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The Brittle Spear Part V: Mine Your Den for Aftermarket 3D Printing

There is a thriving aftermarket in automobiles, including spoilers for cars, new Dubs, and, more obviously, mufflers. Air intakes that don’t take in air and optimization kits for engines are an extensive business. You will be surprised at how extensive it is, that the car aftermarket market is worth $318 billion or 3.2% of GDP in the US.

A section of this market is straight-up replacement parts, OEM and remanufactured spares. Of course, we understand that there is a huge opportunity there for 3D printing these extensive stocks of parts.

Additionally, there is also the aftermarket accessories segment of this market. The accessories business is not made up of replacement, identical components but upgraded, redesigned, changed or somehow improved parts that add to the existing automobile. An outrageous spoiler or ground effect kit, faux carbon fiber are some of the typical examples here. Things like new engine management chips, light packages, and barbecues for your tailgate can also belong in this category. The automotive aftermarket is growing at a steady clip and benefits from hardcore hobbyists and specific subcultures and the public at large improving, customizing or adding to their cars. So, if the automotive aftermarket is so large, why isn’t there an aftermarket for all the other things?

Imagine if we not only produced spares, let people do digital kintsugi and made readymades, but also extended the lives of objects in organized, commercial ways. There are already camera accessories, and this is also a large market. The level of expression and customization found in the automotive market is lacking there, as well. There is a lively and very competitive phone accessories market worldwide, but considering just how many of these devices there are—over 5 billion—the levels of expression there can seem quite tame. Why aren’t there iPhone cases for every subculture in every country? Why can’t you get a customized case for my phone based on my kid’s T-Ball jersey?

It is clear that the extension of these markets toward more low-volume customization is something that we, as a 3D printing industry, could undertake. Any kind of mass-customized, low-volume, local manufacturing and niche application is a potential business case for 3D printing. By coupling our manufacturing capacity with easy-to-customize and design software, we could very well extend our reach to many more markets at comparatively little cost.

LED Camera ring.

This will happen eventually, but rather than everyone trying to make the same five parts, we should really consider many more industries and parts globally. Too much of our collective attention is focused on trying to impress the same five guys in aerospace or in the same three conference rooms in shoes. There are opportunities there, but there are tens of thousands of other companies that could use our help. Additions to cameras and consumer electronics are small, high-value parts that can radically extend the life of a much larger, much more complex object. By letting people radically customize these objects through making them one’s own we can give these markets a new dimension.

A mount that turns 6 action cams into a 360-degree camera.

A person may like to shoot an analog camera but want to attach a digital light meter to it. At the same time, modern flashes may not fit their camera. I’ve talked to dozens of people who wish to 3D print old car nameplates and signage but no one thinks of doing this for anything that is not a car. Maybe you’d like to put your name on your old camera? Or you could think of badges to adorn it.

At the same time, it is insane that there is no service that makes customized handgrips for your camera. There are lots of downloadable, 3D printed camera attachments and many that attach them to drones. There are no businesses that attach cameras to just about anything as a business targeted at consumers.

The expression on the camera is currently limited to what you see through the lens. Why not have replaceable elements in different colors? Why not look at frame parts that fail and redesign them to be superior? Why not do that but in a nice bright pink or neon? Why can’t I have a camera that exactly fits my hand? Why isn’t there a company that weatherproofs existing cameras? Why isn’t there a company that makes many different custom enclosures for cameras to dive with them? I’d much rather go diving with my old camera than my new one.

Why aren’t their kits to turn your old camera or phone into a Ring or dashcam? Why can’t I get new apertures for every camera? Why can’t I buy kits to turn my old Nikon into the best street shooter DSLR?

A RC camera car

If we just take the camera example, we can already see a plethora of ideas emerge. There are many potential niche businesses there that could be very profitable. But, what of old lamps? Kits to change their lightbulb connections into LED holders, make them dimmable, change them to disco lamps? Where is a simple instruction to turn grandma’s old pendant lamp into a cool college kid lamp? Why can’t I just transform my old lamps easily to fit new interiors?

Why can’t kids remake toys or upgrade them to grow along with them? We know that they like to play with physical objects such as LEGOs, but why not let them design a path for Barbie or G.I. Joe to last longer in their lives. Why is extensibility not built-in? In a world where everything is cost-focused and mercenary, we simply don’t have the time or money to make things extensible or long-lasting.

A universal iPhone mount can repurpose many devices.

There is a huge opportunity to extend the life of love objects. But, we can also give new functionality and new experiences to people around existing objects. That drawer you have with eight old phones and 60 cables in it is a goldmine waiting to be excavated. Years ago, I tried to start a maker project around reusing old iPhones for new applications. It went nowhere, but I assured myself that surely someone else will capitalize on this opportunity. People were making millions off of selling new makers new things surely they could also capitalize on them mining their own dens? Somehow this hasn’t worked.

Perhaps it’s a lack of imagination or the fact that it is not as obvious a path to making money, but these kinds of opportunities are underexploited.

With billions of consumer electronics, bicycle, kitchen, and furniture items worldwide, there is a huge potential for repurposing, customizing, and making cooler the things we already have. We could be creative with these objects through readymades, but a well-organized aftermarket could sell billions of accessories for the things that already are. With the world’s attention focused on selling and making the new, adding to the old may make you a new mining baron.

Part I of this series can be found here, Part II is here.

Index image a Blythe c, Public Domain. Stefan Magdalinksy.

