TCT NA 2.2 by TCT Magazine

NORTH AMERICAN EDITION VOLUME 2 ISSUE 2 www.tctmagazine.com

MODERNIZING

MEDICINE

3D SYSTEMS' HEALTHCARE TECHNOLOGY CENTER IS ADVANCING PRECISION HEALTHCARE AND MEDICAL 3D PRINTING SOLUTIONS

ACCELERATING 3D technologies

VOLUME 2 ISSUE 2

ISSN 2059-9641

EDITORIAL HEAD OF CONTENT

James Woodcock james@rapidnews.com GROUP EDITOR

Daniel O’Connor daniel.oconnor@rapidnews.com ASSISTANT EDITOR

Laura Griffiths laura.griffiths@rapidnews.com NEWSDESK

+44 (0) 1244 680222 REGULAR CONTRIBUTORS

Todd Grimm tgrimm@tagrimm.com

ADVERTISING GROUP ADVERTISING MANAGER

Carol Hardy carol@rapidnews.com MEDIA SALES EXECUTIVE

Kelley-Jo Beattie kelley-jo.beattie@rapidnews.com

PRODUCTION Sam Hamlyn Tracey Roberts

M ANAGEMENT C.O.O. / PUBLISHER

Duncan Wood C.E.O.

Mark Blezard

SUBSCRIPTIONS PUBLISHED PRICES N. America Print Subscriptions USA/Canada/Mexico - FREE Outside of these territories - $249 Also available on iOS and Android devices – including back catalogue and Buyers’ Guides.

The TCT Magazine is published quarterly by Rapid News Publications Ltd Carlton House, Sandpiper Way, Chester Business Park, Chester CH4 9QE, UK.

t: + 44 (0) 1244 680222 f: + 44 (0) 1244 671074 © 2015 Rapid News Publications Ltd While every attempt has been made to ensure that the information contained within this publication is accurate, the publisher accepts no liability for information published in error, or for views expressed. All rights for The TCT Magazine are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited.

The path to AM part certification starts with your workforce. UL’s AM Training Program prepares your workforce to produce final, quality parts pa - safely. Gain subject specific proficiency or earn UL Professional Certification in AM. Courses, schedules and global locations now available.

.the art of LaserCUSINGÂŽ

Concept Laser was stronger than other metal additive manufacturing technology available, offered flexible parameters, and fit into our current process seamlessly. HeIdI HoStetteR VP, Faustson tool

Improve Your Bottom Line By Building Metal Parts With Rapid Speed Concept Laser is the global leader in the design and

manufacture of powderbed-based laser metal additive manufacturing systems. With over 15 years of design production experience, Concept Laser has the right solution for your laser metal manufacturing needs. Concept Laser Inc (USA) info@conceptlaserinc.com t: + 1 (817) 328-6500 www.conceptlaserinc.com

Concept Laser GmbH info@concept-laser.de t. +49 (0) 9571 1679-0 www.concept-laser.de

Make Your Ideas Matter with the ProJet® MJP 2500 Series Print precision parts in your office

LEAD NEWS

MODERNIZING MEDICINE

RAPID REVIEW

Dan reports on our trip to Orlando, Florida for North America’s largest 3D technologies event. Featuring interviews with exhibitors about some of the most exciting tech on the show floor.

THE PATH TO GLORY

GUEST COLUMN

TCT guest columnist, David Burns asks: “Is the revolution here?” as several RAPID exhibitors promise to “revolutionize manufacturing”.

HANDLE WITH CARE

Dan also visits Digits2Widgets’ London studio to hear the story of how medical 3D printing not only helped to reconstruct a man’s face but also revitalise his career.

NEW TRICKS

Dan takes a closer look at EnvisionTEC’s unexpected change of direction with its new mammoth SLCOM 1 composite 3D printing technology.

NEW METHODS FOR MANUFACTURING

Assistant Editor, Laura Griffiths speaks with Methods Machine Tools about how they’re embracing additive technologies to deliver complete turnkey solutions with a new venture.

SPONSORED BY

MEDICAL FOCUS

RAPID 2016

Learn more at www.3dsystems.com/2500

We take a look at our cover star 3D Systems’ new state-of-the-art Healthcare Technology Centre in Colorado.

Group Editor Daniel O’Connor meets with world champion cyclist Denise Schindler to find out how one woman’s journey to Rio may open up a world of customized prosthetics for victims of war.

ACCELERATING 3D TECHNOLOGIES

CONTENTS

Combining professional-grade capabilities with TCT office-friendly | VOLUME 2 ISSUE an affordable, footprint and easy 2 part processing, the newest series of 3D Systems’ family of MultiJet Printing, the MJP 2500 and 2500 Plus, are designed to enable a broader range of professionals to create precision parts without leaving their workplace.

RAPID GALLERY

3D PRINTING MANUFACTURING AIDS

Laura looks at how engineers are solving traditional manufacturing problems with custom 3D printed jigs and fixtures.

Reminisce or check out what you missed in our photo highlights from the show floor and conference.

HP AND THE MIGHTY VOXEL

Laura reports on a visit to HP’s 3D Printing Lab in Barcelona in anticipation of its long-awaited Jet Fusion 3D Printer launch at RAPID.

AMUG PREVIEW

Laura reports on her first trip to the Additive Manufacturing User Group Conference in St. Louis.

UNDER THE ARMOUR

Dan speaks with Alan Guyan at Under Armour about how generative design and 3D printing helped create a world-first, ultimate training shoe.

REGULARS

05 48

EDITOR’S letter TODD GRIMM COLUMN

VOLUME 2 ISSUE 2 www.tctmagazine.com

Somos

At the forefront of innovation in 3D printing

With a portfolio consisting of a wide variety of category-leading materials, you are sure to find a Somos® material that will fit the needs of your next project. If you need some extra help or have a job that you can’t handle in-house, we can connect you with a service bureau that will quickly turn your projects into a reality. Get connected with Somos® at www.dsm.com/somos

ACCELERATING 3D TECHNOLOGIES

FROM THE EDITOR

The Intrepid Traveler

ne of the many allures of applying for a role to work on TCT Magazine some three and a quarter years ago was the promise of worldwide travel. Having spent four months schlepping across South East Asia in 2010 the travel bug had claimed its latest victim. In my early 30s without any dependents the idea of getting to see the world as part of my job was an added bonus to being a technology writer. Before starting at TCT I’d been to one German city I’ve now visited eight; the Low Countries were never particularly on the bucket list, in the space of five days I stopped in seven cities seeing seven 3D printing companies in a whistle-stop driving tour; despite spending oodles of time supping noodles in Asia I had never been to China, now I’ve spent two birthdays in Shanghai; I had never been to the USA, I have been to 15 of the 48 Contiguous United States. I was on ten flights in the month of May alone, 3D printing takes you to many weird and wonderful places. “Ok, we get it, you travel a lot.” You say, rolling your eyes at those first two paragraphs, let me lighten the mood… Top travel tip; pre-book taxis when flying into regional airports, especially on a Sunday. I learnt this lesson the hard way, flying into Arnold Palmer Regional Airport, Latrobre, Pennsylvania at 6pm in order to visit the HQ of ExOne for an upcoming story. The hotel I’d booked was a two minute walk to the North Huntingdon HQ of the binder jetting company and ‘conveniently’ just a 30 minute drive from the airport… but taxis in the Latrobe area on a Sunday night spotted as often as Bigfoot – after a 45 minute walk down a freezing cold highway without a sidewalk, in the rain, to the nearest hotel it became apparent that getting an animal stuffed was a more realistic option than getting

a cab as the receptionist’s response when I asked for a taxi in my Beatlesesque brogue was to rifle through a drawer of cards and say, “taxidermist?” Stories in this issue come from all corners of the globe, Assistant Editor Laura Griffiths travelled to Barcelona to visit HP (page 44), the lead news comes from Colorado (page 6), I went to the world’s hippest trade show in Berlin to meet Paralympian Denise Schindler (page 9) and the whole team packed off to Orlando for RAPID, for which we’ve done 16 pages on starting on page 28. In total (as the crow flies not including connections) for this issue alone we’ve travelled the circumference of the globe one and a half times. This is a global industry and there are always new products to see, new facilities to visit, new applications to discover but for now there’s a bit of breathing space. At the time of writing the next big event is TCT Show UK in September, which is amazingly just three short months away. If you’re making the hop over the Atlantic make sure you register, the show floor is bigger and more packed out than ever and the conference line up is shaping up to be another festival of additive activity www.tctshow.com Druck On

Daniel O’Connor Group Editor

VOLUME 2 ISSUE 2 www.tctmagazine.com

LEAD NEWS: 3D SYSTEMS

3D Systems has opened a state-of-the-art healthcare center that marks an “important day in medicine.” TCT finds out more

Modernizing

Medicine W O R D S : DA N I E L O ’C O N N O R



ABOVE: Medical model of a spine printed in Stereolithography

VOLUME 2 ISSUE 2 www.tctmagazine.com

F THERE IS a sector driving the 3D printing industry it is healthcare; 3D Systems has been pushing the envelope in the field for a number of years and has recently opened its Healthcare Technology Center to further advance 3D printing’s unique ability to solve complex medical solutions for the benefit of countless humans across the globe. The new facility in Littleton, Colorado will serve as the central hub for the company’s global healthcare activities, and support its full and comprehensive portfolio of precision healthcare and medical 3D printing solutions. The ribbon cutting ceremony for the new 70,000 square foot facility took place in March. Among the guests in attendance was Zimbabwean Blessing Makwera. At the age of 15 Blessing was left without the ability to use his jaw after suffering horrendous injuries from a land mine explosion. He went eight years before being discovered by the Operation of Hope organization, which referred him to the Dr. Joel Berger, a specialist in oral and maxillofacial surgeries. Blessing underwent a series of successful surgeries in 2013 that were made possible through advancements in Virtual Surgical Planning and 3D printing. “Today is an important day in medicine,” Makwera said. “My story illustrates how life changing this technology can be, and I am overjoyed to think of the many lives that will be impacted and improved by the capabilities made possible here.”

ACCELERATING 3D TECHNOLOGIES

Today is an important day in medicine,” Makwera said. “My story illustrates how life changing this technology can be, and I am overjoyed to think of the many lives that will be impacted and improved by the capabilities made possible here.”

CLEARING THE HURDLES As 3D printing becomes more prevalent in medical applications so does the growing burden on authorities to clear technologies through the rigorous tests that are required for the likes of FDA approval. 3D Systems has moved to make those tests go as smoothly as possible. The Littleton facility is ISO 13485 certified for healthcare solutions, and operates in accordance with the FDA and MDD regulations for applicable medical devices. “With such a high number of printing technologies under one roof, segregation and contamination prevention is essential,” Kevin McAlea, Executive Vice President and Chief Operating Officer, Healthcare, 3D Systems told TCT. “Each lab is protected through a vapor barrier system, has its own air handling and ventilation systems as well as systems to ensure the proper segregation of return and input air. The work up front with the infrastructure of the Center helps in ensuring safe, manageable manufacturing lines.” The facility houses 3D Systems’ huge portfolio of technologies including, Stereolithography, Selective Laser Sintering, ColorJet Printing, MultiJet Printing and Direct Metal Printing, the last of which McAlea told TCT is becoming almost the norm for some medical applications: “More off-the-shelf devices, such as implants, are being manufactured using DMP technology because of the complexity and quality of titanium parts that can be created using this process.” What is clear from the investment poured into the healthcare facility, that we’re no longer talking about what the healthcare sector can do for the 3D printing industry but what the 3D printing industry can do for healthcare.



ABOVE: 3D printed skull model and surgical guide created using Virtual Surgical Planning (VSP®

Dr. Oren Tepper, Director of Craniofacial Surgery at the Montefiore Medical Center, who was also present for the grand opening said: “Awareness and access have been the biggest hurdles to adopting 3D technology in healthcare,” Dr. Tepper said. “This facility will be a tremendous asset to the healthcare community in developing and proving precise methodologies for some of medicine’s most trying cases.” For more information visit www.3dsystems.com

VOLUME 2 ISSUE 2 www.tctmagazine.com

EXPLORING THE INTERSECTION OF DESIGN & TECHNOLOGY

REGISTRATION IS

NOW OPEN! AMERICAS Los Angeles, CA

September 8-9

Skirball Cultural Center Registration is FREE for a limited time at: Converge2016.com/TCT

Refuel your desire to design and join a community of your creative peers and innovators to uncover strategies behind developing top products. You’ll hear from leaders across industries, discover new technologies, and leave with a new approach to product design. The all-inclusive schedule is designed to cover key strategies for product research, conceptualization, and refinement.

