DUSTRIAL RINT
ON THE COVER CJ. Moyna & Sons utilizes BigRep America's printers in theconstruction industry. See page 17.
UPCOMING EVENTS
While Industrial Print is committed to covering corrugated, direct to object, and additive manufacturing (AM) in every issue; we can't help but get excited about AM this edition with so much coming up in the next few months. From MILAM 25 in February to RAPID+TCT in April, there is a lot to look forward in regards to three-dimensional (3D) printing.
This issue includes previews of both MILAM 25 and RAPID+TCT. Exhibitors shared with us what we can expect to see on the floor as well as important topics of conversation that will be held in seminars and during keynote presentations. As a media sponsor of both events we look forward to reporting on everything leading up to, during, and after both shows in print and online at our website, industrialprintmagazine.com.
And let's not forget this edition's other topics-UV curing, humidification systems used in corrugated printing environments, pretreatment for direct printing to glass, and a chart listing digital corrugated printers.
Happy New Year,
Melissa Donovan, Editor
.RIAL 9PRINT
INDUSTRIALPRINTMAGAZINE.COM
Volume 12,Number 1
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MILITARY, AEROSPACE, AND DEFENSE
by Industrial Print Magazine Staff
The Military Additive Manufacturing Summit or MILAM takes place February 11 to 13, 2025 in Tampa, FL at the Tampa Convention Center.
In its ninth iteration, the event attracts anyone involved in military, aerospace, and defense three-dimensional (3D) printing. Between networking opportunities, high-level presentations, and an exhibit hall filled with potential partners, MILAM delivers on the newest trends and technologies in this space. Learn more about attending companies here.
3DCSI, booth 411, demonstrates the latest in industrial grade 3D printer technology. Industries served include aerospace, including heat shielding, casting and foundry cores and shells, electronics manufacturing solutions, and industrial consumer products. INFO# 180
ADDiTEC, booth 615, showcases its latest breakthrough designed to redefine operational capabilities in defense and aerospace. Discover a revolutionary innovation built to excel where others fall short. Experience firsthand how this game-changing technology is set to tackle the most demanding challenges in military and industrial applications. Don’t miss the opportunity to be part of the next big leap in manufacturing and repair technology. INFO# 181
BigRep America, booth 609, demonstrates how its large format 3D printing solutions support the adaptability and mission-critical needs of the military and defense sectors. Featuring sample parts from high-performance machines like the ALTRA 280 and the IPSO 105, BigRep highlights its ability to deliver versatile, scalable manufacturing solutions for demanding applications. Attendees also learn how BigRep’s services, such as Profile-as-a-Service, provide tailored material profiles for specific project requirements, ensuring precision and reliability in production. Additionally, BigRep CONNECT, a collaboration software and job submission tool, enables seamless communication between users and machines, enhancing operational efficiency. INFO# 182
manufacturing (CBAM) technology. Its flagship system, the CBAM-25, is an industrial 3D printer that can produce missioncritical parts up to 15 times faster than traditional methods, delivering unparalleled strength and lightweight performance using advanced materials like carbon fiber and PEEK. Trusted for its precision and reliability, Impossible Objects enables the production of durable components for drones, aerospace, and defense applications. The company’s groundbreaking approach
Impossible Objects, Inc., booth 608, revolutionizes military manufacturing with its patented, composite-based additive
1. ADDiTEC, booth 615, showcases its latest breakthrough designed to redefine operational capabilities in defense and aerospace.
2 to AMempowersmilitaryorganizations to innovate rapidly, reduce supply chain risks, and enhance operational readiness.INFO#183
2. Lithoz, booth 610, showcases its LCM technology, which drives breakthroughs in products like aerospike nozzles. 3. Meltio, booth 514, participates in conjunction with its reseller partner in the U.S., Matterhackers. They exhibit metal parts created with Meltio's unique wire laser technology specifically for the defense and military sector.
Kraetonics, booth 602, pioneers disruptive advancements in additive manufacturing (AM) software, enabling the manufacturing of parts with advanced electromechanical functionality. Its cutting-edge software, OmniSlice, empowers innovators to design and build complex, 3D structureswithany distribution ofconductors,dielectrics,magnetics,and other materials. With OmniSlice, craft
3D volumetric circuits, print functionally-graded materials with ceramics or metals, and perform conformal printing. You can even conformally print onto near-vertical sidewalls using standard three-axis machines. Unlock new possibilities in advanced AM with this modern,versatileslicerthattransforms existing AM hardware into a powerhouse for producing next-generation components.INFO#184
Lithoz, booth 610, showcases ceramic components. Experience highquality parts specifically designed for hypersonic applications at the Lithoz booth, alongside a large material catalog that enables materials engineering on a component-by-component basis. Lithoz's premium ceramic materials feature exceptional tensile strength, hardness, corrosion resistance, and radiation resistance-critical properties for meeting the extreme demands of aerospace and defense environments.Ultra-preciselithography-based ceramicmanufacturing(LCM)technology enables the production of lightweight, complex components using specialized ceramics such as silicon nitride, piezoceramics, and aluminum nitride.Theseinnovationsdrivebreakthroughs in sensors, resonators, aerospike nozzles, and other cutting-edge applications.INFO#185
Meltio, booth 514, participates in conjunction with its reseller partner in the U.S., Matterhackers. They exhibit metal parts created with Meltio's unique wire laser technology specifically for the defense and military sector. These are 3D printed parts in variousmetallicmaterialssuchasstainless steel, titanium, and copper among others.INFO#186
AM in Military
If you are looking to be part of AM in military applications, MILAM is the event for you. Look for a recap of the showinour Aprilissue. /PM
3D PIONEERS
RAPID+TCT Preview
RAPID+TCT is set to take off in Detroit, MI at Huntington Place April 8 to 10, 2025. Billed as North America’s largest additive manufacturing (AM) and industrial three-dimensional (3D) printing event, it includes over 400 technology innovators, more than 200 expert speakers, and 160 conference presentations.
