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3D Printing News Briefs: October 6, 2019

We’ve got lots of material news for you in today’s 3D Printing News Briefs, starting with a Material Development Kit from RPS. Polymaker and Covestro are releasing three new materials and EOS has introduced a new TPU material for industrial 3D printing. Moving on, CASTOR and Stanley Black & Decker used EOS 3D printing to reduce costs and lead time, and Velo3D is partnering with PWR to make high performance heat exchangers.

RPS Introduces Material Development Kit for NEO800

UK 3D printer manufacturer RPS just launched its NEO Material Development Kit, which was designed by company engineers to be used as a polymer research and development tool for its NEO800 SLA 3D printer. The MDK comes in multiple platform and vat sizes, and allows developers to work with different resin formulations, so that R&D companies can work to develop a range of polymers that are not available in today’s industry. Users can print single layer exposure panes with Titanium software and the 1 liter vat in order to find the photo-speed of the formulation they’re developing; then, tensile testing of different material formulations can commence. Once this initial testing is finished, developers can scale up to the 13 liter vat – perfect for 3D printing prototype parts for use in optimizing final configuration settings.

“This NEO Material Development Kit now opens the door for large industrial chemical companies such as BASF, DSM and Heinkel to push the boundaries of UV photopolymers,” said David Storey, the Director of RPS. “The industry is looking for a quantum jump in materials to print end-user production parts from the stereolithography process.”

New Polycarbonate-Based Materials by Polymaker and Covestro

Advanced 3D printing materials leader Polymaker and polymer company Covestro are teaming up to launch three polycarbonate-based materials. These versatile new materials coming to the market each have unique properties that are used often in a variety of different industries.

The first is PC-ABS, a polycarbonate and ABS blend which uses Covestro’s Bayblend family as its base material. Due to its high impact and heat resistance, this material is specialized for surface finishings such as metallization and electroplating, so it’s good for post-processing work. Polymaker PC-PBT, which blends the toughness and strength of polycarbonate with PBT’s high chemical resistance, is created from Covestro’s Makroblend family and performs well under extreme circumstances, whether it’s subzero temperatures or coming into contact with hydrocarbon-based chemicals. Finally, PolyMax PC-FR is a flame retardant material that’s based in Covestro’s Makrolon family and has a good balance between safety and mechanical performance – perfect for applications in aerospace motor mounts and battery housings.

EOS Offers New Flexible TPU Material

In another materials news, EOS has launched TPU 1301, a new flexible polymer for industrial, serial 3D printing. Available immediately, this thermoplastic polyurethane has high UV-stability, great resilience, and good hydrolysis resistance as well. TPU materials are often used in applications that require easy process capabilities and elastomeric properties, so this is a great step to take towards 3D printing mass production.

“The EOS TPU 1301 offers a great resilience after deformation, very good shock absorption, and very high process stability, at the same time providing a smooth surface of the 3D printed part,” said Tim Rüttermann, the Senior Vice President for Polymer Systems & Materials at EOS. “As such the material is particularly suited for applications in footwear, lifestyle and automotive – such as cushioning elements, protective gears, and shoe soles.”

You can see application examples for TPU 1301 at the EOS booth D31, hall 11.1, at formnext in Frankfurt next month, and the material will also be featured by the company at K Fair in Dusseldorf next week.

CASTOR, Stanley Black & Decker, and EOS Reduce Costs and Lead Time

Speaking of EOS, Stanley Black & Decker recently worked with Tel Aviv startup CASTOR to majorly reduce the lead time, and cost, for an end-use metal production part that was 3D printed on EOS machinery. This was the first time that 3D printing has been incorporated into the production line of Stanley Engineered Fastening. In a CASTOR video, EOS North America’s Business Development Manager Jon Walker explained that for most companies, the issue isn’t deciding if they want to use AM, but rather how and where to use it…which is where CASTOR enters.

