TCT North America 10.3

FROM THE EDITOR SAM DAVIES

A brand don’t come for free

On the horizon, a terrifyingly few weeks away, RAPID + TCT will return for its 35th year.

Once again, the North American additive manufacturing market will come together at the continent’s most important additive manufacturing and industrial 3D printing trade show. It comes around fast but it's never easy to lead the charge in the market with the biggest AM installed base. And do so for 35 years.

To be the most important event in an entire continent takes a deep level of expertise, a will to collaborate with a network of industry partners, and an understanding that its mission is to always serve the market. With 35 years in the game, RAPID + TCT carries a strong legacy and a rich heritage – the kind that can have only come from achieving that mission year after year, and the kind that sets itself up for continued evolution.

It started out as a half-day clinic in 1987, with the first event adopting the RAPID moniker coming in 1990. RAPID was held in Dearborn, Michigan throughout most of the 90s, before its tour across the U.S. started in 1999. Rosemont, Cincinnati, Chicago, St. Charles, Orlando, Schaumburg and Anaheim would all welcome the RAPID event by 2010, with Minneapolis, Atlanta, Pittsburgh and Fort Worth hosting the

show across the following decade. This year, the North American AM community is heading to Los Angeles. Next it will be back to Detroit and then in 2026 onto Boston for the first time.

Whatever the year and wherever the location, RAPID (+TCT since 2016!) has provided the same high-quality service to the North American market pretty much since the first technologies were commercialized. Having seen the quality of the exhibitors on the show floor and the speakers across its various conference stages, the 2024 event will be no di erent.

As another of the industry’s leading events organizers, and a leading AM media organization too, TCT is proud to partner with the SME on the RAPID event.

This being our third magazine issue of the year, our coverage of RAPID begins now. From page 49 onwards, you can learn all about the product launches, keynote panels sessions and conference presentations to be delivered this June, with more to come once we touch down in LA. Stick with us as we match North America's most important AM event with the industry's most comprehensive coverage.

EDITORIAL

HEAD OF CONTENT

Laura Gri ths e: laura.gri ths@rapidnews.com t: + 44 1244 952 389

GROUP CONTENT MANAGER

Samuel Davies e: samuel.davies@rapidnews.com t: + 44 1244 952 390

ADVERTISING

HEAD OF SALES TCT PORTFOLIO

Carol Cooper e: carol@rapidnews.com t: + 44 1244 952 386

TELEPHONE SALES EXECUTIVE

Amy Gilham e: amy.gilham@rapidnews.com t: + 44 1244 952 373

PRODUCTION

Sam

Hamlyn  Matt Clarke  Robert Wood   MANAGEMENT

C.E.O. / PUBLISHER

Duncan Wood

Cover story

4

4. MASTERS OF ELECTRON BEAM

JEOL details how it is bringing its legacy electron beam technology sophistication to additive manufacturing.

Aerospace 7

7. I PRINT, THEREFORE I-DAMP?

Sam Davies speaks to Hyphen Innovations CEO Onome ScottEmuakpor about the company’s inherent damping via additive manufacturing processes technology.

11. PUSHING HORIZONS

Stratasys Global Director of Aerospace Foster Ferguson & TriTech 3D Sales Specialists provide insights on the implementation of AM in aerospace.

13. INSIDE GE AEROSPACE

Sam goes through the doors at a GE Aerospace facility to understand the company’s AM strategy.

Polymers

19. WHAT NEXT?

19

3D Systems, Nexa3D, Formlabs and BASF open up on the progress being made to develop more highperformance materials for resin 3D printing technologies.

23. ON THE VERGE

Laura Gri ths speaks to KraussMa ei about the plastic fabrication company’s additive manufacturing o ering.

Jigs & fixtures

27. THE JIG IS UP

Laura highlights the opportunities for gains in the 3D printing of jigs & fixtures, with insights and examples from several industry players.

45. MEET THE INNOVATORS

With the annual TCT Awards ceremony on the horizon, we celebrate the nominees for this year’s TCT Women in 3D Printing Innovators Award.

31. 10 YEARS OF TCT ASIA

After another hugely successful TCT Asia event in Shanghai, we speak to some of the key exhibitors who have been with us every step of the way.

Production

33. A NEW ARC

Laura and WAAM3D CEO Filomeno Martina discuss WAAM3D’s unique capabilities, how to create value in supply chains, and an upcoming product launch.

37. ZEROING IN

Sam reports on how 3T AM is working towards its Net Zero goals as it continues to scale its manufacturing output.

41. CASTING CALL

America Makes Program Manager Litsa Rubino explains how America Makes is driving the integration of additive across sand casting.

49. THE HOME OF US AM

Across 14 pages, we preview what to expect from this year’s RAPID + TCT event, from the products showcased on the show floor to the insights imparted on the conference stage.

64. PLAYING THE LONG GAME

3D technologies consultant Steve Cox asks the question: where are we now when it comes to adoption of AM in the UK?

MASTERS OF THE ELECTRON

JEOL brings beam technology sophistication to AM.

For over 75 years, JEOL has been synonymous with innovation in electron beam technology.

The name JEOL stands for “Japan Electron Optics Laboratory,” and is a testament to JEOL’s commitment and mastery of the electron beam.

Established in Tokyo in 1949, the company initially focused its expertise on electron microscopy, with its development of transmission electron microscopes as well as scanning electron microscopes, semiconductor photomask production and lithography solutions. To this day, JEOL is synonymous with instrument accuracy, reliability and excellent customer support. However, in 2014, JEOL embarked on a groundbreaking journey into a new industry, additive manufacturing (AM), culminating in the development of its latest innovation –the JAM-5200EBM metal 3D printer.

This machine not only highlights JEOL's rich history in sophisticated electron beam technology, but also represents the culmination of decades of precision engineering and beam steering expertise now applied in the dynamic realm of metal 3D printing. This expertise, combined of JEOL’s comprehensive service support network of 180 field service sta across the United States with a median sta tenure of 17.5 years, helps ensure minimal downtime and optimal machine performance. In fact, JEOL USA’s standard warranty and service contracts guarantee a machine uptime of at least 90% along with an onsite response time of 48 hours after an issue has been reported.

TECHNOLOGICAL SUPERIORITY

The JAM-5200EBM distinguishes itself through its cutting-edge Electron Beam Powder Bed Fusion (EB-PBF) technology. Equipped with a robust 6kW electron beam, this machine operates at speeds a thousand times faster than conventional lasers used in similar technologies. This phenomenal speed and power advantage drastically reduces production times and circumvents the need for several postprocessing steps that are traditionally

necessary in metal 3D printing, such as stress relief heat treatments and wire electrical discharge machining (EDM). The JAM-5200EBM’s electron emitting source has a lifetime of >1500 hours, which is the highest lifetime source in the EB-PBF market.

production cycles. Compliance with AMS7032 standard involves several key factors:

● Material Consistency and Traceability: Ensuring the powder used in the printing process meets strict compositional and particle size specifications in accordance with standard AMS7011, which is for Ti6Al4V Grade 5 produced with EBM technology. This is vital for maintaining the integrity of the final printed products.

connection to the build plate. This capability, unique to EB-PBF, allows for the largest quantity of run meet higher production quantities.

EB-PBF is known as a “hot process” as the powder bed is maintained at an elevated temperature using the electron beam prior to melting at each layer. This is known as the “preheat” step and achieves several advantages, including enabling parts to be printed anywhere within its build envelope, even without connection to the build plate. This capability, unique to EB-PBF, allows for the largest quantity of parts to be built in a single run to meet higher production quantities.

REDEFINING INDUSTRY STANDARDS

REDEFINING INDUSTRY

In late 2023, JAM-5200EBM achieved compliance with the stringent AMS7032 standard, a milestone that rea rms its

grade materials with outstanding reliability and

In late 2023, JAM-5200EBM achieved compliance with the stringent AMS7032 standard, a milestone that rea rms its ability to produce aerospacegrade materials with outstanding reliability and precision. The JAM-5200EBM underwent rigorous testing and quality assurance protocols to evaluate its ability to produce parts with consistent mechanical properties, chemical composition, and material properties across multiple

“A culmination of decades of precision engineering and beam steering expertise”

JAM-5200EBM underwent rigorous testing assurance protocols to evaluate its ability mechanical properties, and material properties across multiple

SHOWN: JAM-5200EBM metal 3D printer

BEAM

● Process Stability and Control:

Demonstrating the JAM-5200EBM can consistently produce parts with the same high quality over repeated runs and under varying operating conditions. This includes maintaining precise control over the electron beam parameters and environmental conditions within the build chamber.

Inauguration of JEOL’s JAM-5200EBM at Cumberland Additive in Neighborhood 91

● Consistent Mechanical/Material Properties: Conducting extensive mechanical, material, and chemical composition testing on printed specimens to verify that they meet or exceed the performance criteria set out in the AMS7011 standard, which includes requirements for Ti6Al4V Grade 5 material produced with EBM technology.

The successful compliance with AMS7032 not only highlights the robust performance of the JAM-5200EBM but also positions JEOL as a pivotal player in sectors where the precision, material properties, and repeatability are of utmost importance. For aerospace manufacturers, this compliance provides the assurance that AM parts meet stringent safety and performance standards, for critical aerospace applications.

Demonstrating compliance with AMS7032 is not just a technical accomplishment for JEOL, it is a testament to the company’s commitment to quality, reliability, and industry leadership. It opens doors to new market opportunities where compliance is a prerequisite and enables JEOL to engage more deeply with key industry players who require the highest levels of assurance in material and build quality.

GLOBAL STRATEGY

The strategic introduction of the JAM-5200EBM at Cumberland Additive in Pittsburgh’s Neighborhood 91 was more than just a product launch within the North American market; it represented a significant stride in JEOL’s global strategy. Neighborhood 91 is designed as a comprehensive ecosystem for AM, enhancing synergies by connecting all phases of the printing supply chain. This setting is ideal for showcasing the JAM-5200EBM’s capabilities, emphasising its quick setup and operational excellence.

The collaboration with Cumberland Additive, a contract manufacturer specialising in AM, enables JEOL to leverage Cumberland's extensive expertise in producing high-quality parts for aerospace, energy, defense, and space industries. This partnership not only demonstrates the capabilities of the JAM5200EBM but also serves as a beacon for the potential of EB-PBF technology in critical sectors.

Bill Freyvogel, Chief Commercial O cer, Cumberland Additive, comments:

"We have developed a unique partnership with JEOL as their presence within our N91 facility enables us to a collaborate and expand access to new materials for our customers. We are making solid progress towards supporting our aerospace and defense customers with serial production parts and we view this as just the beginning.”

As JEOL continues to push the boundaries of what is possible in AM, the company remains committed to enhancing the functionalities of the JAM-5200EBM.

E orts are ongoing to expand the range of compatible materials, potentially including high melting point and refractory alloys which could open new avenues in sectors such as aerospace, defense, and energy. Recently, JEOL developed a process parameter set for Pure Tungsten, which notably has a high melting point and is challenging to manufacture from a conventional machining standpoint and printing using laser-based powder bed fusion processes.

Another example of enhanced functionalities of the JAM-5200EBM is the imminent release of JEOL’s Back Scattered Electron Imaging system, a game changer for in-situ process monitoring. Using already established technology developed on JEOL’s Scanning Electron Microscopy, the JAM-5200EBM is capable of scanning and detecting the backscattered electrons emitting from the powder bed and forming an image of the layer. This image allows for potential defects within the melted layer to be detected and reported, resulting in a highly e ective process monitoring and quality control process. Future developments of this technology will allow for defects detected to be repaired in-situ, allowing for improved material quality produced by the JAM-5200EBM.

Future initiatives also include deepening collaborations with leading industry partners and research institutions to explore novel applications of EB-PBF technology. In April, JEOL installed a JAM-5200EBM at the Technical University of Munich, which is deeply engaged in AM research and aims to drive further innovation using JEOL’s EB-PBF technology. These kinds of collaborations are expected to drive further advancements in design and material science, expanding the potential for AM to meet complex and evolving industry needs.

THE FUTURE OF AM

The JAM-5200EBM stands as a testament to JEOL’s commitment to innovation and excellence in metal 3D printing. By seamlessly integrating decades of expertise in electron beam technology with the latest advancements in AM, JEOL is not only following industry trends but actively setting them, o ering new levels of e ciency, quality, and reliability in metal production.

As JEOL looks to the future, it is poised to continue its e orts in transforming the landscape of AM with solutions that meet current demands but also anticipate and shape future developments.

SHOWN:

Titanium Grade 5 electron source chamber

SHOWN:

I PRINT, THEREFORE I-DAMP?

Sam Davies speaks to Hyphen Innovations CEO Onome Scott-Emuakpor about the company’s vibration suppression technology for AM.

So, a little about myself,” begins Onome Scott-Emuakpor.

A college basketball player turned mechanical engineer turned founder/CEO, Scott-Emuakpor is talking ahead of his second appearance as a speaker at TCT 3Sixty. His first, in 2022, saw him present on behalf of the U.S. Air Force Research Laboratory (AFRL), delivering a talk that focused on the development process for verifying the integrity of additively manufactured (AM) parts. Two years on and he’ll be demonstrating how a technology called i-DAMP can enable the binder jetting of a superalloy for high-pressure turbomachinery and aerospace applications. In between, he picked up the TCT Aerospace & Defence Application Award less than a year after setting up the Hyphen Innovations business that has brought i-DAMP to market. i-DAMP, or Inherent Damping via Additive Manufacturing Processes, is the result of years of AM research and engineering. ScottEmuakpor has around 20 years of experience in structural mechanics, structural dynamics assessment, and their correlation to turbine engine structural integrity. He first started working with AM about 12 years ago.

“Once I got to the point in my professional career that I started working on figuring out ways to improve performance of individual components,” Scott-Emuakpor explains, “it was clear that additive manufacturing was a viable path to take leaps and bounds in being able to make components that just couldn’t be made any other way.”

He just had to figure out how to expedite the implementation of AM in a safe and repeatable way. Scott-Emuakpor was lucky that, at the AFRL, he had access to true stateof-the-art technology, giving him insights not just into the challenges of metal AM, but the potential solutions too.

“We’re able to suppress vibration enough that it’s not a concern.”

The challenge that Scott-Emuakpor wanted to sink his teeth into was that of vibrations and vibration fatigue. Vibrations occur, of course, in any product or system that has a motor, from bread makers to cutting tools to turbine engines. At best, they cause a racket or mean a less pleasant ride, and at worst, they can cause critical failures. In 2018, a mother of two on Southwest Flight 1380 died after debris from an engine failure smashed a passenger window on the 14th row, partially sucking her out of the window and delivering blunt trauma to her head. It was caused by severe vibrations in the left engine.

“The thing with turbine engines is that, once a crack initiates and it starts to propagate, the time it takes for that to happen can be within minutes. So, it’s not one of those things where [you can] land the plane in 30 minutes and try to figure it out. Once it happens, it’s done and the damage is there. Because of that, there’s a lot of inspection that goes on, a lot of free understanding of the material and the component before everything’s been assembled, and so, in general, it’s good to reduce vibration.

