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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COVID-19 Doesn’t Shake Reinforced Optimism of 3D Printing Businesses

Recent announcements regarding earnings and financial performance through the first quarter of 2020, have given some insight into the impact COVID-19 has had on major 3D Printing businesses worldwide.

Earnings Results Comparison (by Revenue, M-millions, B-billions).

While ensuring employee safety and business continuity remained paramount, public companies were simultaneously challenged by a sudden decline in consumer demand, a continuing halt or reduction in onsite activities, and global supply chain issues, which began in China shortly before impacting Europe and the Americas.

Revenues for Stratasys and 3D Systems declined by 14% and 11% respectively, whereas strong order backlogs from 2019 led to significantly higher revenues realized for SLM and ExOne. SLM had the best first quarter performance in the company’s history with a 143% increase compared to 2019.

ExOne’s latest system is the 160Pro metal binder jetting 3D printer. Image courtesy of ExOne.

3D Systems saw revenues decline across segments, except materials, which stayed flat. The company faced a drop in consumer demand in automotive, aerospace, healthcare and dental, as well as disruptions in production facilities and on-site services. Despite sustained cost reduction measures and improving operating expenses by 13%, its shares depreciated 5% with 0.04 loss per share for 2020, compared to 0.09 loss per share for 2019.

In addition to the decline in Q1, Stratasys expects a sequential decline in Q2 of 5-10%. Yet the company believes its balance sheet with $325M in cash, coupled with its ability to generate cash and control costs, will help it manage the short-term hit in revenues, and strongly expects margins to recover.

Change in stock prices for several of the major 3D printing stocks, excluding GE, HP and voxeljet.

Across businesses, revenue decline has primarily been attributed to short-term impact of reduced manufacturing activity and industrial production due to COVID-19, resulting in a fall in consumer demand across segments. In addition, a pause and postponement of investment has seen lower capex spend across key industries such as automotive, aerospace, healthcare and oil & gas. Demand for new hardware and software licenses has declined, partly offset by recurring revenues from materials, consumables, or after-sales services. In some sectors, such as dental, material consumption has slowed as elective procedures are delayed or cancelled. In general, machine and software segment revenues have seen a decline, but recurring revenues from the installed base of 3D printers has seen revenues from the materials segment increase or stay flat. For instance, Prodways saw a decrease of 6.3% in machines and software, but a 25% increase in materials revenues.

This change in demand is seen as more of a ‘pushing-out’ of capex spend, than a cancellation. Order intakes stayed flat or reduced overall, as customers in key industries postponed capital expenditure and investment due to COVID-19 uncertainty and impact.

The impact in operations differed, as businesses with localized supply chains were less impacted—such as SLM who also kept safety stocks for high-risk and long-lead time items—as compared to 3D Systems or HP, who faced production and capacity disruptions in their global supply chains.

The NIP mask, developed by Materialise to help treat COVID-19 patients. Image courtesy of Materialise.

Materialise saw a slight revenue decrease of 1.8% with gross profits decreasing 3.7% compared to last year’s quarter. Though their software and medical segments grew, there was a steeper decline in their manufacturing segment revenues, which account for 45% of total revenue. The company delivered higher than expected revenues this quarter with a gross profit of $109M, and despite varied market performance recently, has seen its shares up 25.4% year to date.

ExOne, sold 14 of its metal and sand binder jetting machines in the quarter, with a 40% increase in revenues and a 19% improvement in net loss with $3.6M in Q1 2020, resulting in a $0.22 loss per share for 2020 compared to $0.28 in 2019.

Revenues at GE Group fell 8% to $20.5B, with is power and aviation division significantly impacted by its exposure to the decline in the commercial aerospace sector. However, GE’s Healthcare and Lifesciences segment saw demand surge 6% due to COVID-19. Yet the company has seen its shares lose more than 40% of their value this year and expects the second quarter results to decline sequentially, showing the first full quarter impact from COVID-19.

