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AM is used to coping with challenges. The worldwide COVID pandemic, a dramatic disaster that crippled and destroyed total companies (to not converse of the horrible human toll) has been handled by the AM neighborhood similar to another problem. This horrible illness just isn’t going to let up simply and the world will probably need to take care of its results by way of the subsequent decade, however on this Formnext 2021 overview we are able to present how AM has confirmed it’s able to providing a resilient answer to coping with the pandemic quite than be a sufferer of its results. Regardless of a rising fourth wave of virus an infection in Germany and plenty of elements of Europe, the organizers and the over 600 exhibitors at Formnext 2021 placed on a present of resilience, energy, and a typically optimistic outlook on the long run [read all the news from this edition here]
On the identical time, the digital and digital areas will proceed to have a related function. Formnext has all the time offered the worldwide stage for among the most high-profile launches, with many new and disruptive merchandise debuting on the present flooring. That was largely not the case this 12 months, with many high-profile information bulletins made digitally, earlier than and throughout the present. As a substitute, the present flooring turned a spot to do actual enterprise and see (and contact) actual 3D printing and 3D printed merchandise in particular person. The very best a part of 3D printing is that it’s digital but in addition very a lot bodily. Eliminating the bodily, in-person factor to focus 100% on the digital facets is counter-productive and unimaginable.
A resilient polymer AM manufacturing development
Within the present world scenario, in-person presence at a present needs to be thought of one thing of a privilege and that’s how the AM {industry} – or fAMily, as Formnext organizers have come to name it – lived this version. The present was essentially scaled-down in comparison with the height 2019 version, with fewer exhibitors (600 in comparison with over 750) and smaller cubicles occupying two and a half halls as a substitute of 4. For a lot of Asian and North American corporations, reminiscent of Desktop Metallic or Carbon, taking part instantly on this version was unimaginable (they did so by way of native distributors). Others, like SLM Options, selected to not take part and others, like Solvay and GE, did so with a considerably scaled-down presence. Simply holding the present could be thought of an awesome success [here you can read some numbers], giving each exhibitors and individuals the chance to satisfy in particular person once more after over two years. Most exhibiting corporations additionally reported that, whereas the variety of interactions was considerably decrease, the standard of these interactions was increased.
So how did two years of pandemic form the AM {industry}?
We left off in 2019 with concepts of grandeur: hundreds of thousands of elements to be produced by hundreds of machines. That largely stays the long-term imaginative and prescient for many corporations concerned in AM and steps proceed to be taken in that path, particularly on the polymer aspect of issues. The pandemic helped many see the advantages of AM for provide chain resiliency whereas it additionally put a much bigger emphasis on manufacturing flexibility. The result’s that, as AM gears up for serial manufacturing, demand can also be rising for localized, on-demand small batch manufacturing.
PBF for additive mass manufacturing (AMP)
Which means that as extra corporations look to undertake AM, the subsequent million half functions are nonetheless gradual to emerge in an additive mass manufacturing (AMP) market now led by HP, the primary firm to actively goal this broad space of utility. Guayente Sanmartin, World Head of HP’s Multi Jet Fusion enterprise, confirmed that the polymer enterprise is seeking to construct on its manufacturing expertise to introduce extra wide-reaching functions such because the take care of L’Oreal introduced throughout Formnext. “Our goal for subsequent 12 months—Ms. Sanmartin informed 3dpbm throughout our unique assembly at Formnext—is to proceed rising. We now have been rising at greater than 30% and our machines have now produced over 100 million elements. We are going to proceed to concentrate on key verticals reminiscent of healthcare, industrial, mobility, and shopper merchandise. Ms. Sanmartin additionally stated that the 5200 methods will stay the core machines on the middle of this technique and that they are going to “proceed to develop with the shoppers, with HP constantly engaged on additional enhancing high quality and repeatability”. The third factor of HP’s technique focuses on post-processing and workflow capabilities (extra on that later).
Stratasys and voxeljet are probably the most credible opponents following in HP’s footsteps within the polymer PBF manufacturing phase, with their HSS and SAF applied sciences. Nevertheless, the tables have now turned. In late 2016, when HP formally entered the polymer PBF AM market, the corporate paid over a 10-year delay to the traditional polymer 3D printing market leaders. Now the corporate has a five-year benefit, over those self same opponents, within the area of manufacturing 3D printing. Voxeljet can leverage the distinctive proposition of an enormous construct platform, the biggest within the phase, on the most recent VX1000 system. That is now being utilized in partnership with Covestro to develop extra optimized workflows. Stratasys can leverage a consolidated world community, the expertise of {industry} legends reminiscent of FDM inventor Scott Crump (who took the time to talk with us on the Stratasys sales space), and a newly re-organized construction led by Yoav Zeif.
