TCT Europe 31.6

3D PRINTING & ADDITIVE MANUFACTURING INTELLIGENCE

MAG EUROPE EDITION VOLUME 31 ISSUE 6

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GOING FOR GOLD Introducing Nikon SLM Solutions

Supply chain Honeywell on AM Forward & the MTC on the MoD

COnsumer goods

AM in smartphones & sports

Formnext

The new companies, products & applications to look out for

The right solution for every metal AM application VISIT US AT FORMNEXT: NOVEMBER 07–10, 2023

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VOLUME 31 ISSUE 6

ISSN 1751-0333

EDITORIAL

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HEAD OF CONTENT

Laura Griffiths e: laura.griffiths@rapidnews.com t: 011 + 44 1244 952 389 GROUP CONTENT MANAGER

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from the editor

FROM THE EDITOR LAURA GRIFFITHS

AM's new killer app Have you really been to an additive manufacturing (AM) conference if you haven’t seen at least once slide featuring a GE LEAP fuel nozzle?

Since its introduction in 2013, this aerospace application has been the poster child for 3D printing in industry, the pinnacle of AM adoption in critical environments as one of the first printed parts to be approved by the FDA, while simultaneously serving as evidence for just how long it can take for AM breakthroughs of this calibre to come through.

Another guaranteed dab on your AM conference bingo card will be the 'killer application', and as an industry, we are always looking for the next. If the recent TCT Asia 2023 Conference was anything to go by, we may have found it in Apple's alleged use of metal 3D printing for its latest Apple Watch series. Images of metal casings featured in several conference presentations, according to our team on the ground in Shanghai, and on the show floor on stands like that of metal binder jet company EasyMFG, which claimed to have produced components for the tech giant.

As you’ll read in our Consumer Products feature, the exploration of metal 3D printing in mass consumer electronic devices is growing. As HBD explain on page 19, the technology was chosen by smartphone manufacuturer HONOR for the production of its new foldable mobile phone due to its fine precision and lightweighting capabilities.

The Apple Watch story also came up during the recent AM Summit hosted by our RAPID + TCT partners

SME. In a room full of AM players, from vendors to end-users and supporting organisations, the idea of Apple potentially validating the technology for a wider audience was a welcome one in a conversation that focused on how we raise awareness around additive in order to deepen its adoption. The second part of the summit was about skills, but the two themes are interlinked: You can't have successful AM adoption without the right AM skills, but on the reverse, skills are only worthwhile if the technology adoption is there to demand them. In our Skills and Education feature on page 31, we speak to one UK-based facility that's tackling both sides of the coin through engagement with SMEs and students.

Elsewhere, we revisit the subject of supply chain with a look at how far the US Government's AM Forward initiative has progressed since its launch in 2022, while Sam speaks to an agriculture equipment manufacturer that's putting AM for supply chain in practice (p. 13), and the MTC shares how the UK’s Ministry of Defence is turning to AM to improve its supply of critical spare parts (p. 15).

And yes, it's that time of year again.

We round off this issue with our annual Formnext Preview (p. 37) which highlights just some of the technologies heading to Frankfurt this year. Who knows, perhaps we'll learn more about Apple's apparent adoption while we're there, but with many companies cautiously teasing big reveals and unseen applications, there'll no doubt be plenty of points for your AM scorecard regardless.

31.6 / www.tctmagazine.com / 05

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VOLUME 31 ISSUE 6 8

COVER STORY

8

08. GOING FOR GOLD

Nikon SLM Solutions on the future of one of the AM industry’s biggest mergers.

19

Consumer products

19. IN THE FOLD

Laura Griffiths speaks to one of the companies working with HONOR to 3D print smartphone components.

21. FEEL THE HIT

11 SUPPLY

Sam reports on the use of 3D printing technology to develop an optimised tennis racket dampener.

11. CHAIN REACTION

27. HIGH PERFORMANCE

CHAIN

Honeywell gives us an update on the progress being made with the AM Forward initiative.

13. PRINTING TWINS

Sam Davies speaks to CNH Industrial about developing a digital warehouse for 3D printed spare parts.

15. THE RIGHT PLACE AT THE RIGHT TIME

The MTC explains why the UK’s Ministry of Defence is turning to 3D printing to improve its supply chain for critical parts.

Formlabs discusses the use of its Form 3L printer to prototype bicycle wheels.

METROLOGY

29

29. CHAMPIONSHIP QUALITY

Hexagon & Hendrick Motorsports discuss how their partnership will enact a cultural change in how the NASCAR outfit quality controls parts.

37

Skills & education 31. SKILL UP

Laura speaks to the National Manufacturing Institute Scotland about its Manufacturing Skills Academy.

33. SKILLS CITY

PrintCity shares how it's taking on the AM skills gap by engaging with SMEs and students.

35. THE OLYMPICS OF SKILLS

Oliver Johnson speaks 3DGBIRE, about a new AM competition aimed at post-16 students.

37

FORMNEXT PREVIEW

37. FORMNEXT FIRST LOOK

We take a look at the technology launches, product updates and application highlights being showcased at this year’s Formnext.

EXEC Q&A 15

31

46

46. SPEAKING VOLUMES

We speak to Formnext Start-Up Award winner Vitro3D about its Volumetric Additive Manufacturing technology.

GOING FOR GOLD Nikon SLM Solutions on the future of one of the AM industry’s biggest mergers.

M

etal additive manufacturing is at a crossroads, with the spotlight on innovative powerhouses that challenge norms and elevate standards. In this intense landscape, one merger stands out as a definitive game-changer, ringing in a new golden era: Nikon's acquisition of SLM Solutions.

SLM Solutions, a recognised leader in the additive manufacturing race, has consistently exemplified innovation and excellence. Their laudable introduction of the NXG XII 600 and the NXG XII 600 E — designed to make metal AM serial production a reality — showcases this commitment. The brand's emblematic green served as a statement of futuristic ambition in the 3D printing realm. Yet, in a sector where disruption is the norm, embracing transformative changes is vital.

Their emblematic green branding stood as a beacon of futuristic boldness in the 3D printing world. But change is the only constant, especially in industries teetering on the brink of technological revolutions.

In the rapidly transforming world of additive manufacturing, competition isn't just fierce — it's relentless. Industry giants and newcomers alike constantly push

08 / www.tctmagazine.com / 31.6

“The race is not just about being the best but about redefining the best.” technological boundaries, striving for that elusive blend of speed, precision, and affordability. With rising demands for higher uptime, bigger build chambers, and faster systems that don’t forsake quality to cater to the growing demand for serial production, the race is not just about being the best but about redefining the best.

SHOWN:

Nikon SLM Solutions' NXG 600E

D

COVER STORY

In this context, the merger of Nikon and SLM Solutions isn't merely strategic; it's transformative. As the industry landscape evolves, the combined strengths of these two giants position them uniquely, not just as participants but as leaders poised to set new benchmarks.

The acquisition by Nikon, a globally revered name with a storied history of technological prowess, signals a transformative period not just in branding but in strategic visions, technological capabilities, and market outreach. And what colour better represents this metamorphosis than gold – or more aptly, Nikon's signature yellow.

For Nikon SLM Solutions, this transition goes beyond the aesthetic.

It's a reflection of a golden future, a future characterised by enhanced capabilities, technological breakthroughs, and a greater thrust on research and development.

With Nikon's robust backing, SLM Solutions

is poised to tap into a vast reservoir of technological assets. The collaboration leverages Nikon's legacy in precision optics, digital imaging, and technological depth.

Coupled with SLM Solutions' mastery in AM, the synergy promises ground-breaking innovations.

This combined wealth of resources paves the way for a company that was already pushing the limits in its previous incarnation, to go beyond the limits of what its capable of.

As Sam O’Leary, CEO of Nikon SLM Solutions, comments, “We aren’t here just to redefine our industry, we are here to redefine manufacturing as a whole.”

Another exciting development on the horizon is the introduction of two new large-scale metal AM systems in the coming years. These are two brandnew systems that promise to push the boundaries of what's achievable in additive manufacturing. These machines, designed with precision and efficiency in mind, are set to challenge industry norms and set new golden standards.

However, as pivotal as it is, technology forms just one aspect of this journey. Its cherished client base is at the heart

of Nikon SLM Solutions’ vision.

Over the years, SLM Solutions has sold machines and built relationships, fostered trust, and collaborated on dreams. This rich legacy of partnerships, combined with Nikon's global outreach, places the merged entity in a unique position to understand, anticipate, and cater to diverse market needs.

As we stand at this juncture, it's essential to understand that the phrase "Going for Gold" is not just about market leadership. It's about setting standards of excellence, about being the touchstone against which others are measured. It's about resilience, persistence, and an undying commitment to innovation.

Nikon SLM Solutions embodies this spirit. The merger isn't just a union of two corporate entities but a fusion of visions, aspirations, and dreams. It's a statement to the world and, more importantly, to themselves.

In the fast-evolving realm of additive manufacturing, where change is rapid and relentless, staying ahead requires more than just technological advancements.

It demands vision, agility, and the audacity to reimagine the future.

Nikon SLM Solutions is all geared up for this exhilarating journey.

Here's to a future where every layer added, every innovation introduced, and every challenge overcome shines with the golden hue of excellence in the industry of additive manufacturing.

SHOWN:

Part measuring 1.5m printed with Nikon SLM Solutions technology

31.6 / www.tctmagazine.com / 09

SUPPLY CHAIN

Laura Griffiths gets an update on AM Forward from Honeywell Aerospace.