Company

MEDICAL FOCUS ACCELERATING 3D TECHNOLOGIES

Ed itor, Da nie l O’ C on nor l ooks at ho w o n e w o m a n ’s quest fo r G OL D at R io 2016 c ou l d o pe n u p a w o r l d of c usto m ize d p r os th e s is for v i c t i m s o f wa r.

The Path to Glory D

enise Schindler is officially, according to cycling’s

governing body, UCI, the fastest road cyclist in her classification in the world. She is a World Champion, European Cup Winner, German Champion and London 2012 Silver Medallist. That last one, the silver medal, she’s hoping to upgrade to gold this summer, in Rio de Janeiro in Brazil. The bulk of the work towards gold will be done in the countless hours Denise spends on track and on the road, but, like any top athlete Denise Schindler is squeezing every last drop out of the equipment and there’s one more piece of equipment to add to the bike, the helmet and the sportswear that the likes of Bradley Wiggins, Mark Cavendish and co spend hours tinkering with… her prosthetic. Denise was amputated below the knee at the age of two after an accident, her traditional sports prosthesis are highly customized and precise, they are usually hand-made by orthopaedic technicians, they are expensive and they are not accessible. She hopes with the help of Autodesk and 3D printing technology to not only add a further competitive edge to her medal hunt in Rio but to make sport more accessible to those who require prosthesis. “We started working on a new way of producing my prosthetic one and a half years ago,” Denise tells me at the hip re:publica 2016 event in Berlin. “It was very challenging, we started by scanning my limb and tried to do a fitting directly from the software but we discovered that the traditional way using plaster cast gives the technician a lot of chance to build structure around specific areas, that person is an expert at feeling that certain areas can bear weight, certain areas might be too bony to do so, the scan can’t detect that. The main challenge was to find a way in Fusion360 that we could have the scan and input that orthopaedic expertize.” ››

VOLUME 2 ISSUE 2 www.tctmagazine.com

MEDICAL

AEROSPACE

Hoeganaes Corporation, a world leader in the development of metal powders, has been the driving force behind the growth in the Powder Metallurgy industry for over 65 years. Hoeganaes has fueled that growth with successive waves of technology, expanding the use of metal powders for a wide variety of applications.

AncorTi™ • Spherical Titanium Powder for Additive Manufacturing • Particle Size Engineered for Selective Laser Melting (SLM) and Electron Beam Melting (EBM) • Rigorous Quality Testing

ENGINEERING THAT MOVES THE WORLD MOBILE DEVICE APPS NOW AVAILABLE FOR DOWNLOAD

MEDICAL FOCUS

GOING FOR GOLD The finished prosthetic was printed in Polycarbonate using a Stratasys Fortus FDM machine and painted by hand to finish, Denise says she plans on adding a go-faster-stripe as well as a UCI certification sticker before Rio 2016. The prosthetic bulges at the top for comfort around the limb and becomes sleeker and more aerodynamic towards the shin area; the bottom is flat and is clamped directly onto the bike pedal. A traditional prosthesis would weigh more than 1.5 kilograms, this weighs under 1 kg. It can also take production time from about 10 weeks to five days and be made for about a quarter of the price. A week before showcasing her Paralympic prosthetic to me Denise had been showcasing it to Angela Merkel and POTUS himself, Barack Obama. Of course, the genesis of this idea was to propel her to glory on the road and on the track but as spokesperson for a community of people who require prosthesis, Denise sees this as an opportunity to radically alter the way amputees approach sport.

We have the chance with 3D printing to create a very custom made product for a price that is affordable

ACCELERATING 3D TECHNOLOGIES

Once the team including a Fusion360 expert, an orthopaedic technician and Schindler herself had a design they were happy with they used FDM printing to test it out immediately. “I was very happy that it just fitted,” Schindler enthused. “I was able to test it for stability and power on the track doing various exercises like starts and sprints. Fitting was fine but I needed more stability for the sprints, I was losing power because it was too flexible. In that first version the designer tried to soften a lot of points to take pressure points away for my limb but it was too soft.” Back to the drawing board, but that’s just the beauty of digital design, the team went through 50 to 60 iterations before getting to the point whereby they were happy with the prosthetic. “Every time the designer thought he was finished I came up with a new idea, a new challenge for him. When I was ready then my prosthesis expert would come along and ask for something extra.”

ABOVE: Denise and her 3D

manufactured prosthetic

“Sport for me during my childhood was not a big deal,” Denise recalls. “I was always last in sports class and it was nothing I had fun with. Later on in life I figured out that sport can be really nice, something I can do without pain, something I can have fun with, that’s really a door opener to a person’s confidence. We have the chance with 3D printing to create a very custom made product for a price that is affordable, if this was the case the average amputee would buy prosthetics like everybody else buys expensive shoes.” ››

››

VOLUME 2 ISSUE 2 www.tctmagazine.com

011

3D PRINTING FOR THE FOUNDRY INDUSTRY HPI has the people and technology to make prototype patterns quickly for the foundry industry. With 2 of the largest 3D printers on the market, our 3D sand and PMMA printers can produce pieces quickly. On-time and on-budget. And that is just the beginning. From 3D printing to full service tooling capabilities, HPI meets all of your casting needs from concept to volume production. HPI. Delivering a pattern of excellence.

260.724.9430 | HOOSIERPATTERN.COM | 906 N 10TH ST, DECATUR, IN 46733

If your parts were 4x stronger, what else could you do with them?

Serving the 3D Printing Industry for more than 15 years. Electroplating 3D Printed Plastics for Strength, Stiffness, Durability, EMI Shielding, Electrical and Thermal Conductivity, Abrasion Resistance, and much more... Reach us at: 410-242-5110 â&#x20AC;˘ info@repliforminc.com

MEDICAL FOCUS

THE OTHER SIDE OF THE COIN In 2013 as the civil war in his country reached crisis point, Syrian, Asem Hasna, left his mathematical studies to volunteer as a paramedic. He was loading injured people into his ambulance when an explosion severed his leg. With his life hanging in the balance his medical colleagues sent him off to Jordan where he was amputated and able to get sufficient treatment to be able to walk on a prosthetic leg at the fifth operation asking. While he was hospitalized and undergoing rehabilitation he trained to become a prosthetic technician in order to help out other Syrian amputees, here Asem came into contact with Refugee Open Ware (ROW) and saw how 3D printing could be used to create basic prosthetics for those in dire need. He was immediately addicted, devouring 3D printing texts and teaching himself how to make a functional prosthesis on a basic FDM 3D printer. As ROW’s 3D printing expert Asem was able to help hundreds of victims not just physically but psychologically too. Asem joined Denise Schindler on stage at re:publica to discuss how empowering the amputees to become makers gives them a psychological boost as well as the physical aid from the orthotic itself. On stage Asem discussed Zane, a six-year-old Yemeni boy who

ACCELERATING 3D TECHNOLOGIES

Denise says that now that her scan data is in the system and the team know it works and fits, she can create a specifically tailored prosthetic to different activities. “Just like you have business shoes to look good, everyday shoes for comfort, climbing shoes for climbing this could be the case for prosthetics, so I love diving, I will just use my diving leg.”

LEFT: Asem and Zane courtesy of ROW

lost his hand and was badly burned in an explosion during fighting, ROW made him a 3D printed prosthetic, not any old prosthetic but one in the style of his hero Ben 10. “When we met Zane for the first time he was scared,” Asem said. “He was scared because all of his body was burned but when he started to see this Ben 10 hand he started to be more relaxed, the first day he didn’t take off the hand, only when he went to sleep did his father remove the hand.” Having seen directly, at a makerspace in London, the disappointment of parents whose child’s affliction was not suitable

for a 3D printed prosthetic, I asked Asem if all these feelgood stories we see of 3D printed prosthesis (guilty as charged on that front) could possibly be a negative thing? “3D printed prosthetics are not the best solutions ever, there are bionic hands that costs tens of thousands of euros but for now they are providing an alternative solution for people who can’t get access to advanced healthcare,” Asem explained. “There are 100,000 amputees in Syria, you have two choices you can provide cutting edge prosthesis to one hundred of them or to provide basic arms or limbs to as many as you can.” But Asem sees that changing, Asem sees people like Denise Schindler and believes that more innovation at the top of the market will push prices down and allow for greater innovation in the open-source end were he and ROW operate. “I really believe in the future we will have low cost bionic perfect prosthetics accessible to everyone.” Denise thrives on motivation, she is smashing through the barriers and not just breaking records but opening doors to accessibility, perhaps opening doors to people who will be come her competitor. “I hope my story is an inspiration not to stop,” she says. “An inspiration to see the things amputees can do, I hope people see what I can do, how I chose my path, how I cycle my path and start to ask for things that they want to have, to do the things they did before. I think this is the biggest thing I can do.”  For more information visit www.row.org

RIGHT: Denise Schindler’s competition prosthetic VOLUME 2 ISSUE 2 www.tctmagazine.com

013

To push the envelope for Additive Manufacturing:

Just add Arcam.

Welcome to Arcam – a pioneer and proven leader in cost-efficient Additive Manufacturing solutions for the production of orthopedic implants and aerospace components. At the heart of our total offer are Arcam EBM® systems, based on cutting-edge electron beam melting technology, that offer freedom in design, excellent material properties and high productivity. The build chamber interior is designed for easy powder handling and fast turn-around times. What’s more, you can rely on our highly competent application engineers to support you from design to production – adding value every step of the way. With the Arcam EBM® process, you can take full advantage of powerful electron beam melting technology to differentiate your products and boost productivity. • Freedom in design • Easy to use operator interface • Latest generation EB gun • Fast cooling

See what you can achieve with Arcam. Visit www. Arcam.com

A Strong Future Stands Behind Us! ALUMINIUM & PLASTIC Prototypes In 1-4 Weeks.

Plus Low Volume Production Capabilities! • Machined Aluminium Castings One Shot Casting Rubber Plaster Mold Precision Air Set Sand Graphite Die Casting • RIM – Reaction Injection Molding Rubber Plaster Molding

• CNC Machining & Hogouts • Painting, Finishing & Assembly

One Shot Tool-less Casting

Precision Airset Sand Casting

Graphite Mold Die Casting

Reaction Injection Molding

ARM TCT Ads-UK-FNL.indd 1

AS9100 Rev. C ISO 9001:2008 Certified ITAR Registered

ARMSTRONG RAPID MANUFACTURING: Tel: (315) 437-1517 • email: sales@ARMstrongRM.com For more info visit us at: ARMstrongRM.com 3/30/16 3:30 PM

MEDICAL FOCUS ACCELERATING 3D TECHNOLOGIES

Handle with Care



BELOW: Josh Stephenson with his Umbrella Handle and 3D Printed Skull

There have been many words written, in this very issue even, extoling the virtues 3D printing offers towards advances in healthcare. Additive technologies have been applied to many patient specific devices whether that is in order to aid with surgery in the case of medical modelling or improve lives as seen with thousands of 3D printed prosthesis in use. A recent talk at the London-based 3D printing specialists Digits2Widgets showcased how medical 3D printing has not only helped reconstruct a man’s face but also reinvigorate his career.

