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French Researchers Examine Heat Transfer & Adhesion in FFF 3D Printing

Researchers from Laboratoire de thermique et énergie de Nantes uncover some of the challenges in 3D printing versus thermoplastic injection, releasing the findings of their recent study in ‘Heat Transfer and Adhesion Study for the FFF Additive Manufacturing Process.’

Mechanical properties are often the topic of study today—from researching helpful additives to studying the influences of color, to issues with porosity, and far more—as users attempt to improve the functionality of parts. Adhesion between layers is a common problem, usually leading to further examination of technique and materials. In this study, the researchers focused on heat exchanges in an attempt to improve 3D printing.

Temperature remains one of the most important settings for users, leading to good quality and performance in printed parts—or in other unfortunate cases, major structural issues.

“To find precisely the limit of this optimal processing area, the thermal history needs to be predicted accurately,” stated the researchers.

Polymer printability rules for FFF process.

With a better understanding of thermal factors, users may be able to avoid macro-porosities and adhesion problems. During FFF 3D printing, the following heat transfers occur:

Heat from the extruder
Convection cooling of filament
Exchanges between filaments
Heat from the support plates
Radiative losses
Heat from exothermal crystallization for semi-crystalline polymers

At least 6 different heat transfer phenomena are identified in the FFF process.

(a) Comparison of the heat transfer model existing in the literature of FFF process and (b) geometry for the 2D analytical model. Adapted from [7]

While controlling the 3D printing process with high temperatures, the researchers also reinforced PEKK materials with short carbon fibers. In the beginning of the experiment, however, the team used ABS due to ‘greater ease of implementation.’ An experimental bench was 3D printed on a CR-10 3D Printer from Creality3D for measurements of temperature, and then a simulation model was created via COMSOL Multiphysics® v5.4 for predicting temperature and healing.

Experimental bench showing the heated chamber for 3D printing of high temperature polymers and the infrared camera for temperature measurements.

Before printing, the authors customized the 3D printer in their lab, modifying the hardware so it would be able to attain the proper temperatures of up to 400°C.

“The extruder was changed, for a full-metal unit, with a water-cooling closed circuit system. A closed insulated chamber maintains the part in a 200°C atmosphere. It does not block the three translation moving system of the 3D printer inside the chamber. Electronics and mechanical parts are kept outside the chamber. This heating chamber is mandatory for printing polymers like PEKK,” said the researchers.

Experimental set-up. A single filament wall was 3D printed. The pyrometer measures the temperature from the side in situ.

Geometry and boundary conditions used in the heat transfer model

The other specimen was a basic structure 3D printed with both ABS and PEKK, in the form of a 60×2.2×50 mm wall. For ABS, the researchers took qualitative measurements with a pyrometer, with quantitative measurements taken for both ABS and PEKK.

IR camera qualitative analysis for ABS.

“Because of the poor knowledge of the rheological properties, the calculated degree of healing was found to be equal to 1 very quickly for ABS. However, this is the opposite for PEKK material, which reaches only a degree of healing of 0.45 after the cooling-down of the filament,” concluded the researchers.

“The bench was designed to handle high temperature and future work will consist in studying deposition of PEKK more precisely, and also for carbon fibers reinforced PEKK with different process parameters. The short-term perspectives are to use the model with the thermo-dependent thermal properties, which were characterized in the LTeN laboratory on PEKK polymer.”

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

[Source / Images: ‘Heat Transfer and Adhesion Study for the FFF Additive Manufacturing Process’]

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AMS 2020: Panels on 3D Printing in Implants and Orthopedics, Regulation in Additive Medical Devices

There was much to enjoy and learn at the recent Additive Manufacturing Strategies event, held in Boston and co-hosted by 3DPrint.com and SmarTech Analysis, especially with the addition of a new metals track. There was the ever popular Startup Competition, time to network with colleagues, interesting keynotes, an exhibition hall, industry forecasts by SmarTech, and many different panels and presentations.

On the first day, I sat in on a panel on the event’s medical track about the use of 3D printing in implants and orthopedics. Martin Neff, the Head of Plastic Freeforming for German machine manufacturing company Arburg, spoke first, and provided attendees with a detailed explanation of its patented ARBURG Plastic Freeforming (APF), the process principle behind it, and what the Freeformer can offer.

“Our process can use standard resin, is already on the market and cleared by the FDA for medical devices, and it’s similar to injection molding,” he explained.

Moving on, Neff said the biggest thing to keep in mind for this application of 3D printed implants and orthopedics is how to achieve repeatability, traceability, and position. Additionally, he mentioned that the selection and freedom of materials in this sector is also a “very important area.”