For the first time in its history, RAPID + TCT colocates with three major industry events—SME’s AeroDef Manufacturing, showcasing the industry’s most advanced technologies in the aerospace and defense sectors; SAE’s trademark mobility event— the World Congress Experience, which emphasizes innovation in advanced mobility; and America Makes’ Spring Technical Review and Exchange, the nation’s leading public-private partnership for AM technology and education.
With a single registration badge, attendees access an expansive exhibition floor, showcasing the latest advancements in AM alongside pioneering developments in mobility and aerospace.
We reached out to those exhibiting at the show and asked them to share their plans.
3D Spark, booth 3250, presents its platform designed to enhance operational efficiency engineering, procurement, and sales in manufacturing. It showcases how digital solutions simplify processes such as selecting manufacturing technologies, automating costing analyses, and optimizing Make or Buy decisions, to help streamline requests for quotation workflows and quoting. Visitors can learn about the digital factory twin, which assesses feasibility, costs, and production lead times automatically. Also demonstrated, how integrating these tools with digital warehousing systems supports on demand access to spare parts and better inventory management, using real-world examples to illustrate the impact. Additionally, its CO₂ footprint calculation tools are featured, highlighting their contribution to advancing sustainability efforts. INFO# 165
3DCSI, booth 1325, demonstrates the latest in industrialgrade 3D printer technology for the production of makeready products. A number of industries are served. INFO# 166
Additive Assurance, booth 2655, exhibits its AMiRIS quality control solution for laser powder bed fusion (L-PBF). Realtime information during the production process is critical for making informed decisions. That is now possible with high resolution to resolve the defect modalities in L-PBF, with machine learning models to identify those defects in real time to give instant error reporting, quality assurance reporting at the end of the build, and a highly powerful software package to perform root-cause analysis on the AMiRIS data and even compare with CT data. INFO# 167
ARBURG, booth 2308, showcases the high-temperature Freeformer 750-3X that processes original Ultem 9085 for use in aviation as well as PEAK and PEEK granules for the medical sector. Moreover, interesting applications, customer projects, and material developments are showcased. A new addition to ARBURG’s material portfolio is PA Grilamid TR90, which is approved for food and drinking water. Customer Osko uses a special automation system to handle injection moulded plant pots. The grippers were adapted to the product and quickly 3D printed on demand. Visitors can also see spare parts used by Austrian Federal Railways (ÖBB), implants, valves, parts in hardsoft combination, and much more. INFO# 168
1. DM3D Technology, booth 1425, showcases DMD printed parts made with steels, stainless steels, aluminum, titanium, copper, and Inconel alloys.
Axtra3D, booth 2320, displays its Lumia Xl 3D printer powered by Hybrid PhotoSynthesis technology, which combines digital light processing (DLP) and stereolithography (SLA). This enables the production of high-resolution parts and large flat surfaces at significantly higher throughput. The printer also features TruLayer technology, which ensures efficient layer transitions by rapidly detaching the active print layer and moving seamlessly to the next. Together, these technologies deliver two to eight times improvement in print throughput compared to standard SLA and DLP systems, with performance unaffected by layer surface area. Key applications include concept injection molding with ceramic mold inserts,
electrical connectors, ESD-safe electronic jigs and fixtures, functional prototypes, low-volume production, and dental applications. INFO# 169
BigRep America, booth 2325, demonstrates its large format AM solutions designed to meet the needs of aerospace, defense, and automotive. Featuring the all-new BigRep ONE, VIIO 250, ALTRA 280, and upcoming IPSO 105, the booth highlights how these systems provide a seamless transition from prototyping to end use part production. With a focus on reliability, repeatability, and ease of use, BigRep solutions are engineered to produce high-quality, industrial-grade parts for demanding applications. Visitors can learn how BigRep America supports manufacturers in achieving efficient
production workflows while reducing lead times and costs. INFO# 170
DM3D Technology, booth 1425, is a leading solutions provider for metal AM technology. DM3D's proprietary direct metal deposition (DMD) process is a laser powder directed energy deposition technology that uses a patented closed loop feedback control to enhance quality and maintain dimensional integrity of the parts. DM3D is a full-service provider from product development to production services to building customized DMD equipment for its customers. It showcasesDMD printedparts made with steel,stainlesssteel, aluminum, titanium, copper, and Inconel alloys. These parts are used in wide ranging industrial applications in space, aerospace, defense, and energy industries. The parts are supplemented by a video demonstration of the process in the booth. INFO# 171
EDM Network, booth 1715, exhibits two of its Fast Wire EDMs. One is the large model, Edmmax818W, with a cutting envelope of 800xl,000x800 millimeters, four axis cutting capability, a weight limit of 6,000 pounds, on-board CAD system, AC and DC cutting power, and onsite training included. INFO# 172
Lithoz, booth 3415, showcases midsized ceramic applications enabled by its new ceramic 3D printer-the CeraFab System S320. With a build platform of 246x130 millimeters-five times larger than the CeraFab S65-and a resolution of 60 µm thanks to its premium 4K projection system, the S320 is engineered for the highly productive serial production of technical ceramic components. Parts printed by the S320 are on display, such as Evove's bespoke porosity ceramic filter membranes, Alumina Systems' 15inch gas distribution ring, and optimized semiconductor nozzles for fluid control.
2. Photocentric, booth1127, exhibits its3D LCD JENI and LCTitan printers. 3. ARBURG, booth2308, showcasesahigh-temperature Freeformer750-3Xthatprocesses original Ultem 9085forusein aviation as well asPEAKandPEEKgranulesforthemedicalsector.
