• 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.

A Little 3D Printing History

A revolutionary process that has made impacts in nearly every industrial application around the globe, 3D printed rapid prototyping was created by engineer Chuck Hull in 1983. In its original form, Stereolithography (SLA) was invented to solve a practical problem in speeding up product development. Tired of waiting to get down to business in making new parts, Hull worked in his lab for years to come up with a better solution. Initially inspired by the common practice of using multiple layers of coatings to strengthen products, Hull was curious to see if he could indeed make 3D objects with thousands of layers of resin material cured and hardened by a UV laser. 

While it may have taken decades for his invention to hit the mainstream market, 3D printing quickly played a continued role in success behind the scenes for innovative products being made by automotive companies thinking ahead of their time, along with organizations like NASA. Today however, without the services of 3D printing, many traditional manufacturers still remain stalled during prototyping, waiting for models to be produced by other methods which could hold projects up indefinitely and cost substantially more.

Fast Turnaround Leads to More Efficient Feedback 

Although additive manufacturing is being used for functional parts in important applications, manufacturers rely on 3D printed rapid prototyping services more than ever before. One important difference is that now they may use the same material and technology for both prototyping and functional use. This is made easier due to the ever growing selection of advanced 3D printing materials and technologies to choose from. 

No lead time is required, meaning that designers have the freedom to choose when they want to start prototyping. At Shapeways, the process is as easy as uploading a 3D model and getting an instant quote back along with file analysis to ensure quality 3D printing. While some customers may create 3D printed prototypes for displays or meetings, others may be iterating their way to perfection. 

The 3D printed rapid prototyping process could require a couple of different iterations before product development moves on to the final part, but there are some Shapeways customers who go through a much more intense process, prototyping, making changes after feedback, and then continuing to iterate over a hundred times. Stringent project requirements and design guidelines usually dictate how rigorous the prototyping process will be, but that is completely up to the customer.

Typical 3D Printing Materials & Technology for 3D Printed Rapid Prototyping

Freedom in design is key when prototyping which is why so many Shapeways customers choose materials like Nylon 12 [Versatile Plastic] and technology like Selective Laser Sintering for both prototyping and functional use. SLS 3D printing offers high accuracy, along with good mechanical properties for prototypes. Offered in an array of colors for dyeing, as well as finishes–from Natural to Smooth–Nylon 12 [Versatile Plastic] is extremely popular because it is strong, yet flexible too. This translates to stronger, thicker parts 3D printed with greater rigidity, while thinner parts result in more elasticity.

Because SLS 3D printing operates as a subcategory of powder-based technology, supports are not required–resulting in much greater latitude in 3D modeling as any worries about designing for supports are eliminated, making the prototyping process even faster. Without support structures, the potential for damaging parts after 3D printing is also removed.

Materials like Multi Jet Fusion Plastic PA12 are also used in 3D printed rapid prototyping due to high strength and accuracy, and the same amount of design freedom offered through MJF with no need for support structures. Multi Jet Fusion technology is extremely well-adapted for prototyping due to precision in parts, as well as the excellence offered in surface quality and texture.

For prototypes that require finer details, designers often turn to SLA technology with materials like Accura 60, Accura Xtreme, and Accura Xtreme White 200. SLA 3D printing offers accuracy, good mechanical qualities, and also nice smooth surface finishes which make it a popular choice for designers making 3D printed rapid prototypes or end parts that require a more realistic look.

Find out more about rapid prototyping services with Shapeways here.

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 additive manufacturing solutions, and get instant quotes here.

The post 3D Printed Rapid Prototyping Streamlines Product Development appeared first on Shapeways Blog.

Nothing drives continued progress more than customer demand—and especially when it comes to recreation. The notion of playing games is as old as the human race itself, allowing individuals to connect, whether playing an ancient precursor to chess with hand carved pieces, or connecting in person to play a tabletop game, made all the more colorful with 3D printed characters. 

Spanning every culture, games offer a shared space for relaxing with family and friends. Gaming today offers infinite possibilities for exploring new digital realms, roaming make-believe worlds. This is especially true in role-playing games (RPGs) where players live vicariously through their characters, engaging in fascinating experiences and acting out scenarios that would not be possible in real life. 