Carissa Kennison, the Director of Marketing for New Jersey-based Additive Orthopaedics, explained that the company, which was founded in 2016, designs, markets, and manufactures medical implants.

“We’re inspired by the outcomes these 3D printed implants are having in our patients’ lives,” she said. “The patient testimonials are truly inspiring – often, patients go to multiple surgeons and are told to get a fusion, which limits joint motion, or an amputation. So we’re giving them an alternative solution, and challenging the solutions of standard of care. It’s pretty exciting to be a part of that.”

Jean-Jacques Fouchet on Skype

While he was unable to be at AMS 2020 in person, Jean-Jacques Fouchet, the VP Business Development and co-founder of 3D printing company Z3DLAB – Parc Technologique, was able to join the panel via Skype, and explained to attendees that “Z3DLAB is an expert in materials science,” and that it has developed a 3D printed implant for the dental field. The company’s mission is to deliver a new generation of advanced, titanium-based material for the AM market.

“We do two titanium materials, one based on Ti-64 that’s enhanced and one based in Ti-CP,” he explained. “Our 3D printed implant has an interior porous structure.”

Fouchet went on to say that Z3DLAB had completed a study with EnvA, LNE, and BAM, and that after just two months of implementation, “we got high-resolution scanner results that showed 84% bone inside the implant. Not bone tissue, but bone.”

The last panelist was Andrus Maandi, Sr. Product Development Engineer for Oxford Performance Materials (OPM). He explained that OPM was originally founded as a materials science company, working exclusively with PEKK (polyetherketoneketone), and began adopting 3D printing all the way back in 2008.

Discussing some of the company’s orthopedic applications, Maandi brought up OPM’s OsteoFab 3D printing process, which involves laser sintering with its high-performance OXPEKK material.

“We’ll get a CT scan, and in-house can deliver implants within 24-48 hours to healthcare facilities,” he stated.

OPM started with CMF and spinal implants, and its latest 3D printed device is a suture anchor, which will have its first case performed this month.

“One of the main benefits is the impact we can have on patient care and improving their lives,” Maandi explained. “We see the additive manufacturing industry moving, at least in the orthopedic market, and slowly going down the body…moving down to long bone defects and ankle reconstruction.”

The floor was then opened for questions, and someone asked if OPM had a roundabout price for its 3D printed implants; as we all know, custom medical devices can be pricey. But Maandi responded that it is “overall cheaper than something you could machine.”

John Hornick, the Chairman for the Medical and Dental track at AMS 2020, asked a question next, telling the panelists that two of his friends had recently received knee replacements. One friend had a 3D printed implant, while the other had a conventionally manufactured one, “because his doctor didn’t know anything” about AM technology. Hornick wanted to know how the panelists got the word out about what their companies could offer.

Kennison said that it really depends on the application – surgeons are more likely to engage in word of mouth, and do their own marketing and PR, for some of the more complex cases that use 3D printing.

“It can be challenging to market some of these cases,” she said. “You can’t promote custom devices, so there are some restrictions here.”

Maandi acknowledged that it can be tough, because many of the people they deal with in the healthcare field just aren’t aware of all of the available 3D printed options.

Later that same day, I sat in on a panel called “Regulation of Additive Manufacturing of Medical Devices and Its Impact on Products Liability,’” which I had not originally planned on attending; however, after sitting at the same lunch table as panelist Sean Burke, a partner with the Duane Morris law firm in Washington D.C., I was intrigued.

Panelist Bob Zollo, the President of Avante Technology, was unable to make it, so Burke had the floor all to himself. Acknowledging with good humor that he was the only thing standing in the way of happy hour, he moved through his topic efficiently.

According to his bio, “Mr. Burke’s practice focuses on representation of manufacturers of medical devices in products liability cases across the country, including in consolidated multi-plaintiff matters in both federal court and state courts in California, Illinois, and Tennessee.” In terms of defense experience, he has worked with many things, including surgical instruments and fusion plates, and recently became interested in the use of AM, advising and consulting his clients on best practices in the early product development stages in order to help them lower their risk of liability exposure.

But, as Burke told the room, “Basically, at the end of the day, there are always risks.”

He explained that while many people look at it as more of a barrier, FDA regulation and compliance is “really the best shield that medical device companies have.”

“You’re on a bit of an island if you don’t have the same regulations.”

Burke explained that the FDA is trying to “play catch-up” in determining how exactly to regulate this kind of technology. The agency has issued guidance on design, testing, and manufacturing controls for AM, but this doesn’t mean that it’s offering a solution.

