• Why TPU is such a unique elastomer for 3D printing.
• The benefits of TPU, like chemical and abrasion resistance.
• Why TPU is making groundbreaking strides in applications like automotive and even footwear.
• 3D printing TPU parts with Multi Jet Fusion or Selective Laser Sintering technology.

Created in a German lab in 1937, Thermoplastic Polyurethane (TPU) is now one of those ubiquitous plastic materials that spans numerous technologies in industrial manufacturing, due to the potential for shaping the highly malleable material via a heat source into countless shapes and structures for a wide range of applications. It’s easy to understand why TPU is so popular in 3D printing as well as other traditional types of manufacturing, and why it has become an industry standard no matter the method.

Composed of segmented copolymers, TPU is unique in its chemical makeup. Exhibiting a contrasting juxtaposition in terms of its components, this elastomer features a soft segment, as well as one that is more rigid. Combined, these elements create the rubbery texture found in TPU–leading to simplicity in processing, as well as the material’s mass appeal. 

With deep roots in traditional manufacturing, designers and engineers continue to rely on this special mix of high-grade thermoplastics for methods like injection molding. Common mold designs can be used for creating parts with TPU; however, a handful of additives may be considered for better results, along with processes like drying the material beforehand, molding, and spending time in post-processing.

The Benefits—Where to Begin?

Shapeways 3D prints TPU via both Multi Jet Fusion (MJF) and Selective Laser Sintering (SLS) technologies, offering multiple benefits over other elastomers. Resistance is at the top of the list for production of durable parts meant to stand the test of time. TPU is highly resistant to impact and wear and tear, but also offers excellent abrasion-resistance–a critical property for mechanical parts that are expected to withstand years of friction as parts rub against each other during use and can begin to degrade. The ability to resist chemicals, along with oils and solvents, and harsh weather and heat, also makes TPU an excellent choice for 3D printing and subsequent industrial use.

Other great features include:

• High elongation at break – A material characteristic measured by comparing where a part breaks after being strained, versus its original length, TPU scores off the charts. Featuring exponentially higher elongation at break–or ductility–than other 3D printing materials due to its elasticity, TPU is especially useful in critical applications because it is both flexible and tough and able to handle substantial deformation to its shape without breaking.
• Superior tensile strength – Defined by how much pulling strain a part can take before fracturing, tensile strength is measured through units of pressure called megapascals (MPa). With a high tensile strength of up to 60 MPa, coupled with good flexibility, TPU can be used for high-performance parts expected to withstand rigorous use.
• Excellent load-bearing capacity – This is an important measurement as it testifies to how much weight a 3D printing material can handle before it fails. Load-bearing capacity is an extremely important factor for applications requiring high-performance products that are expected to last, including larger parts as well as smaller mechanical devices like tubing, hoses, and seals.

With the ability to print highly flexible, interlocking products as well as industrial parts on the large scale, both SLS and MJF 3D printing offer greater design freedom too. This is mainly due to a sophisticated system that eliminates the need for supports during 3D printing, meaning that designers aren’t restricted by the worry of figuring in complex support structures.

3D Printing TPU with Multi Jet Fusion Technology

Shapeways offers Multi Jet Fusion (MJF) for 3D printing Ultrasint® TPU 01, resulting in prototypes and parts that are robust, with strong mechanical properties. Like SLS 3D printing, MJF is powder-based; however, it does not rely on laser heat to melt layers together. Instead, one layer of powder is deposited after the other, 80 microns at a time, with an inkjet array moving back and forth jetting out fusing agents to fuse the powder particles together, and detailing agents to assure good detail and smooth surface texture. 

As the layers melt together quickly via thermal heat with MJF 3D printing, resulting parts are stable and well-defined. A standalone cooling system also helps eliminate challenges like warping, shrinkage, or overall failure in parts. 

Design Guidelines

For this material, 3D models must be within the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • At least 1 extant dimension over 19mm
• Bounding Box Max
  • 284 × 380 × 380mm 

This 3D printing material is available in a gray, natural finish. Explore the design guidelines for TPU further here.

3D Printing TPU with Selective Laser Sintering Technology

Featuring power and speed, SLS 3D printing technology makes it possible for Shapeways to 3D print highly accurate TPU parts that are detailed, with smooth surfaces. One of the oldest 3D printing technologies–aside from SLA 3D printing–SLS is a subcategory of powder-bed fusion and heavily relied on for both rapid prototypes and highly functional end parts. 

The process is set into motion as a small amount of powder is dispersed onto the SLS print bed. A high-powered laser traces the shape of the 3D design into the powder as each layer is 3D printed and fused together at a high temperature just below the melting point.

Design Guidelines

For this material, 3D models must be within the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 15 x 15 x 0.7 mm
  • X + Y + Z ≥ 15.0 mm
• Bounding Box Max
  • 200 x 200 x 200 mm

This 3D printing material is available in white, with a Standard matte finish. Explore the design guidelines for 3D printing TPU with SLS technology further here.

Typical Applications for Thermoplastic Polyurethane

Automotive

While the automotive industry has been using 3D printing for decades in prototyping, as well as functional parts for both the interiors and exteriors of vehicles, TPU allows for the design of truly personalized components, allowing for consumer-specific comforts. While such options may become much more detailed in the future, today’s manufacturers are hard at work not only using additive manufacturing for critical components but also in focusing on the drivers themselves and developing new luxuries like customized headrests and seats. TPU is often chosen for these parts because of its versatility in terms of softness for one part, yet hardness and functionality for another. There are a variety of different finishes available too for automotive applications.

Consumer accessories  

The 3D printing industry is well known for expanding options to consumers in the area of accessories, mainly due to the enormous potential offered by expanded design freedom and the ability to customize. This is especially true for items like smartphone cases, allowing customers to completely personalize an item, adding exciting and unique touches to a product that is pretty much impossible for most people to live without today. Not only that, these items are durable enough to last for years. TPU is also an excellent choice for adding quality and customization to highly functional items like soft grip systems and rubber mats.

