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3D Print magazine international edition: from prototyping to manufacturing Additive manufacturing, today known as 3D printing, has already transformed complete supply chains in certain industries. After all, 3D printing allows one to digitize process chains, move to smaller series and even makes mass customization possible. Will the same happen in other industrial branches? Will 3D printing completely transform the entire manufacturing industry? These are the questions many companies are struggling with. These are also precisely the questions that the editors of 3D Print magazine continue to ask themselves. After a successful launch of the magazine in 2014 - with a Dutch edition in the Benelux - we are now preparing to go a step further. As of autumn 2016, we will launch an international edition of 3D Print magazine. We notice that the questions being raised in the manufacturing industry in the Netherlands are no different than those abroad. What can 3D printing do for my business? How does the value chain in which I operate change as a result of additive manufacturing? Should I start using 3D printing now or should I wait?
Suppliers and OEMs
3D Print magazine has one main target group: the manufacturing industry. These may be metal processors, plastics processors, suppliers or OEMs. Our readers are industrial designers, engineers, manufacturing managers, and also managers of companies. Their interest in how 3D printing may change their daily work is a common characteristic. These are precisely the questions that 3D Print wants to answer. We do this
by writing about developments surrounding the technology; by reporting about innovations and materials; by focusing on business related topics such as software, legal aspects and supply chains. We do all of this by highlighting industry-wide 'best practices', during which we not only discuss the benefits and possibilities of 3D printing, but also clearly outline its limits.
Towards production
Using the aforementioned editorial concept, we want to take our international audience on a journey and have them experience 3D printing from prototyping to production. We do all of this in a realistic manner. After all, excessive expectations only lead to disappointment. Instead, our aim is to highlight as many possibilities of this new technology and inspire readers about ways in which 3D printing can be effectively used alongside existing production technologies. Will you join us on this journey?
Franc Coenen
franc.coenen@3dprintmagazine.eu
Print and digital
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The international edition of 3D print magazine will be published both in print and digitally. The print edition will be sent out to all subscribers and will also be distributed at additive manufacturing exhibitions, conferences, workshops and other targeted events. The print edition will have 4,200 copies in total. As mentioned, the international edition will also be available online and, as part of an email campaign, will be sent to the target group as a PFD file.
Subscribe to the free digital edition of 3D Print magazine http://eepurl.com/b6Ds4P
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How is the 3D print industry heading towards industrial applications?
3D metal printing in the manufacturing industry Many manufacturers of 3D metal printers are currently busy developing their machines for production applications. This is where their future market(s) will be. In a number of aspects they go down the same road; in other aspects their developments differ.
Eric Klemp - director of the DMRC at the University of Paderborn in Germany - expects that, in the near future, 3D metal printers will significantly change in terms of machine design. Traditional machine manufacturers are entering the market; or at least, companies that have their roots in machine construction. They will bring more speed, robustness and stability to the process. "It's going to be 90% machine and 10% additive manufacturing, not the other way round, as is often the case today". Over the last few months, several large players in this market have presented their
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vision on this market. Concept Laser may be the most ambitious with the AM Factory of Tomorrow. Essential to this new concept (which the German manufacturer wishes to bring to market at the end of 2016) is the separation of the handling of powder and work piece on the one hand, and 3D printing on the other hand.
Physical separation process steps
Concept Laser has chosen for modules. The three key steps in the additive manufacturing process - pre-production, production
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? and post processing - will be separated. In a separate room, the print job will be prepared in a handling station. This module includes an integrated powder management system, including a sieve for the filter. During preparation, multiple stations can be connected to each other. These handling stations are completely closed, so that operators do not come into contact with the powder. Furthermore, a process module, dosing module and overflow module can also be incorporated, all without directly coupling hoses/tubes and identifiable, using RFID technology. Similar to AGVs, the handling stations automatically drive towards the printing factory, where they connect themselves to the process station, which is equipped with multiple lasers. Once the print job is complete, the module drives towards the post-processing department. "We can automate the AM fabric in many different ways", says Florian Bechmann, head of R&D at Concept Laser. This not only saves a lot of space, but also guarantees a higher productivity. To increase productivity ever further, Concept Laser has developed a new recoater with two axes. These allow the recoater to move back to the starting position while the laser already focuses on the new material layer.
Integrated print line
The separation between exposure to a laser and all other operations is also the core of the MetalFAB1, an industrial metal printer developed by Additive Industries in Eindhoven. The Dutch startup chose to separate different steps and to place them in separate modules. At the same time though, it integrates them in a single machine. The transportation of the construction board of, for example, the unit used for printing to the unit used for heat treatment or storage, is done by a robot. The robot moves along a track at the rear of the machine. Unique to this solution is that the MetalFAB1 features up to four print rooms. “The optical system can switch from one room to another�, says Marc Vaes, technology manager at Additive Industries. “This allows us to process multiple materials at the same time." The positioning of the unit is precise enough to do so. Customers can equip the optical unit with 1 to 4 lasers that can reach the entire construction surface. This prevents so-called 'stitching' in the transition areas between the lasers. A second area in which MetalFAB1 differs
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Outside of the fact that manufacturers are busy pushing the hardware to an industrial level, they are also investing a lot of time in software systems for quality monitoring. EOState Meltpool monitoring documents the buildup per spot, per layer and per product.
from other machines is the integration of a heat treatment oven. The Dutch manufacturer's aim is to be able to remove the completed product from the machine. For the most part, the excess powder is automatically removed and reused, without being discharged from the machine.