From a products liability standpoint, if a company has standards to fall back on when telling a jury about the testing that’s been completed on a 3D printed medical device, the chances are more likely that the jury will be able to understand.

“But when there aren’t standards or testing, but the FDA wants to look at it, that’s a recipe for exposure,” Burke said.

As an example, Stryker’s 3D printed tritanium spinal cage was recalled last year for updates; after conducting a Google search, Burke found four different attorneys who were looking to take these cases to court…bad news for the AM industry.

Burke moved on to current trends about litigation involving 3D printed medical devices. While there haven’t been too many class action suits because the cause for each patient’s failure is usually different, the number of cases is rising.

He listed some of the factors that drive litigation, including the media, company field actions, FDA safety communications and labeling changes, pending litigation, and scientific and medical literature. Burke also provided an explanation on the different types of product liability claims – strict liability, negligence, and fraud/misrepresentation.

In terms of manufacturing defect claims, evidence must be presented that shows there has been a “deviation from the original design.” This can be difficult to validate, but there are many variables involved with AM, such as powder use. To protect against Failure to Warn claims, medical device companies that use 3D printing need to broadcast if there are any developments, and provide up to date information as well.

Burke gave attendees some pretty solid advice at the end:

“I know you all consider this, but think about why you’re 3D printing, and make a concise statement about why you’re doing it, and not just because you’re trying to “keep up with the Joneses” in terms of cool new technology.”

Then it was time for some questions. One attendee said that patient-specific products are not always treated as customized, and wanted to know why this makes a difference in terms of regulation. Burke explained that if a 3D printed patient-specific device is deemed a custom product, then it does not have to go through the same regulatory channels.

Joris Peels, 3DPrint.com’s Editor-in-Chief, was chairing this panel, and asked about the use of 3D printing in courtroom settings, and if regulatory bodies consider it. Burke said that his firm’s experts are definitely on board with this, especially in terms of patient anatomy models. He mentioned a big case centered around hip dysplasia, and how a 3D printed exhibit – I’m guessing it was an acetabular cup – was used to show how things were not fitting correctly in the patient’s body.

Another attendee asked Burke for best practices that startups not yet looking to liabilities could use.

“I think it depends on what they want to do,” he answered. “I work with startups and large companies, but there are some things to do up front to advise them.”

He suggested setting up a meeting with the FDA to hear their thoughts and concerns, and document the meeting.

“It’s an exhibit – the FDA knew we were doing this and that test, and still cleared it,” Burke explained.

Stay tuned to 3DPrint.com as we continue to bring you the news from our third annual AMS Summit.

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

[Photos: Sarah Saunders]

The post AMS 2020: Panels on 3D Printing in Implants and Orthopedics, Regulation in Additive Medical Devices appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

AON3D Launches the AON-M2 2020: Large Volume 3D Printer Built for High-Performance Thermoplastics

AON3D announces the launch of their AON-M2 2020, the latest industrial 3D printer in their flagship product line. The AON-M2 2020 has been designed to print a continuously expanding array of melt-processable thermoplastics, including PEEK, ULTEM, PEKK, polycarbonate, and hundreds of other materials.

Customers can realize the most demanding applications, since the extensive material compatibility offers the opportunity to 3D print parts that can resist harsh chemicals, stand up to extreme temperatures, and withstand intense mechanical stress.

The AON-M2 2020 is ideal for fabricating parts for a wide range of applications, including tooling, jigs and fixtures, end-use parts, or rapid prototyping.

Open Materials 3D Printers Unlock More Applications

Since its founding, AON3D has committed to the open materials standard in contrast with many 3D printing companies that restrict customers to a limited selection of costly, proprietary materials.

In addition, AON3D has focused its materials engineering expertise on developing optimized process parameters for vendors that provide the highest quality materials on the market. These include notable brands such as Solvay, SABIC, Kimya, DSM, Infinite Material Solutions, and many others.

Designed for Part Accuracy and Repeatability

The AON-M2 2020 industrial 3D printer improves upon the original design with its focus on part accuracy and repeatability, as well as reliability. “From the all stainless-steel frame to minimize thermal expansion, to the chamber heater redesign that offers precise control of the thermal environment and heats up in less than 15 minutes, the AON-M2 2020 is an exciting step-up for AON3D,” said CEO, Kevin Han. “We are thrilled to continue offering customers the widest range of material options for their applications and materials expertise that goes well beyond the machine design.”

Parts made on the AON-M2 2020 using SABIC ULTEM AM9085F filament and AMS31F support material.