Footwear

3D printing has made a powerful impact within the footwear industry, and on multiple levels. Designers working from their studios or homes are able to make creative new eco-friendly designs on demand and send them to Shapeways for 3D printing services. Large corporations are using materials like TPU to max out designs for epic, futuristic looking running shoes with a range of features meant to propel athletes and everyday wearers forward in terms of comfort and stamina.

There is also the potential for incredibly personalized fit in shoes, beginning with insoles that can be 3D printed to encourage better support and balanced gait, as well as orthotics that can be made to fit and re-sized easily as needed. With rapid production in 3D printing, more durable footwear products can be made that are also more flexible, and lighter in weight. 3D scanning plays a role for much of the footwear industry as the wearer’s measurements can be scanned quickly, making unprecedented strides in comfort, rather than expecting someone to fit into a typical size, or somewhere in between.

Medical devices

Another area where 3D printing is offering enormous impact, TPU is behind the production of numerous medical devices bearing complex, lightweight geometries that may not have been possible before with traditional manufacturing. Products like braces, prosthetics, and implants can be 3D printed after 3D scans are taken from patients, offering them safe, customized devices that are able to stand up to long-term daily use without causing skin irritation. For children wearing prosthetics or orthotics this is an incredible boon, with fittings taking a fraction of the time and without discomfort. While such devices may have taken weeks or even months to arrive previously, at great expense, now they can be made quickly–and changes can be made to designs quickly also.

Robotics

TPU is also suitable for robotics, and especially softer applications which may require extremely flexible parts like connectors, actuators, and simulated fingers, arms, and flex grippers for performing tasks whether on a manufacturing production line or at the individual level. This material can also be used for tires and other accessories attached to moving robots, as well as those that may be performing 3D printing activities on their own.

Sports gear

Because of the protective nature of sports gear, 3D printing technology with TPU is able to play a very important role in helping to prevent injuries in players. Using lattice structures for interior strength and incredible absorption on impact, 3D printed protective gear may include helmets, guards, and more, all with the potential to be heavily customized for the comfort and safety of the athlete.

Ideas for 3D Printing with TPU? Get Started Now

For faster turnaround time and highly customized, production runs at any volume, contact Shapeways to learn more about on-demand 3D printing. Allowing manufacturers to keep a digital inventory of their stock or spare parts, on-demand printing means decreasing or saying goodbye to warehouse space altogether. 

Upload your design now to get started in 3D printing with TPU.

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here. 

The post A Comprehensive Guide to Industrial 3D Printing with Thermoplastic Polyurethane (TPU) appeared first on Shapeways Blog.

Applications like Automotive Continue to Evolve with 3D Printing

In a recent webinar co-presented by Shapeways, Dr. Cary Baur, Manager of Polymer Material R&D, explained how the EOS Additive Minds team was formed to address the needs of industrial customers—and further, to understand what the real pull is for additive manufacturing in applications they use now and may look to in the future.

“At EOS, it’s my job to help develop our polymer technology and deliver it to our customers specifically working toward new applications,” Baur told Shapeways during the webinar. “I help drive our technology in that direction and enable those new applications via working together with you.”

All of the materials from EOS are powdered-based, and 3D printed with laser sintering—most commonly, Selective Laser Sintering—a technology that is extremely popular with Shapeways customers.

From Concept to Reality with Unlimited Freedom in Design—and Redesign

The focus at both EOS and Shapeways is working with customers to understand their manufacturing needs at any level. Baur points out that the EOS Additive Minds team is centered around finding tailored solutions for product development and then connecting with companies like Shapeways to transfer design and development into productive opportunities related to both manufacturing and business.

Freedom in design is what allows 3D printing to stand out over other technologies. It also allows for improvements on existing parts, as well as the creation of new products that were not possible before via traditional manufacturing. Lightweight materials allow for production of parts that are strong too, and suitable for dynamic moving parts and complex components. 

“Now, we can lightweight parts that used to be very bulky,” said Baur. “We can also make custom lattices and things like that, and reduce the mass and material inputs drastically.”

The ability to take traditional parts or concepts and redesign them with 3D printing can be an eye-opener for manufacturers engaged in designing for a wide range of industrial applications.

Companies like EOS have seen great success in redesign for components for luxury, limited-edition cars, offering impressive price reductions for thousands of small parts that could have been made traditionally; in fact, ultimately they saw a 10-20% cost savings per transferred component. EOS has also streamlined designs for complex grippers, reducing parts exponentially, and even redesigning sports safety equipment like shin guards and helmets for much better shock absorption.

Rapid prototyping leads to much faster feedback and time to market, while customized 3D printing on demand has the potential to change the face of production altogether, leading to better quality, efficiency, and savings overall.

Harnessing the Transformative Powers of Additive Manufacturing

Baur’s Additive Minds team at EOS encourages designers to look at the development and production process more closely: Given our new design freedom, how can we look at this a different way? How can we start designing some of these components to fit in with each other, and how can we reduce the amount of input parts?

Functional integration leads to maximum productivity and cost optimization, allowing for embedded functionality without assembly, greater material efficiency, and no tooling costs. With the ability to take nearly a hundred parts and bring the assembly down to just one piece, it is obvious to see why 3D printing could surpass traditional manufacturing for production of complex parts eventually. This is also due to:

• Greater manufacturing agility
• Simplification for supply chain issues
• Shorter lead times
• The ability to personalize

Technology like Selective Laser Sintering specifically offers greater opportunities in design and production overall. Because unused powder acts as a bolstering system supporting parts during the printing process, there is no need for supports. That means engineers don’t have to factor in designing intricate supports for parts, and in the end, there is much less chance for damage due to added post-processing.