W O R D S : DA N I E L O ’C O N N O R

ABOVE:

Umbrella Handeles are printed using Nylon SLS

N 2009 JOSH STEPHENSON, a graduate of the Royal College of Art, was diagnosed with malignant melanoma – a type of skin cancer which can spread to other organs. After unsuccessful radiotherapy treatment Josh went on to have drastic surgery to remove his left eye, upper left jaw and roof of his mouth. The reconstruction process was extensive and required the expertise Dr. Andrew Dawood of Dawood & Tanner clinic, who have been using 3D printing in dentistry since 1999 and is the founder of Digits2Widgets (D2W). “Josh had a life threatening cancer behind his eye, he received fantastic treatment at Moorfields Eye Hospital and the Royal London Hospital from surgeons Dr David Verity and Professor Iain Hutchison.” Dawood told TCT. “I was required to be part of the reconstruction process using dental implants, we used both 3D printing and digital milling technology to make the reconstruction as accurate and seamless as possible.” Dawood & Tanner has become synonymous with hi-tech dentistry having worked on many high profile reconstruction cases. Josh’s surgery required all the digital expertise Andrew and his team have acquired

over two decades; scanning, digital modeling, 3D printing, milling and more; though it is the 3D printing that catches the headlines, Dawood thinks it is a long way from a complete technology: “We mostly use milling technology rather than strictly 3D printing. We use mills in restoration, which are fitted onto 3D printed models. The ideal scenario for us in implant dentistry is a hybrid technology that combines the worlds of 3D printing in metals for structures, which are then milled for precise mechanical connections. 3D printing is no magical tool; we’ve been using it consistently and steadily for years. Ten years ago I thought we’d be where we are now, in hindsight if I’d have thought it would take us a decade to get to where we are now I might not have bothered!” Like many long-in-the-tooth 3D printing users Andrew’s attitude towards 3D printing is slightly curmudgeonly, the technology has, after all, only incrementally improved in the some 17 years since he first invested in it. But its ability to inspire those who have been less exposed to technology must never be underestimated and it is such stimulation that makes Josh’s story even more wonderful. ››

VOLUME 2 ISSUE 2 www.tctmagazine.com

015

MEDICAL FOCUS ACCELERATING 3D TECHNOLOGIES



LEFT: Josh Stephenson and Jonathan Rowley discuss the handles

GETTING A GRIP After the technology had aided in his facial reconstruction Josh and Andrew became quite close. He accompanied Andrew to a conference talk on how 3D printing was enlisted in his surgery, Josh was able to hold the 3D printed model of his own skull and it was there and then that Josh had his eureka moment: “I have worked in the design industry for 25 years since graduating from the RCA in 1990, specializing in fashion accessories and luxury gifts.” Josh told TCT. “I have long had the idea of creating luxury umbrellas with handles that have some character but due to costs involved in setting up for injection molding, it never seemed possible.” Josh’s idea was to take beautiful objects used in other walks of life and adapt them to create modern curio style umbrella handles: “In design nothing is new,” said the designer who has worked for brands such as Hugo Boss, Laura Ashley, Aquascutum and Harrods. “Products are reworked and adapted to create something new, having a gut instinct about timing is a key importance to a designer.” When he told Andrew Dawood about his idea, he instantly knew where to turn, to bring this idea to life; his own 3D printing design studio Digits2Widgets (D2W): “Josh brought us objects he loved from his home that he thought would make an interesting basis for umbrella handles and our team helped make that a reality,” explained Dawood. In the main those items were traditionally door furniture and other home items; crystal doorknobs, Bakelite handles, dog-headed corkscrews and the likes; all items Josh considered beautiful and perfect for re-purposing into umbrella handles, but how to get them into a printable file?

Josh’s idea was to take beautiful objects used in other walks of life and adapt them to create modern curio style umbrella handles

“All the items were all different materials, shapes and textures,” explained the Design Director at D2W, Jonathan Rowley. “The idea was initially to try to scan them all but some of the objects were easier to draw in CAD from scratch. The crystal doorknobs are faceted transparent spheres, transparent is difficult to scan, so because of this and its nice geometric shape we said ‘forget about scanning it would be easier to draw this.’” It would be easy to forget the product design intricacies involved in manufacturing an umbrella handle, particularly those smaller collapsible ones ladies often produce from handbags on feeling an initial droplet hit a recently coiffured hairdo. “The handles of collapsible umbrellas are very sophisticated,” said Rowley. “They have a recessed collar around the top of the handle that allow the spokes of the umbrella to clip in, holding it together and features like chords that allow you to dangle it off your wrist. We had a good look at these existing design features, the shapes and size of Josh’s original pieces went pretty much untouched but at the drawing stage we added in features like those recesses and channels so that you could pop the chord through, come out the bottom, take it back through and knot.” A few print iterations later in order to perfect the ergonomics, and Josh’s umbrella handles were ready to print. D2W used both SLS and SLA technologies to make the final pieces, the nylon SLS printed pieces were vibrio-finished and died black and the metallic looking pieces were printed in SLA and spray-chromed. The results are unique fashionable umbrellas that would not be out of place in the upmarket stores Josh once worked for but it’s not just old household objects that have been given a new lease of life thanks to 3D printing: “This is a designer who had been out of the picture with illness for a little while,” added Andrew Dawood. “Josh has seen all this 3D manufacturing technology being brought to bear on his medical condition and is now using it to get himself back in to the working world.” For more information visit www.DIGITS2WIDGETS.COM

VOLUME 2 ISSUE 2 www.tctmagazine.com

017

The Most Productive Additive Metal Manufacturing Systems More Laser Power, Larger Build Envelope, Faster Build Speeds

Download the white paper:

All systems in the SLM Solutions product line feature a common development and laser platform with transferable parameters for high quality metal parts from the lab to production.

slm-solutions.us/whitepaper

7 Questions Every Manufacturing Professional Must Ask Before Buying a Metal Additive Manufacturing Machine

Offering build volumes up to 22% larger and build time efficiencies up to 70% faster than the competition, SLM Solutions can enhance your capabilities with selective laser melting! SLM Solutions is a leading provider of metal-based additive manufacturing systems and technology that support fast and flexible metal part production for the aerospace, automotive, energy and medical industries. SLM systems define the gold standard for best-in-class operator safety and greater recoating speed.

SLM Solutions NA, Inc.

www.slm-solutions.us I info@slm-solutions.us 28350 Cabot Drive, Suite 100 I Novi, MI 48377, USA I 248-243-5400

Visit us at IMTS Booth N-71

3D Print Infiltrants

Permabondâ&#x20AC;&#x2122;s low odor infiltrants are preferred for strengthening and sealing 3D printed models produced via granular 3D printing methods. nFast

Cure Surface nBrilliant Color nShiny

nUltra

Fast Cure Gloss Surface nBrilliant Color

nHigh

nDelayed

Set Surface nUltra Low Viscosity nMatte

800-640-7599 www.permabond.com info.americas@permabond.com

3D10 3D30 3D90

MACHINING

ACCELERATING 3D TECHNOLOGIES

New Methods for Manufacturing W O R D S : l a u r a g r i f f i t hs

T RAPID, 3D SYSTEMS’ principal message was that despite the noise, this industry is not all about the 3D printer, it’s about an entire ecosystem. Whether it’s design, manufacturing, scanning or processing, all of the links in the chain need to fit together in order for the technology to achieve its full potential. Toward the end of last year, the additive manufacturing giant expanded that ecosystem even further in partnership with Methods Machine Tools, Inc.. Based in the U.S., Methods has over 55 years of experience in the supply of precision machine tools and automation for manufacturing but in recent years, has kept a close watch on the surge of 3D technologies. Following a year of evaluating the leading companies in the industry, Methods forged a national partnership and long-term agreement with 3D Systems to offer production-level 3D technologies under its newly formed subsidiary, Methods3D. “We saw several industries begin to embrace 3D technologies and employ design for the process,” Mr. Benjamin Fisk, General Manager Methods3D, explained. “At the same time machine builders were releasing the next generation of 3D technologies focused not only on technology but true manufacturing production. As we evaluated the markets and talked with leading industry experts, we realized the tremendous potential that 3D technologies had for our customers.” Methods has installed 3D printing labs at its seven technology centers across the U.S. staffed with dedicated professionals to demonstrate where these advanced technologies fit into the manufacturing processes. Equipped with an established history in metal machining applications which spans industries such as aerospace, medical, automotive and electronics, Methods3D is putting a strong focus on 3D Systems’ Direct Metal Printing (DMP) with a range of machines from the smallest ProX DMP 100 printer to the ProX DMP 320 designed for intense 24/7 production environments. But Methods3D is not resting on metals alone and has expanded the toolbox even further to include SLS, SLA and MultiJet Printing with its most recent installation, the ProJet MJP 3600. “By combining the capabilities of 3D technologies, which allows for the creation of a part from scratch, with the finishing capabilities of traditional technologies, there are great opportunities to integrate and automate the entire production process to combine traditional manufacturing and 3D printing into production

cells,” Fisk continued. “3D technologies allow for concepts such as modular manufacturing, and with the continued development of standardized fixtures, work holding, and interface controls, traditional and 3D technologies will continue to complement each other and achieve seamless integration.” Often the first assumption about 3D technologies is that they’re here to replace traditional manufacturing tools. While that might be the case for some specific applications, and indeed those emerging “killer applications” where 3D printing is making the impossible a reality, there’s no need to hang up your traditional tool kit just yet. Prototyping and customization are tried and tested use cases for 3D printing but where Methods3D believes the combination of traditional and additive is really changing the game is in the manufacture of injection molds. Fisk explained: “3D technologies are employed to create highly complex conformal cooling channels which traditional manufacturing is incapable of producing. However, tight-tolerance and mirror-like surface finish requirements require the die to be post-processed with traditional manufacturing. The result is a mold incapable of being produced by either technology alone, but together creates solutions with unmatched capability and performance.” From small job shops to large corporations, Methods3D is looking at addressing what they see as a shortfall in the integration of 3D technologies into production manufacturing by providing complete turnkey solutions from design all the way to quality assurance. As we experience a growing demand for automation in the industry, Methods 3D hopes to continue its legacy in robotics and automation with fully integrated solutions. “Methods3D sees a tremendous opportunity for automation within the additive manufacturing sector,” Fisk added. “Builders are beginning to understand the need for further product and process integration and we believe Methods 3D will be a leader in developing these capabilities and bringing them to market.” We’re already seeing copious evidence of the benefits afforded by combining traditional manufacturing with additive through the growing number of hybrid machines and established machine tool manufacturers entering the market with their own additive enabled technologies. While subtractive has long dominated the industry, as manufacturing needs continue to evolve, this amalgamation is giving companies the ability to evolve with them.  VOLUME 2 ISSUE 2 www.tctmagazine.com

019

28 SEPT - 29 SEPT 2016

EXHIBIT NOW

JIGS & FIXTURES ACCELERATING 3D TECHNOLOGIES

3D Platform is renowned for its large-format FDM machine that can produce products as big as a piece of furniture or even a motorcycle body with its huge 1 x 1 x 0.5 metER build area. However, with its recently upgraded 3DP1000 machine, the company has found itself an entirely different niche in the somewhat less glamorous but equally noteworthy world of manufacturing aids.

3D Printing Manufacturing Aids W O R D S : L A U R A G R I F F I T HS

new ideas or product designs; we can simply turn to our range 3D printers for a cheap, effective method of prototyping between anything and experimentation.” from simple Another example is this custom designed Thread Rolling guides to complex fixtures Machine Die Holder designed by a fellow PBC Linear and can be used to enhance engineer. The device (pictured bottom) is used to house a manufacturing or assembly several production instruments including a pair of die, blot production. They and test pieces in one easy-to-access place. are traditionally This particular thread rolling machine has produced using over 50 sets of cylindrical dies that require conventional appropriate storage to avoid contamination tooling methods and corrosion over time. The operation but as with any lowrequires a streamlined workflow to ensure volume production each set of dies is stored with its pairing test run, this can prove pieces and blot. Typically, to manufacture a both cost and time die holder in low volume will usually cost consuming. With a minimum of $300 per piece with a 2-5 3D technologies, engineers have the freedom week lead-time. Using 3D printing, this can to design, test and manufacture a simple be reduced to less than a day. With 3D solution in a matter of days. “Before I would create a design and then Take for example this Profile Rail Wiper send it to a tool maker for initial production,” technologies, (pictured top) designed by an engineer at Cameron Paulson, Engineer at PBC Linear engineers have 3D Platform’s parent company PBC Linear. said. “If the design did not work the way Engineered to replace the built-in wiper on an we expected we would have to make the freedom industrial steel rail-cutting machine, the fixture adjustments to the design, which is normal to recognise a pushes away big steel chips while helping in developing process. Every time we have problem and retain oil and lubrication in the rail bearings. to redesign it wastes engineering time, However the original wiper would fail to catch the machine operator’s time, and building design, test and smaller steel chips, which if left on the rail materials. With 3D printing, I can make manufacture a could cause the entire system to stop. Rather rough designs and print them out without than going to the expense of designing and having to worry about machining time or simple solution manufacturing an alternative wiper through material cost.” in a matter tooling, the engineers used the 3DP1000 to The design was modelled using CAD and of days. 3D print an add-on wiper that would fit tightly Simplify3D and 3D printed in one piece on the rail and catch even the smallest chips using PLA. The team set up the 3DP1000 to of steel. print four cases at a time and were able to “We were able to overcome easily a simple leave the machine running after the factory issue that otherwise would have cost us had shut down. After just two iterations, the thousands of dollars in tooling and specialty holder was put to use in less than a week at services,” Mitch Van Vleet, Engineer at PBC a cost of $100 per piece. Linear, explained. “This also benefited me by For low-volume, customised products allowing me to work solo, and not having to like these manufacturing aids, 3D printing take a toolmaker away from another project to can be a simple, fast and inexpensive assist me.” method of manufacture, requiring minimal Using 3D modeling and 3D printing, labour and giving engineers the flexibility Mitch was able to test various concepts and to trial designs with less risk. Just as the materials to determine the best solution. A technology has proved somewhat of an total of eight design iterations were used in order to get unsung hero in the tooling world, for engineers exploring to the final optimised design with each taking just 20 ways of improving conventional manufacturing methods, minutes to print in PLA at a cost of $0.20 per piece. This it is providing the same subtle but valuable benefits as a method proved a massive 500% saving in cost compared catalyst to advance their capabilities. to traditional tooling. “Thinking of fixturing projects with 3D printing “3D printing has allowed us to approach many projects applications will definitely expand the scope of 3D printing,” more confidently,” Mitch explained. “Rather than gambling Cameron commented. “The goal for 3D printing is not to large amounts of time and resources when implementing replace traditional manufacturing methods but use it in conjunction to augment the application possibilities.”  a n u f a c t u ri n g aids

can

VOLUME 2 ISSUE 2 www.tctmagazine.com

021

Bridging the gap between product design & manufacturing

3D Metal Printing • 17-4 SS • Aluminum AlSi10Mg • Cobalt Chrome • Maraging Steel • Inconel 718 • Inconel 625 • Titanium Ti64