I

n April 2022, the Biden Administration announced AM Forward to support smaller US-based suppliers in adopting additive manufacturing (AM). Led

by ASTRO America, a non-profit that supports multiple initiatives addressing AM challenges, it shone a fresh light on AM, with President Biden suggesting ‘not enough American companies are using 3D printing,’ and advocated for its supply chain potential.

Five companies – GE Aviation, Honeywell, Lockheed Martin, Raytheon and Siemens Energy – initially signed up, and Boeing and Northrup Grumman followed, each stating varying ambitions and commitments.

But how much has AM Forward moved… forward? We spoke to Brian Baughman, Chief Engineer of Additive Manufacturing at Honeywell Aerospace, to find out.

TCT: AM Forward intends to support the reshoring of manufacturing in the US and uptake in AM. In your view, what has slowed that adoption?

BB: I’ll quote Jesse Boyer of Pratt and Whitney, when he says “It’s the 3 Cs: cost, confidence, and consistency.” And this is spot on. We need AM to be less expensive, so it can compete better with traditional manufacturing. We need everyone from the users of products that AM makes to the certifying agencies that approve them to be confident in AM’s ability to deliver parts that meet requirements and safety standards. And we need consistency from the suppliers that make AM parts to the machines that are used to do the printing. If we can address all three of these, then that opens up AM to move into the mainstream.

TCT: Is Honeywell already using AM as a tool for supply chain resilience?

BB: Yes, but its not as widespread as we would like. There’s a lot of opportunity in front of us.

TCT: One of the challenges often raised

by SMEs is the difficulty having a voice in supply chain conversations. How does AM Forward address that?

BB: I can think of a few ways. One example is the workshop that was just held at Wichita State. There were multiple SMEs in attendance along with the major OEM’s like Honeywell, Raytheon, Lockheed, Northrop Grumman, GE, and Boeing. This gave everyone a forum to discuss their concerns and perspectives, and, most importantly, get insight into the expectations of the large OEMs for the AM supply chain. For me, it was extremely valuable to have that opportunity to listen to SMEs and understand their challenges when it comes to AM. Another path is through the programs that ASTRO America are running and supporting. The common approach to supplier qualification and sourcing strategy project will draw a lot of input from SMEs and their capabilities to support the requirements of the OEMs. The Regional Engines will engage the AM supply base to help mature and support them. I think there’s going to be many opportunities for SMEs to get their voices heard with the AM Forward initiatives.

TCT: Honeywell is said to be targeting USbased SME suppliers to compete on RFQ packages for products, machinery, tooling, and/or manufacturing process development utilising AM. Can you give us a sense of how that works? And given much of AM’s value comes from design freedom, speed to market, reduced tooling, for example, how do you measure value when making those decisions?

BB: When Honeywell has AM parts that need to be sourced, we work through our qualified AM supply base which includes multiple USbased SMEs. We also partner with US-based SME’s on government programs like those funded through America Makes. As for the second part of your question, there’s no one answer for that. In most cases, the business looks at each AM part individually and its role to that specific program. For some programs, the lead time may be more important than the cost. For others, it may be some performance requirement that only the AM design can achieve, and that triumphs most of the cost concerns. It’s not always a direct cost comparison that influences whether to go AM or not. Still, cost is one of the most important factors so anything we can do to make AM more cost competitive is beneficial.

TCT: Can you share goals that have been set for AM Forward?

BB: For Honeywell, we are focused on supporting ASTRO America with their common AM qualification program.

Having a common framework to qualify AM parts and AM suppliers is going to clear up a lot of confusion in the industry, and also help ease the path for more AM parts in production.

As for AM Forward as a whole, I think the goals remain unchanged. As I pointed out, there’s a lot of work going on to address many of the challenges holding back additive. I get that people wants results fast, but it takes time to make meaningful change. Additive is always going to be moving forward – its just us that need to catch up to it.

31.6 / www.tctmagazine.com / 011

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SUPPLY CHAIN

Sam Davies speaks to the agriculture equipment manufacturer developing a digital warehouse full of back-up 3D printed parts.

T

hree and a half years after the onset of Covid-19, people working in supply chain don’t consider what the next major supply chain disruption will be, only when it will be. It is not a source for speculation, but preparation.

In the agriculture industry, the supply chain crisis triggered by Covid seems to have settled down, with procurement and production operations running as well and reliably as you might have expected before the pandemic – despite the chance of supplier bankruptcy, workforce strike or canal blockage.

And while things tick as intended, it has provided ample opportunity for companies like CNH Industrial to lay the groundwork for the next time a supply chain disruption, big or small, hits.

“If [our] supply [chain] is not able to supply the right quantity at the right time, ‘Can you build them?’ is the question that we are asking ourselves,” Peter Ommeslag, Director Supply Chain Manufacturing Systems and Tools for CNH Industrial, said.

CNH Industrial is the world’s second largest manufacturer of agricultural machinery, has 40+ production facilities worldwide,

“The idea around the AM twin is that you’re trying to make sure everything is ready.” employing 40,000+ people and has a spare part portfolio in the millions. Its supply chain, then, is big and complex.

Since the start of the year, CNH has been working with Materialise’s Mindware additive manufacturing consulting team, assessing how it can grow its additive manufacturing (AM) application to safeguard its supply chain.

The company first adopted AM in 2008 for prototyping, and in recent years has begun applying the technology to tooling and spare parts. Functional parts – designed with the technology in mind from the start – are on the agenda, as is the development of ‘AM twins’.

Because, another question CNH has been asking itself is, if its supply chain breaks down somewhere, ‘Is there any backup solution?’

And ‘Could additive manufacturing be an alternative to the conventional market?’ The answer was yes. Materialise was thus looped into the process of identifying applications that can be manufactured with AM, with the view of designing back-up solutions in case of any supply chain issues.

“The whole idea around the AM twin is that you’re trying to anticipate [and] make sure everything is ready,” Ommeslag explained. “So, at the moment that there is a

disruption, or a supplier says, ‘I can’t deliver’ we don’t lose any more time with starting to look at those parts, try to redesign to make them fit for additive manufacturing. You have everything that you need to be able [to] pull the trigger on an order being sent out to a supplier to have those parts printed through additive manufacturing.”

Ommeslag anticipates that up to 40% of parts manufactured or provided by CNH could be a fit for AM, with between 80-85 AM twins already designed, pending quality checks. CNH is already using AM to produce 250 different spare parts – most of them being polymer components, and most of them being non-critical units like covers, hoods, and pipes – but with its AM twins project is now aiming to reinforce its supply chain.

For CNH, a breakdown in its supply chain typically means a disruption in its manufacturing workflows, regardless of whether AM can be used to save the day and a dissatisfied customer.

“Either you have a cost increase because the unit cannot go through the normal production flow,” Ommeslag continued, “or you’re going to have a penalty, which is difficult to express in financial terms, of having a reduction in customer satisfaction.”

Hence, the AM twin project has been developed. This concept will rely on a virtual warehouse stacked with certified part designs that can be uploaded to 3D printers when needed, meaning CNH won’t have to store more spare parts than it needs, and also that normal service can be resumed once the supply chain issue has been resolved.

Additive manufacturing, then, is set to work as backup capacity for CNH, but not before the company has completed its discovery phase of application identification with Materialise and built up some more internal know-how.

“There are still a number of unknowns that we will have to get the answer on during this journey. We are a little bit too early to make bold statements around what the impact is going to be,” Ommeslag said. “[But] it’s interesting enough to go ahead.”

31.6 / www.tctmagazine.com / 013

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SUPPLY CHAIN

THE RIGHT PLACE AT THE RIGHT TIME MTC AM Technology Manager Ruaridh Mitchinson details why the UK’s Ministry of Defence is turning to 3D printing to improve its supply chain for critical spare parts.

D

efence supply chain management involves coordinating activities related to acquiring, producing, storing, and distributing defence-related goods and services. This includes processes such as procurement, inventory management, transportation, and logistics.

The goal is to ensure that defence teams have the necessary resources at the right time and place to fulfil their mission.

In the world of defence, efficient and effective supply chain management, including logistics and distribution, is crucial for maintaining a credible defence force. Major General Simon Hutchings echoed this sentiment in the UK's Defence Supply Chain Strategy, emphasising the role of the Defence Supply Chain (DSC) in safeguarding the nation.

WHY IS SUPPLY CHAIN MANAGEMENT IMPORTANT? The effectiveness of supply chain management directly impacts the operational readiness of key assets, such as armoured vehicles, tanks, aircraft, and naval vessels.

These assets consist of thousands of components, and a single unexpected component failure can render an asset inoperative. Replacing such components presents a logistical challenge, as it relies on a supply chain capable of swiftly providing them anywhere in the world.

Additionally, it assumes the availability of spare parts and operational suppliers capable of producing components that may not have been produced for decades. To illustrate the scale of the challenge, in 2023, the UK Ministry of Defence (MoD) Defence Inventory Management Report detailed that the MoD is holding over 740 million individual items with a net book value of £11.8 billion.

THE ROLE OF ADDITIVE MANUFACTURING IN DEFENCE Additive Manufacturing (AM) is now playing an increasingly significant role in improving the resilience and effectiveness of defence supply chains, this is playing out in three primary scenarios:

Direct Part Replacement in the Field: AM enables on-site production of critical parts, reducing lead times and ensuring equipment remains operational. This has often been associated with providing a short term "limp-home" option to get defence forces out of harm’s way, where at a later date a traditionally sourced spare part could be provided, or the AM component remains. An example of this is the US Department of Defence providing seven Spee3D WarpSPEE3D machines to Ukraine to allow rapid manufacturing of critical repair parts for armoured platforms and aging military equipment systems.

Part Replacement of Long lead time or Obsolete Components: AM can address challenges of obsolete parts by circumventing traditional supply chains or strategic operating locations.

