BASF Acquires Industrial XSTRAND 3D Printing Filaments from Owens Corning

Last fall, Germany-headquartered BASF 3D Printing Solutions (B3DPS), a 100% subsidiary of BASF New Business GmbH, introduced its new corporate brand presence, Forward AM, to the 3D printing industry during formnext 2019. B3DPS provides service solutions and a wide variety of materials for the additive manufacturing (AM) value chain under this brand, which is ultimately working to propel industrial scalability in the additive manufacturing industry.

The materials that Forward AM currently offers include Ultrasint powders for powder bed fusion (PBF) printing, several Ultrafuse filaments ranging from standard and flexible to support and metal, and Ultracur3D photopolymers. Now, Forward AM is expanding its AM materials portfolio with the announcement that it has acquired the high-performance XSTRAND Business Line from global building and industrial glass fiber-reinforced composites leader Owens Corning.

“Through the acquisition of the Owens Corning XSTRAND business, we are able to serve our customers with new and innovative filaments for 3D printing,” stated François Minec, the Managing Director for BASF 3D Printing Solutions, in a press release sent to 3DPrint.com. “By adding these high-performing materials, Forward AM now offers one of the broadest product ranges in the entire Additive Manufacturing industry, with expert solutions tailored to all industrial customer needs.”

The acquisition was effective as of August 6th, 2020, with a scope that “does not envisage the transfer of any personnel” but does include transferring the brand itself, and all of its important intellectual property (IP), to BASF’s Forward AM brand.

The XSTRAND line of materials is made up of three separate, 30% glass fiber-reinforced filaments that Owens Corning developed: a polyamide, a polypropylene, and a polycarbonate. They are:

  • XSTRAND GF30-PA6, featuring extreme durability and a large operational temperature range
  • XSTRAND GF30-PP, with superior strength, chemical and UV resistance, and low moisture absorption
  • XSTRAND GF30-PC, with high heat deflection temperature and dimensional stability

Parts and components that are 3D printed using glass fiber-reinforced filaments like the XSTRAND line have high strength and ridigity, and it also enables easy printing and handling as well, so they can be used for very demanding industrial AM applications, such as industrial tooling and fixtures, transportation, automotive, electronics and small appliances, and engineering.

The XSTRAND filaments have excellent mechanical properties, due to the integrated glass fiber which reinforce them. Because of this, Forward AM says the materials are able to perform better than the standard polymer filaments you find on the market.

“BASF’s capability will enable the further acceleration of XSTRAND products and support future growth of the composites industry. Owens Corning will continue its collaboration with BASF as we transition XSTRAND® to them,” said Dr. Christopher Skinner, the Vice President of Strategic Marketing, Composites, for Owens Corning.

One of the XSTRAND filaments: GF30-PA6 filament for 3D printing is a reinforced material specifically designed to be compatible with any standard Fused Filament Fabrication (FFF) 3D printer. (Image courtesy of Owens Corning)

By acquiring this advanced AM material line, Forward AM will continue to grow its portfolio, further solidifying its place in the 3D printing industry as a top materials and service provider.

(Source: Forward AM / Images: Owens Corning)

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3D Printing News Briefs, August 5, 2020: Titan Robotics & Braskem, 3DPRINTUK

Today’s 3D Printing News Briefs is about materials and a 3D printed version of a real building. Titan Robotics and Braskem are partnering up to offer new solutions in 3D printed polypropylene, while 3DPRINTUK is expanding its materials and post-processing capabilities. Finally, the Coit Tower House in San Francisco now has a 3D printed miniature replica.

Titan Robotics & Braskem Announce Partnership

Braskem Polypropylene pellets for 3D printing

Production AM solutions provider Titan Robotics and petrochemical company Braskem have announced their strategic partnership, which has resulted in the launch of a new polypropylene (PP) resin that’s been optimized for 3D printing large-format production parts. The two companies spent over a year researching and developing the new material, which is the first commercially available grade of unfilled PP engineered specifically for 3D printing on Titan’s industrial Atlas 3D printers with pellet extrusion. The features of PP include chemical resistance, dimensional stability, impact strength, low density, recyclability, and thanks to this new partnership, Titan and Braskem will be able to offer improved industrial AM solutions.