810 Flightline Boulevard, Suite 2 DeLand, FL 32724 Phone: (386) 626.0001

www.3dmaterialtech.com

AMUG REVIEW ACCELERATING 3D TECHNOLOGIES

W O R D S : L A U R A G R I F F I T HS

AMUG 2016 REVIEW

HEN YOU TELL people you’re headed to AMUG as a first timer, the first thing they will tell you is that it’s different to any other trade event. In the build up to this year’s conference, I had been excited by stories from AMUG regulars who were keen to sing the praises of what feels like a rite of passage in the AM calendar. I’m happy to report, they were right AMUG is very different. From the types of conference sessions to the networking luncheons and surprise theme park trip, AMUG for me was a unique chance to soak up some new perspectives, catch up with friends and make new ones. Taking place in St. Louis with a whopping 1,000 attendees, AMUG began with a casual evening expo at the stunning St. Louis Union Station Hotel, much larger than the usual AMUG floor space. The conference proceedings kicked off with a packed out opening address from Mark Barfoot who took to the stage to honour Mark Abshire with the AMUG President’s Award, shortly followed by Todd Grimm who gave his keynote presentation on ‘The Age of Innovation”. Todd’s message was that innovation is everywhere and we still have a good 10 years of it ahead of us to get stuck into. The ever-popular Jason Lopes of Legacy Effects then took to the floor for a 90 minute rundown of the best 3D prints from his team’s some 4,679 builds since the last AMUG meet including Hollywood blockbusters, Superbowl adverts and Cristiano Ronaldo replicas. Of course one of the biggest stories from this year’s event was the official debut of Carbon’s much anticipated –

and much hyped – M1 3D printer. With its own room to the side of the expo, which had been kitted out like an Apple store, the reveal of Carbon’s first ABOVE: Technical machine was competition winner for truly impressive Advanced Finishing not just for the M1 itself but the range of high-performance materials. THE AMUG Diamond Sponsor Panel Session featuring representatives from 3D Systems, Carbon, Concept Laser, ExOne, GE, HP, Renishaw, SLM Solutions, DSM Somos and Stratasys saw the main conference room filled once more. Our Editor Dan summed the mood up perfectly in his AMUG Blog – “AMUG is a place where hype goes to die, you’re not going to get a good reaction from the baying audience if you talk in marketing lingo.” Another main stage highlight was the Scott Crump interview session, which saw Todd Grimm delve into the mind of 3D printing pioneer and inventor of FDM technology. Scott’s spoke of how his thrill seeking life style has allowed him to take greater risks in business and offered his thoughts on the future of the industry. GE had people queuing out of the door for much of their sessions whilst the medical track featured speakers such as David Escobar for Formlabs talking about more training in healthcare, a surprising talk from Boeing on a communitybased project, which helps wounded war veterans and dental presentation from Perry E. Jones at the Virginia

Commonwealth University which proved both highly informative and entertaining. Not forgetting the technical sessions from companies like; ExOne, Renishaw and Stratasys, and updates from Voxel8 and industry newcomers, Xjet. Of course AMUG is also about recognizing the achievements of those in the industry and the annual awards banquet serves as the place where those figures are acknowledged. For this year’s ceremony, we were all sent off in a convoy of busses to a secret location. We found ourselves at Six Flags theme park where the entire AM community emptied the gift shop of its stock of souvenir sweaters thanks to the unexpected evening chill and 10 new DINOs were welcomed into the fold. Another huge feature of AMUG is the Technical Competition, which each year invites competitors to submit their wares for the chance to win one of two awards for Advanced Concepts and Advanced Finishing. The winners were Alan Guyan from Under Armour for the Architect shoe featuring a generatively designed 3D printed midsole and an incredible replica of Van Gogh’s ‘The Starry Night’ painting from Custom Prototypes which perfectly replicates every point and colour of the original piece. It’s a real testament to its team of volunteers that work tirelessly, year round, to get every detail perfect from the keynote speakers all the way down to the dessert choice at the dinner table, that AMUG continues to emanate its inimitable sense of openness and friendliness. I learned a great deal from my first AMUG trip and I’m already looking forward to what AMUG 2017 has in store for Orlando, Florida. 

VOLUME 2 ISSUE 2 www.tctmagazine.com

023

UNDER ARMOUR

Under the Armour

Daniel O’ C onnor wit h th e qu e s t i o n s , Alan G u ya n with t h e a ns we r s

How the sportswear giant took a huge leap into the world of 3D printed apparel

024

VOLUME 2 ISSUE 2 www.tctmagazine.com

ACCELERATING 3D TECHNOLOGIES

s Steph Curry shot his 402nd three-pointer of the season and Golden State Warriors broke the Chicago Bulls all-time NBA win record the post-match analysis was quick to showcase the MVP’s quick footwork that gets him into the correct positions to effortlessly smash every shooting record in existence. The close up of his Under Armour basketball shoes broadcast to millions across the world is probably just about the greatest exposure a sports brand could ever wish for. Curry’s exploits may have helped the Baltimorebased brand take a huge chunk of a sports footwear market (roughly $700 million in annual sales as of 2015) the company weren’t even involved in less than a decade ago but one of the reasons the likes of Curry, Tom Brady, Jordan Speith and a host of sports teams across the globe is turning to Under Armour in order to give them an extra edge is its focus on technological innovation. And it was innovation out of the Under Armour camp that saw it scoop an award as prestigious in the 3D printing industry as Curry’s MVP is to basketball – AMUG’s Advanced Concepts Technical Competition. The Under Armour Architech is a result of two years in research and development in order to create the ultimate training shoe for athletes using the latest in generative design and additive manufacturing. The striking shoe features a fully 3D printed latticed midsole that offers an unrivalled cushioning thanks to the research into perfect structures in nature and architecture. Alan Guyan, Sr. Innovation Design Manager, stepped up to take the 2016 award for a project that has been his baby since inception, TCT spoke to Alan to find out what goes into redesigning the shoe: ››

VOLUME 2 ISSUE 2 www.tctmagazine.com

025

Q. When did it become apparent that 3D

printing was not just a technology capable of prototyping anymore but for end-use production? And what barriers did you have to overcome to achieve that?

A. One of the challenges we faced was with the

limited materials that are currently offered for Selective Laser Sintering (SLS), and whether or not it could withstand normal force loads-mechanical properties that are involved in standard footwear applications. I think one of the major turning points that we found was with a new elastomeric material from Lehmann & Voss & Co. The LUVOSINT TPU was the first real sign that it was possible to make finished footwear components for production. The combination of mechanical material properties allowed our parts to be flexible, and yet slightly rigid, all at the same time. In addition, the SLS printed parts naturally have a “gritty” surface finish, which is not acceptable for finished footwear products. We also needed post-processing in order to make the printed components viable for finished product applications. This led us to the University of Sheffield in the United Kingdom, where they developed a proprietary licensed technology called The PUSh Process. This post-process added a new level of finish to our SLS polymer footwear components, providing a nice smooth surface finish.



BELOW: To achieve a end-use consumer worthy finish the heel was post-processed using the PUSh Process

ABOVE: The 3D printed latticed heel was

designed using Autodesk Within software

Q. Generative design is a hot topic; can you tell A.

This performance trainer provides athletes with the ultimate stability and cushioning to take on the most intense workouts.

026

There still are a number of challenges to be faced with this technology as the market continues to demand full scale 3D printing production, including machines prices, build times, build volumes, colour selections, material pricing and material processing. I’m very confident that we are on the right path, and the UA Architech training shoe is the first step into this process, which gives us a giant leap forward, and also paves the way for mass production.

VOLUME 2 ISSUE 2 www.tctmagazine.com

us exactly how Autodesk Within’s software has optimised the heel of the UA Architech?

The Autodesk Within software has allowed our team to develop custom lightweight lattice structures, which could be tailored to meet our footwear performance goals. I call this our 3D foundation blocks, which will lead to a number of optimal cushioning options in the future. In the beginning, we were able to eliminate a number of lightweight lattice structure designs with Finite Element Analysis (FEA) simulations, and by conducting multiple mechanical tests. However, this is a two-part equation, and the software requires a number of inputs that can only be achieved by utilising the data from the UA Sport Science team. The inputs of kinematic and/or kinetic data, and material properties were able to give us the road map in creating an optimal structure. We also had to evaluate thresholds between computer simulation, and the final 3D printed products. From here we could determine the performance attributes and the future 3D print technology in all sport activities. This innovation will continue to play an important into our core DNA of performance, and here we will continue to expand our optimization developments into future footwear product platforms.

UNDER ARMOUR ACCELERATING 3D TECHNOLOGIES

Q. What 3D printing technology went into not just the manufacture but prototyping too? Can you talk us through the step-by-step process?

A. During

the shoe manufacturing process, there are always certain levels of challenges to face, and this applies not only to 3D printed sampling, but also with high volume production. Our goal was to create a 3D printed heel component that is engineered specifically for the strength athlete training, and to provide a stable and supportive platform within all three planes of motion. This is demonstrated in the final design by only focusing on the heel section of the midsole. We wanted to focus on heel stability, yet allow for flexibility in the forefoot.

Bonding several different types of footwear material components together is always a concern, and it can really make or break a product. In the early stages of development, we conducted numerous bonding trials to ensure we were selecting the right materials. We achieved this with great success, allowing us to focus on the individual component intergradation, and the overall execution.

Q. What athletes and what sports

will benefit from this technology? Will Autodesk Within create generative design for different sports depending on what different forces of sporting activity put them under?

A. The UA Architech 3D printed

Q. Is a 3D printed shoe becoming

an in-demand product from UA athletes, in the goal to improve performance however incremental that is?

Again, to Under Armour’s dedication to make all athletes better, and to our core DNA of performance, we see that all athletes can benefit from this technology. This is our first-ever 3D printed performance trainer. The UA Architech is a 360-degree performancetraining shoe that features a functional 3D printed midsole and 3D ClutchFit auxetic upper design that creates a “super-hybrid” trainer. This performance trainer provides athletes with the ultimate stability and cushioning to take on the most intense workouts. The UA Architech, went through the gauntlet of mechanical testing, with over 120 hours of physical testing, and over 80 athletes proving wear-test feedback.



ABOVE: To achieve a end-use consumer The UA Architech combines two types of training shoes in one thanks to 3D printing

heel component was engineered specifically for the strength-training athlete to provide a stable and supportive platform within all three planes of motion. The technology is a successful because we engineered it utilising a holistic development approach, considering each aspect of the process and giving those aspects equal importance to the overall outcome of the shoe, i.e. upper design and material geometry, 3D engineering, product testing, and manufacturing. This technology can benefit a variety of athletes, and we look forward to exploring those opportunities with the same thoughtfulness we had for the Architech. Autodesk Within will utilize data from the UA Sport Science team to determine the performance attributes, and inputs of actual kinematic and/ or kinetic data. From there we can look into the future of additional sport activities, but it starts with real biomechanical research and testing.