“Then, when you incorporate additive manufacturing, you incorporate the fact that the variations in manufacturing for additive are significantly more than the variations in manufacturing from forging or machining or casting. For us, we thought, 'what if you just got rid of the vibration completely?' Then, all of a sudden, the stresses are so low that the variation in the material property that you’re concerned about is no longer an issue. That philosophy, that thought process, was the birth of i-DAMP.”

i-DAMP was developed at the U.S. Air Force, with the technology using automated computational code to examine finite element results and strategically place voids in areas of printed parts that avoid high stresses. These voids trap unfused powder

within them, which helps to dissipate energy when the part starts to vibrate, suppressing the overall vibration of the system. The unfused powder, then, is performing much the same role as a pendulum does in the middle of a building that has been constructed in a city susceptible to earthquakes.

Scott-Emuakpor says that the technology opens the door for redesign opportunities, reducing the weight of a part or creating more fuel e ciency, but he also notes that there are immediate benefits when using i-DAMP without changing any external geometry. One project with the Air Force has seen i-DAMP deliver a 10x improvement when it comes to damage resistance without any need to tweak the external geometry of the part.

Hyphen Innovations also sees great opportunity in the consolidation of components by combining i-DAMP with AM. Typically, monolithic parts are considered to be more susceptible to vibration than multi-part assemblies because there are no connecting interfaces to dissipate energy during vibration. So, manufacturers would on the one hand enjoy the weight reduction and fuel consumption improvements enabled by part consolidation, but the part would be more susceptible to failure as a result of the high stress during vibration.

“Some people accept that, if there’s a costbenefit and they can easily track it, but if we do something like incorporate i-DAMP into this system now, not only were you able to consolidate the parts, reduce costs and all these other things, we’re also able to suppress vibration enough that it’s not a concern.”

Though early in its journey, Hyphen Innovations has already engaged in projects with the U.S. Air Force and sees plenty of longterm potential in i-DAMP within the aerospace and defense sectors. Such are the lengthy qualification and certification processes in those industries, however, Hyphen Innovations is also hoping to make a more immediate mark on other markets, such as automotive, maritime, tooling and household appliances.

The company is a small outfit, though, and so as it looks to broaden its horizons, it must think di erently about how it approaches each project. Currently, the modestly-sized Hyphen Innovations team engages on a personal level with each use case that presents itself. But the goal is to take a step back from every development process, and instead provide a software tool that has much of the knowledge baked into it.

“Right now, if an aerospace company is interested in this, they have to reach out to us and then we’re involved in the development process, we have to tell them where to put their unfused powder voids and how to redesign and so on. It can be a bit cumbersome and not quite done in a timely fashion,” says Scott-Emuakpor, before citing nTop’s development of an ‘intermediate step’ that automates elements of part design.

“We’re trying to create this intermediate step where you create your initial design. You say, ‘well, I want to increase damping and I want to be able to optimize this for weight,’ and all of a sudden, this software does that for people in an automated fashion and now we’re able to leverage the full strength and capability of i-DAMP.”

It is the next step of a venture that is, in one way, years in the making and, in another, centuries. As an engineer with a passion for technology, the decision to leave the AFRL and go his own way was a hard decision to make. But as a Black American fascinated by entrepreneurship and technology development in the black community, it was an easy one.

Citing the U.S. Census, Scott-Emuakpor notes how the white community has ten times more resources available to them than the Black Community, and when you look at the history books, members of the Black

Community were for a long time denied the right to own intellectual property. When that was eventually legalized, they were often priced out.

Even today, the Black American community makes up around 14% of the US population but only accounts for around 2% of current patent awards.

The challenges for Black American entrepreneurs throughout history, then, have served as an additional motivation for Scott-Emuakpor, who not only wants to address the challenges in additively manufactured industrial parts but also to be an inspiration to other Black entrepreneurs and engineers.

“From an entrepreneurial perspective, you had obstacles where if you started a business, your biggest concern wasn’t that you may go bankrupt, your biggest concern was that you may literally lose everything, like your family, your entire neighbourhood could get burned down. Despite those significant obstacles, we had so many people from the Reconstruction Era to the Jim Crow Era who developed businesses with that fear and still went through it.

“My only obstacle is that my business might fail. And that’s it. If my business fails, I take myself and my PhD and my experience and go get another job. It’s not a genuine obstacle. If not somebody like me, with the background, with the understanding, to go out and start my own business, then why should I expect someone else to have confidence? I feel like me doing this is honoring the sacrifices that were made by people before me who were putting their lives on the line to come up with new technology and to start businesses. It feels like a natural calling to go out there and take a chance that was much less of a chance than those who came before me.”

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WORDS: LAURA GRIFFITHS

You're always contending with trying to make sure that you have the best readiness for your vehicles and equipment,” explains Foster Ferguson, Global Director of Aerospace at Stratasys, and a retired Lieutenant Colonel for the United States Marine Corps.

It was there where Ferguson, having spent two decades in supply chain logistics, and as a former Commander for a maintenance battalion focused on intermediate level repair for everything from trucks to optics to radios and ground equipment, began thinking about additive manufacturing (AM).

“We started on that journey knowing that there was pretty substantial capability out there and we started looking around and trying to find out who we could partner with,” Ferguson says of how the mission brought them to Stratasys. “We trained a team of about ten Marines, supply guys, warehouse guys, machinists and technicians. We quickly learned that these mechanics that are working on these things day in and day out know the areas that they need to a ect. Additive was just this wonderful alternative.”

As the US Department of Defense's curiosity in AM heightened, policy was being created, but Ferguson was nearing a crossroads: to stay in the military or retire. Instead, Stratasys wanted to hire him to support its government military activity, and the AM journey continued.

FORCING THE FUTURE

Ferguson describes the current state of AM adoption in the aerospace, space and defense industries as being at an inflection point. The Lockheed Martins, Boeings, Northrop Grummans and Blue Origins of the world are taking a digitized approach to production and designing with additive in mind, where it makes sense. Ferguson believes there is great opportunity for AM, primarily around supply chain, localized manufacture, and sustainability, but more could be done to encourage adoption.

“Those days of being a generalist are gone.”

“Awards should have some sort of additive component,” Ferguson suggests. “Policy and awards will drive that if it's written into the language for organizations to really think critically about it. We have to force ourselves to move into the future.”

Global events and pressures have undoubtedly played a role in forcing companies to innovate. We witnessed this at the height of the pandemic when 3D printing experienced a fresh surge of intrigue as its banner ability to manufacture locally and on-demand seemed like a silver bullet in a world of supply chain disruption. But is AM really having the profound impact on the aerospace supply chain that was promised? Ferguson shares an example from a recent visit to an unnamed defense prime manufacturing parts for space in the U.S., and describes being ‘blown away’ by the volumes being churned out of a fleet of seven F900 FDM systems.

“It was everything from production support to design iterations, into the full end of that spectrum for production parts fully integrated into the platform. That's happening in a lot of locations,” Ferguson says. “I think that if an organization is not considering additive as part of their strategy for manufacturing, then they're behind, and I really feel that we've crossed that chasm where we've had the early adopters and now we're getting into this early majority.”

A decade has passed since Stratasys made headlines with its 1,000 3D printed parts for an Airbus A350 XWB aircraft. Each of those parts was printed using Stratasys' flagship FDM technology in Airbus-certified ULTEM 9085 as part of a schedule risk production activity to increase supply chain flexibility. Since then, Stratasys has expanded its polymer technology o ering through a number of acquisitions and internal developments and now counts five core technologies alongside a catalogue of advanced materials. Ferguson believes that polymers, in particular, have provided agile ground for aerospace innovation to happen, especially for in-field defense manufacturing where the barrier can be much lower than metals.

SHOWN:

AM in the aircraft cabin

“When you get into high-performance thermoplastics with our FDM technology, they're filled with di erent types of materials,” Ferguson explains. “We have a nylon material that's 35% chopped carbon fiber, it's essentially the same mechanical strength as aluminum. I can go from 140 parts on an assembly down to 16. That changes the weight, and of course the speed to design. When you're talking about how much it costs to send a rocket into space, every kilogramme has to be measured. That's where polymer additive is nicely positioned.”

In the UK, Senior Aerospace BWT, a supplier to regional, military, private jet, and rotorcraft markets, is using a pair of Stratasys Fortus 450mc 3D printers from Tri-Tech 3D to produce interior components for low-pressure air ducting systems and air handling in aircraft interiors. After delivering its first duct for flight use on regional passenger jets in 2018, the company has supplied hundreds of lightweight, flight-ready interior aircraft parts. More recently, BAE Systems installed the first two Stratasys F3300 systems in the UK via Laser Lines. The F3300 was launched last year to provide a ‘step change’ in print speed with rates up to twice those of current highproduction FDM systems. BAE Systems plans to use the technology to drive product improvements, while reducing time to market across the company’s Air sector products. At the time, Steven Barnes, Additive Manufacturing Lead for BAE Systems Air sector, commented that the machines are giving the British defense company the ability to “rapidly prototype new parts,” and “stand ready-toproduce one-o spare parts at the touch of a button.” Without going into detail, Ferguson concurs that BAE Systems’ engineers are “very visionary” in their plans for the technology.

“It's a completely new platform,” Ferguson says of the F3300. “We've designed a lot of sensors and information flow, so that will continue to evolve, and I think that the user will have a very informative experience, and certainly when it's integrated into their other systems, it'll be a real asset for them.

“It's been a lot of work over the years, but we built this in collaboration with our customers.”

DIGITIZING SUPPLY CHAINS

Stratasys reseller Tri-Tech 3D’s Robert Pitts recently described 'AM utopia’ as the ability to print functional, end-use parts. That 1,000 parts on an airplane figure from 2014 is now more like 2,500, but that doesn’t mean we’ve quite reached utopia yet. At the recent AMADS Conference in the UK, in a conversation about AM in defense, John Sneden, the Air Force Director of Propulsion at the US Air Force Life Cycle Management Centre, commented, “If I’m at war and it takes 6-9 months to deliver the part, how useless is that?” The last time TCT spoke to Stratasys about aerospace in 2021, the takeaway was that AM confidence was an ongoing challenge. And much like the supposed silver bullet in supply chain, digital inventories, often lauded as the holy grail for AM in a production capacity, are far from easy to implement. Though, according to Ferguson, aerospace organizations very much want to.

“Going back to the days of being in the Marine Corps, taking these large defense logistics agencies that have warehouses of stock and contracts that aren't responsive to the needs,” Ferguson recalls, “how do we position a digital inventory, but then of critical importance is, how do you secure it from a cybersecurity perspective?”

The aerospace sector is, naturally, risk averse. You cannot have failures at 33,000 feet in the air, nor on the ground in a combat zone, and while the sector has led the way for a lot of AM adoption, that aversion can be limiting. Yet, in addition to clear avenues like lightweighting and MRO, Ferguson feels there is room for the

aerospace sector to leverage AM to address further challenges.

“I think that there's an opportunity to address quality issues with additive,” Ferguson explains. “When you're getting into testing and quickly developing fit function checks, the things that might be required through a quality inspection, quality assurance inspection, additive is a great tool for that. Quality and safety are major issues. Stratasys has got a great opportunity here to help these engineers with quality and inspection.”

Aerospace, space and defense are often grouped together, but they each have very di erent demands. While aerospace may practice more caution with time tested standards, the space industry is fast moving, and there’s no blueprint for how things should be done. Stratasys recently provided 3D printed samples that will be brought to the lunar surface in a series of Northrop Grumman-sponsored experiments as part of Aegis Aerospace’s first Space Science & Technology Evaluation Facility mission. Whether it’s on the moon, on a commercial airliner or in combat, focusing on each of those unique opportunities will be key to ensuring meaningful adoption continues.

“Aerospace is unique because you generally have a lot of innovation. You're going to push the horizons of technologies, software and materials,” Ferguson says. “Those days of being more of a generalist are gone. We very much have a vertical focus with our customers – it's helping pull us all forward.”

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INSIDE GE AEROSPACE

Sam Davies reports on GE Aerospace’s AM strategy from inside the company’s Additive Technology Center in Cincinnati.

When Thomas Edison made his carbon filament breakthrough in the development of the incandescent light bulb in 1879, the light emitting beyond the glass bulb would last only a matter of hours. Innovative though it may have been, it was ultimately insu cient for the world we were threatening to build.

Edison and his peers persevered, however. The development of a bamboo filament upped the lifespan of a light bulb to 1,200 hours, and the tungsten filament pushed things further along again. Today, fluorescent light bulb technology lasts tens of thousands of hours, and LED lighting technology can last hundreds of thousands.

As Edison spearheaded the research and development of light bulb technology in the US, and separate teams worked to push the envelope across the Atlantic Ocean, he merged his Edison General Electric Company with Thomson-Houston Electric Company to form General Electric (GE) in 1896.

Fast-forward 130 years and General Electric has established itself not only as a leader in energy, but also healthcare and aerospace. And through its endeavors in the latter, it has invested

heavily in additive manufacturing (AM), a suite of technologies that have a not too dissimilar trajectory to the light bulb, according to Benito Trevino, General Manager for GE Aerospace’s Additive Integrated Product Team (IPT).

“The first light bulb lasted several hours, and that’s not sustainable for what we need in the world,” he says. “Now, they last thousands of hours. Same thing here. We need that breakthrough in performance so that we can really unlock all the possibilities of additive.”

THINKING ADDITIVE

Trevino is speaking on a Friday afternoon, dialling into a meeting set up after a tour of GE Aerospace’s Additive Technology Center (ATC) in Cincinnati, Ohio, hosted by then ATC Site Leader Chris Philp. His voice is being sent across the airwaves to provide insights on strategy, supplementing those given by Philp on the ground.

During the tour of the ATC, it is made clear that GE Aerospace has a big play with additive in the defense sector, particularly through the development of its T901 engine and its work with the US Army AH64 Apache and Sikorsky UH-60 Black Hawk military helicopter contracts. Much of the evidence of this work is shielded by coverings and rooms that require authorized access, but it is referenced at regular intervals.

GE Aerospace’s most renowned

additive manufacturing applications –such as the LEAP fuel nozzle – have so far been produced for commercial aircraft, but it is clear that defenze is now firmly on the agenda.

“We’re seeing a significant increase in interest on the military front,” Trevino o ers. “This, coupled with an increase in complexity of the hardware, is pushing the technology to the limits. We want to seize on the opportunity ahead of us.”

“When we first started using additive manufacturing for LEAP and 9X, GE had big commercial engine programmes coming through,” Philp adds. “So, we were able to use those engine tests to validate the potential of additive technology and the rest is history. We built our reputation internally within GE as something that we should be thinking about with new engines going forward. Now, new engines, such as Catalyst, T901 & XA100, were designed with additive capabilities in mind from the beginning.”

BEHIND THE SCENES

When GE Aerospace first began applying additive manufacturing to parts for its mature engines around a decade ago, they were typically replacing existing components one-for-one, as the application warranted. Some of these components, the ones that kickstarted GE’s journey with additively manufactured end-use parts, are presented on a table to the left as we step foot on the factory floor. They visibly grow in size and complexity and lead the eye towards a poster of the Apache and Blackhawk helicopters adorning the back wall of the facility.