Multi laser system
Other manufacturers are working to make 3D printers more suitable for manufacturing applications. For example, several years ago EOS introduced the AM 400. The AM 400 has a separate station for the removal of the construction board and semi automatic removal of powder. This multi laser system will be brought to market before the end of this year. Adrian Keppler - sales and marketing director at EOS - says: "Multiple lasers in a single system reduce the processing time. In combination with having the handling of powders and work pieces done outside of the machine, we can reduce the costs per printed work piece. This is the first step towards industrialization." For EOS, it is especially important that the 3D metal printers can easily be integrated
in an existing production environment. Therefore, no Industry 4.0 concept. "There will only be a few AM manufacturers that will be built from a green field", explains Keppler. The way in which EOS allows for the use of multiple lasers opens up many new possibilities. By having different settings in the software, multiple lasers can be used to build multiple products at the same time. For example, a machine with four lasers can print in four quadrants at the same time. This reduces printing time by 75%. The lasers can also simultaneously work on one element. Furthermore, EOS is currently also developing a software package to which not only 3D printers can be connected, but also other types of production printers. "We don't want to offer a single machine, but a complete manufacturing solution", says Keppler.
Software suit required for all manufacturing data
Software in machines is of increasing importance. Additive Industries has developed a realtime monitoring and planning system that works independently from the location of
The integration of four lasers in the EOS machine opens up new possibilities. For example, one can either simultaneously build up in four quadrants or work on a single work piece at double capacity.
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"For every layer, we check whether the laser is correctly aligned and inspect the position and focus." Because the optical unit positions itself at a micron accuracy, potential deviations due to thermal drift of the machine can be prevented. Customers of the Dutch machine builder may also select the PrintRite3D package of Sigma Labs. Using this package, one can monitor the buildup process in realtime.
Meltpool control Additive Industries has decided to integrate all modules into a single machine. A robot on the rear side takes care of the handling.
the users. Furthermore, the system is fully open, so that other systems and machines may also be connected. The next step the company wants to take is to use big data to analyze the many process parameters and potentially adapt the process to these data. Furthermore, Additive Industries has integrated automatic calibration in the MetalFAB1. This system calibrates both the focus of the lasers and the position of the laser spot. Marc Vaes:
Renishaw: integrating 3D printing into the existing product line
EOS has expanded the existing quality monitoring system with Eostate MeltPool process control. The basis of this system comes from checking the laser welding. Together with partner Plasmo Industrietechnik, EOS has adapted the algorithm to the laser melting of the metal powder. Per printed element, the system (two photo diodes and a camera and signal amplifier) detects whether or not the melting process meets the requirements. Users can set up the accuracy per print job.
Q modules
For a long time now, Concept Laser offers multiple quality modules for its machines, partly to monitor the state of the powder and gas and the recoating process. QM Meltpool is the most essential module. Concept Laser uses a special camera during the melting process per square mm. This is a highresolution camera with a frequency of 10 Khz. This guarantees lots of data, which are analyzed in realtime. In the future, Concept Laser aims to introduce an adaptive process by having the machine adapt itself to the data made available through various quality systems.
SLM Solutions: multilasers
This is what a future 3D printer line at a supplier looks like according to Renishaw's vision. The 3D metal printer, used for printing one type of material, is integrated into a row of measuring and milling machines for a complete product line.
On the road towards production applications, Renishaw has taken a different path with its new 3D metal printer: the AM 500. Powder handling and laser melting are integrated into a single machine. However, the machine contains two containers, one for new powder and one for recycled powder (which is automatically recycled in the machine). As a consequence, less powder is required. More importantly, the quality of the work pieces improves because there is a constant stream of new and recycled powder available. As a result, the quality of the material flow remains the same. In doing so, Renishaw also increases the length of time that the machine can actively print. The machine is also equipped with a double filter system, so that the filter can be changed during printing. To increase accuracy, the AM 500 has an optical unit using Renishaw's own technology, such as encoders for accuracy positioning. Renishaw's vision on the step from prototype to AM for production is reflected in the machine concept of the AM 500. Philippe Reinders Folmer, director of Renishaw Benelux says: "We believe in an additive manufacturing line in which the printer is integrated into a row of measuring and post-processing machines. We also expect that companies will choose for a mono material strategy: one material per printer, which ensures optimum production." www.renishaw.com
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SLM Solutions allows for the manual transport of the construction board to the post-processing location. The North German manufacturer especially focuses on the development of multilaser technologies and process control. SLM Solutions offers a total of four laser sources in a machine. This Qua laser in the SLM 500 HL reduces build-up time by up to 80%. The smaller machines - the SLM 280 HL and SLM 500 HL - can now also be equipped with a 700 W lasers, reducing the printing time in these stand-alone machines.
More information
Additive Industries www.additiveindustries.com Concept Laser www.conceptlaser.de / www.landrĂŠ.nl EOS www.eos.info / www.benderam.nl SLM Solutions www.stage.slm-solutions.com
Concept Laser has unveiled the AM factory of the future.