Hundreds of parts can be nested together in one build too. Shapeways uses proprietary purpose-built software to streamline and condense packing of parts, reducing the height of the build platform, saving materials, and accelerating production.

“Selective Laser Sintering can be used to distribute your manufacturing to digitize your product portfolio—leading to a lot of spare part reduction and a lot faster turnaround times for manufacturing,” said Baur.

The idea of on-demand 3D printing is beginning to appeal to more manufacturers as they realize the implications of how much time, space, and money they could save. With the ability to order parts and customize them when needed, businesses could feasibly say goodbye to large expanses of warehouse space and the expense, which soon may become outdated. That also goes for storing enormous numbers of spare parts and products, left sitting around waiting to be shipped at an unknown time. 

The sheer magic of 3D printing revolves around disrupting traditional ways in manufacturing, along with shining a bright light on the infinite potential for innovation. The sky’s the limit in terms of how this transformative technology will eventually impact nearly every application, and continue to astonish us over the coming years in ways we never imagined.

 About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post Increasing Productivity: Additive Manufacturing with EOS, Part Two appeared first on Shapeways Blog.

In Increasing Your Production Power: Additive Manufacturing with EOS & Shapeways, the long-standing manufacturing partners and industry leaders outline the features of EOS materials, along with identifying the main benefits in developing products for additive manufacturing.

1. Selective Laser Sintering (SLS) is More Powerful than Ever

Relying on SLS 3D printing, EOS harnesses the power of powder-based technology targeted by lasers to solidify nylon particles, layer by layer, into the desired structure. Most SLS printers are large, and capable of printing an average of 500 to 1000 parts in a single build.

Most builds are made up of thousands of layers, resulting in detailed parts with intricate features. Shapeways uses popular nylon thermoplastics like Nylon 12 [Versatile Plastic] in partnership with EOS, along with other materials that according to Cary Baur, Senior Manager-Polymer Technology at EOS, are fairly common engineering plastics which translate well to other applications—including those that are also being used in traditional manufacturing methods like molding or machining.

One layer at a time is recoated at roughly 100 to 120 micron layers. Each layer of powder is deposited and then heated to just below the melting point.

“We use a directed laser in select areas to melt the materials and create the geometries that we want,” said Baur. “Essentially, we print in a two-dimensional method, but we do that in consecutive layers in the sense that we are building up a three-dimensional object. What this really does in terms of creating value is that it allows you to take a digital file and implement it in a way that gives you a huge design toolbox.”

2. Design Freedom is Huge

Freedom in design is boundless with SLS 3D printing. Supports are not required for this powder-based technology due to the bolstering effect of all the unsintered powder bunching up around parts during printing, stabilizing them throughout the process. This means that engineers don’t have to worry about factoring in support structures to the design process, and even better, production specialists don’t have to worry about fitting them in intricately to the print build—or risk the possibility of damaging parts during post-processing as supports are removed.

“We can 3D print lightweight parts that previously were very bulky because we couldn’t make custom lattices like we can now,” said Baur. “Now we can take those, reduce the mass dramatically, and also reduce material inputs.”

“There’s parts we used to have to machine and mold separately and assemble via different processes that all require more time and cost. Given our design freedom, now we can look at the process differently and design components to fit in with each other during printing.”

Complex parts can be made with better tolerances, greater efficiency, and may include dynamic, moving parts too.

3. The 3D Printing Journey Extends from the Concept to Reality

At the customer level, design begins with developing products for a specific application. After that, Shapeways is responsible for understanding the customer’s needs, revving up production, and providing solutions to scale for other manufacturers.

With the ability to eliminate tooling, 3D printing offers better cost optimization. Along with that comes great efficiency in the use of resources—namely, materials—as less are used in additive manufacturing as compared to subtractive, and much powder can be recycled in each build. Assemblies can be reduced in many cases, allowing for embedded functionality, and the ability to produce large parts all in one piece—meaning that quality and speed are improved, and there is also much less chance for error during production.

This is especially true during product development when many changes are continuing to take place. Projects are turned around swiftly, especially with the potential for quick feedback on virtual or tangible models, as well as haptic feedback.

“In comparison to the speed in 3D printing which takes hours or a few days, it can take months to create molds for traditional methods like injection molding,” mentioned Steve Weart, Director of Customer Success at Shapeways. “The time involved in production really adds up too if one or more changes need to be made.”

“Additive manufacturing makes more and more sense, especially in terms of being environmentally friendly. If we can make something locally, it really changes the game too.”

Shapeways customers are able to cater to the growing trend in demands from consumers for customized fit and customized treatment, whether in fashion or critical applications like medicine.

4. Low- to Medium-Volume Production Yields Great Efficiency

On demand 3D printing is a revolutionary concept, and one that is quickly gaining appeal and traction. With the ability to send Shapeways digital files and then set up customized 3D printing as needed whether for one part, low-batch production, or even mass production of parts, customers are able to avoid spending precious capital in buying their own 3D printing equipment and related materials, eliminate the need to keep inventory on hand or pay for warehouse space, and can even enjoy complete product fulfilment, as orders are shipped out directly in customized packaging.

“With a digital twin for parts on file, you can then just have a number of machines on standby ready to print parts on demand to keep company equipment up and running,” said Baur. “There is a very strong business case for converting as many aging parts as possible to digital files, so they are available when needed—and without having these massive warehouses full of aging parts and inventories just sitting there.”

SLS materials and technology are used in a wide range of applications, to include:

• Aerospace
• Consumer goods
• Electronics
• Eyewear
• Footwear
• Medical devices and medical equipment

The automotive industry is a good example of customized products that are in demand for low-volume production—especially for luxury cars where there may be a target audience for complex interior parts that can be made much faster and more economically than with a traditional method like injection molding. For many different parts, weight can be reduced enormously, saving economically and in efficiency.   