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The Brittle Spear Part III: Digital Kintsugi and 3D Printed Spare Parts

In this series, previously we looked at how we’re creating a system designed to spit out less able things and that these things may be better but will be less robust and more challenging to repair. As the tip of the spear grows ever sharper, it also becomes more brittle. We have more things, but they will last longer (in the natural environment), and we will find it easier to throw them away. Rather than individual firms designing certain things for planned obsolescence, we are, all of us, participating in a system that produces more fragile items with shorter life spans. We cannot fight this system head-on, but we may be able to subvert it, change it and help us all. The path to extricating ourselves from a disposable world is Digital Kintsugi.

Kintsugi is a Japanese method of repairing broken pottery with gold and lacquer. A fractured ceramic piece is then proudly restored with a clear remnant of the breakage visible to all.

“Not only is there no attempt to hide the damage, but the repair is literally illuminated… a kind of physical expression of the spirit of mushin….Mushin is often literally translated as ‘no mind,’ but carries connotations of fully existing within the moment, of non-attachment, of equanimity amid changing conditions. …The vicissitudes of existence over time, to which all humans are susceptible, could not be clearer than in the breaks, the knocks, and the shattering to which ceramic ware too is subject. This poignancy or aesthetic of existence has been known in Japan as mono no aware, a compassionate sensitivity, or perhaps identification with, [things] outside oneself.”

— Christy Bartlett, Flickwerk: The Aesthetics of Mended Japanese Ceramics

In terms like “mono no aware” and “wabi-sabi” and the related “kintsugi”, we have a potential philosophical and cultural counterweight to contemporary consumer culture. By accepting transience and transformation, by being okay with imperfection and seeing a repaired thing as somehow improved, we can get passed our shrink-wrapped existence. And its Japanese, too, like manga and sushi.

We live in a world where we lust after things. Indeed, many of our ambitions and desires are for things, and we give our lives for stuff. The moment one acquires the desired something, it fades, slips into being spurned, is then forsaken, and begins somehow to rot. A thing will never fulfill us, but we don’t realize this and instead lust after new newer things. We’re chasing a thing-related high that doesn’t exist.

Kintsugi will help us to break through these barriers. What’s more, we’re no longer making or recycling for making’s sake, nor are we doing it for some grand sustainability goal, we are doing it also to celebrate this thing. Rather than focus our attention on the unattainable new, kintsugi places it on the mindful now of things we already have.

A patina on some steels or worn leather and just-right jeans are already examples of wear and tear that are celebrated. We just have to extend scratches on polymer and other everyday damage to the realm of the beautiful.

With 3D printing, we can make things last longer. We can make spare parts and create out-of-production spares to extend the life of many everyday objects. Many more people will need to be able to design for this to take on meaningful proportions of all the things. Perhaps, if our phones became 3D scanners or if it were easier to take 2D and make it 3D, we could radically extend the life of many things.

In particular, small spare parts are very inexpensive when 3D printed on desktop machines and even through services. If the alternative is for the user to throw away the good, then any single repair using a 3D printed part would be extremely valuable for the environment. Imagine if one CAD file leads to 1,000 coffee makers not being thrown away. Now, digital spare parts are part of grand EU initiatives—or the plans of single individuals running into a part that they need—but a more organized approach would be very valuable.

If we looked at the sum total of e-waste and what were the most popular items to see how they could be repurposed or extended, then we could in, and organized way make the world a lot more sustainable through 3D printing. There are many spares already being made, from Playmobil skateboard wheels, to bass guitar parts to switches for venerable La Pavoni espresso machines. On platforms like Thingiverse or YouMagine we can already see that spare parts are a lively and very popular category.

Organically and without a business model, it is already growing. From handles for Mokka Makers to the incredibly popular vacuum cleaner parts category to the super-specific, such as a faceplate for a joystick used in forestry equipment, we are currently making a mark.

Guided development, easier CAD, and better 3D scanning will help but a philosophical edge, and new coolness will do wonders also. Patagonia’s worn wear is a great example of obviously repaired clothing that gives everyone involved a good feeling while extending the life of things.

In the 3D printing community, we are repairing things because we can, but we need to see if we can make this cool, even desirable. Obviously-repaired objects proudly displaying their scars needs to be an established practice that adds sparkle and history to otherwise quotidian things—especially in a world with so few things that last any effort to extend the life of things, a little bit will do wonders for us all.

The Japanese don’t use transparent lacquer; they mix in gold to heighten the repair, give it luster, and get one to notice it. What could we do to make 3D printed repairs beautifully obvious? Could we use Bronzefill, a particular purple, or make the 3D printed layers more obvious? What do you think?

Creative Commons Attribution: Ervaar Japan, Ervaar Japan, Steenaire.

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Sustainability in additive manufacturing?

2019 has been the year of environmental sustainability, with global protests and increased political and social focus. The additive manufacturing industry isn’t an exception; sustainability is on the agenda. But how?

We are entering a new era for additive manufacturing now. One in which the increase in adoption for production applications requires the industry to mature and demonstrate the reliability, repeatability and quality of more established manufacturing techniques. This was clear during the recent Formnext 2019, where there was a significant message coming from most OEM’s, which was more focused on delivering on previous promises made of their technology. During the recent Formnext 2019, newly appointed CEO of EOS, Marie Langer, was asked about her priorities for the coming years, she discussed a focus on delivering repeatable and transferable processes, usability, quality and reliability. However, there was another significant topic that came up during that press event, and as the week progressed, it was a topic widely discussed on the Formnext floors. The topic was sustainability in additive manufacturing.