The application showcase is concluded after 20 minutes, and Philp is now leading us beyond a fleet of Concept Laser X Line 2000R machines, detailing their 160-litre build volume and dual-laser capability. The X Line systems sit beneath the vast

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o ce space, which is situated within an octagon structure that has several walkways out onto the shop floor, encouraging members of the team to engage with the work being carried out down below.

We keep walking. Philp points out the locations of the facility where such things as prototyping, powder handling and machining are carried out. The conversation eventually lands on inspection and in-process monitoring. As a development center, GE Aerospace accepts that things will go wrong with its print jobs, but there’s an emphasis on understanding why, and doing so quickly.

“We’re flying people all over the world, we have to get it right,” Philp later remarks. Such is life, the company expects issues often happen overnight or over the weekend when building parts on the additive printers, so camera technology is used to record print progress, and recoat analysis tools have been implemented to analyze the builds layer by layer and flag any defects. Pictures are taken before and after each recoat, with an algorithm then looking into the pixelation to identify any peculiarities.

“It's an important part of our development process,” Philp says. “I think it's useful enough that we want to implement this in high volume manufacturing as well, we want to be able to walk down a line of 50+ machines and not have to go and peer in the windows. Instead, you're just walking past and you're looking visually at the monitors.”

EVERYDAY I WRITE THE BOOK

The work carried out at this facility is of mighty significance to GE Aerospace’s application of additive technology - it is one of several sites that will receive additional funding this year as GE invests 650 million USD into its manufacturing locations. And it is here where GE

engineers push 3D printing technology to its limits, understanding just how much they can achieve. The machines are said to be designed to run 24/7, and so GE Aerospace is happy to have some of its machines run jobs that can take several weeks to complete. Although there are plans afoot to bring such times down by more than half.

The ATC is a hub of application development. Once the team here have smoothed out all of the bugs, set the parameters and inspected the components, production can commence at another facility, and the aircraft that installs GE’s engines can start enjoying some new performance, cost, and weight benefits. Those benefits are coming at such a pace now that GE is ‘thinking additive’ when it approaches the designs of components and systems.

“We’re some of the key authors writing this AM chapter.”

There are even parts that, on the surface at least, bring no weight, cost, or performance benefit in isolation, but when integrated into an engine serve to improve the performance of those parts around it. The GE9X, for example, is equipped with eight 3D printed cyclonic inducers. These parts add weight and, in isolation, ‘wouldn’t buy themselves onto’ the engine but work to remove dust from the system and reduce wear on other components.

“We challenge the team ‘what is the benefit to the engine, what is the benefit to our customer, by moving this part or designing this part using 3D printing technology?’” Philp says. “As we mature, and as we grow, and as we industrialize, our costs will come down.”

“We’re evangelists,” Trevino adds. “We believe in the technology, but we’re early. We still haven’t matured the cost to the point that you could take two components side by side and say additive wins every time. So, we have to be disciplined about making the right decisions for parts. I think in the future – 10, 15 years from now – as the printer technology advances, there will be a time in which you will take components side by side, and it’ll be a no brainer to proceed additively.

“It’s early, [but] we’d like to think that we’re some of the key authors that are writing this whole additive manufacturing chapter. As I think forward, I am very hopeful that it’s going to be the way we produce hardware in the future. We have to have the intestinal fortitude to be part of that change and to push the envelope on the advances of the technology.”

This article was originally published via TCT’s monthly Additive Insight Deep Dives newsletter on March 28th, 2024. www.tctmagazine.com/subscribe

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WHAT NEXT?

Sam Davies explores the progress being made in the development of highperformance materials for resin-based 3D printing technologies.

The sight of a stereolithography (SLA) part gradually turning brown while perched on a worktop is a familiar one for many long-time users of the technology.

So too is the same part dispersed into a hundred pieces on the floor seconds after being handled by a butter-fingered colleague.

But these instances are increasingly becoming a thing of the past, as materials, processes and knowledge all continue to improve.

Many people point to di erent developments as the turning point. The introduction of alternative photopolymer 3D printing technologies, the entry of industrial material suppliers or the endeavor of leading end-users in dental, healthcare, consumer goods and beyond. Did materials follow machines or vice versa? Did the big, industrial chemical giants introduce better products and higher standards? Have customer demands forced innovation?

Whichever it is, the quality of resin-based 3D printing turned a corner somewhere along the way, and those manufacturing machines and developing materials are now looking to hit the accelerator.

Formlabs recently made headlines with the introduction of the latest generation of its Form SLA 3D printing series, the Form 4. But it was not only bringing to market a machine capable of delivering maximum vertical print speeds of 100mm per hour

inside a build volume that is 30% bigger, but a set of General Purpose Resins with 2x improvement in elongation at break and a 1.3x increase in impact strength compared with the previous generation of materials too. These improved general purpose materials are supplemented by, for example, a Rigid 10K grade that boasts 88 MPa ultimate tensile strength and a heat deflection temperature of up to 238°C (0.45 MPa), and a Flame Retardant Resin that has certification for UL 94 V-0 at 3 mm thickness.

3D Systems has taken the same approach, and points towards the Figure 4 platform as a key enabler of its progress on the materials side. The Accura AMX Durable Natural is highlighted by 3D Systems Technical Fellow Marty Johnson as a material that, because of its 80% elongation at break and 64 joule per meter impact measurements, is suitable for tooling, jigs and fixtures applications with property deviations less than 10% over eight years for indoor applications. Its flame retardant grades – Accura AMX Tough FR V0 and Figure Four Tough FR V0 – are flame retardant at 2mm thickness with property stability for up to five years.

Nexa3D, meanwhile, o ers materials like the xPRO1100-Black which features a Shore D hardness of 84, tensile strength of 71 MPa and heat deflection temperature of 112°C (0.45 MPa). Among BASF’s line-up is the Ultracur RG 3280, with its heat deflection temperature of >280°C and high sti ness of around 10 GPa.

BASF’s entry into the market through its AM Solutions business was a validation of the additive manufacturing industry. This chemicals giant is so used to having clients work at such high volumes, its minimum order quantities would be a tough ask for most users of AM to match. So, for a company like that to see opportunity in AM spoke volumes. Yet, having operated in the space for coming up to a decade now, the company speaks of a change of mindset when working with AM clients, and still sees prototyping and product development applications as the driving force on the resin side of its 3D printing business.

“DLP technology is evolving, and SLA technology, yes we are going to applicationspecific, but from what I’ve seen in the

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market the majority are still using it for prototyping-type applications or sacrificial parts,” said Meisam Shir Mihammadi, Business Development Manager at BASF AM Solutions. “You’re making your part, it has to be accurate enough or good enough, it gets the job done.”

That’s where the industry stands today, but there is motivation in each of these companies to push the envelope with materials development and continue opening the doors to production applications. After all, that’s where the scale is.

“It’s no secret,” Johnson said. “How do we get into more low-volume production, bridge production, how do we get in to help the production driven customers? How do we get in with your service bureaus so that they can do low volume production? How do we get to the things that help you to that full solution?”

Those are some billion-dollar questions. And it’s a case not only of technical proficiency, but business case too. It’s not just what the machines can handle and what the chemists can come up with, but what businesses can a ord to do. Because developing materials is one thing and having them qualified, certified or verified is another, but who pays for those processes at the front end is a dilemma.

Shir Mihammadi reckons it’s the biggest hurdle when discussing how the AM industry can deliver more high-performance materials. He used application-specific materials, something many in the industry have called for, as an example.

“The demand is there, and we have that manpower, it’s just usually those markets –if you’re going to application specific – take longer to develop the material, and who is going to pay that development cycle cost is always the question. If the business case is not there, or there isn’t confidence, it’s always going to be hard.”

Tuning chemistries to suit a specific application is fundamentally a good idea on paper, but a manufacturing company is always going to want assurances on the volume it can guarantee before undertaking a potentially lengthy and costly development process.

“Who is going to pay that development cost?”

For 3D Systems, a company with over 30 years in the game, it’s a case of speaking to a broad range of customers and truly honing in on the properties required. At Nexa3D, meanwhile, it points to its hybrid approach that dips into its internal expertise and that of the likes of BASF.

“We have an outreach to a lot of customers and we funnel that back in and start looking at how we take those requirements and satisfy the main customers that we’ve got, because we know there’s people that are after those materials,” Johnson explained.

“The ability of having this hybrid approach [allows us] to collaborate with everybody, piggybacking on the R&D investment of the likes of BASF and Henkel, and periodically where we see an interesting niche that is not being currently fulfilled, we will formulate it ourselves,” Nexa3D CEO Avi Reichental o ered.

The open vs closed approach to material development and availability is long-held debate in the additive manufacturing industry. Nexa3D and BASF highlight the pros of knowledge and risk share that comes with the open

mindset, while 3D Systems and Formlabs will note how their less collaborative e orts give them control over the development process. Reichental, who has experience of both models, notes how a closed approach can ‘reinforce what you can do, but not necessarily what you can’t do,’ but Kyle McNulty, SLA Product Lead at Formlabs, believes: “Formlabs has a distinct advantage of being one of the only vertically integrated companies in 3D printing. We are formulating and manufacturing our resin in-house, and have direct capacity to quickly scale up innovative new formulations while controlling costs.”

Whatever your opinion on the approach, that some of the biggest names in resin-based 3D printing are confident of their capacity to deliver high-performance formulations is encouraging for users of the technology.

At Formlabs, the focus continues to be on improving durability, temperature stability, tensile strength, flexural strength, and impact resistance to enable more and more end-use parts. 3D Systems is along the same lines, but also seeks to emphasize its expertise in print process and how the company can work with customers to find the right combination of material and parameters for their application. For BASF, its looking to improve things like shrinkage control, sustainability, and ensuring that, for example, clear materials stay clear for longer. And Nexa3D has its sights set on ‘probably the single most obvious gap out there.’

“Temperature plus toughness,” finished Nexa3D COO Kevin McAlea. “We have some tough materials today in our industry, and they’re very useful, and they’re among the best-selling materials that we have, but there are temperature limiters of perhaps 70-80°C. There are a lot of opportunities for a tough material that gets you into the 100-150°C range, whether it’s automotive, whether it’s eyewear, a whole host of applications. We can’t quite do that today. That’s one of the trade-o s that we are trying to overcome.”

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Abold piece of orange plastic furniture inside KraussMa ei’s Additive Manufacturing Tech Centre in Munich stands as an indicator as to how the plastics processing company is approaching its AM o ering - where it makes sense.

The full-scale 3D printed meeting hub, complete with functional desk and seating, was extruded into existence following demand from sta who needed a quiet place to work amid the bustle of its AM development and services. But it also served as an internal demonstrator, and validation of its polymer 3D printing productivity. The other big motivation was to start a conversation, “food for thought,” around what can be done with large-scale AM, and one that will continue to reverberate at TCT 3Sixty this year where KraussMa ei, along with its meeting pods, will exhibit for the first time.

“We are o ering products and services across mainstream technologies from injection molding to extrusion, and the latest one is additive manufacturing,” says Rolf Mack, KraussMa ei’s Vice President Additive Manufacturing, of the company’s practical approach. “This brings us a unique position to actually consult the customer on the best matching technology for their needs.”

Last year, KraussMa ei celebrated its 185-year history, which found its footing as a German maker of locomotives. By the 1950s, the company would enter a new industry, plastics, where it would quickly establish itself in the development of injection molding machines and plastics machinery. In 2022, another emerging market, which KraussMa ei had watched slowly develop in parallel to its own polymer activity over the three decades prior, was beginning to materialize.

“In the last 20 to 30 years, additive [manufacturing] has established itself to become the gold standard for rapid prototyping and small series production,”

Mack explains. “I believe the market matured and the judgment of KraussMa ei was, at the decision point to enter the market, that we are on the verge [of becoming] a widespread adopted technology.”

KraussMa ei recognized that an AM solution, engineered to deliver reliability and commercial viability, o ered “big potential for growth." At K Show 2022, the company declared it wanted to be a part of ‘opening up additive manufacturing technology for industrial production.’ It introduced two machines, the powerPrint and precisionPrint, based on plastic granulate fused deposition and stereolithography technologies, and designed to meet optimum cost per part and quality assurance whether printing prototypes or parts in series.

“It's not only about the system or the machine,” Mack said. “We are having an end-to-end approach and we are application focused to ensure we have this good fit between the tool and the specific use.”

To KraussMa ei, ‘end-to-end’ means design optimization, exploiting AM’s design freedoms and understanding its limitations; right through to post-processing, finding the best milling parameters to turn large-format near-net shapes into finished parts with the required surface quality.

“We are still a manufacturing company of machines and systems so we put particular focus on ensuring that we get absolute process control when printing,” Mack says. “We want to have reliability in terms of quality, but also ensure when we are printing a part the first time, there's a good part coming out, and therefore you need to precisely control the printing process. We accomplish this with a heat-resistant build chamber, extensive sensorics and a thorough qualifying process.”

KraussMa ei perhaps knows better than most that in order to be successful, AM production systems need to become more like other industrial technologies. It knows this because it has decades of experience designing, manufacturing and servicing industrial machinery.

WORDS: LAURA GRIFFITHS

SHOWN: KRAUSSMAFFEI LARGE-FORMAT PRINTING

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“We want to raise the bar, day by day.”

“This was an excellent starting point and based on our experience across the technology, we hold fundamental and widespread knowledge about how to process polymers,” Mack says. “We saw a strong fit and matching this market opportunity and our capabilities together to make an o ering and push the adoption in the market.”

As the AM industry has developed, the entry of known companies, from household technology brands to chemical giants, has ratified the notion of AM as ‘the next big thing.’ But KraussMa ei, according to Mack, is not interested in hype. Trust, on the other hand, is paramount, and Mack acknowledges that the AM industry is still reeling from the overpromises that were made over the last decade.

“I think it's essential to make clear what is the best fit application for the technology and its capabilities, but also clearly state what cannot be done at this point of time,” says Mack. “We are still in an evolution. It doesn't mean it cannot be done in the future, but it's important, I think, to build the trust in AM and our solution first. It's like a tool. It's for a specific purpose. We are discussing an industrial grade solution to enable mass adoption and there's somehow still the narrative going around that AM can solve it all and I believe this is just not the case. There is not something like an AM Swiss Army knife, which can do it all.”

But KraussMa ei is confident in its o ering. Part of that confidence has come from maintaining its ethos that the first part that comes out of a machine must be right, but also from spending the last two years immersed in the AM market, working with existing customers in sand casting, tooling and pipe and fitting industries, to help them understand where additive can add value.

“Since we have become active with additive, we are getting requests from our customers, from injection molding, from extrusion, and from other areas because

they see the opportunity now to address certain demands they were not able to do in the past,” Mack explains. “For example, our injection molding customers, they are looking for volume business, and if there are small volumes, they were not able to address it because it was not commercially viable. Now we are o ering something to them where they can make a commercially viable o ering to their customer.

“Injection molding, extrusion and all tool-based have a huge advantage. It's about scale. It's about volume, but there's also a certain lead time related to it. If you want to try a new design, additive is perfectly suited to do that. It’s not one way or the other. We are seeing that we can optimize across technologies and this is always founded in our experience that we can consult and make a good recommendation to the customer, which technology or combination best suits their demand.”