Medical devices like orthotics can also be made much more accurately for fit and functionality. Shape and density are improved with 3D printed products, with specific pressure-point areas and insoles that are designed for the weight and mass profile of the wearer. Performance is better, and customers are much less self-conscious due to more aesthetically pleasing choices. Being able to make a lightweight product is extremely important for orthotics too.

5. Customer Demand Drives Ongoing Product Improvement

Currently, Shapeways offers Nylon 12 [Versatile Plastic], Thermoplastic Urethane (TPU), and PA11. These materials are designed to offer flexibility in options for 3D printing, excellence in material properties, and ease in quality control and production.  

“Nylon 12 is our highest-volume material on the market right now,” said Baur. “Nylon 11 also is very popular for applications that require more dynamic mechanical strain and more compliance.”

“A large part of our business is helping to identify the needs of our customers specific to an application,” said Baur. “If we don’t have a current material that meets customer needs, we often can make it, and often we will help enable our customers by working with Shapeways to then look at a material and a production process, with Shapeways filling the production need with the EOS material.”

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for 3D printing with accuracy, complex detail, and no limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Top 5 Takeaways from 3D Printing Solutions Webinar appeared first on Shapeways Blog.

Our recent webinar with Forward AM, the BASF printing solutions brand, showcased the many exciting ways that 3D printing is reshaping the future of the automotive industry. Here are five takeaways from “Driving Advances in Automotive” that highlight what’s underway and what’s ahead for 3DP and the automotive industry.

The role of 3D printing in this sector is exhibiting Tesla-like acceleration. According to 3dpbm Research, expected revenues for traditional automotive parts produced by additive manufacturing should grow from $2.6 trillion in 2020 to $15 trillion by 2030.

1. The automotive industry continues to be a leader in use of 3DP

As far as the automotive industry in Detroit is concerned, 3D printing isn’t new.  “The automotive space has been using 3D printing for a long time, probably as long as any industry,” said Jeremy Vos, business development manager for automotive and aerospace, at BASF Forward AM, North America. “Today, automotive remains one of the major users and therefore is far ahead when it comes to embracing and deploying the technology.”

According to Wohlers Associates’ “The State of 3D printing 2020” survey, automotive represents the top user segment of additive manufacturing. The technology has been showing its transformative powers in different applications. The reason is simple: making vehicles is a very capital-intensive business with millions of dollars spent each year on the design, development and delivery of the latest-and-greatest things on four wheels.

3D printing has proven it can improve the overall speed and agility of manufacturing.

Forward AM’s Vos cited the example of giant automaker Daimler, which utilized 3D printing to accelerate and validate the design process necessary for a new engine bracket to meet a very strict deadline.

According to Vos, about a dozen brackets were needed to complete noise vibration testing. Opting for traditional injection molding would have required months of preparation and wait time. Instead, 3D printing enabled predictable simulation results that led to expedited delivery of functional prototypes that accurately represented how the injection-molded part would function. Shortening development time and iteration steps permitted the company to perform driving tests and meet the target for its new vehicle launch.

2. Functional prototyping and production parts are gaining traction with 3DP

For several decades, automakers have used 3DP to create design prototypes for proof-of-concept and/or testing. Parts then can be refined into functional versions that meet the auto industry’s strict technological readiness levels (TRLs) and form-and-fit tolerances. As 3DP has proven in every other industry segment, the technology is unbeatable when the task calls for rapid design innovations and part iterations.

But prototyping is just the tip of the spear in driving 3DP adoption in automotive.  Increasing reliance on 3DP for manufacturing production parts helps automakers improve their materials usage while reducing scrap and wasted parts. The growing impact of 3DP also empowers auto manufacturers to reduce their carbon footprint—an initiative that all businesses need to address—while attending to noise and air pollution excesses. According to Vos, 3D-printed parts made of thermoplastic urethane (TPU) that become surplus can be recycled and reground for use in other applications—a welcome “green” upgrade over decades-old practices.

3. Customization & 3DP: Only limited by your imagination

The market for designers and providers of customized parts and accessories is very competitive and crowded. Nevertheless, automakers increasingly understand that embracing customization will reap the further benefit of customers’ increased satisfaction and loyalty to their brands. If customization is the key, 3DP printing is the engine.

Imagine 3D-printed seating options that specifically cater to drivers’ and passengers’ orthopedic needs. Special-fitting headrests and seats can be produced using 3D-printed foams. 3DP excels in providing intricate, customized latticework structures that best address applications for heating and cooling capabilities as well as lumbar support—all of which improve occupants’ driving experience. “What we can do with the combination of innovative design, lattice structures and 3D printing is quite amazing,” said Vos. “You can customize for hard or soft, depending on different points, while building for durability.”

The aftermarket for 3D-printed gear also is heating up. Shapeways has worked with 67 Designs, a designer of off-road products, to deliver tens of thousands of its highly durable iPad mounting devices to customers all over the world. 67 Designs created the in-vehicle accessory and Shapeways then printed prototypes that led to the debut of the MagMount G3.

4. Gigantic parts warehouses will no longer be necessary; print parts instead

Vehicle manufacturers and their multiple parts manufacturing partners must maintain gigantic, multi-location warehouses to store a seemingly endless supply of parts and accessories. The promise of 3DP lessens this burden with its ability to replace or at least reduce much of that square footage in the name of a digital inventory.

When a part is needed, instead of searching the aisles and racks, a digital file is called up and the request is printed on demand. In this vein, 3D printers also deliver heightened degrees of supply chain optimization while eliminating expensive tooling costs.

Not only does 3DP reduce the physical need for costly and vast warehousing, the process can be set up virtually anywhere, putting parts acquisition much closer to the end-customer, reducing time-to-delivery. 3DP also represents a great opportunity for owners of vintage or rare vehicles, where parts may have limited availability or are permanently out-of-stock.

