The Formnext 2022 shows that AM can help to decentralize processes and production and make supply chains more resilient, conserve resources and produce with less energy consumption.

Formnext 2022 took place from November 15 to 18 in Frankfurt am Main, Germany.

16:9

Verfahren für die additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, andere

Anlagen für die Additive Fertigung

3D-Druck-Anlage, pulverbettbasiert, Metall

Anlagen Additive Fertigung / 3D-Druck, Metall

3D-Druck-Anlage, strahlbasiert, Metall

Filamente für additive Verfahren

Andere Werkstoffe

Werkstoffe für additive Verfahren

3D-Drucker (für FDM, FFF, etc.)

Additive Fertigung

The Future of Industrial Manufacturing

The trade fair will take place in autumn 2023 at the Shenzhen World Exhibition and Convention Center.

Formnext + PM South China to Be Postponed

Additive manufacturer Grafe has developed a new update for its matting agent in 3D printing.

Compared to its predecessor, the matting agent halves the gloss level once again. 

Farbstoffe und Pigmente

Kunststoff Werkstoffe

Additive

3D Printing with Less Gloss

The MERCUR research project Pr-2017–0003 „Analysis of the product development process in the combination of additive and subtractive manufacturing processes for the manufacture of multi-material products“ combines different manufacturing and post-treatment processes to connect the respective advantages.

Polyamide

Thermoplaste

Investigation of the influence of various post-treatment methods on the properties of additive manufactured FDM Nylon 12 samples

Besides compounds modified for special applications and lightweight components, sustainable materials are also becoming an increasingly important focus. In the additives sector, too, recyclates, the circular economy, and reprocessing are now playing a key role.

Not only Polymers but also Additives and Masterbatches Must Be Sustainable

Zubehör / Hilfsmittel Wärmebehandlung

Wärmebehandlung

Compound

PVC-Additive

Masterbatches

Vernetzungsmittel

Compoundeure

Dienstleistungen

Handel

PVC-weich (Compounds)

Farbkonzentrate (Batches)

Farbstoffe

Verarbeitungshilfsmittel, allgemein

Flammhemmende Mittel, allgemein

Betriebsausrüstung / Betriebsmittel

Verarbeitungshilfmittel

Flammschutzmittel

Gleitmittel für Kunststoff

Attention to Detail

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

Polyacrylate

Oberflächenbeschichtung

Holz

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Hybridwerkstoffe

Polyacetale

Verbundwerkstoffe / Werkstoffverbunde

Oberflächentechnik

Oberflächenveredelung

Lohnfertigung

Polycarbonat

Technology Made Easy

At the Institute of Polymer Materials and Plastics Technology at the Technical University of Clausthal the requirements of the process were investigated, especially with regard to the necessary preparations and conditions of the plant periphery.

Extrusion of Carbon Fiber-Reinforced Polyetheretherketone (PEEK)

Extrusion of Carbon Fiber-Reinforced Polyetheretherketone

Extrusion

Kunststoffverarbeitung: Verfahren

Faser- und Filamentextrusion

Faserverbundwerkstoffe

Manufacture of FFF-Filaments

Polymaker will offer the Polymaker PC-r 3D printing filament made from recycled polycarbonate (PC). The PC for the filaments comes from materials supplier Covestro and consists of a combination of recycled plastic waste and virgin material.

The combination of recyclates and virgin material reduces the<sub> </sub>carbon footprint of the polycarbonate and still allows it to be extruded into filaments

Technische Kunststoffe

Kunststoff

Bauwesen

Baustoffe

Kunststoff-Rezyklat

Water Bottles Become Filaments

Robotics meets additive manufacturing: when Kuka robots produce furniture, they do not take work away from carpenters by any means. The chair and bench modules made of recycled hospital waste, named Twine – designed by HagenHinderdael in London – are a novelty in the world of furniture, engineering, and recycling.

Designers Lisa Hinderdael (left) and Sofia Hagen present a better side of plastic waste. The KR Quantec used to print the larger Twine elements is in the background.

Recycled Hospital Waste as Raw Material for 3D-Printed Furniture

Nachhaltigkeit

Umweltmanagement

Industrieroboter

Montagetechnik

Resting in Good Conscience

J850 TechStyle 3D printer enables haute couture and luxury brands to 3D print on fabric — achieving new levels of creativity in fashion and design.

SSYS 2Y22 design by Jasna Rokegem and Travis Fitch

3D-Drucker J850 TechStyle von Stratasys ermöglicht Haute-Couture- und Luxusmarken den 3D-Druck auf Stoff für äußerst kreative Mode und kreatives Design,

Textil-, Bekleidungs-, Ledergewerbe

Stratasys Introduces 3D Printer for Fashion Industry

In order to minimize the development time for new products, Geberit International AG manufactures many prototypes using 3D printing. Since 2016, the Swiss company uses a Sintratec S1 for design optimization and material testing in its prototyping laboratory. A visit to Switzerland.