Although games like Dungeons & Dragons originated in the 70s they are more popular than ever, experiencing a huge resurgence propelled by the ability to engage and meet online.

Rapid Prototypes for Quality Product Development

3D printing offers many important features, beginning with the ability to customize and design products that may never have been possible before with traditional manufacturing. The original intent of 3D printing, however, was in rapid prototyping–a process that can be highly beneficial in 3D printing for gaming. 

Although 3D printing technology has grown immensely, evolving into the use of additive manufacturing for high-performance parts in critical applications, the ability to create 3D printed models for testing and perfection still offers a great advantage. The process is economical and fast, allowing for fast changes and as many iterations as necessary for the product development process. Prototyping also allows for easier experimentation in terms of different materials for products associated with gaming, as well as choosing the most suitable type of technology for the design.

3D Printed Tabletop Characters and Miniatures

3D printing is a powerful element in the modern gaming world, where the need to connect with characters runs deeper than ever. Immersion into the character is a must for many tabletop gamers, increasing the excitement level further when everyone is using miniatures for better visualization and access into the heart of the story or journey. With the ability to customize to their heart’s content, gamers can bring their characters to life like never before, venturing forth in fantasy with 3D printed miniatures that match their characters precisely. Miniatures can also be created for durability and long-term gaming use, or as collectibles.

Previous to 3D printing, it was not uncommon for characters related to tabletop gaming to be produced via mass production or hand-sculpted from any variety of materials. Beyond that, many dedicated enthusiasts created miniatures by cutting and gluing different pieces and then hand-painted their characters too. While that type of work requires meticulous attention for quality pieces, up until recently many 3D printed characters were still hand-painted too. Such time-consuming work is no longer necessary with the ability to 3D print in exquisite color and detail. This includes exact color matching, and tools for shading and contrast.

Both the gaming industry and the 3D printing industry are accelerating at a rapid pace, and the intersection of the two leads to unprecedented efficiency and production. Shapeways continues to lead 3D printing for gaming solutions, bringing advanced materials and technology to the table for gamers and designers seeking durable products as well as more intense detail with materials like High Definition Full Color. 

With access to more than ten million colors, High Definition Full Color is 3D printed with Material Jetting 3D printing technology. This process offers speed and precision, along with a wide range of impressive hues and textures. Exceptional surface finishes can be achieved, along with fine detail.

Create Custom Game Pieces, Boards, and Accessories

An astonishing array of game pieces can be 3D printed too; for example, parts for checkers games are fun and easy to create and customize. Chess pieces are a popular item to 3D print as well, but can be found in much more complex and artistic designs. Game pieces may be simple, elegant, and even ergonomic.

Simple or complex gaming boards can be made too, in any number of configurations, whether featuring interlocking pieces to be assembled, or even embedded electronics. Gaming dice, puzzle pieces, and parts for consoles are common designs too.

Advanced material like Nylon 12 [Versatile Plastic] and Selective Laser Sintering are good choices for a wide range of pieces and accessories, whether prototyping, creating functional parts, or both. With the ability to customize via 3D printing, completely original parts can be prototyped and created for years of use, and even handed down to other generations. These can even be turned into great 3D printed gift ideas!

Explore Other Material Options

With over 90 materials and different finishes available, high-quality 3D printing materials are a tremendous source of pride at Shapeways. Great care is taken in choosing all resources, as well as reaching out to new manufacturing partners and suppliers. Each material offering is unique, bearing its own technical specifications too. 

To get the perfect look and feel for any 3D printed part, check out the material options that Shapeways offers. Each material listed notes the available finishing options to ensure that your aesthetic parts look good, and your functional parts perform how you need them to in the end. 

Upload your design and get an instant quote now!

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 Gaming Accessories: The Best Things to 3D Print appeared first on Shapeways Blog.

Names and descriptors associated with aircraft and technology like drones abound. From aerospace to aeronautics and from aviation electronics technology to autonomous urban aircraft, drones go by a variety of other monikers too: unmanned aerial vehicles (UAVs), human-controlled devices, 3D printed quadcopters, hexacopters, and more. Drones also offer vast new perspectives on the Earth’s terrain, opening up new ways to handle projects and missions globally, as well as within busy cityscapes and more provincial areas. 