5. Down the road: fully 3D-printed vehicles

Simply put, 3DP is poised to be the biggest change in car production since Henry Ford debuted his moving assembly line in 1913. While the concept of 3D printing an entire vehicle may sound like science fiction, someday it will be commonplace. There are enormous changes underway in the automotive market as traditional dealerships no longer are seen as the only game in town as an increasing number of consumers are buying vehicles online or from non-traditional outlets.

At the same time, there is relentless competition among auto manufacturers to deliver electronic vehicles that are safer and smarter as well more lightweight and energy efficient. 3DP’s brilliance in creating honeycomb-style parts goes a long way toward making vehicles lighter and therefore more energy efficient to operate.

Swedish manufacturer Koenigsegg has made some 300 sports cars with a vast number of parts that were 3D-printed at its own in-house facility. Eventually 3DP can make it possible for all sorts of companies to enter the field to compete with anyone from Ford and General Motors to Tesla and McLaren. Buckle up, it will be a wild ride.

The post 3D Printing Drives Advances in the Future of Automotive appeared first on Shapeways Blog.

Strength and durability are two key benefits of PA11 that make this material ideal for functional parts like gears and hinges. High ductility is a major benefit too, offering excellent impact resistance for parts in applications like automotive or aerospace, as well as other manufactured parts that must hold up to rigorous use like protection equipment for sports. PA11 is also well-suited for applications that require resistance to harsh weather conditions, especially heat. 

Sustainable Origins: PA11 is Naturally Derived and Environmentally Friendly

Here’s an interesting fact about PA11 (also known as Nylon 11, EOS PA11, Nylon Polyamide 11), and one that many find surprising at first: it’s made from castor oil. The castor bean is actually an ingredient included in many different types of additives, from medical and skincare products to materials for industrial manufacturing. 

In terms of 3D printing, the eco-friendly PA11 can also be recycled easily in manufacturing—often up to 70 percent. This leads to one of the other greatest benefits not only for PA11 but SLS 3D printing overall. As one of the oldest, and still one of the most powerful forms of additive manufacturing, SLS 3D printing relies on a laser to move back and forth over each layer as a structure is built, sintering the nylon PA11 powder to build a solid structure. Supports are not necessary as the extra unsintered powder acts as a bolstering mechanism, surrounding and stabilizing the part during printing. Afterward, the powder can be reused.

Indisputable Advantages: Strength in Material Properties

PA11 possesses a wide range of strong material characteristics, making it conducive to additive manufacturing. These include:

• Tensile Strength – Measured in terms of how much stress a part can take before it breaks, tensile strength is often used to compare materials in durability for 3D printing. Force is measured in megapascals (MPa), which are units of pressure. With a high tensile strength like 48 MPa, and significant toughness, PA11 is a good candidate for sturdy, functional parts, as well as prototypes that will hold up over time. 
• High Elongation at Break  – Also known as ‘fracture strain,’ elongation at break measures a part after it has been fractured, comparing the initial length of the part and then the same after it has strained and broken. The goal is to assess how resistant the material is to stress or being stretched, as well as its flexibility, calculating the strain to failure mark in percentages. High elongation at break is an impressive feature of PA11 at 45 percent, as materials are ultimately able to bend and stretch out of their natural state while under stress and then return to normal afterward. With higher elongation at break comes higher ductility and impact resistance too.
• Elasticity – Good elasticity also allows a material like PA11 to return to its original state after being stretched or bent. Technically, elastic qualities refer to the energy left in a material after it has been placed under stress—allowing it to snap back into place. 
• Chemical Resistance – Superior resistance to chemicals like hydrocarbons, the primary elements of petroleum and natural gas, is a highly positive trait found in PA11 also—and often why this material is chosen for industrial applications. PA11 is also resistant to aldehydes, ketones, mineral bases, salts, alcohols, fuels, detergents, oils, and fats.

Exceptional Parts for Demanding Applications

While lending itself to extremely rigorous applications like automotive and aerospace, PA11 is biocompatible too, making it suitable for exterior medical applications, and especially those requiring not only the ability to hold up during long-term use but flexibility too. A good example would be 3D printed knee braces as well as other types of medical supports like prosthetics that offer progressive, patient-specific treatment due to the ability to customize devices, along with creating new ones quickly and affordably for patients like children who may continue to outgrow them. 

Upload your 3D models now to get started with printing in PA11 using industrial SLS technology from Shapeways.

The post PA11 3D Printed Parts are Built to Last appeared first on Shapeways Blog.

Prototyping

Having the ability to rapidly fabricate prototypes keeps workflows moving steadily and avoids costly pauses in the manufacturing line. This is where 3D printing is most used in automotive manufacturing, as it allows for unparalleled speed in producing, editing and evolving iterations. Prototypes can be made for any stage whether it be as proof of concept or high fidelity prototypes that will better validate parts through the whole manufacturing process. It also allows for manufacturers to test new components and continue developing the way parts are made and contribute to a vehicle’s performance. Small scale prototypes can also be created for marketing purposes, like Volkswagen’s 10,000 tiny metal cars for the launch of their electric car model ID.3 in 2018.

Customization

Many consumers jump at the idea of adding their own flair to the commodities in their lives. The ability to pick out colors, patterns and take part in the design process greatly increases customer satisfaction and is something that 3D printing has enabled manufacturers to do while still keeping costs low. Many automotive companies have begun to introduce custom flourishes and parts to their cars as mass customization becomes much more feasible with 3D printing. In traditional manufacturing, a mold and specific tools would be needed to create each personalized component, but using 3D printing, this is easily achieved by editing the 3D file. Thus, 3D printing allows for the production of small batches of custom design pieces without raising the cost that customization would incur with traditional manufacturing.