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Plea to not only support R&D, but also the actual application of 3D printing
CECIMO unveils European AM strategy CECIMO has presented a concept for its European additive manufacturing strategy. Such a pan-European strategy is a necessity in order to keep pace with the European development of AM technology and to accelerate the actual application of the technology, according to the European machine tool builders. For the second time, CECIMO held an AM and 3D printing conference in the European Parliament. "Europe has to move forward, and to do so, we require advanced manufacturing in our industries", says Reinhard Bütikofer, one of the EU MPs who presented his vision during the conference. "This not only requires money, but also actual desire."
Filip Geerts: the growth is not just hype
Individually, European countries contribute a lot to the promotion of additive manufacturing, says Filip Geerts, general director of CECIMO. However, CECIMO believes that additional action is required. "The lack of a pan-European strategy threatens European entrepreneurs and exposes end users to increasing competition from outside Europe. We have to implement additive manufacturing in industries as soon as possible and this is only possible with a pan-European vision.”
10-point plan
The European umbrella organization for machine tool manufacturers has prepared a draft for such a strategy. It consists of 10 points. Education and training is the first point. Standardization is the foundation for the further development of AM. The third point is the adjustment of legislation for patents in Europe, so that they become cheaper and are granted much sooner. CECIMO wants to create support for European SMEs - the backbone of the industry - when implementing additive manufacturing. SMEs must gain access to financial resources in order to actually start using 3D printing. The European instruments for SME support should be
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Filip Geerts, director of CECIMO, with on the left Dario Tamburrano (EU MP and one of the co-hosts) and on the right Peter Dröll, director of key enabling technologies at the DG Research & Innovation of the European Commission.
widened, say the machine tool builders. In the eighth point of the AM strategy, CECIMO calls to attract European venture capital, specifically aimed at technology companies. Funds must also be created for SMEs that invest in this new technology. The European ICT infrastructure must be
improved, in terms of speed, quality, and security. The final point in the strategy is about research into the consequences of additive manufacturing on the working conditions of employees, especially considering health and safety aspects.
3D printing courses for CEOs CEOs of large companies must participate in 3D printing courses. In doing so, they must discover that new business models are the number one success factor for the breakthrough of 3D printing. Furthermore, CIOs (Chief Information Officers) must learn about the effects of digitization. All panel members at the 2nd edition of the CECIMO European AM Conference agreed upon this. Phil Reeves from Stratasys, Stefan Ritt from SLM Solutions, Bart van der Schueren from Materialise and Martin Schaefer from Siemens see the development of new business models as one of the greatest stumbling blocks for the implementation of additive manufacturing. Phil Reeves from Stratasys Consultancy says it most aptly: "A 3D printer is nothing more than a 3-axis CNC machine. CEOs must therefore take a few steps back and think about how 3D printing may change their business."
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ECN: High quality 3D metal printing
At ECN, R&D projects focus on the quality of materials produced by additive manufacturing.
From its branches in Petten and Eindhoven, ECN uses its knowledge of powder metallurgy and ceramics to create solutions for additive manufacturing. The research institute develops an indirect printing method for metals, an extension of its development for printing technical ceramics. A direct method, which is an improvement of selective laser melting that counters the drawbacks of this technique, is an alternative process that is under development. The microstructures produced by this method are better than the state of the art.
ECN has a tradition in 3D printing. It is one of the founding shareholders of Admatec, a company that produced technical ceramics by additive manufacturing. “This development is not a result of a subsidised research project, but is driven by our conviction that we can apply knowledge from processes we developed previously to new processes such as additive
8
manufacturing�, says Bas van Bree, Business Development Manager. ECN’s strategy is to commercialise the technology via a spin-off company to generate revenue for future projects. Admatec produces parts for the market and has recenty ventured into the printer market through the release of the ADMAFLEX 130 printer.
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Indirect metal printing
One of the research directions at ECN is 3D metal printing via an indirect method, analogous to the process that Admatec uses to print technical ceramics. Metal powder is mixed with a liquid polymer. The polymer is cured by projecting an image on a thin layer of the mixture using a beamer. This step is comparable to the DLP technology. Then the polymer is removed from the ‘green’ product in a furnace in a debinding step, after which the product is sintered. ECN has already applied this technology to stainless steel. The challenge that ECN has solved is to get the curing light sufficiently deep into light absorbing materials such as metals. The benefit of the indirect method is the material quality, which is much better than products manufactured by laser melting, such as the current powder bed 3d printers. “Fine details and a smooth surface finish are possible”, indicated Bas van Bree. Most importantly, the resulting material is isotropic and has a very homogeneous microstructure. The drawback of the current direct methods is that microstructure is very difficult to control. The development of the indirect method is not complete yet, but the results are so promising that it is likely that the technology will be commercialised via a spin-off company.