Since commencing sales, KraussMa ei has increased the productivity of the PowerPrint by about 50% by optimizing its output process control, and is also ramping up its service business capacity to meet demand. Its first sold systems are set to become operative soon, and Mack says the company expects “many more” in the coming weeks and months.

“We want to raise the bar day by day, week by week, year by year,” Mack says, and that means continuing to explore large-scale applications where additive is the best fit, and doubling down on those drivers of reliability and commercial viability to ensure AM is at the same level of already established production technologies.

“We definitely entered a market with the ambition to become a market leader with our PowerPoint solution,” Mack concludes. “Obviously this will not fall into our lap so we need to now actually live up to the promise we made with this reliable, commercially viable solution. Within the next five years, it's all about bringing the maturity and the productivity of the solution on a level we are used to in injection molding and extrusion.

“The potential is clear. We see the demand, and our ambition is unwavering. We aim to become the most reliable and commercially viable solution for large-scale additive manufacturing, driving the mass adoption of this technology.”

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THE JIG IS UP

It has been almost ten years since Todd Grimm stood up on stage at TCT Show and encouraged us all to ‘embrace the mundane.’ Gesturing towards manufacturing aids like jigs and fixtures, and tooling, his call went against the grain of the 3D printing projects that were otherwise filling up keynotes in the hazy days of 2014.

Embrace it, people did. Cutting guides and work holding devices might seem ‘boring’ but their impact has been far from it for large companies like Volkswagen, L’Oreal, and Heineken, which have reportedly saved substantial time and money over the last decade by printing these often-overlooked applications. But are they overlooked or did the boring just become, well, normal?

Industry consultant Kevin Ayers believes tooling to be one of AM's most neglected applications. Instead, he thinks these parts should represent around a third of the technology’s applications by volume. According to the 2023 Wohlers Report, jigs and fixtures made up just 7.4% of AM applications worldwide, while end-use parts counted for just over 30%. That’s great news for the march towards production applications but it also means there is likely a lot of low hanging fruit that just isn’t being picked.

“While we have made tremendous progress towards printing [tooling, jigs and fixtures], I still see a huge opportunity,” Luis Rodriguez, Application Engineer, UltiMaker told TCT. “I say that because I help companies, daily, discover that 3D printing is a viable alternative to traditional manufacturing."

Those companies include the likes of IME Automation, North American Lighting and ERIKS, which have each used UltiMaker desktop polymer systems to rapidly produce components like packaging jigs, nesting blocks and welding jigs. It was also UltiMaker machines which allowed Volkswagen Autoeuropa to achieve 98% cost and 89% time savings by bringing its tooling, jigs and fixtures production in-house. Though, Rodriguez says some companies face a key hurdle: they simply don’t know where to start.

“If a company doesn’t commit a person to focus on this a few hours a week then adoption will never happen,” Rodriguez explained. “UltiMaker tries to make this easier by creating an ecosystem of hardware, software, materials, and services that just work. We don't want engineers to waste time tweaking, we want engineers saving time and making money with our printers.”

One of the biggest barriers to AM adoption in general is often application discovery. Fundamental learnings from low-risk applications like jigs, fixtures

WORDS: LAURA GRIFFITHS

and tooling – additive design considerations, limitations, for example – can be used to influence further adoption in other areas across a business.

“When we assist companies with site scans, we focus on high-gain, low-complexity applications first, leaving high complexity or low gain applications for last,” Rodriguez said. “These are indeed low hanging fruit because they have a big impact in a short amount of time. Why is this? The geometry is simpler, easier to design. The environment they operate in doesn’t expose them to high-temperatures, chemicals, or cleaners. This means we can use standard or engineering grade materials that are easy to print. This allows any company to prove out the technology, gaining confidence to tackle additional areas like spare parts for MRO storerooms/ tool rooms or parts within end-use products can even be re-designed in CAD to not only replace but update and improve their function.”

Florian Reichle, Commercial Managing Director at trickle3D, a Berlin-based developer of software solutions for additive manufacturing, agrees.

“We've noticed a clear trend. Once a company discovers a successful 3D printing application, they quickly realize broader potential for 3D printing in their operations, leading to a 'why didn't I think of this before?' moment,” Reichle told TCT. “FDM 3D printers are getting cheaper and easier to use every day, so it’s easy for the newcomer to achieve ROI from day one.”

The main challenge, Reichle believes, lies in the design. To that end, the company has developed software tools that enable users to design their own components. Its fi xturemate tool, for example, simplifies the design process for users, including those with limited CAD skills, allowing them to design custom fi xtures in under 20 minutes. The technology has been adopted by several players in automotive and transport; Ford Motors has automated its design process, taking design time down from 2-4 hours to 10 minutes.

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“These applications remain a hot topic among experts.”

This represents a 95% e ort reduction and enables those without CAD expertise to design tools independently with a userfriendly interface. Similarly, Audi, which was already using 3D printing for fi xture production, has reportedly been able to design a greater number of fi xture designs for the rollout of a new performance Electric Vehicle, cutting design time for tools by 80%.

"You could say 3D printed fi xtures, jigs, and other tooling are the 'killer app' of 3D printing,” Reichle said. “Process simplification and accurate machining are some of the qualities maintained by jigs, fi xtures and other tools, and these qualities are always in demand.

“The benefi ts are clear: Compared to traditional manufacturing, lead times are shorter, and there’s more control over the entire process, leading to better productivity. It also enables production sta to refine the tools they use, improving aspects such as ergonomics.”

Similarly, Heineken, which trialled Ultimaker S5 printers in its Seville plant for a year, was able to reduce costs by 7090%, and decrease its delivery time by 7090% by designing and replacing old parts with new optimized designs. Meanwhile, UltiMaker’s Method X and Method XL 3D

printers have been used by IME Automation to produce numerous parts for its systems, including jigs, fi xtures, and end of arm tooling. With UltiMaker's recently launched Factor 4 system, the company is choosing to focus on light industrial applications, in which the company includes manufacturing tool and bridge parts for production operations.

“Every single application has a return on investment calculation,” Rodriguez said. “For 3D printed applications we analyze lead time and cost. How fast can we print this part and how much does it cost to produce? When pitted against traditional manufacturing, ordering lead times, and minimum order quantities, 3D printing applications every time, especially with low quantities. We say that with an UltiMaker on your production floor, you have your own in-house production. You are ordering from yourself, getting a jig, fi xture, spare part in hours vs weeks and for a fraction of the cost.”

The hopeful end game of any generally hyped-up technology is that it gets to a point where it’s so widely accepted, it’s simply not worth talking about anymore. The word is out, and these applications are evidently

SHOWN: IME AUTOMATION’S 3D PRINTED PNEUMATIC END EFFECTORS, PACKAGING JIG, AND TRAY

being implemented by brands big and small, but any noise or excitement from the industry still seems to favor those applications in end-use parts and serial production. The AM industry talks a lot about maturity, and maybe jigs, fi xtures and tooling have reached it. But if AM overall is still only scratching the surface of possibility, and jigs and fi xtures currently represent just a small fraction of that adoption picture, new users may risk missing out on key low-risk, high-value opportunities that could then set further applications in motion.

“We often say that complexity is free, but that doesn’t mean it has to be complicated,” Rodriguez concluded. “While there is a time and a place for finite element analysis, topology optimization, or generative design, the simplest of brackets can have a tremendous impact for any production environment. Every company, no matter the size or budget cannot a ord to have anything in the production line down.”

Reichle added: “Any company focused on success aims to enhance e ciency and cost-e ectiveness, and adopting 3D printing for production tooling o ers an easy implementation with immediate cost savings. While it might appear that these applications have faded from regular discussion, they remain a hot topic among enthusiasts and experts.”

SHOWN: ERIKS’ WELDING JIG

WORDS: LAURA GRIFFITHS

1 YEARS OF TCT ASIA 2

024 marks ten years of TCT in China. What launched as the brand’s first venture outside of the UK has grown into the biggest additive manufacturing (AM) event in one of the industry’s most interesting markets.

TCT Asia 2024 welcomed a record number of visitors – 43.5% growth compared to the 2023 edition – and a flurry of industrial product launches, proving that these three days in Shanghai are among the most important on the global AM calendar.

Many companies have been on this TCT Asia journey from the start, returning each year as the event moved with the industry from the consumer-focused era of polymer extrusion systems to today’s mammoth stands showcasing large-format, multilaser metal machines and applications.

“The AM market in China has grown significantly in recent years, probably the fastest growing AM market in the world,” Terrence Oh, Senior Vice President Asia Pacific at EOS APAC, told TCT. “In the past, most people [were] unfamiliar with AM and for those that [were], only looked at AM as a machine that does prototyping. In recent times, with more awareness, people are looking at AM as a solution for issues that they face in their manufacturing process using the conventional way to do production.”

theme followed suit in launches from BLT, which unveiled an updated version of its S450 with improvements to cost e ciency, quality, automation and safety; Farsoon with the 12-laser FS811M featuring one of the biggest build volumes on the metal LPBF market; and Eplus3D with its EP-M2050 metal AM system, with optional configuration of a dizzying 64 lasers. These kinds of trend-leading developments are just some examples of why industry spectators are quickly realizing this fast-growing marketplace is one that shouldn’t be ignored.

“TCT Asia is very much a B2B [event] due to the nature of the Chinese market and the manufacturing powerhouse that China is,” Luke Taylor, Creative Director at Polymaker, which launched its PolyDryer filament drying and storage system at the event, shared in a TCT Q&A. “I see a big decline in 3D printer manufacturers from Europe/USA in the market and it seems all innovations are coming out of Shenzhen these days. I don't expect this to slow down and I think that what Bambu Labs has done in the last two years will be copied and improved on by many new companies which will drag the whole industry to a new standard.”

A spokesperson for Materialise shared how, just five years ago, the Belgian AM company surveyed Chinese manufacturers to gauge their attitude toward 3D printing. It found that China was largely focused on prototyping and remained doubtful about the readiness of the technology for manufacturing final products. Today, it’s a di erent story.

“Perhaps even more so than in other regions, we are seeing significant advancements in China,” said Materialise, which provided an exclusive preview of its latest Magics 28 software in Shanghai. “Costs are under control; new machines provide quality and e ciency at scale and a ordable materials make much larger orders feasible. We are seeing largescale applications such as mobile phone components being produced in substantial volumes, and razor-thin titanium hinges for folding phones and the mass production of smartwatch cases. We’re talking millions of parts per year.”

EOS invited visitors to bring their challenges to its AM expert bar to explore how AM can o er a solution. The industrial

Whether it was the famous ‘3D printed wedding dress’ from Xuberance in 2015 or injection molding leader Haitain surprise launching not one but four AM machines in 2023, TCT Asia has continued to be a place where you are guaranteed to see something new. While AM trends come and go, China is now leading the charge for some of the most pertinent, particularly around a ordability and metal laser power. With developments in artificial intelligence and automation emerging alongside, TCT Asia will no doubt surprise us again when we return to Shanghai in 2025.

TCT Asia 202517 - 19th March at NECC Shanghai

Get more from TCT Asia on TikTok @thetctmagazine

June 25-27

LOS ANGELES

April 8-10

DETROIT

April 14-16

BOSTON

A NEW ARC

Born out of a decade of pioneering research into Wire Arc Additive Manufacturing (WAAM) by a team at Cranfield University, WAAM3D, a UK-based developer of large-scale metal 3D printing technologies, has spent the last seven years developing and commercializing an AM process that is geared towards the manufacture of largeformat metal parts for aerospace and heavy industries. Filomeno Martina, CEO and co-founder of WAAM3D, talks to TCT about WAAM3D’s unique capabilities, creating value in supply chains, and an upcoming launch.

TCT: Can you remember the first time you saw 3D printing or the first time it clicked with you?

FM: I was a double degree student at Cranfield and I wasn't particularly excited by any of the group projects that had been o ered to us. In fact, it was our individual master's thesis project and I ended up walking past the lecturer, and he had this metal artifact on his desk.

It was a twisted column, made by WAAM, as I then found out. I was captivated straight away. So, even though I was in Cranfield to do a master's in production, I ended up doing my thesis on the very first trials of titanium deposition using plasma, which is one of our signature features. That was 14 years ago, and I've never looked back.

TCT: How did WAAM3D come about?

FM: We were born in 2018 as a Cranfield University spinout company to create a commercial supply chain for the process which Cranfield had been investigating really since the early 1990s, but definitely with renewed vigor since Stuart Williams, who is still the head of the center and one of the founders of the company, joined Cranfield around 2006.

We were doing a lot of high-profile demonstration work with a bunch of aerospace companies, but at that point in time there wasn't any kind of commercial provider, so we set out to create value in our customer supply chains, leveraging the WAAM process.

TCT: The UK is known for its AM research, but has a bit of a hard time when it comes to translating that into business. WAAM3D managed to take that leap. How challenging was that?

FM: If we compare the approach that the UK takes versus the US, there are some di erences in the way spin outs are managed, but the UK is getting better at that. The big problem that we've had, and I think a lot of other companies will face in the UK, is the much smaller funding pots that we can

access compared to other countries, and the fact that in the eyes of a VC type of operator or a private equity firm, at the end of the day, we are just one of the many opportunities that they will test. We've been very lucky because we have a partner in Accuron Technologies that has been supporting us since the very beginning and with several subsequent cash injections. They are a corporate venture, so they've got much more patience than other investor types. And at the same time, they see a use for our technology in other companies that they have in their portfolio. So the partnership is being delivered over several dimensions.

On top of that, you have to have a clear understanding of what the future holds. The market may not be aware of their needs, or they may be aware of their needs, but the product must serve a clear purpose. I think in 3D printing, for a long time, there was a lot of debate on where the technology could actually be used and could deliver its full potential, and I think by now, over the last 15 years, we've got a pretty good understanding of what that means.

TCT: So why WAAM? What is it good for?

FM: From the point of view of a technology in a production environment or in manufacturing operations, you must be able to demonstrate a way or two, or as many as possible, to create economic value for your customer. And when we look at the way this can be manifested in one, we've got things that can go from prototypes to serial production to supply chain shortening.

WORDS: LAURA GRIFFITHS

Don’t miss: Evan Butler-Jones presenting A Powerful Combination: Faster Print Speeds with Laser Beam Shaping and Engineered Materials Wednesday, June 26 at 11:00 AM, Room: 404 AB Working with aluminum? Bring your

us at RAPID + TCT at Booth 1361

equispheres.com | Suite 4100, 500 Palladium Dr. Ottawa, Canada | 1.613.903.5855 | info@equispheres.com

There's quite a lot of boxes that can be ticked. And this, in terms of the total addressable market, I believe, is a much bigger share compared to other processes which are of course limited in terms of the size that they can really target. But with WAAM, as the build rates keep growing, we are being asked to look at parts that are much bigger, much more complicated, in a growing range of materials.

TCT: Wire arc additive manufacturing seems to have gained more traction recently. Why do you think that is? And how do you remain competitive?

FM: You have a basic technology, which, at its core, is based on fully o -the-shelf technological elements. Really, that's part of our own narrative. If you go back to the kind of academic publications that we were doing in the middle of the 2000s, late 2010s and so on, we always advocated for the lower barrier to entry.