Q. Are professional athletes now

using scanning processes for shoes specifically tailored to each foot? And if so will that trickle down to amateur athletes and the broader consumer base?

A. The innovation team has made

substantial investments in scanning technology, and we’ve been amassing a large 3D scanning database of all athlete foot and body geometry. We see this as the 3D digital blueprint, where we can evaluate their geometry based on their sport and position. We build performance-based products for all athletes, but the process begins with our top tier athletes. From there we can ensure our product meets or exceeds our consumer needs by leveraging our professional assets. Eventually, we see this as a platform where all consumers and all athletes can benefit from this amazing 3D printing technology. We are just getting started…  For more information visit www.underarmour.com/en-us/ 3d-architech



RIGHT: Printed in LUVOSINT TPU using SLS technology.

VOLUME 2 ISSUE 2 www.tctmagazine.com

027

ge of hout SPONSORED BY

Rapid Review WOR DS : DA N IE L O ’C O N N O R

rlando is synonymous

for two things, the heat and theme parks but for three days in May it also took on the form of 3D printing mecca as the world’s top 3D manufacturing companies converged on the Orange County Convention Center (OCCC) for RAPID 2016. The annual event hosted by SME has, concurrently with the industry, grown at a steady rate. The 2016 was the biggest yet with gargantuan stands like that of HP rubbing shoulders with smaller companies like MakeShaper, and established players like 3D Systems rubbing shoulders with startups like Rize, Inc. All showing something novel, something that will help people reduce time to market. CONFERENCING The conference line-up at this year’s Rapid was nothing short of stellar with keynotes from Terry Wohlers, Workshops from FIAT Chrysler automobiles, Seminars from the United States Naval Academy, lectures on the 3D printing of optically transparent glass from MIT and more. It was a veritable feast for the mind but one particular talk this editor enjoyed was the second day keynote, ‘4D Printing in Medicine: Developing Medical Devices for the Growing Patient’ by Robert Morrison, MD and Scott Hollister, PhD from the University of Michigan. The disease that the two doctors were faced with treating is Tracheobronchomalacia - a disease that affects 1:2,100 infants. Current

028

VOLUME 2 ISSUE 2 www.tctmagazine.com

treatment includes complicated surgery and constant ventilation; morbidity rates are high with surgery. With adults who develop the illness a tracheal splint can help, the problem with infantile Tracheobronchomalacia is growth, children grow at a rapid speed and no one splint solution is viable. Growth in this case is the fourth dimension. The team had to create tracheal splints that would grow alongside the pressure of human growth. 3D printing would help create the bespoke splint in the first place but how could they get the splint to react? There were six design considerations that went into achieving this: • • • • •

Archetype Device Design needed to: Resist External Compression Allow Flexion/Bending Allow Radial Expansion/Growth Be Customizable for Variable Anatomy • Be Bioresorbable (Last 2-4 Years) • Be Biocompatible The first four considerations were achieved with design, the latter two with material science and the first surgery was performed in 2012. Patient number one had never been off a ventilator for his entire 16 months on earth, six weeks after the operation he was breathing on his own. “We’re just scratching the surface of what is possible with 3D printed medical devices,” said Dr. Robert Morrison to a rapturous round of applause.



ABOVE: A busy RAPID show floor (top) and the 3D Printed Fashion Show

nd 2500 ge of hout

RAPID REVIEW ACCELERATING 3D TECHNOLOGIES

SPONSORED BY



LEFT: Hans Langer receives his award from Jason Jones

AWARDS At the 26th annual RAPID event, SME hosted its Additive Manufacturing Community Awards, highlighting some of the most influential figures and achievements in the 3D technologies industry. The 2016 SME Additive Manufacturing Industry Achievement Award went to Hans Langer, PhD, founder and CEO of EOS GmbH. Langer is a major pioneer in the additive manufacturing industry, racking up several industry awards and accolades including the Bavarian State Medal and ranking highly on lists of influential industry figures, including one in this very magazine. Jason Jones, PhD, chair of SME’s Additive Manufacturing Community, commented: “This award is a recognition of Dr. Langer’s technical innovations and the widespread impact his company has had on the additive manufacturing industry since its start in 1989.” SME also announced the winners of the Dick Aubin Distinguished Paper Award, named after the late additive manufacturing pioneer Dick Aubin, for “Contact-Free Support Structures for Part Overhangs in Powder-Bed Metal Additive Manufacturing,” written by Kevin Chou, PhD, and Bo Cheng of the University of Alabama, and Kenneth Cooper and Phillip Steele of Marshall Space Flight Centre. The Rochester Institute of Technology sponsored the award, which was given for the paper’s documented concept of employing a novel thermal management strategy to avoid distortion in parts made with metal powder-bed fusion. In the 2016 Design for Direct Digital Manufacturing Competition, high school and college designers and engineers were challenged to take an unmanned aerial vehicle (UAV) design, and improve it using additive manufacturing. The winners were students Tito Arana,

We’re just scratching the surface of what is possible with 3D printed medical devices

Jordan Castillo, Michael Gager, Dan Stella and Joanel Vasquez, along with their academic advisor, Stephen Johnston, PhD, from the University of Massachusetts Lowell. The RAPID Innovation Award, sponsored by Stratasys, recognises new products or services at RAPID that demonstrate the greatest potential impact on the industry. With a record number of 27 entries this year, the finalists were 3DSIM, Additive Industries, Essentium Materials and HP Inc. All four companies brought forth inventive, significant technological advancements. The overall winner was Essentium, which introduced a new and innovative method for welding thermoplastic interfaces of 3D-printed parts using the extreme heating response of nanoparticles. The RAPID People’s Choice Award, also sponsored by Stratasys, was determined by popular vote of RAPID attendees. The award went to HP for being the most interactive, technically impressive and engaging with their Jet Fusion 3D Printing Solution launch.

SHOW FLOOR All aspects of 3D manufacturing were on display at RAPID 2016, from additive manufacturing machinery to powder solutions, a visitor can see a whole supply chain and workflow, that’s one of the beauties of trade shows - a concentrated base of information. It was a technological overload at the OCCC as companies elbowed for room to talk about their latest and greatest product launches. Carbon showcased its M1 CLIP technology to the wider world after a smaller showing at AMUG, Lulzbot debuted the TAZ 6, Formlabs debuted its biocompatible dental resin, Materialise demoed the new Magics 3D Print Suite, you get the picture there were a LOT of new products on show.  Over the coming pages of this Rapid Review Special we’ll be featuring some of the major launches, opinions, galleries and more from the Orlando show. Subscribe to youtube.com/user/tctmagazine for more on those launches ONWARDS AND UPWARDS As you may have read in the last issue, next year’s RAPID Event represents an entirely new beast, SME and our publishers, Rapid News Publications Ltd. have joined forces to bring RAPID + TCT to the North American market. By combining decades of experience of the two brands, the 2017 edition will offer exhibitors and visitors the ultimate in 3D manufacturing trade shows. RAPID + TCT 2017 will be hosted at the David L. Lawrence Convention Center in Pittsburgh, PA on May 8-11, 2017.

VOLUME 2 ISSUE 2 www.tctmagazine.com

029

nd 2500 ge of hout

RAPID REVIEW SPONSORED BY

Cincinnati Inc. goes big at

RAPID

WOR D S : LA U R A G R IFFIT H S

APID NEVER FAILS to deliver on eye-catching examples of 3D technologies, whether it’s the 3D Art Gallery, fashion or huge centrepieces that show the possibilities when all aspects of the 3D ecosystem join forces. Following a ‘space’ theme, this year organisers SME, gathered a collective of 3D technologies experts to produce a replica of NASA’s Orion crew module, which greeted visitors as they entered the exhibition hall. Lockheed Martin, Faro Technologies, Direct Dimensions, Met-L-Flo, Florida Institute of Technology and Cincinnati Inc. teamed up to take the first ever scan of the Orion crew module which was 3D printed and assembled on-site at RAPID. “They [SME] wanted to involve a variety of exhibitors that could show off what they do, from scanning, software and 3D printing,” Matt Garbarino, Marketing Manager for Cincinnati Inc. told TCT at the time. “So we volunteered to do the 3D printing part since we knew we could make a large-scale replica of this capsule.” NASA’s Orion spacecraft was built to take humans farther into space than they’ve ever gone before and will launch on NASA’s new heavy-lift rocket, the Space Launch System. The spacecraft will serve as an exploration vehicle that will carry astronauts to deep space, provide emergency abort capability, sustain and protect the crew, and provide safe re-entry from deep space return velocities. Faro 3D scanned a model of the spacecraft at the Kennedy Space Center Visitor Complex and the file was prepared by Direct Dimensions. 150 small-scale replicas were 3D printed by Met-L-Flo and distributed to visitors at the show. Florida Tech students were also on hand to take part in the scanning process and discuss how the next generation of manufacturing professionals are being educated on advanced manufacturing technology and applications. Finally, the large-scale replica was produced by Cincinnati Inc. with its renowned Big Area Additive Manufacturing (BAAM) technology and

030

VOLUME 2 ISSUE 2 www.tctmagazine.com

ABOVE: 3D printed replica of Orion

Crew Module

Where we have seen the biggest attraction is actually in tool or mould making and rapid prototyping

BELOW: Kayak shows three stages of 3D printng

assembled during the exhibition. The version we saw on the show floor was fresh from the printer and though it hadn’t undergone any finishing, the model allowed visitors to take a closer look at what is possible with large-scale printing technologies. Cincinnati is known for its large-scale prints and they had several big examples on display including a kayak which demonstrated three typical phases of 3D printing from the raw print straight off the machine, to coating in this case with polyurethane and then painting, along with a scaled-down F22 Raptor, which was finished to completion. Cincinnati Inc. is a 117 year old company and supports both traditional and additive techniques. Its BAAM technology is available in two sizes; a smaller machine with a 6ft. (W) x 12 ft. (L) x 3 ft. (H) print envelope and a larger machine that’s probably most well-known for producing the much hyped 3D printed car with its first customer, Local Motors. TCT spoke to Cincinnati Inc. on the RAPID show floor about the technology and the kinds of projects currently coming through the door. “Where we have seen the biggest attraction is actually in tool or mold making and rapid prototyping, which would make sense,” Matt explained. “It’s really varied in industries, from aerospace to automotive to marine and really, what’s dictating our path is the customers that approach us and what products we think we’re able to tackle.” The displays from Cincinnati Inc. formed part of a bigger exhibition theme at this year’s event which included the world’s the world’s largest, fastest and most complex 3D printed UAV produced by Aurora Flight Sciences with Stratasys technology, and featured in the last issue of TCT magazine. 

nd 2500 ge of hout

RAPID REVIEW ACCELERATING 3D TECHNOLOGIES

SPONSORED BY

In the land of the additive manufacturing of metals, whether it is melting powders or the deposition of metals, laser technologies have ruled the roost for some time. At RAPID 2016 a new player with a totally new, and laser free, technology for the 3D printing of metals entered the field.

WORDS : DA NIE L O’ C ON NOR

XJET SYSTEMS

ARE GO

sing a process d u b b e d ‘NanoParticle Jetting’ XJet used the Orlando show to unveil its metal 3D ink jet system created by the founder and former CEO of Objet, Hanan Gothait. “NanoParticle Jetting is the culmination of many years of research in our labs with the highest caliber of developers and scientists including many PhDs,” said Hanan, now CEO and Founder of XJet. “It is a landmark in the additive manufacturing industry having registered more than 50 patents. NanoParticle Jetting overcomes many challenges that Additive Manufacturing has faced until now, and we are very proud of the results.” At AMUG 2016 Chief Business Officer of Xjet, Dror Danai - himself a former Objet man - joked that XJet did not stand for “Ex Objet Employee” (it actually was a temporary name that Hanan used and grew to like). The strides that the company has already made in the 3D printing of metal using inkjet technology can be largely attributed to the experiences at Objet the team is able to draw from. XJet Markets Development Manager, Avi Cohen, another former Objet employee, who has made the switch over to the new project. Having been hired by Hanan himself 16 years ago Avi’s last role was Director of Global Dental Sales and Marketing at Stratasys but this fresh challenge, working with old friends was too good an opportunity to pass up. “We’re not just a start up of three guys,” Avi told TCT. “A problem that may have taken ten years to solve before took me ten days when I got to XJet.” This know-how has meant before their launch XJet were able to draw huge investment – the last funding round saw the Israeli company raise $25 million from Catalyst CEL Fund and Autodesk – and display a fully working technology to the RAPID crowds.