The Ceramic 3D Factory is represented by multi-feature MedTech parts with ultrathin 90 µm wall thicknesses, produced by Bosch Advanced Ceramics at a scale of 1,400 per batch. SiNAPTIC, a U.S.-based service bureau for Lithoz technology, also presents its newest applications at the Lithoz booth. INFO# 173
Meltio, booth 2113, highlights metal parts in different metal alloys, such as copper, titanium, stainless steel, aluminum, and many others. These metal parts are final parts or parts for end users for different sectors such as automotive, aerospace, mining, oil, and gas. INFO# 174
Mimaki USA, Inc, booth 1145, presents the Mimaki 3DUJ-553, a photorealistic full-color 3D printer capable of producing more than ten million unique colors on a 20x20x12-inch build area. High print
speeds enable lower cost production and AM solutions that can be completed within hours. This full-color 3D printer yields fine details, smooth surfaces, and more efficient material usage. It also improves workflow for designers in industrial and other professional segments. Clear ink enables the creation of completely transparent or tinted translucent objects with no yellowing. The water-soluble support material is easy to remove, making it possible to reproduce fine details and intricate parts. INFO# 175
Photocentric, booth 1127, pioneers 3D liquid crystal display (LCD) printing technology to help businesses achieve significant manufacturing efficiencies. From accelerating prototyping to streamlining production, advanced printers and resins reduce lead times, lower costs,
and improve product quality. Discover the workhorse LC Magna, ideal for reliable, high-throughput performance, and the large format LC Titan, designed for precision and scalability in demanding manufacturing environments. It also showcases JENI, its newest automated platform optimized for volume production, alongside a range of high-quality, cost-effective resins tailored to diverse applications. INFO# 176
Heart of Manufacturing
We are in the early stages of preparing for RAPID+TCT but with it taking place in the heart of manufacturing, Detroit, it’s no surprise that the event is slated to offer the top products, services, and conversations surrounding AM’s use in industrial printing. IPM
APPROPRIATE LEVELS
Effective Humidity Management
by
Melissa Donovan
Corrugated board is a finicky, porous material. Improperly maintained environments can reek havoc on it before, during, and after printing.
“Uncontrolled relative humidity (RH) levels in a printing facility can cause a range of issues that directly impact production quality, efficiency, and costs. Maintaining the proper RH balance is essential to avoid these challenges and ensure smooth operations,” explains David Baird, senior application engineer, DriSteem.
Naomi Cassidy, marketing manager, Condair Inc., states that “humidity—being either too low or too high—has a significant effect on the efficiency of printing processes and the quality of the finished product. Since paper is a very hygroscopic material, its moisture content will be directly related to the moisture content of the air.”
dling and printing,” explains Baird.
Correct humidity levels are maintained with the help of humidity control systems like steam generation, evaporative cooling and humidification, dehumidification, and water treatment.
What to Watch For
There are signs that help determine whether a corrugated printer is operating in a space with an incorrect humidity level.
Low Humidity
When an environment is exhibiting low humidity levels the printing material becomes dry and brittle as the substrate is losing moisture content.
Signs of dry, brittle substrates are shrinking or even curling at the edges, notes Cassidy. With low humidity, the material
The drier air also enhances static electricity. This causes “sheets to stick together or misfeed in automated machinery,” says Baird.
“Excess static electricity is created when moving the paper along the surfaces of the press, which increases the chance of a printer jamming,” adds Cassidy.
Ink drying prematurely on press rollers or nozzles before it reaches the substrate is another sign of low humidity. “This reduces print quality, leads to inconsistent coverage, and often requires additional cleaning and maintenance of printing equipment, further delaying production,” shares Baird.
I would say that the printing industry is one where improper humidity control has more visible and immediate consequences and that it is often a major consideration for large print shops.
— Naomi Cassidy, marketing manager, Condair
Also related to ink, low humidity may reduce the quality of the print by causing ink colors to appear more faded, adds Cassidy.
1. DriSteem’s Adiatec highpressure system cooling and humidifying a press room.
High Humidity
High humidity levels are indicated by ink drying too slowly and mold growth.
When ink dries slowly it may “cause smudging or streaks during printing or the colors to be overly saturated,” explains Cassidy.
“Prolonged exposure to high humidity can foster mold growth, contaminating paper stock, emitting unpleasant odors, and creating health hazards for workers. Mold on equipment can contribute to corrosion, reduced efficiency, and the need for costly repairs or replacements,” shares Baird.
Also, “at high humidity levels the paper can become warped, wavy, or curled, causing printing jams,” says Cassidy.
Off Base
Many corrugated printing facilities operate at the incorrect humidity level.
“I would say that the printing industry is one where improper humidity control has more visible and immediate consequences and that it is often
a major consideration for large print shops. However, the importance of humidity is still becoming more prevalent and there are many cases where print shops are not aware of how much their processes could be improved by controlling humidity,” shares Cassidy.
Baird says heat generated from the many pieces of equipment in a building contribute to skewed humidity levels. “Many corrugated printing facilities operate at suboptimal humidity levels, often because the printing process adds heat to the facility’s air, impacting RH levels. High-speed presses and associated equipment, such as motors, rollers, and drying systems for solvent-based or UV-curable inks, generate significant heat during operation. Friction from high-speed printing and cutting, creasing, and folding processes further adds to the heat load.”
And it isn’t just printing and finishing equipment, even an HVAC system is at fault. “Facility HVAC systems, which are usually designed to circulate air, can inadvertently raise indoor temperatures further, particularly if they lack efficient cooling mechanisms. Seasonal variability compounds this issue, as warmer months can intensify equipment-generated heat,” shares Baird.
“Poor humidity control will cause lower yields, quality, and efficiency of the printing process. It will cause more paper to be damaged and wasted, distort
or alter coloring, and increase maintenance to printers and other components of the printing line. It will also cause the drying of ink or glue to take longer or not cure properly at all,” says Cassidy.
Reaching an Ideal
There is an ideal RH level for a corrugated printing facility.