The topic was discussed in press conferences, in panel discussions, at networking events, and in one-on-one conversations.

For Marie Langer sustainability is a critical subject and one the whole industry should be championing. This was echoed by Brian Neff, CEO of Sintavia, who also commented on the opportunity and advantage AM has, as a more sustainable production technology than traditional subtractive manufacturing technologies. Langer spoke about developing more sustainable materials that could be recycled and re-used. Brian highlighted that for metal AM, there is far less material waste and that through distributed manufacturing, shipping could be reduced and therefore the overall carbon footprint of producing a part could be lowered.

The topic of sustainability was also taken up by Rush LaSelle, Senior Director, Additive Manufacturing, at Jabil Additive, as he was on a panel on Formnext TV. LaSelle described the benefits of distributed manufacturing from the perspective of sustainability. Moreover, senior leaders in companies like Carpenter Additive, HP, and DSM, made it clear, that sustainability is on the agenda. Camille Caron, HP’s Director of Education and Sustainability for their 3D printing business has recently written an article about this topic.

It seems clear that AM has the opportunity to lead the global manufacturing market as a sustainable production technology. The benefits offered through reduced material waste, supply chain innovations that reduce the needs for shipping parts thousands of miles, the use of recycled plastics and metals in materials, as well as the development of new recyclable materials, can all position AM as the most sustainable production solution for companies. It comes at a time where large companies are all under pressure to reduce carbon footprint and do more to protect and preserve the environment. Therefore this opportunity is one that could further support the acceleration of the AM industry as a whole. However, while this topic was widely talked about at a senior level, there is still very little being done to actually drive sustainability initiatives. Part of that problem likely lies with the question “Who is responsible?”. How many AM organisations, be they machine OEM’s, Materials Companies etc. have a Head of Sustainability, or at least an internal champion to take ownership? This is something Alexander Daniels Global are going to explore more and early in 2020 plan to prepare a report looking directly at what the major companies are doing to further this very important cause.

By Nick Pearce, Director of Alexander Daniels Global

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3D Printing News Briefs: October 14, 2019

In today’s 3D Printing News Briefs, everything is new, new, new! Carbon is announcing a new RPU 130 material, and STERNE Elastomere introduces its antimicrobial silicone 3D printing. Protolabs launches a new polypropylene 3D printing service in Europe, and Hydra Research has officially released its flagship Nautilus 3D printer.

Carbon Introduces RPU 130 Material

At this week’s International K Trade Fair in Dusseldorf, Carbon will debut its new RPU 130 resin, a rigid polyurethane that’s rigid, tough, impact resistant, and stands up under high temperatures, making it a perfect choice for the automotive industry in applications such as brake caliper covers. Made exclusively for Carbon’s Digital Light Synthesis, the dual-cure engineering resin is comparable to unfilled thermoplastics, and Carbon also partnered with DuPont Tate & Lyle Bio Products to make RPU 130 out of sustainable Susterra propanediol, a 100% bio-based material that uses 46% less nonrenewable energy from cradle-to-gate and produces 48% less greenhouse gas emissions as well.

“We are focused on ways to incorporate more sustainable approaches to developing materials, and our partnership with DuPont Tate & Lyle emphasizes that commitment,” stated Jason Rolland, SVP of Materials at Carbon. “We believe that sustainability can go hand-in-hand with improved performance. In the case of RPU 130, we believe it will make the material even more appealing for our customers, as it makes it possible to create better quality products that are also ultimately better for the environment.”

You can learn more about Carbon’s new RPU 130 at its K-Show booth, H7.2, F12 from October 16-23.

Antimicrobial Silicone 3D Printing by STERNE

French silicone 3D printing specialist STERNE will also be attending K 2019 this month. Three years ago, the company unveiled its silicone 3D printer at K 2016, and its SiO-shaping 3D silicone printing technology makes it possible to fabricate very small pieces, according to standard ISO 3302-01 :2014 (M2) tolerances, at hardness from 30 to 60 Shores A. The printer also offers a full panel of colors in opaque, phosphorescent, and translucent.

The company is now combining 3D printing with antimicrobial silicone, in order to keep the silicone odor-free, avoid bacteria developing, improve the hygiene of a 3D printed object, and strengthen its immune barrier as well. You can learn more about this antimicrobial silicone 3D printing at STERNE’s Stand E23, Hall 8A, at K 2019.

Protolabs Offering Polypropylene 3D Printing in Europe

For the first time, digital manufacturing company Protolabs is offering polypropylene 3D printing, with the launch of a new service in Europe. The company has invested a lot in developing the material to be used with selective laser sintering (SLS) technology, on an SPro 60 system. SLS 3D printing with polypropylene plastic allows design engineers to rapidly develop and test prototypes, and fabricate complex designs as well, like internal channels and honeycomb structures.

“Polypropylene is one of the most used plastics available to modern manufacturers and is widely used for a number of applications. Polypropylene is one of the most used plastics available to modern manufacturers and is widely used for a number of applications. Now that we can produce a prototype in polypropylene, design engineers can develop and test it in an application using the same material that it will be manufactured from. The product design can then be quickly reiterated and retested until they have the perfect solution, before committing to tooling. This breakthrough takes product development to the next level using the most versatile of plastics, ” said Andrea Landoni, 3D printing product manager for Protolabs.