“3D printing large parts using polypropylene resin has been a challenge for many years,” stated Rahul Kasat, Titan Robotics’ Chief Commercial Officer. “In collaboration with Braskem, a global leader in the polypropylene market, we have now solved that challenge. Our industrial customers will be able to print functional parts with this first of its kind polypropylene grade. We are also excited to continue to develop new polypropylene based solutions for our customers in collaboration with Braskem.”

Titan is also an authorized distributor of Braskem’s 3D printing pellet products.

3DPRINTUK Expanding Materials & Post-Processing

PEBA Dyed Close Up

SLS low volume production specialist 3DPRINTUK is branching out with its introduction of the flexible PrimePart 2301, a polyether block amide (PEBA) material with good chemical and water resistance, rubber-like characteristics not dissimilar to TPU, excellent detail resolution, and a higher melting point than most other resin-based elastomers. The material would be a good fit for batch production runs and rugged end-use applications, including handles, sports equipment, air ducts, and gaskets. Additionally, the company has invested in DyeMansion’s PowerShot S system, which uses a proprietary PolyShot Surfacing (PSS) process that allows 3DPRINTUK to offer a shot peening post-processing service that can improve the surface finish of 3D printed parts.

“At 3DPRINT UK we have honed and optimized the SLS 3D printing process over many years to achieve the best possible results off our machines for a wide range of relevant applications, that continue to grow in scope. However, the post processing of parts — from cleaning through to further optimised surface finishes — has always been a necessity for many of our clients. Expanding our post processing capabilities is a vital part of the business, and the DyeMansion PowerShot S system is an important next step in our expansion, enabling us to offer our many and varied clients the benefits of shot peened 3D printed parts from a single source,” said Nick Allen, the CEO and Founder of 3DPRINTUK.

3D Printed Coit Tower House

The 210′ tall Coit Tower was built in the early 1930s in San Francisco’s Telegraph Hill neighborhood as a way to beautify the city. The art deco tower, a recognizable sight on the city’s skyline, was added to the National Register of Historic Places in early 2008, and 12 years later, Yuriy Sklyar, the founder, CEO, and head of design & marketing at design studio Threefifty, has 3D printed a replica tower that stands over 7′ tall…a 1/20 scale. Utilizing a Creality CR10S5, a Replicator 2, and a MakerBot system, Sklyar, who has been utilizing 3D printing since 2013, called this unique project a “great opportunity to leave a lasting mark on the best city in the world – and its art community.” It took a month to create the base of the tower, as he had to redo a lot of it, eventually installing a heated silicone bed and heat enclosure to reduce the amount of warping. The next month was spent printing “the 4 giant sections of the fluted tower design.”

“Each one of these four sections, just like the real tower, consists of 4 sub-sections – I wanted to be very accurate with such details. At first these were limited in height by the 3rd party 3D printer, so only 2 sub-sections were supposed to be printed at a time, and then joined together with metal plates and nuts/bolts, but since I was now working on my own terms, I decided to reduce the amount of work for myself, and at the same time reduce the number of bolts/nuts/plates to just 4 sets, instead of 8,” Sklyar wrote.

“Each one of these sections takes about 3.5-4 days to print using a single 1.1mm shell @ 10% infill, which created for a surprisingly strong structure, since I instructed the infil to have a 45% overlap with inner and outer walls.”

You can check out his post for the very specific details of the project, but I’ll leave you with just a few – including all of the hardware used, the 3D printed Coit Tower weighs a total of 24 kg, and took over 7.5 km of ColorFabb’s nGen filament, SUNLU PETG and Gizmo Dorks PETG filament to print. Sklyar designed the whole thing from scratch, and the columns are joined by steel plates secured by bolts and in-printed nuts.

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3D Printing Webinar and Virtual Event Roundup, August 2, 2020

It’s another busy week in the 3D printing industry that’s packed full of webinars and virtual events, ranging in topics from medical materials and flexible electronics to polypropylene and market costs. There are four on Tuesday, August 4th, two on Wednesday, August 5th, and the week will end with the last KEX webinar on Thursday, August 6th.

