The traditional markets for glass fiber-reinforced thermoplastics remain stable. Thermoplastic composites are gaining fast with 3D-printing and hybrid processing techniques. The fiber composite industry is tackling the recycling issue with pragmatic ideas.

The Oechsler Drivematic drive actuator can be integrated into the 3D-printed CFRP monocoque frame of an Arevo „e-bike“

The Manifold New Collection of Reactive Systems and Thermoplastic Composites

Glasfasern / -matten

Kunststoff Werkstoffe

Verstärkungsstoffe

Reaktionsharze

Duroplaste

Kohlenstofffasern / -matten

Sekundärfasern

Kunststoff-Rezyklat

Fasern

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Verbundwerkstoffe / Werkstoffverbunde

Aramidfasern

Harzsysteme für Composite-Herstellung

Phenolharze

Harzwerkstoffe

Andere Werkstoffe

Werkstoffe für additive Verfahren

Harze, Epoxid

Duroplastische Werkstoffe

Faserverbundwerkstoffe

Hochleistungskunststoffe

Thermoplaste

Fiber-Reinforced Plastics

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

Anlagen für die Additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Additive Fertigung

Medizintechnik

Anlagen Additive Fertigung / 3D-Druck, Metall

Medical Applications of Additive Manufacturing

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 Stereolithografie, Kunststoff

Anlagen Selektives Lasersintern, Kunststoff

3D-Druck-Anlage, pulverbettbasiert, Metall

SLA (Stereolithografie) Kunststoff

Flüssigmaterialverfahren

3D-Druck-Anlage, strahlbasiert, Metall

Selektives Lasersintern von Kunststoff, Metall, Keramik

Pulverbettverfahren

3D-Drucker (für FDM, FFF, etc.)

Fused Deposition Modeling Kunststoff, Glas, Karbon, Metall

Freiraumverfahren

Finer, Bigger, Faster

Arburg Plastic Freeforming is predestined for the additive manufacturing of medtech components. The associated Freeformer-type additive manufacturing systems process the same plastic pellets that are used in injection molding. That makes the open systems very economical to use.

In the AKF process, resorbable original materials such a plate-implants similar to bone, can be manufactured. They are gradually replaced by endogenous tissue

Medical Product Manufacturers Are Processing Original Materials Using the Freeformer

Anlagen Additive Fertigung / 3D-Druck, andere

Biokunststoffe

Medizinprodukte

Arburg Kunststoff Freiformen

New Possibilities for Use  in the Human Body

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

Ultrafast 3D Printing

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

Additive manufacturing processes count as future-oriented manufacturing techniques. Numerous studies and award-winning demonstrators underline the interest of the industry.

The bicycle frame (600 g, produced in 80 min) is printed directly onto a metal sheet. This combination unites the advantages of two worlds

Plastic-Metal Hybrid Cuts Costs and Time in Additive Manufacturing

Anlagen fÃ¼r die Additive Fertigung

Bleche, BÃ¤nder

Metall Werkstoffe

Verbindungstechnik, hybride

Verbindungstechnik Verfahren

Werkstoffe fÃ¼r additive Verfahren

3D Printing with Pellet Extruded Plastics on Metal

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

Kunststoffverarbeitung: Maschinen und Komponenten

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.

16:9

Spritzgießen

Kunststoffverarbeitung: Verfahren

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.

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

Patient-Specific Tablets

Stereolithography Printer, Material and Curing Oven

3D Systems has developed the SLA 750 stereolithography solution for additive manufacturing of large products or high quantities. It comprises the 3D printers SLA 750 and SLA 750 Dual, as well as the new material Accura AMX Durable Natural and the Post Cure 1050 secondary finishing system.

The SLA 750 Dual, a system for 3D synchronous printing with two laser units, offers up to twofold higher printing speeds and up two threefold faster throughput than SLA printers of the previous generation. The SLA 750 is a single-laser configuration that offers up to 30 % higher printing speeds and can be retrofitted to the SLA 750 Dual on the spot. The units are available from the second or fourth quarter of 2022. Both 3D printers have a 15 % larger build chamber and a smaller footprint than the previous models.

The systems have a self-calibrating Dual Rail Recoater, intended to improve the reliability of the printing process and the mechanical properties of the end product. Both models make use of hyper-scan vector technology. According to the manufacturer, the proprietary scanning algorithm increased important speed and productivity elements, such as laser focus and performance, as well as the kinematics of the vector motor in order to increase the printing speed and throughput.

The SLA-resin Accura AMX Durable Natural was tested acc. to ASTM D4329 and ASTM G194 for its mechanical performance in interior spaces for up to eight years and its weathering resistance outdoors for up to 18 months. The material is claimed to have a load capacity and durability similar to conventional thermoplastics.

The curing times of the secondary finishing system Post Cure 1050 should be much shorter than with comparable units. The 360° light distribution allows multiple parts to be cured within a short time without the need for manual intervention. LED light sources, automatic identification and warning in case of light failure, as well as a one-step light output calibration routine ensure the parts have consistent properties.

3D Systems GmbH  

https://www.3dsystems.com

Resistant material: Accura AMX Durable Natural is suitable for applications with high elasticity and high impact strength. © 3D Systems

High-speed synchronous 3D Printer SLA 750 Dual with two lasers. © 3D Systems

2022-05-03 Produkt 3 - 3D-Systems aus KUint4

issue 03/2022

issue 02/2022

issue 01/2022

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