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

Anlagen für die Additive Fertigung

Biokunststoffe

Kunststoff Werkstoffe

Additive Fertigung

Medizintechnik

Medizinprodukte

Werkstoffe für additive Verfahren

Andere Werkstoffe

Arburg Kunststoff Freiformen

Verfahren für die additive Fertigung

Freiraumverfahren

New Possibilities for Use  in the Human Body

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

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

Thermoplaste

Polyacrylate

Oberflächenbeschichtung

Holz

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Hybridwerkstoffe

Polyacetale

Verbundwerkstoffe / Werkstoffverbunde

Polyamide

Oberflächentechnik

Filamente für additive Verfahren

Oberflächenveredelung

Dienstleistungen

Lohnfertigung

Polycarbonat

Technology Made Easy

The manufacture of carbon-fiber-reinforced plastic components for automotive serial production must be fast and cost-competitive. The ideal solution would be a one-stage process. In a potential study, a selective fiber placement unit was tested that combines fiber placement, resin injection, and curing in a single process step – with placement rates of up to 1 m/s. 

Additive Manufacture of Carbon-Fiber-Reinforced Components Using UV Radiation 

Automatisierungstechnik

Automatisierungskomponenten

Harze

Reaktionsharze

Kohlenstofffasern / -matten

Faserverarbeitung

Fasern

Mastermind in the Fiber Placement Head 

After the explosion of developments in polymer formulations over the last year, it is worth taking a closer look during Fakuma at details such as functional additives or application-specific modifications. Overall, lightweight design continues to spur development but defined surface characteristics are also in demand. The reported innovations do not just follow current consumer trends but also provide ideas for advanced product and process developments. 

Functional Modifications Characterize Developments in Additives and Compounds 

Hochleistungskunststoffe

Polypropylen

Compound

Additive

Farbstoffe

Pigmente

Füllstoffe für Kunststoffe

Compoundeure

Distribuenten

Polymers Can Be Expected Everywhere 

Is there a quantum leap on the horizon for 3D printing? The prototype of a newly developed 3D printer is able to process commercial pellets – also those of high-performance plastics such as PEEK, PPS, PSU, PA and PC, with or without fibers. The machine applies the usual strand-deposition process, though with a simply designed print head that includes a radial screw. 

A Novel Type of Print Head Gives Fresh Impetus to the FDM Branch 

Polysulfone / Polysulfide

Faser- und Filamentextrusion

3D-Print with Affordable Pellets 

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  

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 

The combination of luminous fibers with plastics or fiber reinforced-plastics will open up a future-oriented field for functionalizing lightweight materials. Designers will appreciate being able to create previously unperformable filigree contour lines and uniform lighting effects on components. 

Accessing New Fields of Application by Integrating Optical Fibers 

Spritzgießen

Mehrkomponenten-Spritzgießen

Hybridtechnik

Pultrusion

Gewebe, technisch

Luminous Fibers as Design Elements  in Plastics Parts 

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 Additive Fertigung / 3D-Druck, Metall

Medical Applications of Additive Manufacturing

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

Sanitary Prototypes with  High Requirements

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

3D-Drucker (für FDM, FFF, etc.)

Faserverbundwerkstoffe

Ultrafast 3D Printing

Ineos Styrolution announced first results of the PolySLS project, which is focused on developing a new energy saving styrenics based material for additive manufacturing, otherwise known as „3D printing“.

The PolySLS project is focused on developing a new energy saving styrenics based material for additive manufacturing

16:9

Technik Trend

kunststoffe-international.com

Polystyrol

Kunststoff-Erzeugung

Energy Savings with Styrenics Polymer Tailored for 3D Printing

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

Evonik has introduced a PEEK for FFF and FDM printers. The material was developed specifically for medical technology applications such as prostheses, surgical instruments and hearing aids.

The 3D-printable filament can be used, for example, for implants or hearing aids

Kunststoff

Bauwesen

Baustoffe

Biocompatible and Easy to Process PEEK

Currently, small wind turbines can hardly be operated profitably in landlocked regions. This drawback has now been overcome by the partners EAB Gebäudetechnik Luckau GmbH and the Chair of Polymer-based Lightweight Design at the BTU Cottbus-Senftenberg: passive smartblades made from 3D-printed molds adapt independently to wind conditions. This is achieved by an intelligent layer structure and its bending-torsion-coupling.

This newly developed rotor blade is especially suited for weak-wind regions and adapts independently to the wind load

Additive Manufacture of FRP Injection Molds for FRP Components of Small Wind Turbines

Glasfasern / -matten

Verstärkungsstoffe

Kunststoffverarbeitung: Maschinen und Komponenten

Simulation Produkt- / Formteildesign

Software

Simulation

Finite Methoden

Ingenieurwissenschaften

Technische Mechanik

Harze, Epoxid

Duroplaste

Windkraft

Energieerzeugung

Erneuerbare Energie

Analysetools, FEM

Highly Efficient Adaptive  Fiber-Composite Rotor Blades

New printers and Nylon carbon fiber material expand applications for additive manufacturing on the factory floor.

Stratasys announced that the company has expanded its F123 Series of 3D printers and new material reinforced with carbon fiber. The new printers offer high stiffness and strength materials in a hardened machine ready for composite material printing.

The new composite 3D printers are designed for manufacturers and industrial machinists to supplement traditional fabrication technologies with high-strength composite 3D printing. The printers help manufacturers produce end use parts faster and more cost-effectively, and are ideal for jigs, fixtures and workholding tools.

The new 3D printers include integrated GrabCAD Print software that provides a simple and intuitive CAD-to-print workflow and includes advanced features to ensure successful prints. Stratasys also provides enterprise application connectivity through the MTConnect standard and its GrabCAD Software Development Kit.

The composite-ready F123 Series printers include reusable build trays, a built-in camera for remote monitoring and a 7-inch control touchscreen. The F370CR printer also offers auto-changeover of materials, which means there is no need to interrupt a build to replace materials – a new canister is simply put in place and the build continues.

Stratasys has also introduced FDM Nylon-CF10, a new composite material for the F123 Series printers that is over 60% stronger than and nearly three times as stiff as its base nylon material. The chopped carbon fiber material is just one of many thermoplastic materials available for the F123 Series printers. When used with Stratasys soluble support, manufacturers have the ability to print any geometry without restriction. The F190CR and F370CR printers also support several other engineered thermoplastics.

Stratasys Inc.  

https://www.stratasys.com

New 3D-printers and Nylon carbon fiber material expand applications for additive manufacturing on the factory floor.

2022-05-11 PM Stratasys

New 3D-printers and Nylon carbon fiber material from Stratasys expand applications for additive manufacturing on the factory floor.

Stratasys F123-Series:
Two New Composite-Reday 3D-Printers

You can also learn more by visiting the <a href="https://www.stratasys.com/en/3d-printers/printer-catalog/fdm-printers/F123-composite-ready" target="_blank">F123 Series product page</a>.

You can also find more exciting 3D printing stories in our <a href="https://en.kunststoffe.de/processing/additive-manufacturing">AM topic channel</a>.