BMW’s Mini car makers introduced a personalization service in 2018 called “Mini Yours” in which customers can choose colors and finishes, customize door handles, LED lights and panels, and can even add their own text or signature to various parts.

Similarly, Volkswagen began rolling out individualized cosmetic parts such as key rings, gear shift knobs and tailgates, all of which can feature custom lettering of the customer’s choice to be printed in stainless steel using the HP Metal Jet tool.

Tooling & Manufacturing Aids

3D printing also gives manufacturers the ability to produce lower cost manufacturing aids and tools for custom parts like jigs and fixtures. A 3D printed mold for a new part can provide a higher level of design freedom and 3D printed tools can be lighter and stronger. It also allows for more ergonomic tools for manufacturers. BMW and the Department of Ergonomics at the Technical University of Munich created 3D printed orthotic thumb devices to support and prevent strain for assembly workers. The workers’ thumbs are 3D scanned and each device is molded to fit each person’s thumb.

Creating Complex Designs for New Parts

The ability to produce viable end parts, paired with the design freedom that 3D printing allows for means that more complex and perfectly suited components can be incorporated into vehicles, creating further innovation in aesthetic and performance.

Several German additive manufacturing (AM) companies collaborated on a prototype for a vehicle seat called ULBS that combines safety and comfort with ultra light-weight structure. The prototype uses a filament winding process with parts printed in plastic, stainless steel and backrest cushions printed in Thermoplastic Polyurethane (TPU).

When Volkswagen recreated their 1969 mini bus, they 3D printed aluminium cast wheels using generative design, a method that uses an algorithm to produce many versions of a design idea that the designer can then choose from. They created 3D printed hubcaps with a clear resin that were electroplated to have the appearance of metal. These details allowed them to put a modern design twist on an iconic vehicle.

Bentley’s design studio has taken advantage of 3D printing to produce parts with a high level of intricacy. They have produced grille mesh, side vents and door handles with micro-scale detail precision that would not have been possible using another manufacturing method. They are able to design parts with complex geometries that create a bold aesthetic that builds on their classic designs.

Spare Part Production

As automotive manufacturers begin using 3D printing for general end part production, it also becomes possible to print spare parts as needed. If someone driving an older can model needs a part replaced that is out of production, this leaves the driver in a difficult position. Being able to 3D print that missing part solves that issue without car companies having to maintain an ever expanding inventory of old parts they may never need again. It gives manufacturers the ability to produce rare and hard-to-replace parts on demand while optimizing their inventory.

End Part Production

We’ve seen how manufacturers can use 3D printing for prototypes and select customizable parts, but as 3D printing technology evolves, so does its ability to produce end parts for industrial use. For one thing, 3D printing allows automotive manufacturers to consolidate multiple parts into one, thereby decreasing the vehicle’s overall weight while increasing fuel efficiency.

The materials that 3D printing has to offer are rising to meet the standards for end parts as well. Shapeways has partnered with BASF to provide access to high performance materials including Ultrasint® PP nat 01 and Ultrasint® TPU01 that are well suited to functional automotive end parts because of their versatility and durability.

Another excellent material choice is DSM’s Arnite® T AM1210 (P). Available through Shapeways’ partnership with DSM, this Arnite material is ideal for automotive parts needing to withstand high temperatures. This powder is easy to print with and is also environmentally friendly, as it can be recycled back through the powder bed process.

Whether you’re in the automotive industry looking to incorporate 3D printing for your manufacturing process, or you’re looking for help with additive manufacturing for another industry, we can provide a custom solution to help you scale your business.

The post The Impact of 3D Printing in the Automotive Industry appeared first on Shapeways Blog.

Wakanda Forever

Not only did we get to see “Black Panther” this month, we also found out that some important parts of the magic of Wakanda were 3D printed. Working with 3D designer Julia Koerner, legendary costume designer Ruth Carter incorporated 3D printed elements into the film’s regal fashions. Watch the Racked feature on it here.

A still from Racked’s feature on the costumes of “Black Panther”

So many feels

In medical news, we’re going to pull a “This Is Us” and start with… well, you’ll see. That would be this ugly-cry-inducing story from the BBC about rescue doggo Duke, who needed a paw. Luckily, 3D printing was there to give him just that. And in other touching, adorable news, 3D printing is helping visually impaired children in the classroom. Watch the video and feel nothing, we dare you:

But, we’re not done yet with your heart just yet. Ten years ago, professional snowboarder Mike Schultz had an accident that led to the amputation of his left leg. He turned his injury to his advantage, creating a company, BioDapt, that makes the specialty prosthetics sported by this year’s Paralympians — including Mike Schultz himself. Read more about how 3D printing powers his creations at Engadget, and see what adaptive athletes have done with BioDapt’s prostheses, below:

There were a lot of other astounding medical 3D printing accomplishments announced in February. This beautiful brace (the UNYQ Align by Francis Butonti) was displayed this month at the Smithsonian Cooper Hewitt Design Museum in NYC. Meanwhile, UK researchers made progress toward creating 3D printed cell tissues, and one startup, BioLife4D, announced that it plans to focus on “building” hearts. Godspeed, BioLife4D.

PROTOTYPE YOUR BIG IDEA

Style is ageless

In up-and-coming style icon news, this month we met incredible teenager Shami Oshun, who taught herself 3D printing for apparel design, which is so much cooler than what I was doing as a teen. See her tweets and bow down:

Hi Twitter, my name is Shami Oshun. I am 18. I taught myself how to 3D print in August 2017. As of today I am the youngest person and first black person to 3D print fashion. I hope this inspires other black girls to pursue careers in tech and fashion #BlackHistoryMonth pic.twitter.com/OST0ScgttM

— Oshun (@bluexheeta) February 8, 2018

And if you follow car news, you’ll know that Porsche has figured out what you have known for so long: 3D printing is great for replacing parts that don’t exist anymore for the classic things that you love. The iconic, stylish carmaker is 3D printing things like a clutch release lever for the 959. Sounds… like a car thing!

