Arburg GmbH + Co. KG, Loßburg, Germany, is new on the market with its Freeformer 300-3X. The large machine will process three components using the Arburg Plastic Freeforming (APF) process, enabling the industrial additive manufacturing of complex functional parts in resilient hard/soft combinations with support structure as a world first. 

More Applications for Arburg Plastic Freeforming 

Additive Fertigung

Resilient Functional Parts in Hard-Soft Combination 

Audi expects significant reduction in prototyping lead times for tail light covers by using a full color 3D printer. Compared to traditional methods, the turnaround times should be halved. The Stratasys J750 makes it possible to produce transparent, multi-colored parts meeting texture and color-matching requirements of Audis stringent design approval process . 

Audi Shortens Release Cycles with Full-Color Multi-Material 3D Printing 

Design in the Fast Lane 

As part of a collaborative initiative, the Brightlands Chemelot Campus focuses on the development and implementation of advanced additive manufacturing technologies. Three current biomedical projects illustrate the multiple possibilities for start-up companies in this market. 

Medical Device Developments at the Brightlands Chemelot Campus 

Polyamide

Medizintechnik

Breeding Ground for Additive Manufacturing 

Arburg Plastic Freeforming (APF) is based on qualified original materials in the form of plastic granulates as used in injection molding. Current researches illuminate influences on the resulting part quality of this additive process. Because the open system permits adaptation of the parameters, the mechanical and geometric properties of the parts can be optimized in a targeted manner. In this way, tensile strengths and part densities comparable to those of injection molded parts can be achieved. 

Arburg Plastic Freeforming: Current Investigations on Part Optimization 

Rapid Manufacturing

Werkstoffprüfung, mechanisch

Droplets to the Beat of Milliseconds 

A new joint venture is getting a hybrid manufacturing cell ready for market. A screw-based plasticizing unit is mounted on a 6-axis robot. The novel processing approach facilitates additive manufacturing of structural parts from granular and fiber-reinforced standard compounds.   

High-Speed Additive Manufacturing of Fiber-Reinforced Structural Parts 

Compound

Kohlenstofffasern / -matten

Flexible Fertigungssysteme

Layer-by-Layer from Granulate to Part 

ElogioAM B.V., a newly formed Joint Venture between Swedish Perstorp AB and Dutch 3D4Makers B.V, introduces new filament solutions. Facilan HT is specifically designed for 3D printing. It is a safe copolyester with high temperature resistance with heat deflection temperature of 89°C. Its high stiffness enables design optimization for faster rigid part print jobs. 

Joint Venture Introduces New Filament Solutions 

Kunststoff Werkstoffe

Durable Parts with Facilan HT 

Researchers at the Massachusetts Institute of Technology (MIT)  have shrunk 3D objects to nanoscale. The scientists' approach is based on a framework made of polyacrylate. It is a very absorbent material commonly found in diapers.   

System Produces 3-D Structures One Thousandth the Size of the Originals 

Technik Trend

kunststoffe-international.com

Shrink Objects to the Nanoscale 

The combination of luminous fibers with plastics or fiber reinforced-plastics will open up a future-oriented field for functionalizing lightweight materials. Designers will appreciate being able to create previously unperformable filigree contour lines and uniform lighting effects on components. 

Accessing New Fields of Application by Integrating Optical Fibers 

Verbundwerkstoffe / Werkstoffverbunde

Faserverarbeitung

Spritzgießen

Mehrkomponenten-Spritzgießen

Hybridtechnik

Pultrusion

Gewebe, technisch

Luminous Fibers as Design Elements  in Plastics Parts 

Evonik has become the first company in the world to develop a polymer filament based on PEEK (polyether ether ketone) in implant-grade quality for use as a 3D printing material for implants. This high-performance material can be used in fused filament fabrication (FFF) technology and is expected to enable additive production of three-dimensional plastic parts for medical implants in the human body. 

Evonik Develops PEEK Filament for Medical Use 

Kunststoffverarbeitung: Maschinen und Komponenten

Kunststoffhandel

3D Printing Filament in Implant-Grade Quality  

The development of additive manufacturing processes, such as selective laser melting (SLM), has significantly extended the options for manufacturing extrusion heads. Extrusion head designs can now be realized with very slender geometries, which not only have integrated mixer functions, thereby improving the melt homogeneity, but can also be used to attach the mandrel to the head. This allows compact heads to be manufactured with a very high potential for saving operating costs. 

Improved Extrusion Head Designs thanks to Additive Manufacturing 

Extrusionswerkzeuge

Blasformwerkzeuge

Blasformen

3D-Printed Minimalists 

Evonik Resource Efficiency GmbH, Essen, Germany, has developed a polymer powder for applications in higher temperature range as part of its polyamide 6 series. 