“Before, if you wanted to use polypropylene then you were limited in what you could design by the manufacturing technology available to you. Now the only limitation is your imagination.”

Hydra Research Releases Flagship 3D Printer

Oregon company Hydra Research, which began in a closet three years ago as a peer-to-peer print service, has announced the release of it flagship 3D printer, the Nautilus. The fully enclosed, industrial-grade desktop system – assembled in Portland – features a quick-change Tool Cartridge system that integrates E3D’s V6 hotend for fast nozzle switching, in addition to an integrated software solution. It also supports a variety of materials, provides Cura profiles for easy slicing, has a small footprint in a sleek frame, and offers customizable HydraCare support and consulting packages

“As a company, our primary goal is producing world-class hardware on an open source platform,” explained John Kray, the Founder and CEO of Hydra Research. “Manufacturers like E3D, Duet3D, and Fillamentum combine these values perfectly.”

You can now purchase Hydra’s Nautilus 3D printer on the company’s website, in addition to spare parts, accessories, and filament.

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3D Printing News Briefs: October 10, 2019

We’re talking about events and business today in 3D Printing News Briefs. In November, Cincinnati Inc. is presenting at FABTECH, and Additive Manufacturing Technologies and XJet are heading off to formnext. Moving on, Thor3D has announced a new partnership with Rhinoceros.

Cincinnati Incorporated Showing at FABTECH

Machine tool manufacturer Cincinnati Incorporated (CI) is going to FABTECH 2019 next month in Chicago, and plans on showcasing its recently announced partnership with Hendrick Motorsports, along with the #88 car driven by Alex Bowman, and its latest machines at the event. CI is now a full-season associate sponsor of the team’s four-car stable for the next ten years, in addition to its Official Metal Fabrication and Additive Equipment Provider. The racecar will be in booth #A2973 at the show, along with CI’s Hyform and AFX press brakes, Roboform cell, and new CLX laser, which was built specifically for automation-minded metal fabricators. The company’s high temperature Small Area Additive Manufacturing (SAAM HT) machine will be on display in booth #A3839, and its Medium Area Additive Manufacturing (MAAM) machine will make its official debut to the public.

“We’re ready to get to FABTECH and show the fabricating world what we’ve been up to in the past year. Walking through our facility, you can feel the energy and see the production happening. It’s exciting and it’s contagious, and we can’t wait to share it,” said Matt Garbarino, Director of Marketing Communications at Cincinnati Incorporated.

XJet Bringing Extended Carmel Product Line to formnext

FABTECH isn’t the only show in November – formnext is taking place in Frankfurt from November 19-22, and XJet announced that it will be introducing two new versions of its Carmel 1400 3D printer at the event. The Carmel 1400M for metals and the Carmel 1400C for ceramics, both of which use XJet’s NanoParticle Jetting technology, are part of the company’s continuing work to, as XJet put it, “redefine metal and ceramic AM.”

“Formnext is always a highpoint on XJet’s calendar. Each year we hit new milestones, and this is particularly evident at Formnext. From Formnext, XJet will offer two systems, the Carmel 1400C devoted to ceramics and the Carmel 1400M dedicated to metals. While both systems use the same NanoParticle Jetting technology, they are different and have been optimized to handle the different materials. Both will be demonstrated on our booth throughout the show,” said XJet’s CBO Dror Danai.

At Booth C01 in Hall 12.1 of formnext, XJet will demonstrate multiple applications and sample parts that showcase its NPJ technology for both metal and ceramic 3D printing. Representatives from the company’s distribution network will be on hand to answer question, and visitors can also enjoy an immersive, virtual reality experience into XJet’s NanoParticle Jetting at the booth.

Additive Manufacturing Technologies Presenting Modular, 3D Printed Booth at formnext

Sheffield-based Additive Manufacturing Technologies (AMT) will also be attending formnext as it officially exits stealth mode. The company will be showcasing a customizable, modular, and sustainable stand construction at the event, with over 6,000 3D printed parts that will connect 1,100 meters of aluminum tubing to create the booth, which was designed and constructed by Steel Roots Design. Materialise printed the parts out of Nylon PA 2200 material, using SLS technology by EOS, and they were then post-processed with AMT’s own PostPro3D platform. The lightweight parts have complex geometries, with moving features and internal threads that would have been impossible to create using another fabrication process.

“The whole point of exhibiting at a show like Formnext is to demonstrate your technologies and capabilities. At AMT we don’t want to just tell people how good our technologies are, we want to really show them. Our unique stand will show how functional and sustainable 3D printed parts — even at higher volumes — can be utilised when using our automated post processing technologies,” stated AMT’s CEO Joseph Crabtree.

“This level of sustainability commitment is a fundamental principle for AMT at every level of the business. Every decision we make takes sustainability into consideration.”

See AMT’s 120 kg stand structure for yourself at Booth 361, Hall 12.1, at formnext next month. Once it’s been constructed, several other company innovations will be showcased inside, such as the automated Digital Manufacturing System (DMS).

Thor3D and Rhinoceros Sign Partnership Agreement for New Product

3D scanner manufacturer Thor3D and Rhinoceros software developer McNeel have signed a partnership agreement so that Rhino software can now be resold by Thor3D’s distribution partners, along with multiple plug-ins, in a bundle with the Calibry handheld 3D scanner. Rhino’s set of tools for analysis, animation, engineering, free-form 3D modeling, and engineering can now be supplemented by Calibray scans, which can be used as base models. In addition, the bundle can also be extended using Brazil and Penguin rendering software, the Flamingo nXt rendering engine, and integrated animation by Bongo.