Baird says it is between 45 and 55 percent, as it helps maintain the substrate’s structural integrity while preventing static buildup and smudging.
Cassidy agrees. “I would say the most common RH designed for these spaces is 45 to 55 percent. The ideal humidity range for printing is 35 to 60 percent RH. With water-based ink, it is often recommended to be at the higher end of that range, about or just under 60 percent.”
Tools are available to find your current level and then adjust accordingly.
A humidistat is helpful, in that it will regularly report the current RH in a space, suggests Cassidy. “It is important to note that humidity will vary depending on location and time of year, as well as temperature of the space. Humidity will be lower during the colder months, and this is increased the higher the temperature is in your building.”
“Spot checks can be performed using hygrometers to determine the current humidity level in a facility. At the same time, continuous monitoring systems provide real-time data for more accurate and consistent tracking,” notes Baird.
Specifically, humidification systems can help achieve—and maintain—the correct RH in a corrugated print facility.
According to Cassidy, a common type of humidification system for print environments is misting using in-space spray heads, nozzles, and a high-pressure pump skid. The Condair ML Series
2. Print finishing room, cooled and humidified by DriSteem’s Adiatec high-pressure system. 3. The Condair GS Series is a gas-powered steam humidifier that is engineered to meet high standards of efficient performance with cost-effective gas operation.
direct room humidification system offers low operating costs, reduced cooling costs, and requires minimal maintenance. The systems can be combined or customizedto fitmultiple zones, high loads, many different room configurations, andapplications.
"This system provides accurate humidity control, is easily retrofitted into sites that don't have ductwork or plan on expanding humidity in the future, and has exceptional energy efficiency," shares Cassidy.
Adiabatic-or evaporative-humidifiers are efficient solutions for print shops. "These systems utilize existing heat in the air to evaporate finely atomized water droplets dispersed by the humidifier. As the droplets are absorbed, evaporationcoolsthesurrounding air, reducing the cooling load and delivering significant energy savings. This dual function of cooling and humidifying is particularly advantageous for print shops, helping to lower operational costs while maintaining optimal conditions," saysBaird.
DriSteem's Adiatec high-pressure system combines evaporative cooling and humidification to meet the diverse needs of multi-zone facilities. By customizing humidity levels in different areas, the system provides targetedcontrol that ensures ideal environmental conditions throughout the space. This tailored approach supports production consistency and enhances comfort and stability, benefiting both the workspace and employeewellbeing.
The Adiatec high-pressure system is equipped with DriSteem's Vapor-logic controller, which continuously monitors environmental conditions to adjust nozzle operation for optimal absorption and minimal water waste. Designed for seamless integration, the system is compatible with Modbus and optional BACnet or LonTalk protocols, enabling fastresponse times andtightcontrol via building managementsystems.
Beyond Humidification Systems
Other ways to control humidity include using steam generation, dehumidification, andwater treatmentsystems.
Steam units are common in printing environments. "These produce clean atmospheric steam either directly in the room or through the ductwork using eitherelectricityorgas," explains Cassidy.
The Condair EL Series uses electrode steam technology to achieve economic, simple, and reliable humidificationforin-ductordirectroomhumidification. EL humidifiers offer unprecedented installation flexibility. They can be configured for both small and large systems. All EL humidifiers are completelypackagedfor installation ease.
TheCondairRSSeriesprovidespure, clean, atmospheric steam from potable orDI/ROwaterwithhighprecision.With SSR heating element control coupled with a high precision humidistat, the RS Series can achieve +/-1 percent RH, perfectforhumidity-criticalapplications.
The Condair GS Series is a gas-powered steam humidifier that is engineered to meet the highest standards ofefficient performancewithcost-effectivegasoperation. Itisdesignedforeaseofinstallation, adaptability, simplicity of operation, ease ofmaintenanceandservicing, energyefficiency, cleanliness, andlong-term reliability. GS Series humidifiers offer complete applicationflexibilitytosystemengineers, contractors,andcustomers.
DriSteemalsoofferssteamgeneration systems,includingelectricsteamandgasfiredhumidifiers.
Electricsteamhumidifiers,suchasthe RTS resistive electric humidifier; offers precise humidity controlwith easy installation and maintenance. Electrode humidifiersincludetheXTseries,oneofthe most affordable humidification systems topurchaseandinstall.TheSTSHumidifier is a steam-to-steam humidifier, which uses an existing boiler steam to produce chemical-free humidification steam, ideal for high-impurity environments. Finally,
-
its GTS LX humidifier utilizes natural or propane gas to generate steam, providing energy-efficient humidification for large spaces.
Dehumidification systems are helpful as well. DriSteem's Evair Dehumidifier RL Series is designed to remove excess moisture, helping to prevent condensation, mold,andmildewwhilemaintaining optimalhumiditylevels.
Finally, water treatment systems aid in maintaining the proper humidity. DriSteem's RO 200 and RO 400 series reverse osmosis systems provide highpurity water for humidification, ensuring efficientoperationandequipmentlongevity. Pretreatmentsystems aredesignedto condition incoming water; they enhance theperformanceandreliabilityofhumidificationequipment.
Regular RH
Identifying RH in a print production facility is important-and maintaining it is even moreso.
"By maintaining optimal humidity levels, corrugated printing facilities can protect the quality of printed materials, improve equipment performance, and minimize disruptions to production. Proper humidity control is essential for consistentresults,operationalefficiency, and long-term cost savings," concludes Baird. lPM
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INTELLIGENTCURING
Al-EnabledTechnologies
by Melissa Donovan
Artificial intelligence (Al) is a buzzword. It pops up in every conversation, whether it belongs in it or not. What is Al's purpose? In most instances it is utilized to enhance a process and make it more worthwhile by yielding importantdata while buildingefficiencies. Al certainlyhasa place in the industrial print segment, but where it is used might besurprising.