“They have a very cool software in which we can just upload the part of the assembly CAD file, and within a matter of minutes, it can automatically analyze the part, and give us the feasibility of whether the part is suitable for additive manufacturing or not. And in case it is not suitable, it can also let us know why it is not suitable, and what needs to be changed. It can also tell us what is the approximate cost, which material and printer we can use,” said Moses Pezarkar, a Manufacturing Engineer at Stanley’s Smart Factory, in the video.

To learn more, check out the case study, or watch the video below:

PWR and Velo3D Collaborating on 3D Printed Heat Exchangers

Cooling solutions supplier PWR and Velo3D have entered into a collaborative materials development partnership for serial manufacturing of next-generation heat exchangers, and for the Sapphire metal 3D printer. PWR will be the first in the APAC region to have a production Sapphire machine, which it will use to explore high-performance thermal management strategies through 3D printing for multiple heat exchange applications. Together, the two companies will work on developing aluminum alloy designs with more complex, thinner heat exchange features.

“PWR chose Velo3D after extensive testing. The Velo3D Sapphire printer demonstrated the ability to produce class-leading thin-wall capabilities and high-quality surfaces with zero porosity. Velo3D and PWR share a passion for pushing the limits of technology to deliver truly disruptive, class-leading, products. We are a natural fit and look forward to building a strong partnership going forward,” said Matthew Bryson, the General Manager of Engineering for PWR.

“Heat exchanger weight and pressure-drop characteristics have a huge impact on performance and are significant factors in all motorsport categories. Using additive manufacturing to print lightweight structures, enhancing performance with freedom-of-design, we have the ability to further optimize these characteristics to the customer’s requirements whilst providing the necessary cooling. The broad design capabilities and extremely high print accuracy of the Velo3D Sapphire 3D metal printer will help us optimize these various performance attributes.”

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The post 3D Printing News Briefs: October 6, 2019 appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

GE Additive Announced that Concept Laser’s M LINE Factory 3D Printing System Will Be Delivered in Q2 2019

A little over two years ago, GE acquired a 75% stake in metal 3D printing leader Concept Laser. Ever since then, GE Additive has been working to review and redesign the system, software, and design architecture of Concept Laser’s M LINE FACTORY 3D printer so that it’s in line with established GE processes. The modular system has also been undergoing beta testing with some selected customers. But today at formnext in Frankfurt, GE Additive announced that its first Concept Laser M LINE FACTORY systems will finally be delivered to customers in Q2 of 2019.

The M LINE Factory provides excellent reliability and automation, which in turn drives scalable, economical series production on an industrial scale – something that most current standalone machine solutions cannot achieve. As the technology continues its transition from prototyping to production, the demand for quality 3D printers, along with operators to run them and floor space to house them, is rising.

“The positive impact the M LINE FACTORY can have on our customers’ operations and their bottom line is huge,” said Jason Oliver, the President and CEO of GE Additive. “It’s important we provide technologically advanced systems that are reliable and add value to our customers. M LINE FACTORY delivers on those commitments.”

The system is an important part of GE Additive’s focus on providing reliable, repeatable 3D printers that are ready for series production. The M LINE FACTORY has a maximum build envelope of 500 x 500 x up to 400 mm³ (x,y,z), and is optionally equipped with one to four laser sources, each one delivering 1,000 W of power.

During the last two years of lifetime and rig testing, the company identified several areas for improvement that have since been incorporated, such as the onboard software system, which offers real-time, in-situ process monitoring, modularized architecture, and superior exposure strategies. The 3D printer’s automation and in-machine architecture have been improved, and its ease of service, scalable modular system design, serviceability, process control, and thermal stability have all been enhanced.

The set-up and dismantling processes, along with part production, actually occur in two independent machine units, which can either be combined or operated separately from one another, according to the customer’s preference. This makes it possible to run production processes in parallel, instead of sequentially, which increases the output quantity and availability of the process chain and lowers downtime.

The M LINE Factory LPS, which stands for Laser Processing System, increases the laser ‘on’ time by separating the pre/post processing unit from the individual work process, while at the same time maintaining an integrated machine design. Instead of forming a single continuous unit, the LPS is made up of an independent powder module, build module, and overflow module, which are of a uniform size and can each be activated individually now for the first time. An easy to use internal transport system is used to automatically transport the modules, and to maximize the efficiency of the system’s footprint, the modules can be stacked up in a series alignment as well.

