up to five, or even six, floors. However, the latter can be increased to a working field of 40 x 11 x 80 m, which Spetsavia says makes it “the largest 3D construction printer in the world.”

“New models of the S series are essentially the next generation of building printers. We’ve always been asked for a solution for multi-storey construction,” said Alexander Maslov, the General Director of AMT-SPETSAVIA. “Now we declare with confidence that such a solution exists! The AMT S300 and S500 printers are high-performance equipment with unprecedented capabilities and competitive price. During the development we’ve taken into account the wishes of the developing companies, at the same time maintaining the inherent reliability of our equipment, ease of management and maintenance.”

Both the S-300 and the S-500 have a direct flow print head for increased productivity, in addition to a new feed station that prepares the concrete mixture. The first shipment of the S-500 is scheduled for this fall, and a team of engineers will accompany the 3D printer to the customer for training.

University of New Brunswick to Use Concept Laser M2 Cusing

L-R: Keith Campbell, Senior Sales Director, GE Additive; Dr. Mohsen Mohammadi, Director of Research and Development for the Marine Additive Manufacturing Centre of Excellence; Hart Devitt, Director of Industry and Government Services; Duncan McSporran, Director, Programs and Innovation, Office of Research Services, University of New Brunswick

GE Additive has announced that the University of New Brunswick (UNB) in Canada, together with commercialization partner Custom Fabricators & Machinists and training partners Nova Scotia Community College (NSCC), New Brunswick Community College (NBCC), and the College communautaire du Nouveau-Brunswick (CCNB), has chosen its Concept Laser M2 Cusing metal 3D printer to use in its latest research.

UNB is in charge of the country’s first Marine Additive Manufacturing Center of Excellence, which will be the very first in Canada to fabricate certified parts for the marine industry with metal 3D printing. The M2 Cusing will mostly be used by UNB’s Dr. Mohsen Mohammadi, who will be the Director of Research and Development for the new center, and his team for multiple R&D areas, including bast resistance, enhanced corrosion protection, and hybrid 3D printing processes.

Mass Portal Announces Reorganization of Software Team

Latvian 3D printer manufacturer Mass Portal has reorganized, and appointed new leadership for, its software team, which is now an independent company called FabControl. The company will be building an open, next-generation software platform for managing 3D printers and AM workflows, and Mass Portal’s current CEO and co-founder Janis Grinhofs, the founder of FabControl and in charge of developing Mass Portal’s flagship Pharaoh 3D printers, will now serve as the CEO of the new company. Imants Treidis has been named the new CEO of Mass Portal.

“We will continue to serve our existing customers and industrial partners, in the same time striving for excellence in supplying the industry with highest quality machines and tailor built solutions for additive manufacturing needs,” Treidis said.

All About Aluminum at AMAP Forum 

Not too long ago in Aachen, scientific and industry experts gathered at the AMAP Forum (Advanced Metals and Processes) to demonstrate the continuing potential of researching non-ferrous metals, like aluminum, for the purposes of lightweight automotive design. 14 entrepreneurs from industry and five of the RWTH Aachen University institutions formed the AMAP Open Innovation Research cluster at the forum, and discussed topics ranging from new production technologies and materials development to modeling and metallurgic process technology. Some of the specifics included using aluminum hollow castings to create structural components with functional integration, additive manufacturing, and new design and calculation methods for high-strength aluminum alloys.

Dr. Klaus Vieregge, Chairman of the AMAP Advisory Board and Head of the Hydro Aluminium Research and Development Center in Bonn, said, “We are an efficient network. New members are always welcome, but a high number of members is not the focus of the AMAP cluster, we want to convince people by the efficiency of the work and the research results.”

SelfCAD Partners with MyMiniFactory

Online 3D design platform SelfCAD, founded in 2015, combines 3D modeling, slicing, and several other tools and functions in one easy program. Earlier this year, the platform announced a partnership with popular 3D printable model marketplace MyMiniFactory.