HP Inc has reported second quarter results with net revenues were down 11.2% to $12.5B compared to 2019, with personal systems declining 7% and printing 19%. In Printing, the company has set long term margin targets of 16-18%. In 3D Printing, HP has recently partnered with New Balance and Superfeet to grow its end-user solutions in scanning and printing, and is counting on key verticals such as healthcare for continued growth. The company is continuing its focus on structural cost optimization and productivity gains, hoping to generate over $2B in savings. It has also provided guidance of $2.33-2.43 per share for 2020 and $3.25-3.65 per share for 2022.

Superfeet secures New Balance license agreement for insoles 3D printed using HP technology.

Voxeljet’s share price has reduced dramatically over the last five years, despite steadily growing revenues. It has until December, 29, 2020 to regain compliance with NYSE after its average closing share price had fallen below $1.00 standard and the $50M market capitalization standard. Yet the company has reported Q4 2019 revenues with an 11.4% increase over 2018, and a record order backlog. While it does expect disruptions in operations and supply chain due to COVID-19, it anticipates demand for its large-scale printers to continue, expecting annual revenue for 2020 to be between €25-30M.

Companies have also been proactive within their organization to manage the impact of the crisis to their employees, customer base and business operations. From introducing remote working, reduced work week or shifts, and other employee-facing policies, to implementing safety and health protocols, freezing non-essential hiring and travel, and short-term optimization measures to ensure business continuity and avoid large-scale layoffs. For instance, salaries for all Stratasys employees and executives was reduced by 20%. Executives and board members at 3D Systems took a 10% pay cut with a majority of employees on limited furloughs, and partial activity measures were introduced for almost 50% of Prodways employees worldwide. Businesses have also taken measures to optimize operational costs, revaluate their supply chain and production costs, and increase focus and spend in digital, particularly in sales and marketing, for the long-term.

Overall, while Q1 earnings do show some signs of business impact, businesses are pointing towards Q2 as to where the full impact will be seen, since the pandemic peaked largely in the latter half of the first quarter, through March and April. In this regard, businesses have trended toward withdrawing guidance for the rest of the year, as uncertainties due to COVID-19 continue, while stating that second quarter results are expected to show a more considerable impact. Although there is a near-term focus on cost reduction, optimization and ensuring liquidity, 3D printing businesses are positive in their long-term outlook. Key industries are expected to remain structurally unaffected, with markets returning to the new normal in the second half of this year, and AM’s increased relevance has reinforced optimism in the industry’s long-term growth. No major shifts in long-term strategy or investment have been made yet due to COVID-19, with investments in on-going R&D continuing.

With their real-time response and contribution during COVID-19, 3D Printing businesses have led the way and impacted the front-line pandemic response, providing rapid, direct support for personnel safety and in essential medical devices and equipment. The response also proved AM’s capability in high-volume and bridge production, its potential in localizing and distributing manufacturing, flexibly and at speed, whether to retool or expand existing production, or to develop new, improved products faster, especially in healthcare. If anything, the pandemic response has only underlined the critical and long-term value of AM in addressing real-world gaps and needs, in ways that traditional manufacturing and supply chains just cannot.

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Prodways Group reports financial results for Q1 2020

French 3D printer manufacturer and service provider Prodways Group has reported its financial earnings for the first quarter of 2020.  Consolidated revenue for the three months ended March 31, 2020, amounted to €15.5 million, representing a decrease of 11 percent from Q1 2019, which was  €17.4 million. With a mandatory home confinement order issued in […]

Is 3D Printing a Threat to Forging?

If you close your eyes and meditate hard enough, plunging yourself into a deep transtemporal trance, you may be able to conjure up your ancient ancestors wielding a mighty hammer to smash and shape a hot piece of iron against an anvil. The world’s oldest recorded metalworking process, forging still exists today, albeit in a form somewhat removed from its inception over 6,000 years ago.

Forging processes apply force to shape metal. Most often, modern forging is associated with high temperatures heating metal workpieces to the point that they can be formed by machine-driven hammers or presses, sometimes using a die to smash the material into a specific geometry. However, there are other forging techniques that use warm or cold temperatures that ensure that metal parts don’t expand as a result of high heat and then shrink, thus resulting in better tolerances.