“Rhino software is widely known and used worldwide. Many of our customers already use it and our goal is to make it even more accessible to a wider audience. Engineers and digital artists alike, will find this software, in combination with our 3D scanners, extremely helpful in their day-to-day work,” said Anna Zevelyov, the CEO and Co-Founder of Thor3D.

Recommended retail price for the new Calibry and Rhino bundle will be €5,700.

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

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3D Printing News Briefs: June 27, 2019

In today’s 3D Printing News Briefs, we’re starting with a couple of stories from the recent Paris Air Show: TUSAS Engine Industries has invested in GE Additive technology, and ARMOR explained its AM materials partnership with Airbus. Moving on, Formlabs just hosted some live webinars, and PostProcess Technologies released a whitepaper on surface finishing metal 3D printed parts. Modix is sharing a lot of news, including four new 3D printer models, and finally, FormFutura has introduced sustainable packaging.

TEI Invests in GE Additive Technology

TUSAŞ Engine Industries, Inc. (TEI), founded in Turkey as a joint venture in 1985, has invested in GE Additive‘s direct metal laser melting (DMLM) technology. GE Additive announced at the recent Paris Air Show that TEI had purchased two of its M LINE factory systems and two M2 cusing machines. While the financial terms of the investment were not disclosed, the 3D printers will be installed at TEI’s Eskişehir headquarters, joining its current fleet of laser and Arcam EBM printers.

Professor Dr. Mahmut Faruk Akşit, President and CEO of TEI, said, “Today, we invest in TEI’s future by investing in additive manufacturing, ‘the future of manufacturing.’ Our longstanding partnership and collaboration with GE is now broadening with GE Additive’s machine portfolio.”

Armor and Airbus Partner Up for Aerospace 3D Printing

Air pipe prototype printed using the Kimya PLA HI (Photo: ProtoSpace Airbus)

Continuing with news from the Paris Air Show, ARMOR Group – a French multinational company – was also at the event, exhibiting its Kimya materials and a miniFactory printer, as well as its new aeronautics filament, PEI-9085. While there, ARMOR also met up with Airbus, which has frequently used 3D printing to create parts and prototypes, such as an air nozzle for the climate control system of its 330neo passenger cabin. The company has now requested ARMOR’s expertise in better qualifying its materials in order to standardize its own AM process.

“We have qualified the PLA-HI and PETG-S. We are currently testing more technical materials, such as the PETG Carbon before moving on to the PEI and PEEK. We have requested a specific preparation to make it easier to use them in our machines,” Marc Carré, who is responsible for innovation at Airbus ProtoSpace in Saint-Nazaire,

“We expect to be able to make prototypes quickly and of high quality in terms of tolerances, aesthetics and resistance.

“Thanks to ARMOR and its Kimya range and services, we have found a partner we can share our issues with and jointly find solutions. It is very important for us to be able to rely on a competent and responsive supplier.”

Webinars by Formlabs: Product Demo and Advanced Hybrid Workflows

Recently, Formlabs hosted a couple of informative webinars, and the first was a live product demonstration of its Form 3. 3D printing expert Faris Sheikh explained the technology behind the company’s Low Force Stereolithography (LFS) 3D printing, walked through the Form 3’s step-by-step-workflow, and participated in a live Q&A session with attendees. Speaking of workflows, Formlabs also held a webinar titled “Metal, Ceramic, and Silicone: Using 3D Printed Molds in Advanced Hybrid Workflows” that was led by Applications Engineering Lead Jennifer Milne.

“Hybrid workflows can help you reduce cost per part and scale to meet demand, while taking advantage of a wider range of materials in the production of end-use parts,” Formlabs wrote. “Tune in for some inspiration on new ways of working to advance your own process or to stay on top of trends and capabilities across the ever-growing range of printable materials.”

PostProcess Whitepaper on 3D Print Surface Finishing

PostProcess Technologies has released its new whitepaper, titled “Considerations for Optimizing Surface Finishing of 3D Printed Inconel 718.” The paper discusses a novel approach to help improve surface finish results by combining a patent-pending chemistry solution and software-driven automation. Using this new approach, PostProcess reports increased consistency and productivity, as well as decreased technician touch time. The whitepaper focuses on surface finishing 3D prints made with alloys and metals, but especially zeroes in on nickel superalloy Inconel 718, 3D printed with DMLS technology.

“With current surface finishing techniques used that are largely expensive, can require significant manual labor, or require the use of hazardous chemicals, this paper analyzes the benefits of a novel alternative method for post-printing the part’s surface,” PostProcess wrote. “Key considerations are reviewed including part density and hardness, corrosion (chemical) resistance, grain structure, as well as manufacturing factors including the impact of print technology and print orientation on the surface profile.”

You can download the new whitepaper here.