Take for example UV curing solutions. "AI is increasingly important across many industries, and its potential impact on UV curing is noteworthy," states Eugene Mikhaylichenko, director of sales and marketing, Uvitron International.
''AI-enabled technologies represent the future of UV curing, offering adaptive and sustainable solutions to meet the industry's evolving demands," comments Mark VandenBosch, technical sales, IST America.
According to Volker Selg, director sales (business unit cur- 1 ing), Hanle, AI enables real-time monitoring, predictive maintenance, and process safety for UV curing.
''Applications gain process safety as intelligent systems adjust curing parameters dynamically for consistent out-
put. Al also improves diagnostics with predictive analytics, investment for customers and improve the efficiency of our which improve system reliability and reduce downtime," con- systems," continues Waddington. tinues Selg.
Product development and energy optimization are two WhereWeAre other areas that Bob Waddington, product line leader - cur-
Depending on the vendor, AI is being used in certain waysing and drying, BW Converting, sees holding significant po- with more integration promised in the future. tential for AI in UV curing.
ISTAmerica'sSMARTcure system is aprimeexampleofAl's
AtHonieweareintegratingAlintoUVcuring solutionstoenhanceefficiency andadaptability.
-VolkerSelg,directorsales(businessunitcuring),Honie
"For example, AI can streamline the design of new sys- application in UV curing. It leverages AI to optimize energy use, terns, trace energy flow, and optimize engineering processes. Additionally, AI is used to examine data to find trends in product lifecycle as well as better predict preventive maintenance programs. This will net a higher return on
extend LEDservicelife, and facilitate predictive maintenance. SMARTcure dynamically adjusts system parameters based onreal-time data-such as substrate and ink properties-to 1. Uvitron'sNovaRayUVflood curingsystem incorporates advancedintelligentfeatures.
J.L
minimize power consumption and maximize efficiency.
“By incorporating features like cloud connectivity it provides actionable insights for operators and establishes modern, ecofriendly workflows,” adds Vandenbosch.
AI is in the early stages of implementation at BW Converting’s Baldwin portfolio. Despite this, Waddington says “it’s clear that AI-driven advancements will play an increasingly important role in improving efficiency, reducing costs, and accelerating innovation in UV curing.”
“At HÖnle we are integrating AI into UV curing solutions to enhance efficiency and adaptability. You may expect more AIdriven innovations as industries demand smarter, data-driven production lines,” shares Selg.
As a precursor to AI-driven systems, there are products that integrate advanced intelligent features. For example, Uvitron’s NovaRay UV flood curing system incorporates advanced intelligent features. The NovaRay is equipped with automated data logging, which captures
metrics such as exposure duration, intensity, and system performance.
“This enables comprehensive quality control and facilitates process optimization over time. With its customizable intensity profiles and microprocessorcontrolled touch interface, the NovaRay allows for precise, efficient curing, while its smart features pave the way for future AI advancements in UV curing technology,” explains Mikhaylichenko.
Obvious Benefits
AI benefits are obvious. How it will be used in relation to UV curing systems continues to change as more companies implement the solution into their products. AI’s clear and current strength is its use for preventive maintenance in relation to UV curing, which optimizes efficiencies. IPM
MOVINGINTO3D
BigRep Printers InfluenceC.J. Moyna
by IndustrialPrint Magazine Staff
The use of additive manufacturing (AM) in construction continues to grow as decision makers realize the advantages of manufacturing parts with the technology. Compared to conventional methods, AM offers a faster time to completion as well as a more cost-effective process when creating parts in iterations as small as one.
Multi-Generational
C.J. Moyna & Sons, based in Elkader, IA, is one of the Midwest's premier grading contractors. It specializes in earthmoving and aggregate processing and mining. A familyowned business, it started in the 1940s with a single bulldozer and by the 1970s it was bidding and completing work for the Iowa Department of Transportation.
Today, the third generation of the
Moyna family runs the business and employs over 200. It ex- to honor its legacy in a unique way. The Earthmoving Legacy panded its offerings to include demolition; aggregate materials Center is a 38,000 square foot facility in Elkader built to showproduction and delivery; utilities installation; equipment devel- case the history of earthmoving. It displays historical construcopment, manufacturing, and delivery; and advanced technolo- tion vehicles like antiquecaterpillars, tractors, and scrapers. gies like drones. Vehicles often come to C.J. Moyna with missing parts. Dur-
In addition to C.J. Moyna, the company runs four subsid- ing and even after the COVID-19 pandemic, it became diffiiaries-Moyna Materials, Mobile Track Solutions, Progressive Structures, and Just Move It. These employ an additional 200plus staff members.
Historical Construction
With a rich history in construction, it makes sense that the company wanted
Intwoorthreedaysyoucanhavea large,functionalpieceprintedbythe BigRepPRO-readytorockandroll.
- RyanYoung, product manager, C.J. Moyna
cult to source these pieces. Looking for an alternative, Ryan Young, product manager, C.J. Moyna, turned to AM. Starting with a threedimensional (3D) printer designed for hobbyists, it
1. The Earthmoving Legacy Center is a 38,000 square footfacilitythat showcasesthehistoryofearthmovingatC.J. Moyna.
was determined that an industrial large format 3D printer with an open material system would work better. After
2. Part yielded from the BigRep PRO.
researching what was out there, Young chose the BigRep PRO for its build volume, accuracy, reliability, and 3D printer ecosystem offered by BigRep America. The build chamber-fully enclosed-
measures one cubic meter, which allows for large-scale part production. And while the device is compatible with BigRep filaments, it also works with third-party materials-which Young says makes the 3D printer versatile.
His favorite filament is PRO-HT-a biopolymer with reduced environmental impact. It is easy to print, FDA compliant for food safety, and formulated for ease of support removal.
Patrick Palmersheim, system administrator, CJ. Moyna, is hands on in the restoration of parts in the legacy center. He enjoys a repertoire with BigRep's engineers when troubleshooting during production.
