Production is becoming ever more flexible, diversified and decentralized. Without doubt, additive manufacturing processes make a crucial contribution to this, also initiating the transformation from production-based design to design-driven production. In this article, the 3D printing service provider FIT outlines a best-practice panorama of current technologies.

The biggest ever 3D-printed lattice structure was assembled along over 2000 precisely fitting joints into an 8 m-high retable

What Additive Plastic Manufacturing Can Do. The View of a Full-Service Provider

Verfahren für die additive Fertigung

Anlagen für die Additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Anlagen für die Stereolithografie, Kunststoff

Anlagen Selektives Lasersintern, Kunststoff

3D-Druck-Anlage, pulverbettbasiert, Metall

Anlagen Additive Fertigung / 3D-Druck, Metall

SLA (Stereolithografie) Kunststoff

Flüssigmaterialverfahren

3D-Druck-Anlage, strahlbasiert, Metall

Selektives Lasersintern von Kunststoff, Metall, Keramik

Pulverbettverfahren

3D-Drucker (für FDM, FFF, etc.)

Additive Fertigung

Fused Deposition Modeling Kunststoff, Glas, Karbon, Metall

Freiraumverfahren

Werkstoffe für additive Verfahren

Andere Werkstoffe

Finer, Bigger, Faster

What AM technology is considered capable of today and how it can be applied in many areas of application is shown (representative) by this expert’s view of medical technology.

To enhance the mobility of the spine, the upper and lower shell of this disc prosthesis are connected with an elastic double spring made of titanium. The core also contains a cushioning silicone filling. The prosthesis can be manufactured according to the patient’s anatomy using the LaserCusing process 

Status and Perspectives for Human Medicine

Medizintechnik

Medical Applications of Additive Manufacturing

Hybrid production chains have been increasingly in the spotlight in recent years. This also applies to the combination of conventional manufacturing and additive processes in tool construction. With the example of an injection molding tool, it is shown how mold inserts produced by additive manufacturing can greatly shorten cycle times, and thereby significantly reduce unit costs. The important thing is to find a suitable combination of processes from the variety available.

Tool insert for a spacer of a glass fiber-reinforced PA66. The example shows that hybrid manufacturing is suitable and provides added value, even with comparatively simple parts

Additive Manufacturing and Hybrid Molds in Combination with Conventional Machining

Spritzgießen

Kunststoffverarbeitung: Verfahren

HSC- / HPC-Bearbeitung

Spanende Verfahren

Werkzeugkonstruktion

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

The Potential of Redesign and  Part Consolidation

 Erofio Group 3D Produces Mold Core on GE Additive Concept Laser M Line.

3D view of the eight conformal cooling channels

Selektives Laserschmelzen von Kunststoff, Metall, Keramik

Konturnahe Kühlung

Successful Pre-Series Test

Evonik has acquired a minority stake in Chinese company UnionTech through its Venture Capital unit. The Shanghai-based company is active in the field of stereolithography 3D printing.

With the minority stack Evonik strengthens its position in the growth market of additive manufacturing

16:9

Photopolymere

Kunststoff Werkstoffe

Duroplaste

Kunststoff-Erzeugung

Kunststoffverarbeitung

Evonik Acquires Stake in Chinese 3D Printing Specialist

New developments by the raw material producers are responding to current application trends. Requirements are changing due to the advent of networked and semi-automated electric vehicles and the different mobility infrastructure. Products for digitalization and energy and resource efficiency are also moving center stage.

New Mobility Forms and Digitalization Are Shaping the Development of Engineering and High-Performance Plastics

Polyetherketon

Thermoplaste

Polyacrylate

Oberflächenbeschichtung

Holz

Hybridwerkstoffe

Polyacetale

Verbundwerkstoffe / Werkstoffverbunde

Polyamide

Oberflächentechnik

Filamente für additive Verfahren

Oberflächenveredelung

Lohnfertigung

Polycarbonat

Technology Made Easy

On October 16, 2019, on the first evening of the K fair in Düsseldorf, Germany, Carl Hanser Verlag awarded the Dr. Richard Escales prize for the eighth time in memory of the founder of the journal Kunststoffe. Prof. Dr.-Ing. Andreas Gebhardt achieved the award for “outstanding achievements in the advancement of technical knowledge”, as the citation on the certificate states.