Massifying SLS
Most innovation within the SLS phase is now coming from the most recent entry market gamers, with present market leaders EOS and 3D Programs focusing totally on consolidating their companies. The underlying ideas listed below are that increased throughput manufacturing could be achieved by optimizing the workflow. That’s what 3D Programs is doing with the brand new SLS 380 with 3D Dash, DuraForm supplies and post-processing options from AMT. The workflow additionally features a new Materials High quality Management system, the MQC 600, which ensures that printers are outfitted with the most effective ratio of recent to recycled powder, delivering materials to as many as 4 printers directly, growing total manufacturing automation.
Essentially the most credible different to the high-end SLS methods from EOS and 3D Programs is coming from Sinterit, the corporate that has established itself as the worldwide chief in benchtop SLS and has now begun to develop in direction of SLS manufacturing with the NILS 3D printer. Sinterit’s latest Lisa X guarantees the quickest, industrial-level 3D printing in a compact package deal. Different gamers on this area embody particularly Nexa3D, though the corporate ked by Avi Reichental is often related to its high-speed photopolymerization expertise. Nexa3D latest SLS system, the In accordance with Nexa3D, the corporate constructed the QLS 350 for optimum pace and throughput. With half density set to twenty p.c, the printer can course of eight liters of fabric per hour due to 4 100W CO2 lasers. Manufacturing effectivity is moreover elevated by the exchangeable constructed unit function.
Different operators working to massify SLS included Wematter, Sintratec and even low-cost SLA phase chief Formlabs. Its Fuse1 system, slowly rising, confirmss that this low-cost SLS phase just isn’t straightforward to construct however does present nice potential to realize mass adoption.
Photopolymerization in transition
With hundreds of thousands of adidas midsoles and hundreds of sports activities merchandise now in manufacturing, the high-speed photopolymerization manufacturing phase additionally has a transparent chief: Carbon. This carries sure vital implications for each the {industry} and Formnext. One is that this stable management allowed the Carbon crew to keep away from the lengthy and sophisticated journey from Silicon Valley to Frankfurt and depend on native key companion Oechsler to current among the newest key improvements inside which, by the way, an elevated concentrate on software program and the digital aspect of issues.
Among the most credible opponents on this phase embody Stratasys, Luxcreo and Nexa3D, with EnvisionTEC (the inventors of this expertise) now very a lot absorbed by transitioning into turning into a part of the Desktop Metallic group (additionally not current instantly at this version). After Carbon, Nexa3D has been increase the biggest put in base of high-speed photopolymerization methods for manufacturing, though the corporate’s largest launch at Formenxt was the XiP desktop system, which inserts right into a market phase (round $10,000 to $15,000 MSRP) till now lined solely by EnvisionTEC. The XiP incorporates a Sensible Resin Cartridge and Toolless Vat System to allow touch-free materials loading and clever polymer ranges within the vat.
After buying Origin in 2021, Stratasys turned the third-largest participant on this market as effectively. Right here the corporate is following in Carbon’s footsteps (actually) working with shoe producer ECCO on designing, prototyping them and in addition manufacturing restricted runs of footwear. That is achieved due to the speedy manufacturing of 3D printed molds and lasts produced from customized resin supplies from Henkel’s Loctite portfolio. Chinese language-American firm LuxCreo can also be concentrating on footwear a key utility. So is one other Chinese language firm, Kings 3D, nonetheless it’s doing so with commonplace giant format SLA methods used for footwear tooling and prototyping, now accessible in Europe by way of German distributor Omnitec 3D (we are going to hear extra about this).
360° new expertise
Whereas not as many as earlier editions, some solely new polymer AM applied sciences made their debut at Formnext 2021. Most likely probably the most attention-grabbing new product of the complete present was introduced by the startup Axtra 3D. Founder and CEO Gianni Zitelli, the previous co-founder of the corporate that turned Nexa3D and a serial inventor in AM (he additionally created Sisma’s EVERES line of DLP 3D printers), developed the brand new HPS Mild Engine to beat the boundaries of SLA, DLP and LCD applied sciences. It does this by efficiently combining laser stereolithography with LCD or DLP processes, leading to high-speed manufacturing of high-resolution elements with easy surfaces. The sunshine engine is obtainable as a part of the LUMIA 3D printer, the primary machine powered by HPS expertise, however it can be applied into another DLP, SLA or LCD 3D printer, together with high-speed photopolymerization ones.
A wholly new strategy to photopolymerization AM was introduced by Austrian startup Cubicure. The brand new Cerion 3D printer leverages and additional evolves the corporate’s scorching lithography course of, providing a radical departure from acquainted ideas reminiscent of resin baths or materials vats. It does so by introducing a brand new printing expertise, that includes a cell printing head and a revolving resin provider movie. Cubicure additionally developed a variety of sturdy supplies for this method.
One more new strategy to polymer AMP was introduced by dp Polar. Leveraging Xaar’s printheads and ALTANA supplies, the brand new AMpolar i1 3D printer implements a fabric jetting photopolymerization single-pass printing course of to ship industrial-scale manufacturing with construct volumes of as much as 240 liters throughout its progressive constantly rotating print platform, with a construct space of just below one sq. meter.
