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

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

Anlagen Additive Fertigung / 3D-Druck, andere

Filamente für additive Verfahren

Formnext + PM South China to Be Postponed

The pathways to plastics can be many – even metalworking in the case of AIM3D. That is what first got this start-up up and running. Fast forward to now and the young Rostock company can cover both bases.

Versatile: the 3D printer developed by this young company can process virtually all fusible materials.

16:9

Start up

Wirtschaft

Unternehmen und Unternehmer

When We Break through  Material Boundaries

To an increasing extent, additive manufacturing is finding its way into series production. This was clearly shown at last year’s Formnext.

T-Crow night vision camera: except for the electronic components, the entire stand is produced additively. 

Polyetherketon

Kunststoff Werkstoffe

Thermoplaste

Streifinger, Florian

Ehrhardt, Melanie

Hochleistungskunststoffe

Print-Ready for Series Production

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.

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

Luft- und Raumfahrt

Fahrzeugbau

The First 3D Printed Helicopter Cradle

3D printing is a fast-growing market, opening up completely new product and manufacturing options for customers and industry. The newly developed SEAM process significantly extends the options for the efficient manufacture of printed components. An impression of this is conveyed by the example of a fiber-reinforced clamping fixture.

Vacuum clamping fixture of a B-column segment, manufactured by the SEAM process 

Additive Manufacturing of Plastic Components in a High-Speed Process Using Standard Pellet Stock

Faserverbundwerkstoffe

Ultrafast 3D Printing

Researchers have developed software that can adjust important parameters during the printing process.

Miaozi Huang‘s team uses intelligent software in 3D printing to optimize the properties of plastic components.

Software Optimizes Properties of the Components

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

Additive

3D Printing with Less Gloss

With the Formiga P 110 FDR polymer system, extremely fine and yet stable components can be realized.

EOS Introduced New FDR System

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

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

Polyacrylate

Oberflächenbeschichtung

Holz

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

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

Biologic Models, US-based 3D-printed protein model and medical animation provider, is using Mimaki’s 3D printing technology to produce intricate molecular visualization models, bringing protein into the tangible world in incredible detail.

Virus model of SARS-CoV-2 produced with the 3DUJ-553 full color 3D printer

3D Printer Enables Precise Models of Protein Cells

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.

For four days, Formnext 2022 turned host city Frankfurt into the global capital of industrial 3D printing. In addition, this year’s exhibition was very much in tune with the times. The numerous innovations demonstrated that AM can help to decentralize processes and production and make supply chains more resilient, conserve resources and produce with less energy consumption.

A glance at the figures shows just how important Formnext has become. With 802 exhibitors (the corresponding figure in 2021 was 606) and 51,148 m² of booked exhibition space, the performance of the world’s leading exhibition for additive manufacturing and modern production was virtually on a par with pre-Covid levels. And with the lineup of eager experts and executives expanding by 65.6% to 29,581 (the corresponding figure in 2021 was 17,859), Formnext 2022 was a testament to the enthusiasm that exists for meeting and sharing ideas face-to-face. These figures confirm the impressive record of accomplishment of the event, which is now in its eighth year.

Leading international companies such as 3D Systems, Additive Industries, AddUp, Arburg, BigRep, Carbon, Desktop Metal, DMG Mori, Dyemansion, EOS, Farsoon, Formlabs, GE Additive, HP, Keyence, Markforged, Materialise, Renishaw, Ricoh, Siemens, Sisma, SLM Solutions, Stratasys, Trumpf, Voxeljet, XJet, and Zeiss dazzled visitors with even more efficient production systems and an array of innovations. In addition, numerous well-known international corporations, including BASF, Covestro, Evonik, GKN Sinter Metals Components, Henkel, Höganäs, Linde, Mitsubishi Chemical, Nikon, Oerlikon, Sandvik, SMS Group, and many more presented innovative solutions for every stage of the process chain. The numerous world premieres and innovative developments included novel AM technologies and new and improved AM systems, as well as new materials ranging from wood to ceramics, software solutions, service offerings, post-processing solutions, and much more.

“We are proud of the fact that Formnext has returned to its impressive pre-Covid level,” says Sascha F. Wenzler, Vice President Formnext at event organizer Mesago Messe Frankfurt GmbH. “We have once again demonstrated the importance of Formnext as the world’s premiere AM platform and the vital role of face-to-face interaction at Formnext for the further development of this highly innovative sector.”

Visitors to the event were impressed by how Formnext has grown and by the sheer number of innovations on show. “The possibilities of AM are limitless and we have to unleash this potential in a way that ensures more sustainable manufacturing“, states Frank Rosengreen Lorenzen, CEO at Danish AM Hub. “Having Formnext as the world’s leading meeting point to discuss and develop these opportunities is of extreme importance for the AM ecosystem, but also for manufacturing as a whole.”