Humankind may have exhibited an ongoing obsession with the idea of being able to fly, but now we also have the capacity to let machines do some of the work and the flying without us from above, improving life below. With industrial drones, the focus is less on soaring through the clouds to while away the time, and more on expanding productivity like never before.

3D Printed Drone Systems Take on the Difficult Assignments

When the sky really is the limit, people tend to get excited; after all, there is a sense of exhilaration in seeing technology of the future come to fruition, suddenly accessible and affordable. This goes for both 3D printing and drones.

While regulations may be having some impact, drones seem to be evolving at a rate far more sophisticated and accelerated than rulemakers can keep pace with. And in the meantime, large organizations, businesses, and enthusiasts seem to have little trouble embracing the use of drones; after all, the door is wide open to countless opportunities, especially with the capacity to use new methods for gaining valuable information, and the new ability to take action in places that humans may not normally be able to access.

Both semi-autonomous and completely autonomous drones are already in use for a variety of applications, although initial concepts like delivery of consumer goods may still be stalling in comparison to use in the following areas:

• Construction – Because drones can reach building projects from above rather than just on theground, they bring a whole new approach to creating new infrastructure and assisting in reaching architectural structures at elevated heights.

• Delivery – The transport concept is particularly exciting not only because consumers love the idea of retail products being dropped right on their front lawns, but also because critical items can be delivered to hospitals, labs, and businesses too.

• Disaster recovery – This is an incredibly useful service drones are able to offer humankind, as they have the ability to go into areas where humans cannot or should not. This is especially true after a disaster, and in fact, it may be impossible to transport water, medicine, or various other types of aid into certain areas without the help of drones. 

• Military – While much of the military’s use of drones is kept ‘under the radar,’ the technology is known to be used for defense, especially in terms of surveillance and gathering of intelligence. It’s also no secret that the military has been engaged in the use of 3D printing for longer than most people realize, drawn to the technology due to the level of customization possible, and the ability to make and maintain parts in the field.

• Surveying – It’s impossible to compete with the aerial perspective afforded by drones, making them highly suited to applications requiring mapping and surveying, as well as covering large areas of land like farms that may require scanning, monitoring, and inspecting. In terms of real estate, sales and marketing efforts can be substantially expanded with features like interactive 3D showcasing of properties and of course, aerial footage.

Customization and Optimization for Industrial Applications

With the ability to bypass street traffic and cover short distances quickly while equipped with cameras, video equipment, and varying payloads, it’s obvious that drones will soon become necessary to chipping away at the endless list of tasks humans need help in completing. Undeniably useful in playing a role for taking on skyward duties within both the public and private sectors, features and functions continue to grow for drone technology, along with the advanced materials and technology used to make them.

Technology like 3D printing offers even greater opportunity and freedom in design, along with fast prototyping and turnaround of end-use parts. At Shapeways, customers rely on a variety of resources for drone applications, depending on their exact needs. Most 3D printed drones share the same two requirements initially: they must be lightweight, and they must be fast. Whether rapid prototyping or manufacturing end-use parts, Shapeways offers materials for 3D printing drones, to include:

Aluminum – Offering the strength of metal for 3D printed drone frames and parts, this material is recommended for high-performance components. Aluminum is lightweight, yet offers the toughness and durability necessary to survive air travel, as well as holding up during any unfortunate collisions while traveling. 

Nylon 12 [Versatile Plastic] – Used in a wide range of industrial applications, Nylon 12 [Versatile Plastic] is known for the ability to offer flexibility for thinner structures, yet great rigidity for thicker parts. Large-scale 3D printed drone parts can be manufactured with this material via Selective Laser Sintering (SLS), whether for prototypes or end-use parts.

Multi Jet Fusion PA12 – Superior in terms of strong yet lightweight material, along with excellent mechanical properties, MJF PA12 continues to be popular for drones of all types, including those with intricate details. 