Reach the Maximum Potential for Your Material

With its higher chamber temperature of 135°C (275°F), and bed and hot end temperatures of 200°C (392°F) and 470°C (878°F) respectively, the AON-M2 2020 unlocks an even wider range of high-performance materials that are in demand by industries such as aerospace, defense, R&D, and manufacturing. Operators can achieve better mechanical properties for printed parts with its precision thermal control, enabled by the innovative chamber heater design and engineered convective flow path. Also, its huge 454 x 454 x 640 mm (18 x 18 x 25 in) build chamber accommodates larger parts, and its dual independent tool-heads can print support material for complex designs with ease.

AON3D pairs its industrial 3D printing platform with a comprehensive process expertise offering; application engineers, trainers, and PhDs combine forces to support users in achieving exceptional part outcomes.

“We are seeing a growing demand for an additive manufacturing platform that can print the strongest thermoplastics, as well as an increasing recognition that reaching the maximum mechanical property potential for any part-material combination is a challenge best met with expert support,” said Director of R&D, Andrew Walker. “The AON-M2 2020 is the bedrock of a complete solution we offer customers for getting from CAD file to end-use parts, without sacrificing affordability.”

The AON-M2 2020 is already shipping and you can get a quote today.

A part made from Solvay KetaSpire® AM FILAMENT CF10 LS1 – a carbon fiber-loaded PEEK material.

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3DGence, Arkema and Armor partner to expand PAEK 3D printing applications

Polish 3D printer manufacturer 3DGence has partnered with advanced material companies Arkema and Armor Group to make its ESM-10 (Engineering Soluble Material) compatible with the Kimya PEKK-A high performance material. The partnership between the three companies aims to expand the use of open-market applications for PAEK based materials in 3D printing. PEKK-A, developed by Armor Group’s […]

Interview with Scott Sevcik, VP Aerospace Stratasys, on 3D Printing for Aviation and Space

Out of all the possible industries that are deploying more 3D printers, aerospace is probably the most exciting. By reducing the weight of aircraft components, by iterating more, by integrating components and reducing part count and by making parts others can not, we can have a real impact on aerospace. From rocketry to commercial aviation, we’re seeing new applications grow across the board with OEMs and Tier 1 through 3 investing in qualifying parts and moving carefully into production. Stratasys has had a long history in making polymer aviation components, mainly for military applications. We interviewed Stratasys’ Vice President for the Aerospace Business Segment, Scott Sevcik, on what was happening in 3D printing for aerospace. Sevcik is an aerospace engineer who spent eight years at Lockheed in various engineering, project management, and business roles. He next worked in trying to deflect asteroids from hitting the earth and later worked at UTC aerospace, managing teams of 100 or more engineers and significant budgets before becoming their Manager Program Management. He then worked on MRO with 3D printing before working in various roles at Stratasys. He now manages their Aerospace business.

Sevcik was very enthusiastic about the prospects of both polymer and metal 3D printed parts for aviation and aerospace. Although Stratasys has worked behind the scenes extensively for military customers they were now really for the first time able to share some more public business cases. He really enjoyed working with Boom on their supersonic passenger plane initiative, for example. Sevcik connected with Boom over two and a half years previously. What started as a simple tooling engagement using Fortus systems evolved into much more.

“They were building up their factory” and “for the sake of speed started deploying 3D printing more extensively.”

He was happy that “very quickly it became a real partnership” and that he and his team were able to “work right there with them” and “dive in deep.” From the initial tooling, jigs and fixtures were also added to the project as was work on parts of Boom’s simulator aircraft. Now they’re looking at putting 3D printed parts on the actual model and later on the Boom aircraft. On the test vehicle alone there were “100’s of potential 3D printing applications, especially once the Boom team understood the technology comprehensively.”

Sevcik maintains that there is a “level of maturity with additive adequate for prototyping, tooling, and some parts on aircraft” but that many customers “see the risk on additive and see it as an unproven technology.” Now the industry is entering a different phase though, increasingly “you’re dealing with procurement people, the conversation is about risk reduction.” Especially for some applications, the combination of “Ultem 9085 for aircraft interiors with the Fortus 900mc system has a high level of maturity.”

“9085 is very useful when looking at the heat release from larger aircraft interior parts”, if “you’re looking at a foot by a foot parts or parts with more volume then let’s say a fist the heat release requirements of those parts makes 9085 a good material to use.”

As examples of such parts Scott cites “luggage bins, bulkheads, panels.” The company also has examples of parts being flown in business aircraft including serial production parts. Commuter aircraft parts, speaker enclosures and many more applications exist.