At the recent the DSEI Exhibition in London Gp Capt Leonie Boyd – Royal Air Force made the point, “…Defence inventory is compromised, often due to part obsolescence, long lead times or closure of production lines, leading

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Fin parts from Advanced Innovative Engineering rotary engine, manufactured using laser powder bed fusion

31.6 / www.tctmagazine.com / 015

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SUPPLY CHAIN

to poor equipment availability, AM can provide an alternative means, alongside conventional manufacturing not replacing, for the defence industry to produce parts much more rapidly or cost effectively (i.e. if production lines are too costly to reopen) to maintain operational output.”

One exemplar (in a non-defence setting) is that of Germany railway company Deutsche Bahn who have produced 100,000 spare parts using AM since 2015. These parts are used to keep older rail fleets operational, allowing Deutsche Bahn to overcome supply chain challenges such as obsolete parts or very small quantities.

Deutsche Bahn is now expanding its digital warehouse, which stores around 1,000 virtual models, with an aim to increase this to 10,000 by 2030.

Deutsche Bahn have noted that this not only saves space and reduces storage costs but also shortens delivery times and supply chains, building supply chain resilience.

Designing Parts Specifically for AM: Designing parts specifically for AM enables innovative designs that leverage the technology's unique benefits.

Successful use cases demonstrate how companies realise benefits such as consolidating assembles to reducing part counts and enhance product performance. This in turn simplifies

“Those not involved in AM often perceive it as riskly and costly.”

the supply chain associated with the assembled component.

A notable example is Advanced Innovative Engineering (AIE), a provider of lightweight power solutions for unmanned aircraft systems and high-performance vehicles, which fully embraced design for AM to develop groundbreaking rotary engines.

Collaborating with MTC’s AM engineers, they effectively reduced the engine's weight from 6kg to 4kg, significantly diminished the component count, and consequently lowered manufacturing costs, all while maintaining the engine's operational capability.

TACKLING COMMERCIAL CHALLENGES Although the benefits of AM may be apparent to those immersed in the technology, those not involved often perceive it as risky and costly. Technical hurdles like enhancing process stability, ensuring material quality, and achieving part suitability through qualification and certification are ongoing concerns.

However, the industry is making progress, with an increasing number of AM parts being used.

Yet, softer commercial aspects also hinder AM adoption. When using AM for part replacement or acquiring obsolete components, it's crucial to shift from a per-part cost approach to a broader more holistic cost model. Procurement and senior management teams may not be fully aware of AM's broader advantages, leading them to base decisions solely on part price, disadvantaging AM. Moreover, a sense of risk aversion can hinder adoption, as proven technologies are favoured over AM without comprehending its long-term return on investment.

An illustrative example where wider cost savings are being highlighted is within Project Tampa, funded by the UK MoD, which is focusing on accelerating AM to address logistical challenge, and in particular the inventory management of critical spares. In the build up to the project, The MoD cited examples derived from vehicles undergoing maintenance where the original supply cost of a Hose Clamp for a Titan and a Flange for a Challenger 2 tank were significantly cheaper than the AM cost. However, when the vehicle daily downtime costs and the lead time for the conventionally manufactured parts (Above 190 days) were factored in, the AM components offered savings in the total cost to the MoD - from £72k-£89k in the worst case scenario to £227k-£254k in the best case scenario. Although the initial supply cost of certain parts seemed lower conventionally, considering vehicle downtime and lead times, AM offered significant savings, showcasing its cost-effectiveness and enhanced operational availability. AM also allows for sidestepping minimum quantity orders for spare components, common in conventional manufacturing, reducing order and storage costs.

Embracing additive manufacturing and promoting broader cost models when evaluating its adoption, along with ongoing efforts to reduce part costs, are a key enabler to unlocking the benefits of AM. This extends beyond the defence sector, impacting industries like oil & gas and aerospace for their repair, maintenance, and overhaul operations.

By doing so, it is possible to enhance operational efficiency, bolster supply chain resilience, and realise substantial cost savings, ultimately ensuring the continued readiness and effectiveness of critical assets and systems.

SHOWN:

The MTC is working closely with Spee3D and defence organisations to evaluate the XSPEE3D deployable metal AM system. Pictured at The MTC in Coventry

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IN THE

Laura Griffiths speaks to HBD about AM in the 3C industry.

T

hough the parts may be tiny, the buzz around additive manufacturing (AM) in consumer electronic devices is huge. Apple may have stolen the headlines this summer with speculation around its use of metal AM in its latest watch series, but smartphone manufacturer Honor has also been busy working with several AM companies on its HONOR Magic V2 foldable phone.

One of them is HBD. The company worked on the Luban Titanium Alloy Hinge, a crucial component which played a significant role in achieving its 9.90mm thickness breakthrough. Leveraging titanium alloy, HBD says it was able to successfully reduce the overall thickness and weight of the folding screen.

Here, Celine Xie, HBD Overseas Business Development Manager explains why HBD's metal technology is a perfect fit for lightweight, integrated, and finely structured metal parts for 3C (Computer, Communication and Consumer electronics), and how this project could influence future AM in consumer devices.

TCT: How did HBD get involved in the HONOR foldable phone project?

CX: HBD has found that 3D printing has significant advantages in the consumer electronics sector. Downstream product manufacturing costs are effectively reduced and efficiency is improved. 3D printing eliminates the need for moulds and machining, directly transforms design drafts into solids, efficiently creates product models that can be tested and evaluated, simplifies the production process, reduces the time and assembly costs of the traditional manufacturing process, and promotes subsequent development and innovation. All these advantages pave the way for HBD to participate in the innovation of cell phone production.

TCT: Why was 3D printing chosen for this particular component?

CX: The metal structural parts of electronic products are generally based on stainless steel and aluminium alloy. Stainless steel has a good glossy feeling, but the weight is not advantageous. Aluminium alloy has the advantage of lightweight, but the general hardness. The strength of the alloy is higher than stainless steel, the weight is only half of the same volume of stainless steel - it can do both hardness and weight. Due to the alloy of the traditional processing difficulty, low yield, resulting in higher production costs, it has not been widely used by the 3C industry.

In this case, 3D printing emerged as the ideal choice for the Luban Titanium Alloy Hinge due to its capacity to streamline the production process. By eliminating the need for moulds and machining, we achieved a delicate balance between lightweight design and enhanced hardness.

The innovative use of 3D printing not only simplified production, reducing time and assembly costs but also allowed us to create intricate titanium alloy structures, reduce cell phone weight, elevating the user experience.

TCT: Why do you think this project is so significant?

CX: Metal 3D printing can be very effective in solving the problem of moulding alloy materials. Prior to this, metal 3D printing of alloy parts has been widely used in aerospace, medical and other fields, and now in the 3C industry is undoubtedly a

major breakthrough. The HONOR Magic V2, leveraging 3D printing technology, achieved a groundbreaking reduction in thickness and weight, surpassing previous models in the market. This achievement speaks volumes about the potential of 3D printing in the high-end market for folding screen cell phones. It not only meets consumers' demands for lighter devices but also opens the door to personalised, customised products tailored to individual preferences.

TCT: What does this project tell us about future adoption of metal 3D AM in consumer electronics?

CX: This project serves as a testament to the transformative power of 3D printing in consumer electronics design. It liberates products from the constraints of traditional manufacturing, allowing for richer use of materials, more flexible use of process technology, and customisation according to individual preferences. As consumer demand for personalised electronic products increases, and companies demand more cost-effective, productive products, 3D printing technology offers the freedom to customise products to enhance the user experience. We believe this trend heralds a promising future where metal 3D printing will continue to revolutionise mass-produced consumer electronics, offering innovative solutions and endless design possibilities.

SHOWN:

HONOR Magic V2 features 3D printed components

“Groundbreaking reduction in thickness and weight.”

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Sam Davies speaks to the company behind a latticed tennis racket dampener, developed with 3D printing technology.

I

t’s September 2013 and a feltcovered rubber ball is being zipped back and forth across a tennis court by what is now considered to be the two most successful men to ever play the sport.

Inside the USTA Billie Jean King National Tennis Center, Rafael Nadal crashes a 100+mph serve down to Novak Djokovic’s lefthand side, only for the Serb to return with a double backhand. Fifty-two more shots are knocked back and forth, with only the occasional sliced dropshot breaking the succession of grunts and thuds as the pair compete in one of the sport’s most famous rallies.

Those grunts stem from two fierce competitors harnessing every bit of their strength to overcome the other, but the thud emanates from a tiny piece of silicone rubber clipped onto the lower central strings of the rackets.

Djokovic, Nadal, and an estimated 75% of the 90 million tennis players worldwide rely on these bits of silicone rubber to reduce the shock upon impact and tune the sound into a thud rather than an irritating ping.

In Italy, a company leveraging additive manufacturing technology to enhance consumer and sporting goods has seen the tennis racket dampener as an opportunity. For where there is a part that absorbs shock, there is often a role for additive to play. Additive Appliances thus developed a patent-pending lattice structure, which is said to

“We're finally pushing the boundaries of manufacturing.” work in much the same way as a tuned mass damper does in large buildings.

Designed to mimic the vibration of the structure it is embedded in while ‘accommodating the movement to dampen the vibration,’ the dampener is said to intercept vibrations that can cause inflammatory issues, while also allowing players to ‘feel the hit’ as they strike a ball.

“What we do is we have a set of lattice structure that we can simulate pretty seamlessly,” said Tommaso Beccuti, CEO of Additive Appliances. “We simulate the behaviour of this lattice structure, and we target the natural frequency of each racket system.”