Beyond Restoration
It was evident fairly quickly that the BigRep PRO would be helpful in other parts of C.J. Moyna's business. Sister company Mobile Track Solutions relies on the machine for manufacturing prototypes, functional dashboards, and final pieces.
Prior to AM, dash parts were created using injection molding, which took weeks or even months to produce. With the BigRep PRO, the process is completed in a couple of days. "In two or three days you can have a large, functional piece printed by the BigRep PRO-ready to rock and roll," shares Young.
Growing Forward
While C.J. Moyna is just at the beginning of working with AM in its daily processes, Young predicts the technology's use in how the company manufactures and engineers will grow in the future. "In another ten to 15 years, 25 to 30 percent of parts are going to be 3D printed." 1PM
“Physical interference can often be described as contaminants. They are things that get onto the surface but can be removed ‘fairly easily.’ Dirt, dust, wax,
and oil are typical impediments,” explains Lanigan.
On the other hand, chemical interference is the material itself that makes
bonding difficult. In this scenario, things that bond to the surface must be changed, removed, or covered up.
Overall common pretreatment options are plasma, wet chemical—solvents and primers, and flame treatment.
Plasma Treatment
Plasma treatment is a solution used in conjunction with digitally printing on ceramics and glass.
“Solid, liquid, and gas are the three states of matter. However, there is an important, lesser known fourth state of matter, plasma energy, and it’s produced within the surface treatment industry’s plasma treatment systems,” comments Erik Kiel, owner, 3DT LLC.
Bonding problems are pervasive in manufacturing because many materials refuse to bond to other materials as a result of their chemical structure. “Plasma treatment overcomes these manufacturing and decorating challenges by raising the surface tension and functionality of numerous materials,” notes Kiel.
Lanigan sees plasma as generally a better, cleaner, option compared with flame treatment. “It does a better job of removing contaminants and the improved surface tension can last longer
1. According to Applied Surface Technologies, Pyrosil is used as a pretreatment in glass decoration because SiOx and silicon dioxide share a chemical structural similarity. 2. Example of a flat glass application from Applied Surface Technologies.
than flame treatment. Plasma uses electricity as its power source, so once the equipment is paid for, the cost of operation is low.”
Plasma works well on smaller surfaces that would use a treatment burner of a few inches in width. “The challenge is that as the treatment area increases, the cost of the plasma equipment expands exponentially. Seeing a two- or three-inch plasma treatment unit is quite common, but systems six inches and larger are rarely seen because the cost of equipment is very high,” notes Lanigan.
Kiel points out that the term “atmospheric plasma” is used to describe the technology for plasma treatment performed at atmospheric pressure and does not require placement of products inside of a vacuum chamber.
Atmospheric plasma treatment offers high-volume, inline production since the process is not conducted within a vacuum chamber, which can involve slow and laborious batch processing, adds Kiel.
Atmospheric plasma systems typically utilize an electrical generator and step-up transformer, along with pressurized air, which streams the plasma discharge onto an object via a treating head. Kiel says high-volume, inline production is achieved since the process is not conducted with a vacuum chamber.
3DT’s plasma treatment system, PlasmaDyne Pro, is designed to raise surface tension and improve the functionality of materials.
PlasmaDyne Pro is highly customizable in terms of the number and type of treating heads, programming options, product handling, and automation.
3DT’s PlasmaDyne Pro’s discharge and power are easily adjusted to accommodate various substrates, treating modes, and applications.
3DT has engineered plasma systems for treating glass including exterior glass lighting to improve adhesion of
gaskets and housings; automotive glass touch displays for the adhesion of print and coatings; the outside edge of glass windows to improve the adhesion of seals; and eyeglass lenses for improved adhesion of coatings.
Wet Chemical Treatment
Wet chemical treatment options can be cleaners or primers/adhesion promoters. Lanigan says cleaners, washers, wipe down products, and solvent cleaning agents can work for surfaces that are dirty or even have chemical interference; and can increase surface tension.
The advantage of wet chemical treatment is that some cleaners—like glass cleaners, soaps, and some solvents—can be very inexpensive and many don’t require equipment to apply.
Wet chemical primers are available to treat nearly every surface and there are thousands of options. “There are a variety of application methods available from wipe on, to hand and automated spray, and even jettable—printhead applied. Some primers, once applied, can last days or even weeks,” suggests Lanigan.
One wet chemical treatment is Pyrosil, which is a type of combustion chemical vapor deposition. Lanigan explains that Pyrosil burns chemistry in the flame, creating silicon oxide (SiOx), which is deposited onto the surface. “Unlike flame treatment, where the process is a
form of heat treatment and temporary, Pyrosil uses the flame as a carrier agent for the SiOx. The SiOx is permanently deposited onto the substrate and creates a highly reactive surface for superior surface tension or wettability.”
One key advantage of Pyrosil is there are a number of equipment choices available, including hand-held, portable units, semi-automated, and fully automated systems.
Lanigan says glass is one of the largest applications for Pyrosil. “In the glass printing industry, when durability is required—abrasion, handling, dishwasher safe, etc.—Pyrosil is the most used pretreatment option.”
Lanigan explains that one reason why Pyrosil has such dominance as a pretreatment in glass decoration is that SiOx and silicon dioxide, which makes up 50-plus percent of glass, share a chemical structural similarity and this creates covalent bonding. “This means
that as a pretreatment, Pyrosil easily bonds to and creates a very reactive surface, which is excellent for screen or digital printing.”
For preventing wear and tear on glass objects, which is generally considered scratch, abrasion, and weathering resistance, as well as dishwasher
durability, Pyrosil is a chosen product according to Lanigan.
Of course, Kiel admits that working with chemicals can be hazardous to personnel and the environment.