Nylon 11 [PA11(SLS)] – This material offers some of the same benefits as Nylon 12 [Versatile Plastic] in terms of flexibility and suitability for interlocking parts in 3D printed drone designs; however, Nylon 11 [PA11(SLS)] is also versatile for high-performance applications like drones and aerospace overall, featuring high ductility and resistance to impact.

Depending on the type of drone, technology like Stereolithography (SLA), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF), or Binder Jetting may be used.  

Shapeways Customers Excel with 3D Printed Drone Systems

Companies like Munich-based Quantum-Systems have relied on Shapeways for 3D printed drone parts since the inception of their company which specializes in the development and production of automatic, electric vertical take-off and landing (eVTOL) fixed-wing drones. Featured as a prime example of the incredible impacts drones are making in applications like delivery and medical simultaneously, Quantum-Systems showed the exponential difference in time when their Trinity F90+ drone transported medical samples to labs. Compared to travel via courier in street traffic which could take an hour or much more, the Trinity F90+ delivered test samples in just seven minutes. These benefits could easily translate to delivery of medications and other items carried within the drone’s transport box.

Menlo Park, California-based Kespry sought out Shapeways for 3D printed drone parts due to scalability, speed, and reliability. The collaboration began before Kespry even had their first customer, and as volume has increased, the transition to 3D printing at higher volumes has been seamless. Demand quickly grew for the Kespry lightweight, autonomous drone systems, capable of surveying and mapping out hundreds of acres within just a couple of hours. 

To enjoy exploration of the skies in uninterrupted, unpiloted flight, high-quality manufacturing with the ability to customize and optimize drones depending on the business solution is key. Drone technology isn’t a novelty at this point anymore, and neither is its intersection with 3D printing; what is impressive, however, is the rate at which both technologies are accelerating in terms of industrial manufacturing–and complementing one another in the process.

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 additive manufacturing solutions, and get instant quotes here.

The post 3D Printed Drones for Industrial Applications: New Perspective for Higher Productivity 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.

Understanding Customer Applications and Needs is Key

In a recent webinar, co-presented by Shapeways, Dr. Cary Baur, Manager of Polymer Material R&D explained that the EOS Additive Minds Team is focused on understanding manufacturing customers and partners. To increase productivity, the key is to see where AM technology can be applied to make a real difference. This means tailoring a solution through:

• Identifying relevant applications
• Developing applications to fit into the product portfolio
• Creating business value
• Increasing and certifying production

SLS 3D Printing Technology Opens the Door to Expanding Productivity

Shapeways and EOS have been long-time manufacturing partners, with a focus on delivering 3D printed materials via Selective Laser Sintering (SLS). The process begins as thin layers of polymer powder are dispersed over the build platform. A computer-controlled CO2 laser traces the cross-section of the 3D design on the powder. It then scans many fine layers, fusing them all together at a high temperature, just under the melting point,  until the 3D printed structure is complete. 

“In the end we’re able to build parts with very fine features and details,” said Baur. “For the most part, we use fairly common engineering plastics that tend to translate well to applications that are already out there and maybe being used via other methods too, like injection molding or CNC machining.”

Baur also points out that in looking at many 3D printed parts it becomes obvious how difficult it would be to manufacture such complex geometries any other way.

A great by-product of powder-bed fusion is unsintered powder surrounding and stabilizing parts during printing, acting as a natural support. In re-using powder while also preserving material integrity, Shapeways contributes to increased sustainability in manufacturing, lessening environmental impact. Without a need for supports, the benefits are triplefold. Much greater design freedom is afforded to the industrial engineer creating the 3D model, hundreds of parts may be included in one build through nesting, and the potential for damage during post-processing is greatly decreased.

SLS industrial 3D printers can range in build volume size; for example, smaller printers may have a build volume of 200 mm x 250 mm x 330 mm, but printers from EOS can range in build volume from 650 mm x 350 mm x 550 mm to 700 mm x 380 mm x 580 mm, with a layer thickness of 100 to 120 microns.  

“What this technology really does in terms of creating value is it allows you to take a digital file and implement it with what is essentially a ‘design freedom toolbox,’” said Baur. “This new freedom offers the ability to look at design and manufacturing in a whole new way, along with designing components to fit in with each other during printing and reducing the number of parts.”