Our key di erentiator is really how we've been able to take those o -the-shelf components and add a bunch of newly designed bespoke sensors, safety devices, control, and to make the machine a lot more capable, underpinned by software, which we've been developing over the last 15 years now. Because back in the day, you have the robot and you have the power source, but we had no means to actually program it.

So, we started from there. Then we created a bunch of algorithms to calculate processes automatically. The layer height not being fixed, actually getting the geometry right is where we take a lot of responsibility as a supplier of machines and technologies by adding algorithms that do the calculation automatically for you, for a bunch of di erent materials, for a bunch of di erent geometries, and then obviously the control system.

SHOWN: End e ector

We're trying to push ourselves as a slightly premium provider, with machines that can be customized to suit all budgets, capabilities, but on the higher end range of the of the specification and we've got some pretty unique features, the least of which that we have been talking about for the last year, this new high productivity WAAM variant which moves 15 to 16 kilogrammes an hour, which is something that we have patented, and that's unique to us.

TCT: In your 14 years in the industry, what is one thing that you think will be useful for anybody new to additive to understand now that would save them a lot of pain and a lot of time in the future?

FM: Really do your due diligence, make sure you come prepared from a technical point of view.

I think, like all new technologies, you have a bunch of firms that really know what they are doing and others that are sort of riding the hype and the marketing excitement. Sometimes it's tricky to distinguish between the two groups. The only way to do that is to understand the subject matter, and understand that 3D printing is just another tool in the arsenal of the modern engineer. It's not a panacea for all problems in manufacturing. It needs to be used tactically and cleverly.

TCT: WAAM3D will be at TCT 3Sixty on 5-6th June. I hear you’ll be launching something. Can you give us any hints at what that may be?

All I can say for what's coming at TCT 3Sixty this year is we're going to show and release something new on the hardware side, which will probably be seen by our friends out there as a bit of a departure compared to what we've been traditionally associated with. There'll be some more teasing happening over the next couple of weeks on social media, but if you want to see what's new, you've got to be at the show in June. year something more

This interview has been edited for brevity and clarity. Listen in full on the Additive Insight podcast.

SHOWN: Filomeno Martina, CEO of WAAM3D

EDMMax 433W

EDMMax 433W

X axis: 400mm 15.7"

X axis: 400mm 15.7"

Y axis: 320mm 12.6"

Z axis: 280mm 11.02"

Y axis: 320mm 12.6"

Z axis: 280mm 11.02"

Max. Workpiece Wt: 400kg 880lbs Footprint: 2130 x 2000mm (84" x 79")

Max. Workpiece Wt: 400kg 880lbs

EDMMax 434WW

EDMMax 434WW

X axis: 400mm 15.7"

X axis: 400mm 15.7"

Y axis: 320mm 12.6"

Y axis: 320mm 12.6"

Z axis: 410mm 16.14"

Z axis: 410mm 16.14"

Max. Workpiece Wt: 400kg 880lbs

Max. Workpiece Wt: 400kg 880lbs

Footprint: 2130 x 2000mm (84" x 79")

Footprint: 2130 x 2000mm (84" x 79")

Uses pure water - no additives!

EDMMax 656W

EDMMax 656W

X axis: 630mm 24.8"

X axis: 630mm 24.8"

Y axis: 500mm 19.7"

Y axis: 500mm 19.7"

Z axis: 625mm 24.6"

Z axis: 625mm 24.6"

Workpiece Wt: 1200kg 2640lbs

Max. Workpiece Wt: 1200kg 2640lbs

Footprint: 2130 x 2000mm (96" x 95")

EDMMax 434W

EDMMax 434W

X axis: 400mm 15.7"

X axis: 400mm 15.7"

Y axis: 320mm 12.6"

Y axis: 320mm 12.6"

Z axis: 410mm 16.14"

Z axis: 410mm 16.14"

Max. Workpiece Wt: 400kg 880lbs

Footprint: 2130 x 2000mm (84" x 79") Uses pure water - no additives!

Max. Workpiece Wt: 400kg 880lbs

Footprint: 2130 x 2000mm (84" x 79")

Footprint: 2130 x 2000mm (84" x 79")

EDMMax 818W

EDMMax 818W

X axis: 1000mm 39.4"

EDMMax 1100HW (Single Axis)

X axis: 1000mm 39.4"

Y axis: 800mm 31.5"

Y axis: 800mm 31.5"

Z axis: 800mm 31.5"

Z axis: 800mm 31.5"

Max. Workpiece Wt: 2000kg 4400lbs

Footprint: 2130 x 2000mm (96" x 95")

EDMMax FC45HW

EDMMax 1100HW (Single Axis)

X axis Clearance: 1100mm 43.3"

X axis Clearance: 1100mm 43.3"

Y axis Stroke: 1400mm 55.1"

Y axis Stroke: 1400mm 55.1"

Z axis: 1250mm (49.2") can be increased

Max. Workpiece Wt: 2000kg 4400lbs

Footprint: 2130 x 2000mm (104" x 89")

Z axis: 1250mm (49.2") can be increased

Max. Workpiece Wt: 3000kg 6600lbs

Max. Workpiece Wt: 3000kg 6600lbs

Footprint: 2130 x 2000mm (104" x 89")

Max. Workpiece Size: 31" x 31" x 70"

Footprint: 3500 x 3100mm (138" x 122")

Max. Workpiece Size: 31" x 31" x 70"

Footprint: 3500 x 3100mm (138" x 122") ALL 4-AXIS MODELS EQUIPPED WITH

ALL 4-AXIS MODELS EQUIPPED WITH

● CNC Control

● CNC Control

● Molybdenum Wire .007" dia.

● Touch Screen

● Tapering

● Molybdenum Wire .007" dia.

● Touch Screen

● Tapering

● Two (2) Paper Filters

● Two (2) Paper Filters

● 3.5kVa Input 220/3/60

EDMMax FC45HW

400 x 400mm build plate

● 3.5kVa Input 220/3/60

● 3-Pass Cutting Technology

● 3-Pass Cutting Technology

● On-board CAD System

400 x 400mm build plate

300mm high, Submerged

● On-board CAD System

300mm high, Submerged

Inverted Horizontal cutting

Uses pure water - no additives! (Taiwan)

● No Chiller or Air Pressure Required

Inverted Horizontal cutting Uses pure water - no additives! (Taiwan)

Footprint: 1600 x 1800mm (63" x 71")

● No Chiller or Air Pressure Required

● AC & DC Cutting Power

● AC & DC Cutting Power

● USB, LAN and MDI Input

Footprint: 1600 x 1800mm (63" x 71")

● USB, LAN and MDI Input

●

● On-site training Included

Sam Davies on how 3T AM is working towards its Net Zero goals as it continues to scale its manufacturing output.

Drop the mic, exit stage left. Have I convinced you?”

3T AM CEO Dan Johns has stopped speaking. For now.

He stands in the 3T AM production facility, not on a stage and not with a microphone – yet – but he’s doing a lot of convincing. Johns has already spent a couple of hours articulating why 3T considers additive manufacturing as a tool for outputting billets rather than parts, and now his attention is turning to how the company will achieve Net Zero status by 2032.

But before he continues, a pit stop to make sure his audience is keeping pace. Is it making sense? Are there any questions? Do you believe?

Of course, none of that really matters, so long as Johns, his colleagues, and 3T’s customers are on the same page. And it seems, such is the health of the company’s books these days, that they are. Johns freely admits that he’s no carbon accounting expert, but he won’t ignore what’s working.

The phrase Net Zero followed by a number in the relatively early 2000s is a common goal in the 21st century for companies and countries alike. The magic number for the UK, for example, is 2050. For 3T AM, it’s 2032 – ten years on from the new management’s first year at the helm of the company.

Ten years, it was felt, would be a good runway. Far enough into the future for it to seem realistic, but soon enough to focus minds. “We’re not doing it because of external forces, customer directives, legislative targets, we’re doing it because we believe in it,” Johns says. “Now that the legislation is consolidating and customers’ CSR and ESG agendas are strengthening, it has become a perfect storm.”

3T AM has seen sta – whether they’re 30 minutes into their career or 30 years – fully engage with these e orts. Meanwhile, clients like Rolls Royce are said to have noted how, merely by having a vision, 3T AM is ahead of many of its other suppliers when it comes to achieving Net Zero.

That vision is being enacted already. From the installation of LED lighting to the incorporation of renewable energy, to the electric van, to its lean manufacturing philosophy, 3T AM is already making strides towards its 2032 goal.

Metal additive manufacturing technology is proving quite important to those ambitions. As documented in the previous issue of TCT Magazine, earlier in his career, Johns commissioned studies into the potential of additive manufacturing to deliver reductions in mining, feedstock, and machining. One study assessing the additive manufacture of an Airbus A350 bracket found three times less of the former, thirteen times less of the latter, and five times of the one in between.

Johns has now applied the same maths to the 10,000 components 3T AM is contracted to manufacture throughout 2024. If each of those components was made the traditional way, machining from a billet of material, 3T AM would create 45,000 kilogrammes of waste. Using AM to produce a billet at nearnet shape that will then be machined? It’s just 1,000 kilogrammes. In terms of mining, it’s 13,000 tonnes of rocks that need to be extracted compared to 45 tonnes.

“I’ve normalized the actual mass of the parts to standardize it to create a model, I’ve used that same maths and scaled it,” Johns says. “When we start to look at it through that lens, it’s just bloody obvious.”

Metal AM is one of the foundations of 3T AM’s approach to sustainable manufacturing at volume. In the years since the BEAMIT acquisition in 2021, the company has implemented a three-pillar strategy that has seen it build out something of a one-stop shop that encompasses the core elements of the manufacturing value chain postmining. It has then sought to digitize, developing a digital twin of the entire factory, and automate processes as much as it can – when it does its breakdowns, labour amounts to less than 10% of the cost of a part.

These pillars will ensure many things – one of them is consistency, which will be essential for the company to deliver on its Net Zero 2032 ambitions. Data capture and data analytics are also going to be important facets, so 3T AM is in the process of applying energy monitoring technology to every piece of equipment involved in the manufacture of components, from printing through machining through inspection. This will allow each piece of machinery to be audited, with 3T AM able to first monitor how much energy will be expended as parts move through the workflow, converting that into kilogrammes of CO2 per part, and second, to hopefully be able to put a Net Zero digital certificate against every part that goes out the door.

“That, in the end, is the vision. Every part net zero,” Johns says. “Our consciousness about this is about setting the sustainable manufacturing standard. That’s it. Our mission is to be net zero by 2032 – and as a consequence of the success we’re having –and be greater than 150 million [GBP] in revenue. The reality is, I never have visions or missions around revenue, but I’m not the only one who sets the vision and mission, I work with my team, and we created a purpose. We’ve instilled our values into 3T. Net zero is the focus. And if we get that right, the revenue comes.”

What does net zero really mean, though?

In essence, it’s the balance between the greenhouse gases that are produced and the greenhouse gases that are removed from the atmosphere. In manufacturing, to produce anything with zero emissions will be a tough ask, so it’s instead about doing as much as you can to reduce the carbon value of a part and o setting the rest via a carbon exchange program.

3T AM has recently carried out a study on a part that was previously manufactured the conventional way and now leans on additive manufacturing. The original component tallied 106 kilogrammes of carbon per part. Once additive manufacturing was incorporated, that came down to four kilogrammes per part. A 102kg per part reduction, which would leave just four kilogrammes to be o set. And this is with further improvements to 3T’s lean manufacturing practices still to come.

“This is where we start to know that we are going in the right direction,” Johns says. “Anybody in manufacturing needs to be buying AM printers and getting into this. If you don’t, you’re not going to be in the future. It’s as powerful as that because the corporates are going to be challenging their supply chain strategies and they’re going to hit something called Scope Three. Scope Three is having to have net zero through the supply chain. If you’re a supplier in that supply chain and you do not have a net zero agenda or you’re not doing the things that help achieve carbon emission balance, they won’t use you anymore.

“If companies like us don’t figure out how we’re going to demonstrate that we can reduce our carbon emission, we will end up with a carbon tax and therefore prices go up, and it goes to the customer. So, either the customer pays it, or they find somebody else that’s doing it, and then we’re out of business. You have to future-proof yourself because this is coming. And it’s coming really, really fast.”

Eight years ago, a spirit of innovation and practical problem-solving is what President Barack Obama described as essential if the challenge of climate change was to be taken on before he performed what may be the most famous mic drop ever at his final White House address.

Eight years into the future and Johns will be hoping such spirit has seen 3T AM reach the kind of milestone that Obama was calling for. The kind of milestone that is required for the future of the planet, of manufacturing and of business. The kind of milestone that Johns will advocate when he picks up the microphone as a keynote speaker at this year’s TCT 3Sixty.

WORDS: Litsa Rubino

Additive manufacturing (AM) technologies are known to provide benefits for lowvolume, high-mix casting production. They o er advantages for tooling design and opportunities to improve productivity rates in upstream or downstream operations from the casting process. As such, the U.S. government, and the Department of Defense (DoD) recognize the need to prioritize AM integration in casting applications.

Although AM promises to augment the casting industry, its current limited utility, especially in defense and sustainment, prohibits full integration. Additionally, a decline in U.S. foundries exacerbates an existing workforce shortage, further hindering progress.

Nonetheless, AM's potential to improve the casting sector is enough to draw on the broader industry for innovative solutions with America Makes, the national additive manufacturing innovation institute, at the helm. Tasked by the DoD, the Institute, in partnership with Deloitte Consulting, developed a multi-year technology roadmap to create and deploy AM capabilities in the casting and forging (CF) industry. This roadmap assessed issues a ecting the CF industry, identified AM opportunities to mitigate these issues and determined the investments needed to support AM integration into manufacturing operations. Based on these findings, a portfolio of projects and their corresponding execution plans were defined and are now being deployed to drive AM usage in the casting and forging industry.

CASTING CALL

CASTING CALL

How America Makes is driving AM integration across sand casting

The need to scale sand printing capabilities was a high priority, high impact project that emerged from the roadmap activities. To address the immediate need, America Makes released a project call to meet market demand.

Aerospace industry leader, Honeywell was awarded the project, and in October 2023 began working on the two-year endeavor to improve the casting quality of parts produced with AM sand molds and cores.

Areas of focus included:

● Evaluating and implementing measures to improve surface roughness.

● Identifying methods to minimize dimensional variations.

● Determining cause and identifying methods to reduce porosity caused by sand mold outgassing.

● Developing methods to disseminate findings and best practices to industry.

NAVIGATING PART QUALITY PAIN POINTS IN AM SAND CASTING COMPONENTS

Binder jetting is among the AM techniques used for creating sand molds and cores. However, like other AM technologies, its limitations currently restrict usage due to its influence in critical part applications.

These include:

● Surface roughness (caused by stepping where finished metal parts retain the layered texture of the 3D sand mold).

● Dimensional inaccuracies.

● Porosity due to mold outgassing during the casting process.

The project explores the application of AM sand molds and cores to produce Honeywell's gearbox housings, covers, and inlet housings for the Chinook Helicopter T55-714C engine. Working in tandem with project partners ExOne, Hoosier Pattern, Ohio Aluminum, and Chicago Magnesium, Honeywell is evaluating the current processing parameters for AM sand molds and cores. Cast part assessments based on design requirements will ultimately identify quality gaps and gauge technological improvements.