Temperature-Resistant PA Powder for 3D Printing 

Selektives Lasersintern von Kunststoff, Metall, Keramik

Thermal Properties Modified 

Additive manufacturing processes provide a very high degree of design freedom and short development times. However, the nature of the process and the limited size of build chambers restrict the size of such components. Adhesive bonding enables additively manufactured components to be joined together to form large parts. 

Increase of the Adhesive Strength by Modification of the Surfaces 

Chemisches Fügeverfahren

Advancing into New Dimensions 

A gap exists between growth in equipment sales and numbers of manufactured parts. Most likely, a lot of experimentation is still going on. A symposium provided insights into projects, problems and prospects for additive manufacturing. 

Additive Manufacturing ¿ Between Growth Euphoria and a Sense of Reality 

Fluorkunststoffe

Putting 3D Printing to the Test 

The machine manufacturer Arburg has introduced an operating example of a digitalized AM-factory (additive manufacturing) at Hannover Messe 2019 (Hanover Fair). A turnkey system will functionalize vacuum grippers in six different versions "on demand" ¿ fully automated and 100 percent traceable. The new ATCM Scada-System simultaneously collects, visualizes, and transmits the relevant processing data. 

Fully Automated Traceable Additive Manufacturing of Small Batches and Single-Unit Parts 

Automatisierungstechnik

Industrie 4.0

Industrieroboter

Rückverfolgbarkeit, Traceability

Gripper Variants According to  Customer Requirements 

Injection is the process step in injection molding that is most quality critical. The injection speed profile and its reproducibility have a direct influence on the internal and external properties of a part. The adjustment of the injection step is therefore of particular importance. Engel injection-molding machines with electrical injection units now feature optimized setpoint computation of this profile, with clear visualization, which increases the process transparency and ease of operation. 

Improved Setpoint Calculation of the Injection Speed Profile 

Dynamic Injection ¿ Made Easy 

IKV develops process for non-planar additive manufacturing with a jointed-arm robot and screw extruder.

The IKV has developed a process for non-planar additive manufacturing with jointed-arm robots and screw extruders. Compared to conventional additive manufacturing, the surface roughness can be reduced by up to 76 %.

Through the layer-by-layer production of plastic parts, additive manufacturing offers a high level of geometric freedom. Components with complex geometries and internal structures can be quickly manufactured without any set-up operations. However, these layers have until now always been planar in form and aligned parallel to the construction platform. Compared with other manufacturing technologies, layer-based processes thus have disadvantages with regard to the surface quality of the parts, caused by the step effect. Because of the lower load resistance in the build direction (attributable to the adhesion between the individual layers), the mechanical properties of the component are also anisotropic. In order to overcome these difficulties, a process for non-planar additive manufacturing with variable layer thickness was developed at IKV. With this method of path planning, it was shown that the surface roughness can be reduced by 76 % compared with conventional additive manufacturing.

With non-planar additive manufacturing, the exact form of the component and the existing load cases are taken into account when calculating the machine code. The layers generated in this way can be freely arranged in the space and can be curved. This applies both to the layers on the outer sides of the components for producing high-quality surfaces and for all layers on the inside of the component. The latter allows the specific exploitation of the technology-related anisotropy through the load path-oriented design of the individual plastic strands. The variable layer thickness, which is achieved through the specific variation of the material output, allows a gap-free transition between different curvatures and orientations.

Larger Parts, Material Variety And Accelerated Production

In order to increase the size of the part, the diversity of materials and the production rate, the implementation of non-planar path planning on a large-volume additive manufacturing screw extruder – IKV‘s hybrid production cell – is being examined in a research project. The machine‘s robot arm allows a large build volume and the use of three additional freedom levels, which are utilised to adjust the extruder according to the gradient of the component to be manufactured. In this way, the quality of the part can be further improved. In addition, the possibility exists of adjusting the load path with large-volume additively manufactured parts. By processing fibre-filled standard granules, which show very good mechanical properties in the strand direction, in combination with the specific orientation of the individual strands by non-planar additive manufacturing, the technology-related anisotropy can be exploited. This technological lead is especially relevant in the industrial application of additively manufactured parts.

IKV‘s hybrid production cell for the additive manufacturing of large-volume parts.

16:9

2022-07-27 - IKV

Additive Manufacturing at the 31st IKV Colloquium

Additive manufacturing will be the topic of Session 14: Additive manufacturing of large components with a keynote speech from industry by Dr. Wolfgang Meyer, Head of Central Function and Innovations, Volkswagen AG and two scientific presentations by IKV. For further information cklick <a href="https://en.kunststoffe.de/a/news/research-meets-practice-2769135" target="_blank">here</a>.

issue 08/2022

issue 07/2022

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