Targeting the natural frequency of each racket system with tailored dampener products was something that tennis racket manufacturer Head1 outlined as important during a study undertaken in 2009. Doing that with injection moulding, however, was always going to prove difficult. But with 3D printing, Additive Appliances is confident it can tweak the design of its dampeners to suit each brand and model of racket, and do so in an economically viable way, to supplement its already available ‘universal product’.

Across both the universal and brandspecific tennis racket dampeners, Additive Appliances is deploying its lattice IP to ‘scatter the vibration’ through the myriad beams and nodes that the lattice is made up of. By channelling the forces through these paths, the energy is dissipated. According to the literature that Beccuti has studied, there is a belief that lattices proffer superior dampening properties to the conventionally shaped products. This has chimed with Additive Appliances, who has endeavoured to dive deep into the design space to generate solutions for a range of consumer and sporting goods, among them the tennis racket dampener.

SHOWN:

Additive Appliances' 3D printed tennis racket dampener

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ADVERTISEMENT FEATURE

Making 3D printing easy Leaning on the combination of its in-depth materials expertise and its connections to some of the most reliable service manufacturers in the industry, earlier this year Arkema launched its Easy3D digital platform.

Recognising that additive manufacturing users are digital natives, but adoption and application of the technologies are not always easy, Arkema has felt compelled to help solve their challenges through the introduction of Easy3D. Namely, Arkema has identified that while most manufacturers know the requirements of their parts, they don’t always know which combination of material and additive manufacturing process is the right one to produce them. There are also scant recourses for users to efficiently compare all the various options open to them, and that’s before they consider where and by whom they have the parts produced.

Easy3D has been developed to address these issues. With just a

few clicks, users of the platform can tap into the deep material expertise of Arkema. First, they need to upload a 3D printable file, answer a few questions about the requirements of the component (such as the temperature and elements it will be exposed to), and then the platform will provide its material recommendations. Users will also be provided with a list of suppliers, with price quotes and turnaround time estimations helping to inform their decision. One more click: They can order their parts!

“Arkema's expertise is condensed into Easy3D,” said Pierre Gonnetan, Business Development Manager at Arkema. “It's a way to articulate our expertise in materials to make it more accessible, and user friendly for additive manufacturing.

But also still keeping the possibility of having human interactions and asking for help if there is a need for direct communication to experts in materials.”

The Easy3D platform has been developed

in partnership with 3YOURMIND, allowing Arkema to complement its material expertise with the digital competencies of a leading on-demand manufacturing software provider. In the building of this platform, 3YOURMIND leant on materials data from Arkema so that when the user inputs the part requirement information, it can offer up material recommendations with a technical scoring. This technical scoring will rate each specific material against, for example, the required impact resistance of the part. The more requirements provided at the first stage, the better the recommendation at the end.

Easy3D, then, provides additive manufacturing users with an intuitive pathway to get their parts made in the most suitable material in the quickest time. To this end, Arkema has aligned with a range of manufacturing partners running machines that are compatible with Arkema materials, including partners to the EOS and HP manufacturing networks.

“These networks are certified by HP and EOS, which are leading providers of industrial 3D printing solutions,” said Pierre Gonnetan. “This helps building confidence in the quality of the parts that will be produced and delivered to the users directly from these partners.”

Through this ecosystem, users can have their parts additively manufactured in materials such as 100% biobased Rilsan® Polyamide 11, Pebax® thermoplastic elastomers, Kynar® PVDF and Kepstan® PEKK, with Arkema always working to develop and deliver more materials solutions. Soon, new materials and additional AM technologies will be introduced on the platform.

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SHOWN:

The dampener is used at the base of the racket so as not to impede the player as they strike the ball

“We focus mainly on lattice structures. All our other applications that we have done are related to the so-called metamaterial – you act not on the microscale of objects, you don’t take the problem from a specialty chemistry standpoint, but you rather work on the mesoscale, so talking about microns, millimetres, and you change the shape of the object so that he can actually achieve certain properties. That can be thermal properties, mechanical properties, like in this case, but also electromagnetic properties. It’s very interesting.

To me, it is one of the most exciting areas of 3D printing, alongside bioprinting. In terms of simple approaches to mechanics, I think metamaterial has a huge potential.”

Additive Appliances’ tennis racket dampener is additively manufactured using HP’s Multi Jet Fusion technology, with the build volume of the 5200 platform said to be capable of processing thousands of parts at once. The parts, printed in BASF’s Ultrasint TPU material, measure between around 15 to 20 millimetres, and weigh less than 1 gram – up to 70% lighter than the minimal mass requirement of a traditional dampener.

For the design of the components, Additive Appliances has leant on a set of internally developed equations that are transformed into CAD designs through implicit modelling software, such as Altair’s Sulis platform, with the equations being validated using advanced simulation techniques like Optimad Engineering’s proprietary software, before extensive in-house testing is performed with vibrometers and sound spectrum analysers. Post-print, chemical smoothing can help to enhance the aesthetics of the part but has no impact on the mechanical properties and so it can be quicker and cheaper to forego this step.

So far, the 3D printed dampener has come through in-house tests at Additive Appliances with flying colours, with third-party testing now underway.

Ranked professional players, such as Federico Gaio – who typically prefer not to use a dampener – have also provided positive feedback. And, Beccuti told TCT, Additive Appliances is in the process of spinning out the product into its own company, with a number of investors helping to set up a business called Athleticae to give a further push to the tennis racket dampener, before other applications are explored.

In terms of the tennis racket dampener, it is expected sales of its universal product will continue via an e-commerce platform, while a reseller network is to be developed. Requests for licensing will always be listened to, but Becutti’s preference would be – in a perfect world – that there is no exclusivity. He concedes that the 3D printed tennis racket dampener is slightly more expensive than a conventionally made one, but there is confidence that a superior performance will ensure value for money. Buoyed by a couple of other recent high volume consumer applications, Becutti is thinking big.

“The real target is millions of pieces,” Becutti said. “Let me be ambitious here. I think the technology is ready for that. We [as an industry] have other use cases.

The mascara brush from Dior, I think, is the most famous one and it’s again a small component. Now we have the very positive example of Apple producing the Apple Watch in binder jetting. [The technology

is] maturing and it’s an exciting moment. We’re finally pushing the boundaries of manufacturing and getting at least a little bit closer to traditional manufacturing.”

1 ‘Dynamics of a String-bed Dampener on Tennis Rackets’ by Mohr et all.

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The first of nine sectors of the plasma chamber was positioned on supports in May 2022

How 3D scanning has made ambitious energy engineering a reality Author: Mathieu Kerbiguet, Regional Manager at Oqton Fusion, the process that powers all stars in the universe, holds the key to solving Earth's growing energy crisis.

The quest to achieve fusion has become one of the most significant technological endeavours of our time. It promises to generate vast amounts of carbon-free energy, addressing the mounting energy challenges we face today.

However, achieving fusion is an enormous challenge.

It naturally occurs at the core of stars like the Sun, requiring scientists to recreate those extreme conditions here on Earth.

The forces, pressures, and temperatures necessary to push atoms together are mind-boggling.

To tackle this grand ambition, the International Thermonuclear Experimental Reactor

Project (ITER) was established in 1985. This global initiative brought together 35 nations to prove the feasibility of fusion as a large-scale, carbon-free energy source.

Today, we are on the cusp of witnessing the fruits of this remarkable initiative.

The realisation of ITER's goals heavily relies on the expertise and guidance provided by advanced technologies, such as 3D scanning, with Geomagic Design X at the forefront.

In this article, we delve into the significance of nuclear fusion and how 3D scanning has played a vital role in this project's development.

Understanding nuclear fusion and its timeliness At the core of stars, including the Sun, nuclear fusion reactions occur billions of times per second.

These reactions generate

an immense amount of energy, capable of powering the Earth many times over.

Harnessing nuclear fusion here on Earth offers several advantages. Firstly, it provides a nearly limitless supply of energy without carbon emissions and with minimal nuclear waste.

In contrast, traditional power plants rely on fossil fuels, nuclear fission, or renewable sources like wind and water. Nuclear fission produces radioactive waste that poses longterm storage challenges, sometimes spanning hundreds of years. In contrast, nuclear fusion produces less radioactive waste that decays more rapidly and eliminates the need for fossil fuels.

However, achieving fusion on Earth presents significant obstacles. Scientists must recreate the extreme

conditions found in the center of the Sun, including the extraordinary forces, pressures, and temperatures required to fuse atoms together.

ITER's approach to fusion and the role of 3D scanning ITER's approach to achieving fusion involves creating and controlling plasma, a state where gas is heated to incredibly high temperatures, causing electrons to separate from nuclei.

This plasma will be confined and controlled within a device called a tokamak, which employs powerful magnetic fields in the shape of a torus or doughnut.

The completed tokamak is expected to produce 500 MW of fusion power.

Equipment and Nuclear SA (ENSA), a Spain-based company, has played a crucial role in designing

ADVERTISEMENT FEATURE the components that make up the tokamak vacuum vessel. Constructing this monumental device, which weighs 23,000 tons and measures 28 meters in diameter, necessitates precise engineering and cutting-edge technology.

To ensure the perfect alignment of the vacuum vessel's nine sectors, ENSA employed 3D scanning and made-to-measure designs. The company used 3D scanning techniques, including photogrammetry and laser scanning, to capture detailed scans of the lateral edges of each sector. AsorCAD, an engineering specialist, also based in Spain, collaborated with ENSA and utilised Geomagic Design X from Oqton to convert the scanned data into editable 3D models.

Leveraging these geometries, ENSA's engineering department developed custom splice plates and biscuits to connect and secure the different sections of the sectors. Once fabricated, the sectors will be welded together, marking a significant milestone in the construction of the tokamak.