Improving SLM
Despite its difficulties, a direct method such as SLM also has its advantages, if only that it requires less process steps. ECN therefore executes a second development programme to improve current selective laser melting methods. Bas van Bree: “We think that improved parameters and other improvements to the technique can reduce material stresses and result in a better surface finish”. The improvements aim to transfer energy from the laser source into the material in a more controlled fashion. Bas van Bree: “Other players aim to increase speed, we are primarily interested in material quality.” This requires a lot of materials knowledge. A spin-off company is ECN’s preferred route for commercialisation for this technology as well. www.ecn.nl
XJet accelerates precision 3D metal printing 3D metal printing seems to be the holy grail that everyone is looking for. During the recent AMUG conference, the Israeli company XJet presented its first new 3D printing technology. The technology is similar to that of inkjet printers, only with metals. Nano particles of metal are present in a liquid substance. Ultrafine layers of these droplets are placed on each other, allowing one to build the metal product. The substance is packaged in sealed cartridges, just like with a 2D printer. Every nano particle is surrounded by this substance. Due to the heat in the build chamber (300 degrees C), the substance evaporates and pure metal remains. Up to 221 million droplets can be printed per second. The layer thickness is under 2 microns, 10 times lower than most powder bed systems. The founders of XJet call it NanoParticle Jetting. If support materials are required, they can be included as separate materials in a separate cartridge. The support structure is removed through sintering.
The main advantages
This technology has a number of advantages. The first is that the surface quality of the printed components is much greater than powder processes. Furthermore, because all materials are included in sealed cartridges, the operator no longer has to use powder. In terms of ergonomics and safety, the Israeli company makes a strong argument. They say their XJet technology is just as user-friendly as traditional inkjet printing. The third advantage is that no laser sources are required. XJet uses standard inkjet print heads for its 3D printers. XJet says that its process is five times faster than laser melting. www.xjet.com
For the indirect process, products must be sintered. Here, the material is 316L.
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Print and digital The international edition of 3D print magazine will be published both in print and digitally. The print edition will be sent out to all subscribers and will also be distributed at additive manufacturing exhibitions, conferences, workshops and other targeted events. The print edition will have 4,200 copies in total. As mentioned, the international edition will also be available online and, as part of an email campaign, will be sent to the target group as a PFD file.
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Subscribe to the free digital edition of 3D Print magazine http://eepurl.com/b6Ds4P
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Rösler and Shapeways are currently developing technology for plastics; PostProcess Technologies goes a step further
Automated post processing
Before......
After
Now that 3D printing (especially for plastics) is moving towards production, the demand for automated cleaning technologies is increasing. Together with Shapeways, Rösler Benelux has developed the RapidFinish process. In the US, the startup PostProcess Technologies has undertaken this challenge. Shapeways and Rösler have continued to develop the existing finish processes of Rösler into a solution for 3D printing. For Shapeways, mechanical post processing is important, as it speeds up the production process while the geometrical shape of the product is maintained. When all is said and done, one operation must be able to post process a number of products in a reproducible way. Rösler RapidFinish offers the solution for Shapeways' high demands. The RapidFinish mechanical surface treatment has no negative impact on the environment. The treatment is specifically designed for 3D printed work pieces of any materials and geometry. Complex geometries with canals and holes can also be internally post processed, as long as the process media are able to move through hollow spaces. The Dutch Rösler office has already created a test center and provides customers with extensive outsourcing opportunities.
Automatically remove support
In the US, Daniel Hutchinson - founder of PostProcess Technologies - is working on the automation of the finishing process. With his technology, he focuses on all types of materials, both plastics and metals. He believes the removal of support should also be automated. PostProcess Technologies uses a special liquid in tanks - including the to be cleaned elements - that continuously remains in motion for a certain period of time. The movements are fully computer controlled
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on the basis of a special algorithm, which prevents damage to thin-walled products. The process is suitable for all types of 3D printing with plastics, meaning FDM, SLS and SLA. PostProcess has also developed a technology that uses a special slurry to remove supports from metal products, while at the same time improve the surface quality. Since late 2015, the process is allowed for dental applications. The application was developed together with a US manufacturer of printed dental products.
Machines at IMTS 2016
In the next phase, Daniel Hutchinson wishes to use his technology to increase the strength of 3D printed parts. The first tests were already performed with Ultem, a nylon of Stratasys. The third step is the automatic application of coatings and the potential coloring of printed parts by including dye in the plastics. Technologies are also being developed for the certification of medical applications. The American company aims to present a full line of post processing machines at the IMTS in September in Chicago. There are currently already 42 machines available in the market, especially at 3D print service agencies. www.postprocess.com www.rosler.nl/assortiment/3d-rapidfinish
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DSM strengthens position with high performance filaments DSM is strengthening its position in the 3D print market by, in collaboration with Nexeo, introducing new materials for FDM 3D printers to the market. The focus is currently on high quality performance filaments, copolyesters and polyamides. With its subsidiary Somos, DSM has long been active in the additive manufacturing industry. Its main focus is on industrial SLS printers. With its collaboration with Nexeo Solutions, the Dutch concern aims to improve its position in a market in which is dominated by FDM printers. Nexeo Solutions is a worldwide distributor of chemicals and plastics. DSM's approach emphasizes the confidence that the company has in the (future) growth of the 3D printing industry.
Arnitel ID: co-polyester
Two filaments have been developed. Arnitel ID is a flexible thermoplastic co-polyester, used worldwide in industries including electronics, sports and other high end application industries. On the one hand the filament distinguishes itself with its high degree of UV and chemical resistance; on the other hand it distinguishes itself with its high elongation upon breaking, namely up to 400%. According to DSM, the filament ensures a better adhesion to the previous layer and the printing speed is faster than usual. The material was developed on the basis of the cable industry material knowledge that DSM possesses.