In the additive manufacturing (AM) industry, we love to talk about the various traditional manufacturing processes that are already being disrupted by 3D printing and forging is no different. Exactly how AM will disrupt the world of forging, however, is different from how it is impacting, say, casting and machining.

Forging has its major advantage in the physical strength of forged parts, which, due to the fact the internal grain structure deforms to follow the general shape of the part, are stronger than cast or machined parts. The cost of materials for forging processes is usually cheaper, but forging presses and dies can be costly, and parts usually require secondary processes, such as CNC machining, to achieve final tolerances.

Therefore, forging is usually reserved for less geometrically complex parts that need to be manufactured in a highly repeatable way from less expensive metals, such as iron and steel. This might mean wheel spindles, kingpins, axle beams and shafts for automotive parts; valves and fittings in oil and gas; pliers, hammers, sledges and wrenches in hardware and tools; connecting rods, cylinders, discs in general industry; shells, triggers, and other artillery parts; and bulkheads, spars, hinges, engine mounts, brackets, and beams in aerospace. Obviously, some of these parts can crossover from one vertical to another (e.g., brackets and hinges)

Those familiar with AM technologies may start to get a feel for where AM is best situated for impacting the forging market: low-geometric complexity, yet high strength material properties. If you’re thinking like we are, you are starting to consider the possibility of directed energy deposition (DED) for the fabrication of near-net-shape parts.

DED offers many of the same benefits and fits many of the same applications as forging, while providing some additional advantages. Using blown powder or a metal wire, DED can rapidly form a medium-to-large sized part to near-net-shape. Often referred to as “blanks”, these components are then finished using CNC machining.

Blanks 3D printed using Norsk Titanium’s Rapid Plasma Deposition process. Image courtesy of Norsk Titanium.

DED can create a metal part closer to the final desired shape than forging, without the need for tooling. And, when it comes to more expensive materials like titanium, DED can potentially be more cost effective. For forged parts that would typically require dies, DED can be significantly faster. In turn, DED has the potential to reduce die, material and machining costs for certain components.

That same Norsk blank machine finished to final shape. Image courtesy of Norsk Titanium.

Specifically, those components will be low in number, when mass manufacturing doesn’t make sense and AM will actually be cheaper than forging. This means short runs of specialty components and prototypes. In other words, aerospace is the primary sector for DED as an alternative to forging at the moment. There are numerous DED companies targeting the aerospace industry, with aircraft manufacturers qualifying the processes and parts for installation on aircraft.

When it comes to part strength, DED components experience large thermal gradients during the deposition process that result in residual stresses that can lead to distortion and negatively affect the overall strength of the part. In some cases, heat treatment may even need to be implemented during the actual production of a part in order to relieve stress.

Naturally, systems manufacturers are working to overcome these issues, including closed-loop quality control and monitoring, as well as simulation software capable of compensating for stresses that will be experienced in a printed part.

Due to the issues discussed here, forging is not likely to be threatened by AM, but complemented by it. Forging is still the go-to choice for mass manufacturing sturdy, geometrically simple components, while DED can be used for small numbers of (often medium-to-large) specialty parts that would otherwise require tooling or must be made from high-performance, expensive metals. This might include structural components for the Boeing 787 Dreamliner or titanium brackets for the A350 XWB.

Once a DED system is brought in for such projects, auxiliary applications can then be found for the technology. For instance, DED machines can be used to repair dies for forging or to deposit additional features onto forged parts. Arconic actually developed a novel additive process called Ampliforge in which DED parts are first manufactured and then finished with forging to ensure the proper material properties of the components.

[Feature image courtesy of AMETEK.]

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Prodways Announces Clear Aligners Manufacturing Ecosystem

At Lab Day 2020 in Chicago, Prodways has announced the development of its Clear Aligners Manufacturing Ecosystem, meant to cover all aspects of the design and production of clear aligners. Developed in partnership with prevalent companies in the digital dentistry space—3Shape, Full Contour, Imes-Icore and Dreve—the product ecosystem can deliver up to 1200 aligners daily, according to Prodways.