Fig. 3. From artwork to replica: the data were read with a hand scanner in about an hour (left); Antonius Köster discusses the result at a 3D fair (center); Stratasys Manager, Michael Eichmann, with a print in virtually the original size (right), which at first glance cannot be distinguished from  the original

Award for Technical Author on Additive Manufacturing

Messe K-Kunststoffmesse

kunststoffe-international.com

Bildverarbeitungs-Software

Fertigungsautomation

Bildverarbeitung

Klotz, Karlhorst, Dr.

Outstanding 3D Achievements

Fiber-reinforced plastic components, including those for load-bearing areas, are established alternatives to metals in vehicle construction. It is not just their low specific weight that makes them interesting, but also their acoustic properties, which reduce noise transmission.

Fig. 1. Internal combustion engine and its connection to the vehicle structure via engine support and support (colored black)

3D Printing Shortens Development Times for Load-Bearing Parts under the Hood

Spritzgießsimulation

Software

Simulation

Functional Prototypes for  Car Components

In a joint project, the Fraunhofer Plastics Technology Center Oberlausitz, the University of Zittau/Görlitz, KraussMaffei and Elbe Flugzeugwerke, have enhanced an extruder-based method for additive manufacturing of large-format plastic parts using a flexible melt pipe.

Thermal analysis of the deposited plastic strand in the large-format, extruder-based 3D printing process

An Alternative Approach to Large-Format 3D Printing with Plastic

Granulate

Extruder

Extrusionsanlagen

Large but still Economical

Würth Additive Group is now a partner for the distribution of the Freeformer in the USA and Canada.

“The Freeformer and APF process allow us to open up completely new possibilities in the field of industrial additive manufacturing,” said AJ Strandquist, chief executive officer for Würth Additive Group.

Machines for the USA and Canada

Both companies aim to open up market access to new large-scale industrial applications in the higher temperature range.

Component made from Evonik’s Infinam PA 6005 P material and produced on a Farsoon system

Evonik and Farsoon Strengthen Collaboration

Italian manufacturer Roboze has equipped its Argo 500 3D printer with automation technology from B&R. The printer offers repeatable high precision and full process control. This reduces lead times and lowers the cost of creating custom metal-replacement components

Roboze uses B&R technology to integrate its 3D printer into industrial production. Customized high-performance plastics can now be processed faster and easier

Steuerungen (Hardware und Software)

Automatisierungstechnik

High-Precision 3D Printing

Rehau is developing an additive manufacturing process that can turn out large polymer manholes in single-unit batches.

Kevin Winter (left) and Jonas Wilfert from Rehau in their 3D printing production environment. Components can have a maximum diameter of 1.2 m and height of 85 cm

Additive Manufacturing Process Revolutionizes Process Chain in Civil Engineering

Hoch- und Tiefbau

Bauwesen

Baubetrieb / Bauwirtschaft

Large Components Custom-Built  in One Week

Over the four trade-show days in November, Formnext 2021 transformed the metropolis of Frankfurt am Main, Germany, into an international innovation center of global additive manufacturing and modern industrial production. At the plastics side, some of the focuses were on the manufacture of voluminous parts, the use of injection molding pellets as a material basis, and the processing of high-performance plastics.

A high-strength carbon fiber-reinforced polyamide is printed on a plasma-treated stainless steel sheet.

Formnext 2021: Successful Relaunch as a Face-to-Face Show

Doriat, Clemens, Dr.