Novamid: resistant to high temperatures
The second new printing material is Novamid. This polyamide was originally developed for the automotive and electronics industries. It is a ductile and strong polymer, suitable for harsh environments and can withstand temperatures of up to 150 degrees C. Here, too, the adhesion of two layers is better than what the 3D printing industry is currently used to, at least according to the producer of the filament. The filament is suitable for the printing of overhanging parts. www.dsm.com www.nexeo3dsolutions.com
Fraunhofer ILT develops magnesium 3D printing The Fraunhofer ILT has managed to create magnesium parts through additive manufacturing. This was achieved using an SLM machine of Aconity 3D, an in-house startup. The technology was presented during the AKL 16 laser congress. The great challenge for German researchers was to develop a solution for the smoke released when melting magnesium (as well as copper). In doing so, the build-up chamber of the SLM machine was adjusted and the gas flow was optimized in collaboration
with Aconity 3D. Furthermore, a special system was developed for copper and other materials that are susceptible to crack formation in order to pre-heat these specific powders. In the Aconity 3D machine this is possible up to 1200 degrees C. This greatly reduces the risk of micro-cracks to such a degree that the printing process is reliable enough for industrial applications.
Stronger than castwork
The Fraunhofer ILT believes that with this new breakthrough it has created new applications for 3D printing of metals. On the one hand, this is all related to 'Leichtbau': magnesium has a specific weight, which is 30% less than aluminum. To illustrate the possibilities, the engineers have developed a model of a triple clamp for a motorcycle, the clamp to which the front fork legs are attached. The triple clamp has been topologically optimized and has a greater mechanical strength than a cast clamp, but weighs significantly less. Another application can be found in the medical world. Magnesium is a material that is not rejected by the body. Magnesium implants are already being used today. Now that these can be 3D printed as well, many new possibilities arise. www.ilt.fraunhofer.de www.aconity3d.com
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Stratasys JC750: 3D printing without post processing Realistic looking 3D printing that doesn't requires post processing. In lifelike colors. This is what Stratasys promises with the latest J750 3D printer. Is this truly the revolution in prototyping that the 3D print manufacturer promises? Alongside the Objet Connex machines, the Stratasys J750 is the first full color printer in Stratasys' portfolio. What makes this printer unique is that it not only makes 360,000 color shades possible, but also allows for different material properties without having to manually change materials because the printer has room for 6 different material cartridges. Among the available materials are digital ABS and ABS 2, multiple rubber-like materials, a number of Vero materials and a water-soluble support material. The maximum building volume is 490 by 390 by 200 mm.
Shorter process flows
In the development of this printer, Stratasys has expressly examined the process flow during the development of prototypes. This entire chain has been considerably shortened. Not only because the models created by the JC750 immediately have the correct color and require no post processing, but also
because the new software package (New PolyJet Studio) has an intuitive interface that makes the selection of materials a lot easier. Color textures can be immediately loaded using VRML files from a CAD application. The JC750 is a system that can also print tools, molds and training models. The latter is exemplified by the medical model that was shown at the presentation of the printer. www.stratasys.com
SEIDO Solutions sees demand for industrial 3D print parts greatly increase SEIDO Solutions, the 3D print service center, wants to expand further. The eight 3D printers that are currently set up in Kortrijk are insufficient to meet the growing demand for professional 3D printing (end-use) parts, says Hans Valkenaers, application engineer at SEIDO Solutions. "After all, we always want to have printing capacity available in order to be able to react fast." The activities of SEIDO Solutions as a service provider in the international 3D printing market are clearly gaining momentum. The company from Kortrijk has a total of eight professional Stratasys 3D printers: five Fortus 450mc, one Fortus 900mc, one Objet 500 Connex3 and several other smaller polyjet printers. These printers are used daily to print for industrial clients. Not only prototypes, but also mechanical components for machine manufacturing. "We more and more often also make small series or pre production series", says Valkenaers.
3D printing of injection molds
Increasingly, injection molds are being 3D printed as well. On the one hand, a customer may want to use them to cast prototypes and small series and on the other hand he/she may want to use the 3D printed mold for pre production, until the definitive mold is ready. As a result, one can already bring products to market while waiting. Hans Valkenaers: "Depending on the complexity of the product and plastic, the number of shots you can make with a printed mold ranges from 10 to 400, the latter being the maximum we have achieved until now." A lot is dependent on the design. One area that is still a problem is the experience of the 3D print
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service office. If you convert (one-for-one) the design for a metal injection mold to 3D printing, you run into problems. A good design tailored to 3D printing reduces the duration of the printing process. Hans Valkenaers, who - as an application engineer advises customers about the optimization of mold design: "If it's really necessary, we can move from design (by printing the mold) to the the first injection products within 24 hours." Seido Solutions generally has a lead time of several days, including a check of CAD models and shipping. In order to continue to deliver at a quick pace, the service bureau continues to invest in 3D printing. "With extra capacity we can guarantee greater flexibility." www.seido-solutions.com
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With 3D printing and digital workflows, Dentsply Implants is industrializing the production of individual support structures for dental prostheses on implants
From full CNC milling to a hybrid process within one year Additive manufacturing can be a disruptive technology, because it fully suits digitized supply chains and allows for mass customization. Thanks to digitization and additive manufacturing, Dentsply Implants in Hasselt is currently revolutionizing the total value chain for dental restauration of implants. In doing so, machining technology remains indispensable. However, fewer machines are used.