Joseph Maria Sanchez, Technical Manager at AsorCAD, highlighted the benefits of Geomagic Design X for this project.

He said: “Geomagic Design X is the most capable reverse engineering software for handling large point clouds, and the entire reverse engineering process is parameterised, allowing future corrections to be made more quickly.

Considering the large size and high resolution of the point clouds we work with, the files we deal with are very large.

“In this particular project, 3D printing has assisted us in designing and manufacturing several tools necessary for conducting

measurements with our Creaform 3D scanners.

We have created tools to place dynamic references, necessary to guarantee design precision.

“We have also designed grips for using our 3D scanners with extensions, which helped minimise crane movements, as well as tools to expand the working capacity of our mobile tripod tracker, reducing the need for aerial platform movements.”

The transformative power of 3D technologies in the energy sector The energy sector is embracing the power of 3D technologies, including 3D printing, 3D scanning, and 3D simulations. These cutting-edge tools offer numerous benefits, such as enhanced speed, efficiency, and accuracy, driving significant advancements in energy projects worldwide.

One key advantage is the cost-saving potential achieved through increased accuracy.

Tools like Geomagic Design X leverage 3D scanning technology to identify potential flaws or misalignments in parts. By comparing the scanned data with the initial design, engineers can quickly identify areas requiring adjustment.

Without 3D scanning, extensive time and resources would be wasted on multiple iterations and molding attempts.

The reliance on 3D scanning and printing has significantly accelerated the completion of ambitious projects like ITER. Without these technologies, endeavours such as nuclear fusion would be exceedingly lengthy and costly.

Today, we have the capability to employ 3D technologies in almost every aspect of

engineering, enabling the realisation of projects that were once unimaginable.

As technology continues to advance, data handling capabilities become increasingly important.

State-of-the-art 3D software excels in acquiring and reverse engineering realworld data. Its intuitive functionality allows engineers to rely on accurate scanned data with ease, making modifications and optimisations for specific purposes, particularly within the fusion sector.

Antonio Sanchez, CEO of AsorCAD, concludes that “3D printing and 3D scanning have provided us with increased productivity by creating custom-made tools tailored to our needs, simplifying fieldwork,” contributing to the overall success of endeavours like ITER. Future challenges for 3D scanning and printing While 3D scanning and printing have already revolutionized many industries, there are still challenges to overcome.

One key hurdle lies in making the technology

more accessible and userfriendly. The complexity of using these tools often requires extensive training, limiting the number of skilled practitioners. Future developments, potentially powered by AI, could simplify the process and enable more individuals to leverage these technologies effectively.

Materials also pose an ongoing challenge.

Extensive research and development efforts are devoted to finding the ideal materials that strike a balance between cost, constraints, and performance.

The continuous evolution of 3D printers and scanners, advanced 3D scanning software, and the emergence of hybrid materials, such as plasticmetal composites, are game-changers that offer greater cost-effectiveness and expanded capabilities.

As we look to the future, these technologies will only become more refined, empowering engineers and researchers to tackle grand challenges with unprecedented efficiency and creativity - no matter how complex.

3D scanning delivers perfectly fitting joints for the plasma chamber

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HIGH PERFORMANCE Oli Johnson speaks to Balázs Kisgergely, Content Marketing Lead at Formlabs, about applications of the company’s technology in the creation of bicycles.

A

s cycling is increasingly embraced for commuting to work, exploring nature, working out or racing, it is important for bike manufacturers to keep up with trends and technological developments.

TCT spoke to Formlabs to learn how two companies, Hunt Bike Wheels and Privateer Bikes, are using 3D printing technology and materials for in the prototyping stage of creating bike parts. Both companies are owned by The Rider Firm, a UK-based e-retailer that secured seven figure funding from Santander in 2022.

Hunt Bike Wheels has been using the Form 3L printer with the Grey Pro Resin to 3D print prototype wheels. The company 3D prints the rims and then builds them with standard components such as spokes and hubs. Tyres are then put on the rims and inflated to 3.5 bars pressure to test in a wind tunnel. The testing results are then analysed, with the company iterating different designs and concepts with 3D printing until the perfect wheel profile is found, which will later be manufactured with traditional carbon fibre methods.

Privateer Bikes 3D prints entire bike frames, which enables them to test designs for fit, assembly, and clearances. The company also uses Formlabs 3D printing to create functional prototypes of frame protectors that prevent the chain from potentially damaging bike parts.

Speaking about how creating prototypes through 3D printing is key to improving the performance of bikes, Balázs Kisgergely,

“Bringing high quality bikes to customers faster and cheaper.”

Content Marketing Lead at Formlabs told TCT: “By 3D printing prototypes in-house, Hunt Bike Wheels and Privateer Bikes can save both money and time, enabling them to focus on designing the best wheel profiles that can improve a bikes drag, crosswind handling, and speed. 3D printing is also key to making their products faster by eliminating wait times for outsourced prototypes. Hunt Bike Wheels can iterate small changes easily in-house to bring their products to market sooner, and the lowered production time and cost enable them to sell their high performance parts at an accessible price, bringing high quality bikes to customers faster and cheaper.”

Formlabs says that the Form 3L was beneficial to Hunt Bike Wheels and Privateer Bikes as the 33.5 x 20 x 30 cm build volume made it possible to print largeformat objects such as bike wheels and frames. The company says that Hunt Bike Wheels’ engineers can 3D print prototypes in-house in five or six sections, saving 90% of the price of outsourcing the same designs.

The Grey Pro Resin is used by Hunt Bike Wheels as it enables the prototypes to be complex and accurate geometrically while being strong enough to be fitted with racing tires, inflated, and tested in a wind tunnel according to Formlabs. The prototypes made with Grey Pro Resin can be filled with up to three and a half bars of pressure and take around 65% of the tension of a carbon fibre wheelset. Privateer Bikes uses Grey Pro resin to prototype its bike frames due to the durability of the material, as well as its ability to withstand roughness while handling the prints.

Kisgergely told TCT about the time and cost saving benefits allowed by using the Form 3L for these applications: “Before Formlabs, Hunt Bike Wheels outsourced all prototypes, with each outsourced wheel costing 2,500 USD. The Form 3L cut costs down by 90%, to bring prototypes to around 250 USD each. In addition to the lowered costs, Hunt Bike Wheels can run Form 3L printers through the night to have new prototypes ready daily, rather than waiting two to three months for outsourced designs. Before 3D printing, Privateer Bikes was not able to prototype their frame protectors as the tooling for this part is expensive and must be custom made.

Without prototyping first, Privateer Bikes would send the design to be manufactured, costing 3,000 to 4,000 USD and taking three to four months. Being able to 3D print prototypes has saved Privateer Bikes six months of time and around 4,000 to 5,000 USD per prototype.”

Kisgergely also told TCT about the potential for Formlabs 3D printing technology and materials to be used for end use parts in bicycle manufacturing: “With Formlabs’ ever-expanding library of 45 unique materials, new ways to use 3D printing for end-use parts are emerging. For example, Silicone 40A Resin, the first accessible pure silicone 3D printing material, and TPU 95A Powder for SLS printing, could be used to print handlebar grips, seat covers, or other elastic bike parts made to be stretched, flexed, and compressed. 3D printing these parts in house would eliminate traditional labour-intensive moulding and casting processes.”

SHOWN:

3D printed prototypes from Hunt Bike Wheels

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metrology

CHAMPIONSHIP QUALITY WORDS: rhiannon temporal

In the final stages before the car is loaded, final body and underwing details are verified and adjusted to get the last pieces of aerodynamic performance for the race car.

Finally, we have a Leica tracker that we use to verify that our fixtures and plates correct and calibrated.

Roy Crump, Quality Control Supervisor at Hendrick Motorsports, Tad Merriman, Engine Engineering Manager and Quality Control Manager at Hendrick Motorsports, and Scott Grumbles, Commercial Operations Manager at Hexagon’s Manufacturing Intelligence Division, discuss the motivation behind Hexagon's metrology partnership with Hendrick Motorsports as the team aims to reach its 300th Cup victory and 500th NASCAR national series engine win.

MQ: What do you consider to be the most effective change you will bring to the Hendrick Motorsports operations?

RC: The biggest changes at Hendrick Motorsport will be a cultural change in how we quality control our parts, and how we use them. NASCAR has put us in such a tight box that we have to make sure all the parts we have are compliant to NASCAR rules.

The technologies allow us to grade the quality of our parts so we can determine which parts can provide the biggest performance advantage on the track. Instead of just putting parts on the car, we now ask ourselves, “Is this the best part? Can we measure these parts and grade them based on the results of the measurements?” We want to quantify all parts, and the tools from Hexagon allow us to do that.

SG: Hexagon and Hendrick can speak engineer-toengineer about new tools Hexagon is developing to accelerate inspection time and improve

efficiencies even as we help Hendrick implement its new systems. Among those systems are an optical CMM (coordinate measuring machine) and a robotically loaded CMM for measuring smaller components, which helps free up valuable manpower for more useful tasks. The value to Hexagon is that our engineers and developers receive important feedback in terms of how we can improve both hardware and software to the benefit of Hendrick and other users.

MQ: Can you tell us about specific metrology applications Hexagon’s technology will be used for?

RC: Hexagon portable measuring arms are used for measuring the chassis and suspension components to input into our simulation tools. The arms and the AS1 (Absolute Scanner) scanners are used during the body hanging build process to maximise the aerodynamic performance of the car. The equipment is also used for reverse engineering parts to speed up the design process and improve the accuracy of the parts created by the design group.

During the setup process, the arms are used to measure suspension features on the car to validate their location to the desired location from the simulation tool. They also check for certain suspension parameters to make sure they are compliant with NASCAR’s rules.