The success of this project will provide a new baseline of recommendations for improving AM sand molds/cores for the broader sand casting industry.

TRANSITIONING BEST PRACTICES AND TECHNOLOGY IMPROVEMENTS

AM technologies provide an opportunity for greater profitability, new markets, and new business models, but without an expansive understanding of how to address workforce gaps and limited capacities of small-to-medium-sized foundries, the industry will remain at a crossroads.

“A high priority, high impact project.”

A second layer of this project is to support small and medium-sized foundries lacking the necessary data and models for their casting operations, which is crucial to mitigate business risks while competing in the bidding process for low-volume or high-mix products.

These e orts, led by the American Foundry Society (AFS), include developing training materials and courses for domestic sand casting industries. The objective is to promote best practices and methods to improve the quality of cast parts produced with sand-printed molds and cores. Additionally, industry events will feature presentations that highlight technology improvements and best practices for additively producing sand castings.

AM SAND CASTING AND BROADER INDUSTRY IMPACT

America Makes recognizes that transitioning from AM usage to wide adoption requires a joint e ort to assure the needs of the larger market are met. The ongoing project demonstrates the Institute's commitment to staying ahead of innovative solutions, providing practical steps that create a significant impact.

This project lays the groundwork to enhance the quality of sand-cast parts, accelerating AM adoption across tooling for sand casting applications. From a broader perspective, leveraging the America Makes road-mapping e orts to identify and address CF industry gaps presents a significant leap in AM maturation, ultimately enhancing national security.

“The objective is to promote best practices.”

Litsa Rubino manages the National Additive Manufacturing Innovation Institute’s technology projects and is also responsible for leading internal strategy development and formation of new project e orts that focus on integrating additive manufacturing into casting and forging technology.

MEET THE INNOVATORS

The finalists for the 2024 TCT Women in 3D Printing Innovator Award sponsored by EOS have been revealed.

Now in its fourth year, the award is a joint collaboration between TCT and Women in 3D Printing (WI3DP) and celebrates the contributions of female innovators in the additive manufacturing (AM) space. Each year, we invite the public to put forward their nominations, and a panel of judges at TCT and WI3DP have the di cult task of whittling those nominations down to a shortlist, which then goes back to a public vote.

In a panel session co-hosted by TCT Head of Content Laura Gri ths and Women in 3D Printing President Kristin Mulherin, the five finalists spoke about their journeys into 3D printing, current projects, and their views on the industry today. Here’s a taste of what each of them had to say.

BRIGITTE DE VET-VEITHEN

CHIEF EXECUTIVE OFFICER – MATERIALISE

"The shift is happening towards the use of additive manufacturing in production of end-use parts and that is where there is huge potential. To use AM in the production of end use parts, the needs of people to e ectively and e ciently do that are very di erent from using AM for prototyping, and it's really exciting to be at the helm of Materialise in a time where we see new user needs and where we can drive the adoption in that end use parts segment because we understand the future needs of customers.

If you look at the world from a broader perspective, sustainability has become a much more important topic, and we need to make sure that this planet is sustainable and will be there for our children and grandchildren. We all know that AM can play a super important role in reducing CO2 footprint in many di erent ways so contributing to that shift, being at the helm of Materialise with the solutions that we o er and driving the use of AM makes it particularly important and exciting."

CORA LEIBIG FOUNDER AND CEO – CHROMATIC 3D MATERIALS

"What we did at Chromatic was take an established 3D printing technology, and instead of a melting process, we have a reactive process. Our goal is to make it possible to print with the materials that are really trusted in industry, namely thermoset and other very durable materials.

What we were able to do for the dress [collaboration with designer Anouk Wipprecht] was print directly on the textile and because it's not a high-temperature environment, we can essentially do that printing process in a temperature that works for the material. We [also] needed to develop the printing technology itself. Printing on the dress required essentially 90° overhangs with no support structures and that's all from developing that chemistry and printing techniques to make that possible. We chose the dress as a great way to demonstrate just the versatility of the process for applications well beyond apparel."

Announcing all new BuildTak Plus surfaces

3D print surfaces pre-coated to take the struggle out of 3D printing with Polypropylene, Nylon, Polycarbonate, and more!

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MELISSA ORME

VICE PRESIDENT OF AM – THE BOEING COMPANY

"We're not printing parts for the sake of printing parts and one of the biggest pieces of hype is that you can use additive for everything. Well, the question is, should you? You really have to find the business case. In our case, we're adding value to an entire platform; increasing its performance, increasing range, making it cheaper, more sustainably.

I still have to explain to people that, for making spare parts on aeroplanes, you need to have engineering rigor, requirements, testing. You can't just print a part out in the field somewhere and put it on a helicopter and expect it to fly. For aeroplanes, the biggest amount of hype that really bothers me is that you can reduce requirements on spare parts. Really what has been underestimated is what's required for implementation, the amount of data you need to have to qualify a material source, to understand the material system, to create design allowables, to understand the damage and durability. And that goes for all parts."

NESMA ABOULKHAIR –DIRECTOR OF ADDITIVE MANUFACTURING –TECHNOLOGY INNOVATION INSTITUTE

"We're developing new materials specifically for metal AM, which is one of the amazing capabilities of the technology. It's not just to manufacture, but you can create new materials, new microstructures from scratch, while manufacturing.

We're capitalizing on that and we've recently filed patents for two new alloys that are the first materials to come not only from the UAE, but from the MENA region. We're also working on processes, design, and then the applications that put all these together and trying to solve the problems of the industrial landscape. This ties in really nicely with what the UAE government is pushing for, trying to transition from an oil and commodities-based economy to the knowledge-based economy. I think we're playing a very critical role there."

OLGA IVANOVA –DIRECTOR OF APPLICATIONS & TECHNOLOGY – MECHNANO

"I think AM has endless possibilities and the allure of the technology is undeniable. However, the inherent novelty of AM sparked exaggerated claims and inflated expectations. People would become captivated by the shiny and new revolutionary breakthroughs, promises to disrupt industries, and this creates this contagious frenzy driven by a desire for a quick fix all solution.

What we're dealing with right now is the aftermath of this peak hype period in AM history. We have to burst the bubble and bring [customers] to reality and show them the limitations, yet at the same time, keep the enthusiasm alive. For these customers, you have lure them out of all their fears and build the trust and confidence. We, as a community, have work to do and the best customer, like all of you on this panel, is the enlightened one, who bought in the hype, endured the painful implementation processes and learned their lessons. They understand that AM is just a tool in a vast manufacturing toolbox."

Lithoz Presents the Ceramic 3D Factory: Producing 14 Million Parts per Year

Lithoz ceramic 3D printing:

Experience the Next Generation in 3D-Printed Ceramic Serial Production at RAPID+TCT

Unlocking the next generation of surgical and multi-functional tools

Ceramic tools come into play where metal devices reach their limits, with ceramics increasingly becoming the preferred material for various medical applications. Thanks to their exceptional heat and wear resistance, perfect biocompatibility and easy sterilization, ceramic surgical tools are quickly gaining interest as an alternative to metal. Traditional manufacturing methods are typically only economical when used for large-scale production, greatly limiting the possible designs of ceramic surgical tools until now. Lithoz’s ceramic 3D printing technology introduces a new level of design flexibility coupled with efficient scalability to mass production.

The 3D printing of highperformance ceramics is fast growing into an established production technique. With clear demand for ceramic 3D printing at an industrial scale across industries, Lithoz has already empowered the e cient realization of a wide range of previously unimaginable applications across industry, medicine and beyond. The fact that more than half of their customers have invested in multiple CeraFab S65 3D printers to add to their machine park of Lithoz LCM (lithographybased ceramic manufacturing) systems highlights the success innovators have found with this technology.

part, resulting in an annual total volume of almost 14 million parts.

3D-printable ceramics available - such as alumina, zirconia, silicon nitride and ATZ - greatly expands the range of possible innovative tools and applications.

new tube geometries with sharp bends and inner contours, minimal wall thicknesses of 200 µm, and perfectly smooth surfaces with roughness values of Ramax = 0.4 µm. The full innovative value of the LCM solution was needed to achieve the required narrow tolerance of +20 µm in the outer geometry at a reproducibility of 12,000 pieces per year

At the upcoming RAPID+TCT, Lithoz will showcase the next dimension in utilizing LCM ceramic 3D printing for large-scale industrial production. With the arrival of “The Ceramic 3D Factory”, Lithoz technology and service bureaus all over the world are united in one global network for interconnected serial production. An impressive showcase of 260 identically designed aerospike nozzles produced at varying sizes will demonstrate the perfect reproducibility and powerful scalability of LCM technology to industrial dimensions. With 100 Lithoz CeraFab System S65 printers connected, the smallest parts shown can be manufactured with exact reproducibility at a printing speed of 3:46 minutes per

With its flexible all-rounder qualities and straightforward scalability to more than 100 interconnected printers, the CeraFab System S65 is the technological backbone of “The Ceramic 3D Factory”. This industry-leading machine has been specially designed for interconnected mass production, delivering the highest possible build speed at a constant accuracy even for the most intricate application. Its ultra-precise exposure ensures zero tolerance over the whole build platform and guarantees perfect part reproducibility during every print job - without compromise.

In the medical field, the 3D printing of highperformance ceramics is unlocking previously unachievable advantages – not only in terms of geometry, but also resources. This technology enables rapid and efficient production of both large and small batches of tools, while the wide range of

One example of such a surgical tool is an arthroscopic knee shaver 3D-printed via lithography-based ceramic manufacturing (LCM) technology. Traditionally, these shavers are simple tubes manufactured from metal - but thanks to ceramic 3D printing, multiple new design features can now be produced. In this instance, the shaver tip has an integrated channel for optical fibres, ensuring constant illumination of the critical area. These channels could also be used for rinsing, suctioning, or wiring an electrocautery tip.

One success story of a company using powerful Lithoz technology to drive their innovation is Steinbach AG, who are considered pioneers in the use of additive manufacturing (AM) for the mass production of high-performance technical ceramics. The German company were contacted to produce high-precision tubes with sharp bends and inner contours for use in the Da Vinci™ surgical robot.

These burs also avoid the risk of metal debris during procedures - a crucial factor in metal-free surgeries. Produced using the Lithoz CeraFab S65 Medical 3D ceramic printer with its 40 µm resolution, this machine not only offers intricate precision for complex parts but also has a build envelope specially designed for efficient high-volume production. Over 100 burs can be manufactured in a single print run, meaning an individual burr is very costeffective at less than €10.

Steinbach AG, a German company at the forefront of ceramic 3D printing, recently presented a 3D-printed ceramic tube fabricated using Lithoz technology for integration into the Da Vinci™ surgical robot. 12,000 tiny yet highly precise tubes were manufactured per year, with sharp bends and

Six months after receiving the order, Steinbach achieved the full annual production volume requested at the required parameters and with comparable reject rates to conventional manufacturing technologies. This success story not only proves the outstanding productivity of the ultra-precise Lithoz LCM technology, but also shows how this leading technology has made “The Ceramic 3D Factory” an industrial reality.

Lithoz CeraFab System industrial 3D printers installed at their facility. Thanks to the scaled-up manufacturing power of LCM technology, experts at SiNAPTIC are working on the large-scale production of technical ceramic parts for industrial and medical applications.

intricate inner contours to accommodate optical fibres. The tubes featured perfectly smooth surfaces with roughness values of Ra max of 0.4 µm and minimal wall thicknesses of 200 µm, showcasing how the capability of Lithoz ceramic 3D printing processes has already been scaled up for successful large serial production.

As close partners of Lithoz, SiNAPTIC and Steinbach are integral parts of the large network bringing “The Ceramic 3D Factory” to life. Also making up this network are important global players such as Germany-based Bosch Advanced Ceramics and the Japanese Mitsui Kinzoku group. Together with the showcase of “The Ceramic 3D Factory”, parts printed by expert partners will be on display at RAPID+TCT 2024 alongside a ‘touch and feel’ experience of medical and industrial components. These parts, all printed on CeraFab industrial 3D printers, will highlight the added value that innovators have unlocked using Lithoz LCM technology to complement their production processes.

The emergence of ceramic 3D-printed surgical tools, with their precision, durability, biocompatibility, and cost-effectiveness, marks a transformative era in modern medicine. As research and development progress, the medical community anticipates a future where surgical precision and patient well-being are elevated to unprecedented heights through the fusion of highperformance ceramics and cutting-edge 3D printing technology.

Dental burs made from ATZ are another application showcasing the endless possibilities enabled by combining advanced geometries with the hardness and enhanced durability of ceramics.

Alongside Steinbach, Lithoz is partnered with many other experienced service bureaus all over the world to bring “The Ceramic 3D Factory” to your application. SiNAPTIC Technologies, as the major LCM technology hub for North American innovators interested in ceramic 3D printing, already has seven

At the beginning of the project, the biggest challenges Steinbach faced were to meet some of the dimensional parameters defined in the production order, including completely

Visit the Lithoz booth (1613) at RAPID+TCT to experience “The Ceramic 3D Factory”!

alumina-toughened zirconia (ATZ).

Milling dental burs made from alumina-toughened zirconia (ATZ).

THE HOME OF US AM

RAPID + TCT, the largest, most influential additive manufacturing and industrial 3D printing event in North America, is returning to the West Coast for the first time in nine years.

Held at the Los Angeles Convention Center on June 25-27, 2024, the expansive show floor will showcase over 400 solution providers’ latest advancements alongside three days of conference programming, featuring more than 160 timely talks, presentations, workshops and panels presented by experts from leading institutions worldwide.

Across the next 9 pages, you’ll find just a selection of exhibition and conference highlights.

3D Systems | #2401

3D Systems will present its unique solutions portfolio designed to address advanced healthcare and industrial applications. Visitors can discuss their manufacturing challenges with the company’s application engineers who collaborate with customers to transform how products and services are delivered. Visitors are also invited to attend a number of presentations including 'Rekindling Artistry in the Automotive Aftermarket Through Additive Manufacturing' with Dmitriy Orlov, COO, BBI Autosport and Joe Dopkowski, Application Engineer, 3D Systems (June 25th at 11am) and 'Will Bioprinting Define the Next Era of 3D Printing?' with Katie Weimer, VP, Regenerative Medicine, 3D Systems (June 27th at 12pm).

Additive Industries | #1513

BigRep | #839

BigRep is set to showcase the ALTRA 280, a high-temp, largescale, reliable, and highly automated machine for the very first time. Key features include a build chamber of 500 mm x 700 mm x 800mm (280 liters), up to four extruders reaching 450°C, open material system, and heated vacuum print bed. The large-format 3D printing specialist says the machine is positioned as the definitive solution for industries requiring high-performance materials, including aerospace, defense, and automotive. The printer will be available across North America starting July 2024. BigRep says it also has more 'big' news, which will be revealed at the show.

Additive Industries will showcase its unique MetalFAB system, a versatile modular metal AM printer that o ers a range of cuttingedge automation and customization options. With its unique optional modules, the printer optimizes e ciency and is said to significantly streamline automation processes. The MetalFAB's modular design provides options for growth, allowing users to expand at their own pace. Incorporating the Herding filter, Powder Load Tool, and fully automated inert powder recovery, the Dutch AM company says 'operators are safer with this printer than with any other on the market.'