In over a year, Dentsply Implants has changed the production process for support structures of dental implants from 100 percent CNC milling into a hybrid process: 3D metal printing in combination with milling. Jo Massoels - business unit manager - admits that the company was able to make a flying start by using the complete dental technology and know how of Renishaw and implement them into its production process at the start of 2015. Five months later, the first 3D printed support structures in cobalt chrome were ready for delivery. In the meantime (faster than expected), the company has purchased two Renishaw 3D metal printers and will start with the production of titanium products this autumn. By the end of the year, 80% of all 15.000 products that Dentsply Implants manufactures will be 3D printed.
Critical point: from print to milling machine
The company has not only greatly approved its quality, but also managed to reduce costs. Jo Massoels: "1 build per day is already cheaper than when milling everything. Despite the expensive powder, we've created a significant cost saving at current occupation." Admittedly, AM Machines require a high investment and CNC processing centers are not cheap. When it comes to the business case, Massoels says the most important part is how much free capacity becomes available if you 3D print near net shape. "By investing in a 3D metal printer, we were able to triple our free capacity." This free capacity was even the direct reason to move to 3D printing: the capacity was at a maximum. In other words, new investments in milling machines would be required. "If you have no capacity problem, the 3D printing business case can be more difficult to justify."
Hybrid process
The Flemish company uses a hybrid process: the 3D printed products are still post processed using a CNC machine. This is a necessity, because the tolerances are tight at those locations where the support structure is attached to the implant are very precise (up to microns). This is a crucial point. A poor fit greatly reduces the wearing comfort for the patient. Moreover, there is a risk of the implant (the screw) coming loose in the jaw. The accuracy of AM
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In Hasselt, CAD models and CAM applications are being made that are digitally sent back to the dentist for approval before they are 3D printed or milled. By digitizing the workflow, Dentsply Implants works paperless.
machines is insufficient to meet this micron-accuracy. The crux was to devise such a solution that the clamping cone is directly printed alongside the support structure and is accurate enough so that the milling machine does not have to be set up for each new product. Dentsply Implants has been successful in doing so. Every support structure is provided with a clamping cone that fits on the special clamping tool developed for the milling machine. After removing the structure of the construction board, the operator only has to place it in the clamping on the pallet and place it in the magazine of the robot-operated CNC milling cell. Post processing is then automated.
The impact of 3D printing
According to Jo Massoels, such a shift from machining production to hybrid production has had a significant impact on the company, something you shouldn't underestimate. "We have moved from a single flow process to a batch process. Instead of milling 1 structure in 5 hours, we can now 3D print 20 in 12 hours." The consequence is not only that if something goes wrong during printing you have to throw away 20 products, but it also means that 20 customers are not supplied on time. "We don't have that much time to solve such problems", says the Dentsply Implants manager. The lead time of 5 days is tight. Dentsply Implants has managed to achieve a a supply reliability rate of 99% for all products. This also includes the second 3D printed product: the personalized drilling jigs. These are created
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Mass customization: every bearing structure is unique. Nevertheless, Dentsply has industrialized the process.
using stereo lithography. With this drilling jigs, adjusted to the jaw of the patient, the dentist can risk-free drill the holes required for placing implants. Delivery times are two days.
CADCAM process
Just like the production of the support structures, Dentsply Implants has also fully digitized the workflow for drill jigs. This means that the dentist receives a 3D CAD model, created in Hasselt. This CAD model is created on the basis of a 3D scanned gypsum model designed by the dentist or in the future - on the basis of oral scan data, a technique that is becoming increasingly popular. The dentist can easily analyse and approve the CAD model using the software developed by Dentsply Implants. In doing so, the CAD model is mostly automatically processed with CAM software for the 3D printer. The specific CAM applications for the milling machines are still partly created manually by experienced CAM programmers. This is done in Hasselt, both for local production and for milling
departments in satellite factories in North America and Japan. Jo Massoels: “We have decentralized the physical production. This reduces shipping times. We do the programming from Hasselt, where we have bundled all know how." Because Japan and the US have identical milling cells, one can easily move the production process to a different factory in the event of emergencies in Hasselt (or vice versa). "We have a truly global manufacturing network", says Massoels.
material: "You cannot simply change the material. With 3D printing it is even more difficult than with milling." Nevertheless, Jo believes in the future of this technology for the dental sector. The next step is already close: the 3D printing of crowns, provided with a connection with the implant crew, that is given a ceramic or porcelain layer by the dental expert. 3D printing offers the advantage that the net surface can easily be increased by printing open structures, which ensures improved adhesion.