Two of two varieties
Some applied sciences don’t fairly slot in bigger households. For instance, there is just one Massivit. The corporate’s expertise is a singular type of photopolymerization hybridized with a big format extrusion course of, which implies it’s quick, dependable, correct and large. Till not too long ago Massivit focused visible advertising and marketing and different non-functional giant fashions (reminiscent of full-size automobile prototypes). That is still the core enterprise nonetheless not too long ago the corporate started introducing extra purposeful supplies and for end-use and particularly tooling functions, on the brand new Massivit 5000 and Massivit 10000 methods.
The startup Chromatic supplied an attention-grabbing and distinctive course of to see in particular person. Its distinctive polyurethane extrusion capabilities allow the ultra-affordable manufacturing of very giant, versatile elements, together with huge dense elements. No different firm produces all these 3D printed elements in polyurethane, one of many world’s most used supplies, for mass segments reminiscent of clothes and railroad transportation. It’s value taking a better look (within the pictures under)
Mass composites and LFAM
One other space of polymer AM manufacturing that noticed nice development in adoption over the previous two years is giant format additive manufacturing, both through giant CNC or robotic methods. The sort of AM manufacturing is nearly solely finished with chopped fiber polymer composites at this time. And whereas speaking about giant format composites manufacturing we even have to focus on the most recent system from Anisoprint, the Promenade IS 500, now lastly prepared for market. That is now the biggest steady fiber 3D printer available on the market, integrating industry-level parts and made Bosch Rexroth’s MTX, a tried-and-proven CNC system, together with the power to print utilizing a number of fibers and a number of matrix supplies.
Essentially the most huge composite polymer productions are actually coming from machine software {industry} leaders. Right here nobody can rival the Camozzi Group (Ingersoll Machine Instruments) and its Masterprint platform when it comes to dimension and capabilities. Nevertheless many different gamers are actually coming into the market (primarily from Italy, Formnext 2021 visitor nation), together with CMS and Berton. They’re squaring off with startups which were focusing particularly on this phase from the start, together with CEAD and Caracol, which are actually reaping the advantages of their pioneering improvement work. On this vibrant and distinctive AM {industry} phase, the place the large dimension of the elements produced requires huge portions of superior supplies, progressive supplies corporations reminiscent of Airtech are rising as key suppliers.
Advancing polymers for extrusion
With the brand new F770, Stratasys plans to handle the broader adoption market by providing a high-level machine, priced beneath $100,000, designed for prototyping, jigs and fixtures, and tooling functions requiring commonplace thermoplastics. Stratasys stays the undisputed chief in industrial extrusion 3D printing however competitors is getting harder, as this phase of AM strikes to leverage its distinctive strengths: versatility and the power to proficiently work with probably the most superior thermoplastics for metallic alternative, from ULTEM to PEKK and PEEK. Whereas Stratasys does supply a variety of ULTEM supplies, others are creating superior capabilities in processing PEEK and PEEK composites.
Among the many many corporations concentrating on industrial extrusion of superior thermoplastics, nobody has made extra progress than Roboze. The Italian firm has established a robust presence within the US and is actively concentrating on the Power phase, which is turning into one of many largest adopters of AM for manufacturing, by providing unparalleled capabilities in producing giant PEEK and PEEK composite elements. The new Argo 1000 system, on show at Formnext with a number of giant parts, can produce elements as much as one cubic meter in dimension in PEEK, Carbon PEEK and ULTEM AM9085F.
Nice developments have additionally been made by AIM3D. After a number of years working virtually in “stealth mode”, with data on the corporate’s machines barely accessible, AIM3D emerged at Formnext with the brand new ExAM 510, providing the distinctive means to work with superior thermoplastics reminiscent of PEEK, PEI, PSU, PPS (and composites) inside a bigger construct chamber and utilizing the fabric within the rather more cost-effective granular (pellet) kind.
The workflow will go on
Lots of the manufacturing methods talked about on this article have to work with superior post-processing gear with a purpose to scale and ship mass-produced elements. That is an space of 3D printing that’s all the time troublesome to quantify and would want extra devoted protection. From our benefit level, it appears clear that the Rosler Group, with its AM Options division and offers with a number of extra events (reminiscent of PostProcess Options), is the market chief in each polymers and metals, with its methods now additionally built-in into commonplace HP MJF manufacturing workflows.
On the identical time, there are extremely specialised operators that emerged with extremely particular polymer AM post-processing methods. Essentially the most seen at Formenxt have been DyeMansion and AMT, with Dutch firm AM Circulate additionally rising as a key supplier of manufacturing unit automation and half recognition methods particularly developed for AM manufacturing. The standard of the elements after they emerge from these post-processing methods — particularly from thermoplastic PBF processes — now simply rivals conventional manufacturing on a rising quantity and vary of elements, from eyewear and sportswear all the best way to some very stylish and standard facemasks…
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