“Around 15 years ago Stratasys first got into tooling for aerospace and later into cabin interior.”

Other applications can be wholly new but Sevcik likes it when customers “challenge us” or “form a strong team with us.”

Sevcik can’t tell us much about Stratasys’ defense business lines. What is known is that the company has a strong defense base working with Lockheed, NASA and others. In military aviation repeatability on the 900mc has been demonstrated by the University of Dayton Research Institute (UDRI) and certified for parts for the Air Force. This year and a half process has led to “C5 and C130 parts being made.” Additionally, the United Launch Alliance, Atlas rocket has seen 3D printed ducting.

One other thing the company has been able to talk about is its Antero PEKK material. Sevcik says it’s especially useful for aerospace “because PEEK crystalizes so quickly” but with “Antero you have much more control over crystallinity” which lets you “make large PEKK parts.” Antero is “best suited for applications outside the cabin while Ultem is ideal for in it.”

“Filled Ultem grades can also be brittle and in some cases, semicrystalline PEKK can give a better fit depending on what you’re looking for.”

Antero can also be ESD safe which can extend its usefulness. He’s buoyed by their materials partnership with Solvay and thinks that Strategic Materials Partnerships strike the right balance between “open and closed.” It will “help expand the portfolio of materials….and give customers access to fully tuned closed systems.” Additionally, the company is looking at unlocking aerospace for “TPU” and “working with DSM on materials for SLA.”

Along with machine sales Stratasys is approaching the aviation market through its Stratasys Direct Service business and the Harvest unit which is AS 9100 certified. Many OEMs have “15% in house fabrication and outsource the rest to partners” and for these cases, OEMs want multiple partners. This means that in some cases Stratasys will work with partners and in some technically compete with them. Stratays wants to “support OEMs and help its partners and customers move into production” in this way it “meets OEMs and customers where they want to be met.”

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Hexcel makes Boeing’s Qualified Provider List for 3D printed aircraft components

Advanced composite materials company Hexcel Corporation has received 3D printed part approval from multinational aeronautical corporation Boeing. Now recognized on Boeing’s Qualified Provider List (QPL), Hexcel is cleared to produce aerospace structures from its high performance thermoplastic HexPEKK. HexPEKK parts provide strong mechanical performance and significant weight reduction. Aviation applications of HexPEKK include optimized brackets, […]

Interview with Hexcel on PEKK for 3D Printing

PEKK is one of my favorite 3D printing materials. With very high service temperatures, high strength, and chemical resistance it is a high-performance polymer that has applications in very demanding areas such as aerospace. PEKK is much less known and used than PEEK and PEI in 3D Printing. Where the former is the high-performance material with the irresistible brand and the latter has been used to make thousands of aerospace parts for decades PEKK is little known or understood. The material is on the march however with new capacity being made available by Arkema en Gharda, while exciting medical applications being explored by Oxford Performance Materials and Kimya. Companies such as 3Dxtech also offer it as a filament for FDM. Meanwhile, Intamsys, Roboze, Stratasys, and Minifactory have added the material to their arsenal in FDM while EOS is doing so for sintering. Tantalizingly PEKK may offer performance similar to that of PEEK but some grades could be easier to process and be more versatile. One firm with big plans for PEKK is Hexcel. Hexcel is a $2 billion revenue company that makes carbon fiber materials, carbon fiber parts, other composites, and composite structures. Used in commercial and military aviation as well as space Hexcel is used to making complex structures with very demanding requirements. It acquired OPM’s aerospace business and went on to develop the material and resulting structures for 3D printing. We asked Dr. Whitney Kline, Engineering Manager at Hexcel, to tell us more.

A HexPekk cubesat frame.

Why is PEKK so exciting?

PEKK is engineering grade top-level polymer with a wide usable temperature range qualified from -300F to +300F, 600F melt high performance, great chemical compatibility, and it performs well in tests that are important for aircraft applications such as flammability tests and measurements of smoke and toxicity.

What products do you make?

Hexcel globally supplies products including carbon fiber, woven composite fabrics, prepregs and specialty aerospace products such as honeycomb core and our Acousti-Cap product family. Specifically with additive products, we offer our Selective Laser Sintered (SLS) PEKK-based materials—HexPEKK-N which is a pure resin material and HexPEKK-100 which uses Hexcel’s high-performance carbon fiber alongside the PEKK. We supply build-to-print, ready-to-fly parts for our customers, and all of them are manufactured in our ISO9001/AS9100 approved facility based near Hartford, CT.