ASTM’s AM General Personnel Certificate Program

Last week, the ASTM International Additive Manufacturing Center of Excellence (AM CoE) training course all about additive manufacturing safety.  Now, the AM CoE is starting its AM General Personnel Certificate course, which will begin August 4th and run through the 27th. One of its key focus areas is promoting AM adoption, and helping to fill the knowledge gap with training for the future AM workforce is a major way that the AM CoE is doing this. The online course is made up of eight modules covering all the general concepts of the AM process chain, and attendees will learn important technical knowledge that will allow them to earn a General AM Certificate after completing a multiple-choice exam.

“This course will feature 17 experts across the field of additive manufacturing to provide a comprehensive course covering all of the general concepts of the AM process chain to its attendees. The course will occur over the month of August consisting of two modules per week for four weeks. More information can be found in the course flyer.”

Online registration will open soon. This is not a free course—you can learn about the fees here.

Nexa3D & Henkel: Medical Materials Webinar

Nasal swabs

Recently, SLA 3D printer manufacturer Nexa3D and functional additive materials supplier Henkel announced that they were partnering up to commercialize the polypropylene-like xMED412, a durable, high-impact material that can be used to 3D print biocompatible medical and wearable devices; in fact, it’s already been cleared to print nasal swabs. Now, the two are holding a virtual leadership forum on “Advances and Breakthroughs in 3D Printed Medical Equipment and Device Materials,” like xMED412. Topics to be discussed will include new possibilities for 3D printing medical equipment and devices, the benefits of using AM to fabricate these products, and the advantages additive manufacturing has over medical materials made with traditional manufacturing. Panelists will engage with attendees after the discussion in a live Q&A session.

“3D printing has introduced all kinds of new possibilities for developing stronger and lightweighted equipment but we’ve only scratched the surface of what’s possible. These past few months have driven the industry to new realms of creativity with the need to quickly deliver medical supplies, devices and materials. With new lightweight, sturdy materials designed to withstand impact, moisture and vibration, access to lower cost medical equipment is becoming more widely available thanks to 3D printing.”

Register here for the 45-minute virtual forum, which will take place on Tuesday, August 4th, at 1:30 pm EST.

SOLIDWORKS Design Solution Demonstration

Also on August 4th, at 11 am EST, Dassault Systèmes will be holding a brief demonstration of its 3DEXPERIENCE SOLIDWORKS design solution. This demonstration of the platform’s capabilities will last just 22 minutes, and will teach attendees how to collaborate and stay connected to data while creating new designs with SOLIDWORKS when connected to the 3DEXPERIENCE platform, exploring the latest tools available on the platform, and design a model using both parametric (3D Creator) and Sub-D modeling (3D Sculptor) tools with the help of complementary workflows.

“SOLIDWORKS is the design tool that has been trusted by engineers and designers around the world for decades. Part of the 3DEXPERIENCE WORKS portfolio, SOLIDWORKS is now connected to the 3DEXPERIENCE platform with cloud-based tools that enable everyone involved in product development to collaborate on real-time data. Doing so enables you to efficiently gain the insight needed to create revolutionary new products.”

You can register for the demonstration here.

NextFlex Innovation Days

The last August 4th event in this week’s roundup is NextFlex Innovation Days, the flagship showcase event for the consortium of academic institutions, companies, non-profits, and local and federal governments that make up NextFlex and are working to advance US manufacturing of flexible hybrid electronics (FHE). The event will run through Thursday, August 6th, and will include panel discussions on how FHEs are continuing to transform the world, including a panel featuring a special guest speaker from the US Senate. FHE innovations that will be highlighted during the event include a wearable biometrics monitor from Stretch Med, Inc., flexible skin-like sensors from Georgia Tech, a flexible UV sensor out of the NASA Ames Research Center, miniaturized gas sensors that GE Research integrated into wearables and drone formats, and Brewer Science’s integrated FHE solutions in a brewery application.

