TCT Europe 23.5 by TCT Magazine

OCTOBER 2015 www.tctmagazine.com

HIGH IMPACT 3D PRINTING

3D SYSTEMS BRINGS NEW ENGINEERING-GRADE NYLON AND INFINITY RINSE-AWAY MATERIALS TO THE DESKTOP

REDEFINE PROTOTYPING

GET INTO THE FAST LANE WITH STRATASYS® 3D PRINTING Meet us at TCT, 30 September – 1 October 2015 in Birmingham, UK. Stratasys rapid prototyping solutions enable you to iterate fast, avoid reworking expensive tools and drastically reduce time to market. Using the widest range of 3D printing materials from Stratasys, you’ll be able to produce tough functional prototypes for highly accurate performance testing, or realistic models that look and feel like ﬁnished products. Trusted around the world, Stratasys leads the 3D printing industry with end-to-end solutions dedicated to solving prototyping and additive manufacturing challenges. Learn how Stratasys can help you gear up your 3D printing and redeﬁne manufacturing in your business.

ACCELERATING 3D TECHNOLOGIES

OCTOBER 2015

ISSN 1751-0333

EDITORIAL HEAD OF CONTENT

James Woodcock james@rapidnews.com GROUP EDITOR

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

Laura Griffiths laura.griffiths@rapidnews.com NEWSDESK

+44 (0) 1244 680222 REGULAR CONTRIBUTORS

Todd Grimm tgrimm@tagrimm.com

ADVERTISING GROUP ADVERTISING MANAGER

Carol Hardy carol@rapidnews.com ADVERTISING MANAGER

Nicola Tattum nicola.tattum@rapidnews.com

PRODUCTION Sam Hamlyn Tracey Roberts

MANAGEMENT C.O.O. / PUBLISHER

Duncan Wood C.E.O.

Mark Blezard

SUBSCRIPTIONS

SUBSCRIPTIONS NOW OPEN FOR TCT NORTH AMERICA PRINT EDITION

PUBLISHED PRICES Europe Print Subscriptions - Qualifying Criteria UK - Free Europe - Free US/Canada - £79 ROW - £99

N. America Print Subscriptions - Non Qualifying Criteria UK - £79 Europe - £89 US/Canada - £99 ROW - £119 FREE on iOS and Android devices – including back catalogue and Buyers’ Guides.

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

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

BPA Worldwide Membership OCTOBER 2015 www.tctmagazine.com

ACCELERATING 3D TECHNOLOGIES

FROM THE EDITOR Not so Happy Anniversary

ne thing that really gets my goat (and ask the rest of the team there are lots of things that get on my nerves) is the idea of a six-month ‘anniversary’, have a look online, it’s a thing, you can even buy cards for it. Nobody mentions that the word ‘anniversary’ literally means ‘returning yearly’, the correct terminology if you did want to celebrate such a milestone would be a sixth mensiversary. Despite all the mainstream press the technologies have had in the past few years I’m still often met with amazement when talking about how long this technology has been around for, some think the technology is about to celebrate its ninth mensiversary since they first saw it on Newsround. Fortunately, we know better than most just how long this technology has been in development for and dotted throughout this issue are several substantial milestones that are worth celebrating. Starting off on page 13 with my flying visit to Mcor’s Dunleer, Ireland, HQ for their tenth anniversary celebrations. There’s a ritual on the flight from Liverpool to Belfast that almost grinds my gears as much as the anniversary thing; what is the point of serving anything when the plane is only out of take off/landing mode for all of five minutes? Anyway, the visit to Mcor was a fruitful one and not just for Deidre’s mother’s homemade scones. We also have a report on Concept Laser (page 33) who are celebrating 15 years of metal additive manufacturing with a very interesting case study, Laura has been looking to the future after a visit to the Birmingham Jewellery

Quarter (page 18) to see how new technologies are advancing that sector, I delve into the world of materials to see how a massive company are helping to bring new materials to the desktop and as always we have our excellent columnist Todd Grimm (page 82) bookending this piece with his piece on the Critical Mass the industry finds itself in. Of course, we have a milestone of our own looming on the horizon/ disappearing over the ridge, depending on when you are reading this letter. The 20th edition of TCT Show + Personalize sure to be the biggest yet, at the time of writing we’ve just had the highest number of registrations in a single day ever. You can find some Q&As with a selection of TCT Show speakers towards the back of this issue. As ever we want to hear from you, if you have any interesting 3D technology stories then feel free to drop me a line. You can find my contact details in the staff box on the previous page. Druck on

Daniel O’Connor Group Editor

Redefine your design Explore the potential of additive manufacturing Renishaw’s additive manufacturing systems use powder bed fusion technology to produce fully dense complex metal parts direct from 3D CAD. Find out more at www.renishaw.com/additive

Mechanical bracket for a satellite to be used in the space sector produced on a Renishaw AM250

Renishaw's Fingers Strip ad TCT 0815.indd 1

www.renishaw.com 20/08/2015 09:35:00 OCTOBER 2015 www.tctmagazine.com 05

PERSONALIZE PRINTING PRESS

A pick of some of the best 3D prints we’ve spotted over the last month.

LEAD NEWS

FLEX YOUR CREATIVE MUSCLE

HIGH IMPACT 3D PRINTING FOR THE PROFESSIONAL DESKTOP

3D Systems explains how 3D printing in Nylon on the CubePro desktop printer is nothing short of revolutionary.

FEATURES

NEWS

A roundup of all the latest news from the last month, for more on each of the stories visit www.tctmagazine.com

MCOR: 10 YEARS OF RISK AND REWARD

Dan reports on his visit to Mcor Technologies’ HQ in Ireland to celebrate the pioneering company’s 10 year anniversary.

WHEN TRADITION MEETS TECHNOLOGY

Laura takes a trip to Weston Beamor to find out how the UK’s first jewellery lost-wax company is spreading its wings.

A NEW WAY OF THINKING

A report from the PRECIOUS Project, Future Technologies Seminar at the Birmingham School of Jewellery.

MAKING MATERIALS GO FURTHER

Dan takes a look at the changing world of 3D printing materials.

THE MAGIC IS IN THE DESIGN

Dan gets a first look at the latest version of 3D Systems’ Geomagic Design X software.

CONCEPTUAL KNOWLEDGE

REPRAP TO THE RESCUE

As Concept Laser marks 15 years in the additive manufacturing industry we take a look at how the company has managed to stay ahead of the game.

THE EVOLUTION OF ROTITE

Dan speaks to MediSieve founder Dr George Frodsham to find out how 3D printing is being used to cure malaria.

A MATERIAL FOR THE 21ST CENTURY

Laura meets with Stuart Burns of Rotite Technologies to find out why the company is taking a new direction.

STRAIGHT OUTTA CROMPTON

Dan finds out how Liverpool Hope University Master’s student, Jade Crompton is using 3D printing to bring ceramics into the 21st century.

Laura takes a look at the evolution of graphene from a “2D material” to a future in 3D printing.

60 SECOND INTERVIEWS

We ask some of our TCT Show + Personalize speakers what they’re most looking forward to at this year’s show.

DESKTOP 3D PRINTING

Laura finds out how Type A Machines are looking to ride the next wave of AM from the world’s largest 3D technology startup cluster. year’s show.

We delve into the latest developments in the 3D printing space including some TCT Show + Personalize firsts.

SIX MACHINES ARE BETTER THAN ONE

A SOLUTION FOR SILICONE

We take a look at WACKER’s recent announcement of a new technology for 3D printing with silicone. to find out what it takes to set up a successful bureau.

Dan speaks to Polymaker to find out more about a new material science partnership that’s set to change desktop 3D printing.

CHILDREN OF THE REVOLUTION

GOING CLEAR

We find out how Lenovo is empowering 3D artists and engineers with their most powerful workstations yet.

Laura finds out about how a partnership between Robox and Kitronik hopes to inspire the next generation of engineers.

REGULARS

05 17 82

FROM THE EDITOR’S DESK GUEST COLUMN TODD GRIMM COLUMN

OCTOBER 2015 www.tctmagazine.com

ACCELERATING 3D TECHNOLOGIES

CONTENTS

TCT | OCTOBER 2015 EDITION

LEAD NEWS: 3D SYSTEMS

High Impact

3D Printing for the Professional Desktop WO R D S : 3 D S YS T E M S

Over a few short decades, 3D printing has evolved from a feat of science fiction to a very real and ubiquitous aspect of daily life. Whether you realise it or not, 3D printing is a part of life-saving surgeries, energy-saving transportation and HOW NYLON the timesaving manufacturing of AND INFINITY products large and small. Like the technology that came RINSE-AWAY computer before it, 3D printers have evolved MATERIALS from gargantuan machines to ARE GIVING reasonably sized appliances that fit unobtrusively in a college 3D SYSTEMS’ can dorm room. Though large-scale CUBEPRO 3D printers remain for large3D PRINTING scale tasks, smaller machines becoming increasingly more SUPERPOWER are capable through advancements in speed and expanded materials portfolios. The CubePro desktop 3D printer is one such machine that recently doubled its materials capabilities with the addition of Nylon 6 and a water-soluble support material, Infinity Rinse-Away. Though Nylon is a familiar household name, its introduction to CubePro desktop 3D printing is nothing short of revolutionary. Now, desktop engineers and small office entrepreneurs can print for concept, function and end-use with the durability, versatility and reliability of Nylon. For inventors and entrepreneurs like Luke Schantz, Technologist at SoftLayer, Nylon carries us one step closer to a world where we are a click away from

OCTOBER 2015 www.tctmagazine.com

bringing any part, product, accessory or invention into being. Luke is in the process of custom-building a visual effects robot, and though many common 3D printing materials are suitable for fit testing, Luke has found the CubePro and Nylon product-material combination to provide “unmatched performance.” In building his robot, Luke has gladly used materials like ABS to verify concepts, but because final parts will be subjected to on-going use, Luke needed a material of endurance. “The real work needs to be done in Nylon,” Luke says. In spite of Nylon’s unique material properties, some may argue it is in fact Nylon’s compatibility with Infinity Rinse-Away that really raises the stakes for desktop 3D printing. For those unfamiliar, the magic of Infinity RinseAway is its graceful disappearing act in the grand finale. This water-soluble material breaks down in water, washing away to reveal smooth surfaces with intricate detail. Combined with Nylon’s rugged capabilities, this blank check of complexity enables designs and turnaround testing like we’ve never before seen. To get a better understanding of what this means, 3D Systems’ Principle Engineer Marty Johnson explains, “With Infinity Rinse-Away, we can now print difficult geometries better, such as overhangs in hard to reach areas, tubular parts, and figurine type parts. Not only that, but we can print better bottom surfaces too.” The complexity, intricacy and functionality this brings to desktop 3D printing translates to end-use 3D printing with minimal finishing and maximum function. Marty, who has spent the past eight years at 3D Systems developing and integrating printers with materials, says that a key focus for him and his team of engineers is streamlining operator use while enhancing operation outcome. “The focus is to allow the user to print and enjoy the creation they printed,” he says. According to Founder and Lead Designer of 3D Brooklyn, Will Haude, this goal has been achieved with flying colours. Will uses 3D Systems’ Infinity RinseAway support material to achieve intricate designs with

ACCELERATING 3D TECHNOLOGIES

BELOW: Parts printed with

the CubePro Nylon material

BELOW:

The rinse away material makes removing support from difficult to reach places a cinch.

moveable, functional parts. “Infinity Rinse Away has changed the way I think about designing from the very start,” he says. “Before, I had to design around my idea, rather than bring it to life directly. Because Infinity is water soluble, I don’t have to worry about that limitation and can make more freely.” Now, Will revels in the ability to print parts with interlocking knobs and moving parts that bind together with Infinity and are freed and functional once cleaned. Infinity Rinse-Away has also made a splash at Medtronic, PLC. As the world’s largest standalone medical technology development company, Medtronic is equipped with an abundantly capable team of scientists, clinicians, and engineers, as well as a robust fleet of the most sophisticated, cutting-edge technologies. Alongside larger 3D printers and traditional tooling machines, Medtronic has several CubePro 3D printers, which have added the cherished elements of availability and low cost to Medtronic’s design process. William Harding, Medtronic Distinguished Technical Fellow, says the release of Infinity was received “like a Christmas present,” and the introduction of this capability bodes an upgrade from Medtronic’s CubePro Duos to CubePro Trios. For William and his team of biomedical engineers, “the time saved on cleaning prints is a godsend,” not to mention the incredible potential now offered by combining Infinity with Nylon. Though many of the products Medtronic develops are protected as IP, William says the properties of Nylon make it a tremendous advantage to his team and their mission. The strength of Nylon, and its robustness relative to other desktop 3D printing materials, makes it capable of withstanding greater stress for more informative testing. Visualise the daily life of a wearable or implantable medical device: the environment it will be exposed to

With Infinity Rinse-Away, we can now print difficult geometries better, such as overhangs in hard to reach areas, tubular parts, and figurine type parts.

will not be gentle and the consequence of failure may put new designs in jeopardy. For this reason, and gratefully so, testing is rigorous and thorough. Nylon has proved itself to Medtronic, and is now a trusted reliable material William and his team can turn to when they need concept solutions that will last through multiple handoffs for testing and exposure to rough elements. The value of trustworthy forecasts can save lives, and the more trustworthy the better. William also notes that Nylon responds well to radio frequencies (RF) in a similar manner as human features, which gives Medtronic an even more accurate read on the best path of development for technologies that are saving and improving the quality of lives. Many of William’s engineers are trained in design thinking, and the fact that 3D printing enables products to be designed for function rather than for fabrication is of fantastic significance. If designers and engineers, the people who shape the world around us, are no longer limited to the verdicts of their tools and can instead put their ingenuity into overdrive, the world is in for a wild ride. And if they can do this from their desktop, design evolution will come rapidly.  For more information visit www.3dsystems.com

OCTOBER 2015 www.tctmagazine.com

Accelerate into Direct Digital Manufacturing and Rapid Prototyping with SYS Systems As the leading supplier of Stratasys 3D Printers, we can help you quickly get up to speed with advanced 3D printing technology. Unleash your imagination and revolutionise your product.

T: 01283 585955 E: info@sys-uk.com www.sys-uk.com

EMEA PARTNER OF THE YEAR 2 0 11 / 1 2 & 2 0 1 4 / 1 5

PA R T N E R | 2 0 1 5

Find out more at the TCT Show, NEC, Birmingham, September 30th â&#x20AC;&#x201C; 1st October, Stand G18

PHILIPS HEALTHCARE TUNGSTEN 3D PRINTING TEAM LEADER JOINS ADDITIVE INDUSTRIES 

Washington-based Naked Prosthetics is using the Formlabs Form 1+ 3D printer to create custom finger prosthetics. Naked Prosthetics is the brainchild of Colin Macduff, who founded the company in 2012 after fabricating the first biomechanical prosthetics fingers (BPF) device out of spare parts in his garage. The company works with clinics, physicians and surgeons to produce simple, functional BPFs customised to individual lifestyles. 

NEWS

There’s an element of sophistication in this news roundup with new ventures welcoming the expertise of industry leaders, strategic investment plans and even consumer technology creating life-enhancing devices.

Additive Industries has announced that Harry Kleijnen, currently responsible for the Philips Healthcare team printing tungsten grids for its X-Ray systems, will join the young Eindhoven technology company. In his role as Manager of Process & Application Development, Harry Kleijnen will be responsible for the processes and customer applications for the company’s industrial metal additive manufacturing system, the MetalFAB1 set to launch in Q4. 

FOR THESE STORIES IN FULL CLICK TO WWW.TCTMAGAZINE.COM

MADE IN SPACE MAKES 3D PRINTING IN VACUUM OF SPACE A REALITY 

MIT’S MULTIFAB 3D PRINTER PRINTS UP TO 10 DIFFERENT MATERIALS AT ONCE  Researchers at MIT’s Computer Science and Artificial Intelligence Laboratory have developed a low-cost 3D printer capable of 3D printing in 10 different materials at the same time. The MultiFab system is the first 3D printer to use 3D scanning techniques to deliver advantages in accuracy and convenience and aims to be a more accurate, cheaper and user-friendly alternative to current multi-material machines. 