Why should I work with you?

Hexcel is a global leader in advanced composites technology with an extensive portfolio and proven performance in delivering composite solutions that are stronger, lighter and tougher. Moreover, we have deep technical expertise and a history of supporting the largest aerospace and defense companies with high quality, high-performing products. Combining that expertise with the excellent properties of HexPEKK and the extensive material characterization we have, our team provides a proven, high-performance material at aerospace-quality levels.

What advantages does PEKK have over PEEK?

PEKK has a wider processing window than PEEK, a better compressive strength, and increased wettability.

What about PEI?

We are frequently asked to replace PEI in customer applications. PEI is a great material for prototyping and development, but when you look at a production environment in aerospace applications it’s often incompatible with the chemicals and fluids that are used, including jet fuel, cleaning and defumigation solvents and oils. PEKK is also stronger and has a higher usable temperature range than PEI.

Integrating functionality into parts can reduce part count as well as weight

For what applications is it most suited?

There’s a lot of ductwork required in aero/defense applications and those are often in tight envelopes with high structural performance. We also supply brackets and a variety of part types that traditionally would be made out of cast aluminum or magnesium. Any application where there is a need for weight savings, envelope savings, and high performance is a great candidate for HexPEKK

An aerospace AEC ducting example.

What kinds of customers do you have?

Hexcel supports customers in the commercial aerospace, space and defense, and industrial markets.

What kinds of people would you like to work with?

We are interested in many types of customers not only within our current markets, but we also are continually looking for new opportunities.

What do you see as emerging applications in your field?

We are excited to see the impact additive manufacturing will have on retrofits and upgrades, which are very important parts of the defense and commercial aerospace markets. It is also exciting to support space customers as the frequency of satellite and commercial space launches increases, driving the need for quick and innovative parts.

What capabilities do you have?

With our expertise in additive manufacturing, our Hartford site offers selective laser sintered parts as a contract manufacturer. We offer end-use components, as well as coordinate secondary processes, such as machining, NDT, painting, plating, and bonding.

Why is PEKK so interesting in aerospace?

It is a chemically robust, high strength, and wide temperature ranging polymer which lets it be used in some of the most challenging applications in the industry.

What advice do you have should I be a company looking to manufacture using 3D printing?

When using 3D printing in applications that support manned applications or high-performance systems, it’s important to remember the fundamentals of good manufacturing: process, quality, repeatability and traceability.

There is a lot that goes into bringing a new material and process to market in the aerospace industry. The process for qualifying a new material for aerospace often takes more than a year and there is a large investment that goes into the process and machines. It’s important to consider whether your company needs to be in-house experts on every kind of 3D printing technology or material, or whether it is more valuable to rely on the experience of established parts and materials suppliers who know how to get quality product out the door so your company can focus on making cool end products.

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Additive Manufacturing and 3D Printing in 2019

Additive manufacturing is changing the world. Another term for 3D printing, additive manufacturing differs from other forms of manufacturing in that, rather than removing material like machining, it adds material to create a product. This offers many unique advantages, from unprecedented customization and precision to a whole new world of shapes that are not possible with other techniques.

3D printing works by providing a carefully planned CAD file to a computer that runs a 3D printer. This machine prints the material layer by layer. There are a variety of materials and methods for 3D printing. You can 3D print plastic, nylon, metal, and more. Products can be printed through traditional 3D printing or through more specialized processes like selective laser sintering (SLS) or multi jet fusion (MJF), where there is no need for support structures to print complex designs. Between the design, material, and the process, no additive manufacturing job is quite alike.

These factors allow for some incredible customization of designs. You don’t have to modify an existing template or object. Additive manufacturing allows for strangely shaped spaces and corners. Weight can be more easily managed thanks to this kind of customization and the wide range of available materials. Some designs are incredibly delicate yet smooth. There is no need for support structures for these designs, allowing a lot of creative freedom that wasn’t previously available once you got off the drawing board.

Additive manufacturing already sees a lot of use. There are plenty of hobbyists out there, certainly, but it’s also being used by businesses to do things like produce prototypes or even their main product from custom parts for almost anything to modeling kits. Companies such as HP and Honeywell are developing 3D printing technology as we speak. They’re looking to improve quality and efficiency as well as allow for a new range of materials to be printed. These are not pie-in-the-sky ideas, but real developments that are already making a mark.

This is because a company has a lot to gain from switching from traditional manufacturing techniques to additive manufacturing. 3D printing is a great way to save money. The ability to reduce weight can be a major factor, especially if you are looking to make parts. It’s possible to create hollow or honeycomb-structured parts that are just as strong and capable as solid ones, but much lighter.

