Large-Scale SLA Comes to North America via RPS

British stereolithography system manufacturer RPS has begun introducing its large-scale 3D printer to North America. While the company first introduced us to the NEO800 in 2016, this is its first sale in the U.S. The first customer is Midwest Prototyping, a service bureau based in Wisconsin.

RPS NEO800 3D printers. Image courtesy of RPS.

The NEO800 gets its name from its 800 x 800 x 600 mm build envelope, on the large end of vat photopolymerization systems on par in terms of scale with the RSPro800 from UnionTech, Prodways’ MOVINGLight series, the Rapid Meister ATOMm 8000 from CMET, 3D Systems largest machines, and several others. The machine also relies on an open resin system, meaning that it is not limited by the use of proprietary resins. For Midwest Prototyping’s use of the NEO800, Dutch chemical company DSM has been selected as the material provider. Customers could buy and use other resins, however.

Since the system was launched in 2017, the company has made steady progress in expanding its presence. Large customers such as Clarks Shoes acquired one earlier this year for prototyping footwear designs. Meanwhile, RPS has been involved in significant activity in the world of high-performance automobiles. Specifically, Briggs Automotive Company used Malcolm Nicholls Limited to produce parts with the large-scale printer for its BAC Mono R supercar. The Oxford Brookes Racing (OBR) Formula Student racing steam also used the system for its 2019 vehicle.

Given the size of the machine, it makes sense that it would be the tool of choice for service bureaus, which produce large batches of part at once. While one of the industry’s oldest service bureaus, Materialise, uses its massive Mammoth 3D printing systems in-house, smaller or newer businesses have access to larger machines via companies like RPS, which is why service firms such as Ogle Models & Prototypes in the U.K. and One3D in the Czech Republic turned to the NEO800.

As the company extends beyond Europe and into the U.S., it has also continued its partnership with DSM. DSM materials have routinely been selected for use with the NEO800 in the aforementioned projects. In 2019, RPS and DSM formed the TriCollective, a method for companies without the knowledge or capital resources to lease in 3D printing hardware and materials. This is one of many partnerships with smaller firms that DSM has made, which also include Origin and Inkbit.

A part 3D printed by the NEO800. Image courtesy of RPS.

For its own technology, RPS uses the NEO Material Development Kit, a polymer research and development tool that allows material developers to test new resins for NEO systems using a one liter vat, single layer exposure panes and RPS’s Titanium software. This allows them to determine the necessary exposure time and material formulations before moving on to a larger 13-liter system.

The fact that RPS relies on an open materials approach to its SLA technology is representative of the larger trend away from hardware-specific materials in the industry as a whole. While early stalwarts like 3D Systems and Stratasys have sold their materials directly to customers, the open materials approach allows newer machine manufacturers entry into the marketplace as customers look to them for lower cost feedstock options. In turn, this gives companies like DSM a greater footprint, while expanding the adoption of 3D printing across industries.

While RPS continues to grow, it and every other manufacturer of SLA technology will have to look over their shoulders for competitors working on large-scale, continuous-DLP technology, such as Azul.

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Holiday Fun During COVID-19: 3D Printed Easter Eggs, Seder Plates, and Ramadan Lanterns

Because of the COVID-19 epidemic, this spring is going to be really difficult for a lot of people. On top of cancelled classes, closed restaurants, and people panic-buying at grocery stores, Passover began earlier this week, Easter is this Sunday, and Ramadan starts in two weeks. Many people like to spend time with their loved during holidays like these, and with countries all over the world in various stages of lock down and quarantine, that’s likely not going to happen. The ongoing coronavirus crisis has upended life for a lot of people, and additive manufacturing companies and makers at home have been rushing in to help, to the best of their abilities, by 3D printing things like face shields and masks, nasal swabs, ventilators, field respirators, and even hands-free door openers.

A face shield made with a 3D printed adapter and a standard hard hat. (Image: GE Additive)

However, while this call to arms is admirable, we need to remember that regulations and certifications for 3D printed medical devices are put in place for a reason. Even the best intentions can lead to some harmful consequences, and we must make sure we’re not causing additional harm by 3D printing items that don’t need to be 3D printed. My suggestion is that maybe, we use 3D printing to take care of our mental health, which is just as important during these strange times. So I refer back to my opening statement – it will be hard not spending the holidays with your family and friends.

So, if you’re stuck at home with a 3D printer, why not make the best of things and create some holiday-themed prints? For instance, just because you’re not expecting a passel of guests doesn’t mean you can’t still decorate with this Easter Egg-shaped holder for electric candles, published by MyMiniFactory user 3dprintinggeek, or this ‘Happy Passover‘ print on Thingiverse, which user jrembrandt created with the Customizer feature.

Ramadan Moon

This Ramadan Moon decoration by Thingiverse user YehiaJammoul can be 3D printed in different sizes, so long as the bed is “perfectly leveled.” I also like this Ramadan lantern print by the same user, who designed it in SOLIDWORKS and printed it on a Creality CR-10S.

