With K 2016 in Düsseldorf, Germany, and formnext in Frankfurt/Main, Germany, professionals with an interest in additive manufacturing had two opportunities last year to gain a sense of the spirit of innovation in the industry. One issue was particularly prominent: the increase in production efficiency. This improves the economy of using the different 3D printing processes. 

A Diversity of Suppliers and Physical Cross-Linking Make Possible New Business Models and Application Scenarios for Additive Manufacturing  

Steuern, Regeln

Werkstoffe für additive Verfahren

Additive Fertigung

Rapid Prototyping

Rapid Manufacturing

Selektives Laserschmelzen von Kunststoff, Metall, Keramik

Selektives Lasersintern von Kunststoff, Metall, Keramik

Faserverarbeitung

Spritzgießwerkzeuge

Industrieroboter

Qualitätssicherung

All Elements at a Glance 

Much as when injection molding materials were being developed 30 years ago, the current trend in additive production is toward higher melting materials and materials with improved mechanical properties. The latter can be achieved, for example, by fiber embedding. In machine technology, the developments are increasingly aimed at adapting processing times, sensor systems, and quality monitoring to the demands of high-tech companies.  

Materials Manufacturers and Process Developers Face Growing Demands in 3D Printing  

Biokunststoffe

Kohlenstofffasern / -matten

Rapid Tooling

Pulver-Spritzgießen

Schleifen, Polieren

Additive Adolescence 

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.

Status and Perspectives for Human Medicine

Anlagen für die Additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Medizintechnik

Anlagen Additive Fertigung / 3D-Druck, Metall

Andere Werkstoffe

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.

Additive Manufacturing and Hybrid Molds in Combination with Conventional Machining

Spritzgießen

Kunststoffverarbeitung: Verfahren

HSC- / HPC-Bearbeitung

Spanende Verfahren

Werkzeugkonstruktion

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

The Potential of Redesign and  Part Consolidation

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.

3D-Druck-Anlage, strahlbasiert, Metall

Farsoon Technologies Grows Revenue Despite Corona

In order to avoid bubble ruptures during the production of blown film, the velocity of the cooling air is often reduced. The use of air guiding systems (AGS) can prevent such bubble instability. A novel AGS was developed at IKV in Aachen, Germany, using iris diaphragms in order to increase the cooling efficiency of blown film extrusion and thus improve the productivity of an existing plant

Increase in Mass Throughput and Improved Mechanical Product Properties

Extrusion

Blasfolienextrusion

Nachhaltigkeit

Umweltmanagement

Kühlanlagen

Konturnahe Kühlung

Energieeffizienz

Extrusionsanlagen

Extrusions-Zubehör

Flexible Guiding Systems  for Cooling Air

The production costs for complex injection molded parts not only depend on material costs but also to a considerable extent on cycle time. The cycle time is divided into the injection, holding pressure, (residual) cooling phases and the tool movements. The cooling phase takes up 60 to 90 % of cycle time, depending on the particular plastic material and part component. Adequate cooling can therefore reduce not only cooling time but also cycle time.

Improving Conformal Cooling with Design, Simulation, and Processing Know-How

Werkzeug- und Formenbau

Kühlelemente, aktive

Elektromechanik

Kühlkörper

Fine Channels, Maximum Efficiency

Buzz words such as rapid prototyping (RP) and additive manufacturing (AM) are more relevant than ever in medicine. But only a few experts would know that the additive processes underlying these concepts have been employed in healthcare with growing success for more than three decades. Major care centers now routinely employ 3-D planning and 3-D printing in highly specialized surgical disciplines, such as oral and maxillofacial surgery. 

An Innovative Manufacturing Process for Custom PEEK Implants 

Polyetherketon

Custom Implants for Humans  from a 3-D Printer 

Over 6,500 visitors from 55 nations flocked to the Arburg Technology Days 2016. With approx. 50 exhibits, the Black Forest-based machine maker presented a comprehensive overview of its latest activities in injection  molding, additive manufacturing and on the topic of "Industry 4.0 in plastics processing". The highlight of the event was the world premiere of a new electric machine series. 