BELOW: XJET

Machine

That technology, NanoParticle Jetting, uses inkjet heads to disperse XJet’s unique materials – including silver and stainless steel, developed in-house to suspend a metal particle inside a liquid bubble that evaporates once it is laid onto the bed leaving only the metal. The ultra-fine metal particles bind together to form a solid shape that requires a further sintering process that Avi Cohen describes as like “baking a pizza”. Not only does this process do away with the laser but also the metal handling process, you simply insert XJet’s cartridges into the system and it uses the



BELOW: NanoParticle Jetting

required amount of metal for said print. Adding to this almost plug –and-play simplicity is the ability to use a separate material for support, meaning the postprocessing of parts does not require delicate hand finishing often required for other metal processes. “The mere fact that we are using two different materials; one for the model itself, the metal itself, and the other one is exclusively to support the structure is unique,” CBO, Dror Danai told TCT. “The usage of two different materials allows us to, virtually, reach any geometry. That opens a lot of new applications for metal additive manufacturing that may have been difficult or limited before.” The parts on display at RAPID showcased the machines ability to print super fine details and moving parts, this interesting new technology along with the vast experience of the some 60 staff means XJet are certainly one to keep your eye on. 

VOLUME 2 ISSUE 2 www.tctmagazine.com

031

International exhibition and conference on the next generation of manufacturing technologies

Frankfurt, Germany, 15 – 18 November 2016 formnext.com

Touch tomorrow! Over four days in November, professionals of the industrial manufacturing industry will meet in Frankfurt am Main, Germany to be inspired by solutions designed to bring product ideas to life more quickly and efficiently. With its unique combination of additive manufacturing and conventional technologies, formnext powered by tct presents the next generation of intelligent manufacturing solutions – from design all the way to mass production. It will definitely be worth the trip, so don’t miss out!

Where ideas take shape.

Exhibition Movie 2015

Information: +49 711 61946-825 formnext@mesago.com

@ formnext_expo # formnext16

nd 2500 ge of hout

GUEST COLUMN ACCELERATING 3D TECHNOLOGIES

SPONSORED BY

The current trends that I see that will be transformational are centered on the integration of industrial 3D printing into traditional machine tools and machining lines.

David Burns

is the Principal and Founder of Global Business Advisory Services LLC, an international advising firm specializing in the field of manufacturing technologies. With more than 35 years of experience, David provides insight to businesses and individuals focused on industrial and manufacturing processes ranging from traditional manufacturing to 3D printing. www.gbadvisoryservices.com

Is the REVOLUTION HERE? AT RAPID 2016, I saw and heard multiple claims that exhibiting companies were there to “revolutionize manufacturing”. That phrase has become over-used and almost trite. By definition, “revolutionize” means to “change something radically or fundamentally”. Do the newest forms of 3D technologies meet that criteria? In the context of many centuries of manufacturing, I think not. That said, are there fundamental trends in 3D printing that will, in fact, transform manufacturing? The answer in my eyes is an absolute yes. For at least 30 years, manufacturing practitioners have embraced the idea of pursuing an optimal state in manufacturing – one in which there is zero waste. Our training in Lean Manufacturing tells us that the journey to that optimal state is never through, but that each step along the road yields immense benefits to companies involved in manufacturing (like lower costs, shorter lead times, bigger profits), to customers (through more customized products at lower prices) and to society (using less resources to create greater output, raising the standard of living). The current trends that I see that will be transformational are centered on the integration of industrial 3D printing into traditional machine tools and machining lines. There are a few different ways that this is being done: • Some traditional machine tool builders are adding 3D printing “stations” within machines that contain other machining capabilities. Thus, using pallets, the user can add material in a 3D printing process and then index the part into a station for machining of the part, including sections that were 3D printed. • Other machine builders are showing machines that allow parts to be 3D printed in their entirety, with machining operations possible on-machine, during the 3D printing process. • Finally, a new idea is emerging of rotating a 3D printing head through the tool changer, just as tools and inspection devices are carried in the tool changer.

W O R D S : DAV I D B U R N S

I do not want to comment upon the strengths or weaknesses of each approach. Instead, let’s look at these from a macro-trend perspective. A few years ago, industrial 3D printing was basically in the experimental stage, and in stand-alone configurations. Now, just a few years later, major machine tool companies are embracing industrial 3D printing and integrating it into their core products and processes. This rate of adaptation by major machine tool companies is very significant, not only because it validates that industrial 3D printing is feasible, but also because the significant resources that these machine tool companies can apply to product development far exceed the resources of companies that were involved in industrial 3DP a few years ago. The natural result of machine tool companies entering the 3D printing market will be a further and rapid acceleration of product development. Additionally, machine tool companies understand all of the factors that are required to make products really operate in a manufacturing plant – from reliability to service to the supply chain required in a production environment. Resulting products will be more robust and production-ready. The emergence of multi-function machine tools that have 3D printing capability, combined with the sort of companies producing those tools, means that we have taken a significant step toward embedding 3D technologies into the production process. That, in the end, is truly transformational. I think back to the teachings of people like Taiicchi Ohno (considered by many to be the father of the Toyota Production System) and Richard Schonberger (the author of World Class Manufacturing). I believe that both would be convinced that the current trend of multi-function machines - that have embedded 3D printing - represent steps forward on the journey towards lean optimization. While not a revolution, this DOES change manufacturing forever. 

VOLUME 2 ISSUE 2 www.tctmagazine.com

033

3D Printing

RAPID REVIEW ACCELERATING 3D TECHNOLOGIES

family of MultiJet Printing, the MJP 2500 and 2500 Plus, are designed to enable a broader range of professionals to create precision parts without leaving their workplace.

SPONSORED BY

Learn more at www.3dsystems.com/2500

Directly from CAD WOR D S : Da n i e l O ’C o n n o r

BELOW:

Full color shoe prototype

Fresh from a hugely successful launch of the new J750, Stratasys strode into RAPID armed with a collection of incredibly photorealistic colour parts printed on the latest addition to the Objet Connex Family. The new multi-colour, multi-material PolyJet machine was printing incredibly detailed prototypes alongside its FDM Fortus counterparts and in the future they will be printing thanks to a software package Stratasys launched at RAPID, GrabCAD Print.

“GrabCAD print runs in the cloud,” Stratasys’ Senior Vice President of Global Software, Jon Stevenson told TCT. “You can access it from anywhere, from any computer, you can check your print jobs over the phone, you can check it on your mobile app.” Stratasys acquired GrabCAD - the world’s largest community of mechanical engineers - back in 2014 and has been working bringing the community ABOVE: on Multi-material greater access to its range medical model of 3D printing solutions. The new GrabCAD Print software allows that community to print directly from CAD, negating, Stratasys say, the sometimes-tricky conversions in order to create a 3D printable file from CAD software. “STL files have been around for almost 30 years but now you don’t have to create them anymore,” explained Jon. “Using GrabCAD print you can simply retrieve your Solidworks file, Creo file or any CAD file and print it.” This investment in software showcases how Stratasys, like many of the big companies, is seeking to offer users end-to-end solutions. The new app will be available in BETA later this summer with additional rollout throughout the year to the 3 million designers on the platform. GrabCAD

Print will allow users to get more out of their printers by integrating features like print schedules and real-time notifications, it will also unlock the full potential of new machinery. “To fully expose the hardware capabilities of the J750 you need new software,” said the Senior VP. “That’s part of the GrabCAD print mission. The J750 is great for people doing industrial design, people that care about the cosmetics of their part, but it’s also a great printer for vertical applications like medical. People want to print MRI models and use them in surgical training, surgical planning and print surgical guides for use during the surgery itself.” Interestingly, although Stratasys are a member of the 3MF Consortium, which is all about replacing the STL with a new format that makes it easier to print with added data like colour, GrabCAD Print actually does away with the business of file formats altogether, well at least for the end-user. “You should be able to use GrabCAD print without any training whatsoever,” Jon stated. “If you can use your iPhone, if you can use the web, you can use GrabCAD print. It’s simple and easy to use.” 

Free Stratasys Webinar on www.tctmagazine.com/webinars

The Benefits of 3D Printing for Your Business Learn how 3D printed molds can cut turnaround time for your injection molded (IM) prototypes. Stratasys will discuss when 3D printed molds are a best fit, material selection and customer stories, as well as process limitations and tips for successful molding. 3D printing is at the front lines when it comes to the future of business technology. In this dynamic webinar, two industry experts will

engage in a lively discussion of what 3D printing can do for your business. Marketing expert Bruce Bradshaw from Stratasys chats with Dr. Kevin Dowling, the lead engineer at 4Moms, a company dedicated to making innovative baby products. Tune in to gain essential information on how to strengthen, modernize and accelerate your business through 3D printing. www.tctmagazine.com/webinars VOLUME 2 ISSUE 2 www.tctmagazine.com

035

nd 2500 ge of hout

RAPID REVIEW ACCELERATING 3D TECHNOLOGIES

SPONSORED BY

New Tricks Daniel O’Connor takes a look at how EnvisionTEC pulled a rabbit out of the hat at RAPID 2016.

ABOVE: The EnvisionTEC team

unveil the SLCOM 1 at RAPID

W OR DS : DA NIE L O’ C ON NOR

It’s fair to suggest that recent developments in resin-based 3D printing had some industry experts at least contemplate, EnvisionTEC’s standing in the upper echelons of 3D printing manufacturer royalty. Many wondered what kind of effect Carbon’s promised speed, Formlabs’ consistent development or the heft Autodesk were putting behind Ember would have on one of the industry’s traditional big players. When whispers began to circulate that EnvisionTEC was to launch something significant at RAPID, it was safe to assume that it would be an upgrade to its existing technology. That, like 3D Systems with the SLA-bot1, it would launch its answer to the glut of systems using “Continuous”

resin printing. However, as EnvisionTEC CEO, Al Siblani prepared to launch the company’s brand new machine to the waiting RAPID crowd, it was evident from the gargantuan device too big to hide behind curtains that this would be a totally different beast. “In keeping with EnvisionTEC’s traditions of being first to market we’re very excited to launch the brand new technology of SLCOM, which stands for Selective Lamination of Composite Object Manufacturing,” Siblani told TCT at the time. “It’s a new technology that allows you to build thermoplastic reinforced composites with different types of fibers and different types of thermoplastics to create materials and parts that have

Create materials and parts that have never been done before in the Additive Manufacturing (AM) space

never been done before in the Additive Manufacturing (AM) space.” The SLCOM 1 is quite the departure for the company known for its high-resolution smaller machinery suitable for precision projects like jewelry and dentistry. This machine EnvisionTEC say is the first and only thermoplastic reinforced woven composite 3D printer, capable of manufacturing parts in materials like PEEK, Polycarbonate, fiberglass and carbon fiber. COMPOSING COMPOSITES Traditional processes of manufacturing composite parts involve intensive manual labor and that’s after sheets have been cut using a CNC. Laying up sheets of differing composites over ››

VOLUME 2 ISSUE 2 www.tctmagazine.com

037

nd 2500 ge of hout

RAPID REVIEW SPONSORED BY

epoxy molds cutting to exact size, vacuum sealing, baking and post processing is all done by hand. The advancements in materials available over the past decade have meant that, despite this labor intensive process, investing in composites has been worthwhile to countless sectors from aerospace to sporting goods. Any ability to shorten the process would be thoroughly welcomed. There are only a few other companies offering a composite 3D printing solution on the market at the minute including Markforged, whose Mark One and Two series of printers are desktop machines that embed strands of composites into matrix thermoplastic materials; and Impossible Objects, whose beta machine takes sheets of composite material prints a thermoplastic onto each layer and is then baked in the oven in order to fuse the layers together. EnvisionTEC’s SLCOM1 is a step towards a more industrial offering from a company with almost two decades of building machinery. With an impressive build envelope of 24 inches in Y, 30 inches in X, and 24 inches in Z Al Siblani said the