This partnership makes it easy for SelfCAD users to access the design library in MyMiniFactory, and also gives them the ability to download their 3D models directly from the marketplace while still in the SelfCAD program. In addition,  it’s also possible for users to upload their models directly to MyMiniFactory for maximum exposure.

To learn more, check out this helpful video:

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3D Printing News Briefs: June 26, 2018

We have plenty of business, material, and 3D printer news to share with you in today’s 3D Printing News Briefs. 3D printing led to increased savings for GM over the last two years, which is now increasing its use of the technology as a result. ExOne is saying goodbye to one CEO and hello to another, while Polymaker announces a global distribution arrangement with Nexeo Solutions and CollPlant receives R&D project approval in Israel. The US Patent and Trademark Office will be hosting its annual Additive Manufacturing Partnership Meeting this week, and RP Platform has announced a rebrand and a new AI software platform. Finally, the UK’s National Centre for Additive Manufacturing has decided to add Digital Metal’s binder jetting technology to its portfolio.

GM Increasing Use of 3D Printing at Plants

Zane Meike, AM lead at GM’s Lansing Delta Township assembly plant, holds a common 3D printed tool used to align engine and transmission vehicle identification numbers. [Photo: Michael Wayland]

According to Dan Grieshaber, the Director of Global Manufacturing Integration for General Motors (GM), most of the company’s factories have 3D printers, which are used to build accessories and tools for workers. A $35,000 3D printer at GM’s Lansing Delta Township assembly plant has actually helped save the company over $300,000 over two years: it’s used to make multiple items, such as part hangers, socket covers, and ergonomic and safety tools. A common tool used to align engine and transmission vehicle identification numbers cost $3,000 to buy from a third party, but is less than $3 to 3D print at the factory. Realizing that these kinds of savings can add up quickly, GM is increasing the use of 3D printing – part of its new Manufacturing 4.0 processes – at its plants in order to help streamline operations.

“We’re quickly evolving, creating real value for the plant. This will become, as we progress, our footprint. We’ll have this in every one of our sites,” Grieshaber said.

Grieshaber also said that GM is working to standardize 3D printing, as well as share best practices across all of its global plants.

ExOne Welcomes New CEO

The ExOne Company, which provides 3D printers and 3D printed products, materials, and services to its industrial customers around the world, has announced that its CEO, James L. McCarley, is departing the company, effective immediately, to pursue other interests and opportunities; he will be assisting the company in transitioning his responsibilities to the new CEO. ExOne’s Board of Directors has also announced who the new CEO will be – S. Kent Rockwell, the company’s Executive Chairman, who has served in the position in previous years. Rockwell’s new title is effective immediately.

“On behalf of our Board and management team, I would like to thank Jim for his efforts and wish him all the best in his future endeavors,” said Rockwell.

Polymaker Makes Distribution Arrangement with Nexeo Solutions

Shanghai-based 3D printing material producer Polymaker has entered an arrangement with chemicals and plastics distributor Nexeo Solutions, Inc., also based in Shanghai. Nexeo will be a global distributor for three new materials in the Polymaker Industrial line, but plans to introduce more of its materials over the rest of the year. C515 is an advanced polycarbonate (PC) filament that has excellent toughness and a low warping effect, while C515FR is a flame retardant PC with high impact resistance. SU301 is a polyvinyl alcohol (PVA)-based polymer that’s water soluble and was developed as a support material for FFF 3D printers.

Paul Tayler, the Vice President of EMEA at Nexeo Solutions, said, “Expanding our portfolio to include industrial grade filaments from Polymaker Industrial gives our customers access to a wider range of filaments that solve new 3D printing challenges and meet the demands of manufacturers. Industrial customers benefit from Nexeo Solutions’ access to world leading plastic producers coupled with additive manufacturing technical expertise.”

