PERFORMANCE MODE

When your first release turned out to be such a big hit, it’s only natural to experience classic second album nerves. It’s a feeling DyeMansion founders Felix Ewald and Philipp Kramer are now familiar with after the highly anticipated launch of their next-generation additive manufacturing (AM) post-processing technology.

“We have a reputation in the market and need to fulfil that,” says Kramer, DyeMansion’s CTO, of the extensive testing the new systems have undergone in preparation for the big reveal. “Pilot testing is essential.”

That reputation has been built on a wealth of successful adoption stories from customers like Daimler, ic! Berlin and ProGlove which have used DyeMansion’s technology to add color and injection mold-like finish to their powderbased polymer parts. Even Oprah’s a fan. The Munich-based company is now building on that momentum with three new products, launched in March, including a new Powershot Performance series and the next generation of its classic Powershot C & S post-processing systems.

The centerpiece is the new Powershot DUAL Performance which, in a first for the company, provides both depowdering and surface treatment processes in a single system. It’s laser focused on industrialization according to Ewald, DyeMansion's CEO, built for the socalled “factory of the future” and high-volume production. Launching alongside it are the Powershot C Performance for cleaning and the Powershot S Performance for surfacing, which the company describes as the “next-level” in blasting technology.

The series is the first to feature DyeMansion’s integrated wide trough Multi Belt, which allows users to automate the loading and unloading of parts and is capable of processing full-sized build jobs with an increased load capacity of 150%. For reference, you could process around 500 eyewear frames in a single job. Despite this bigger capacity, DyeMansion says the DUAL actually takes up 60% less workspace compared to the current Powershot models, while efficiency has also increased with process times now up to 20% less than that of previous systems. Parts go in, excess powder is removed, surfacing automatically starts and once finished, parts can then be rolled out from the belt and onto a tray, ready for any additional post-processing steps.

Also new are the “PolyShot Cleaning” process and plastic blasting medium, an alternative to the industry standard glass beads, which have been engineered to deliver the optimum shape, size and weight for powder removal without causing damage to parts. The process is expected to enable a wider range of process parameters and improve the depowdering of challenging materials such as TPU. PolyShot Cleaning is compatible with the next-generation Powershot and Performance series and can be used with all common powder-bed technologies.

AUTOMATION-READY

The primary focus for the Performance series is around the requirements of industrial production environments: quality assurance, traceability, connectivity and automation. With those factors in mind, DyeMansion says these new Performance models will enable traceability throughout the complete production chain through connectivity to MES and ERP systems, and full integration into automated production setups.

The series has been designed for flexibility, to allow machines to easily slot into real, dynamic manufacturing spaces and complement current automation setups.

Ewald explained: “There are different automation concepts and we want to make sure that our systems perfectly fit into all of those systems. So, it’s really about being automationready and our goal is just to have machines that customers can easily integrate into their automation concept.”

Building on an existing collaboration, the launch also sees DyeMansion working with Siemens to equip the new line-up with new features which aim to “set the stage” for automation in AM.

Karsten Heuser, VP Additive Manufacturing Siemens Digital Industries described the Performance series as, “the next milestone in the strategic partnership between DyeMansion and Siemens towards industrialized additive manufacturing.”

FUTURE-READY

Ewald says the classic series is “a perfect entry level product” for the automation of manual post-printing steps, while the Performance series brings additional capabilities which

WORDS: LAURA GRIFFITHS PERFORMANCE MODE make it “Industry 4.0 ready” and a step closer to industrialization. Ewald elaborated: “When normal people come in from the classical manufacturing industry, they have certain expectations when it comes to automation, reproducibility and connectivity. And so far, when you look at how the factories look; [there’s powder everywhere], a lot of manual work, this has nothing to do with industrialization. So, that’s our clear strategy and I think the industry is absolutely going into this direction.”

The Performance series, which includes the DUAL and separate C and S systems, will be rolled out with select pilot customers and DyeMansion has already shared that 3D printing service provider 3DPRINTUK will be one of them. The new generation of the classic Powershot C & S is readily available today while the Performance series systems will be ready to order in Q4 2021.

During its virtual launch event, DyeMansion also teased plans to build out its ‘Print-to-Product’ workflow even further with a low-cost, fully automated system for unpacking. It’s still in the early stages of development and Ewald tempered expectations by telling viewers not to expect a launch around this year’s Formnext where the company has historically launched its latest product iterations, but as pilot testing gets underway ready for orders of the Performance Series to begin later this year, there’ll be plenty to keep the team busy until then.

“We believe that the industrialization phase of 3D printing has started,” Ewald said. “Our goal is to be the key enabler of this era with the vision that 3D printed parts become part of our everyday lives.”

SHOWN:

DYEMANSION’S NEXT-GENERATION PRINT-TO-PRODUCT WORKFLOW

“The industrialization phase of 3D printing has started.”

SHOWN:

PHILIPP KRAMER, DYEMANSION CTO AT THE PERFORMANCE SERIES VIRTUAL LAUNCH

MOSCA: BUILT TO LAST

More than 100 series or spare parts can be 3D printed with the freeformer from ARBURG

SERIAL PRODUCTION WITH 3D PRINTING

Mosca has considered Additive Manufacturing (AM) for low-volume production of small components and spare parts. When they approached ARBURG, it quickly became clear that the freeformer was capable of much more than expected. It marked the beginning of a new level of innovation with reduced storage requirements and unmanned production if required.

We have installed more than 100,000 strapping machines worldwide,“ explained Stefan Kessler, Innovation and Technology Manager responsible for developing process improvements at Mosca‘s German headquarters in Waldbrunn. Each machine is made from over 2,000 individual components. Many of them are difficult to reproduce using conventional methods. Against this background, Kessler began looking into additive manufacturing and the economic benefits it could bring to Mosca.

First, Mosca identified over 100 different components or spare parts that were too costly to manufacture using conventional methods.It was quickly realized that the freeformer would meet the requirements for strength, dimensional stability, and speed. The move towards digital warehousing and spare parts on demand increases efficiency, improves the relationship with the customer and eliminates bottlenecks for the production team. Mosca could now manufacture overnight and ship the parts immediately instead of waiting weeks or months for components to be delivered. And the ability to produce complex, lighter components significantly helps reduce the energy costs.

In addition, the majority of the components in question used to be made of either aluminum or plastics such as POM and PE. Today, the components are 3D printed from PA10, which can be sourced from standard suppliers and at much lower prices.

Mosca, an international manufacturer of end-of-line packaging solutions, is one of the largest and most prominent suppliers of systems for strapping and securing goods for transportation.

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Further information:

www.mosca.com