Medtech won’t quit

Thanks to scientists at the Ecole Polytechnique de Lausanne, we are now closer than ever before to something you might not have even dreamed about, which is printing microscopic devices inside the body. And, in the meantime, their technique could simply deliver super-ultra-high-res 3D prints. Merci, y’all.

In Australia, the excellently named Centre of Excellence for Nanoscale BioPhotonics has created something equally excellent: a clip-on smartphone microscope that can help people in remote locations analyze water cleanliness, test blood samples, and detect disease at an early stage. So… our iPhone addictions could save our lives? Right?

It’s 2018. Stop watching ‘Encino Man.’

Brits learned this month that their ancient ancestors looked different than many had imagined. With the help of DNA analysis and 3D printing, a team from London’s Natural History Museum and University College London revealed the face of a 10,000-year-old Cheddar Grove, Somerset man. With dark skin, blue eyes, and curly hair, “Cheddar Man” most surprised people who’d seen “Encino Man” too many times.

If we build it…

A Long Island company has proven that they can 3D print a home that’s 70% cheaper and 200% stronger than traditionally constructed homes. While that company’s paperwork clears, Chinese manufacturer WinSun continues to forge ahead with large-scale 3D printed construction, this month unveiling these Shanghai-area bus shelters.

Not to be outdone, Made in Space printed out the world’s longest single 3D printed piece (a beam) in the world — in their terrestrial offices. Next up: condos on the moon (dibs).

See you in March! And in the meantime…

PRINT SOMETHING

The post The (ALL-NEW) Month in 3D Printing: February Amazed Us appeared first on Shapeways Blog.

How long have you been working with models? 

Fifty-one years. I started when I was eight, and continued building until I was in my late teens. At that point, I had built over 200 models up to 1/4 scale in size. But then I just kind of quit until about two years ago. I found myself working on a 1/6 scale ’34 Ford Coupe that nobody seemed to have parts for. Through a moment of serendipity, I heard about 3D printing. Since I’ve been working with computers for over 30 years, I figured I’d try my hand at it. What started as me making parts for myself blossomed to a full-blown business when others wanted my designs too, so I started 3D Model Specialties to meet demand.

Tell us about a project you’re particularly proud of.

My biggest, and most exciting project is still the ’34 Ford coupe. I’ve actually been working on it for 20 years, but was trying to scratch build everything, which was not working out well in that large scale. I’m very proud of my collection of engines that has grown immensely in the past two years that I’ve been creating parts for the Shapeways store.

“Through a moment of serendipity, I heard about 3D printing. Since I’ve been working with computers for over 30 years, I figured I’d try my hand at it. What started as me making parts for myself blossomed to a full-blown business when others wanted my designs too…”

How did you learn to make 3D models? What software do you use?

It was quite challenging at first, but I picked it up quickly. I started in OpenSCAD, a free command-line CAD software. I’ve typed hundreds of thousands of lines of code to create parts, but I’ve started to work in Rhinoceros to make better models for my customers. That, and my fingers are sore.

My first parts were for the twin turbo engine for the ’34 Ford. I can now add about 20-30 new parts a week to my store, which can be hard to keep up with!

How does it feel to do what you do? How does it feel, after the hours you put in modeling, tweaking, and getting things just right, to finally hold that finished piece in your hand?

Modeling is a great way to express oneself, by customizing, painting and assembling unique cars, trucks, etc. Creating new, fresh and unique parts is a passion for me. It’s exciting to offer parts to the thousands of modelers out there that are tired of just buying a kit and gluing it together. They want individualism, uniqueness. Something that knocks their project out of the park.

I try to offer parts that have never been offered, as most kits today are the same ones I remember from 30 years ago in new boxes — sometimes not even that! There are very few, if any, updated engines, intakes, chassis, and wheels available, so I try hard to offer as many as I can. And I’d say I’ve succeeded. 3D Model Specialties now has over 1,050 parts in the store across 10 scales.

“It’s exciting to offer parts to the thousands of modelers out there that are tired of just buying a kit and gluing it together. They want individualism, uniqueness.”

What has 3D printing added to your appreciation of model cars?

3D printing is a scale modeling paradigm shift. Nowadays, as long as it fits in your printer, you can make it. I use full-scale car parts catalogs as guides to create new parts. With 3D printing, if it looks cool, I can make it. And there’s a ton of cool parts out there.

“With 3D printing, if it looks cool, I can make it.”

How did you buy or make model cars before you discovered Shapeways?

Like everyone else: kits, aftermarket, scratch building, and resin parts.  In my teens, I ended up basically building everything from scratch, as normal kits weren’t cutting it for me even then. It took 40 years and the advent of 3D printing to get me back into it.

How has Shapeways changed the way you do business?

When I started out, I only offered 1/8 scale and up, which was the limit for my home printers. It’s also more fun for me because I can get into much more detail over smaller scale builds. 

But with Shapeways, I can offer all of my parts down to 1/25  scale and some I can do as tiny as 1/32, which most home printers can’t even touch right now. I love starting from scratch and making super-detailed parts, knowing that thanks to the power of Shapeways, they’re available to everyone.

Give us some of your favorite memories interacting with the Shapeways community.

A lot of my customers have connected with me on social media. We talk almost every day on and off the site. Many of them have become very good friends, and it’s always great when I get a message from a customer telling me how much they loved one of my parts.

On a more personal note, I’ve worked with a lot of clients to produce custom parts for cars that have special significance to them — the car they drove to high school, or in one case, the car this particular customer’s father owned before they died. Making custom parts to get it just right means a lot to them, and I’m proud to help them out.

“I love starting from scratch and making super-detailed parts, knowing that thanks to the power of Shapeways, they’re available to everyone.”