“This multi-day virtual event will feature over 50 customer, partner and member company presentations online available at no cost. If you watch live, you’ll have the chance to interact with presenters and flexible hybrid electronic (FHE) experts from the comfort of home via webinars and virtual labs, or you can watch video demonstrations at your availability.”

Register for NextFlex Innovation Days here.

Additive America & HP AM Webinar

HP is currently sponsoring a webinar series highlighting business in the AM industry that worked to transition their production processes in order to help fill the supply chain gap that’s been caused by the COVID-19 pandemic. This week’s episode, which will take place at 1:30 pm EST on Wednesday, August 5th, will feature a discussion with Additive America on “the lasting impact of COVID-19 on additive manufacturing.”

“Listen in on conversations with our customers to learn how they have adapted to the change in business climate, whether it be a shift in production workflow to address supply chain gaps, enabling a faster product development cycle to support changing customers’ needs, or bridge production.”

You can register for this webinar here.

Prodways, BASF, & Peridot Talk Polypropylene

Also on August 5th, Prodways, BASF, and full-service product development company Peridot Inc. will be holding a free webinar together called “Rethink Additive Manufacturing with Polypropylene.” Led by Lee Barbiasz from Prodways, Jeremy Vos from BASF, and Peridot owner Dave Hockemeyer, the webinar will focus on how PP 1200, a tough, chemically resistant, low density polypropylene enabled by BASF for selective laser sintering (SLS) 3D printing, is being used to bridge the gap between additive manufacturing and injection molding, as well as growing opportunities and applications in short run manufacturing. Hockemeyer was an early adopter of the material, and will share a variety of use cases for PP 1200. There will also be a chance for attendees to ask questions about the material.

“3D Printing with Polypropylene is here! After more than three decades, 3D printing technology has evolved the ability to 3D print polypropylene material. Polypropylene enables scalability in manufacturing, reduces barriers to entry in 3D printing and reduces manufacturing costs by 25-50%!”

You can register for the webinar, held on Wednesday, August 5th, from 1-1:45 pm EST, here.

KEX Knowledge Exchange on Market, Costs & Innovation

The last entry in this week’s roundup will take place on Thursday, August 6th. KEX Knowledge Exchange AG, a former spinoff of Fraunhofer IPT, held webinars in July about powder bed fusion technology and post-processing, and the last in its series will be an online seminar on Market, Costs & Innovation. Sebastian Pfestorf from KEX and Lea Eilert, the project and technology manager for the ACAM Aachen Center for Additive Manufacturing, will be the speakers for this webinar.

“In this online seminar, you will learn:

  • Current AM market and industrial trends

  • What markets the technology has penetrated the most and why

  • How to go about implementing AM, including risks and uncertainties

You can register for the hour-long webinar here. It will take place on Thursday, August 6th, at 8 am EST.

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! 

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

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

M. Holland Distributing Braskem’s Polypropylene

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

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

Nexa3D Launches High-Performance xCE-Black Polymer

Belt pulleys 3D printed on NXE400 with xCE-Black

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

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

Nexa3D Announces Reseller Partnership with 3DZ

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

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

Formlabs Expanding APAC Management Teams

L-R: Jiadong Sun, Yoshinori Hasebe

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

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

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

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Reducing Warpage in 3D PrintingPolypropylene (PP)

As authors Martin Spoerk, Clemens Holzer, and Joamin Gonzalez-Gutierrez perform research from Montanuniversitaet Leoben, they outline improvements for material extrusion‐based additive manufacturing (ME‐AM/FDM/FFF) using polypropylene (PP). Details of their work have been outlined in the recently published ‘Material extrusion-based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage.’

Schematic illustration of the material extrusion process adapted from Ref. 4. The components are labeled as: (1) spooled material storage, (2) thermoplastic filament, (3) horizontally movable, heated deposition unit consisting of (4) counter‐rotating driving wheels, (5) a liquefier, (6) a nozzle, (7) structural element fabricated in a layer‐by‐layer manner, and (8) vertically movable build platform. [Color figure can be viewed at wileyonlinelibrary.com]

Polypropylene (PP) is a popular thermoplastic used in many applications due to suitable mechanical properties, along with biocompatibility, resistance to chemicals, and inertness; there are challenges in using PP industrially, however, mainly due to shrinkage and warpage—known to be a typical problem.