MQ: With the partnership between Hexagon and Hendrick Motorsports lasting a decade, what does the future hold for the collaboration?

RC: For Hendrick Motorsports? More wins and championships! Realistically, the future holds tools that will help elevate the QC group to in turn help the race teams find performance. For Hexagon, I hope it holds a fantastic showroom that can be used to demonstrate use cases for the tools it provides.

TM: We also believe that these partnerships are two-way streets and that each participant can make the other better.

We could not have the success that we have had without our partners, but we believe that we can make our partners better, as well.

SG: In line with this close relationship, the Hendrick Motorsports campus will also become a site at which new concepts can be demonstrated and where we can receive valuable feedback from Hendrick as a highend user of our systems.

MQ: Can you share your insights on the importance of metrology technologies in the motorsport sector?

TM: As motorsports have evolved, the constraints we are required to work within have become significantly tighter, so the margins have become ever smaller.

We coined the phrase “measuring for performance, not for conformance” to illustrate that we now use instruments such as the portable arms and CMMs to characterise the components of the race car not just for acceptance, but for tuning, as well. Having the ability to understand the features of our inventory and combine components in a favourable way is a distinct performance advantage and one that is only going to increase in significance over time.

Get more metrology, inspection and quality control insights by subscribing to our new Manufacturing Quality website manufacturing-quality.com

31.6 / www.tctmagazine.com / 029

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education TCT 3SIXTY & skills PREVIEW

SKILL UP

Laura Griffiths speaks to Stewart McKinlay, Skills Director at National Manufacturing Institute Scotland (NMIS) Manufacturing Skills Academy TCT: Tell me about the motivation behind the centre and the need for a skills academy?

SM: The motivation and the business case behind the centre is a pretty compelling one and indeed within the UK with a rich history of manufacturing. We're world leaders and still are in many areas.

I guess two things happened at the same time.

There was a view that we were actually falling behind and perhaps to the point that it wouldn't be as attractive for manufacturing companies to stay or new ones to come. So, that was a compelling case. The other compelling case was the work that the Advanced Forming Research Centre had done, which at that point was a direct part of University of Strathclyde's DMEM (Design, Manufacturing & Engineering Management). The AFRC was specifically, as the name suggests, all about forging and forming, which is quite a narrow focus.

But increasingly, as they progressed, they were being asked to get into a whole lot of different advanced manufacturing things. They demonstrated that having a centre like this on a small scale would be a really productive and effective way of being able to do something larger. So, the concept of a National Manufacturing Institute Scotland was born.

I think our view is very much that you can't do those things if you've only got two legs of the stool. So, if you only have the technology piece, or you only have the infrastructure piece and the supply chain piece through all the companies you're working with, but you don't have the skills, education and training, then the stool will just fall over.

TCT: Who is the Skills Academy aimed at?

SM: We're not in the space that universities are in, where they're teaching undergraduates or postgraduates or doctoral students about

new technologies and processes and theories. We're not in the commercial world competing with employers, but we're in that middle space to bridge that gap. So, our primary audience is actually people who are either in employment or looking to move into employment.

Having said that, we also have a mandate and a responsibility to shape and influence what is happening in the education world as well. For example, we work with the photonics sector who find that they've struggled to recruit people that can actually work with lasers, which is a growing industry. So, we worked with employers to design a course that helped people to prove their ability; a short, high intensity course, theory, practical, end test designed by the employers.

TCT: In addition to photonics, can you talk about where the demand is coming from?

SM: Manufacturing is a broad church and it's not all engineering jobs.

We require coders, IT people and administrators, etc.

Originally, through the AFRC there was a heavy focus on aerospace companies.

So, that's helped us grow and it's helped us work to very incredibly high standards. But now we're working with a much broader base of employers in different sectors. We're doing a lot of work with food and drink, and we've already started some work in the hydrogen sector, aerospace is buoyant, we're working with the space sector,

we're working with the defence sector, in particular shipbuilding, which is on a resurgence.

TCT: Do you think there is a need to reframe what a career in advanced manufacturing looks like in order to either attract or retain talent?

SM: We need to find new ways of engaging with a broader audience to say, 'this is engineering' or 'this is manufacturing.'

That's certainly something that's a personal objective of mine as well. There are lots of different stakeholders and organisations that have been promoting engineering and we need to continue to do that.

But we need to be much more innovative and creative about how we're reaching out to parts of the audience that we're not reaching.

One of the big problems we have is many people still ask school children in particular, 'What do you want to be when you grow up?'

Let's stop doing that. Let's actually show and engage with children and ask, 'What do you think about this? Do you find this exciting?'

And then when they find things exciting, say, 'Did you know that's additive manufacturing?'

Let's get them hooked and excited first. Then we can tell them what it is afterwards.

Editor's note: This interview has been edited for brevity and clarity.

READ THE FULL INTERVIEW AT: TCTMAGAZINE.COM

S HOWN:

National Manufacturing Institute Scotland

31.6 / www.tctmagazine.com / 031

education TCT 3SIXTY & skills PREVIEW

Laura Griffiths explores how PrintCity is tackling the skills gap from two sides.

SHOWN:

FDM printers at PrintCity

“We want the best for the industry and our students.”

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ur first TCT UK User Group this summer, no matter which direction the conversation steered, there was one thread our group of experienced additive manufacturing (AM) users continued to pull on: skills.

The so-called ‘skills gap’ has many facets.

For some, it's about building education programmes that cater to the manufacturing skills of the future. For others, it means equipping industry with an understanding of AM's how and why. PrintCity, a thriving AM centre based at Manchester Metropolitain University in the UK, is tackling both.

In addition to offering its unique MSc Digital Design and Manufacturing course, PrintCity is using its growing fleet of AM technologies to educate SMEs, and just wrapped up a 3.2 million GBP European Regional Development Funded project to help companies in Greater Manchester adopt digital manufacturing technologies.

Speaking with Mark Chester, Product Development Specialist at PrintCity, there are multiple reasons companies are looking to explore new methods of manufacture: supply chain rigidity, magnified by the pandemic; sourcing challenges brought on

by Brexit. But for PrintCity, a hub where both students and businesses can learn firsthand about AM, it’s a two-way street.

“It's really beneficial for us to help companies adopt these technologies so

that our graduates then have opportunities in the marketplace,” Chester explained.

150 companies were targeted through the project. Some would come in with preconceived ideas about AM and leave with an entirely different view, and a machine on their shopping list. Others who had already tried 3D printing without any real support on how to leverage its benefits, went away armed with fresh ideas. As Chester shared, a tour around PrintCity’s lab which includes primarily polymer machines from Formlabs, Prusa, HP, UltiMaker and Stratasys, amongst others, alongside an abundance of real-world applications, is usually where the lightbulb goes on.

“It's our duty to make sure that people don't get the wrong technology,” Chester said. “We've had companies that have come to us and said, ‘We bought this really expensive machine and it's just gathering dust,’ or they might have jumped on the technology years ago and it wasn't very good. We don't want companies to learn about a technology, have a bad experience, and then put them off even further.”

Jacobson Group, which owns the sporting goods brand Gola, came to PrintCity from another project focused on reducing its carbon footprint. The company wanted to use 3D printing to reduce the number of shoe samples it was manufacturing and

shipping over the world every year. With guidance from PrintCity, the company decided to use Keyshot digital visualisation software to create realistic vendors of its samples, which could be instantly shared globally while reducing lead times and environmental impact. Using that same 3D data, 3D printing was then identified as a perfect alternative to its traditional shoe mould making process.

AM adoption and AM skills go hand in hand.

While manufacturers bemoan a lack of digital skills in the talent pool, there are plenty of graduates coming out of universities with them in tow. In fact, some companies that have come through PrintCity’s programme have directly hired students afterwards.

“We have an advisory board for our masters course where we get companies to tell us what skills they want from students,” Chester shared. “It’s alright having an amazing course, but if it's not fixing any problems around the skill gap, then what's the point?”

The work continues. PrintCity just launched its Centre for Digital Innovation programme, funded through a 100 million GBP Government Innovation Accelerator to enable SMEs in the North West to access knowledge, research and facilities across artificial intelligence, cyber security, industrial digitalisation, and immersive technology.

“We're definitely open for business in that sort of regard,” Chester added. “We just need to keep that conversation between industry and places like [us], but also the [TCT UK] User Group, and just share what everyone's doing. […] We want the best for the industry and the best for our students – and the best for 3D printing in general.”

31.6 / www.tctmagazine.com / 033

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education TCT 3SIXTY & skills PREVIEW

THE OLYMPICS OF SKILLS

Oli Johnson speaks to Steven Taylor, Technical Trainer at 3DGBIRE, about the additive manufacturing competition launched in partnership with WorldSkills UK and CREATE Education.

I

n February 2023, 3DGBIRE and the CREATE Education Project announced that they had partnered with WorldSkills UK to launch a new additive manufacturing competition, aimed at post-16 students in education and training.

The competition is designed to test young people’s 3D design, 3D printing, and 3D scanning skills, and is sponsored by UltiMaker and Shining 3D. The first edition of the competition is set to conclude in the national finals in November 2023 at the University of Salford in Manchester.

In this first edition of the competition, nearly 90 young people from colleges and apprenticeship providers across the UK signed up to take part. With the number of applications being higher than anticipated according to the organisers, students were asked to take part in an online entrance skills test. The skills test consisted of timed questions relating to 3D printing, alongside a series of design tasks using Autodesk Fusion360 design software.