MATERIALS SOLUTIONS SECURES STRATEGIC INVESTMENT BY SIEMENS VENTURE CAPITAL 

Made In Space has successfully completed a round of testing to prove that its next generation of 3D printers can operate in the vacuum of space. The world’s first space manufacturing company spent a week testing a modified version of its Additive Manufacturing Facility with proprietary vacuum-compatible extrusion heads in a vacuum chamber. Various specimens were produced using aerospacegrade thermopolymers and will be tested this month. 

UK-based Materials Solutions Limited, an additive manufacturing company specialising in AM for metals in the aerospace and auto industries, has announced it has secured a strategic investment from the Venture Capital Unit of Siemens (SVC). The investment will accelerate Materials Solutions’ focus on the manufacture of high performance nickel superalloy components for both land and aero-based gas turbines, specialist steels and titanium components for aero systems and auto parts. 

SENVOL DATABASE ADDS OVER 100 NEW INDUSTRIAL 3D PRINTING MACHINES AND MATERIALS The world’s most comprehensive AM database has expanded yet again by adding over 100 new searchable machines and materials. The Senvol Database is the first database of its kind and has now passed 1,000 machine and material entries. The free database was set up earlier this year to provide free searchable access by more than 30 fields including build size, price, material type or material tensile strength. 

OCTOBER 2015 www.tctmagazine.com

011

ACCELERATING 3D TECHNOLOGIES

COMPANY USES FORMLABS 3D PRINTER TO CREATE CUSTOM FINGER PROSTHETICS 

MCOR ACCELERATING 3D TECHNOLOGIES

Daniel O’Connor took the short hop over the Irish sea to Mcor technologies’ HQ on the outskirts of Dublin to help the team celebrate a decade of innovation and growth.

MCOR:

10 YEARS OF RISK AND REWARD

WOR DS : DA N IE L O ’c o n n o r

owards the end of

2004 heading into 2005 Ireland was the fastest growing economy in Europe. Technology was a huge driving factor in the economic growth of what became known, in financial terms, as the Celtic Tiger mk II; Google opened offices in Dublin, Dell’s major European manufacturing plant was in Limerick, 25% of European computers were manufacturing on the Emerald Isles. At the time it was the perfect place to start a technology company, the Irish Government was investing heavily through the newly founded Science Foundation Ireland and everything was looking rosy. Brothers Conor and Fintan MacCormack had been engineering and tinkering from an early age thanks to their father, a metalwork teacher. After using the 3D printers available only to large corporations and universities the brothers decided to produce a printer that was both affordable to buy and maintain as well as being easyto-use.

Like most companies starting off we took big risks; we remortgaged our houses, we maxed out our credit cards, we took out bank loans and probably the hardest thing to do was to take loans from family.

“In the summer of 2005 Fintan and I made the huge decision to give up our jobs and set up a company in Ireland.” Dr Conor MacCormack said at an event to mark Mcor’s tenth anniversary. “Like most companies starting off we took big risks; we remortgaged our houses, we maxed out our credit cards, we took out bank loans and probably the hardest thing to do was to take loans from family.” Just three years later the global financial collapse hit Ireland as hard as, perhaps harder than, anywhere else, plunging the country into a similar darkness to that which Greece currently finds itself in. By 2010 Ireland was per capita the most indebted country in the EU. Public spending cuts were heavy, “masochistic” according to the Financial Times, Dell pulled its Irish production facility with the loss of more than 5,000 jobs, things, especially for a fledgling company like Mcor, didn’t look good. A SEED OF HOPE Despite the economic downturn InterTradeIreland a cross-border trade and business development body were still able to offer up hundreds of thousands of euro in prize money for new businesses through its Seedcorn awards. The competition for funding in a recession was fierce and Mcor faced an uphill battle to win top spot. ››

OCTOBER 2015 www.tctmagazine.com

013

MAKERBOT

MAKE THINGS. EFFICIENTLY. Reduce time to market & Discover ROI behind desktop 3D printing Making MakerBot® Desktop 3D printers part of your engineering workflow enables real-time prototyping and encourages more widespread usage. Learn more about collapsing design cycles, which in turn accelerate your products‘ time to market. In this free white paper, you get a deeper insight in how the NASA, GE‘s FirstBuild, Lockheed Martin and many more are using desktop 3D printing to streamline their design cycles and reduce costs. Download your free white paper to learn more and visit us at tct SHOW + personalize. Birmingham, booth A12 MakerBot Europe GmbH & Co. KG • Motorstraße 45 • 70499 Stuttgart, Germany T +49.711.228.380 • eu.makerbot.com • eu-contact@makerbot.com

FREE DOWNLOAD goo.gl/eD4s b

MCOR

Ministers Nash (Left) and Bruton (Centre)

BELOW: Deirdre, Conor and Fintan

show off their Mcor printed selfies

“In 2008 we won the Seedcorn competition, not only was that a fantastic PR opportunity to win but there was a €100,000 prize fund for first place, but what Margaret Hearty (Of InterTradeIreland) probably doesn't realise is that was our funding plan for that year,” Conor quipped with a wry smile. “There was no plan B and if we didn't win that competition we wouldn't be here today.” Though we’re sure, knowing how driven Mcor is as a whole, that there was a Plan B that Seedcorn award for Best Emerging International Company was a veritable boon for Mcor. It was awarded for Mcor’s innovative approach to 3D printing - selective deposition lamination - which takes regular reams of A4 office paper and turns it into 3D models and the technology was debuted at none other than TCT Live 2008 in the Ricoh Arena. A DECADE OF INNOVATION From that day Mcor has never taken a backwards step, despite the economic downturn in Ireland outlasting many other European countries it is a country on the up again, thanks in no small part to companies like Mcor, in the last twelve months the company has doubled its workforce. The company’s success has not gone unnoticed by the Irish Government, who sent Richard Bruton T.D., Ireland’s Minister for Jobs, Enterprise and Innovation, and Minister Ged Nash T.D., Minister of State for Business and Employment to mark the anniversary. Minister Bruton said when unveiling a plaque to celebrate the achievement: “At the heart of our Action Plan for Jobs is supporting more innovative Irish companies to start up and create employment. Mcor is a great example of what we are trying to achieve through our plan – an Irish company, in a regional location, developing cutting edge technology in a fast-growing area, growing a viable business and creating jobs. Conor and his team deserve huge credit for what they have achieved. I am delighted to be here to help them celebrate their 10th anniversary and I wish them every success for the future.”

Mcor is a great example of what we are trying to achieve through our plan – an Irish company, in a regional location, developing cutting edge technology in a fastgrowing area, growing a viable business and creating jobs.

Minister Nash adding: “As a local TD, I know the value that a company like Mcor brings to Dunleer and the wider county of Louth, with high quality jobs in R & D as well as sales and marketing. Mcor is truly an innovative Irish company at the forefront of affordable 3D technology, which is eco-friendly to boot. I am delighted to mark its 10 year anniversary today with Conor and his team.” All the backslapping and pleasantries in the world will not stop the fiercely ambitious Mcor Technologies continuing to grow, this year saw them not only garner awards like GeekBeat.TV’s Best of CES 2015 and Best-inShow at Solidworks World 2015 but they also launched their Iris HD technology that makes theirs the only 3D printer to comply with the global-standard ICC colour map. “We see ourselves as an R&D company at heart,” enthused Conor MacCormack. “This will enable us to realise our long term vision of putting a 3D printer in every office, classroom and eventually every home. We think the DNA in our technology will enable that to happen. We believe that over the next three years we’ll be looking at a very massive growth, within that time we can grow to over 250 employees.” This is an example of how 3D printing can grow an economy, not only by creating manufacturing jobs in the piecing together of machines but by creating economies to themselves. Each machine could be helping one to one hundred people start their own business through prototyping or even as we’ve seen with Mcor recently creating finished products like jewellery. It is this very reason that has seen governments sit up and take note of firms like Mcor Technologies and the new business models they create.  For more information visit www.MCORTECHNOLOGIES.com

OCTOBER 2015 www.tctmagazine.com

015

ACCELERATING 3D TECHNOLOGIES

LEFT: Conor showcases Mcor’s technology to

DR. BLACK COLUMN ACCELERATING 3D TECHNOLOGIES

A FOUNDATION FOR THE FUTURE OF AM

WOR DS : D R. K AT E B L AC K

AM is certainly capable of building complex architectures but there is a risk that we are simply creating beautiful baubles unless we can add greater functionality to these components and products.

Dr. Kate Black

is a Lecturer in Additive Manufacturing at The University of Liverpool, School of Engineering. Kate’s research interests are focused on the development of novel functional materials, using inkjet printing for the manufacture of electronic and optoelectronic devices. Kate is also the Chairman for Liverpool Women in Science and Engineering, which celebrates and supports women in STEM.

dditive Manufacturing (AM) has often been referred to as a revolutionary technology with the potential to steal a march on conventional manufacturing techniques. It has been demonstrated that AM can, in some cases be faster, less materialsintensive and reduce the time to market. However, the perception of AM in the popular media seems to have outstripped reality, with the unfortunate misconception that large scale AM of big, complex, multi-material products is possible right now. AM is certainly capable of building complex architectures but there is a risk that we are simply creating beautiful baubles unless we can add greater functionality to these components and products. Materials are the biggest hurdle faced in adding new functionality, but they also present us with the greatest opportunities for AM. A more sympathetic approach to materials selection for AM could see some of the public’s less wild imaginings become a reality. There are five main planks that need to be put in place to make the most of AM; the first is that we need to broaden the pallet of starting materials. While it is currently possible to create industrial AM products out of metals and plastics, the range of materials is limited and needs expanding and optimising. We need to put more focus on accelerating the transition of AM with innovative and unusual materials from research laboratories into factories. There is also an immediate need to develop industrial-grade AM equipment with multi-tool heads, so that a range of innovative materials can be directly printed in one build operation. No single AM technique will steal the show, it has to be a combined effort with which hybrid machines (AM and subtractive processes) are created that are capable of processing metals, plastics and ceramics simultaneously. Thirdly, AM has been good at creating complex 3D structures but there has been relatively little focus on integrating them with direct printing of novel thin film materials for electronic components, such as power supplies or sensors. Direct printing of thin films has

been limited by the restricted pallet of materials available to AM but this will be overcome by adopting increasingly sophisticated approaches to the materials science and chemistry involved in producing materials for AM. The fourth plank is the need to monitor the materials in AM processes in-situ. To be able to observe in real-time the physical, chemical and biological processes involved in the printing, will enable us to understand and then control AM processes. Smart in-situ monitoring could involve the full range of analytical methods from spectroscopy to thermal or even magnetic imaging. This would enable us to develop whole new classes of material systems not possible by conventional means. The final plank is that these wonderful, complex, multi-material AM products will require their properties to be robustly tested. It is not good enough to simply say “we can make…”, it is imperative that we know the exact properties, be they mechanical, optical or electronic. This level of materials development and testing requires that we work more closely with, and adopt the skills of, chemists, physicists, materials scientists, biologists and machine manufacturers. We need to work hard to make the most of the opportunity that AM presents us with. We need to think big, make ingenious and complex products and adopt ever more efficient and creative approaches to fully let the genie out of the AM bottle. By combining the five main planks together we will form a solid base for the future of AM. 

OCTOBER 2015 www.tctmagazine.com

017

WESTON BEAMOR

There are more than 500 shops and companies specialising in gems and precious metals in Birmingham’s famous Jewellery Quarter. This unique environment in the heart of the city is quite literally dazzling with flecks of gold and silver glimmering through rows of storefront windows, as a sign of the Quarter’s proud heritage and expanding community.

Where tradition meets

technology

estled

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

amongst

what’s

become somewhat of a tourist attraction for the city, lies Weston Beamor. Founded in 1947 as a casting house, the jewellery manufacturer is one of the most respected names in the industry and more significantly, was the first jewellery lost-wax company in the UK. 15-years ago, visionary owners Vivian and Patrick Fuller took a gamble by installing a 3D Systems Viper machine into the company’s production facility. Back when additive manufacturing systems had not yet been designed for the jewellery sector, it was complete a leap of faith but judging by the three machines now installed at the workshop, it seems as though it’s definitely paid off. “It was all driven by wanting to deliver a more accurate product and a product to market more quickly,” explained Weston Beamor’s Creative Director, Naomi NewtonSherlock. Despite the positive press surrounding 3D printing for the jewellery industry, the image of a lab style, automated manufacturing environment is far from the picture as I tour around the site at Weston Beamor. Having visited many factory floors and university labs, I’m used to the hightech, complex examples of laser sintering. I am however, not too familiar with the more traditional processes that go into making jewellery. Crafting a piece of jewellery is truly an end-to-end process at Weston Beamor from the dedicated CAD team all the way to its in-house hallmarking service.

018

OCTOBER 2015 www.tctmagazine.com



ABOVE: Naomi Newton-Sherlock

As consumers we have much higher expectations in terms of what we want and expect. There’s a huge personalisation trend across the board in all industries and retailers really need to compete.

3D printing is merely a small part of the production process, small but highly effective. The workshop houses its original Viper machine, a Solidscape Max 2 and a more recently installed EnvisionTEC Perfactory 3D printer of which Weston Beamor is one of the prime pilot customers for new developments. These are used to reduce lead times and rapidly produce casts for custom pieces of jewellery driven by a desire to the lead the field and improve current processes. “It has completely opened up the doors of bespoke manufacture, the types of people we can work with and the types of product we can work with,” Naomi commented. “It really has exploded and it’s become a huge growth area for us.” Some of those types of products range from personalised chess pieces to custom table football figures in the giftware industry – think getting a 3D body scan and having your figurine 3D printed in silver – all the way to architects, product designers and even leading automotive names seeking the finesse and detail that the industry stalwart is known for. “I think part of this is driven by consumer expectations because rather than us pushing the consumer experience, it’s quite often the other way round,” Naomi explained. “As consumers we have much higher expectations in terms of what we want and expect. There’s a huge personalisation trend across the board in all industries and retailers really need to compete.” The jewellery market is a relatively small industry in comparison to other high profile

A TECHNOLOGY TO REPLACE TRADITION? As AM technology continues to progress, there’s the increasing demand to advance from using it as a prototyping method to applying it as a full-on production tool. Research into precious metals is a key interest in the AM jewellery sector and there are projects being undertaken right now that are looking into mixing these metals and even placing stones during the build process. For Weston Beamor, materials are important and one of its key differentials is the alloys it works with. If a material such as its distinctive 18K white gold, which has a very high palladium content, were to be applied in AM, multiple properties such as whiteness, purities and hardness would have to be considered - that’s before you’ve even begun to look at post processing. “It’s not all going to come overnight. Speed is very important, costs are

ACCELERATING 3D TECHNOLOGIES

ABOVE: Domino CAD ring

sectors such as aerospace and automotive which have benefited from significant investment in the AM space. There is a lot of value placed on skilled labour and traditional techniques from the millimetre wide strands of leather used to finish a wedding band to the painstakingly intricate job of setting tiny stones into a bespoke engagement ring. It’s hard to imagine AM could ever be a worthy substitute and experiencing the process first-hand, I can’t help but emphasise with the romanticised hand-crafted element I’m told some customers favour when presented with the option of a digitised process. “There are some customers who would still put greater value on what they perceive to be a handmade piece versus a computer produced piece,” Naomi explained. “For me I don’t think the value is behind the production process for the customer, I think the value is around what they’re getting at the end of that process. They’re getting what they want but what the technology is allowing the retailer to do is deliver a far better, faster, efficient service.”

It’s skilled, it requires skilled technicians, dedication to make it work. What does work is a wonderful thing which has revolutionised making jewellery.

very important, waste is very important, capacity is important. Of course if you can only produce one or 10 pieces it’s very limited capacity so we would want it to be on a much larger scale,” Naomi added. “It’s skilled, it requires skilled technicians, dedication to make it work. It isn’t a quick fix. What does work is a wonderful thing which has revolutionised making jewellery.” For now, Weston Beamor is looking to push its current arsenal to the limits by throwing the platform wide open to customers exploring the possibilities of experimenting with metals in unconventional product categories, a challenge they’re welcoming at this year’s TCT Show + Personalize. Keeping its forward-thinking head on, the company is open to new technologies that will offer greater definition for its prototyping services and enhance its armoury of both digital and traditional practices. “I think it’s always got to be married with hand techniques,” Naomi concludes. “I don’t think it stands in isolation, you’ve got to see it as part of the bigger picture but in terms of how it has enhanced the production process, it is fantastic.”