Rapid Prototyping Accelerates Product Development

Initially rapid prototyping was the whole point of 3D printing; however, as the technology has evolved since the 1980’s, the ability to prototype and to create iterations on an as-needed basis has only become more enticing; in fact, a dedicated customer may order one or two–or a hundred prototypes–until deciding on the best form and fit for a high-performance, end product. 

Extremely helpful in the early phases of working on a project, rapid prototyping plays a prominent role in so many applications today, behind the development of everything from architectural pieces to fine jewelry. Designers and engineers often end up making end-use parts with the same material they were testing and refining products with. Nylon 12 [Versatile Plastic] 3D printed with SLS technology is a perfect example.

“Rapid prototyping allows you to dip your toes in the water in the sense that you can build geometries up front, investigate product failure, and integrate improvements into the products,” said Baur.

Customization and Functional Integration are Driving Change

The ability to customize is one of the most appealing benefits of 3D printing. It’s no longer a one-size-fits-all world, with customer demand motivating manufacturers to offer greater personalization. In terms of applications like medical 3D printing, products and devices can be tailored completely to an individual, changing the face of that particular industry forever with the ability to offer better and better patient-specific treatment–in and out of the operating room.

Mass customization also allows businesses to look further into their development process and consider how they can be more in tune with their customer base. This includes examining what types of products they want in a particular shape or size, and building them on-demand. With the ability to set up customized 3D printing as needed, whether in low-volume or mass production, businesses can say goodbye to the expense of buying their own equipment or storing inventory where it just gathers dust in a warehouse. Shapeways does all the work from the ordering process to product fulfillment and delivery. 

“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 just sitting there,” said Baur.

With the ability to design nearly anything, manufacturers can use 3D printing to make custom parts that used to be very bulky but are now significantly reduced in mass, lighter in weight. Material inputs can be reduced dramatically too along the same lines. With functional integration, parts that used to have to be machined or molded separately and assembled with different processes can now be made in one large print build.

“You can actually make a real difference in how many components you’re using to make a functional part work,” said Baur.

With a focus on both metal and polymers, Shapeways and EOS are continuing a partnership that means bringing the most advanced materials and technology together for ongoing growth in product development–transforming manufacturing with a focus on reducing material waste, sustainability in processes, and opportunities for greater efficiency.

“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 Shapeway 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 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 Your Production Power: Additive Manufacturing with EOS, Part 1 appeared first on Shapeways Blog.

• How PA6MF is unique in terms of strength as a 3D printing material.
• Why this industrial material is so popular for engineering applications.
• The power of Selective Laser Sintering technology in combination with PA6MF.
• The advantages of low-volume production and on-demand 3D printing at Shapeways.

Nylon 6 Mineral Filled, Ultrasint® (PA6MF) is an undeniably unique and powerful 3D printing material that Shapeways offers for high-performance parts and prototypes requiring strong mechanical properties. Reinforced with polymer particles, PA6MF provides adaptability and accuracy for quality 3D printing of parts which often possess complex geometries. 

The Real Advantage: PA6MF for Small Production Runs

As an industrial-grade 3D printing material, PA6MF continues to be extremely appealing to many manufacturers because it offers properties similar to parts created with injection molding.  

“PA6 is essentially one of the most commonly used materials on the planet in traditional manufacturing,” says Steve Weart, Director of Customer Success at Shapeways. “By enabling our customer base to create end-use products with this material through additive, we can provide the ideal solution for low- to mid-volume production requirements for many of our customers throughout the product life cycle.”

While PA6MF is an excellent option for prototyping, Shapeways takes it one step further in offering this material as an excellent alternative for end-use parts. The benefits become even more clear for companies focused on creating highly customized designs for low-volume production. There’s no reason to worry about the complexities of mass production or making molds when 3D printing can do the job quickly, efficiently, and more affordably. Not only that, the ability to make changes quickly in 3D adds a serious advantage to the development and production process–again, saving time and expense; in fact, some customers may make over a hundred iterations in bringing a functional part to perfection.