Modix Announces New 3D Printers, Reseller Program, and Executive

Israel-based Modix, which develops large-format 3D printers, has plenty of news to share – first, the company has come out with four new 3D printer models based on its modular design. The new models, which should be available as soon as Q3 2019, are the 1000 x 1000 x 600 mm Big-1000, the 600 x 600 x 1200 mm Big-120Z, the 1800 x 600 x 600 mm Big-180X, and the 400 x 400 x 600 mm Big-40. Additionally, the company has launched a reseller program, where resellers can offer Modix printers to current customers of smaller printers as the “best next 3D printer.” Finally, Modix has appointed 3D printing veteran John Van El as its new Chief Commercial Officer; he will help build up the company’s partner program.

“We are proud to have John with us,” said Modix CEO Shachar Gafni. “John brings aboard unique capabilities and experiences strengthening Modix’s current momentum on the path to become a global leader in the large scale 3D printing market.”

FormFutura Presents Recyclable Cardboard Packaging

Dutch filament supplier FormFutura wants to set an example for the rest of the industry by not only raising awareness about sustainability, but also by stepping up its own efforts. That’s why the company has moved completely to cardboard packaging – all of its filaments up to one kilogram will now be spooled onto fully recyclable cardboard spools, which will also come in cardboard boxes. All of FormFutura’s cardboard spools and boxes are manufactured in its home country of the Netherlands, which helps reduce its carbon footprint in terms of travel distance, and the material is also a natural drying agent, so it will better protect filament against humidity.

“Over the past couple of months we’ve been brainstorming a lot on how we can make FormFutura more sustainable and help renew our branding. As over this period we have received feedback from the market about helping to find a viable solution to the empty plastic spools, we started setting up a plan to reduce our carbon footprint through cardboard spools,” said Arnold Medenblik, the CEO of FormFutura. “But as we got to working on realizing rolling out cardboard spools, we’ve also expanded the scope of the project to include boxes and logistics.”

Because the company still has some warehoused stock on plastic spools, customers may receive both types of packaging during the transition.

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3D Printing News Briefs: June 25, 2019

Recently, HP released its sustainable impact report for 2018, which is the first item we’ll tell you about in our 3D Printing News Briefs. Then it’s on to more good news – the 3D Factory Incubator in Barcelona is reporting a very positive first 100 days in business, while AMUG has named the winners from its Technical Competition. We’ll close with some metal 3D printing – Nanoscribe published a fly-over video that illustrates the design freedom of nano- and microscale 3D printing, and Laser Lines is now a UK reseller for Xact Metal.

HP Releases 2018 Sustainable Impact Report

HP recycling bottle shred: Through its recycling programs, HP is transforming how we design, deliver, recover, repair, and reuse our products and solutions for a circular future.

HP has released its Sustainable Impact Report for 2018, which talks about the company’s latest advancements in achieving more sustainable impact across its business, as well as the communities it serves, in order to create a better green future. Its sustainability programs drove over $900 million in new revenue last year, and the report shows how HP is using 3D printing to drive a sustainable industrial revolution, such as reducing the amount of materials it uses and expanding its recycling program. The report also states new commitments the company set for itself in order to drive a low-carbon, circular economy.

“Companies have critically important roles to play in solving societal challenges, and we continue to reinvent HP to meet the needs of our changing world. This isn’t a nice to do, it’s a business imperative,” explained Dion Weisler, the President and CEO of HP Inc. “Brands that lead with purpose and stand for more than the products they sell will create the most value for customers, shareholders and society as a whole. Together with our partners, we will build on our progress and find innovative new ways to turn the challenges of today into the opportunities of tomorrow.”

To learn more about HP’s efforts to reduce the carbon footprint, such as investing in an initiative to keep post-consumer plastic from entering our waterways and the recycling program it started with new partner SmileDirectClub, visit the company’s dedicated Sustainable Impact website.

Successful First 100 Days at 3D Factory Incubator

On February 11th, 2019, 3D Factory Incubator – the first European incubator of 3D printing – was officially inaugurated in Barcelona. It’s now been over 100 days since the launch, and things are going very well. In that time period, the incubator is reporting a total of 15,000 3D printed pieces, and 20 incubated companies, and still has room for more interested projects, though all its private spaces are now occupied. The original goal is to incubate 100 companies in 5 years, and it seems as if 3D Factory Incubator is well on its way.

Located in the Zona Franca Industrial Estate, the unique initiative is led by El Consorci de Zona Franca de Barcelona (CZFB) and the Fundación LEITAT, and has received an investment of €3 million. The goal of the incubator is promote the growth of 3D printing initiatives, and there are a wide variety of companies hosted there, including consumer goods, a logistics company, healthcare companies, design initiatives, and mobility.

AMUG Technical Competition Winners Announced

(top) Erika Berg’s digitally printed helmet liner components and Riddell’s SpeedFlex Precision Diamond Helmet; (left) Maddie Frank’s cello, and (right) Bill Braune’s Master Chief reproduction.

At the Additive Manufacturing Users Group (AMUG) Conference in April, 17 entries were on display to compete for the gold in the annual Technical Competition of excellence in additive manufacturing. The winners have finally been announced, and it seems like the panel of judges had a hard time deciding – they were unable to break the tie in the Advanced Finishing category. Maddie Frank of the University of Wisconsin, with her 3D printed electric cello, and Bill Braune of Met-L-Flo, with his 30 inch-tall model of “The Master Chief” Halo video game character, are co-winners in this category for their attention to detail and “exceptional execution,” while Erika Berg of Carbon won the Advanced Applications category with her digitally printed helmet liner for Riddell’s SpeedFlex Precision Diamond Helmet.