On the left the prototype of the valve connection angle made of Sintratec TPE and on the right the series component made of EPP

Geberit: „Selective Laser Sintering Really Sparks our Imagination“

Anlagen Selektives Lasersintern, Kunststoff

Rapid Prototyping

Sanitary Prototypes with  High Requirements

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

Anlagen für die Stereolithografie, Kunststoff

SLA (Stereolithografie) Kunststoff

Flüssigmaterialverfahren

Selektives Lasersintern von Kunststoff, Metall, Keramik

Pulverbettverfahren

Fused Deposition Modeling Kunststoff, Glas, Karbon, Metall

Freiraumverfahren

Finer, Bigger, Faster

In addition to numerous new developments of the exhibitors, especially the versatile and extensive supporting program should convince the visitors.

Verbände, Institutionen, Messen

Almost at Pre-Pandemic Levels

Stratasys will showcase additive manufacturing solutions for every stage of the product value chain at Formnext under the theme “Let’s Talk Manufacturing”.

Components printed with Covestro‘s Somos PerFORM resin using a Neo stereolithography 3D printer.

Stratasys Shows Automated Post-Processing Cell

To ensure that a camera tripod remains attractive and universally useful, an ability to make quick adjustments is hugely important – this is the perfect scenario for 3D printing.

T-Crow is a practical and convenient way to capture images of living creatures and wildlife from inside a vehicle.

To ensure that a tripod remains attractive and universally useful, an ability to make quick adjustments is hugely important – this is the perfect scenario for 3D printing.

 Series Production thanks to a Combination of SLA and SLS

Elektrotechnik, Elektronik

360° Vision in the Dark

For a current project, Leonardo found that the existing brackets did not meet the requirements and turned to SFM Technology. The result: the first helicopter cradle from the 3D printer.

Main rotor blade restraint cradles on helicopters prevent the blades from flapping, among other things. For a current project, Leonardo found that the existing brackets did not meet the requirements and turned to SFM Technology. The result: the first helicopter cradle from the 3D printer.

Rough seas not only make smooth sailors. They also make smooth engineers who can find innovative solutions to choppy conditions. This is especially true when it comes to aviation, as helicopters are frequently tasked with embarking onto ships during all different types of weather conditions.

Once helicopter flying operations have ceased, helicopters will either stay on the flight deck or be stowed in the ship’s hanger. Helicopters use automatic folding software, folding in their blades like a bumblebee. Nonetheless, the issue of stabilization remains a key priority when it comes to the smoothest embarkation possible. This is achieved by using a main rotor blade restraint cradle.

Nonetheless, as Gary Wilson, head of Technical Sales at the AeroAddtive divisionby SFM Technology tells: „When a helicopter is on board a ship, it has the facility to fold its helicopter blades back. Once the helicopter blades are folded back at sea, it‘s still windy, and the blades can flap. So, these blades need to be restrained so this flapping doesn‘t occur.“

For the aerospace company Leonardo – tasked by the Ministry of Defence to provide AgustaWestland AW101s for the Royal Navy – they found that their pre-existing main rotor blade restraint cradles were not living up to their standard. Leonardo turned to SFM Technology and their AeroAdditive section to provide a solution. The result was the first main rotor blade restraint cradle – measuring 900 x 230 x 160mm – created with 3D printing.

As a solution had to be found very quickly, SFM turned immediately to the possibilities of additive manufacturing. “This is quite a long process, so we had a look at many aspects of 3D printing. We must look at cost, efficiency, and of course, the size, which pushed us to BigRep. Eventually, we looked at the BigRep Pro as we had to look at a production 3D printer, which I believe the BigRep Pro can provide. The machine is used as a production machine, so every rotor blade restraint cradle will be going to the end customer“, Wilson says.

In the aerospace industry, lightweight yet strong parts are essential. SFM Technology found through stress-testing that their 3D-printed printed parts performed better than original, non- printed parts. By using Hi-Temp CF – a carbon fiber reinforced material with versatile, high- strength properties – the blades have a powerful resistance to wear and tear as well as any external pressure.

The benefits have been manifold. As Wilson attests, “To date, we have printed 30 cradles, consisting of 60 halves, since January. If we were to do that in a traditional way, we would have done about a quarter of that. So, you can see that 3D printing is far quicker, as we don’t have any adjustments to make, or if we do, they’re very minor and can be quickly overcome. And the material is just as strong.”

Choosing the right material was crucial in SFM’s choice. As Mr. Wilson mentions, “We carried out many tests to establish which was the most suitable material within the budget given. Having looked at the data sheets, we felt that Hi Temp had a slight advantage over the other BigRep materials.”

Once they remove the support material, they use sandpaper and its equivalents to smooth the surface. Then bushes are inserted in the hinges, before using helicoil inserts when required. Once the cradle is painted to the customer’s specification, the rest of the metal parts are added along with the foam on the inside of the cradle, protecting the main rotor blade when the restraint cradle is fitted.

With the main rotor blade restraint cradles already in use, Mr. Wilson attests that this experience shows what 3D printing can achieve in the aerospace industry and that it‘s only a matter of time before additive manufacturing becomes the norm. “In the aerospace industry, there are many designers still slightly nervous about 3D printing. By using these cradles, we can demonstrate that 3D printing can be used in the aerospace industry quite comfortably from a strength, repeatability, and quality side. I know for a fact, that as the industry gets more technically forward on 3D printing, certainly there will be more and more paths because of the accessibility to them.“

The AgustaWestland AW101, called the EH101 until 2007, is a medium-weight military transport helicopter.

Main rotor blade mount for AgustaWestland AW101.

The attached brackets: SFM Technology now intends to use the BigRep Pro as a batch 3D printer.