OCTOBER 2015 www.tctmagazine.com

019

EXPERT > FAST

FRIENDLY > EXPERIENCED

3DPRINT BUREAU WWW.3DPRINTBUREAU.CO.UK

The nipi cooler prototypeD with the help of 3D Print Bureau

E: GARY@3DPB.CO.UK T: 01763 241436

To push the envelope for Additive Manufacturing:

Just add Arcam.

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

See what you can achieve with Arcam. Visit www. Arcam.com 020

OCTOBER 2015 www.tctmagazine.com

TOTAL

DESIGN FREEDOM

COST

EBM

EFFICIENT MULTIBEAM PRODUCTION

FUTURE TECHNOLOGIES ACCELERATING 3D TECHNOLOGIES

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

A NEW WAY OF THINKING

As Frank Cooper from the Birmingham School of Jewellery addresses the room at the somewhat intimate 3D printing in jewellery Future Technologies seminar, his message is this: “The jewellery industry is extremely CAD literate and aware.”

t’s a point the entire additive manufacturing industry is constantly striving to drive home – “this isn’t new”, “AM has been around for decades”, “Industries have been using this for years”, etc. As one of the earliest adopters of 3D technology, it is especially relevant in jewellery and even more so today where experts gathered for the Future Technologies Seminar at the Birmingham School of Jewellery to not simply talk about 3D printing but a recent project that’s set to change the goalposts all over again – 3D printing in gold. The PRECIOUS project is an initiative supported by the UK’s innovation agency, Innovate UK. It’s mission? “To demonstrate the viability of precious metal additive manufacturing within the UK Jewellery industry from design and manufacturing through to finishing, polishing and retail.” Speakers from all corners of the consortium including jewellery design, production, software, additive manufacturing and finishing took to the floor to explain how they’re pushing the technology forward at various points in the supply chain. Robin Wilson, Lead Technologist for High Value Manufacturing at Innovate UK, opened by explaining how Innovate UK has awarded £7million in funding for projects that are ‘Inspiring design freedoms in additive manufacturing’. Robin explained how the jewellery industry is the perfect fit as it’s about a whole new way of making. “If you have a new way of making something,

chances are you can design it differently and offer more to the customer,” Robin commented. “One of the tricks of this new technology is to use the power of design.” This idea of not simply ‘cloning’ what we’ve seen and done before is reflected in the designs this groundbreaking project has produced. These are not typical pieces of jewellery, some are intricate complex structures and others are quirky and interactive. Lionel Theodore Dean of Future Factories told how 3D printing is empowering the jewellery industry’s interest in customisation. Though AM might not be the most efficient way of making, there are varying levels of customisation that make it very appealing to customers from individualisation, to online co-creation and collaborative customisation. GETTING IT RIGHT In order to get the best results with AM you have to ask “how do you build a part?”. PartBuilder, the latest piece of software from Delcam/Autodesk, can repair problematic CAD models, position the part for optimum orientation and determine where parts need fixtures. As Kevin Hamilton, Delcam/Autodesk put it, “software is the centrepiece” and we’re presented with some rather intriguing objects showing tree-like support structures that have been generated with this sophisticated piece of technology. Then there’s the actual production part in which Tony Staniorski, Technical Director at Cooksongold OCTOBER 2015 www.tctmagazine.com

021

ST TC E AN T 44 D 20 15

Ninety square metres of the best in 3D scanning and 3D printing at TCT Europac3D are resellers of the fantastic Kreon range of highly accurate portable measuring arms and laser scanners, including the blue light Zephyr, suitable for scanning reflective surfaces.

As one of the largest authorised resellers of 3DSystems equipment, our technicians will be on hand to showcase the composite material, plastic and wax/casting machines on display and answer your 3D printing queries.

We will be demonstrating the Artec Eva and Spider hand-held 3D scanners which, based on video technology, can capture in 3D an impressive array of objects ranging from industrial parts to heritage items and the human form.

The DS2 and CS+ top quality desktop automated 3D scanners from Solutionix will showcase a variety of detailrich scanning uses including industrial, dental & jewellery parts.

(Plus a special 3D scanning surprise!) Tel: 01270 216000 Email: sales@europac3d.com Web: www.europac3d.com

FUTURE TECHNOLOGIES

straightforward part of the entire process. Labelled as one of AM’s ‘dirty secrets’, post processing is one of the most time-consuming and costly areas of the technology. In order to produce successful prints, you’ve got to think about how they will be finished and Richard Ainsworth from Finishing Techniques reveals how the company has been researching cost effective polishing solutions for laser sintered jewellery products. ALL THAT GLITTERS? These complex gold parts show real promise for the jewellery industry though it’s still very much in the early stages of development. As Tony commented: “You can’t adapt research into your business, you need to have plug and play processes,” and that’s an opinion I find increasingly common as I talk to old-school jewellery makers and retailers. As the School of Jewellery celebrates 125 years with the introduction of a new Masters course in Innovative Metal Manufacturing next year, perhaps a new generation of talent and minds will take the helm, unfazed by constraints of the past and do things we would have never imagined. 

ADDITIVE MANUFACTURING

TOYOTA MOTORSPORT GmbH

EXPERTS AT ADDITIVE MANUFACTURING TMG is on the cutting-edge of additive manufacturing, with 10 laser sinter (SLS) machines and with 35 years of top-level motorsport experience, we pride ourselves on delivering superior quality, fast. Our strong relationships with key suppliers ensures TMG works with a range of materials, including the new DSM Somos® PerFORM material which offers high-resolution production with even shorter lead times.

www.toyota-motorsport.com +49 2234 1823 0 | contact@toyota-motorsport.com OCTOBER 2015 www.tctmagazine.com

023

ACCELERATING 3D TECHNOLOGIES

openly stated, “Additive manufacturing will never replace casting, it’s too easy. The AM process brings a whole range of capabilities to your designs. “It’s a welcome and realistic take on the technology and one that’s echoed by the informed questions from a clearly educated audience about speeds, costs and finishing. It’s great for custom pieces, even better for otherwise-impossible pieces but as far as being a complete, replaceable production method, it’s not quite there yet - thankfully, nobody here is proposing it will be. As for people implementing this technology now, Tony explained, “The reason won’t be cost, it will be application.” The PRECIOUS M 080, developed in conjunction with EOS and Cooksongold, is a purpose-built machine for precious metal laser sintering and was recently installed at the Birmingham School of Jewellery. With a build envelope of 80 mm x 95 mm, the machine is capable of producing various designs together in the same print job. As Frank explained: “A batch of one is fine, a batch of 10 ‘ones’ is even better.” In fact the physical manufacturing element is probably the most

MATERIALS ACCELERATING 3D TECHNOLOGIES

SponSOred by

Over the next four pages Daniel O’Connor takes a look at the changing world of 3D printing materials and how big companies are set to shape what we see next.

MAKING MATERIALS

Go Further

aterials have become the lifeblood of the 3D printing industry. Increasingly new applications are using the technology thanks to developments in materials science rather than innovations in hardware. This focus can be felt right across the 3D printing spectrum from new super-alloys launched for metal additive manufacturing systems to the desktop composite materials MakerBot is set to launch next year. The escalation in choice of materials since the early days of 3D printing are astronomical, Gary Miller of 3D Print Bureau told TCT: “When I first started using Objet machines I had one material that I could 3D print with, which was FullCure 720. Now with Stratasys’ Digital Materials and the amount of permutations you can have I’ve lost count of the number of materials I can print with, there’s probably over a thousand.” Materials are now shaped by demand, if a specific industry calls out for a specific material there will more than likely be a material scientist capable of finding the right 3D technology to make it work. But for Gary the increasing range of materials hasn’t made his job any easier.

ABOVE: 2015 UConn SAE race car “I’ve become more of a consultant these days, years ago it was ‘I’ll build your prototype’ if you didn’t like the material it comes in then tough cookies, now there’s a range of different materials and you have to consult with the customer to understand their needs in order to give them a prototype, a production model, a wind tunnel part, whatever it is they need it for it has to perform in the best way and different materials behave in different ways.” LEADING THE WAY The most famous quote from Bernard Williams – the great British moral philosopher - is: “Man never made any material as resilient as the human spirit.” Perhaps not, however Somos is doing its best to do so as they continue to lead the way in high performing materials for the 3D printing industry. “We’re constantly in the lab formulating materials that open new applications for

Man never made any material as resilient as the human spirit.

OCTOBER 2015 www.tctmagazine.com

025

SLS, SLA, DMP, CJP, MJP...

So many technologies. We have you covered. We have all the right technologies and we have the experience to help you decide which technology to choose. Get in touch for sample materials, demonstrations and parts. www.hkh3d.com

01788 577 288

SOLUTIONS 3D Printers | Software | Materials | On Demand Parts 026

OCTOBER 2015 www.tctmagazine.com

MATERIALS ACCELERATING 3D TECHNOLOGIES

SponSOred by

the 3D printing industry,” explains Somos Business Director, Melissa Lutz. “We keep in contact with our customers to fully understand their needs and create new materials to help them to grow their business.” The company now has over 15 different stereolithography resins all tested to ensure its goldstandard reputation that has been built since the very early days of Chuck Hull’s first 3D Systems machines. Somos materials are used in applications as wide ranging as injection-moulding systems to sealing valves for car engines. The latter example may seem a little specific but as this recent case study by Somos shows, Somos materials stand up to some fairly rigorous testing:

ABOVE: 3D Printed

Runner boots ©InterPRO Models

TESTING IS PARAMOUNT During the conversation with Gary Miller he eluded to the fact that some customers approach him with questions he simply can’t answer about a material’s properties. One customer approached him about submerging a clear prototype in oil 24/7; the fact is that because the technology is only just becoming mainstream all instances are yet to be tested. Somos fully tests all of their 3D printing materials and recently has been evaluating long term aging properties as applications are moving in use for prototyping to end use parts. This kind of approach along with over 40 years of experience in material development and the increasing backing of a material science giant like DSM mean that Somos are still likely to be leading the way in 3D printing materials for many years to come.  For more information visit www.somos.com

TURNING THE HEAT UP FOR TESTING –

A MATERIALS CASE STUDY Every year, the University of Connecticut’s Formula SAE (Society of Automotive Engineers) race team builds a new car from the ground up. This group of enthusiastic engineering students is constantly seeking new and better ways to reduce weight and improve performance. 3D printing service provider, InterPRO Models has provided assistance to UConn’s student team for several years, helping them design and build better, faster race cars using additive manufacturing and Somos high performance materials. Recently, the car’s engine parts were experiencing sealing issues in the area of the engine block where the runner boots connect to the intake runners. With the Formula SAE regulations forbidding the use of rubber for this use, the team was tasked with finding an alternate means to resolve their problem to get them back on the track. Their challenge was to find a material that would withstand the heat of a 200°F engine head and also support the carbon fibre runners that soften as they approach 175°F.

InterPRO suggested using Somos PerFORM, a new high-strength material that withstands high stresses and temperatures up to 500°F. By using this technology, the team would be able to reduce manufacturing time by printing the fuel injector bung directly into the part. The UConn team agreed. InterPRO 3D printed the Somos PerFORM parts overnight on a high-resolution SL Viper. They were bolted to the four-cylinder engine and dynamometer tests were run to measure horsepower and torque outputs. During hours of high RPM engine testing, the Somos PerFORM parts performed perfectly. After a few design revisions, the 3D printed injector bungs were remade and the team integrated them into their final assembly. UConn Formula SAE placed 19th out of approximately 120 teams at the Michigan International Speedway competition. It marked their most successful season as a team ever. This group of young engineers is expecting to race an even better and faster car in 2016 with the help of additive manufacturing and Somos high performance materials.

OCTOBER 2015 www.tctmagazine.com

027

SEE WHAT CLOUD MANUFACTURING SERVICES CAN DO FOR YOU 3D Systems’ Quickparts® Solutions is your single source for custom manufactured parts from rapid prototypes to low-volume production plastic and metal parts. With instant quoting, buying custom parts now takes minutes instead of days. Bring your prototypes to life and create real functional end-use parts with any of our additive manufacturing or production processes. Quickparts can do it all quickly and expertly.

For a QuickQuote® on parts, call +1 770.901.3200 or visit www.3dsystems.com/quickparts © 2015 by 3D Systems, Inc. All rights reserved. Quickparts, QuickQuote and the 3D Systems logo are registered trademarks of 3D Systems, Inc.

028

OCTOBER 2015 www.tctmagazine.com

MATERIALS ACCELERATING 3D TECHNOLOGIES

SponSOred by

Daniel O’Connor speaks to Polymaker to find out about a material science partnership that could break new ground for desktop 3D printing.

Going Clear WO R D S : DA N I E L O ’C O N N O R

that I am writing this gearing up to my third TCT Show + Personalize. During my first TCT Show I was privy to a lengthy conversation between a 3D printer manufacturer and a huge plastics processing company, in which the co-creator of the Threedy printer was bemoaning the lack of quality control and variety in desktop 3D printing filaments to a director at Clariant International Ltd. During that back-and-forth it was clear that in order for the burgeoning desktop 3D printing market to appeal to the masses, huge multinationals needed to offer, at least, their expertise in the R&D of plastics suitable for extrusion or even curing. The filament market then was one in its infancy with many people focussing on bringing the cost down as opposed the quality up. Fast-forward almost two years to the day and an interview with filament manufacturer, Polymaker, reveals just that: a billion-dollar corporation joining forces with a 3D printing consumables supplier in order to perfect a 3D printing filament. The material is a polycarbonate designed with Covestro formerly Bayer MaterialScience – employer of 14,000 in over 30 production facilities dotted across the globe. “3D printing is a very attractive market, we foresee huge growth in this industry,” Yvonne Wang, Marketing Manager – New Segments APAC, Covestro, tells TCT. “We see Polymaker as an innovative materials supplier that have truly raised the quality standards within the 3D printing industry. With our expertise in materials and Polymaker’s extensive knowledge in the development of materials for the 3D printing market, together we have, and will continue to, develop innovative, groundbreaking materials for the 3D printing community.” t seems apt

We see Polymaker as an innovative materials supplier that have truly raised the quality standards within the 3D printing industry.



BELOW: PC materials will open up a raft of new applications

For Polymaker the partnership goes beyond that of leveraging the R&D of a leading material science company in order to create the best possible material, this is a slice of history for the Chinese headquartered company. “Polycarbonate is a material with a long history, over 60 years in fact, most people involved in the 3D printing industry have grown up around the material.” Explains Aaron Jennings, Design and Communications Manager at Polymaker. “It was invented in 1953 by Bayer MaterialScience so partnering with them and their years of experience in this material brings a lot to the table for Polymaker.” THE BIG DEAL The two main reasons 3D printing with polycarbonate is something of a holy grail for desktop users are its toughness – it has one of the highest strength to weight ratios of any polymer – and its resistance to heat. Whereas a PLA mobile phone holder for your Californian road trip may seem ›› OCTOBER 2015 www.tctmagazine.com

029

The UK Total Solution Provider THE SYSTEMS

FDM 3D Printers

Polyjet 3D Printers

Metal 3D Printers

Entry-level 3D Printers

Reverse Engineering Scanners

Laser Lines Ltd has been supplying 3D Printing and 3D Production system to the UK Market for over 20 years. Whether you need to build parts in plastic or metal we offer an impressive portfolio of 3D Printers and 3D Production systems. The team at Laser Lines has over 100 years experience selling and supporting the Stratasys range of systems and compliment this by offering the SLM Solutions selective laser melting systems for metal parts.

For expert assistance with your 3D Printing or 3D Production needs, speak to us.

See u Stan s on d No .

C18

THE BUREAU

at T Pers CT + onali ze

15 In-house Machines for Fast Turnaround | Build Envelope up to 914 x 610 x 914mm Build in ABS, PC-ABS, polycarbonate, Nylon 12, ASA, ABS-ESD7, ABSi, PC-ISO, Ultem 9085, PPSF Laser Lines specialises in offering rapid manufacturing solutions for low volume production parts typically 250-off or less, eliminating the need for expensive mould tools that have a long lead time. Our materials are also best suited to manufacturing tools such as jig, fixture and work-holding applications offering a cost effective and rapid turnaround of parts.