Speaking about how the UK competition came about, Steven Taylor, Technical Trainer at 3DGBIRE and CREATE Education Ambassador, told TCT: “I joined 3DGBIRE back in 2020, and prior to that I’d worked at an Autodesk distributor and I’d actually got going the digital construction competition for WorldSkills UK, so when I came to 3DGBIRE and moved into the additive manufacturing realm, I found it interesting that there wasn’t actually a competition for additive manufacturing.

There was quite a new competition globally, but at that time WorldSkills UK hadn’t adopted it into its portfolio of competitions. So, I reached out to WorldSkills UK, having known some of the team there and said, 'obviously additive manufacturing is a technology that lots of organisations are adopting, it’s the future and there is a skill shortage in that area, what do you think about us setting up a competition in the UK?'” From the entrance test stage of the competition, 32 students were invited to take part in three National WorldSkills UK Qualifiers held in June 2023, and hosted at Cheshire College South and West, University of Sheffield, and Imperial

College London. At the qualifiers, students were set a design and 3D printing task to complete using an UltiMaker 3D printer.

The top eight competitors from the National Qualifiers were invited to take part in the WorldSkills UK National Finals at the University of Salford in Manchester in November 2023, with the winners at the finals set to be part of the UK squad taking part in the WorldSkills event in Lyon, France in 2024.

Speaking about the long term goals of the competition, Taylor told TCT: “What we want is for the UK to have the best young additive manufacturing engineers, my goal is to get our youngsters into the WorldSkills arena to compete with the best of the best on a global scale, and put us on the map.”

Speaking to TCT about the importance of the competition, Taylor said: “One of the things I find when we’re selling the new technologies is that people haven’t necessarily got the skills they need in the current teams, or they need to develop the skills in their teams. A lot of industries are employing graduates and people coming fresh from college and university that have potentially had exposure to these technologies in their educational environment, so this is to raise the profile of additive manufacturing technologies within the educational institutions and help to drive the skills agenda in this area.”

Taylor also told TCT his view on what the UK Government can do to improve additive manufacturing skills in the country: “There’s no real sort of apprenticeship in additive manufacturing. We’ve done a lot of enquiries when we’re going out to industry and doing face to face training, a lot of people are asking if there are any qualifications specific to this or any certifications. Now as a company we can give our own certification, but it’s not recognised by any official organisation. So, some sort of formal certification from this would be ideal. We’re currently looking at

the potential of a trailblazer group for an apprenticeship, but also what you find is because it’s such a broad arena, what you’re doing in additive manufacturing complements qualifications already out there. So its about keeping up with that and trying to get more of an emphasis within these institutions of, don’t just train them on a CNC machine or traditional hand tools, additive manufacturing is coming and they need to know how to reverse engineer, get hands on with scanners, they need to see these new technologies that are out there and use them.”

SHOWN:

Steve Taylor, CREATE Education Ambassador and Technical Trainer at 3DGBIRE

31.6 / www.tctmagazine.com / 035

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FORMNEXT PREVIEW

FORMNEXT FIRST LOOK

Ahead of this year’s Formnext, we spoke to a number of exhibitors about the additive manufacturing (AM) technologies they’re bringing to Frankfurt on 7-10th November.

New Polygonica 3.3 features

Join EOS experts on the AM Expert Bar EOS is inviting visitors to explore its new industrial 3D printing technology, materials, applications, and more.

Whether attendees are just entering the world of industrial 3D printing or looking to expand their existing AM business, EOS says it works alongside your team to move your production forward.

A highlight on the booth this year will be the AM Expert Bar, where visitors will be able to engage in in-depth discussions with EOS experts on the challenges and solutions around AM. Attendees can book an exclusive meeting slot at the show today to talk all things industrial 3D printing, expert to expert.

HALL 11.1 | STAND D14

The Polygonica team will demonstrate new functionality in Polygonica 3.3 including initial releases of edge blending, shelling, Z-compensation and 1D medial skeleton generation. Also included are new registration and alignment functionality and enhancements to remeshing to adjust remeshe vertices to lie on the original CAD patch surface and boundary curves.

HALL 11.0 | STAND C02

Exhibitor Q&A | LITHOZ | HALL 11.1 | STAND D48 Q: Lithoz is showing its multi-material 3D printing capabilities. Tell us about the unique proposition this brings to the AM market.

A: We will show our multi-material printer CeraFab 2M30 to the public for the very first time. Our technology leverages LCM technology to create highly complex structures and geometries with not only one, but two materials to create nextgeneration multifunctional parts. This is made possible by using two separate rotating vats in one printer, moving over the projecting system as needed, curing the respective layer. The materials can not only be combined layer by layer, but also within one single layer to realise parts with perfect gradual variation in material composition.

The material choice can be either two different ceramics, or the same ceramic material printed at different porosities.

But the most thrilling aspect of this machine is that it also combines ceramic with metal or polymer.

In just one print run, entirely opposing material properties, such as conductive versus insulating or magnetic versus non-magnetic, can be flexibly combined in one single multifunctional part. That does not only drastically expand the possibilities in part design but has the potential to substitute time-consuming multi-stage production processes in the industry and also in the medical sector.

Q: You're offering a 'touch and feel' experience. Who or what industries should come and see these parts?

A: This close-up experience is a must-see at Formnext for everyone from industry, medical and academia who is involved in the construction of multifunctional parts. There will be many fascinating multi-material parts to be closely examined outside of the showcases as we really want to make visitors feel the magic of this technology to create next-generation functionally graded components or materials.

Q: Lithoz has the highest total number of technical ceramic 3D printers installed worldwide. What do you think has been key to that success?

A: Our LCM technology has evolved to level of precision that makes it a reliable key technology for its users.

This widely known quality and our way to actively support customers in their innovation have formed a strong foundation of business. Beyond that, we have successfully scaled up LCM to the highest industrial productivity requirements.

Q: Anything else visitors should look out for on the Lithoz booth?

A: Definitely the many industrial parts on display showing how fast LCM technology is making progress in terms of building “ceramic AM factories”.

Whenever metals reach their limits, ceramics can be the solution to unlock an application’s hidden efficiencies.

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Exhibitor Q&A | BRIGHT LASER TECHNOLOGIES | HALL 11 | STAND E11

Q: BLT are planning to make an exciting announcement around Formnext. What can you tell us about it ahead of the event?

A: BLT is excited to introduce the BLT-S400, a metal 3D AM solution for large-scale batch production of industrial parts, and the automatic powder circulation system at the exhibition. With its configuration of three lasers, the BLT-S400 boosts production efficiency, making it an ideal choice for mass production of small and middle-size components.

The global official launch date of BLT-S400 is November 7.

Q: BLT has shown some interesting - and often huge - AM application examples recently. What kinds of applications can visitors expect to find on the booth?

A: One notable highlight was the debut of the BLT-S1500-produced Intermediate Compressor Case. It is a crucial load-bearing component in aviation engines, directly influencing engine performance.

BLT 3D-printed Intermediate Compressor Case is made from titanium alloy material, with external dimensions of Φ1350mm×205mm, and the wall thickness is only about 2mm. Besides, we also bring large components in energy, automotive and so on.

Q: Who is BLT looking to connect with this year? Who should be visiting the booth?

A: BLT has served many clients in aerospace and aviation, medical, energy, industrial mold, automotive, and other fields for more than ten years. We welcome other customers

from different fields to visit our booth and talk to our specialists to explore 3D printing technology to increase efficiency and reduce costs.

Q: Aside from the announcement, what is the one thing visitors must see on the BLT booth?

A: Efficient powder circulation plays a pivotal role in mass production workflows. The BLT-S400 introduces an innovative powder circulation system designed to safely transfer, recover, sieve, and recycle metal powders in an on-site test lab. This system simplifies and secures the movement of large volumes of 3D printing powders from containers to multiple machines, effectively eliminating the risks associated with spillage, contamination, explosions, or contact with personnel. This system empowers manufacturers to meet their serial production needs while achieving substantial cost savings in their operational endeavours.

HP Inc. Personalization & 3D Printing teases debut

Arburg’s high-temperature plastic, carbon fibre and liquid silicone AM

HP Inc. Personalization & 3D Printing will be showcasing its momentum in metals as well as debuting an expanded portfolio of advanced manufacturing services for polymers at Formnext specifically designed to bring higher repeatability and reliability to the forefront with enhanced customisation and faster speedto-market for full-scale production. Come and learn about the applications disrupting industry verticals enabled by HP’s leading Multi Jet Fusion solution, alongside exciting new customers and partners that are pushing the boundaries of innovation, manufacturing more sustainably, and accelerating their scale in additive manufacturing.

HALL 12.0 | STAND D42

ARBURGadditive will be presenting its complete range of products for industrial additive manufacturing based on granulates, filaments and liquid silicone (LSR) at Stand D79 in Hall 12.1.

One highlight will be the new 750-3X hightemperature Freeformer from ARBURGadditive, which produces resilient air distributors from certified Ultem original granulate. TiQ and LiQ series 3D printers from innovatiQ will be demonstrating the processing of fibrereinforced filaments and certified LSR. There will also be many sample components on display, including brand-new APF components made of short-fibre reinforced thermoplastics HALL 12.1 | STAND D79

31.6 / www.tctmagazine.com / 039

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FORMNEXT PREVIEW

Interview | INCUS | HALL 11.1 | STAND D42 Farsoon Europe to show multi-laser capabilities With over a decade of 3D Printing experience in Industrial 3D printing, Farsoon has developed a large portfolio of metal and plastic laser powder bed fusion systems offering a wide range of build envelope sizes and material capabilities. With its “Open for Industry” ethos, the company says it has supported customers across multiple aspects of production-targeted additive manufacturing, from machine configurations, material, process development to applications. At Formnext, Farsoon Europe will be showcasing two multi-laser, industrial-scale 3D printing systems targeting series production, as well as many real-world end-use applications.