No push on the button
Dentsply mainly shows how digitization and additive manufacturing allow for the production of personalized products in an industrial environment. Jo Massoels: "We will still be using traditional technology for high volume products for a while. However, additive manufacturing will become increasingly desirable for medium sized series, products with many variations and mass customization.�
Dentsply Implants has made additive manufacturing a core competency in very little time. However, the team in Hasselt is aware of the limitations of the technology. 3D metal printing is still no 'push on the button' technology like CNC milling. It requires a lot of manual work. For example, the removal of the construction board and post processing. It also takes at least half a year until one fully understands the process for new materials. Jo says the real disadvantage is the changing of the
www.dentsplyimplants.com www.sirris.be
Digital workflow in Factory of the Future Dentsply Implants in Hasselt is one of the first 'Factories of the Future' within the MadeDifferent project of Sirris, which aims to transform 50 Flemish companies in 7 different areas. One of these transformations is the digital factory. Dentsply has digitized the entire process. As soon as a dentist places an order, all data become digitally available for all required steps. If the dentist still works with plaster models, a parcel service will be automatically requested to pick up the model
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within several hours (anywhere in the world) and bring it to Hasselt. The quality check is also digitized: for every product, the customer is provided with a digital measurement report. Dentsply Implants has also continued to develop the product - the support structure - with digital technologies. By using analyses such as the FEM analysis, the entire model has been adapted to bite forces that may burden the structure.
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Grand opening Photonics Cluster in Aachen More than 500 laser technology experts and 100 scientists, business leaders and politicians who attended the AKL’16 lasercongress in Aachen, also attended the grand opening of the new Photonics Cluster building at RWTH Aachen Campus. “With the addition of the Photonics Cluster on RWTH Aachen Campus, our international reputation for laser technology will expand even further,” said Prof. Reinhart Poprawe, Director of the Photonics Cluster. “Now the Fraunhofer Institute for Laser Technology ILT and RWTH institutes can work together with companies under one roof to explore the future of lasers and their versatile applications.” The Photonics Cluster specializes in researching and developing techniques designed to generate, shape and harness light – in particular as an industrial manufacturing tool. Industrial companies looking to conduct research and development in the field of optical technologies in close cooperation with RWTH Aachen and Fraunhofer ILT will move into the cluster’s first building complex. One of the R&D topics is additive manufacturing.
ACAM first edition of 3D Valley Conference Aachen Center for Additive Manufacturing organizes 3D Valley Conference on 14 & 15 September 2016 in Aachen. In the morning there are keynote lecturers from as well scientist as the industry. Second part of the conference program on the 15th of September are presentations about additive manufacturing embedded in industrial manufacturing processes and the importance of materials. In the afternoon participants can choose between a workshop about metal 3D printing and plastics 3D printing. www.3d-valley-conference.com
Stratasys GrabCAD makes 3D printing easier with integrated workflow Stratasys unveiled a new software strategy designed to make 3D printing significantly easier, more intuitive and highly accessible. The approach is powered by a new, open architecture ‘design-to3D print’ workflow application, GrabCAD Print – residing on the popular GrabCAD SaaS platform. GrabCAD Print is designed to make 3D printing fast and easy-to-use, while reducing errors by eliminating requirements to translate and repair computeraided
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design (CAD) files. Product designers, engineers, and 3D printer operators can now send native CAD files to a Stratasys 3D Printer or service bureau directly from their familiar CAD environments. Further bolstered by an extensive new business intelligence environment, the application also accelerates data-driven decisionmaking. “Underscoring the critical nature of software as an essential ingredient for complete and smooth 3D printing workflow, GrabCAD Print is our first new application built on the GrabCAD platform - empowering customers with a single, open, cloud-based environment for job preparation, scheduling and monitoring. Accelerating integration of additive manufacturing on the shop floor, GrabCAD Print also generates real-time business intelligence which can be prepared in actionable reports for Stratasys 3D Printers on the user’s GrabCAD Print network”, said Josh Claman, Chief Business Officer, Stratasys. GrabCAD Print works with a variety of Stratasys FDM and PolyJet 3D Printers and can natively read several popular CAD formats from PTC Creo, Dassault Systèmes’ SOLIDWORKS, Siemens PLM Software’s NX software, CATIA and Autodesk Inventor.
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Audi Werkzeugbau makes excellent use of additive technologies for production tooling
A bridge from conventional to additive Series models of modern cars do not include 3D printed parts. Nevertheless, many car manufacturers use the technology for much more than the printing of prototypes. For example, Audi uses the technology in its tool department. Various classic metal operations are performed with tools that are, some way or another, produced through AM.
Michael Breme, head of Audi Werkzeugbau, also uses the potential of 3D metal printing for Audi's mass-market models. The car manufacturer mainly uses additive manufacturing to, as Michael Breme says, bridge a gap between conventional and additive production. An example he gives is the pressing tool for mudguards on the new Audi A3, drawn with sharp lines that characterize the latest generation of Audis. "The front part of the tool is tapered and quite filigree. Up until recently we always milled it. Now we 3D print the insert for the pressing tool." To his own surprise, the 3D printed metal part has managed to last longer than the fully milled part. "Because it has a homogeneous material structure."
3D metal printing is required to incorporate such sharp lines in the bodywork of Audi models.
Function integration
In the meantime, Audi has made the second step towards the use of additive manufacturing: function integration. By adding certain functions to a tool - which cannot be created in conventional ways - one is able to create higher quality tool concepts. An example is a die for the hot pressed formation of high-strength steel for body parts. In the press, the plate is heated to 900 degrees Celsius, followed by a cool down cycle. To shorten this cycle, deep drill hole cooling channels are created in the massive steel parts. "Now that we use 3D printing, we can attach the cooling channels much closer to the surface and create more effective channels", says Breme. The hybrid tool has a 15% greater cooling effect, which, in practice, means a 15% shorter cool down time.