Mark Tyrtania | 01295 672515 | 3dworld@laserlines.co.uk

www.3dprinting.co.uk

MATERIALS

NEW FRONTIERS As MakerBot has discovered over the past couple of years the home 3D printing market is not yet mature enough for a company to operate at a sufficient profit. The Brooklyn manufacturer has started to focus on designers and engineers. Polymaker and Covestro think they’ve spotted a gap in that market. “Polycarbonate is an engineering plastic as opposed to being a commodity like the other materials currently available,” details Covestro’s Wang. “There are a lot of engineers and designers who already

ACCELERATING 3D TECHNOLOGIES

a good idea, the material will simply not last the cause and will end up as a pool of molten plastic in your foot well, an ABS printed coffee mug will perhaps last one or two drinks, either of these items printed in polycarbonate will withstand heat of upto and above 110 degrees. “Another benefit is that polycarbonate is also optically clear,” adds Jennings. “Our filament is crystal clear but when 3D printed the layer resolutions distorts the transparency slightly. If you sand the material and get it down to a fine surface then you can spray the surface with a clear lacquer, like the automotive industry does with damaged headlights, this can give your print a beautiful transparent aesthetic.“ Though there are already polycarbonate materials on the market, many users have found them a frustrating set of materials; a common problem is a lack of adhesion to print beds causing warping. To ensure minimal warp and a good adhesion to the print bed, Polymaker bundles both their products, PC-Plus and PC-Max, with a sheet of BuildTak. For those who already have BuildTak, both products will also be available as a stand-alone product. “We’ve listed around eight to ten polycarbonate filaments already on the market but most of them are blends,” explains Jennings. “They’re not truly polycarbonate. You lose the real benefits of the material when it is blended with PLA or ABS, they’re blended in order to make them printable at the temperatures most desktop machines can reach, this is the quick and easy way.” He continues: “What we have done, with the help of Covestro, is engineered our polycarbonate so that it can print at moderate temperatures between 250 -270 degrees C. This makes it much more adaptable and much more consumer friendly when you consider what printers are dominating the market.”

SponSOred by

If you want to close source that is limiting the innovation

use polycarbonate and for them 3D printing with PC-Plus or PC-Max will be a quick win because they already know the mechanical performance of the material.” Although Polymaker do offer a selection of very well refined filaments aimed at the consumer with their bright colours and jam free technology they’re also beginning to see a shift in focus for the desktop 3D printing industry with a growing number of applications coming from prosumers. PC Plus and PC-Max are materials developed for them. “Orthopaedists and prosthetists, who are designing devices to be 3D printed, have been limited with the previous materials choices,” says Jennings. “Limited because they need so many different tensile strengths for varying forces. With ABS and PLA they’re having to over engineer these products so that the wall thickness is 10–12mm, which makes the part too heavy to be comfortable. With our polycarbonate materials and their high strength-to-weight properties, designers will have the freedom to design and print intricate and delicate designs.” OPENING A CLOSED LOOP Because the 3D printing industry is so often compared to that of its two dimensional namesake some 3D printer manufacturers went with the business model of selling cheaper hardware that ties the consumer into purchasing proprietary consumables. This business model, according to Polymaker, is detrimental to mass adoption of the 3D printing industry.

“If you want to close source that is limiting the innovation,” exclaims a passionate Hang Qu, co-founder of Polymaker. “3D printing gives people the freedom to design, create and innovate, what the close-sourced approach does is limits that freedom. The more freedom of choice of materials the more innovation you will see, we, at Polymaker, want to simplify the innovation.” Though one would expect this opinion from a third party filament supplier it was echoed in CEL Robox’s Kickstarter campaign. After initially suggesting their printer would only print with the proprietary SmartReels CEL listened to its customers and allowed users to print with third party materials and now even allows users to write material profiles directly onto the SmartReel’s chip. “Customers want a choice, they want a selection, they do not want to be limited, says Aaron Jennings. “Innovation comes from the end-users; they’re the ones unlocking new applications. Engineers and industrial designers, who were previously hesitant to adopt the technology due to the limitations of the final print’s material properties, will benefit from a wider range of material choices.” Polymaker won’t stop at the polycarbonate materials (PC-Plus and PC-Max will be released in the coming months) they have ambitious plans to increase 3D printing’s adoption through material science and with the help of Covestro they may just be on to a winner.

››

OCTOBER 2015 www.tctmagazine.com

031

16587-Rutland Plastics Prototyping Advert 3_Layout 1 17/04/2014 11:44 P

THIS IS ONE TOUGH PIECE OF PLASTIC

Q6391

EMS517192

MD596423

METALISE IT… 3DDC specialises in the metal plating of 3D printed parts and prototypes. If you require additional strength for your 3D printed part to produce a lightweight tough component our expert team can help. The metal coating can also be used for RFI shielding or improving the cosmetic finish of the component. We offer an unrivalled service and commitment to offer the right metal plating solution for your project. Quite simply, the Metalise it... process takes 3D printing to the next level.

Our innovative 3D printing process can help you quickly turn your ideas into working prototypes, allowing you to test your design before committing to production. Call 01572 723476 to find out how we can turn your ideas into prototypes

3DDC Ltd Unit 4B Hurst End Farm, North Crawley, Bucks, MK16 9HS, UK T: +44 (0)1234 391894 W: www.3ddc.eu F: +44 (0)1234 420323 E: 3ddc@3ddc.eu

032

OCTOBER 2015 www.tctmagazine.com

Rutland Plastics Limited, Cold Overton Road, Oakham, Rutland LE15 6NU enquiry@rutlandplastics.co.uk www.plasticprototypes.co.uk

CONCEPT LASER ACCELERATING 3D TECHNOLOGIES

LEFT:

CEO Frank Herzog

Conceptual Knowledge In an industry as fast moving and shape shifting as the additive manufacturing industry, celebrating a year in business is quite an achievement, managing 15 of those anniversaries is almost unheard of. Most people in the street don’t even know that plastic printing has been around that long but tell them that we’ve been 3D printing in metal since the turn of the millennium and their minds will be well and truly blown. In 2015, Concept Laser are celebrating a decade and a half of its pioneering LaserCUSING technology, which has seen the company grow from a prototype machine that founder and CEO Frank Herzog operated by hand to an install base of over 400 machines across the globe, placing them in the top echelons of metal-based additive manufacturing companies. It all started with a firm belief from Mr Herzog that what was working in the plastic sintering world must work for metals and, thus, he set about finding a solution. Stresses in the component and the failure of the metal powder to fuse completely were the major hurdles

to begin with. This was remedied in part by Herzog’s development of what is known as stochastic exposure, for which he filed a patent one year later. This process involves stochastic control of the slice segments (also referred to as “islands”), which are processed successively. The patented process significantly reduces tension during the manufacture of very large components. The second milestone was the use of a solid-state laser, which completely fused the component to a tenth of a millimetre, thereby ensuring dense components. “It’s been a very, very exciting time,” said Herzog. “We have far exceeded a lot of what we were expecting. Back in 2000, who would have thought that 3D metal printing would be such a massive hit? Even I’m amazed. “ Even though there’s a sense of achievement in, not just the Concept Laser ranks but industry wide. Frank thinks there’s a long way to go before additive manufacturing is adopted by the masses. “In the aerospace industry, things are moving rapidly towards additive

manufacturing. In the USA and, for example, with Airbus over here, I would say that we’re witnessing a paradigm shift. There is no way back. The automotive sector is also fully immersed in the adaptation phase because build envelopes and rates have reached the acceptable range. However, I think there is still a lot of need to catch up in the German mid-sized sector, on the user side, in particular.” DRILLING DOWN TO THE MATTER One project that Concept is, rightly, very proud of involves the use of LaserCUSING technology in precision tooling. Traditionally there’s been a ‘this town ain’t big enough for the both of us’ standoff between the tooling and additive industries, the additive manufacturing techniques seen to be encroaching on tooling’s turf. But precision tool specialist, Mapal are, for the first time, additively manufacturing drills. “Dr. Kress, the owner of Mapal, has taken a very close look at what can be developed conventionally and what would be possible using additive methods,” explained the Concept Laser

››

OCTOBER 2015 www.tctmagazine.com

033

034

OCTOBER 2015 www.tctmagazine.com

CONCEPT LASER ACCELERATING 3D TECHNOLOGIES

Compared with the previous central coolant supply with ‘y’ diversion, a spiral coolant routing increases the coolant flow by 100%

CEO. “As an innovator, he was very quick to realise the opportunities of a hybrid construction method.” The new QTD-series insert drill from Mapal is manufactured using additive laser melting. These are hybridmanufactured parts: The tool shank is machined conventionally and the drill is laser melted with additive methods. This approach makes the manufacturing process significantly more economical. Dr Dirk Sellmer, Head of Research and Development at Mapal, said: “Hybrid strategies are the ideal method of choice: Simple component parts are machined and more complex areas are then built up additively.” The greatest advantage of transitioning from a conventional manufacturing



ABOVE: Original Concept Laser prototype

strategy to additive manufacturing was that it facilitated an entirely new geometry, increasing the performance of the tools. “The additively manufactured insert drill has a cooling concept with spiral ducts,” detailed Dr Sellmer.” This improves the cooling performance. Compared with the previous central coolant supply with ‘y’ diversion, a spiral coolant routing increases the coolant flow by 100%.” It also increases the core stability with coolant ducts, which run parallel to the flute. Mapal is using two Concept Laser M1 cusing systems, the QTD insert drills are created as 10x10 or 11x11 unit solution in the 250 x 250 x 250 mm build envelope. 100 to 121 drills are produced in one set-up. According to Dr Sellmer the use of additive technologies has been somewhat of a revelation: “We soon found that all of the concepts would enable us to change our previous machining environment. Just 12 months after choosing the Concept Laser technology, we put the first series-ready products on the table, in spring 2014. Our boss, Dr. Dieter Kress, is so impressed that he often carries an additive part to show visitors these minor miracles.” STAYING AHEAD OF THE GAME Projects like the Mapal one and the much-publicised Airbus bracket put Concept Laser in a strong position. This strong position sees the company employ over 130 employees and they

are paramount to everything Concept Laser want to achieve. “The Concept Laser company represents the conservative values of the German small and medium-sized sector,” sair Mr Herzog. “It is characterised by pragmatism, long-term action and a sense of responsibility towards jobs and employees. Our employees are loyal to the company and their colleagues and, in turn, the company is loyal to its employees. This is why we are technology-driven, not capital-driven, because we aren’t tied to any trading prices. At the same time, we aren’t driven to extreme risks. This means that we can retain our equity ratio and expand it in order to concentrate our forces entirely on development. Basically, we put all our money into the product.” The fact that 50 of Concept’s employees are within R&D shows that the company takes its long-term future incredibly seriously. With ever-improving hardware and software combined with the use of new materials Concept Laser is perfectly placed to become another giant of manufacturing from Germany. Frank thinks that over the course of the next few years, as more industries wake-up to the abilities of additive manufacturing the market will truly flourish. “What is clear today, is that whenever a digital, additively manufactured component would be better, more efficient, available sooner, lighter and/or cheaper, then the additive manufacturing option is the right solution.” 

OCTOBER 2015 www.tctmagazine.com

035

VISIT US ON STAND E22

Bring your ideas to life... Stratasys 3D Printers from Tri-Tech3D enable designers and engineers to quickly transform their 3D designs into parts and working prototypes. Alterations become easier, design perfection is faster and time-to-market is reduced.

Advanced 3D Printers from the UK leading experts

T: 01782 814551 | www.tritech3d.co.uk

COMPLEX PROTOTYPES AND SMALL SERIES A

WE ARE THE FIRST PLACE FOR YOU TO LOOK… A A A A

When you need rapid results When your success depends on it When difficult technological processes are involved When you want everything to come from a single source

Alphaform Ltd. 450 Brook Drive, Green Park, Reading, RG2 6UU  +44 1183 34 03 35 sales@alphaform.co.uk  www.alphaform.co.uk

036

APRIL 2015 www.tctmagazine.com

12_af_001_Anzeige_TCT-Magazine_final.indd 1

13.02.12 09:51

ROTITE ACCELERATING 3D TECHNOLOGIES

The Evolution of Rotite WO R D S : LAUR A G R IFFIT H S

A few years ago TCT reported on a breakthrough technology that had the potential to revolutionise engineering for industries the world over. In what founder and Managing Director, Stuart Burns describes as a true light bulb moment, Rotite was introduced in 2012 as a scalable fastening technology employing a rotary interlocking system, based on a mathematical principle, with the ability to fine tune to any specification.

course, if you are fortunate enough to be the brains behind a unique invention like Rotite, the go-to strategy would be to keep it on the quiet and get the idea patented. Patent they did but Stuart says the company is now much more enthusiastic about giving potential users the opportunity to play about with Rotite and discover its possibilities for themselves. “We’re happy to have this culture of people investigating it,” Stuart comments referring to the slew of interesting projects from aerospace, defence and even quadcopter design that have utilised the provision of Rotite’s free 3D print files to experiment and evaluate the technology. “They’re not normal products, they’re hybridised by people and Rotite has had an awful lot of interest in that. It’s nice that other people have latched on to it. It’s proliferation and helps get the technology out there.” A lot has changed since TCT last met with Rotite Technologies. The company has grown through investments and partnerships and Rotite has become a f

substantiated technology with interest from huge names in the aerospace and automotive sector. Even more impressive, working closely with the North West Composites Centre (NWCC) at the University of Manchester they have managed to do what many thought was impossible by proving the ability to injection mould Rotite. “We know where we’re going now,” Stuart explained. “People want to try and find a use for Rotite because it’s an elegant solution, not a complex system. People can very easily perceive it as a solution to what their requirements are but what they need is quantification, facts and figures.” This increased interest has meant the business focus of Rotite has also taken a new direction. Early on, the idea was to patent and license the technology but now as a technology business, it’s much more focused on engaging with people and developing through technical consultancy partnerships where the individual benefits of Rotite like lightweighting, faster assembly and enhanced consumer experience, can be explored.

SILVER LININGS As a lecturer at the University of Liverpool and product designer, Stuart is well versed in the technologies that Rotite supports and now boasts an enviable contact book bursting with high-profile names in various levels of industry. “It’s not the classic success, from rags to riches story. I’m lucky to have had a good foundation and knowledge of these technologies as a product designer,” Stuart explains. “Who we are as a business has been shaped by the people we’ve consulted, leading industry experts who have seen Rotite, given us advice to shape our pitch, material and even our funding applications. The success that we’ve afforded hasn’t just come from my hard work, its from the technology’s simplicity, its not complicated - people believe in the technology and can see it’s got applications.” As a self confessed opportunist, silver-lining kind of guy, Stuart says many doors that were once closed to OCTOBER 2015 www.tctmagazine.com

037

038

OCTOBER 2015 www.tctmagazine.com

ROTITE ACCELERATING 3D TECHNOLOGIES

the company have now been flung wide open, leading to some pivotal chance meetings and being scouted onto prestigious technology programmes. Perhaps the biggest news for Rotite is that the company has been invited onto the 18-month National Aerospace Technology Exploitation Programme (NATEP), which supports grassroots technology in the aerospace sector, funded by the Advanced Manufacturing Supply Chain Initiative (AMSCI) set up by the Department for Business, Innovation and Skills. As the saying goes, when one door closes another one opens, the result of a failed funding application led to an introduction to the robotics laboratory at UCLAN where the company was put on the radar of NATEP. Within a matter of weeks, Rotite was presented to some of the world’s leading aerospace companies where a strong consortium was created working in conjunction with the likes of Airbus Group Innovations, and Sigmatex. Working with the NWCC, Rotite aims to develop the use of Rotite in high-strength lightweight composite materials and make structures stronger and simpler by removing traditional metallic fasteners, reducing both weight and magnetic signatures. MOVING FORWARD In the early days, Rotite gained its reputation, primarily for being such a ground-breaking system but also for its connection to 3D printing led by strong relationships with names like Stratasys and UK-based 3D printing bureau IPF. Now Rotite plans to invest in its own Objet 30 Prime and RGD525 material.

People believe in the technology and can see its got applications.