The MetalFAB is equipped with a Multibeam Laser calibration tool that allows the operator to conduct all five beam measurements automatically, dramatically increasing e ciency. With extensive experience in manufacturing metal AM components, Additive Industries says it has the expertise to assist users in maximizing machine productivity and delivering consistent printing results at a large scale.

JUNE 25-27, 2024

Los Angeles Convention Center

Meet the leaders harnessing cutting-edge applications of additive manufacturing. Hear these visionaries reaffirm the possibilities of technology, explore inventive opportunities, and discuss key trends shaping the future of industrial 3D printing.

The New Space Race: How Relativity Space is Revolutionizing Rocketry with AM Joshua Brost Chief Revenue Officer

Driving Innovation: BMW Group’s AM Strategy and Vision

Maximilian Meixlsperger Head of Production, Additive Manufacturing Campus

JUNE 26 The Story Behind COBRA GOLF’s AM-enabled Golf Clubs

Ryan Roach Director of Innovation JUNE 27

Evolve Additive Solutions | #2645

Following the recent launch of STEP Parts Now, an additive parts on-demand service, Evolve Additive Solutions says it is excited to showcase serious production capabilities of its STEP technology alongside partner and largest customer, Fathom Digital Manufacturing. Together, the two will demonstrate STEP’s unique ability to reliably manufacture high fidelity production parts using engineering thermoplastics – and present a preview of multi-material, co-printing capabilities to come. Evolve says STEP enables all the freedoms and benefits of additive, with injection molding quality and properties. The combination of Evolve and Fathom is said to yield scalable production for demanding applications and markets including automotive, medical device, irrigation, emblem plating and more.

Caracol | #2201

BMF | #1139

BMF will be showcasing its newest printer, the microArch D1025, the first platform in a new hybrid resolution technology series. Powered by PµSL and based on BMF’s new hybrid resolution technology, the microArch D1025 prints in dual resolution in 10µm and 25µm single-use modes and within the same print layer. The microArch D1025 delivers improved built-in automation, which enables greater e ciency – saving time, resources and cost. Delivering BMF's same ultra-high resolution, accuracy and precision, the new D1025 aims to revolutionize the prototyping and production of parts requiring micron-level precision and repeatability.

HP | #2839

Caracol is bringing its Large Format Additive Manufacturing technology to California. The company will be announcing a number of strategic partnerships at the show which aim to further boost the development of its technology in North America, from design to production of complex parts. The show floor will feature live demonstrations of its Heron AM platform robotic-based pellet extrusion large-scale printer, together with several parts from sectors such as automotive, aerospace, and design. Caracol invites visitors so look out for some 'exciting announcements' on June 25th.

EOS | #2639

EOS is inviting visitors to explore the capabilities of its new EOS M 300-4 1kW metal AM system, built for high-temperature production materials such as aluminum and copper. The system features four powerful, one kilowatt lasers to meet the requirements of applications such as aluminum brackets, heat exchangers, inductors, e-mobility components and more. In addition to the EOS M 300-4 1kW, fine detail resolution (FDR) selective laser sintering (SLS) technology, AMCM customized solutions, and recent software developments will be featured on the EOS booth.

The EOS Additive Minds applied engineering team will also be hosting an AM Expert Bar, where attendees can book 1:1 meetings with industrial 3D printing experts on a variety of topics. From AM design and material compatibility to supportfree metal 3D printing, EOS says 'the Additive Minds team has you covered.'

HP Personalization and 3D Printing is set to exhibit its latest advancements in metal and polymer 3D printing, including new materials and hardware functionality. Attendees will see HP's entire range of materials, including the recently introduced HP 3D HR PA 12 S, created in partnership with Arkema. Experts will be present to discuss HP's ongoing material innovations and a wide array of applications, illustrating how HP users in the medical, industrial, and consumer industries are 'expanding the frontiers of innovation and driving growth in additive manufacturing.'

Impossible Objects | #2013

Impossible Objects will introduce the CBAM 25, which claims to be 'the world’s fastest 3D printer.' Using Impossible Objects’ Composite Based Additive Manufacturing (CBAM) process, the machine is 16 times faster than its nearest competitor, running at a speed of 25ft per minute. Using long fiber composites, the company says the technology leverages advanced materials to produce production-ready parts at a lower cost than conventional 3D printing methods.

'at a substantially

The machine provdes fine detail, 50 micron layers, better dimensional accuracy and compatibility with advanced materials including carbon fiber and PEEK along with low cost materials like fiberglass and PA 12. The result is stronger parts at 180 MPa tensile strength with carbon fiber and PEEK temperature performance 343 °C and dimensional tolerances of 100 microns. With fiberglass and PA12, Impossible Objects says CBAM can produce parts 'at a substantially lower cost' and 'much faster speeds.'

LDO | #2071

LDO will be showcasing what is believed to be 'the world's first portable upsidedown printing 3D printer.' The Positron V3.2 is foldable and compact, fitting neatly into a filament box. This design allows for unprecedented portability, enabling users to carry their printers with them wherever they go.

In addition to this new printer, LDO says its Voron lineup, from the Voron 0.2 to Voron V2.4, has something to o er every visitor whether they're looking for a desktop printer or a professional-grade printer. LDO also provides highperformance motors, extruders and other printer parts.

Lithoz | #1613

With growing demand for ceramic 3D printing at an industrial scale across industries, the success of Lithoz’s partners and technology in serial production is becoming ever more apparent. Lithoz will showcase the arrival of “The Ceramic 3D Factory”, uniting Lithoz technology and service bureaus all over the world in one global network for interconnected serial production across fields such as semiconductor production, aerospace and more. Lithoz says this year's event will be the main touchpoint for the showcase of this global “Ceramic 3D Factory” network, strengthened by its new CeraControl software, which allows for up to 100 globally interconnected CeraFab S65 3D printers.

Materialise | #2821

Materialise will unveil the latest version of Magics, the leading data preparation and build preparation software for additive manufacturing. Prioritizing consistent, successful prints, this update enhances Magics for both polymer and metal 3D printing. Users can now optimize designs and reduce part weight by handling complex beam lattice data. Upgraded 3D Nester and Support Generation modules ensure superior build quality. Responding to user feedback, Magics now o ers unprecedented speed and a new dark theme, further improving e ciency and user experience.

nTop | #1546

nTop is inviting visitors to ‘swing by’ its golf simulator to try COBRA Golf’s LIMIT3D 3D printed irons, which were designed using its software. The first commercially available 3D printed irons on the market, LIMIT3D irons incorporate a complex lattice design for a soft feel and launch with explosive distance and forgiveness.

Visitors can then learn about nTop, the advanced computational design software which enabled COBRA’s game-changing design. nTop is a platform for designing and developing high-performance, complex product designs quickly and e ciently. Visitors can see how nTop can help them create their most advanced parts yet, all within their existing workflow.

Ripperden Resources | #1851-5

Ripperden Resources, LLC o ers functional 3D design, scanning, and additive manufacturing services. Committed to excellence and sustainability, the company says it prioritizes quality, reliability, e ciency, and customer satisfaction. Leveraging proven and cuttingedge 3D technologies, including additive manufacturing, Ripperden’s skilled team delivers dynamic solutions tailored to clients' specific needs, including functional 3D design, precise scanning, rapid prototyping, and production printing services, enabling e cient product development processes.

Roboze | #2127

RAPID + TCT 2024 will see the U.S. debut of the ARGO 1000 HYPERMELT. The machine features Roboze's HYPERMELT Technology, which the Italian 3D printer manufacturer says aims to 'disrupt large-format additive manufacturing.' Capable of producing components up to 1 cubic meter, it utilizes pellets for raw materials, achieving 10 x faster speeds and 60% lower costs than traditional filament methods. With a heated chamber up to 180°C and dual extruders, it enables high-performance parts from super polymers and composites.

Solukon | #2161

AM post-processing specialist Solukon will present its enhanced depowdering system SFM-AT350/-E which, thanks to its adapted arm design, can now accommodate parts weighing up to 100 kg, including plates from EOS M 400 and Nikon SLM 500 printers. This is the first time the upgraded depowdering system can be viewed live.

For the first time in the US, Solukon will also showcase a new version of the SFM-AT350 with piezoelectric (=ultrasonic) excitation. The E-version of the depowdering system is ideal for delicate structures like medical applications.

The SFM-AT1000-S depowdering system, designed for extra-large and heavy parts, will also be shown alongside a special discount campaign for its SPR-Pathfinder software.

SPEE3D | #2439

Volkmann USA | #1667

SPEE3D will be showcasing its WarpSPEE3D printing Nickel Aluminum Bronze (NAB), a new full release for the company’s Cold Spray Additive Manufacturing (CSAM) technology. Ideal for marine applications, SPEE3D’s NAB provides excellent corrosionresistance and demonstrates mechanical properties comparable to or exceeding those of several commonly used copper alloys, such as High-Leaded Tin Bronzes C93200 and Red Brass C836000. You can rapidly print and postprocess parts in NAB in less than 24 hours. Stop by the booth to see SPEE3D printing live.

Thermwood Corporation | #2301

Thermwood Corporation is set to exhibit its advanced manufacturing solutions and applications. Attendees can explore the CLA (Cut Layer Additive) system through live software demonstrations and inspect various tools on display. The LSAM (Large Scale Additive Manufacturing) system will also be featured, highlighting its capabilities with several tools. Additionally, Thermwood will present its comprehensive range of 3- and 5-axis CNC routers, showcasing versatility and precision.

Purdue University's Composite Manufacturing and Simulation Center will also join the event to demonstrate its cuttingedge Additive 3D software. This powerful predictive tool is designed to enhance additive manufacturing processes, and o er valuable insights and optimization for complex projects.

Volkmann USA plans to unveil its vHub 250 metal powder storage system, a versatile powder storage bu er for both pre- and post-processing, which features an inline holding container that can be installed upstream of a 3D printer as a reliable powder supply, and downstream to collect and hold excess metal powder from a build box after printing.

Serving one or up to six di erent 3D printers at a time, the Volkmann vHub 250 includes a 250 L (~8.8 ft³) stainless steel hopper and touch-screen controls with integrated Volkmann pneumatic vacuum conveyor for safe, smooth, dust-free powder transfer. The vHub is ATEX-certified as explosion-proof.

Operating as a stand-alone unit or within a closed loop system, the vHub is suitable for tungsten, cobalt, silver powder, iron, stainless steel, alumina, nickel chrome, copper, titanium, and other metallic powders in both normal air environments and under inert conditions as an option.

Equispheres | #1361

Equispheres is focused on enabling mass production with AM through material design. Its proprietary technology enables the modification and management of powder properties, and its engineers have designed a line of powder products which allow users to maximize the power and scanning speeds of their printers, and produce parts at full speed, more reliably and economically. Equispheres is encouraging visitors working with aluminum to bring their current print performance metrics to the show where they can learn 'what more you could be getting, and how to get it.'

Equispheres' Evan Butler-Jones will be presenting 'A Powerful Combination: Faster Print Speeds with Laser Beam Shaping and Engineered Materials' on Wednesday, June 26 at 11:00am.

EDM Performance Accessories | #2652

EDM Performance Accessories will release the Flip and Tilt production cut o system for HB800 and HB600 wire EDM machines, enabling flawless part separation and fall o on high volume builds similar to a horizontal EDM. EDM's proprietary high-precision pivot table and linear guide rails allow horizontal plate bolt in and simple manual flips into the cutting position. Once flipped the assembly easily glides to the back of the machine and locks in place for cut o . Another breakthrough is the ability to cut three plates at once on a HB800. If an application is better suited for full vertical cutting, the entire system can be switched back to vertical in under 45 minutes.

America Makes is the leading collaborative partner for additive manufacturing and 3D printing technology research, discovery, and innovation in the U.S. Structured as a public-private partnership, we innovate and accelerate AM/3DP to increase global manufacturing competitiveness.

Focused on additive manufacturing, America Makes is the first institute of the Manufacturing USA® network.

EXECUTIVE PERSPECTIVES KEYNOTE SERIES

The 2024 edition of RAPID + TCT will include a first for the additive manufacturing industry. This year, when attendees gather around the main stage for the usual keynote kick-o sessions, they will have the unique opportunity to hear from 15 leaders across the global additive manufacturing (AM) ecosystem.

Presented across three panel sessions, the inaugural Executive Perspectives Keynote Series will feature C-level insights and thought-leadership from some of the industry's biggest companies, setting the tone for the day ahead on the show floor, and the future of the AM industry.

This trio of panels promises a series of engaging conversations among the industry’s leading voices with a focus on technology, applications and more.

The Executive Perspectives Keynote Series will cover:

● AM’s biggest challenges and opportunities

● Applications driving adoption and ultimately moving to full-scale production

● Convergence with AI and automation

● Trends on the horizon to enrich human health and wellbeing

● Supply chain impacts

● State of sustainability and its long-term potential

At a time when AM has reached a critical inflection point in its growth and evolution, the Executive Perspectives Keynote Series gives RAPID + TCT attendees access to the most powerful minds shaping the global additive manufacturing landscape,” said Bob Willig, Executive Director and CEO of SME. “Convening these leading voices in this first-of-its-kind series is a demonstration of SME’s unwavering commitment to advancing AM technologies and to providing a platform where innovators can come together to chart the course for the future of manufacturing. I’m looking forward to seeing the series continue and evolve at RAPID + TCT 2025 in Detroit and RAPID + TCT 2026 in Boston.

Panels will be moderated by Laura Gri ths, TCT Head of Content, and will take place daily from 8:30am on the Main Stage.

“The most powerful minds shaping the global AM landscape.”

TANIOBIS

Based on our 60 years expertise in manufacturing and development of refractory metals, we have developed AMtrinsic® atomized tantalum and niobium spherical powders and their alloys for demanding additive manufacturing technologies. Our ability to adjust specific intrinsic material properties enables us to push the limits according to the requirements of your application.

AMtrinsic® spherical tantalum and niobium powders provide outstanding combinations of material properties customized for specific applications. Aligned with 3D-printing technology, AMtrinsic® powders can help overcome hurdles in various high-tech industries. The high temperature stability, excellent corrosion resistance and biocompatibility of AMtrinsic® Ta, Nb powders and their alloys deliver a perfect fit for biomedical (Ta, TNT and TNTZ), chemical (Ta, Nb, Ta-W) and aerospace (Ta-W, C103 and FS-85) applications. In addition, AMtrinsic® Nb with its prominent superconducting properties is ideal for the superconducting industry.

TANIOBIS offers atomized AMtrinsic® C103 (Nb-10Hf-1Ti) and FS-85 (Nb-28Ta-10W- 1Zr) pre-alloyed powders. High-temperature strength, superior creep properties and their excellent workability with Additive Manufacturing make these alloys great candidates as structural materials for various aerospace applications. AM offers design freedom enabling manufacturing of lightweight components with complex features e.g. rocket thruster with integrated cooling channels which is one of the many applications of our AMtrinsic® C103 and FS-85 alloys.

Speakers

Savi Baveja President of Personalization and 3D Printing, HP

Alain Dupont Chief Commercial O cer, Colibrium Additive, a GE Aerospace Co.