Easter Cookie Cutters

A lot of people are getting through these difficult times by stress-eating. So long as you use food-safe filament, help feed your craving with the help of these cute Easter Cookie Cutters by MyMiniFactory user Benjamin_Lau, or this one from aptly named Cults3D user Cookiemonster. Thingiverse user ianwarelec turned to Fusion 360 to design this Ramadan Kareem Cookie Cutter, shaped like a crescent to represent the lunar month of Ramadan. Also on Thingiverse, I found this Matzo Slicer by Shoogon and a Matzo holder by itaysp.

You can celebrate the holidays by dressing up if you want, and these Easter Bunny Earrings by MyMiniFactory user Idea Lab, or this adorable Bunny Ears Head Band, will surely land you on the Easter Bunny’s best-dressed list…if he makes one.

Bunny Ears Head Band

“Don’t forget to cut off the tabs, they are present to act as a strategic brim to help bed adhesion and prevent curling,” Cults3D user bLiTzJoN writes about the head band.

I found this really lovely Vertical Seder Plate on Thingiverse – user stevemedwin’s wife is a rabbi, and challenged him to make the vertical plate.

Vertical Seder Plate

” I ended up designing a seven piece assembly that holds the traditional seder plate liners. OpenSCAD came to the rescue as the tolerances on the pieces was critical for it to be stable,” he wrote.

“The arms can be rotated independently in order to fit the items as needed.”

He 3D printed the plate on his MakerBot Replicator 2, with no raft or supports, at 10% infill and a layer height of 0.200.

Of course, it wouldn’t be Easter without 3D printed eggs, like these Floral Easter Eggs and Woven Easter Eggs by MyMiniFactory user TechDave204, and I also really like this Resin Easter Egg Collection on MyMiniFactory from user ChrisBobo, “made with Fusion 360 and Meshmixer and printed on an Anycubic Photon.”

If you’re interested in an indoor hunt for your 3D printed Easter eggs, you can hide them in this 3D Printable Grass by Cults3D user Superbeasti, which can be cut to length and should be printed with a raft for better adhesion.

3D Printable Grass

“As with any “hairy” print, these are printed sideways, and then one of the plates is cut free. The parts should be oriented so, that each strand starts printing from the top of the grass and ends on the root (Cura changes this when you rotate the block 180 degrees on the Z axis).This way you get a nice effect, where the grass is thinner on the top, and adheres better to the bottom plate. You can choose, if you want to have a thick bottom plate or the thin one, by simply orienting the parts accordingly and cutting the opposite plate off,” he wrote.

Bringing things full circle, Thingiverse user menzach created this Coronavirus Easter egg, which needs a raft and supports and will require an extra step of gluing the red S-proteins to the rest of the egg. Once you’ve collected all of your 3D printed eggs, you can place them in this Easter Eggs Basket by Cults3D user SE_2018. But maybe leave the coronavirus egg where you found it…we’ve had enough of that, I think.

Happy holiday 3D printing and stay healthy!

Did you create any holiday 3D prints? Let us know at 3DPrintBoard.com or share your thoughts in the Facebook comments below. 

The post Holiday Fun During COVID-19: 3D Printed Easter Eggs, Seder Plates, and Ramadan Lanterns appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Short Carbon Fibre-Reinforced Polyamide Using FDM 3D Printing vs. Polymer Injection Molding

Researchers from Spain are investigating more effective 3D printing materials with different techniques in the recently released ‘Investigation of a Short Carbon Fibre-Reinforced Polyamide and Comparison of Two Manufacturing Processes: Fused Deposition Modelling (FDM) and Polymer Injection Moulding (PIM).’

FDM 3D printing is extremely common for digital fabrication by users on all levels, beneficial due to affordability and accessibility—and offering a way to create complex structures for many different applications today, from medical to bioprinting, automotive, and aerospace. Selective laser sintering (SLS) and selective laser melting (SLM) are also methods preferred in manufacturing today, although the researchers note that FDM 3D printing is ‘more developed,’ with the following popular polymers:

  • Acrylonitrile butadiene styrene (ABS)
  • Polylactic acid (PLA)
  • Polyvinyl alcohol (PVA)
  • Polyamides (PA)
  • Polyether ether ketone (PEEK)

Poor mechanical properties are an ongoing issue, related to varying parameters, issues with adhesion, and materials which are not suitable. Composites are often used as a solution, with many different projects employing additives making up new materials like bronze PLA, composite hydrogels, and numerous metals. Carbon and glass are common additions used for strengthening the polymeric matrix, but the researchers note that they have not been the subject of comprehensive studies.

CarbonXTM CRF-Nylon was used with an Ultimaker 2 Extended + to fabricate the samples, designed with Autodesk Inventor, and sliced with Cura 3.5.1.

Stereomicroscope images (×1.25) of the appearance of the injected and different patterned printed samples.

The authors, comparing 3D printing and injection molding capabilities, evaluated fiber length first.

Results of the fibre length distribution in the raw material, injected and printed samples (A) and measurement of diameters in fibres using 400× with a microscope (B).

“The critical length obtained by Equation (1) was