“There’s a real synergy between Rotite and 3D printing,” Stuart explained. “3D printing for me has always been something very different to most other people. For us 3D printing has always been a way of speeding up that developmental process.” Determined not to be bound by the past, from those first 3D printed prototypes, the company has achieved major funding milestones from the likes of the Innovate UK (formerly the Technology Strategy Board) Smart award and the UK Manufacturing Accelerator. Rotite’s Technical Project Manager, Cat Silva has been instrumental in Rotites’s funding success, having her work recognised by Innovate VIC and NATEP programmes and securing a funding total of around £250,000. The story really has come full circle with government funding gaining Rotite the credibility it needed which later gained them investment. Now that investment is gaining even further credibility and it’s not showing any sign of stopping. “Where we are as a business is not just a product of my efforts, its come from the support from people in industry, universities, Innovate UK, NWCC. It’s a team of people that have brought us to where we are.”  You can hear more from Stuart Burns at the TCT Show + Personalize Conference at 3.05pm on 30th September when he presents ‘Beyond the Hype and into Space’. For more information visit www.rotite.com

OCTOBER 2015 www.tctmagazine.com

039

JADE CROMPTON ACCELERATING 3D TECHNOLOGIES

WOR D S : DA NIE L O’ C ON NOR

The world of ceramics is often perceived as an old fashioned one; the images that are conjured up by ceramics production are of 18th century Staffordshire potteries with workers huddled around cramped workstations hand finishing Royal Doulton teapots. One Liverpool Hope University Master’s student is shaking off that stuffy image and dragging ceramics kicking and screaming into the 21st century with the use of 3D technologies. Jade Crompton’s first works combined digital design with techniques like lasercutting Perspex and slip casting. These techniques earned her a royal seal of approval as HRH Prince of Wales himself awarded Jade with a £2,000 Queen Elizabeth Scholarship Trust (QEST) certificate in order to further develop her unique techniques. Jade commented to the Southport Visiter at the time: “Meeting Prince Charles was a real honour, he was so friendly and charming. When he presented me with my certificate, he commented on how unusual it was to combine my chosen materials.” That royal donation is being spent wisely; Jade’s most recent work is her Crystal Collection, which takes her processes of digital design one step further by incorporating 3D printing into her workflow. Jade designs her models using Solidworks and now as opposed to using laser cutting prepares them to be 3D printed. “The benefit of 3D printing the model is that I can create multiple copies of the mould without the model wearing away or distorting as does plaster or clay models, this helps speed up my production time casting.” Jade told TCT. “3D printing has also allowed me to see my final product in

the flesh before committing to making the mould. I can test its functionality and size, which has been particularly helpful while designing a tableware collection. I have been able to test the grip on my cups; an important feature as they were all designed without handles. The missing handles meant that I needed to add a doublewalled feature to allow it to be functional.” Jade orders her 3D prints via i.materialise selecting the relevant material for each piece, the most common pieces use the polyamide material printed using EOS’s laser sintering technology. Being something of a pioneer in this field it meant that Jade discovered the hard way that the surface finishes of 3D prints often aren’t perfect, some trial and error was required

before the process was perfected. “I can’t make a mould straight from the 3D printed model, firstly I have to lightly sand and coat the print in a lacquer, and this gives my moulds a smoother surface, protects the 3D print from water absorption and allows me to remove the model from the mould easily. She continued: “The use of 3D printing for making moulds has dramatically sped up production time and increased the accuracy in my designs, I can design almost anything in the software, I can account for firing shrinkages, the clays casting thickness, number of mould parts needed and where the seam lines will be.” The result of Jade’s hard work is Crystal Collection - a selection of very 21st Century tableware ceramics. The collection is being debuted in Liverpool’s über cool space the Baltic Creative in October and has drawn attention from the wider ceramics world with industry magazine Ceramics Review in attendance.  TCT Show + Personalize 2015 visitors will be able to get a sneak peak of the work on the showfloor.



ABOVE: ESC duct from ULA made with ULTEM 9085

OCTOBER 2015 www.tctmagazine.com

041

We have big news. And itâ&#x20AC;&#x2122;s tiny.

Proto Labs introduces additive manufacturing to its suite of services

Our advanced 3D printing technology is capable of incredible new levels where the layers are as thin as 50 microns. With this tiny level of detail, you can be confident when creating intricate designs, from small parts with complex geometries to large parts with precise patterns. And youâ&#x20AC;&#x2122;ll have your product fast, because we build with rapid stereolithography (SL) to produce a range of plastics for prototypes and low-volume production runs in as little as one day.

Get a fast interactive quote at protolabs.co.uk or call +44 (0) 1952 683047 for more information.

ADDITIVE MANUFACTURING CNC MACHINING INJECTION MOULDING

International exhibition and conference on additive technologies and tool making

Frankfurt am Main, 17– 20 November 2015 formnext.com

Think global. Act Frankfurt. Representatives from the tool/form-making and additive technologies/ 3D printing sectors as well as their suppliers and partners will be showcasing their expertise to trade visitors from around the world at formnext in Frankfurt from 17 – 20 November 2015. Benefit from this fascinating new exhibition concept in one of the world’s most spectacular halls.

Where ideas take shape.

For further information, call +49 711 61946-825 or write to formnext@mesago.com

044

OCTOBER 2015 www.tctmagazine.com

DESKTOP 3D PRINTING ACCELERATING 3D TECHNOLOGIES

SponSOred by

DESKTOP

3D Printing

technologies that helped to shape the industry – FDM and SLA from its rapid prototype beginnings have found their way very successfully onto the desks of designers, engineers and artists across the globe. Despite the fact that the home market is not growing as much as the manufacturers would like there is a considerable slice of the prosumer pie to be had to keep the market growing. You only have to look at 3D Hubs trend reports to see how the market has grown in the past few years. On their platform alone there are now over 20,000 machines, the majority of which are desktop machines. There are varying reports as to how many desktop 3D printers there are out there, last year Dr Adrian Bowyer, the creator of the RepRap project said their best guess is that there are between 50,000 – 100,000 RepRaps in the wild. If 3D Hubs’ trend reports are anything to go by RepRap machines make up about 15% of the market so that could put the number in the millions – but this is highly unlikely. Few desktop manufacturers release sales statistics and the open-source nature of many machines means the actual number of machines in the wild is very difficult to guess . Best estimations are around the 250,000 mark in total. How many of these are operational is another question, but the thirst for 3D printers is clearly evident. The market is an ever changing one; each printer that launches claims that it does something unique. A recent survey by YouMagine suggests that the top three things that need to improved to make 3D printing easier are reliability, speed and size, the survey also suggests that the most popular things to print amongst their users are household items with 3D printer parts coming a close second. he two main

Here is a selection of some of the most important recent developments in the desktop market that you will be able to see in the flesh at this year’s TCT Show + Personalize.

A recent survey by YouMagine suggests that the top three things that need to improved to make 3D printing easier are reliability, speed and size, the survey also suggests that the most popular things to print amongst their users are household items with 3D printer parts coming a close second.

The desktop 3D printer market has matured, of this there is no question, while some companies still chase the ‘3D Printer in every home’ dream others have come to the realisation that though the technology is not yet mature enough to be in every home it is mature enough to be on every engineer’s desktop.

MAKERBOT’S COMPOSITE MATERIALS

BOOTH

A12

Many will say that we’ve had composite materials in extrusionbased 3D printing for some time; Kai Parthy has been creating composite filaments for the best part of five years. But MakerBot’s optimised materials have to be seen or held to be believed, particularly the hammer, the handle of which is printed in their Maple Wood PLA and the head with the Iron composite. To the untrained eye you’d be certain you were holding a hammer made the traditional way, yet it was produced using MakerBot’s Smart Extruder system. The materials won’t be available to buy until 2016 but there are sure to be some sample prints on the MakerBot booth (A12).

BELOW:

MakerBot Composite Materials

OCTOBER 2015 www.tctmagazine.com

045

046

OCTOBER 2015 www.tctmagazine.com

DESKTOP 3D PRINTING ACCELERATING 3D TECHNOLOGIES

SponSOred by

FORMLABS DRAFT MODE

A common complaint with 3D printing and particularly resin-based 3D printing is that it is slow, in fact this is not just a complaint constrained to the desktop. Carbon3D may be addressing the speed issues for the industry but on the desktop some firmware/software tweaks mean Formlabs Form 1 + stereolithography printer can now churn out the classic rook piece at 200 microns in 46 minutes. The new draft mode shaves some 55 minutes off the time it takes a leading FDM machine to print at the same resolution, as well as the draft mode Formlabs (Booth D44) recently launched Tough Resin of which CEO Max Lobovsky said: “We’re excited to release our new Tough Resin because now Form 1+ users can create high resolution prints in a really durable, resilient material.”

BOOTH

D44

BOOTH

J24

ULTIMAKER’S NEW FAMILY

According to those 3D Hubs trend reports Ultimaker is not only the most popular 3D printing brand in Europe but in Asia Pacific too. The Dutch manufacturer comes to TCT Show + Personalize 2015 armed with their new 3D printing family; Ultimaker 2 Go, Ultimaker 2 and Ultimaker 2 Extended – a small, medium and large treble that all boast Ultimaker’s proven 3D printing reliability and all working on its all-new Cura software. Ultimaker will be demonstrating the new Cura with features like undo/redo, optimised structure support, a new plug-in based system and more on their booth (J24).

IRA3D’S POETRY INFINITY 3D PRINTER

That’s new material, software and firmware covered but what about a new machine? There are several new desktop machines to see at the show including Create it Real (D37), Centrex (F42) and Print-Rite Europe (D45) but one of the most intriguing debuts at the show will be IRA3D’s Poetry Infinity machine. The Italian firm claims that the Poetry Infinity will be one of the fastest machines on the market with a print speed of up to 400mm/s. An all-metal dual extruder allows the machine to print at temperatures of up to 280°C meaning you can print with materials like polycarbonate and graphene. The machine is being shown for the first time at TCT Show + Personalize 2015 on their booth (G20).

BOOTH

G20 OCTOBER 2015 www.tctmagazine.com

047

048

OCTOBER 2015 www.tctmagazine.com

WACKER ACCELERATING 3D TECHNOLOGIES

A SOLUTION FOR

SILICONE

WOR DS : L A U R A G R IFFITH S

here is an interest in materials across the entire 3D technologies spectrum from desktop manufacturers looking at more sustainable filament options to major industrial companies looking towards precious metals and strong, lightweight materials. Global chemical company WACKER might be a little known name in the field of additive technologies but it sparked a burst of interest when a recent quarterly report from the German company revealed how it has successfully developed a method for 3D printing silicone. As one of the world’s largest manufacturers of silanes and silicones, the company’s WACKER SILICONES division has turned its attention to 3D printing in a bid to increase the range of materials available to industrial users and address potential new markets. The development was inspired by WACKER employee and marathon runner, Maximilian Peter, who set out to explore the possibilities of creating custom-made shockabsorbing insoles. Traditionally, silicone parts could only be produced by expensive injection moulding processes which can be costly for custom products and until now researchers have found it incredibly difficult to print with elastomers. However, together with colleagues at WACKER SILICONES and engineers at product development company, Enders Ingenieure GmbH, a viable solution was born. “Injection moulding is the established process for series production, and will remain so,” Pachaly explains in the report. “But people who design prototypes or only want to make a few copies of a part can now very rapidly and flexibly modify such small series to meet changing demands. That is the unique advantage of the process.” Unlike other 3D printing materials, silicone is not melted by heat or deposited in the same way as thermoplastics or metals. In the space of a year, the team came up with a process whereby a robot featuring a nozzle rapidly deposits single droplets of silicone on a base surface. Controlled with custom software, the robot regularly pauses to emit UV beams over the drops to vulcanise the silicone into an elastomeric material in less than a second before the next layer is added. So far little information about the formulation of the silicone has been disclosed apart from the fact that it contains a platinum catalyst that crosslinks the molecules under UV light.

Each silicone strip is about 0.6 millimetres wide which makes it possible to produce perfectly formed, precision structures with a smooth surface finish.

During a test print of the WACKER logo, after 15 minutes, each centimetre tall and several millimetre thick letter is visible. In the long term developers aim to speed this up to process around 100 grams of silicone every hour. Each silicone strip is about 0.6 millimetres wide which makes it possible to produce perfectly formed, precision structures with a smooth surface finish. According to the report the parts are comparable with that of injection mouldings. WACKER says this development opens up many possibilities for the manufacture of small series and one-off products that are bio-compatible, heat resistant and transparent for industries such as the automotive and medical sectors and also household appliances and optics. “We have a lot of ideas, and we want to provide our customers with much more than just silicone for additive manufacturing,” added Pachaly. With this new technology, WACKER aims to unlock the potential for 3D printing in valuable, rubber-like materials and assist the call for more printable materials, efficient machines and processes in the German manufacturing market.  For more information visit www.wacker.com OCTOBER 2015 www.tctmagazine.com

049

Lighter, Stronger Parts without the Learning Curve

Inspire delivers an easy-to-use set of tools for generating structurally efficient concepts. When paired with a 3D printer, users often reduce costs, development time, material consumption, and product weight while increasing part performance. ď&#x201A;Ź Learn more at solidThinking.com/TCT

Company

EDUCATION ACCELERATING 3D TECHNOLOGIES

CHILDREN OF THE

RIGHT: Crossover design 3DPRINTUK

REVOLUTION With over 6,500 units sold worldwide, the Robox 3D printer from UK-based CEL is in the business to make 3D printing easier and bring it to the masses. What better way to do that than to partner up with a company that’s already introducing inspiring technology and startup kits to thousands of UK schools with a mission to empower the next generation of engineers.

fellow UK company dedicated to bringing design and technology products and resources to students and their teachers. Starting out with a range of electronic kits, tailored to the national curriculum and supported by teaching notes that make it easy for teachers to implement this new breed of technology into the classroom, Kitronik has brought everything from amplifier kits to e-textiles, to secondary education students. Kitronik has been doing this for 10 years, providing over a million project kits to 3,500 schools in the UK. In its latest initiative, the company has turned its attention to 3D printing and partnered with CEL to put the Robox in 5,000 UK schools and show children how they can create real functional objects. “We’ve looked at 3D printers for quite a while,” explained Kitronik Co-Founder Kevin Spurr. “We went into classrooms and they were having a lot of problems with them. We stayed away because it didn’t seem to be at a point where we would want to be involved. The Robox printer overcomes a lot of those issues.” The Robox is a simple, accessible desktop printer. Launched in 2012 on the back of a successful Kickstarter campaign, it is one of the most easy-to-use machines on the market and features a set of unique capabilities which make it the ideal introductory 3D printing tool for the education market. ›› itronik is a

OCTOBER 2015 www.tctmagazine.com

051

052

OCTOBER 2015 www.tctmagazine.com

EDUCATION ACCELERATING 3D TECHNOLOGIES

A 3D printer makes real things so children can take their design, make something real and have a real life working product without that huge development which you would expect For the school environment, safety is paramount and Robox features a lockable lid that prevents younger users from touching the heated print bed or melted plastic. In addition to safety, the printer is probably the closest to “plug and print” you could hope for with minimal setup and simplistic software that is as easy as; select file, choose colour, settings and print. These features, along with its affordability and reliability, make Robox the perfect companion to the D&T projects being implemented in schools. “What we’re interested in is the mechanical side,” Chris Elsworthy, CEO of CEL and creator of the Robox 3D printer, commented. “A 3D printer makes real things so children can take their design, make something real and have a real life working product without that huge development which you would expect.” A key piece of kit that has the potential to add a new dimension to how students learn is the BBC micro:bit, a groundbreaking pocket-sized computer that allows children to get creative with technology. As part of the BBC’s ‘Make it Digital’ initiative, the project is a collaboration between 29 partners including Kitronik, Barclays, Lancaster University, Microsoft, Nordic Semiconductor, Samsung, ScienceScope, Technology Will Save Us and the Wellcome Trust, to give every year 7 child in the UK a BBC micro:bit for free. In what Kevin describes as a “piece of hardware for the 21st Century”, the device is a small electronic board (PCB) which can be plugged into a PC or connected to other hardware to teach children how to programme and make things like stepometers and even wearables. “The BBC micro:bit brings this stuff to a lower level of understanding to kickstart people’s inspiration into programming. Traditionally you can do a lot if you’re a powerful programmer, ABOVE: but often getting started is difficult,” BBC micro:bit Chris commented. “It’s very easy for students to get into when they start with the simple graphical programming language,” Kevin added. “They can then progress to more advanced programming languages too, so

they can learn textual programming which is the next stepping point, but they don’t need that to get started.” Right now Kitronik is busy putting together resources for schools to show how they can implement the technology in the classroom. Educating teachers about the importance of nurturing these skills and ways of doing so within the curriculum is a huge focus. Finding approaches to delivering these projects and having successful outcomes within a typical school day is a big part of the challenge. Chris explained: “You talk to kids about 3D printing, developing new ideas and electronics and the scope they have for new ideas is just immense. You show them what a 3D printer can do and they just leap on it. The blockade comes from adults and teachers because they’re new to this technology, it’s much harder to make them adopt it and have inspiration in this field.” Kevin added: “Teachers want something the kids can take home and show their parents. It excites the parents about what they’re learning at schools. You need that success at the end of that and that’s what we’re trying to help with, making that more deliverable in a classroom with the time frames they have.” One of the key messages from this partnership is about placing value on giving young people the option to explore careers that are not traditionally academic. Encouraging children who are practically minded, full of imagination and enjoy making stuff provides them with the stepping-stone to allow them to shine in the classroom and develop much sought after skills for the working world. “Just being able to talk to people about how important I find engineering and what you can achieve from it and having a whole generation of kids coming up knowing that really excites me,” Chris commented. Kevin added: “I’m sure there’s a really good pool of students out there with the ability to go on and learn about these subjects but they’re choosing to do other things. I don’t know why so many people aren’t choosing engineering – it’s one of the most enjoyable things you could do as a career. Anything to get kids excited about choosing a career path where they produce and make things is a good thing.”  OCTOBER 2015 www.tctmagazine.com

053

PERSONALIZE

TCT Show + Personalize is the perfect place to see 3D printing in all its glory and a selection of the products on these pages - all of which used the technology at some stage in the manufacturing process – will feature on this year’s show floor.