Lanigan sees a number of downsides to using cleaners, which include the cost of labor and finding quality cleaners that work—and work with different materials. “The cost of labor is expensive because most of the cleaning is manual.
There are some custom washing systems—like dishwashers, flat glass washing machines, and custom units for many shapes and sizes—but they require a lot of labor or the equipment can be extremely expensive.”
Further, many wet chemical primers have limited durability, or they work on specific substrates. “Almost no primers will work with different materials—plastic, glass, metal, etc. Testing to find a primer that works with a specific application requires many samples, and testing is labor intensive. Most quality primers have a shelf life and can cost more than $1.00 per square foot,” says Lanigan.”
Flame Treatment
Flame treatment is utilized to remove light physical contaminants like dust and increase wettability, for an improved printing surface. “The equipment is relatively inexpensive and the consumables are natural gas or propane, so operating costs are low,” offers Lanigan.
Flame treatment has a few limitations related to adhesion of UV inks. It usually can’t remove heavy physical interference nor can it remove or change most chemical interference from surfaces. The increased surface tension on many substrates like metals and glass can be short lived, and frequently the increase in surface tension isn’t enough for sufficient wettability.
Prepping Glass
Directly printing to glass is useful for a variety of applications, from consumer goods like glassware to industrial applications like tile. Preparing the surface prior to print is an important step. Options include plasma, wet chemical, and flame treatment. IPM
3. 3DT's PlasmaDyne atmospheric plasma systems are widely utilized for the treatment of glass.
THE URE
UV LED and UV Lamps Coexist
by Melissa Donovan
UV curing is a pivotal part of the direct to print process and Thetwotechnologies-lampandLED-arecomplementary. advancements like the introduction of LED only make the "The coexistence of arc lamp and LED systems ensures that technology more attractive. Lamp or arc curing continues to manufacturershavetheflexibilitytochoosethemostappropribe used as it fills some ofthe gaps that LEDhas yet tobridge. ate technology for their processes, reinforcing the continued Bob Waddington, product line leader - curing and drying, demand and relevance ofUV arc lamp systemsalongside the BW Converting, foresees LED systems capturing a larger growing adoption ofLEDs," believes Eugene Mikhaylichenko, market share as their capabilities improve, but "arc systems director ofsales andmarketing, Uvitron International. will likely remain indispensable for specialized, high-precision needs." Above:
Honie LED PowerlineFocusonasheetfed printing machine.
Recognizing the need for both UV lamp type and insert another without lamp and LED curing, some vendors' major modifications. Hybrid systems, lamp-based systems are designed to which are a mix of UV lamps and LED make changeover to LED uncomplicat- lights, installed on one piece of equiped. These allow users to slide out one ment, arealso becoming popular.
Working Side by Side
While UV LED technologyis advancing, it isn'ttaking theplaceof UV lamps.
Each type offers distinct advantages and limitations, states Volker Selg, director sales (business unit curing), Hanle. "Their coexistence stems from complementary strengths, catering to variedindustrial needs."
Selg notes advantages of UV LED technology as energy efficiency, instant on/off functionality, lower operating temperatures, and a longer lifespan. UV lamps feature a broader wavelength range, higher peak intensity for certain applications, and a greater flexibility in curing specificmaterials.
ThereisacriticalneedforUV lamps, or more specifically mercury arc systems, according to Waddington. "This is especially true in applications requiring UVB and UVC wavelengths, such as sterilization. Current LED diodes lack the irradiance, and in some cases the wavelengthsneeded forthesetasks, and predictionssuggestitcouldtakeanother four to six years for this technology to mature in thoseranges."
UV LED technology has made significant strides but is currently limited in terms of wavelength output, particularly below 365nm in industrial applications. "High-power LED systems that can compete with traditional UV lamps are still under development. For applications requiring full surface coverage or required anti-scratch properties, traditional UV lampsremainessential,"notesMarkVandenBosch, technicalsales, 1STAmerica. UV lampsystemsprovideadvantages inpackagingandlow-migrationprinting. "For instance, certain photoinitiators
1. GEW's patented interchangeableArcLED technologyenablestheuseofaconventionalUVarclampor LEDarrayonthesameprintunit,bychangingthecassette. 2. 1STUVlamp systems are designed foreasy upgradestoLED technologyinpreselectedpositions. 3. Uvitron systems arepurposeengineered with key components including high-voltage power supplies, lamp housings, and precision control electronicsseamlesslybuiltintoaunifiedunit.
required for low-migration applications are not yet available for LEDs. Moreover, arc systems allow for more affordableand versatile coatings, which remain critical in regions with stringent regulations, like Europe. In these cases, arc systems often serve as the go-to solution for coatings, while LEDs are more commonlyusedforinks," sharesWaddington.
"Many varnishes, coatings, and special colors still require conventional UV curing, but for mainstream inks UVLED is very much a viable alternative. Bearing in mind the many production advantages of working with UV LED, added to the significant energy cost savings it brings, the adoption of LED is rising rapidly," admits Duncan Smith, marketing manager, GEW (EC) Limited.
one lamp type and insert another without major modifications.
According to Selg, the transition from lamp to LED is possible due to modular frameworks. "These frameworks include replaceable lamp housings, drivers, and power supplies that accommodate future upgrades to LED technology without requiring a complete system overhaul. This future proofing approach is increasingly popular in industrial printing."
For example, GEW's patented interchangeable ArcLED technology
While UV lamps offer a broader enables the use of wavelength range, UV LED emits light a conventional UV at narrow, very specific wavelengths. arc lamp or LED array on the same print unit, by changing the cassette. "Both arc and LED cassettes are compatible with GEW's RHINO power supply
This is why energy efficiency is so high, the targeted wavelengths enable precise energy delivery. "The use of UV LEDs is advantageous for applications where thermal management is crucial, such as curing heat-sensitive substrates or optimizing energy consumption in environmentally conscious production processes. Additionally, the longer operational life and instant on/offcapability ofLEDs contributes to reducedmaintenanceand energycosts," explains Mikhaylichenko.