Pyramid of polymeric materials as a function of the availability of the materials in the ME‐AM market. Please refer to Ref. 37 for the commonly used polymer abbreviations. The asterisk on PP refers to the unclear commercial availability (refer to Commercially Available PP Filaments section). [Color figure can be viewed at wileyonlinelibrary.com]

Elongation at break as a function of the Young’s modulus for commercially available ME‐AM materials that are subdivided into thermoplastic elastomers, amorphous and semicrystalline polymers, and semicrystalline composites. The scientifically available PP‐based materials are highlighted by black rectangles. The mechanical properties are based on the technical information provided by the respective material suppliers and scientific publications.8, 13, 27, 59-63 The material abbreviations are described by the corresponding references in the legend. [Color figure can be viewed at wileyonlinelibrary.com]

Polypropylene (PP), a standard material in 3D printing, may have potential as an alternative to other engineering plastics and metals, offering the following qualities:

  • Good mechanical properties
  • Suitable tensile strength
  • Toughness
  • Impact and abrasion resistance
  • Low density

This material is suitable for customization as well as improvements to mechanical properties depending on fabrication needs, as well as being easily modified with additives like:

  • Fillers
  • Impact modifiers
  • Fibers
  • Other polymers

PP is also nontoxic, with so many benefits for ME-AM production that the researchers state it can only be outdone by less affordable materials like poly(ether ether ketone).

“Particularly, the outstanding chemical resistance of PP to polar solvents, nonoxidizing acids, aqueous alkalis, and aqueous salt solutions creates novel possibilities for ME‐AM, as other commercially available filament types are considerably less resistant to chemicals, which has limited the applicability of parts produced by ME‐AM,” state the researchers, who go on to remind us that polyolefins also take on very little moisture absorption, meaning that vaporized water does not interfere with 3D printing.

In terms of warpage issues, PP tends to warp ‘extensively,’ causing major problems for users. And while this may be a problem with ABS, it is far more serious a challenge for PP being used with ME-AM as the semi crystalline polymers cause a drastic change within the polymer chains. It is possible to reduce crystallinity by adding ethylene monomer segments or blending in other thermoplastics, ‘significantly improving warpage behavior of 3D printed PP components.’

“Currently, several PP filaments are available on the market that have been chemically modified in order to improve the quality of the products fabricated by ME‐AM. In this review, it was observed that none of the commercially available filaments are isotactic PP homopolymers, as such homopolymers have a great tendency to warp during the ME‐AM process, leading to specimens with poor geometrical accuracy,” concluded the researchers.

“Besides the chemical modification of PP by blending with other polymers or by copolymerizing, other strategies to improve the geometrical accuracy of PP specimens include: (1) use of different build platform materials to guarantee ideal adhesion during the printing process; (2) insulate the printing chamber and maintain the chamber temperature relatively high to reduce thermal stresses through a process similar to annealing; and finally (3) the addition of fillers, specially thermally conductive ones in order to prevent shrinkage during the fabrication process and to decrease the time to reach thermal equilibrium in the deposited layers.”

The study of materials appropriate to a variety of different 3D printing applications continues, and while researchers and manufacturers create new filaments and powders with polypropylene (PP), a wide range of other materials are considered for use in creating not only prototypes, but also models and functional parts.

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

The temperature evolution of a contour strand of the third printing layer of the first Charpy specimen for neat PP and the CF‐filled composite PP/CF10 (a) along with 3D‐printed specimens that are particularly prone to warpage12 for PP (b) and PP/CF10 (c). For a detailed setup of the thermography measurement, please refer to Ref. 13. The temperature difference between the peak maximum around 90 min and its previous minimum (peak amplitude) is marked for PP (ΔTPP = 20 °C) and PP/CF10 (ΔTCF = 5.5 °C) in (a). [Color figure can be viewed at wileyonlinelibrary.com]

[Source / Image: ‘Material extrusion-based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage’]

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