PA6MF is a good choice for parts that require high stiffness, strength, and heat stability. While all Ultrasint® PA6 materials combine high modulus, high strength, and excellent thermal distortion stability, PA6MF offers added reinforcement with minerals embedded in the powder particles. This promotes better homogeneity in the material, along with improved potential for spreading during the 3D printing process–and recycling after.  

Selective Laser Sintering (SLS) – How the Technology Works

SLS reigns not only as one of the earlier forms of 3D printing, but also still as one of the most powerful and respected methods–even over the original technology known as Stereolithography (SLA), and popular methods too like fused deposition modeling (FDM). This powder-based technology is used to manufacture a host of complex structures that are often not possible with conventional methods, including products with moving or interlocking parts too.

SLS 3D printing begins with distribution of the powder over the print bed, with a computer-controlled CO2 laser tracing the cross-section of the 3D design on the powder. It then scans each layer, fusing them all together at a high temperature (just under the melting point) until the 3D printed structure is complete. SLS 3D printers may range in volume size from 200 mm x 250 mm x 330 mm to 700 mm x 380 mm x 580 mm, with a layer thickness of 100 to 120 microns. 

Thousands of parts can be printed in one build, made possible due to the ability to ‘nest,’ by strategically placing parts together in each build. This is also due to another advantage: no supports are required, as the extra powder in each print surrounds and bolsters the desired structures during production. Powder can be reused later too, allowing Shapeways to continue manufacturing with sustainability and lessening the impact on the environment.

Industrial Background on PA6MF

BASF produces PA6MF under the iForward AM corporate brand. Due to a long-term manufacturing partnership, Shapeways has access to the full spectrum of BASF’s extensive portfolio of resources–providing superior materials designed to meet the highest in customer requirements for 3D printing. Materials like PA6MF play an important role in modern manufacturing as businesses of all sizes begin to explore new ways to improve production, including new hardware, software, materials, and processes like on-demand 3D printing. 

Also known as Polyamide 6, Nylon 6, or polycaprolactam, PA6MF is a well-known thermoplastic for engineering applications. It’s common for the focus to be on lighter weight materials–specifically PA11 or PA12–where such requirements are critical to applications like robotics and drone technology. Materials like PA6MF, however, are typically used with strength in mind, for mechanical devices like bearings and structural applications. 

Along with its high melting point, PA6MF is also known for:

• Abrasion resistance
• Chemical resistance
• Fatigue endurance
• Good rigidity
• Toughness, and strength against impact

Parts printed from Ultrasint® PA6 MF are naturally black, with a standard matte finish that has a slightly rough surface.

Bounding box requirements are as follows:

Bounding Box Minimum

X + Y + Z > 10 mm

Bounding Box Maximum

375 x 375 x 440 mm

Companies that are new to additive manufacturing may wonder whether or not 3D printed industrial parts will be as good as those made traditionally. The answer is yes. Not only that, these 3D printed parts have the same level of structural integrity.

In low-volume production, 3D printing with PA6MF pays off due to the ability to make a small number of parts quickly and economically, with exact repeatability for every part, every single time.

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 solutions, and get instant quotes here.

The post Material Guide: PA6MF Offers Unique Industrial Strength for 3D Printed Parts appeared first on Shapeways Blog.

• Why Nylon 12 [Versatile Plastic] continues to rise in popularity for 3D printing across a wide range of industries.
• How the Premium finish adds an upscale touch to 3D printed products.
• Comparisons between the Premium finish and the Natural Finish in terms of material properties, detail, painting, and more.

Shapeways offers over 90 different materials and finishes, with Nylon 12 [Versatile Plastic] topping the list in popularity. 3D printed with Selective Laser Sintering (SLS) technology, this material is an industry favorite–and a well-named one–in terms of incredible versatility. 

Flexible for thinner structures and strong for thicker ones, Nylon 12 [Versatile Plastic] offers excellence in mechanical properties, including tensile strength, durability for long-term use, and resistance to abrasion, fatigue, and stress.