Despite the advancements and growing adoption of UV LED systems, Mikhaylichenko believes the market for arc lamp systems isn't wavering. ''Arc lamp technology continues to be critical for applications requiring broadspectrum UV output, which is essential for curing complex materials and a wider range of photoinitiators. The coexistence of these technologies allows manufacturers to tailor their curing processes precisely."
Switch to LED
unit (PSU) and fit in the same housing, to enable fast and easy changeover. The only tool required to change a cassette is a hex key. The RHINO PSU enables any combination of curing technologies to be used, by instantly and automatically switching the supply to either DC power for LEDs or highvoltageAC power for arc lamps. The entire process is operator
UV lamp systems are designed to easily controlled," exaccept LED lights. Users can slide out plains Smith.
IST's UV lamp systems are designed for easy upgrades to LED technology in preselected positions. "This allows
INTELLIGENT UV CURING SYSTEM
PRECISION TOUCHSCREEN CONTROLS CUSTOMIZABLE INTENSITY PROFILES COOLER CHAMBER TEMPERATURE CG AUTOMATED DATA LOGGING ADVANCED UV FLOOD CURING UVITRON INFO@UVITRON.COM 'ONTROLS UVITRON.COM
users to transition to LEDs seamlessly when production requirements or preferences evolve,” notes VandenBosch.
Besides a modular system, there is another option—a fully integrated product range, as offered by Uvitron.
“Our systems are purpose engineered with key components, including highvoltage power supplies, lamp housings, and precision control electronics, seamlessly built into a unified unit. By optimizing every component specifically for either arc lamp or LED technology, we eliminate the compromises often associated with modular setups. Our systems are engineered to deliver precise, consistent curing results, maintaining optimal UV intensity, spectral distribution, and thermal stability across all applications,” explains Mikhaylichenko.
Waddington notes that while the changeout can be simplified, the technologies are fundamentally different. “Arc lamps operate using electrodes and a quartz tube filled with argon and
mercury, while LEDs use semiconductor diodes to emit light. As a result, while the physical installation can be simplified, the lamp heads and other critical components must still be fully replaced.”
Meredith Stines, president, American Ultraviolet, also points to the power supplies and cooling as differing between lamp and LED systems.
Hybrid Approach
Hybrid UV curing systems—which allow both lamp and LED technologies to be used interchangeably—do exist.
Hybrid configurations share common components like power supplies, connectors, and mounts, says Waddington, and then the lamp heads are interchangeable. “This hybrid approach allows users to transition between the two technologies as needed without requiring an entirely new system. There are nuances to this hybrid setup and we suggest potential customers speak with us to iron out the details on optimal setup of the system,” he cautions.
The ability to switch between technologies provides greater flexibility and cost efficiency. “For example, certain hybrid systems include dual-slot configurations for easy integration of either lamps or UV LEDs,” shares Selg.
Smith notes that some GEW ArcLED users choose not to remove all the arc cassettes when upgrading to LED, which provides them with the flexibility to continue working with lamp systems to cure varnishes, coatings, and special colors.
Hybrid systems, such as the IST MBSc and its compact variant MBScx, support interchangeability with Modulux LED systems. These systems provide flexibility for production setups that demand a combination of traditional UV and LED technologies, according to VandenBosch.
A Practical Bridge
Hot-swappable systems allow users to alternate between UV lamps and LED without downtime.
Interchangeable solutions are a way to “future proof” a machine, says Smith. “Interchangeable lamp cassettes mean that a user can future-proof their machine—even if they have an all-arc UV system now, it can easily be upgraded to LED in the future. Similarly, the user can change back from LED to arc UV on any or all print/coating stations, according to whatever is best for the job in hand.”
“In industrial printing, these systems are currently preferable because they indeed do offer adaptability to different materials like inks and curing needs. Additionally, they reduce longterm operational costs by integrating LEDs for energy-intensive jobs and retaining lamps for specialized tasks,” explains Selg.
While hot-swappable systems are available, VandenBosch believes “their
4. LED UV hybrid system by Hönle.
adoption depends largely on the industry’s job structure. LED curing is gaining traction in applications with high-value, low-coverage inks, while end-of-press varnish curing typically relies on traditional plasma lamps. Furthermore, evolving regulatory requirements—such as those addressing migration and odor—necessitate highenergy curing solutions. Ultimately, the decision will hinge on the development of ink systems that are compatible with these technologies.”
Hönle believes swappable solutions only “bridge technology until the full range of suitable LED curable materials are available,” admits Selg.
“Once LEDs can fully cover the UVB and UVC ranges, they are expected to replace arc systems across application
requirements. Until then, hot swappable systems offer flexibility for printers and converters who want to utilize both technologies,” agrees Waddington.
Conversely, Mikhaylichenko isn’t seeing a lot of demand for hot-swappable systems at this time, as Uvitron customers have a clear preference for either UV arc lamp or LED technology based on their specific curing requirements. “Most of our clients are focused on optimizing their processes with the technology that best fits their materials and production environments, rather than seeking interchangeability between the two.”
Symbiosis
At this time, the coexistence of UV lamp and LED technologies is necessary. UV LED isn’t yet tailored to meet all
the needs that UV arc lamp technologies can, so they must work together to achieve this.
“Hybrid approaches enable flexible manufacturing setups where both arc lamp and LED systems can be integrated based on the requirements of specific applications. This symbiosis provides industries with the ability to balance energy efficiency, curing speed, and material compatibility, ensuring optimal performance across diverse curing environments,” states Mikhaylichenko.
Keeping this in mind, it goes without saying that UV LED and lamp technologies’ coexistence is highly advantageous. Visit industrialprintmagazine.com in February to learn more about UV LED and arc lamp curing technologies in our latest webinar. IPM