World Premiere of the "Golden Electric" Electric Machines Series 

Automatisierungstechnik

Industrie 4.0

Spritzgießmaschinen

Gold Fever 

Royal DSM is partnering with Nexeo Solutions, a global chemical and plastics distributor, to bring new, high-value, performance filaments to customers who do 3-D printing using fused deposition modeling (FDM) technology. 

High-Performance Filaments for 3-D Printing 

Polyamide

Arnitel ID and Novamid ID 

When it comes to 3D printing hair or fur, the problem is not so much the printing itself, but rather the generation of the necessary three-dimensional model. The usual CAD software requires an extreme amount of time, frequently taking the computer hardware to its limits.  

MIT Software Cilllia for Generative Manufacturing of Delicate Structures 

Technik Trend

kunststoffe-international.com

3D Printing: A Hairy Issue  

Using a sophisticated, custom-designed 3D printer, regenerative medicine scientists at Wake Forest Baptist Medical Center, Winston-Salem, NC/USA, have proved that it is feasible to print living tissue structures to replace injured or diseased tissue in patients. 

Ear, Bone and Muscle Structures from the Printer 

Thermoplaste

3D Printing of Replacement Tissue 

On the eve of the K 2016, and following the two most successful years in the company’s history, Arburg is cloaked in silence – as far as the planned product launches in Düsseldorf are concerned. Meanwhile, the newly opened factory in the Lossburg parent plant fuels speculations about an advance into the large machine sector. 

Arburg Enjoys Booming Business and Keeps its Plans for the K Show Secret 

Guessing Games 

Stratasys Ltd. offers world’s only 3D printer to produce full color, multi-material prototypes and parts in a single 3D print, eliminating time-consuming processes and accelerating product concepting, design, decisions, and delivery. The J750 enables customers for the first time to mix-and-match full color gradients alongside an unprecedented range of materials to achieve one-stop realism without post-processing. 

One-Stop Realism Drives near Instantaneous Decision-Making 

3D Printer J750 

Preventive maintenance, autonomous readjustment in ongoing processes, large-scale production in lots of just one item, human-machine collaboration – K2016 had a treasure trove of Industry 4.0 technologies in store for visitors. Injection molding machine makers and their partner companies from the fields of toolmaking, automation and sensor technology especially did not hold back on their sample applications. 

K 2016 Makes the Digitization of the Industry Tangible 

Instandhaltung

ERP-Systeme

Werkzeugwechselsysteme

Werkzeugwechselsysteme, Spritzgieß

Instandhaltungsmanagement (TPM)

A Treasure Trove of "Industry 4.0" Technologies 

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

Erofio Group, a long-standing user of GE Additive’s DMLM laser technology (Direct Metal Laser Melting), was selected to test and put the GE Additive Concept Laser M Line through its paces ahead of its commercial readiness. Less than three months since receiving and installing an M Line system at its mold making facility in Batalha, Portugal, Erofio has successfully 3D-printed its first mold core.

The Core was manufactured using M300 hot work tool steel – a material often used for the production of injection molding and die-casting tool inserts with conformal cooling, as well as functional components. The Core contains more than eight independent, internal conformal cooling channels, stretching over 8 m in length and between 5 to 8 mm in diameter. Additively manufacturing the part affords the team the design freedom to enable conformal cooling to create a more efficient heat exchange. This improved cooling will increase the overall plastic injection process productivity through decreased cooling cycle time and warpage, and the improvement of the injected plastic part aesthetics.

In addition to the benefits of geometric freedom on the design of inner channels, using additive manufacturing has reduced finishing requirements by 90 %. Another advantage identified, when compared with conventional manufacturing processes, was a reduction in the total manufacturing time – from powder to mold assembly -- by 30 %. According to the company, this involved making only very minimal changes to the existing parameters of the Concept Laser M2 Series 5 to adapt it for the M-Line system. Following remote optimization support from the GE Additive team in Lichtenfels, the part was successfully printed on its first attempt, over a six-day period.

CONCEPT Laser GmbH  

https://www.concept-laser.de

EMG  

https://www.emg-pr.com

The finished tool insert made of M300 hot work tool steel produced on a Concept Laser M Line

3D view of the eight conformal cooling channels

2021-11-22 GE_Additive_cd

Verfahren für die additive Fertigung

Pulverbettverfahren

issue 08/2021

issue 07/2021

issue 06/2021

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