Alex Kingsbury, Industry Consultant at Additive Economics underlines the importance of AM for industrial production and states: “As modern manufacturers look to become more agile and responsive, they inevitably need to look to advanced and emerging technologies. Additive manufacturing is an innovative technology that when properly harnessed can supercharge manufacturing capability. Formnext is the world’s premier 3D printing event that showcases the depth and breadth of additive manufacturing hardware, software, materials. Despite the fact that you can access additive manufacturing technology from all over the world, Formnext remains the center of gravity where everyone in the AM ecosystem converges.”

Formnext’s partner country France cemented its status as one of the world’s most important suppliers and users of additive manufacturing solutions. In total, more than forty French companies, associations, and research institutes were represented at Formnext. French AM manufacturers such as AddUp, Lynxter, Constructions3D, Pollen AM and VLM Robotics, material manufacturers Fabulous and Constellium, and numerous other exhibitors displayed their exciting innovations and impressive additive manufacturing expertise.

The French delegates’ presentations on the AM4U stage on Wednesday afternoon covered a wide range of themes, from research and development, through automotive and aerospace applications, to sporting goods and international strategies for the widespread use of additive manufacturing in Europe.

A Broad and Varied Program of Supporting Events

The program of supporting events at Formnext 2022 was broader and more varied than ever before, leading visitors through the world of innovative startups, 3D-printed houses, and cutting-edge applications in medical technology.

Recurring themes included the implementation of decentralized additive manufacturing, the promotion of sustainable manufacturing solutions, and the growing maturity of additive manufacturing in the industrial setting.

The special “BE-AM | Built Environment Additive Manufacturing” showcase and symposium provided an impressive demonstration of how 3D printing can be used in architecture and construction. The showcase by the VDMA’s Additive Manufacturing Association presented applications and developments in industrial 3D printing for tools, machine components, prototypes, and much more besides.

For the eighth time, the international Formnext Start-up Challenge has recognized young companies from the world of additive manufacturing for their innovative business ideas and technical developments. Visitors once again flocked to the Pitchnext event, where start-ups competed for the attention of investors. The purmundus challenge ideas competition celebrated its tenth anniversary with a reception and a special show entitled “Best of 10 Years.”

The Discover3Dprinting seminars were another popular port of call every day during the exhibition, especially for newcomers to additive manufacturing. The seminars are set to continue at various locations throughout 2023. Participants at the TCT Conference @Formnext got an opportunity to experience and discuss numerous exciting applications and to catch a glimpse of the future of additive manufacturing. On 14 November, the day before the start of the exhibition, the ASTM Standards Forum focused on the importance of standards and standardization for 3D printing. On the same day, the new “Wohlers Report LIVE at Formnext 2022” event celebrated its debut at Formnext 2022.

With attendees from 96 nations and a remarkably high proportion of international visitors (51%) and exhibitors (58%), Formnext once again demonstrated its status as the leading international trade fair for additive manufacturing and modern industrial production.

The impressive volume of visitor traffic and the high standard of discussions were also applauded by exhibitors: “Formnext is always a pool of ideas at which people inspire each other. We’ve managed to attain a great number of leads, had very qualified visitors with concrete projects and are returning home with equally concrete orders,“ affirmed Johannes Matheis, Managing Director at Murtfeldt Additive Solutions GmbH.

Andreas Rudolf, MDM Additive Manufacturing at nLight is equally enthusiastic: „If you want to visit a trade fair on the subject of additive manufacturing, this is it. There is no way around Formnext. All of our target groups from the automotive, aerospace, medical and contract manufacturing sectors, among others, were here on-site with the best teams. This includes OEMs and especially end users, who are otherwise difficult for us to reach.“

For the first time, Desktop Metal united a company portfolio of nine companies on a European booth: „We reached a very international audience with a great many new contacts. The stand visitors, including representatives from the oil and gas industry, OEMs from the automotive sector and foundries, were pre-informed and came to us with concrete projects and budgets. There were business deals for our sand, polymer and metal equipment,“ reports Guersel Demircali, Vice President EMEA Sales Channel, Desktop Metal.

Mesago Messe Frankfurt GmbH  

https://www.mesago.de

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

2022-11-21 - Formnext 2022

All content from the AM4U stage as well as impressions, opinions, and more were recorded for viewing after the event on Formnext.TV on Demand. Together with AM4U, Formnext remains an innovative driving force in additive manufacturing all year round, with the AM Directory, Formnext.TV, Formnext Magazine, AM Field Guide, and much more besides.

The 2023 edition of Formnext is scheduled to take place from 7–10 November in Frankfurt am Main.

Formnext’s portfolio of international events includes:

<ul><li>Formnext + PM South China: 20–22 December 2022</li><li>Formnext Forum Austin: 28–30 August 2023</li><li>Formnext Forum Tokyo: 28–29 September 2023</li><li>Formnext + PM South China: September 2023</li></ul>

Further information is available at <a href="https://formnext.mesago.com/frankfurt/en.html" target="_blank">formnext.com</a>.