PRINTING PRESS Britannia-upon-Globe Mascot

3D technologies have the ability to bring to life pieces and artefacts that would otherwise be lost. Essex-based Impossible Creations has done just that with the reproduction of the Britannia-upon-Globe Mascot that featured on a Rolls Royce RF 14 commissioned by the Prince of Wales in 1921 and recently restored by Overton Vehicle Overhauls. With one iconic piece still missing, they turned to Impossible Creations to replicate the mascot from The King’s Car. The piece was 3D scanned, 3D printed, cast in brass and nickelplated. 

054

OCTOBER 2015 www.tctmagazine.com

ACCELERATING 3D TECHNOLOGIES

Hortus Filamentus

HeartBeat

One our favourite finds this past month was Hortus Filamentus, a nine-panel art piece of 3D “micro worlds” created by Dutch artist, Martijn Hage with two Ultimaker 3D printers. This unique project came about as a result of a radio broadcast where the artist was tasked with spending 5 days in solitude at De Torenkamer studio at the VondelParkCS in Amsterdam where he found inspiration by the park’s natural surroundings. Martijn told TCT: “My art has the virtual 3D depth but lacked the real tangible factor, so 3D printing - as well 2.5D printing - could give me this.” 

Never mind a piece of jewellery to show your love, how about heartbreak? Spotted at the Birmingham School of Jewellery, product artist Lionel T Dean has been working in conjunction with the Precious project (see p. 21) to demonstrate the viability of precious metal additive manufacturing. One of his creations is HeartBeat, a custom piece of jewellery, which invites the wearer to quite literally stomp, smash and hammer at a metal heart, which is then 3D scanned and laser sintered with gold powder to produce a bespoke heart pendant. 

Nipi Cooler The Nipi Cooler may have been featured in GQ Magazine’s ’10 coolest things in the world this week’ feature but we’re sure the bigger accolade is featuring on these hallowed pages. Despite reaching their Kickstarter campaign with days to spare the guys at Nipi Cooler pulled their funding in order to make the smart cooler ‘even more awesome’. Fortunately for them, prototyping new features will be a cinch due to the fact that they’ve enlisted the services of 3D Print Bureau to help quickly iterate the design. 

Wound Up – Coffee-based Filament

Had this product appeared on April 1st, particularly with a name like that, one would be forgiven for thinking that this was indeed a wind up. But no, 3Dom USA have launched a material that is made using waste by-products from coffee leftovers to create a special 3D printing material with some unique print qualities including a rich brown finish and natural grain. Coffee-lovers will be happy to hear that during printing there is apparently a very distinct sweet coffee aroma. 

OCTOBER 2015 www.tctmagazine.com

055

YOUR CREATIVE MUSCLE

FLEX

LENOVO

We’ve completely reengineered desktop workstations from the ground up

enovo is one of the most recognised brands in the computer manufacturing industry. Its coveted Think stamp can be found on the desks of engineers and designers the world over from desktop machines to portable devices. Now as the tech giant unveils its brand new generation of powerful, mobile workstations, TCT finds out how this new generation of technology is set to empower engineers and 3D artists. “We knew technology was having a big shift this time round,” explained Mike Leach, Workstation Technologist at Lenovo. “We did a complete reengineer back to the drawing board, what we call a clean sheet design. We’ve completely reengineered desktop workstations from the ground up.” Starting with the Lenovo ThinkStation P series, this powerful family of machines has been specifically designed to accommodate the needs of demanding engineering and 3D workflows. Powered by the latest Intel Xeon E5 1600v3 and 2600v3 processors, and using Nvidia Quadro Professional 3D graphics cards, these machines feature a completely modular chassis design for total flexibility. Unlike traditional desktop PC’s, which can quickly be rendered out of date, the ThinkStation P series employs a new innovative FLEX system (Fully Loaded Experience) so it can be tailored and future proofed for any project. This tool-less red touch point system allows users to easily strip the machine down and upgrade, change spec and service for their particular needs in a matter of minutes. “We now have the best designed workstation on the market which delivers the best performance, the industry’s highest levels of reliability, a superb range of features and those features have been optimised and designed for particular market verticals,” Mike commented. Some of those markets include design, architecture, animation and perhaps one of its

WORDS : laura griffiths

biggest sectors, manufacturing and engineering. It’s a constant evolution as hardware pushes software and then in turn pushes hardware. As demands for better efficiencies in real time analysis, simulation and rendering continue to grow, there is an increasing need for a fluent design process that allows teams to work in parallel and keep pushing forward. MAKE IT MOBILE Anything with a Think name is military spec tested so you know it’s durable and reliable. For designers working in areas where they might need to take their work from the office, to the client, the coffee shop and down to the factory floor, it has to be reliable in all environments. Lenovo’s ThinkPad W550S mobile workstation aims to remove the need for the laptop and desktop by cramming as much of that productivity as possible into a mobile piece of kit. “The efficiencies in the design environment today mean you cant afford to have someone locked in an office. You need to give them the flexibility of working from anywhere. You need to be making changes in front of a client – it’s fast paced, make a change there and blow them away,” Mike added. This brings a wealth of benefits to the engineer who might be working as part of an industry leading team, or perhaps the 3D designer who needs to make changes in front of a client and seal that deal straight away. Then there is the additional benefit of having a secure design environment afforded by bringing down the need for multiple devices and collating those elements in a slim, portable environment.  TCT Show + Personalize will be the first time the new mobile workstations will be displayed in the UK and is the first time the entire ThinkStation and ThinkPad series will be seen together in one place. For more information visit www.LENOVO.com



LEFT: Family of Think products

056

OCTOBER 2015 www.tctmagazine.com

ACCELERATING 3D TECHNOLOGIES

Learn about the latest: • Vortex high-efficiency area clearance • Mill/turn programming techniques • Direct modelling capabilities • Multi-axis milling innovations • Reverse engineering tools • On-Machine Verification options and much more!

Unlock the power of Delcam software Visit www.delcam.tv/lz and see how Delcam software could benefit your business!

“PowerMILL’s Dynamic Machine Control gives us the confidence to run parts first time on our 5-axis machines.”

Small Heath Business Park, Birmingham, B10 0HJ T: +44 (0)121 766 5544 | E: marketing@delcam.com | www.delcam.com

Brian Kerkstra, Paragon D&E

Learning-Zone-Advert-2014-A5.indd 1

OCTOBER 2015 www.tctmagazine.com 10/06/2014

057 11:03

Somos

Accelerating innovations

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

VISIT US

STAND C32

GEOMAGIC

in the DESIGN

I was privy to a demo of the latest iteration of 3D Systems industry leading software Geomagic Design X. Before that live demonstration by Gregory George, Geomagic Solutions Product Specialist, I was asked if I would like a beta version of the software to try out myself. Not being proficient in CAD or any kind of 3D modelling I declined the opportunity, it is testament to the software’s new userinterface (UI) that, post Greg’s demo, I think I’d actually be able to extract some exact geometries from scan data. 3D Systems acquired Geomagic from Ping Fu and co. back in February 2013 and it has remained one of the market’s most recognisable brands, particularly for its industry leading software packages. For swathes of reverse engineering firms Design X is an essential tool in their workflow for delivering full history-based models from scan data into all major MCAD platforms. “The reason the product exists in the market place is because historically when people made scanning devices, you could scan objects but you couldn’t do anything with the data,” explains Gregory George. “It’s one thing for a software package to say that it can load scan data into a CAD environment but it is another thing entirely to be able to extract accurate geometry, measurements and other data you need from a scan like Geomagic Design X can.” As suggested earlier, Geomagic Design X has had a complete UI overhaul for

ACCELERATING 3D TECHNOLOGIES

The MAGIC is

W O R D S : DA N I E L O ’C O N N OR

ast week

the 2016 edition. The intuitive new UI, that even a layman like myself could find his way around, has been redesigned from the ground up. New features include:

New Ribbon UI brings all the tools to the surface. Quick and easy access and visibility into the entire toolset.

Mode-less mesh

editing: For quick and easy mesh editing without the need to enter and exit an editing mode or being forced to roll back your history to edit the mesh.

New quick access

toolbar consolidates common selection, visibility, and view controls into a familiar and easy to use interface, while simultaneously reducing icon clutter.

Improved Accuracy

Analyser tool choices to easily access and choose comparison models and data for analysis.

Right-Click

contextual menu puts commonly-used functions right at the users’ Mouse Tip. Save mouse travel time and improve efficiency by choosing from our contextual function menu

Improved tooltips to better understand a function at a glance

ABOVE: The new HD Mesh Construction For reverse engineering firm Physical Digital Geomagic Design X remains the industry leading software. Rado Iliev, a Physical Digital Design Engineer, who also provides training to clients on the whole Geomagic suite, told TCT: “Incorporating parametric reverse engineering and NURBS freeform reverse engineering it is an unique combination of the two and is the quickest way of creating CAD data from scan data.’ For the higher-end users like Physical Digital many of the key features have been updated particularly the exact surface algorithms. “With our expanded surfacing tool set controlling and editing surface layouts is now even easier,” says my demo buddy Greg. “When a user needs precise, perfect NURBS surfaces for CAD modelling the software can automatically deliver what is needed every time.” A new feature I found particularly interesting was Geomagic Design X’s HD Mesh Construction. During the demo Greg was able to take some fairly poor scan data and still create an accurate representation of the object with the software’s automatic hole filling feature. For somebody, like myself, who has done some pretty inaccurate 3D scanning with some budget devices it was quite amazing to see how the software improves bad scans. In all the 2016 edition of Geomagic Design X not only reaffirms its standing as the best scan-to-CAD software on the market but pushes it further forward.  OCTOBER 2015 www.tctmagazine.com

059

PROTOTYPING

CREATIVE

PRODUCTION

BIG The 3DP1000 offers a large build area of 1000 mm x 1000 mm x 500 mm. More than 74 times bigger than the average desktop 3D printer.

PERSONALIZATION

ECONOMICAL

74X

ACCURATE

Low initial capital investment, costs 1/20 of other similar size professional printers. Low operating expense, with material costs 1/10 typical proprietary materials.

ROBUST The 3D Platform leverages open market advances in materials, motion controls, print hardware and software. The customer benefit is a natural upgrade path and superior ROI.

Industrial mechatronics enable layer resolutions down to 70 microns. Sure Print Technology and industrial strength SIMO Series actuators ensure consistent 3D prints.

Visit 3D Platform at TCT + Personalize, Stand G12 www.3dplatform.com | marketing@3dplatform.com 6402 East Rockton Road, Roscoe, Illinois 61073 | United States

MEDISIEVE

WHEN DR ADRIAN BOWYER FIRST SET UP THE REPRAP PROJECT AT BATH UNIVERSITY IN 2005 HIS QUEST WAS TO CREATE A MACHINE THAT REPLICATED ITSELF, A BENEFICIAL OFFSHOOT OF THAT MISSION COULD POTENTIALLY SAVE HUNDREDS OF THOUSANDS OF LIVES. DANIEL O’CONNOR SPEAKS TO THE MAN USING 3D PRINTING TO CURE MALARIA.

RepRap to the rescue

recent film by

the Economist depicted a world in which malaria drugs stopped working; a very plausible scenario that thought leaders of the world, like Bill Gates, say could lead to insurmountable casualties. The film is set in the year 2023 but in the year 2015 it is already a very real threat with three of the five strains of the disease that affect humans resistant to antimalarials and spreading across Cambodia, Laos, Thailand, Vietnam and Myanmar. MediSieve, a spinout company from University College London, may just have found a solution, a 3D printed solution. Initial trials show that a 3D printed magnetic blood filter, designed by founder Dr George Frodsham, could extract up to 90 per cent of infected cells from a person with malaria in less than four hours. Red blood cells infected with a malaria parasite have magnetic properties. This enables MediSieve’s device to capture them without affecting healthy cells. The process is similar to dialysis in that infected cells are captured as blood passes through an external loop. This in turn, quickly reduces

WOR DS : DA N I E L O ’C O N N O R

symptoms, severity and mortality. This revolutionary device was made possible thanks to the RepRap project as Dr Frodsham explained to TCT: “I first came to 3D printing due to a resource issue, during my PhD we had relatively little funds but a clear idea of what I wanted to do and the answer was to buy a RepRap machine. I used it to make some early prototypes in-house and it made a huge difference because it meant I was able to iterate designs and try them out for a really low cost, really quickly. “When I was happy with the design I was able to produce the numbers I needed to run my experiment, mass manufacture is a strong word but it wasn’t far off.” Those initial prototypes have proved so successful that the company has been able to raise £350,000 to fund a clinical prototype and initial safety trials for the magnetic blood filter device, and 3D printing will be used throughout the process. “We’re still looking at using 3D printing to produce the clinical prototypes,” explained Dr Frodhsam. “But we’ll be looking towards injection moulding when we scale up to manufacturing. This

is a product that we’re hoping to help hundreds of thousands of people with, with those kinds of volumes I personally don’t feel like 3D printing is the most efficient way of doing it.” Though we’re perhaps not quite there in the mass manufacture department MediSieve’s ingenious story shows how 3D printing on a printer that costs less than £500 to assemble can have huge ramifications across the world. Dr George Frodsham has found himself becoming somewhat of a 3D printing evangelist. “I ended up using the RepRap not only for my project but to support a number of other research groups to make early prototypes, custom experimental apparatus, adapters for microscopes. Sometimes these things costs hundreds even thousands of pounds and you can print them for basically nothing. He continues: “It adds huge value to the product development process when you’re talking about the development of new medical devices but also as a lab tool. For me it is an essential piece of lab equipment right now, I recommend 3D printing to everybody I speak to and it is only going to get better.” 