You can also order to demand. other manufacturing techniques may require you to order a minimum number of products that is much larger than what you actually need. This is because there is a much larger start-up cost to these techniques for a product line and the company needs to make a profit, not a loss, on your order. Additive manufacturing does not work this way. You can order three or three-hundred products, whatever you need. The cost of an order largely comes from the material that needs to be used to make it.

This makes 3D printing an excellent choice if you do not need a massive, expensive order. The quality will still be high, but the price will be much lower and you won’t be stuck with stock you can’t sell, taking up room that can be better used for other things.

Additive manufacturing is less wasteful, too. Traditional manufacturing techniques are messy and leave a lot of scraps behind. Not so with additive manufacturing. It’s far more efficient with material. What scraps are produced are often recycled, melted back down to be used for more 3D printing. You are only charged for the material that is actually used to create the product(s), not what’s used plus the scraps that end up on the shop floor.

This incredible and increasing cost efficiency of 3D printing means additive manufacturing making waves in manufacturing. It’s not just for custom phone cases and graduate student research projects anymore. More and more businesses are choosing to use 3D printing to make their products. This has prompted new technological developments as the possibilities of 3D printing have been explored.

Check out these major developments in 3D printing for 2019 (which is only half over!):

HP just opened its 3D Printing and Digital Manufacturing Center of Excellence in Barcelona, Spain. HP has been on the leading edge of 3D printer development. HP has just released new materials like Nylon 11 and TPU (a material that is highly flexible like rubber). This facility is a center for testing and collaboration between industry experts and customers alike. Expect to see a lot of additive manufacturing news to come out of here.

Photocentric introduced its Liquid Crystal (LC) Magna system. This is their second largest LCD printer.This new 3D printer is 10 times faster than its predecessor. It has 23.8 inch 4K Ultra HD screen with a custom backlight. These allow for an average print accuracy of within 50 µm and model tolerances of less than 100µm. It takes only a few hours to produce batches of custom products.

Autodesk, one of the major players in the additive manufacturing software world, released new add-ons for its 3D modeling software Fusion 360. This entry-level platform now provides cost-estimation and generative design. It’s a popular choice for those looking to start getting into 3D printing design and it is now an even better choice.

EOS and ALM have just released HT-23, a new PEKK carbon fiber material that is a high-performance polymer that is extremely chemically resistant, has a high melt point, and is inherently flame retardant.

At Jawstec, we are ready to help your business take advantage of 3D printing. We keep track of the latest developments in the industry and our experts can leverage them to help you create the product you want. Whether you’re looking to produce a prototype or a whole product line, our 3D printing services offer an efficient, budget-friendly option. Contact us today to get a free 3D printing design quote so we can help you move your business forward with additive manufacturing.

The post Additive Manufacturing and 3D Printing in 2019 appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Interview of Erik Henstra of Armor Group’s Kimya On Custom 3D Printing Materials

Our industry is currently being entered by a number of very large polymer and metals companies. These firms see the potential of our market. Even though the volumes are comparatively small high-value applications and strong growth means that they have to have a 3D printing play. In the polymer market, we see some companies invest nig by buying materials vendors, others build capacity by starting departments centered on verticals while others invest big in high volume applications. Some go direct others only indirect. From the inside looking out I find it fascinating to see very different firms face the same business conundrum and all find a very different way to solve it.

Armor Group is a French multinational active in 20 countries with over 1900 employees and 265 million euro in revenue. From thermal transfer ribbons, inkjet cartridges and 2D print the firm is now trying to tackle 3D printing. Their approach? Armor has created a startup Kimya. Backed by Armor’s resources and R&D the small versatile startup is meant to be able to quickly engage the 3D printing market. The company has a strong focus on customized materials for very specific applications. This positioning and go to market is unique and pits the company against established small 3D printing materials firms and compounders such as Lehmann & Voss. Rather than try to push their own brands Kimya is focused on making the right material for your particular application. If the firm is versatile enough to make the right very specific materials, then their heft may drive high volume good margin applications to real profitability. They’re positioning themselves right at the frontier of the possible in industrialization. However, will louder market entrants drown out the startup or will they make the wrong choices in terms of the materials that they make? This will retard their progress. We interviewed Erik Henstra, their Business Development Manager, Nordics and Benelux to find out more about the firm and their plans (are you a new 3D printing market entrant, email joris (at) 3Dprint.com to also get interviewed).

What is the ARMOR group?