Ric Fulop Co-Founder, Chairman and CEO, Desktop Metal

Charlie Grace Chief Commercial O cer and President of the Americas, Nikon SLM Solutions

Je rey Graves President and CEO, 3D Systems

Laura Gri ths, Head of Content

Marie Langer CEO, EOS GmbH

Michelle Sidwell Chief Commercial O cer, Velo3D

Maxim Lobovsky Co-Founder and CEO, Formlabs

Nils Niemeyer General Manager, DMG MORI

Avi Reichental Co-Founder and CEO, Nexa3D

Victor Roman Managing Director, ARBURGadditiv

Yoav Stern CEO and Member of the Board of Directors, Nano Dimension

Shai Terem President and CEO, Markforged

I'm very much looking forward to hosting this inaugural Executive Perspectives Keynote Series at RAPID + TCT. While we might spend our days talking to industry execs here on the TCT editorial team, very rarely does the additive manufacturing community get a chance to hear from our industry's leaders in this sort of setting.

The conversations I've had with each of our panelists in preparation for these keynotes have been refreshingly open and enlightening. We're going to be discussing everything from the challenges of scale and serial production to technology convergence with AI and automation.

These panels are the perfect way to set the tone for your day on the show floor, and indeed beyond, as you take insights learned back to your business.

Register for your ticket: rapid3devent.com

Fried Vancraen Chairman of the Board, Materialise

Yoav Zeif CEO, Stratasys

Our Capabilities:

3D Modeling & Design

Utilizing 3D Modeling software and our experience, we can design and model your parts and assemblies based on your requirements.

3D Scanning

We are capable of 3D scanning of all sizes; from objects smaller than a pen cap to objects larger than a car.

3D Printing

We can 3D print using Fused Filament Fabrication (FFF) and Fused Deposition Modeling (FDM) methods.

Materials

We can deliver parts and assemblies from PLA & PETG to PEKK & PEEK and everything in between.

THE CONFERENCE

The RAPID + TCT 2024 Conference will feature more than 160 presentations from renowned AM end-users, research institutes and technology providers.

Here, TCT Head of Content Laura Gri ths, Group Content Manager Sam Davies, and Conference Manager Lu Tikrity share their picks from this year’s line-up.

Lu's Picks

HEALTHCARE

Additive Manufacturing of Medical Devices: The FDA Perspective

Matthew Di Prima, PhD, Materials Engineer –U.S. Food and Drug Administration

Tuesday June 25

10:00am-10:30am | Room 409 A

CREATIVE

Building an InHouse 3D Print Studio for Early Phase Concept Development at Tapestry

Tomer Emmar, Rapid Prototyping Manager, 3D Print Studio –Tapestry, Inc. (Coach, Kate Spade, Stuart Weitzman)

Wednesday June 26

10:00am-10:30am | Room 405

Sam's Picks

DEFENSE

US Department of Defense’s Extreme Cold Point of Need Manufacturing Challenge

James L. Zunino, Senior Scientific Technical Manager Advanced Manufacturing & Future Concepts – US Army DEVCOM

Wednesday June 26

10:00am-10:30am | Room 408 B

MATERIALS DEVELOPMENT

Recyling & Reusing Aerospace Parts by Converting into Powder for Additive Manufacturing - Lessons Learned & Technical Summary

Robert Higham, founder & CEO – Additive Manufacturing Solutions, Ltd.

Tuesday June 25

11.30am-12.00pm | Room 406 B

CREATIVE

Blockbuster Magic: Behind the Scenes with 3D-Printed Props and Sets

Matt Winston, co-founder –Stan Winston School of Character Arts

Wednesday June 26

3.30pm-4.00pm | Room 405

HEALTHCARE

3D Printing from Magnetic Resonance Imaging: A One-stop Shop for Soft Tissue and Bone Modeling

Nicole Wake, Director, Research and Scientific A airs –GE HealthCare

Thursday June 27

10.30am-11.00am | Room 409 A

READY TO SCALE YOUR AM PRODUCTION?

READY TO SCALE YOUR AM PRODUCTION?

READY TO SCALE YOUR AM PRODUCTION?

In the fast-evolving landscape of additive manufacturing, Laser Powder-Bed Fusion (LPBF) is at the forefront of innovation. Especially, when it comes to building quality parts in high quantities. But still, scaling up production remains challenging. It demands high laser power, ring-mode lasers or big spot configurations to rapidly fill bulky parts and easy integration of process monitoring for process and quality control. Additionally, large part sizes require meticulously calibrated multi-laser machines, especially in overlap regions. AM production can be puzzling!

In the fast-evolving landscape of additive manufacturing, Laser Powder-Bed Fusion (LPBF) is at the forefront of innovation. Especially, when it comes to building quality parts in high quantities. But still, scaling up production remains challenging. It demands high laser power, ring-mode lasers or big spot configurations to rapidly fill bulky parts and easy integration of process monitoring for process and quality control. Additionally, large part sizes require meticulously calibrated multi-laser machines, especially in overlap regions. AM production can be puzzling!

In the fast-evolving landscape of additive manufacturing, Laser Powder-Bed Fusion (LPBF) is at the forefront of innovation. Especially, when it comes to building quality parts in high quantities. But still, scaling up production remains challenging. It demands high laser power, ring-mode lasers or big spot configurations to rapidly fill bulky integration of process monitoring for process and quality control. Additionally, large part sizes re calibrated multi-laser machines, especially in overlap regions. AM production can be puzzling!

In the fast-evolving landscape of additive manufacturing, Laser Powder-Bed Fusion (LPBF) is at the forefront of innovation. Especially, when it comes to building quality parts in high quantities. But still, scaling up production remains challenging. It demands high laser power, ring-mode lasers or big spot configurations to rapidly fill bulky integration of process monitoring for process and quality control. Additionally, large part sizes re calibrated multi-laser machines, especially in overlap regions. AM production can be puzzling!

To solve this, you need the right pieces - and this is exactly what RAYLASE delivers. With our AM MODULE we provide a high-power large-field beam deflection unit explicitly designed for AM production. Its patented zoom optics maintain the focus profile of ring or top hat beams also when enlarging the spot size for big spot applications. Its integrated collimation and interface for process monitoring ensure easy integration and optimum alignment. And thanks to our automated calibration tool, the SCAN-FIELD-CALIBRATOR, single and multi-field machines are quickly and reliably calibrated, ensuring optimum part quality throughout the production process.

To solve this, you need the right pieces - and this is exactly what RAYLASE delivers. With our AM MODULE we provide a high-power large-field beam deflection unit explicitly designed for AM production. Its patented zoom optics maintain the focus profile of ring or top hat beams also when enlarging the spot size for big spot applications. Its integrated collimation and interface for process monitoring ensure easy integration and optimum alignment. And thanks to our automated calibration tool, the SCAN-FIELD-CALIBRATOR, single and multi-field machines are quickly and reliably calibrated, ensuring optimum part quality throughout the production process.

So, let’s get the missing pieces and scale up your AM production!

So, let’s get the missing pieces and scale up your AM production!

To solve this, you need the right pieces - and this is exactly what . With our AM MODULE we high-power large-field beam deflection unit explicitly designed for AM production patented maintain the focus profile of ring or top hat beams also when enlarging the spot size for big spot ap integrated collimation and interface for process monitoring ensure easy integration and optimum alignment. And thanks to our , the SCAN-FIELD-CALIBRATOR, single and multi-field machines are quickly and reliably calibrated, ensuring optimum part quality throughout the production process.

To solve this, you need the right pieces - and this is exactly what . With our AM MODULE we high-power large-field beam deflection unit explicitly designed for AM production patented maintain the focus profile of ring or top hat beams also when enlarging the spot size for big spot ap integrated collimation and interface for process monitoring ensure easy integration and optimum alignment. And thanks to our , the SCAN-FIELD-CALIBRATOR, single and multi-field machines are quickly and reliably calibrated, ensuring optimum part quality throughout the production process.

So, let’s get the missing pieces and scale up your AM production!

So, let’s get the missing pieces and scale up your AM production!

DFAM

The Art of 3D

Printed Origami: Unfolding the Future of Robotics

Dora Strelkova, University of Windsor

Wednesday June 26

3:00pm-3:30pm | Room 407

Laura's Picks Workshops

ENERGY

Wire Directed Energy

Deposition of a Large-Scale Gas Turbine Component for Siemens Energy

Tad Steinberg, Business Development –Siemens Energy Inc.

Tuesday June 25

10:00am-10:30am | Room 405

AUTOMOTIVE

E ciency Meets Sustainability: Exploring Sustainable Additive Manufacturing and Design Innovations for Automotive Applications

Nanzhu Zhao, PhD, Senior Researcher – Nissan Technical Center North America

Tuesday June 25

2:00pm-2:30pm | Room 406 A

Workshops at RAPID + TCT bring attendees face-to-face with industry leaders. All workshops will take place on June 24th, giving attendees the opportunity to participate fully in hands-on educational experiences in addition to the full conference and show floor programme.

Certified Additive Manufacturing Fundamentals (CAMF) Review Course & Exam

8:00am-4:00pm | Room 406 A

This review course and Certified Additive Manufacturing Fundamentals (CAMF) exam are ideal for individuals working in or seeking to work in AM roles in automotive, aerospace, and medical equipment, in addition to students as a capstone or stand-alone achievement to increase AM workforce readiness.

Symposium: The Expansive Applications of 3D Printing in Healthcare

9:00am-4:00pm – Room 409 A

This workshop will explore the current state of 3D printing in healthcare for medical and medical-aligned professionals, including live demonstrations and peripheral applications. The breadth of applications highlighted will showcase the growing role of 3D printing and 3D aligned-technologies.

Polymer Additive 101 - A Primer on Polymer Technologies and Materials

9:00am -12:00pm – Room 405

This workshop will look at the history of polymer AM, including detailed discussion about printers and materials. Attendees will be taken through an analysis of the current state-of-the-art and the future of these technologies. There will be a chance to bend and break some parts and prizes to be won.

3D Scanning for Additive Manufacturing

1:00pm - 4:00pm – Room 408 B

The workshop will include presentations describing the history of measurement technology and the need for 3D scanning, particularly in the context of AM. Stations around the room will give hands-on experience with practical examples for both reverse engineering and inspection.

How to Build an Additive Manufacturing Business Case

1:00pm-4:00pm – Room 404 AB

This interactive workshop session delves into the creation of a business case for additive manufacturing. The session will focus on common adoption drivers for AM versus conventional manufacturing as well as technology, people, and supply chain factors to include in a business case.

Metal Additive 101 - A Primer on Metal Technologies and Materials

1:00pm-4:00pm – Room 405

This workshop will include in-depth discussion about the advantages and disadvantages of metal technologies, enabling attendees to make educated choices on which process is right for their application. The session will also look at materials and take participants through an analysis of the current and future of these technologies.

Mitigating Safety Risks Helps Grow Your Additive Manufacturing Market

1:00pm-4:00pm – Room 406 B

This workshop will provide safety considerations and validation approaches for technology, materials and 3D printing equipment which can help grow the additive manufacturing market for equipment manufacturers, material suppliers and operational users.

DfAM - Recent Advancements in Design for Additive Manufacturing

1:00pm-4:00pm – Room 407

Advancements in DfAM such as lattice generation, real-time simulation tools, generative design, and interactive optimization, are expected to 'produce a tsunami of change' in the design process. In this workshop, these technologies will be presented and demonstrated with practical examples.

WORDS: Steve Cox, 3D Technologies Consultant, AMFORi Consulting

PLAYING THE LONG GAME

We've tried 3D printing, it’s rubbish...." Whenever I hear that kind of statement it feels like a dagger right into the heart of what I do. As an independent consultant, I tell people that the only brand I really represent is that of “3D Printing & Additive Manufacturing,” and I want them to have the best possible experience.

You’ll probably already know that 3D printing is just another tool in the manufacturing toolbox and that it needs careful selection. So, those people who have had that poor experience have either been sold the wrong technology, oversold the benefits or sold something that wasn’t ever going to be appropriate for what they want to do.

Using the toolbox metaphor, it’s akin to being sold a hammer when what you really need is a screwdriver; being sold a screwdriver on the promise it can build you a house; or being sold a hammer on the promise it can help take you to the moon. Vendors are sometimes complicit. They know the customer needs a screwdriver but what they are selling are hammers and will try to convince a customer that’s the right tool for them!

So, lots of careful work and due diligence is required when it comes to adopting AM and 3D printing to ensure success. I hope that’s where people like me come in, advisors who have no vested interest other than ensuring you see this technology in the best way and get the maximum benefit from adopting it.

So, where are we now with adoption in the UK, especially within industry? In my experience it’s a mixed picture and continues to feel like challenging work.

In my opinion there are some cultural barriers in the UK that I feel hold back adoption. Throughout my forty-year career working in engineering and manufacturing, it feels like short-term thinking is a mindset that exists in a lot of UK industry.

This technology is one that needs to grow over the long term and adopters, just like the stars of reality TV, tend to go on “a journey” with it. That journey takes time. The way AM fits into a business develops and grows, which runs contrary to the short-term focus I see so often.

I often talk about personas when it comes to adoption. A key persona is someone I call “The Change Agent” who has the foresight to see the potential for 3D printing in a business. Very often this person is someone who is 3D printing at home as a hobby and has an appreciation for what it’s capable of. The other key persona is “The Banker” who needs to release the funds needed for adoption. What ensues is often a battle between the Change Agent, who perhaps has a long-term view, to convince The Banker of the benefits when they only see the short-term e ect on the balance sheet.

and hope it puts people on a successful trajectory to a longerterm relationship (and reward).

Working with adoption in the UK is not an easy gig, yet I know that it can put people on a path that can grow and scale over time. For that reason, it’s a part of my role that I find very rewarding.

I’ve seen many cases where the case made by the Change Agent is both compelling and backed up with good return-on-investment numbers, yet the short-term approach wins out in the end and the adoption stalls.

the moment, that’s not surprising. We can only cast an envious eye at the AM Forward

small companies in particular with adoption.

Another particular UK handicap is the lack of government support in this area, but as we have no overall industrial strategy at the moment, that’s not surprising. We can only cast an envious eye at the AM Forward programme in the USA that helps assist small companies in particular with adoption.

A further adoption challenge for a technology still seen as fairly new and developing is the number of hoops that a potential adopter will have you jump through to prove its initial use case. Producing endless samples, often free of charge, and lots of cost data seems par for the course. When the profit margins involved are sometimes slender, the amount of upfront e ort and cost involved feels out of balance with the rewards.

endless samples, often free of charge, and

Adoption is about playing the long game. You have to persevere

playing the long game. You have

“Careful work and due diligence is required.”

Expertise

Gain practical knowledge through proactive participation and hands-on experience

n Become more productive through AMUG’s community of problem solvers

n Learn and share expertise, best practices, challenges, and application developments

Network

Impactful networking without any agendas

n Embrace the camaraderie and enjoy effortless networking

n Form meaningful connections through casual conversations

Value

Get the most value of any conference with an ALL-INCLUSIVE program

n 4-day conference

n Hands-on workshops

n Technical competition

n AMUGexpo

n Meals and entertainment throughout