Premium Nylon 12 [Versatile Plastic] offers an upscale finish, elevating designs with a smoother and glossier surface, offering a surface texture that is soft to touch. The Premium finish is recommended for the following:

• Interlocking parts
• Fine jewelry
• Home decor and art pieces
• Accessories like phone cases

Shapeways employs  a multi-step tumbling, polishing, and dyeing process to create a consistent color and surface finish, while removing the grainy feel and layered look of 3D printed parts. Customers continue to rely on Nylon 12 [Versatile Plastic] and finishes like Premium for some impressive projects, on the small and large scale:

Verner Architects designed a six-foot vanity for a luxury remodel on a home in California. Shapeways 3D printed their interior statement piece with durability and water resistance in mind since it was for a childrens’ bathroom. Other manufacturers like Tilt Hydrometer collaborated with Shapeways to 3D print free-floating monitoring devices for homebrewing, while 67 Designs has installed 3D printed luxury accessories like iPad mounts in their off-roading vehicles.

Over time, there have been many questions about the Premium finish, answered in the FAQs section below:

Material Properties

Are the material properties the same between regular Nylon 12 [Versatile Plastic] and Premium?

Yes. The same 3D printing material and SLS technology is used for Premium.

Appearance

But exactly how is it different then? Are there images of samples available?

Premium finish was created to enhance 3D printed products with a more finished look that equals the aesthetics of injection-molded products. The smoothness and eggshell sheen of Premium should meet the demands of high-end consumers too, lending a more professional appearance for unique, customized products.  

Feel and Surface Roughness

How much smoother is Premium?

Just saying Premium is smoother can be too vague, so Shapeways performed surface roughness tests. A surface roughness tester quantifies the texture of a surface by measuring the distance between the peaks and valleys. The larger the distance and the higher the value, the rougher the surface is. Small values indicate a smoother surface.

Surface roughness is measured by its Ra value. Ra is the average of these distances between the peaks and values on the surface to its ‘mean line.’ You can think of the mean line as the center line between the peaks and values.

Looking at the values in the table above, the Ra of Premium measured around 5 micrometers whereas regular Nylon 12 [Versatile Plastic] measured around 10 micrometers. This means that Premium is about twice as smooth.

Dimensional Accuracy

Is dimensional accuracy different with the Premium finish?

Shapeways also tested the effect of Premium finishing on the dimensional accuracy of parts by measuring multiple dimensions both before and after post-processing. Six measurements were taken on six different parts. On average, the parts decreased in size by 0.9mm. The maximum material removed was 0.1mm.

Scaling up your design slightly to account for this difference is recommended if dimensional accuracy is important for your product’s application.

Detail Level

Do you lose intricacy in detail with Premium?

Although the dimensional accuracy changes slightly with Premium, no visible difference in details are found. Both embossed and engraved details looked very similar before and after finishing during testing.

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 solutions, and get instant quotes here.

The post 3D Printing Materials Spotlight: Premium Nylon 12 [Versatile Plastic] appeared first on Shapeways Blog.

3D printing enthusiasts are usually eager to find out what Shapeways is offering in the materials lineup, and especially for 3D printing with metal. The demand for manufacturing with materials like aluminum continues at a rapid pace too, as other companies work harder to offer new services to their own customers. Working smarter–and manufacturing smarter–often intuitively means outsourcing metal additive manufacturing to the experts at Shapeways.

AlSi10Mg Provides Unique Features for 3D Printing

Shapeways offers AlSi10Mg for 3D printing with selective laser melting (SLM). A blend of aluminum, silicon, and magnesium, AlSi10Mg is used to make strong, highly functional parts and prototypes which help speed product development and enhance performance. 

While this metal may lack the superior strength of steel or titanium, aluminum is popular for parts requiring resistance to corrosion, as well as thinner walls within the geometry–something that can be a challenge to find in additive manufacturing. AlSi10Mg offers resistance to temperature as well as high pressure, and is suitable for products requiring high strength and accuracy.

There are also small amounts of iron included in this aluminum alloy, but it is the silicon levels which strengthen AlSi10Mg beyond use of the pure metal itself. Corrosion resistance occurs because of the oxide layer which forms on the surface of the material naturally. AlSi10Mg is also skin-friendly and heatproof to 570c/1058f.

Other material properties include:

• Good strength to mass ratio.
• Low density, which allows for the production of very strong, but lightweight parts.
• High thermal conductivity, useful for 3D printing parts like heat exchangers for many engineering applications.
• Very high electrical conductivity, useful for parts like electric wires used in power applications.