True 3D printed parts for Lamborghini vehicles
By 3D printing the press stamps before the heat forming of high-strength steels - allowing for internal cooling channels - Audi reduces the pressing cycle and increases the productivity up to 15%.
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Are there really no printed parts in cars? Audi is close. The internal construction of Lamborghini doors consist of a combination of aluminum with carbon fiber reinforced plastics. In total, there are roughly 20 different parts that need to be assembled. This requires a lot of tools. Michael Breme: "Lamborghini builds five cars per day. Together with the Fraunhofer ILT, we are considering whether we can use 3D printing for the door parts. If so, we can choose a bionic structure and will only require one component instead of 20." Michael Breme presented Audi's experiences with additive manufacturing at Formnext in Frankfurt, where a special exhibition about Audi tool production was organized.
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Added value with additive manufacturing
This nozzle is in a pick and place unit in one of the Grauel machines. The part was designed for AM and can not be created at once. In the past, the part was composed of multiple components that had to be assembled, partly by means of laser welding.
As long as manufacturers are not aware of the possibilities and impossibilities of additive manufacturing, the high tech engineering sector will not use the technology. As a supplier, you must therefore acquire knowledge about the subject and talk to customers as soon as possible. "You can only acquire AM knowledge by experiencing it yourself", says Henk Tils, business unit manager High Precision Parts at AAE.
AAE, supplier of precision mechanical parts, OEM systems and modules, and a high tech engineering company, has been in the possession of its own 3D metal printer for a year now. To be more specific: an SLM 280. The business case behind this investment was the acquisition of knowledge. 3D metal printing is a bit like a chicken-and-egg story. Henk Tils: "Everyone is struggling with the question of whether it is applicable to their product. However, without prior knowledge you can't get started and find out."
No plug and play technology
3D metal printing is in fact far from being a matter of pressing the start button. The devices are absolutely no plug and play devices, as Joost van Bussel - engineer at AAE - knows all too
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well. "The difficult part is that all parameters are linked to each other. Everything you do, has direct consequences for your work piece. A different orientation of your work piece directly influences the accuracy and post processing that is required. "With additive manufacturing, you can always turn lots of switches. The choices an engineer makes in the preliminary stages have an influence on the eventual production. Some people expect that software will solve a number of these problems in the future. At AAE, we believe this will only partly be true.� The AAE engineers use SolidWorks and Siemens NX drawing packages based on standard geometry. However, AM lends itself to more complex shapes - mesh structures for example. These are not included in the packages yet. This will likely change in the future, but Henk Tils questions whether
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AAE believes in the breakthrough of AM as long as engineers learn to think in different ways you can expect the software to simply solve the problem of many parameters settings. "CAM software cannot solve all problems during milling either." Handson experience will be a necessity, he believes. "Just bump your head a few times and you'll eventually get there."
Setup times per batch, not per product Henk Tils and Joost van Bussel are convinced that additive manufacturing suits the production techniques (alongside existing ones) in high tech engineering. "If you print one set of components in one material every day, you'll maybe no longer require storage for separate components. In that case, one no longer speaks of setup times per product, but setup times per batch. Logistically, this provides new opportunities", believes Henk Tils. Weight savings for higher dynamics can be another advantage for the high tech engineering industry. Less assembly could be a third argument for AM. The current generation of engineers is still too little accustomed to look at the entire chain. Therefore, the rise of AM will be slow. Real change will only occur once engineers become familiar with the new production techniques and start thinking on the basis of 3D possibilities. Moreover, they must learn how to take methods into account that may not seem obvious at first. The standard drawing of surface roughness of Ra 0.8 does not suit AM. Just as the standard accuracy that engineers often aim for or are used to
Joost van Bussel (left) and Henk Tils at the SLM metal printer, which AAE has been using for over a year to expand its knowledge regarding additive manufacturing.
with the current technologies. Joost van Bussel: "People must realize that all this is not yet clear in AM. If you want to see the mirror quality of a milling part in an AM part, this requires a lot of post processing. Or in other words: time and money."
Adding value
Both believe that, as a supplier, you cannot survive by simply printing 3D products for customers. If your purchaser sends a STEP file, you're actually already too late. Joost van Bussel: "Redesign for additive manufacturing is not a bad thing, but once the design is ready and you have to start over again, you lose a
lot of time and money." Precisely because AM raises several new possibilities, you must map them as early as possible in the development of a product or machine. AM technology allows system suppliers such as AAE to create additional value for their customers. Added value will be more important than ever. Henk Tils: "We create solutions for our customers, instead of products that raise questions. If you only start 3D printing for the customer, you won't realize the essence of AM, because you'll be not adding value." www.aaebv.com
3D printed element replaces pick and place station In one of the Grauel machines (part of AAE) for printing plastic vials, a plastic component must be horizontally turned 180 degrees. To do so, the engineers at AAE have developed a complex component which has been 3D printed in metal. The plastic component is pressed through this part and automatically turned. "In the past, we would have been required to solve this mechanically, with a pick and place robot (that would rotate the product) and software. Now we can solve the problem with a single 3D printed component. This makes the process more robust and the machine cheaper."
This 3D printed component replaces a complete handling unit in a machine. (photograph Twister)
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