HALL 11.1 | STAND C11

Incus launches metal lithography production system Austrian metal 3D printing company Incus GmbH will debut its Hammer Pro40 lithography metal 3D printing platform, weeks after launching the machine.

The company is bringing to market a 3D printer capable of addressing production needs four years after coming to market with the Hammer Lab35 R&D and small-scale production printer.

HALL 12.0 | STAND E81

Incus introduced itself with the Hammer Lab35 ahead of Formnext 2019, spinning out of Lithoz with a proprietary technology that sees metal powder homogeneously dispersed in a light-sensitive resin before being selectively polymerised by exposure with light. The process is capable of producing parts with smooth surface finishes and complex geometries, and has been well received by many manufacturers.

Until now, Incus has been confronted with doubts as to whether the technology could scale to address serial production needs. The Hammer Pro40 is the company’s answer.

It is equipped with a 2x 200 x 76.8 x 150 mm build volume, two new scrolling projectors, and a built-in material reservoir that enables continuous printing.

The machine also exhibits a high potential throughput of 700cm³/hour (print speed of up to 240 layers/h) seven times that of the Hammer Lab35 and a pixel pitch of 40µm in X/Y to enable ‘excellent resolution.

Printing cost per cm³ is said to be four times lower than the Hammer Lab35.

“The biggest shortcoming that people would see for us was scalability,” Incus CEO Gerald Mitteramskogler told TCT. “It’s assumed binder jetting can go super fast, super big, super efficient, [but our process cannot]. With this machine, we’re going to change that perception. Upscaling lithography is possible.”

Incus is expecting to be able to have the Hammer Pro40 machine operational at Formnext, with the company already accepting pre-orders for its latest product.

Unique laser configurations from Prima Additive Prima Additive will showcase its Print Genius 150 Double Wavelength powder bed fusion system.

This platform is equipped with two lasers of different wavelengths: a 500W infrared laser and a 200W green laser which can work alternately on the same Ø150 x 160 mm cylindrical work are. The Print Genius 150 Double Wavelength system can alternate between the two lasers on the same work area, ensuring high performance, reliability and accurate results.

The interchangeability of technology ensures that both conventional materials such as steel, aluminium, nickel, titanium, and cobalt chrome alloys can be processed on the same system, thanks to the infrared laser, and highly reflective materials such as pure copper or precious materials, with the implementation of the green laser.

Prima Additive will also be exhibiting its IANUS Direct Energy Deposition multi-process robotic cell.

31.6 / www.tctmagazine.com / 041

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FORMNEXT PREVIEW

Exhibitor Q&A | RIVELIN ROBOTICS | HALL 12.0 | STAND E41

Q: What can you tell us about your stand at Formnext?

A: We are aiming to show visitors that we have moved to the next level with our stand at Formnext this year. Last year, we formally launched the Netshape Robots and we were inundated with people keen to understand how our technology could deliver automated post processing solutions for metal AM parts. This year’s stand will highlight our solutions once again and will feature a Netshape Robot for metal support removal and finishing as well as offer a demonstrator concept system of a project we have been working on in partnership with Solukon.

Q: What can you tell us about the solution with Solukon that is being introduced at the show?

A: Rivelin and Solukon have identified areas where the two companies can collaborate and combine their expertise to develop autonomous post processing solutions that many metal AM users are demanding. The key goals identified by the two companies will align Solukon’s large automated powder removal solution with Rivelin’s precise and reliable robotic solutions for support removal and finishing, featuring Rivelin Netshape software and Yaskawa EU robots.

Q: Rivelin was a winner of the Formnext Start-up Award last year.

How have things developed since then?

A: Winning the Start-up Award at Formnext last year was a tremendous honour, and kind of highlighted to us that we were on the right track with our solutions to meet industry demands for automated post processing. Formnext really gave us the spring board we needed and we have made tremendous

progress as a company with a number of commercial deals and extending and growing our pipeline of customers. Our team continues to grow and we have moved premises to full accommodate our growth.

Q: Who should come to see you at Formnext?

A: Any and all users of metal AM systems that are facing a bottleneck when it comes to post processing the parts.

Q: Why should people come to see you at Formnext?

A: To find real solutions for automated post processing of metal AM parts. Whether that is for essential support removal or finishing and polishing the parts, it’s often a really dirty, sometimes dangerous, always labour intensive and inconsistent stage of the AM workflow that adds considerable costs. Rivelin Netshape Robots offer a real, efficient, repeatable and cost-effective solution, and we can show you how at Formnext 2023.

Interview | ENDLESS INDUSTRIES | HALL 11.1 | STAND D31 Endless Industries to exhibit patented printhead for composite 3D printing Berlin-based start-up Endless Industries will be showcasing how its proprietary printhead technology for fibre-reinforced parts works.

Named as one of five Formnext Start-up Award winners ahead of the event, Endless Industries will exhibit a small-format converted 3D printer with an Endless Industries print head and a selection of case studies from its booth space.

With Endless Industries’ patented printhead, users are able to upgrade FDM polymer 3D printers to give it composite 3D printing capabilities. The printhead’s nozzle works by cutting the fibre – and only the fibre – towards its hot end where the polymer is already

molten. Typically, fibres are cut higher in the nozzle at the cooler end, but with this method, Endless Industries says it can cut thicker strands of fibre compared to other nozzles on the market, meaning users can benefit from stiffer parts and lower costs, since thicker fibres tend to be cheaper.

Currently, Endless Industries’ printhead can only process materials at temperatures up to 250°C – making it possible to reinforce PETG, PA12, PA11 and PP materials with fibres – but a next-generation product that can reinforce polymers like PA6, polycarbonates and potentially PEEK is in the works.

“We see ourselves as complementary to what’s already on the market,” Stephan Koerber, Business Development & Finances at Endless Industries, told TCT. “We see

that there’s so much more potential if we give everybody a chance.

Currently, the market for carbon fibre 3D printing is hindered.

There’s lots of applications that would make sense with fibres, but it can be hindered by material selection, price, machine selection, and we want to see what it can achieve.”

31.6 / www.tctmagazine.com / 043

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EXEC Q&A

In October, Vitro3D was named as one of five Formnext Start-up Award winners, with the company recognised for the potential of its Volumetric Additive Manufacturing (VAM) technology.

This technology was initially developed at the University of Colorado Boulder in a bid to solve a number of challenges involved in photopolymer 3D printing. With the company raising 1.3 million USD in seed funding last year, it is targeting commercialisation by 2025.

Recently, TCT Group Content Manager Sam Davies sat down with Vitro3D CEO Camila Uzcategui, PhD as part of an as yet unreleased Additive Insight podcast episode to learn more.

TCT: Vitro3D talks about addressing the limitations of photopolymer 3D printing.

What are those limitations and what has been the key to addressing them?

CU: So, by the time that I graduated [from University of Colorado Boulder], and I joined the [Bob] McCleod Lab as a postdoc, we were starting to pivot from digital light production and stereolithography, to really seeing what volumetric additive manufacturing could do in these complex parts and new application spaces. And when we started to do that, we realised that volumetric additive manufacturing could solve some of the biggest challenges when we start to think about photopolymer additive manufacturing, such as the lack of ability to go into really high viscous materials, the fact that you need support structures, in many cases, in order to print these complex parts, and also just the speed of the process. When I was early in my PhD, 3D printing scaffolds for surgeries that we were implanting in some animal models, I was spending 20, to 30 minutes to print one five millimetre by five millimetre by two millimetre part. And then [when] I started working on this technology when I was doing volumetric work, we could print something of a similar size in just a few seconds.

046 / www.tctmagazine.com / 31.6

TCT: So, can you tell us as much as you can about Vitro's Volumetric Additive Manufacturing technology?

CU: The best way that I can describe our volumetric additive manufacturing technology is through the idea of a CAT scan. So, [with a CAT scan] you go into a machine, that machine has a circular structure around you and it's taking pictures from a bunch of different angles through some sort of light source. What that does is it takes pictures at these different angles, and then it uses a computational algorithm to then take those pictures and add them all up to create a three dimensional virtual image.

So, that is how we get the CAT scan results and have a 3D virtual image of what's going on inside of the body. The principles of the particular volumetric additive manufacturing technology that we work on is an inverse CAT scan. So, rather than taking a picture from a bunch of different angles of a 3D volume, what we do is we take a 3D virtual object, and we deconstruct it into all the different angles that make up that part.

We say that the magic is in the software, because we don't use just a standard slicer to slice a three dimensional virtual object into its two dimensional constituents slices, we have to go through a very robust algorithm that takes this three dimensional virtual object, deconstruct it into these different angles, and then allows us to use this algorithm to then incorporate the properties of the material itself, and then project a two dimensional image for each angle into the volume of a photopolymerisable resin. And then, as those intensities overlap, where they're highest, those are the only regions that are going to go from liquid to solid and go through that photo polymerisation.

TCT: I understand that one of the key elements to Vitro3D’s VAM technology is the speed. So, how has Vitro3D been able to facilitate rapid printing while preserving accuracy and resolution?

CU: One of the aspects that make volumetric 3D printing or volumetric additive manufacturing so magical is our ability to materialise something all at the same time.

So, because the process works, by getting to a certain energy

dose that then that critical energy dose is what actually allowing us to go from liquid to solid and photopolymerisation, we're able to materialise the entire part all at once, rather than in this layer by layer process. So, that makes it not only much, much faster, but it gives us new capabilities, such as printing around existing objects, as well as printing in first part and then printing around that first part in a secondary process through this volumetric additive manufacturing over moulding and over printing capability.

Vitro3D will be exhibiting at Formnext in HALL 11.1, STAND B55C.

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