CollPlant Receives R&D Project Approval

Two years ago, regenerative medicine company CollPlant received funding from Israel’s Ministry of Economy for its research in developing collagen-based bioinks for 3D printing tissues and organs. CollPlant, which uses its proprietary plant-based rhCollagen (recombinant human collagen) technology for tissue repair products, has now announced that the Israel Innovation Authority (IIA) has approved a grant to finance the continued development of its rhCollagen-based formulations intended for use as bioinks. Terms of the grant require CollPlant to pay royalties to the IIA on future sales of any technology that’s developed with the use of the funding, up to the full grant amount. The total project budget is roughly $1.2 million (NIS 4.2 million), and the IIA will finance 30%, subject to certain conditions.

“In addition to providing immediate non-dilutive funding, this grant from the Israel Innovation Authority represents an important validation of our BioInk technology and its market potential. With the recent opening of our new cGMP production facility in Rehovot, Israel, we are well positioned to meet growing demand for our BioInk and tissue repair products. We are grateful to the IIA for this recognition,” said CollPlant CEO Yehiel Tal.

Additive Manufacturing Partnership Meeting Hosted by US Patent and Trademark Office

For the last several years, the US Patent and Trademark Office (USPTO) has been hosting the Additive Manufacturing Partnership Meeting, and this year’s meeting takes place tomorrow, June 27th, from 1 to 5 PM at the USPTO headquarters inside the Madison Building in Alexandria, Virginia. The USPTO will be seeking opinions from various participants at the informal meeting, which is really a forum for individual 3D printing users and the USPTO to share ideas, insights, and personal experiences.

“We value our customers and the feedback provided from individual participants is important in our efforts to continuously improve the quality of our products and services,” the USPTO meeting site reads. “Your willing participation in this informal process is helpful in providing us with new insights and perspectives.”

Scheduled speakers at this year’s meeting are coming from CIMP-3D, HRL, Kansas State University, Lawrence Livermore Laboratories, and the NextManufacturing Center, and an RSVP is required to attend the AM Partnership Meeting.

RP Platform Launches New AI Software and Rebrand

London-based RP Platform, which provides customizable workflow automation software for industrial 3D printing, is launching a new software platform, which will use AI for the first time to automate 3D printing production. With customers in over 30 countries, the company is one of the top automation software providers for industrial 3D printing. In addition to its software launch, RP Platform has also announced that, as it continues to expand its software capabilities to target AM end part production, it is rebranding, and has changed its name to AMFG.

“We want to help companies make their 3D printing processes much smoother so that they can produce more parts with greater visibility and less effort. And we have more exciting releases to our software over the coming months that will further enhance our production automation capabilities,” said Keyvan Karimi, the CEO of AMFG.

“Ultimately, we’re creating a truly autonomous manufacturing process for industrial 3D printing. For us, this means taking manufacturing to a new era of production. The launch of our new software, as well as our company rebrand, fully reflects this vision going forward.”

NCAM Installing a Digital Metal 3D Printer

The National Centre for Additive Manufacturing (NCAM) in the UK, headquartered at the Manufacturing Technology Centre (MTC) in Coventry, has decided to add the unique binder jetting technology developed by Digital Metal to its large range of advanced manufacturing equipment, and will soon be installing one of its high-precision metal 3D printers – which are not available anywhere else in the UK. The 3D printer will be available for use by NCAM’s member companies, and other organizations, who are interested in testing the capabilities of Digital Metal’s proprietary binder jetting technology.

Dr. David Brackett, AM Technology Manager at the NCAM, explained, “The Digital Metal binder jetting technology falls into the category of ‘bind-and-sinter AM’, where a multi-stage process chain incorporating sintering is required to achieve full density. It’s a very fast technology that can create complicated and highly detailed designs, and there is potential for wider material choice than with AM processes that use melting. We are delighted to be able to offer this to the companies we work with.”

The Digital Metal 3D printer will be operational later this summer, and NCAM personnel are already training with it to ensure they can operate it efficiently and safely.

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