What do you have coming up, and what plans do you have moving forward for your model-making?

For me, it’s just business as usual. I want to continue to offer different model bodies that most other stores don’t have. Another space I want to get into soon is motorcycles and top fuel boats. But of course, I’m always looking for insane engines and chassis parts to design and print.

(We usually don’t post this, but Ron’s answer was too good to not share. We can only imagine he typed this with a very self-satisfied (but well-deserved!) smirk.)

Can you tell us about another modeler with a storefront that should be featured?

I don’t know of any of the current modelers that have a storefront. They’re all coming to me for their parts.

You can find Ron’s store right here, where he offers over 1,000 model parts ranging from 1/6 scale all the way down to 1/32 scale. 

The post Ron Olsen, The Man of 1000 Models (and counting) appeared first on Shapeways Blog.

Our Hometown Is so Next Level

Eindhoven birthed Shapeways, and now, geniuses at the Eindhoven University of Technology are creating the first 3D printed steel-reinforced concrete bridge. As Engadget reported, the bridge will be installed in September, and will serve bike commuters. In the meantime, it’s being 3D printed, with the steel elements cleverly integrated into the concrete printing process. That saves on concrete, which saves on CO2 emissions, which might just help save us all.

The Eindhoven University of Technology Built Environment program’s 3D printer at work on the bridge (Courtesy Eindhoven University of Technology)

The Navy Throws a Sick Block(chain) Party

Blockchain distributed database technology might have originated as a way to support bitcoin transactions, but lately, it’s so popular for its inherently strong security that even the U.S. Navy is getting in on the action. As the Department of the Navy reported, they’re bringing all their 3D printers onto a decentralized network that will assure that all the data that goes into the design and production of 3D printed parts is secure across a huge network of connected nodes. To get that 3D file of a critical piece of defense infrastructure, you’d have to hack into every computer the database lives on at once. Good luck with that, hacker foes.

Traditional, less secure networks vs. decentralized blockchain networks (via U.S. Department of the Navy)

High-Performance, Lego-Inspired Driving Machines

CNBC brought us the story of Kevin Czinger, whose 3D printed sports car, the Divergent Blade, uses aluminum joints that, conveniently, fit together like Legos. Czinger touts the environmental friendliness of his manufacturing techniques, and sees a future of local automotive manufacturing via 3D printing. We see a new frontier in car customization. If our RC car accessories designers are any indication of the possibilities that come with full-sized 3D printed rides, THERE WILL BE MODS. Check out Czinger’s hangs with known car guy Jay Leno, below:

Oh Yeah, We’re the Factory of the Future

The Economist had a 3D printing party this week with a string of pieces on how 3D printing is changing manufacturing. Our CEO recently gave them his take on this manufacturing revolution, and now it looks like they’re tripling down. So, what’s so revolutionary? Well, we are abandoning traditional economies of scale, enabling mass personalization, and reinventing “mass” production. Color us flattered!

The post The Week in 3D Printing: Bridges, Blockchains, and Cars, Oh My appeared first on Shapeways Blog.

To the Moon!

It’s finally happened: a (mostly) 3D printed rocket engine has blasted into space! Taking off from New Zealand, the Electron rocket engine was printed in 24 hours and is more efficient and higher-performing than other existing rocket systems. 3D printed components are ideal for space travel because they can be designed to provide incredible strength with little actual material use — making them lighter, and therefore more flight-ready. There are still a lot of challenges to overcome before 3D printing itself will work robustly off-planet. And that’s why we decided to set up shop on Earth. FOR NOW.

Down to Earth, But Still Out of This World

Michelin has unveiled a 3D printed tire-and-wheel concept that might just blow your mind (just watch the video). Not only is it made from recycled materials, it’s also printed as a single part, and is puncture-proof. I’m not sure we’ll quite reach the printing speeds required for a roadside wheel print anytime soon, but hey, throw those alternate snow tires in the trunk and you’re good to go. Good job, Michelin — you’ve literally reinvented the wheel.

Helping Amputee Kids Reach for the Stars

What’s the cutest, sweetest, most touching thing you can imagine? How about this little girl, holding a ball with her new 3D printed prosthesis? Bristol, England-based Bristol Bionics is working to give amputee kids low-cost hands, all (yep, it gets cute again) based on Disney characters! The aim is to give kids something they’ll want to show off, rather than something they’ll want to hide. I mean, with little Tilly and her Deus Ex-themed hand, I feel like she’ll be the most popular kid in school. She would definitely be the most popular kid in our office.

Courtesy Open Bionics

We’ll Always Have Pittsburgh…

“They” are calling Steel City the next Silicon Valley of 3D printing, and folks from The ‘Burgh are like, “We’re proud to be the Pittsburgh of 3D printing, thanks.” But seriously, with companies like GE at the forefront and brainpower flowing in from Carnegie Mellon, the University of Pittsburgh, and Robert Morris University, Steel City has all of the potential to become, once again, an American manufacturing hub — but with the environmental sustainability of additive manufacturing at its core. Sounds like this slice of America could be even greater this time around….

Right on Track

Forbes’ Alex Knapp brought us the story of racing’s acclaimed Team Penske, who have signed a deal with Stratasys to 3D print prototype parts, car components, and tools to maximize performance on the racing track. With the speed at which these cars travel, it’s no surprise that Team Penske is tapping into digital manufacturing to maximize production efficiency. Plus, you can innovate and iterate at breakneck speed, leading to lighter, more efficient parts. See a trend?

Careful, This Axe Shreds

A Swedish designer and professor has created the world’s first 3D printed aluminum electric guitar. While not everyone’s a fan, this is a musical feat we can get excited about. Especially because the designer has a band that plays with 3D printed instruments. Maybe they can play our company party?

The post The Week in 3D Printing: Good News? Yes Please! appeared first on Shapeways Blog.