ARMOR specializes in the industrial formulation of inks and the coating of thin layers onto thin films. The Group is the global market leader in the design and manufacture of thermal transfer ribbons for printing variable traceability data on labels and flexible packaging. The European market leader in innovative and sustainable printing services and consumables, the Group is a pioneer in the development and production of industrial inks and innovative materials, such as organic solar films, coated collectors for electric batteries and bespoke filaments for additive manufacturing. With an international presence, ARMOR has nearly 1,900 employees in some 20 different countries. In 2018, it posted annual revenue of €265m. Each year the group invests nearly €30m in R&D and industrial development. ARMOR is a responsible company committed to stimulating innovation within society.

What is KIMYA?

The division ARMOR 3D developed the offering Kimya to committing to its industrial clients and printer manufacturers by offering three products & services packages:

Kimya Lab:

To formulate and produce customized materials in accordance with a set of specifications agreed with a team of chemists based at our production and R&D sites in Nantes (France).

Specific development

Dedicated team of chemists

Characterisation laboratory

Bespoke production lines

Kimya Services:

To support professionals in their Additive Manufacturing projects. Kimya selects and works with expert partners to provide training, print services of installation and maintenance of 3D industrial printers.

3D print services

Training

Kimya Materials:

A range of high-performance, engineering and basic filaments for professionals as well as a range of eco-designed filaments, combined with a collection service for your 3D print waste (available via our distribution network).

Kimya technical filaments
Eco-designed filaments
Collection program

Why did you choose to start a startup?

To benefit from the advantages of being in a group, but also with a vision of a start-up, meaning going fast in our development to serve our customers in the best way possible.

What unique capabilities or products do you offer the market?

On-demand material and solution to help industrials and printer manufacturers print final parts with the material that suits their specific needs.

What advice would you give a company wanting to manufacture with 3D printing parts?

Take it as a global project to take into account all the aspects of a successful print process: material + printer + software + designed part.

What materials do you offer?

We offer high-performance materials that we formulate to offer specific properties to final products. Some of our materials are: PEKK-A, PEI-1010, PEI-9085 and PPSU.

What companies do you wish to partner with?

Industrial end-users willing to integrate Additive Manufacturing for their production process and production of end-use parts;
3D printer manufactures for characterization and making print profiles available;
Resellers and distributors (dedicated per region) who see added-value in our proposition towards industrial end-users and 3D printer manufacturers.

What kinds of custom materials do you make?

All kind that have specific usage and certifications.

How do you make a custom material?

Based on specifications, we formulate in house materials that we then use to produce a filament.
Then we validate the material produced by printing parts.
We make specific profiles for printers and printed parts that are adapted to our material.

What filaments are doing well now in production?

PEKK-A filament co-developed with KEPSTAN by Arkema is among those doing especially well now.

What new filaments have you brought to market?

We’ve focused on high-temperature filaments easier to use than PEEK, such as the PEKK-A Kimya. What we also do is very specific products such as railway compliant smoke fire filaments for an industrial (EN45-545 standard).

In what way are materials limiting 3D printing?

The main limitations of FDM are the Z layer adhesion, surface quality and overall quality.

INTAMSYS Launches its Customer Applications Enabling Program

In order to better meet the market and the customer’s needs, INTAMSYS, a Shanghai-based leading industrial 3D printer manufacturer, is launching its Customer Applications Enabling Program.

Current issues:

1. Customers know little about materials and applications. It is difficult for customers to choose suitable materials and 3D printers for their application. Some specific industrial applications may require customized filaments.

2. There are some gaps between filament manufacturers and 3D printer manufacturers, it is difficult for customers to immediately run a 3D printer for specific filament material.

Solution:

Qualify and test high-quality filament. Then provide application and a filament database in collaboration with filament manufacturers.
Smart selection program to choose suitable filament and 3D printer based on customer requirements.
Provide optimized printing profiles for each qualified filament and printer. Pre-configure this information in the INTAMSYS slicer software.

Not only will the settings be optimized for a large number of filament manufacturers, but this will also enable customers to have better quality prints thanks to perfectly accurate printing settings that don’t have to be manually selected.

By extending the field of applications, this program will enable INTAMSYS customers to get the most out of 3D Printing & of INTAMSYS printers.

Every manufacturer filaments will be tested according to their best settings & will be required to meet the highest quality standards of the industry.

Even though pre-defined profiles will be available for each material & application, customers will still be able to use their own settings with the filament of their choice, following our open materials machines policy.

INTAMSYS is proving once again it is continuously trying to deliver innovative ways to ‘’customize our future life’’.