Additional features of the M LINE Factory LPS include:

Improved laser productivity potential due to increased overlap within the build field
Frontload transport system of automated internal transport system

A flexible configuration makes it possible for the build and process time to dictate the LPS to the ratio of the M LINE Factory MHS, or Material Handling Station. This processing unit, which comes with an integrated sieving station, is for powder management and pre/post processing, and automates both the upstream and downstream stages of the production process.

Additionally, the MHS uses automation, digitization, and interlinking to provide interfaces to more conventional manufacturing methods. The MHS has high safety standards, including an automated module lidding system that contains full powder and inert gas, water-flood passivation of filters, contactless powder handling, and no manual handling in the process chamber.

To learn more about the innovative M LINE Factory, which will ship to customers in Q2 of 2019, visit GE Additive at formnext this week in booth D30, Hall 3.

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[Images provided by GE Additive]

CIPRES Introducing New Industrial Dyeing Machine for 3D Printed Parts at formnext

In 2004, coloring process service provider CIPRES Technology Systems was founded by Carlos Prestien; two short years later, the German company branched out and began offering serial production of SLS 3D printed components. Over the years, it’s continued developing color techniques, color units, and solutions for surface finishing. This summer, CIPRES GmbH was formed to take over the original company’s service sector, and also provides coloring and finishing machines for 3D printed components.

At formnext 2018, which opens tomorrow in Frankfurt, CIPRES will be presenting a new industrial dyeing machine: the eCOLOR Type 1/350/1 for 3D printed serial parts and components made out of polymer materials. The company partnered with Thies GmbH & Co. to produce the industrial machine, which was made specifically to treat 3D printed serial components, functional prototypes, and spare parts. The highly productive system offers excellent dyeing results and high reproducibility, in addition to a lower environmental impact and cost.

The new eCOLOR system, which can precisely adapt chemicals and dyes, can run at operating temperatures of up to 140 °C and at maximum 5bar operating pressure. With its user-friendly software and high-tech controller for monitoring each and every step of the process, the system offers what the company calls “perfect process reliability.” The software also helps users define and optimize jobs, according to their application-oriented or technical needs.

The eCOLOR Type 1/350/1 is designed to cover standard production capacities up to 37 liters, and has a packing diameter of 310 mm and packing height of 500 mm. It also has a flexible loading system for small (8 L), medium (19 L) or large (31 L) batch sizes, and all Thies machines comply with safety regulations and pressure vessel codes of various operating sites, such as ASME. In addition, the system’s frequency inverter driven pump allows for an accurate and economic adjustment of the liquor flow and the flow direction, which helps optimize each stage of the dyeing process.

In order to ensure it’s making the strongest products, CIPRES needs the strongest partners, like Thies, which originated in the traditional textiles area of Münsterland, Westphalia over 120 years ago. Together, the two companies are working to complete the product chain in terms of refining 3D printed nylon parts.

“The combination of our complementary expertise in colors, coloring and finishing solutions will open a new chapter in our common history,” CIPRES wrote in a press release. “We will entrance the excellences of this partnership to improve and expand your portfolio.”

In addition to Thies, CIPRES has several other strong partners, such as Additive Manufacturing Technologies (AMT). which offers automated post processing solutions with its complementary PostPro3D technology. CIPRES is also partnering with Swiss specialty chemicals company Archroma, which brings 130 years of color expertise with its soon-to-launch 3D Cosmic range for coloring 3D printed goods, and surface preparation and finishing leader Rösler Oberflächentecknik GmbH. We’re seeing a lot happening in post processing which should bode well for people wanting less expensive better looking 3D printed parts. If we as an industry want to produce high-quality consumer-friendly parts at volume then automation and automated post processing is what will get us there.

Visit CIPRES at formnext this week at booth G38 in Hall 3.1.

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[Images provided by CIPRES]

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

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

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

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

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

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

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

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

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

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

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

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

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