038

VOLUME 2 ISSUE 2 www.tctmagazine.com

ABOVE: Model printed on SLCOM 1 machine’s sizeable build volume was “significant enough to appeal to many industries.” Using rolls of pre-impregnated thermoplastic composites, there are three main obvious innovations in the mechanics of the SLCOM 1; the use of an ultrasonic cutter to eliminate fraying on the cut of the thermoplastic sheets; a rotating platform that allows for multi-directional layering of the composite sheets, which can be turned clockwise and counter clockwise in 15 degree increments thus significantly increasing strength; and the use of an inkjet-like head to spray an anti-adhesive around the outside of the plotted layer inhibiting the next sheet from sticking to that area, meaning removal of the excess material (AKA decubing) is exponentially easier. Those are significant advancements in the hardware but perhaps, as all good magicians

they’re acting as a distraction to another very revolutionary and hugely important part to SLCOM technology, the ability to deliver bespoke materials to the customer. Because of EnvisionTEC’s unique laminated roll system a customer can demand any combination of prepreged thermoplastic including PEEK, Nylon, polycarbonate mixed with the desired fiber making the SLCOM 1 a hugely versatile machine for the customer. RUNWAY TO SUCCESS The manufacture of composite parts is a massive departure for EnvisonTEC this much is clear, but it is one that has been carefully deliberated and seemingly impeccably executed. Al Siblani told TCT more at RAPID: “When you look at the 3D printing and AM space in general we found that there’s a huge attraction in metal AM especially coming from the aerospace sector,” said Siblani. “But there are too many players in that space. We thought about an area where we could go and develop a technology in an uncrowded space and when we looked at the

RAPID REVIEW ACCELERATING 3D TECHNOLOGIES

We’ve had some great and amazing reaction from the aerospace industry. composite market, specifically carbon fiber and fiberglass we found out that there’s no actual player in the space for AM and given that aerospace companies spend 50% or more of their budget on composites we thought that would be the right place for us to invest in.” Siblani, like all CEOs, has always talked a good game so perhaps we should take that 50% as ambitious but if the Boeing 787 is anything to go by then that stat is dead on the money. The “Dreamliner” – Boeing’s largest passenger jet is made up of exactly 50% composite parts, the previous model, the 777, was made up of just 12% composite material. Boeing’s main rival, Airbus, are currently flight testing the A350 XWB that comprises of 53% composite material, not only that but the XWB is the same plane that we were told has over 1,000 3D printed parts on board from the Concept Laser’s LASERcusing bracket to the Stratasys’ multiple FDM internal parts. In her 2013 report into “The use of composites in aerospace: Past, present and future challenges”, Dr. Faye Smith of Avalon Consultancy Services Ltd concluded that: “Environmental regulations have meant that the cost of introduction of lightweight composite structures is now often offset by the gains and has significant increase in the use of aerospace composite structures.” But that a current challenge was the “development of rapid rate manufacturing process.”

5ABOVE: Boeing 787 materials chart Plenty are trying to create a solution for this challenge, Hexcel – one of the largest suppliers of carbon fiber in the US – have announced a strategic investment in Oxford Performance Materials to advance composite 3D printing in aerospace. Hexcel’s CEO commenting; “Aerospace adoption of reinforced manufactured parts using Hexcel carbon fiber is becoming a viable and meaningful design solution due to its performance and processing advantages. With the adoption of these lightweight, high-performing materials expected to accelerate, this is an ideal opportunity for our two companies to work together enabling faster product development and adoption for our customers.” It comes as no surprise then that Al Siblani told TCT at RAPID, “There’s a lot of people in many industries that have expressed excitement in SLCOM technology already. We’ve had some great and amazing reaction from the aerospace industry.” By not joining the metal 3D printing game, circling the airport, waiting to land that major aerospace client, the SLCOM technology has EnvisionTEC signalling them in to their own private airfield. Of course, there’s room for both technologies on the factory floors of conglomerates like Airbus and Boeing each offering their own unique features. SLCOM, for instance, is unlikely to be able to create the complex internal

structures that generative design creates. STEALTHILY DOES IT The SLCOM 1 project has been in the making for a number of years and goes someway to explaining why EnvisionTEC staff seemed to exude a confidence in their company like no other, they knew they had a trick up their sleeve that they’d shock the industry with. There are several reasons why EnvisionTEC were able to keep SLCOM under their hats for so long, firstly Al Siblani likes to demonstrate running technology rather than concepts at trade shows and it is likely that the SLCOM 1 was only finished shortly before being displayed at RAPID. Plus, unlike many of the other industry big boys, EnvisionTEC is a private company, in an interview with the BBC recently the top British fashion designer, Paul Smith, said that a big advantage of still being a private firm is that you don’t have “shareholders breathing down your neck the whole time”, the same may well apply to Al Siblani and company, they don’t have to placate anyone every single time a new piece of technology comes to market, they can go about their business quietly and efficiently. And for their next trick, less than a month after RAPID, EnvisionTEC announced that Continuous DLP method we were all expecting them to.  For more information visit www.envisiontec.COM

VOLUME 2 ISSUE 2 www.tctmagazine.com

039

Redefine your design

Bracket for a satellite produced on a Renishaw AM250

Explore the potential of additive manufacturing Renishaw’s additive manufacturing systems use powder bed fusion technology to produce fully dense complex metal parts direct from 3D CAD. Also known as 3D printing, this technology is not constrained by traditional manufacturing design rules. Create complex geometries such as conformal cooling

channels for tooling inserts, reduce component weight by only placing material where it is needed, and consolidate multiple parts in one assembly. Additive manufacturing is also complementary to conventional machining technologies, and directly contributes to reduced lead times, tooling costs and material waste.

■

No requirement for tooling.

■

Increased design freedom—complex geometries and hidden features.

■

Rapid design iterations right up to manufacture.

Renishaw.com/additive

Renishaw Inc Hoffman Estates, IL www.renishaw.com

Additive TCT 12_15.indd 1

10/27/15 5:11 PM

and

Accurate • Repeatable • Economical Stereolithography Systems en.union-tek.com

RPSA3D.com | 641.204.2357

nd 2500 ge of hout

ACCELERATING 3D TECHNOLOGIES

SPONSORED BY

Rapid Review 3D SYSTEMS

Continuing its 30-year anniversary celebrations, 3D printing pioneer, 3D Systems was out to remind North America’s additive manufacturing community why it’s still leading the way.

WOR D S : L A U R A G R I F F I T HS

NLIKE THE MANY new machine launches at this year’s event, the theme on 3D Systems’ booth was that 3D printing is about much more than just a 3D printer but rather an entire ecosystem of processes, materials, services and more. Displaying everything from its comprehensive end-to-end healthcare solutions to its vast partner network, the additive manufacturing giant had the entire process chain covered. “Our customers have great ideas - we partner with them and come up with a solution,” Charlie Grace, Chief Revenue Officer at 3D Systems commented. “It’s more than just the printer itself, more than the material, it’s the actual solution.” Stretching further than its own booth, there were more than 20 stands dotted around the exhibition flying the flag for 3D Systems and demonstrating the many partnerships the company has developed over the years. One of those was metal 3D printing service bureau 3rd Dimension, which exclusively uses 3D Systems’ machines and accompanying Geomagic software solutions in its Indianapolis workshop. Bob Markley, founder of 3rd Dimension told TCT how the bureau is “unbelievably excited” about the growth of metal 3D printing technology and how 3D Systems’ metal solutions have changed the way they look at manufacturing. Neighbouring company and 3D measurement expert, FARO Technologies was also on hand to demonstrate its latest partnership with 3D Systems, which saw the launch of two Geomagic software bundles for its new FARO Design ScanArm tailored to 3D modelling, revere engineering and CAD-based design applications. “FARO and 3D Systems share a similar philosophy and that is that we need to solve a problem, we need to develop a complete end-to-end solution, and you cannot provide that without 3D scanning, you cannot provide that without the modeling and software and you cannot provide that without the printers,” Gannon O’Reilly, Product Marketing Manager at Faro

Technologies. “Having a really deep understanding of our customers needs, and their workflows and their processes, and coming to them with bundled solutions that meet each and every one of their needs is the way we best provide our customers value.” Of course, development is still very much alive on the machine front and alongside the company’s flagship ProJet MJP 3600 3D printer and multi-material ProJet MJP5500X, 3D Systems displayed its latest addition to its MultiJet series. The ProJet MJP 2500 is an entry level, affordable, professional grade 3D printer that’s designed to fit seamlessly into the office. Offering five different materials including rigid and elastomeric, the machine addresses various prototyping applications for a number of industries. “We have some amazing printers out there but people are really looking for really functional prototyping materials as well as production materials,” Derek Johnson, Product Manager at 3D Systems, commented. “So we see a lot of opportunity not only with the ProJet MJP 2500, but with all of our technologies that we offer with 3D Systems to really move into functional end-use parts” It’s fair to say that 3D Systems used its AMUG 2016 presence and surprise SLABot2 demonstration to reaffirm that it’s continuing to shape this industry as it did back in 1987 when SLA was first born. Just a month later, the feel at RAPID was a little different and rather than setting out to impress with yet another new piece of innovative tech which you might expect from such a huge event, the goal was to give real, tangible examples of how the company is championing every section of the industry with a competitive ecosystem of materials, software, on demand manufacturing services, partner network and not least, 3D printers. “We work with a whole community of partners worldwide that share our printing technologies but also share the end-to-end solution,” Gina Strickland, Director, Global Sales & Channel Strategy, Software at 3D Systems, explained. “We’re very proud of the network we’ve created and I think that it leads back to the years of experience and that trust that we have with the community, and bringing these technologies to them.” 

Our customers have great ideas - we partner with them and come up with a solution

VOLUME 2 ISSUE 2 www.tctmagazine.com

041

Combining professional-grade capabilities with an affordable, office-friendly footprint and easy part processing, the newest series of 3D Systems’ family of MultiJet Printing, the MJP 2500 and 2500 Plus, are designed to enable a broader range of professionals to create precision parts without leaving their workplace.

RAPID ALLERY G

SPONSORED BY

Learn more at www.3dsystems.com/2500



ABOVE: 3D printed accessories on the catwalk at the popular 3D printed fashion show.



LEFT: The 3D Art Gallery showcased how 3D technologies are being applied creatively. This piece, Duet was designed by Aaron Trocola and produced on a MakerBot Replicator 2.

042

VOLUME 2 ISSUE 2 www.tctmagazine.com

BELOW LEFT: 3D Platform brings large-format 3D printing to the show

floor with the upgraded 3DP1000 machine.

BELOW: Metal 3D printed medical implants.

RAPID REVIEW ACCELERATING 3D TECHNOLOGIES



FROM LEFT: Kick-off event panel discussion featuring Kevin Creehan from America Makes, Leo Christodoulou from Boeing and Barbara Negroe at GE. Todd Grimm gives a keynote presentation on key trends in the industry.



RIGHT: Mazak talk hybrid technologies and the i400AM on the LaunchPad stage.

LEFT: Another print from

the 3D Art Gallery, ‘Twenty Something Sullivan Architectural Ornament’ by Tom Burtonwood captured with Artec Eva 3D scanner



LEFT: LulzBot launched the latest evolution in the TAZ line of 3D printers, the LulzBot TAZ 6.

ABOVE: Originally spotted in the last issue of TCT, the world’s

largest, fastest and most complex 3D printed UAV from Aurora Flight Sciences printed using Stratasys technology.

BELOW: Ramon Pastor speaks in the HP theatre about the

launch of its Jet Fusion 3D Printer.

VOLUME 2 ISSUE 2 www.tctmagazine.com

043

nd 2500 ge of hout

RAPID REVIEW SPONSORED BY

HP and the

MIGHTY VOXEL ABOVE:

Chain link could feature embedded technology in near future

It’s the news we’ve all been waiting for, nearly 18 months after a packed out press conference in New York where HP first uttered the words Multi Jet Fusion and signalled a ‘reinvention’ of 3D printing, the computer technology giant’s big 3D debut has finally been unveiled as the HP Jet Fusion 3D Printing Solution.

ACK IN MAY, HP invited a group of select media to its huge Barcelona campus to share its big news and fill us with enough tapas to last us a lifetime (that’s not true, you can never have enough 600 Euro ham). In a super slick grand unveiling - strobe lights, curtain lifting and all - we were able to catch a glimpse of the company’s first 3D printing systems, a full end-to-end solution that went on display publically for the very first time at RAPID in Orlando. But if you are as eagle-eyed about floor plans as us, you wouldn’t have expected anything less from the two mammoth booths HP had locked for North America’s biggest 3D technologies event. Far from the mock ups we saw back in 2014, HP has delivered two 3D printing systems – the HP Jet Fusion 3D 3200 Printer and the HP Jet Fusion 3D 4200 Printer – the former designed for prototyping and the latter for short-run manufacturing. Though the final package may look different, the company is right on track for the goals it set itself in the beginning: superior part quality, breakthrough productivity and to lower cost-per-part by 50%.

