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

Werkstoffe für additive Verfahren

Additive Fertigung

Rapid Prototyping

Rapid Tooling

Rapid Manufacturing

Selektives Laserschmelzen von Kunststoff, Metall, Keramik

Selektives Lasersintern von Kunststoff, Metall, Keramik

Spritzgießwerkzeuge

Pulver-Spritzgießen

Schleifen, Polieren

Additive Adolescence 

It is a hot runner nozzle such as had never been seen before Fakuma 2021: with a honeycomb structure on the outside and, in the nozzle interior, integrated insulation gaps manufactured in one part by the additive SLM process, in which even the fastening nut is captively printed on the nozzle body. The pride of the concept is the special algorithmic modification of the nozzles for any application case.

A mold-making job with up to 30 nozzles is processed in the SLM machine in about 24 hours. 

16:9

The First Additively Manufactured One-Part Hot Runner Nozzle

Spritzgießen

Kunststoffverarbeitung: Verfahren

Doriat, Clemens, Dr.

Verfahren für die additive Fertigung

Pulverbettverfahren

Heißkanalsysteme

Kunststoffverarbeitung: Maschinen und Komponenten

Komponenten für die Kunststoffverarbeitung

Algorithmically Modified  Inner Workings

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

Faserverarbeitung

Industrieroboter

Qualitätssicherung

All Elements at a Glance 

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

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.

Tool insert for a spacer of a glass fiber-reinforced PA66. The example shows that hybrid manufacturing is suitable and provides added value, even with comparatively simple parts

Additive Manufacturing and Hybrid Molds in Combination with Conventional Machining

HSC- / HPC-Bearbeitung

Spanende Verfahren

Werkzeugkonstruktion

Dienstleistungen

Werkzeug-, Formen- und Modellbau

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.

Falcontech Super AM Factory with currently 20 Farsoon metal 3D printing system.

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

Flexible air guiding system in blown film allows higher mass throughputs and greater process stability

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.

This mold determined the maximum cycle times (rendering)

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

Werkzeug- und Formenbau

Kühlelemente, aktive

Elektromechanik

Kühlkörper

Fine Channels, Maximum Efficiency

Perstorp Holding AB, Perstorp, Sweden, and 3D4Makers, Haarlem, the Netherlands, are developing a new generation of high quality, high performance filament. As the world’s first fifth-generation 3D filament, Facilan enables applications previously unobtainable with other 3D printing materials. 

Next-Generation 3D Printing Filament 

3D Filament Facilan 

At the beginning of May, Jürgen Becky took over the helm of BASF’s European plastics business. He is steering the ship in the direction of polyamides, 3D printing, and digitalization. In the interview, he explains why BASF is not just a material supplier, why business could not be going better, and why the company will not get everything it would have liked from Solvay. 

Interview with Jürgen Becky on Goals, Markets, and Trends for BASF Plastics 

Industrie 4.0

Kunststoff Werkstoffe

Polyamide

"Service Requires Trust" 

Sabic has launched the new Lexan EXL AMHI240F filament. This  product is based on the company’s Lexan EXL polycarbonate (PC) copolymer technology, which delivers high impact performance and low-temperature ductility. 

High Toughness, High Strength 

Polycarbonat

Lexan EXL Filament 

Eos GmbH, Krailling, Germany, introduces Eos P 500, he automation-ready manufacturing platform for laser sintering of plastic parts on an industrial scale. According to the manufacturer, Eos P 500 yields high quality components at the lowest cost-per-part ratio as well as maximum productivity for processing polymers at operating temperatures of up to 300°C. 

Eos P 500 

Operating Temperatures of up to 300 °C 

PET plastics such as water bottles and packaging are one of the most prolific wastes found on the battlefield. U.S. and coalition forces produce large volumes of this waste. A collaboration between the U.S. Army Research Laboratory and the U.S. Marine Corps shows, how useful a used plastic water bottle might be for the military. 

3D Filament from Post-Consumer PET Used to 3D Print Spare Parts 

Polyethylenterephthalat

Kunststoff-Recycling

Technik Trend

kunststoffe-international.com

From Plastic Waste to a Valuable Resource 

When surgeons operate on the aorta, they generally rely on computer tomographic images. For the first time, a team at the Medical Center of the Johannes Gutenberg University of Mainz, Germany, has applied the 3D printing process to visualize and diagnose complex conditions more quickly. Transparent 3D models support a better understanding of diseases and also serve to train future vascular surgeons. 

The Medical Center of the University of Mainz Improves Vascular Surgery  with 3D Printed Patient Specific Models  

Main Arteries from the Printer 

For individualized implants, mainly powder-based processes with titanium alloys are used in additive manufacturing. However, PEEK would have advantages in terms of imaging as well as its bone-like density and mechanics. Thus, the FFF process has to be adapted to the high demands of high-performance plastics like PEEK. 

Individualized Implants Made from High Performance Polymers via Additive Manufacturing 

Polyetherketon

Hot Printer 

 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

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

issue 07/2022

issue 06/2022

issue 05/2022

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