As SmarTech Analysis has reported, the market for additive manufacturing in dentistry was on track to surpass $2.7 billion in 2019, with an anticipated 500 million dental devices and restorations projected to be produced annually by 2022. If you’ve seen an TV ads lately, you’ve likely caught one 3D-printed dental item that is already in high demand.

Clear dental aligners were among the first consumer products to be mass manufactured with the use of 3D printing. These devices are typically made by the following workflow: an intraoral scan of a patient’s mouth captures the 3D data used to design a model of their teeth; this model is 3D printed before the aligner thermoformed on top of the mold.

Given the success of clear aligners, not only are there now numerous competing aligner brands, but also 3D printing companies vying for their business. Prodways aims to stake out its own territory in the segment with what it considers the first end-to-end digital manufacturing solution. This includes 3D scanning, data preparation, treatment design, 3D printing, thermoforming, laser marking and trimming, with hardware and software integration and automation along each step. Part of this automation comes in the form of the automatic platform loader and unloader (seen in the video below), a semi-automatic thermoforming module and an automatic laser marking and trimming module.

With Prodways linking together 3Shape, Full Contour, Imes-Icore and Dreve, each companies’ hardware and software are interoperable. This results in the ability to manufacture up to 1200 aligners per day at what Prodways suggests is a low cost-per-part and a short time to market.

This ecosystem is a significant one for Prodways, which has been building its spot in the dental market for some time. The company’s MOVINGLight DLP technology is known for its high throughput, making it ideal for batch production of products like dental molds for aligners. The release of the LD3 system marked the company’s entry into smaller systems that can be used in dentistry, as well as jewelry and other fields. The acquisition of Solidscape also added to its footprint in the dental market.

As Prodways works to fully automate the process of making clear dental aligners, they may have some stiff competition, particularly from the likes of HP, which is already claiming to make 50,000 molds for aligners per day via its customer, the Smile Direct Club.

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Prodways expands in the US by becoming first Dental Value-Added Reseller of 3DBioCAD

Prodways, a French 3D printer manufacturer and service provider, will work with 3DBioCAD, the dental CAD/CAM division of B&B Dental Ceramic Arts’ full-service dental laboratory. Prodways will be the first dental reseller for the Renton-based company, strengthening its footprint in the US. 3DBioCAD, aiming to deliver premium CAD/CAM solutions and services chose Prodways for the […]

3D Printing Industry News Sliced: Essentium, Tommy Hilfiger, Prodways, Arkema, Smart International

In this week’s edition of Sliced, the 3D Printing Industry news digest, concrete 3D printing is looked as at a solution for rebuilding a village; fashion brands are integrating 3D printing for a “sizeless” solution, and generative design is used for architectural planning. We also cover news from Essentium, Ricoh, Smart International, Arkema, Prodways, Endurance Lasers and […]

Prodways announces sales to BASF and DSM

Prodways Group, a French 3D printer producer and service provider, has announced a series of 3D printer sales to major chemical companies for R&D and manufacturing applications. The company has sold a selection of its selective laser sintering machines to DSM, BASF and an unnamed French chemical company, including its ProMaker P1000 and ProMaker P2000 […]

MBDA adopts Prodways Rapid Additive Forging technology to 3D print large aeronautic parts

European developer and manufacturer of missiles MBDA has chosen Prodways Rapid Additive Forging (RAF) system to 3D print large titanium aeronautic parts. With the RAF system, which operates using a robotic head depositing molten metal in an atmosphere of inert gas, MBDA intends to reduce costs and lead-times of such components by 25%. The Rapid Additive […]

What happened in 3D printing at RAPID & TCT 2019?

As one of the biggest 3D printing events of the year, last week’s RAPID + TCT conference created the busiest news week of 2019 so far. Reporting live from the show, backed by a team covering all of the latest press releases from the event, 3D Printing Industry provided leading coverage of North America’s must-see […]