OCTOBER 2015 www.tctmagazine.com

061

ACCELERATING 3D TECHNOLOGIES



LEFT: Dr George Frodsham of MediSieve

colorfabb.com learn.colorfabb.com

colorFabb ofﬁcial Europe distributor

+ 31 (0)77 – 398 09 09 sales@colorfabb.com stacker.colorfabb.com stacker3D.com

062

OCTOBER 2015 www.tctmagazine.com

GRAPHENE

ACCELERATING 3D TECHNOLOGIES



LEFT: National Graphene Institute

BELOW:

Graphene Exfoliation

raphene is the thinnest material on earth with exceptional extreme properties that make it incredibly versatile. The ‘2D material’ can be as tough as a diamond, 200 times stronger than steel and as flexible as rubber. It’s also a great conductor, a property that makes it a compelling choice for researchers working in manufacturing and electronics

A material for

the 21st Century

Graphene was discovered in Manchester by Prof. Andre Geim and Prof. Kostya Novoselov during one of their frequently held scientific “Friday night experiments” – a tradition which is apparently still going strong at the University of Manchester today. During a simple experiment with a lump of graphene and sticky tape, the two noticed they were able to separate graphite fragments into flakes just one atom thick. Their findings were first published in 2003 but it wasn’t until 2004 that global interest in this curious material was truly sparked. Dubbed Graphene City, Manchester is the home of graphene so it seems fitting that researchers at Manchester Metropolitan University (MMU) have set out to develop a 3D printer and a process to enable the construction of 3D objects with the material. Toby Heys, Digital Research Fellow and Media Research Centre Leader at MMU, has partnered with Dr. Craig Banks, Reader in Nano and electrochemical

technology, and Prof. Peter Kelly, Professor of Material Science at MMU, to develop a new approach to 3D printing graphene. It’s very much a collaborative effort and Tony’s interest in the material is uniquely focused on art-based projects rather than straightforward engineering. “My interest in developing a 3D printer and process for 3D printing graphene comes from producing interactive tactile surfaces and environments for robotic sculptures for exhibitions in museums, galleries, and biennials,” Toby explained. “I currently use ABS plastic in 3D printers but require materials that offer greater strength and conductivity.” A COMPLEX MATERIAL Toby started researching graphene’s properties back in 2012 and later met with Banks and Peter Blake from Graphene Industries where a focus on the possibilities for artists, designers and scientists led to a KEIF R&D grant from MMU. This is where their first 3D printer was born, the ‘Gbot’. Soon after, the project led a successful application to the EPSRC to; develop a novel and advanced bottomup fabrication route to produce graphene 3D architectures, study their properties, develop UV curable 3D printable graphene inks and demonstrate relevant applications. The complexity of 3D printing with graphene comes from the necessity to ››

Having the capacity to 3D print with graphene will be an important breakthrough in the evolution of printing very strong lightweight materials.

OCTOBER 2015 www.tctmagazine.com

063

064

OCTOBER 2015 www.tctmagazine.com

GRAPHENE ACCELERATING 3D TECHNOLOGIES

The current limitations of graphene are in the need to manipulate and regulate its architecture in order to maintain benefits and apply it to long-term applications

manipulate it into a usable material that can be controlled. The starting material has a fluffy powder-like property and this requires special processes to incorporate into manageable polymers. Toby explained: “The requirement is to be able to incorporate polymers with suitable nanofillers that can be polymerised/cured in-situ following printing, such that another layer can be rapidly applied and so on. This will allow structures to be built without recourse to curing in an oven after each layer, as is currently the case and will significantly increase throughput/fabrication times.” The current limitations of graphene are in the need to manipulate and regulate its architecture in order to maintain benefits and apply it to long-term applications. Right now the challenge is finding a suitable carrier to blend graphene with in the 3D printing process in order for it to truly become fundamental to 21st Century manufacturing. AN IMPORTANT BREAKTHROUGH Graphene has undergone significant development in the 3D printing space in the last couple of years. Since launching in 2014, US-based Graphene 3D Lab has gone from strength to strength doubling its production capacity, securing major partnerships, unveiling its 3D printed graphene battery technology and successfully releasing Conductive Graphene Filament onto the market. Speaking to TCT back at RAPID 2015, Co-founder Dr. Elena Polyakova revealed plans for the company’s own 3D printer which will allow users to combine different materials in a single part and

LEFT:

GBot graphene 3D printer

ABOVE:

Graphene Membranes

next-generation additive manufacturing technology to be developed that allows graphene to be rapidly printed into a range of useful 3D structures.”

relinquish the limitations of current FDM technology. “It is likely to become one of key materials in functional 3D printing,” Elena explained. “Graphene enhanced polymers are great conductors of electricity. We will need many different materials to print optical elements, energy storage devices, transistors, etc. Graphene composites can be adapted for many of these elements. Needless to say, speed and accuracy of deposition techniques must be improved. The next generation of hardware that can print with dozens of materials must be created.” That’s where research projects such as that at MMU and hardware plans at Graphene 3D Lab will provide the necessary foundations for progressing the technology as a manufacturing material for real functional items like smart products, micro batteries, super and ultragraphene capacitors and solar devices. Toby commented: “Having the capacity to 3D print with graphene will be an important breakthrough in the evolution of printing very strong lightweight materials. More specifically, in terms of our current research project it will allow a

WHAT’S NEXT? Graphene is still very much in its infancy but researchers expect its presence to be pivotal in changing the way we travel, develop medical equipment and delivery systems and tackle issues such as water purification. As Toby puts it, regardless of the hype, “there needs to be patience” if Graphene is to be fully understood and developed. Last month, a PhD student at the University of Manchester became the recipient of the annual Eli and Britt Harari Graphene Enterprise Award for a business proposal to develop a range of graphene based inks for printed electronics. Daryl McManus, a PhD student at the university impressed judges with a business proposal demonstrating the depositing of graphene in more consistent and environmentally friendly ways. The £50k prize money will be used to found a new graphene start-up company that will harness graphene’s properties for applications in printed electronics. With the recent launch of the National Graphene Institute, a £61m world leading facility for graphene research in Manchester, the possibilities for this revolutionary material have never been more promising for researchers and graphene start-ups setting up camp in graphene’s place of origin. 

OCTOBER 2015 www.tctmagazine.com

065

Visit us at the TCT Show, Stand F19

More than 3D printing 3D Printing specialists with the largest Polyjet capacity in the UK. IPF are an industrial 3D Printing service, with high-end technologies and materials at your disposal. Offering Polyjet and FDM prototypes with a range of material properties including; flexible, durable, high-temperature, clear and colour combinations, complimented by our plastic Machining and Fabrication service.

3D Printing Service

Plastic Machining Service

• • • • •

FDM Polyjet Ultem Nylon ABS

CNC machining and fabrication Diffusion bonding Diamond polishing Laser profiling and engraving Design intent materials

Industrial Plastic Fabrications Ltd fast, friendly and reliable IPF - Show Guide Ad 192x136 V1.indd 2

066

OCTOBER 2015 www.tctmagazine.com

sales@ipfl.co.uk +44 (0)1992 893231 ipfl.co.uk 21/08/2015 06:47

60 SECOND INTERVIEWS ACCELERATING 3D TECHNOLOGIES

The Keynote 60 Second Interviews

Al Siblani, CEO EnvisionTEC, Main Stage, Sep 30, 10:15

At TCT Show + Personalize 2015 we’re delighted to introduce some of 3D printing’s most illustrious names to the main conference stage. We’re fairly confident that you will not find a more distinguished line up of 3D technologies speakers at any other conference on the globe, especially not for free. We’re particularly proud of the keynote slots that encompass a spectrum of speakers with plentiful experience and upcoming innovation. We’ve posed some of our keynotes a set of questions to see what makes them really tick.

First up is CEO of EnvisionTEC, Al Siblani, a man who has been involved in rapid prototyping as long as TCT has. EnvisionTEC has one of the largest install bases of 3D printers in the industry and Siblani has masterminded this rise from the very beginning. We posed him six questions… How did you first become involved in 3D technologies? I started working for Helisys Laminate Object Manufacturing (LOM) in 1993 as a service and applications engineer for the Automotive Industry, dealing with major companies such as Ford, GM and Chrysler. When people ask you what 3D printing is good for what specific example do you serve up? Mass Customisation especially within medical applications. What are you looking forward to seeing most at this year’s TCT Show + Personalize? I always look forward to seeing any new technology platforms as well as more innovation in materials and their performance.

This is TCT’s 20th Edition of TCT, what would you say have been the most significant advancements in those 20 years to lead us to this point? The acceptance of 3D printing as a potential solution for an engineering team. And in 20 years time, what should we expect to see at the show then? A mature technology delivering functional parts in production quantities. Lastly, Additive Manufacturing or 3D Printing? Which do you prefer and why? I prefer 3D printing because it is easier for everyone to understand and relate to. Being easier to understand will make it more mainstream and easier to accept and adopt in the future.

AL SIBLANI OCTOBER 2015 www.tctmagazine.com

067

OCTOBER 2015 www.tctmagazine.com 0683DPrintCloud@materialise.com

60 SECOND INTERVIEWS ACCELERATING 3D TECHNOLOGIES

The Keynote

60 Second Interviews

Todd Grimm, Main Stage, Oct 1, 13:00 How did you first become involved in 3D technologies? I contacted a former boss to congratulate him on setting up one of the first service bureaus in the world. Near the end of the conversation he offered me a job and a chance to be an early entrant in this exciting field. When people ask you what 3D printing is good for what specific example do you serve up? The examples I use depend on the needs and situation. But manufacturing tools (e.g., fixtures) is my most often cited application. I believe that it is doable today by any company, and it has several advantages, including easy justification (ROI) and widespread need. I also cite manufacturing tools because it can be a bridge from prototyping to production.

What are you looking forward to seeing most at this year’s TCT Show + Personalize? We are in a phase where there are a lot of new innovations. Looking forward to seeing all of the new technology, materials and applications. This is TCT’s 20th Edition of TCT, what would you say have been the most significant advancements in those 20 years to lead us to this point? I am reluctant to name a few advancements because I believe that what has led us to where we are is the cumulative effect of many incremental advancements – advancements that have been chipping away at what users have been demanding for decades: better quality (accuracy), better material properties and higher throughput.

And in 20 years time, what should we expect to see at the show then? The technology will have progressed significantly in 20 years, but I can’t fathom what it will look like and what it will be capable of. Can’t wait to see what it becomes! I also can’t wait to see what manufacturers are doing with the technology as a “go-to” production methods. My biggest dream is that we have true topology optimisation where software does the design work based on the real output from a specific combination of machine and material, accounting for any peculiarities (advantageous and disadvantageous) in the output. Lastly, Additive Manufacturing or 3D Printing? Which do you prefer and why? I prefer “Additive Manufacturing” because it carries a context of being more capable than “3D printing”. However, I most often use “3D printing” as it is a more recognisable term.

TODD GRIMM

Double Todd Grimm in this month’s TCT Magazine as we pose one of the industry’s thought leaders six questions ahead of his, sure to be excellent, talk on the main stage on day two of TCT.

OCTOBER 2015 www.tctmagazine.com

069

Additive manufacturing of complex metal components

Metal Powders for 3D printing

Two technologies – one provider Inspire industry to make more with less. www.hoganas.com

070

OCTOBER 2015 www.tctmagazine.com

60 SECOND INTERVIEWS ACCELERATING 3D TECHNOLOGIES

The Keynote 60 Second Interviews

President of Stratasys EMEA, Andy Middleton is one of those people in the industry you have to see speak. His passion and knowledge of the industry is first class and his answers to our six questions make fascinating reading. Andy Middleton, President at Stratasys, Main Stage, Sep 30 13:00 How did you first become involved in 3D technologies? 10 years ago I had the opportunity to meet current Stratasys CEO David Reis, we worked in a 2D printing company together for a couple of years, we sold this company to Hewlett-Packard. Afterwards David put a 3D model in my hand and said “Andy, we’re going to go on a great journey together, this is a 3D printed part.” I love getting involved in start up technology and that small part was enough, I was sold. I joined David at Objet and the rest, as they say, is history. When people ask you what 3D printing is good for what specific example do you serve up? What’s 3D printing good for? First of all I say it is good for the planet. We can now make parts additively instead of subtractively so we save raw materials. But on a more personal level it is a technology that helps people have better lives through medical applications.

What are you looking forward to seeing most at this year’s TCT Show + Personalize? Sharing what 3D printing can do with people and seeing their enthusiasm. This is what I love about trade shows, sharing the knowledge that we have, sharing how far the technology has come and seeing people’s eyes trying to digest how that could improve their business. You get a very strong feeling of purpose when you’re at a trade show because you’re imparting knowledge and experience to people who take a huge benefit from it. This is TCT’s 20th Edition of TCT, what would you say have been the most significant advancements in those 20 years to lead us to this point? It is the acknowledgement in the last five years or less of the true potential of 3D printing. Previously, even for Stratasys, it was a method of digitally creating prototypes but now it has gone way beyond that, it is stepping into the manufacturing stage. The big industrial companies now recognise that this technology will transform the manufacturing industry.

And in 20 years time, what should we expect to see at the show then? We will be seeing control systems and manufacturing lines of 3D printers printing materials that we cannot even imagine today. Those machines will be producing end-use components with better materials that can be achieved conventionally. We don’t even know what materials we’ll be printing with and at what speed in 20 years time but it will be an absolutely embedded manufacturing process across industry segments. It will be the norm. Lastly, Additive Manufacturing or 3D Printing? Which do you prefer and why? 3D printing is more of a technology and a process, additive manufacturing is taking that process and implementing it into a manufacturing space so for me it is not an either/or situation.

ANDY MIDDLETON OCTOBER 2015 www.tctmagazine.com

071

EOS e-Manufacturing Solutions

Tool insert and injection moulding component. (source: Innomia, Magna)

EOS Additive Manufacturing: Productive and Flexible Tooling Solutions EOS Additive Manufacturing enables highly productive, flexible, individualized tooling solutions. It allows complex forms and functional integration: conformal cooling channels result in reduced cycle time, lower scrap rates and attractive costs per part. Please read the full EOS customer case study and scan the QR-code below.

www.eos.info

072

OCTOBER 2015â&#x20AC;&#x192; www.tctmagazine.comâ&#x20AC;&#x192;

60 SECOND INTERVIEWS ACCELERATING 3D TECHNOLOGIES

The Keynote

60 Second Interviews Maxim Lobovksy, Main Stage, Oct 1, 10:15 How did you first become involved in 3D technologies? I first started working with 3D printers as an undergraduate student at Cornell University in 2008. I worked on Fab@Home project, one of the first efforts to develop both a desktop and open source 3D printer. One of my developments was a metal and ceramic printing process for the Fab@Home machine.

If you’ve seen the Netflix documentary Print The Legend you’ll know Formlabs’ CEO to be a man who prefers to concentrate on his technology than the limelight. Fortunately Max has agreed to take to the TCT stage to relay the most fascinating of 3D printing stories.

When people ask you what 3D printing is good for what specific example do you serve up? Mass customised jewellery and dental applications. Prototyping detailed plastic parts like plastic parts in a phone. What are you looking forward to seeing most at this year’s TCT Show + Personalize? I am always looking forward to seeing the latest products and technology coming to the 3D printing world.

MAX LOBOVSKY

This is TCT’s 20th Edition of TCT, what would you say have been the most significant advancements in those 20 years to lead us to this point? I think the most significant advancement in 20 years is making 3D printing accessible to everyone who works in 3D design, not just engineers in the best funded aerospace or automotive companies. The combination of desktop machines and low-cost service bureaus has made this possible. And in 20 years time, what should we expect to see at the show then? As opposed to hardware developments, I think that much of the focus will have shifted to materials and software. Lastly, Additive Manufacturing or 3D Printing? Which do you prefer and why? I believe that “3D Printing” will remain the dominant term, and Formlabs will use that term because we need to use terminology that our customers understand. But personally, as an engineer, I prefer “Additive Manufacturing” as the more accurate term. 3D printing has nothing to do with printing.

I think the most significant advancement in 20 years is making 3D printing accessible to everyone who works in 3D design, not just engineers in the best funded aerospace or automotive companies.

OCTOBER 2015 www.tctmagazine.com

073

Industrial-Grade 3D Printing with Binder Jetting Technology

ExOne 3D Printing systems & services deliver complex metal parts, sand casting cores and printed mould packages with less cost and increased efficiency for prototype to production volumes. ®

Select from a variety of build sizes:

NEW: Exerial™

Industrial Serial Production 2200 x 1200 x 700mm

074

S-Max™

S-Print™

M-Flex®

1800 x 1000 x 700mm

800 x 500 x 400mm

400 x 250 x 250mm

+49 (0) 821 7476 0 • ExOne.com

OCTOBER 2015 www.tctmagazine.com

Booth #E20

60 SECOND INTERVIEWS ACCELERATING 3D TECHNOLOGIES

The Keynote

Towards the front of this issue you can read how Conor and his team have created a multi-award winning company and on day two of TCT Show + Personalize 2015 you can see him discuss that journey live on stage.

• Heritage – Technology is pushing curators to re-evaluate how they can potentially reinterpret collections for the benefit of audiences. Imagine 3D printing the hand of a Mummy so that visitors could interact and touch the Mummy’s hand. • Education - beyond just teaching CAD and 3D printing to engineering students – using 3D printing in a myriad of other subjects and projects – creating teachable objects – in history lesson printing a sword from a battle scene or testing a hypotheses in maths class.