Hochleistungskunststoffe

High-Performance 3D Printing

Additive manufacturing has the potential to manufacture tablets individualized for the particular patient, and thereby further digitalize the pharmaceutical industry. In medication development, the properties of a tablet, such as its shape, dosage or release of the active substance, can be individually tailored – by making just a few changes to the digital 3D print file. Merck scientists have used a Freeformer for their lab tests.

Merck researcher Dr. Thomas Kipping (right) and Nabil Lamrabet value the advantages that the Freeformer offers as an open system.

The Freeformer Allows a Tailor-Made Combination of Several Active Ingredients

Arburg Kunststoff Freiformen

Patient-Specific Tablets

Farsoon Technologies Grows Revenue Despite Corona

Farsoon Technologies is pleased to share news of doubled revenue growth in the Chinese market during Q1-Q3 of 2020 compared to the same period of time in the previous year.

Farsoon Technologies, a leading supplier of industrial grade plastic laser sintering and metal laser melting systems, is pleased to share news of doubled revenue growth in the Chinese market during Q1-Q3 of 2020 compared to the same period of time in the previous year, and will be continue with a significant growth rate until the end of the year.

In the latter half of 2019, with the rapid raising industrial additive manufacturing applications in China, Farsoon made significantly progress with increasing sales orders in major industries such as aerospace, manufacturing, and molding – which offers a strong revenue contribution to the first three quarters of 2020.

Being an important part of the success in 2020, Farsoon’s large-frame metal systems including the FS621M (build platform size of 620×620mm and vertical axis of 1.1 meter) and the FS421M (build platform size of 425 × 425 × 420 mm) offer industrial customers large-sized parts and volume production capabilities that are unique in the additive market. FS621M systems have been installed at various Chinese large-scale manufacturing customers; and the FS421M has an accumulative sale of over 30 systems globally.

Falcontech, a leading manufacturing service provider in the metal additive market, has just received its 20th Farsoon metal system, of which 19 are large-format Farsoon FS621M and FS421M systems – well on the way to their target of 50 machines for Falcontech’s proposed Super AM Factory expansion plan.

Multi-Machines Orders for Plastics Production Systesm

Farsoon’s plastic production platform 403P also sees increasing multiple-machines orders in both China and the global market. Advantages including high-productivity, ease of use, open configurations and economics help customers to achieve high-volume, industrial scale plastic AM production.

WeNext, a key production and prototyping customer, currently has a total of 11 Farsoon plastics produkction systems in operation at their new AM facility. Earlier in June, rapid product manufacturing GmbH (rpm) announced installation of two new machines from Farsoon in replace of their older SLS machines to increase their manufacturing capacity in their factory in Germany. Furthermore, the major laser sintering part producer FKM Sintertechnik in Germany now operates in total four Farsoon plastic production systems, including the Farsoon HT1001P.

After the impact of the Covid-19 pandemic in China during early February, Farsoon headquarters has seen a return to normal operations in Q2 and Q3. The Chinese AM market has seen a good recovery with increasing sales orders. Farsoon’s production operations have expanded to meet growing demand with multiple shifts working 7 days a week to meet machine delivery dates. On the other hand, Farsoon headquarter is planning a large-scale expansion of production facilities in 2021.

In the global market, despite the Covid19 pandemic and economic crisis, Farsoon Europe GmbH has already achieved revenues equal to that of the previous year by end of July, 2020. Farsoon Americas has seen increased business during the second half of 2020 and has actively expanded sales and support capabilities to better serve the North American customers.

Despite the economic challenges in 2020 Farsoon has seen significant growth to its business. With operations returned to normal at Farsoon headquarters we are eager to support our customers and partners both in China and globally to fulfill their needs during these challenging times. With growing production capacity and support capability we are confident in growing the additive manufacturing market going into 2021.

Farsoon Europe GmbH  

https://www.farsoon.com

Falcontech Super AM Factory with currently 20 Farsoon metal 3D printing system.