“The 17 entries in the Technical Competition were amazing in their beauty, innovation, and practicality,” said Mark Barfoot, AMUG past president and coordinator of the Technical Competition. “Our panel of judges deliberated at length to make the final decision.”

The winners each received a commemorative award, as well as complimentary admission to next year’s AMUG Conference.

Nanoscribe Shows off Design Freedom in Fly-Over Video

The versatility sample impressively illustrates the capabilities of Photonic Professional systems in 3D Microfabrication.

German company Nanoscribe, which manufactures and supplies high-resolution 3D printers for the nanoscale and microscale, is showing the world how its systems can up many opportunities in 3D microfabrication, with a new fly-over video, which truly highlights the design freedom it can offer when making 3D microparts with submicron features. The video shows actual scanning electron microscope (SEM) images of extreme filigree structures that were 3D printed on its Photonic Professional GT2.

From a variety of angles, you can see diverse geometries, which show off just how versatile Nanoscribe’s high-resolution 3D printing can be – all 18 of the objects and structures were printed in just over an hour. The company’s microfabrication technology makes it possible to create designs, like undercuts and curved shapes, and customizable topographies that would have been extremely difficult to do otherwise. To streamline the microfabrication process for its customers, Nanoscribe offers ready-to-use Solution Sets for its Photonic Professional GT2 printers, which, according to the company, “are based on the most suitable combination of precision optics, a broad range of materials and sophisticated software recipes for specific applications and scales.”

Xact Metal Names Laser Lines New UK Reseller

Pennsylvaniastartup Xact Metal welcomes Laser Lines – a total solutions provider of 3D printers and laser equipment – as a UK reseller for its metal 3D printers. These machines, which offer extremely compact footprints, are meant for customers in high-performance industries that require high-throughput and print speed, such as medical and aerospace. Laser Lines will immediately begin distributing the Xact Metal XM200C and XM200S systems, as well as the XM300C model once it becomes available next year.

“We are delighted to be the chosen UK supplier for Xact Metal, whose metal printing systems are establishing new levels of price and performance. Making quality metal printing accessible requires innovation. Xact Metal’s printing technology is built on the patent-pending Xact Core – a high speed gantry system platform where light, simple mirrors move quickly and consistently above the powder-bed on an X-Y axis. It’s another step change for our industry and opens a whole range of exciting opportunities,” stated Mark Tyrtania, the Sales Director at Laser Lines.

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Designer Julia Daviy Introduces Her Digitally Customizable 3D Printed Skirt

3D printing is moving ever closer to gaining a true home in mainstream commercial applications, thanks to the impact the technology is having on consumer fashion products such as jewelry, footwear, and clothing. While 3D printed fashion was still considered to be more of a novelty a few years ago, efforts have been increasing to make it more common – even in the classroom. Additionally, the technology is helping to usher in a more sustainable and eco-friendly way of manufacturing garments…and designer Julia Daviy is helping to lead the charge.

In addition to designing clothes, Daviy is also an ecologist and clean technology industry manager, and uses 3D printing to make cruelty-free, zero-waste clothing. She believes that the technology will change how the world produces clothing, especially when it comes to some of the more problematic issues of garment manufacturing, such as animal exploitation, chemical pollution, energy consumption, and material waste.

“Our goal was never to demonstrate the viability of 3D printed clothing and leave things at that. We’ll have succeeded when beautiful, comfortable, ethically manufactured and environmentally friendly clothes are the standard,” Daviy stated. “The innovations we’ve made on the production and marketing side of the equation are just as important as the technological breakthroughs that have gotten us this far.”

Concerned with the economically and environmentally irresponsible ways most clothes are made, she created an activewear line made with organic fabrics, and went on to study 3D printing at the University of Illinois in an attempt to find a better, “more complete alternative.” Daviy created her first wearable, 3D printed piece in 2017, and continued working to grow her knowledge base. She experimented with multiple 3D printing techniques, like FDM and SLA, and spent time working with manufacturers on various filament specifications.

At New York Fashion Week in September, Daviy released the first 3D printed, functional, women’s fashion collection in the US that uses large-format 3D printing. While I wouldn’t have called most of the pieces in that collection appropriate for everyday use, all of them, like the Pure Nature Suit, definitely looked wearable. But now the pioneering designer has come out with something that I would definitely classify as a functional garment: what she’s calling the first digitally customizable, widely available 3D printed skirt.

The skirt is environmentally friendly, made with ethical manufacturing, and can be custom designed and purchased on Daviy’s website so it fits the size and personality of the customer. The 3D printed, digitally customizable skirt meets, according to the website, “your highest sustainable and technological expectations.”

“This is a truly sustainable, zero-waste skirt that was designed and produced in the USA using groundbreaking technology invented and patented by Julia Daviy. This method allows Daviy to 3D print clothing with less than 1% of waste in the clothing production process,” the website reads.

“The skirt is produced by combining innovative 3D printing practices with fabric linings and luxury trimmings that meet the highest environmental and ethical standards.”

Customers can choose almost everything about the skirt, from its color and style down to the waistline. Then, Daviy and her team create a digital model of the skirt using this information, and fabricate it on a large-scale 3D printer, using Daviy’s patented, zero-waste process, out of recyclable TPE material; the organic, stretchable lining is 5% Lycra and 95% silk.