Dr Conor MacCormack, Main Stage, Oct 1, 10:45 How did you first become involved in 3D technologies? When I was doing my PhD in Trinity College Dublin I saw a 3D printer in action for the first time – I was amazed but also appalled at how expensive it was to operate. This planted a seed – why shouldn’t everyone have the right to 3D print – the idea was conceived - Imagine making a printer that had a zero running cost? When people ask you what 3D printing is good for what specific example do you serve up? • Plastic surgery – meet patient, scan face, digitally alter model, print 3D model, show patient & finally perform the surgery

What are you looking forward to seeing most at this year’s TCT Show + Personalize? I always like meeting old and new 3D printing friends, seeing the latest technology, catching some interesting keynotes and seeing Jim running around with his hair on fire making sure speakers are there on time! This is TCT’s 20th Edition of TCT, what would you say have been the most significant advancements in those 20 years to lead us to this point? Machines When we first started going to TCT there was no “entry level” 3D printers. Seeing the evolution of hardware has been a privilege and we’ve been part of that change by being the first company to dare to make a 3D printer that challenged the big boys in mid noughties by presenting a 3D printer that costs almost nothing to run.

Materials The choices for engineers have vastly improved beyond the ABS or sandstone available 10 years ago. Today, the non-engineers are saying ‘I want great quality, low cost and full colour parts’ this means that the world of 3D is expanding from not just the makers, innovators and hobbyist but into the mainstream. Software The ability to easily generate 3D models on any device has changed the way users interact with printers. Content is what’s going to drive this industry, and this process is getting easier. The ability to have a hand held scanner and capture stunning details in full colour has been transformed from being a £50k device to a €200 clip on to your iPad and eventually integrated into your phone. And in 20 years time, what should we expect to see at the show then? In 20 years’ time 3D printed objects will produce parts in seconds and minutes. Materials will be indistinguishable with today’s materials. Every classroom will have a 3D printer, electric cars will have 3D printed parts, tailored drugs will be 3D printed, human trials of 3D printed organs will have taken place, 3D printers will be essential tools for space missions. Lastly, Additive Manufacturing or 3D Printing? Which do you prefer and why? 100 per cent ‘3D Printing’. Additive Manufacturing is a term used by engineers, more interested in the process than the output – it’s like someone in the office using an electrophotography machine (a photocopier). 3D printing, although not accurate to the purists, is a catchall name and one that fits best I feel across the spectrum of possible use cases better than Additive Manufacturing.

DR. CONOR MACCORMACK

60 Second Interviews

OCTOBER 2015 www.tctmagazine.com

075

FARO EdgE ScAnARm Hd HigH speed sCAnnig perForMAnCe MeeTs Hd dATA ClAriTy! ®

Seamlessly scan across diverse surface materials regardless of contrast, reflectivity or part complexity without any special coatings or target placement. The extra wide scan stripe and fast frame rate boosts productivity by increasing coverage and reducing scanning time. Call us at 00 800 3276 7253 for a free demo today! More about the FaroArm family at: www.faro.com/scanarm

076

OCTOBER 2015 www.tctmagazine.com

Visit us at TcT Show Live, Birmingham, 30 Sept – 1 Oct 2015, Stand B32

60 SECOND INTERVIEWS



ABOVE: Carsten Engel



RIGHT: Frank Cooper

are also a production technology for high-tech sectors, especially when I explain them how vital lightweight structures are for space applications, automotive and in general for airplanes.

Frank Cooper (FC), Birmingham School of Jewellery, Main Stage, Oct 1, 14:45

FC: The creation/printing of master patterns for volume jewellery production using moulds or the creation/printing of wax patterns for one-off lost wax investment casting.

How did you first become involved in 3D technologies? CE: I started as a research engineer in Belgium 6 years ago (in 2009) and I was in charge of developing the metal machines for the biomedical and aerospace sectors. Eventually, when the technologies were ready, these prototyping machines became industrial ready machines for implants, satellites and airplane components.

What are you looking forward to seeing most at this year’s TCT Show + Personalize? CE: I am always happy to see that the community grows. Moreover, I like to learn new things or discover new materials, technologies that could eventually help us with our business. And last but not least, I am always looking forward to making new contacts there and discuss the current technical challenges of 3D printing.

FC: The jewellery industry has been using 3D Printing/ prototyping and CAD for 15 years or more so it’s something we have ingrained into our psyche and you can’t get much more 3D than making fine jewellery can you?

FC: The plethora of low cost, often open source, DLP resin printers that are hitting the marketplace now many of which produce castable resins ideal for the small jewellery workshop. I also need to catch up with the latest developments in 3D scanning in all it many forms.

When people ask you what 3D printing is good for what specific example do you serve up? CE: The medical applications, demonstrating the powerful state-of-the-art developments 3D Printing can be used to help patients with severe bone traumas. Then, I often continue to explain that 3D printing has existed longer than 2012. They quickly realize that 3D printers

This is TCT’s 20th Edition of TCT, what would you say have been the most significant advancements in those 20 years to lead us to this point? CE: Communication is key! Not only to engineers, but also education of future engineers, scientists, entrepreneurs and in general, every tech-geek. Teaching and spreading

information about 3D Printing, its limits and possibilities is key to develop further the community of TCT and all of the 3D Printing community in general. FC: The ending of a number of patents in recent years opening things up to the smaller player and from my jewellery speciality standpoint the development of DLP.

ENGEL & COOPER

Carsten Engel (CE), Xilloc, Main Stage, Oct 1, 13:50

ACCELERATING 3D TECHNOLOGIES

Of course, the TCT main stage is not just about our keynotes there’s a jam-packed programme throughout both days. Our two quick fire interviews on this page are for two gentlemen who both grace the stage on day two.

Lastly, Additive Manufacturing or 3D Printing? Which do you prefer and why? CE: Well … 3D printing is known to everyone, Additive Manufacturing is a term for engineers, which in my opinion will fade with the years. We still use both, AM makes it look professional, 3D printing makes it look desktop printing. Media attention and Google hits tend to suggest 3D printing. And the standards (ASTM, ISO) use AM. Thus, our strategy to use both is good and if we want to have more hits, we use 3DP. For us, it has two meanings. FC: I am lucky enough to be right there at the forefront of the emerging AM in precious metals technology. The jewellery industry is already enthusiastically embracing the DMLM/S of precious metals and for the reason why I refer you to my first answer. We have always been an industry that is an early adopter and of course helped by the fact that we have no qualifying standards to worry about, unlike the aerospace, medical and automotive industries. All we need is to produce beautiful jewellery that will pass its assay mark!

OCTOBER 2015 www.tctmagazine.com

077

TYPE A MAchines

Standing in place of what was once an old Chrysler manufacturing plant in San Leandro, California, the heart of the world’s largest 3D technology startup cluster beats away. One of those startups is Type A Machines, a small company, founded in 2012 as an early adopter of the RepRap movement and now on a mission to lead the next wave of additive manufacturing.

WORDS : L A U R A G R IFFIT H S

SIX areMACHINES better than one Residing

in this huge space, rich in industrial

manufacturing history, Type A is happy to share its home with a coalition of rising machines companies focused on materials, servicing, training, software and just about every other part of the 3D printing ecosystem. “It’s a more accessible approach to building up the company where we’re letting other people come in and play with us and it’s turned out pretty well so far,” Espen Sivertsen, CEO of Type A Machines, commented. The Series 1 Pro 3D printer is Type A Machine’s answer to what they’re seeing as a big shift in the industry moving towards a more distributed approach to manufacturing. The modular desktop machine is a scalable fused filament production system which can be used individually or as part of a Print Pod system of up to six printers. This means it is possible for manufacturers to scale their production from 1-10,000 parts using the same machine and upgrade the system for their own specifications. “The power of the distributed approach is actually a really interesting play for production companies where you might not need that capacity immediately when going into the market,” Espen explained. “The idea is you scale organically as you need to. We believe it’s the future of manufacturing.” Right now the Series 1 supports 40 materials including flexible, conductive, magnetic and carbon fibre filaments. The plan is to turn that number into 140 within the next few months to include just about any material that can extrude below 300°C.

078

OCTOBER 2015 www.tctmagazine.com

Type A Machines presented the machine at RAPID 2015 and were met with positive feedback from people who were somewhat sceptical about a $3,000 printer being a real production tool. As the company evolves into more of a platform company with the development of its own OS, service platform and hardware, its focus is on professional users of additive manufacturing and companies wanting to bring new products to market, quickly. Espen explained: “The idea is we’ll be able to provide our customers the entire ecosystem from materials, to 3D printing services, to 3D printers, training, operator training, certification, so that from a manufacturing point of view, you can use Type A Machines to bridge that gap that’s existed in the past between prototyping and volumetric production.” Type A Machines has just released a whitepaper that demonstrates an idea they’re particularly excited about, the prospect of AM taking on injection moulding in the sub-10,000 unit space and winning. They’ve also received the seal of approval from companies like Autodesk, Intel and Google and most recently installed a machine at Berkeley University. The company wants to prove to industrial users that low cost desktop machines can be a real valuable production tool and that multiple, smaller units working in unison to provide parts on demand might actually be more valuable than one huge machine. “The industry is really starting to wake up to the idea that AM is a production tool and we’re trying to lead the way on the fused filament side for that.” 

ACCELERATING 3D TECHNOLOGIES

THE DIRECTORY 3D SLS scanners • Hobby from £1600 • Professional from £6000 www.3denterprise.co.uk

•

info@3denterprise.co.uk

•

Tel: 07865 218765

3DPRINT-UK 3DPRINT-

3D Enterprise panel advert.indd 1

SLS NYLON

10p PER CM3

23/01/2015 10:45

.co.uk

WOW!

Your Online Quotation Solution for Additive Manufacturing

www.3DPrinteo.com

TO ADVERTISE HERE

CONTACT CAROL HARDY ON 01244 680222 or email carol@rapidnews.com OCTOBER 2015 www.tctmagazine.com

079

THE DIRECTORY TO ADVERTISE HERE

CONTACT CAROL HARDY ON 01244 680222 or email carol@rapidnews.com

Crucible Design that delivers

www.crucibledesign.co.uk + 44(0) 1235 833785 - 20 years’ experience of additive layer processes - Design for cost-effective nylon & metal sintering - Specific expertise in the design of production parts

BUREAU SERVICE & PRODUCT SALES Breuckmann 3D scanners Geomagic software Reverse engineering & inspection Best accuracy & resolution

Tel: 01420 88645 www.reveng.co.uk

3D Scanning 3D Printing 3D Inspection 3D Sales 3D Services

Europac3D are resellers for many of the world’s leading suppliers of 3D equipment, including the full range of 3DSystems printers and 3D scanning equipment from Artec and Solutionix. We also offer a competitive full scanning and printing service to suit your project needs.

Sales & Services Tel: +44 (0)1270 216000 | Email:sales@europac3d.com | www.europac3d.com

Technology Metals | Advanced Ceramics

AMPERSINT® Gas Atomized High-alloyed Metal Powders for Additive Manufacturing Applications Contact H.C. Starck by calling +49 5321 751-3239 or sending an email to info@hcstarck.com to explore opportunities for future strategic partnerships. www.hcstarck.com

080

OCTOBER 2015 www.tctmagazine.com

ACCELERATING 3D TECHNOLOGIES

IRELAND’S 3D PRINTING BUREAU SALES: Printers - Scanners - Consumables SERVICES: Design - Manufacturing - Prototyping www.inspire3d.ie Mobile: 00 353(0) 87 739 0226 Email: info@inspire3d.ie

“FDM is taking on increasing importance as an alternative manufacturing method for components made in small numbers” - Gbnter Schmid, BMW.

www.np3.si

r, ette ss it b d le Do er an ly. e t fas ensiv exp

NP3

DES PRO IGNIN TOT G & YPIN Ne wc G 48 onc h of 3 our in ept in Pro 0 day stead rap totypin s! id p ace g at a .

.o.

d.o

L G ITA DIG CTURIN FA

NU MA

SE NUF RIAL ACT URIN

pano_NP3_930x400mm.indd 1

18/05/15 09:10

The first truly consumer 3D printing filament maker. Create filament at home! 01172 300 330

Pre-order at omnidynamics.co.uk

MIDWEST PROTOTYPING

We’ve been 3D Printing, Rapid Prototyping, and Low Volume Production specialists - for 15 years

w w w.midwestproto.com

OCTOBER 2015 www.tctmagazine.com

081

GRIMM COLUMN

CRITICAL MASS Efforts, Influence and Interests across the Entire Gamut WOR DS : T O D D G R I M M

The passion of the veterans has coalesced with the optimism of the rookies and been tempered with the wisdom of maturity

Todd Grimm

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

tgrimm@tagrimm.com

082

For many years progress in additive real challenges. They are starting by gathering manufacturing felt a bit like swimming against intelligence on the industry to discover unmet the tide. A small, albeit passionate, collection needs, not devising solutions in hopes of finding of individuals and companies shouldered the problems that may be addressed. Today, there is a burden of moving the industry, technologies and sense of direction and purpose to the innovations applications forward. Passion kept them going, and advancements, and that provides power. but there just were not enough resources to The tide’s increased breadth stems from the range of innovations and advancements as well make a sizable impact. In recent years, the number of participants as the scope of users and applications. For the latter, all of the attention over the in additive manufacturing swelled, as did their diversity. CRITICAL MASS: past few years has driven greater of additive manufacturing. Fueled by the sensationalistic The size, number, adoption There is now a sense that additive proclamations of revolution and or amount of manufacturing is a reality and that disruption, there was a rush of new players. The tide had something that is the time has come to make use of tool. Having reached a state turned. Instead of swimming needed to cause a this of critical mass, organisations feel against it, the tide was propelling particular result. compelled to adopt the technology additive manufacturing. for product development and However, that torrent was a bit production. shallow. Fueled by wild-eyed enthusiasm and gut-level beliefs that additive With increased use comes increased justification manufacturing was the next big thing, the new to devise new business ventures to capitalise on entrants did not bring much staying power with the growth opportunity. Although the additive manufacturing industry is still tiny, relative to them. Optimism ran high but substance did not. That brief history brings us to today, an age in many established markets, it has enough mass which I believe we have achieved critical mass. to draw the attention of huge corporations and Measured not only by numbers, this critical mass budding entrepreneurs. is comprised of a diverse body of interests that These organisations are tackling hardware, span the entire gamut of tools, solutions and software and materials, which results in the services that enable the business of additive technical advancements that fuel even greater manufacturing. Driven by realistic, business- user adoption. But what excites me most is that minded and balanced initiatives, the critical mass companies are addressing the unmet needs brings with it substance and the financial and beyond the day-to-day operations in the additive manufacturing lab. New solutions have been, and intellectual resources for advancement. The tide continues to flow in the same direction, will be, devised that address all aspects of the but its depth and breadth have increased, which business of additive manufacturing. makes it a force to be reckoned with. Critical I believe that we have reached critical mass mass offers substance, influence and the power because we are building an ecosystem of to make lasting changes. products and services that make additive Increased depth has resulted from a shift in manufacturing a “real” industry that moves mindsets and motivations. The passion of the it beyond a novelty to a practical and veterans has coalesced with the optimism of the powerful resource. With critical mass, additive rookies and been tempered with the wisdom of manufacturing has a strong foundation for maturity. Startups and established organisations growth and the propellant for accelerated are devising practical and sensible solutions to advancement. The tide is rising, which according to the aphorism, will lift all boats. 

OCTOBER 2015 www.tctmagazine.com

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

hyphenser vices.com

Redefine your design

Mechanical bracket for a satellite to be used in the space sector produced on a Renishaw AM250

at: See us 15 how 20 TCT S F20 , stand Hall 3A

Explore the potential of additive manufacturing Renishaw’s additive manufacturing systems use powder bed fusion technology to produce fully dense complex metal parts direct from 3D CAD. Also known as 3D printing, this technology is not constrained by traditional manufacturing design rules. Create complex geometries such as conformal cooling channels for tooling inserts, reduce component weight by only placing material where it is needed, and consolidate multiple parts in one assembly. Additive manufacturing is also complementary to conventional machining technologies, and directly contributes to reduced lead times, tooling costs and material waste. • No requirement for tooling. • Increased design freedom - complex geometries and hidden features. • Rapid design iterations right up to manufacture.

For more information visit www.renishaw.com/additive

Renishaw plc Brooms Road, Stone Business Park, Stone, Staffordshire, ST15 0SH, United Kingdom T +44 (0)1785 285000 F +44 (0)1785 285001 E additive@renishaw.com