044

VOLUME 2 ISSUE 2 www.tctmagazine.com

“Our unique position today is, we very much have a focus on production manufacturing,” Stephen Nigro, President of HP’s 3D Printing Business, explained. “We’re going to serve the prototype market and we definitely have a focus on production because that’s really the market opportunity. The open market approach we’re taking will be essential to the industry.” As promised, HP is offering competitive print times and equally impressive cost-per-part numbers. Using SLS as its benchmark, it’s ten times faster and parts can be printed at half the cost of current systems – for a small part like a cog, it’s claiming users could 3D print around 5,000 in a day. The platform uses a unique dual-carriage, multi-agent printing process whereby a layer of powder is deposited onto the build platform (406 x 305 x 406 mm) followed by a fusing and detailing 3D Agent, which are passed in a second movement by HP Thermal Inkjet arrays. Energy is then applied to catalyse the fusing agent and a new layer of material is deposited.

The open market approach we’re taking will be essential to the industry.

RAPID REVIEW

The machine can produce functional parts at the individual voxel level (the 3D equivalent of 2D printing pixels) and has the ability to address over 340 million of these per second for a single layer. The benefit of this is not only rapid build speeds but also the ability to manipulate part properties at the tiniest level. MORE THAN JUST A 3D PRINTER Perhaps the biggest surprise of all was the reveal of an accompanying Processing Station. In what HP describes as a “pain point” for the industry, through months of collaboration and conversations with users already active in the industry, the idea for a postprocessing machine was born. A tour around HP’s 3D Printing Lab revealed around 10 iterations of the printer, a working display of the machine’s evolution, but most importantly, the workshop showed barely any signs of powder spillage, no need for safety glasses or overalls but instead a tidy and smooth working environment. Parts travel from the printer housed in a separate build unit across to the Processing Station, which is synced up with the printer, eliminating the need for manual handling and any unnecessary mess. Prints come out of the machine looking near on finished, requiring only one additional process such as sandblasting. On top of that, the machine is also used to recycle material. Any excess powder is filtered back into the system mixed with a portion of clean powder from a fresh cartridge and deposited back into a container ready for transporting to the next build. The cartridge system resembles that of which we’re used to experiencing in the 2D world where slot-in cartridges, in this case filled with powder, are used to make it as clean and pain free as possible. “We knew some sort of post processing was needed and since we had this very early customer engagement process where customers were in the lab with us it became very apparent that there was a real need to improve the workflow,” Stephen added. Scott Schiller, VP Market Development at HP 3D Printing, commented: “We have model shops all over the world and we have 3D printing technologies that we have been using for many years. The observation was that for a powder-based technology we really want it to be an experience where it’s not difficult - it’s taking friction out of adoption. We want that workflow to be so smooth and clean that people forget that there’s a powder approach.”

ACCELERATING 3D TECHNOLOGIES



RIGHT: HP 3D Printer

It needs to be so powerful that it’s not just economically justified - it changes a corporate or institutional behaviour

On the software side, HP has introduced HP SmartStream 3D Software, a cloud-enabled, in-box solution that’s designed to streamline the design to print workflow and provides useful features like time and cost estimators. SmartStream currently supports both STL and 3MF but as one of the 3MF Consortium’s founding members, HP were clear about their intentions to eventually do away with STL in favour of its successor which is better equipped to support its voxel level control. INTEGRATING INTELLIGENCE Since its initial announcement, HP has focused heavily on promoting an open approach and they’re keeping to that focus in two ways. The first is through partnerships with companies who are already leaders in the 3D printing industry like BELOW: Materialise, Shapeways, Proto Labs, Jabil and HP Build Unit Siemens who have each been working with HP to trial the technology and d e v e l o p s o f t w a r e solutions. “We’re unabashedly very open in terms of how we engage the market because there are a lot of people who have been in this space for quite some time and we have found the market to be amazingly receptive and I think everybody has been looking for the catalyst,” Scott added. “Historically it’s always been about barriers to entry and control and what we see is that power moving from a very vertical focus to ›› VOLUME 2 ISSUE 2 www.tctmagazine.com

045

nd 2500 ge of hout

HP LAUNCH SPONSORED BY



RIGHT: HP Processing Station

one that’s a bit more horizontal, it’s about the relationships and the partnerships and what comes as a function of that – we believe we can only be successful by partnering very successfully.” The second way it’s opening up the platform is through material development working with certified partners like BASF, Evonik, Arkema and Lehmann&Voss&Co. Initially, the machines will be available with HP’s own 3D High Reusability PA12 material (solely in black because it’s age resistant and according to Stephen “a good starting point” for functional production) but in the future this will expand to include more HP developed and certified partner materials featuring colour, ceramics and eventually embedded intelligence. Intelligent material properties are perhaps one of the most exciting prospects and HP suggest that in the future, voxel level control will allow us to embed sensors which can be used to alert the user if a part is under stress. For example, in something like the famous chain link we saw back in 2014, an LED or colour indicator could show when layers have been removed through wear and

tear. HP envisions driving this further by offering a Material Development Kit, which will initially allow companies and eventually universities to create their own HP approved materials. LIVING UP TO THE HYPE It’s clear that HP is confident it can achieve the same in the 3D market as it has done in the graphics industry – so confident in fact that we could see future short run HP products manufactured with Jet Fusion printed parts. In fact, 66 parts in the Jet Fusion Solution itself have been printed using the tech - a novel way of proving part functionality and we’re told this number could increase to around 50% of its total parts in the future. In doing so, HP is demonstrating how Jet Fusion could be bordering closely on rivalling injection moulding in cases where the benefits of printing for a small batch production run outweigh that of injection moulding. HP showed us some confidential data where Jet Fusion offered substantial savings in terms of reduced inventory, logistics costs and overall cost-per-part.

They’re already working with highprofile brands like Nike where Jet Fusion has been used to accelerate the sportswear giant’s prototyping and manufacture of high-performance footwear. BMW is also an early adopter using HP’s technology to further investigate the potential of 3D technologies in its prototyping and concept modelling capabilities. “The way we describe our value proposition objective is that it needs to be so powerful that it’s not just economically justified. It’s so powerful that it changes a corporate or institutional behaviour,” Scott added. “That is something that I think we’ve become quite good at over the last 15 years.” Delivery of the HP Jet Fusion 4200 is set to commence later this year and the 3200 will follow in 2017. Standalone machine prices start at $130,000 and the full solution including Processing Station will be available from $155,000. Before writing this article I went back and read our Head of Content, Jim’s report on HP’s New York launch just to see if the promises made have in fact remained true. It’s hard to say just yet if they will ‘lead the business’ as Meg Whitman, now President and Chief Executive Officer of Hewlett Packard Enterprise, proposed but the key drivers – cost, speed and quality, remain high on the list of targets. HP isn’t shying away from its mission to ‘win in 3D’ and with so much opportunity in the open market, if they stick with their key goals, there’s a very good chance their impact will be significant. As Stephen Nigro said during the launch, “the amazing thing is we’re just starting” and though we might not see these pivotal shifts right away, it will be interesting to see how the industry takes to the technology and where HP’s roadmap will lead. 

ABOVE (L-R): Functional print sample. MIDDLE: Comparison between Jet Fusion, SLS and FDM. RIGHT: Flexible part sample 046

VOLUME 2 ISSUE 2 www.tctmagazine.com

Large format stereolithography machines from Z

ACCELERATING 3D TECHNOLOGIES

THE DIRECTORY

Rapid Technologies

• Fast • Precise • Affordable

TCT business card ad_March 2016.indd 1

2/19/16 10:42 AM

For sample prints and estimates please contact info@CustomPrototypes.com

TAKING YOUR

IDEA

TO THE NEXT LEVEL Industrial Design . Engineering Product development Innovation . Prototyping www.grunetechnica.com t.503.667.4100

MIDWEST PROTOTYPING

3D Printing, Rapid Prototyping, and Low Volume Production specialists - for over 15 years

w w w.midwestproto.com Advanced Additive Manufacturing 3D Metal Printing, Rapid Prototyping, Conformal Cooling, Engineering, Production Featuring PrintRite3D® In-Process Quality Assurance with every Build

w w w. sigmalabsinc .com +1 - 505 - 43 8 -2576

TO ADVERTISE HERE

CONTACT CAROL HARDY ON +44 1244 680222 or email carol@rapidnews.com VOLUME 2 ISSUE 2 www.tctmagazine.com

047

nd 2500 ge of hout

GRIMM COLUMN SPONSORED BY

One audience member asked what AM technology I would buy if given $1 million.

Todd Grimm

is a stalwart of the additive manufacturing industry, having held positions across sales and marketing in some of the industry’s biggest names. Todd is currently the AM Industry advisor with AMUG

tgrimm@tagrimm.com

048

THE MILLION DOLLAR QUESTION

S THE TCT TEAM has reported, RAPID 2016 was home to many interesting and exciting product announcements. HP provided the long-awaited launch of its Jet Fusion systems, Carbon demonstrated its M1 and announced three new materials, EnvisionTEC surprised attendees with its SLCOM 1 composites printer and XJet debuted NanoParticle Jetting for metal additive manufacturing. Many others joined these companies with introductions of hardware, software, material and service solutions. Prior to these announcements being made and before the opening of the show floor, I offered a fast-paced presentation of what’s new in additive manufacturing (AM). In 45 minutes, over 80 items covering R&D efforts through product launches were summarized, and the list could have been much longer if time allowed. All of these activities show that additive manufacturing (AM) is in a truly dynamic and fast-paced era of new solutions, some of them true innovations. The array of options is simply mind boggling and a bit overwhelming — at least according to those that drank from the firehose during my presentation. This was evident when one audience member, seeking to cut to the chase and distill the options into some semblance of clarity, asked what AM technology I would buy if given $1 million. That question, at least as it was posed, has no answer. There is no simple, easy path to AM technology selection and no universal answer for all. Another audience member reinforced this position by noting that he had made a purchase based solely on price and envelope size. When his shiny, new system arrived, he discovered that much of what he intended to do was not possible. His is a story shared by countless others that did not do their homework. The reason for the challenge in making a sound buying decision is that there isn’t a single solution that does all things well for all applications. That is compounded by the reality that there are very few technologies that are equal, or even somewhat comparable, in all operational and output characteristics. While tempting to make quick work of the selection process by ignoring these facts, that approach may lead to disappointing results. The million-dollar question could only be answered after defining what success looks

VOLUME 2 ISSUE 2 www.tctmagazine.com

like for specific situations. Before sifting through all of the technology options — or naively writing a check for the latest and greatest — start by defining the desired applications and the products that will be additively manufactured, down to the component level. Next, determine what the requirements are for each combination of application and product. Finally, fold in the operational considerations like staffing, ease of use and running cost. Odds are that the resulting requirements are beyond what any one technology can do. So now it is time to ask the tough questions to ferret out what is truly important for success in the applications that are most beneficial. It is after this work that it becomes appropriate to investigate all the options that this dynamic industry offers and match them to your needs. That process covers performance specs, but it doesn’t fully answer the question of what to buy. Equally important is an evaluation of the reputations of the systems as well as the companies that offer them. A machine that looks good on paper but suffers from downtime issues or problems with some geometries won’t be ideal. For this reason, and the inevitable surprises with new systems, I recommend a wait-and-see approach for new products unless resources are available to work through any issues that arise. The offerings from HP, Carbon, EnvisionTEC and XJet are attractive and look quite promising, but I’d suggest waiting to hear the experiences of early users before adopting these new AM solutions. The converse of the million-dollar question is what technologies are in danger of becoming obsolete? That question also has no answer. The answer will only become clear with time, use and experience. More than likely, this dynamic age will create more difficulty in selecting the best technology. Rather than displacing established solutions across the board, odds are that new AM offerings will expand your options, increase potential applications and create more technology overlap. AM selection will not become easier in the near term. Without further insight, the only answer that I can offer to the million-dollar question is to buy two, three or four technologies. One technology won’t do everything so why not spread the investment across different AM solutions to increase the breadth of your applications. 

Bring your ideas to life and reduce your time to market. Hyphen is the most comprehensive additive manufacturing and environmental testing facility open to the public in North America. www.hyphenservices.com sales@hyphenservices.com