I went to the website to design my own skirt, which is typically delivered in ten days’ time, though you can choose faster delivery options. The only pattern choice is organic, but there are three styles to choose from: mini, A-line, and pencil. You can select a high or short waist wrap, or none at all, and you can also choose to add pockets (yes, pockets! Pause for a moment of celebration!). Color choices are black, blue, white, nude, and yellow, and the lining can be black, white, or nude.

“You are unique,” the website states. “Wear a garment that reflects your identity.”

The skirt is designed for a slightly loose fit, and should be hand washed separately in cold water and dried flat; it should not be ironed.

Based on looks alone, I would wear multiple versions of this cute skirt anywhere. But, as to be expected with customizable products, the more things you add on, the higher the price tag goes. A mini skirt with no waist wrap and no pockets is already breaking the bank for me at $780, and when I designed an A-line skirt with a short waist wrap and pockets, the price shot up to $1,350. But again, customized garments anywhere don’t come cheap, and at least you can sleep tight knowing that Daviy’s zero-waste pieces are more eco-friendly.

“I started to experiment with 3D printing because I believe that in an age of radical change and global challenges, people need absolutely new clothing. The first stage is to simplify digital customization and 3D printing of flexible and wearable clothing. We’ve accomplished that, and I think that consumers will respond,” Daviy said. “Once we’ve brought this technology into the mainstream, we plan to use 3D printing to make smart clothing that integrates technology even further into the design and function of our collection.”

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[Images: Julia Daviy]

Conifera: COS Commissions Sustainable Bioplastic Structure

Milan Design Week always has many offerings, so much so the courtyard itself is drawing eyes. The Palazzo Isimbardi, located behind the 16th-century palazzo, the establishment houses a 3D printed design marvel. Commissioned by fashion brand COS, Conifera is London-based architect Arthur Mamou-Mani’s sustainable bioplastic structure greets attendees at the centre of the premises. It is one of […]

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WASP Launching Long-Term ‘3D Printing for Sustainable Living’ Construction Project

In September, WASP, or the World’s Advanced Saving Project, debuted its new Crane construction 3D printer, in Italy. It’s actually a modular 3D printing system, or “infinity 3D printer,” with different configurations to choose from, and was presented to the public in Massa Lombarda, where the 3D printed village of Shamballa is being constructed.

In October, a two-day program was held, starting with a conference titled “A call to save the world,” surrounding the introduction of WASP’s Crane 3D printer and its innovative 3D printed Gaia Module. The livable, tiny 3D printed house is the first structure that the WASP Crane 3D printed, and was made out of actual raw earth, with straw and rice husks added to the interior for insulation.

“Everyone in the world will have a fine, healthy, sustainable, self-sufficient and ecological home for birthright,” WASP wrote in a press release. “The earth is our witness, took form in Gaia.”

Now that the 3D printed architectural Gaia model is complete, WASP is beginning a brand new technological phase “in view of Expo 2020,” and kicking things off in 2019 with a long-term program called “3D Printing for Sustainable Living.”

GAIA represents an important case study for understanding just what’s possible when using 3D printing in the construction industry. The 3D printed earth module is an important part of WASP’s new program, which focuses on developing construction process using digital fabrication and 3D printing in an effort to move towards an all-new concept of building houses.

“As already announced in the conference “A Call to save the World”, WASP runs for a collaboration with partners belonging to every sector, from architectural design to the university research, from humanitarian associations to national ministries, able to fully share the project,” the company wrote. “It proposes a strategic program of constructive activities, expressly designed for on-site 3D printing and developed through the use of local raw materials.”

The program centers around an advanced, eco-sustainable model of construction, especially due to the lower cost and higher interior comfort the walls in the Gaia model provide with their combination of raw earth and natural waste as construction materials.

Some of the partners expected to work with WASP on its new project include a few universities, humanitarian associations, banking institutions and foundations, both public and private authorities, and several ministries, including Education, Health, Environment and Protection of Land and Sea, Infrastructure and Transport, Labor and Social Policies, Foreign Affairs and International Cooperation, Food and Forestry Agricultural Policies and Tourism, and Economic Development.

The project is based on six main macro-areas, starting with the promotion of human and material resources from the territory. This area features the capitalization of human knowledge, the use of renewable energy sources and materials found on site, the democratization of technology for the purposes of production, and using local manpower, rather than people with advanced training.

The second project area is sustainable construction processes with low environmental impact, including such items as lowering construction costs, CO2 emissions, the use of concrete, and transport operations, as well as using natural waste and better planning out the construction life cycle. Recycled materials, like natural waste from the agricultural chain and rubble, make up the third area, while the fourth is centered around the digitalization of the construction site through features such as digital data acquisition through 3D scanning, site monitoring, using on-site measuring to lower the amount of mistakes, and constantly defining the correct spatial coordinates.

Multi-purposes construction is the fifth project macro-area, which includes coordinating the use of multiple methods of digital fabrication like CNC technology, embedding supply facilities during initial construction rather than after, adding natural ventilation and thermal insulation right onto the walls, and using controlled material deposition to achieve high performance construction. Digital design is the final project area, and will focus on features including integrated design with BIM software, sharing digital contents available on the Internet, using a material optimization algorithm for construction, and making construction projects fully digital.

With this new project, WASP hopes to become a leader in the housing market, due also to its network of collaborators that will help to foster and share the project. The company knows that are some real opportunities in the future for green building, and also plans to develop a new eco-district in order to implement its “3D Printing for Sustainable Living” project goals and set up new constructive strategies that can be replicated in multiple environments.

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[Images provided by WASP]