Shapeways offers this metal in a standard finish only.

How Selective Laser Melting Works

At Shapeways, SLM technology makes it possible to 3D print strong metal parts rapidly, and without tooling. Aluminum alloys like AlSi10Mg allow for the stiffness, accuracy, and high thermal conductivity required for functional parts and tools.

Selective laser melting (SLM) is known for its origins in the mid-90s, created along with other methods of powder-bed fusion at the Fraunhofer Institute ILT in Germany during a major research project. SLM is a subcategory of laser powder-bed fusion technology, which also encompasses 3D printing with thermoplastics; here, however, metal 3D printing with SLM uses a laser to completely melt each layer above the melting point rather than just taking it to the minimal point where particles are fused. And while heat may be distributed more evenly in comparable technologies like electron beam melting (EBM) where high temperatures are used in a vacuum atmosphere, surfaces are generally rougher and accuracy is decreased.

Laser bed fusion technology is somewhat akin to that of welding, as metal particles are melted and fused together–and in fact, this method is often referred to as ‘laser welding.’ 

“Metal – Laser Powder Bed Fusion is a mature technology, that has been used in many end-use applications within Aerospace to Medical industries” said Thomas Murphy, Senior Product Manager, Physical Products at Shapeways, in explaining why so many OEM’s still rely on that method for metal 3D printing today.

SLM offers a host of great benefits, to include:

• The ability to work with a variety of 3D printing metals, including aluminum, that offer high density.
• A highly efficient process that uses less energy and less material resources in comparison to traditional manufacturing.
• Quality production of highly complex products with intricate designs.
• Heavy customization to maximize performance in functional parts for critical applications.

It all begins with a digital file as CAD data is translated into a 3D design which is sliced and readied for 3D printing. In the case of aluminum, metal powder particles are dispersed over the build platform and then sintered as a laser provides heat, thus melting the layers together until the final structure is complete. 

Supports Are Required in SLM 3D Printing

Supports are key to protecting parts with intricate features and overhangs from deformation that can occur as a result of internal or residual stress during 3D printing. Depending on how complex the geometry is, there could be a lot of supports used to protect a part from cracking or warping during production. This is especially true for larger metal parts, which may require a much more sophisticated support system too.

“When you sinter that metal powder it actually becomes more dense,” said Murphy. “That material would fall down and you would not be able to sinter the next layer onto it without supports securing the part onto the build plate.”

After parts have been completely cooled, supports are removed in post-processing with compressed air. 

Aluminum is Used in Critical Applications

The ability to 3D print with newer resources like metal means greater opportunity for innovation and manufacturing, as well as more opportunity to expand in a wide range of applications. This also means that designers and engineers are able to go forward with products that would have been impossible to manufacture using conventional methods–looking toward aluminum and the opportunity to print a very solid structure that can also be very flexible and offer great features like thermal properties too.

SLM 3D printing with the fine metallic powder derived from AlSi10Mg is extremely valuable for applications like:

• Functional automotive and railway parts and prototypes
• Aerospace parts
• Drone technology
• Bicycle parts
• Tools and fixtures
•  Structural components

Innovative or redesigned components can be 3D printed in metal for applications like aerospace, improving turbines with new parts installed in larger assemblies for improved performance–harkening back to one of the greatest advantages in 3D printing overall: the power to make parts that would not have been possible previously.

3D printing with metal and other materials like aluminum is also paving the way for companies involved in automotive and railways to rebuild and make obsolete parts, and to keep spare-part inventories as needed; for example, an older vehicle or a train that is being restored, fixed, or just maintained may need a part replaced that is impossible to find because no one sells them anymore. With a quick 3D scan, that part can be replicated in 3D print. It is even possible to make additional improvements and customizations, along with numerous iterations to ensure the perfect fit.

Spare parts can also be kept for an on-demand basis, offering the potential to revolutionize how parts are kept and warehoused. Rather than collecting dust on shelves and eventually becoming obsolete themselves, parts can be stored on digital files and 3D printed as needed. 

Metal 3D Printing Continues to Accelerate

Understanding the technology is key, especially when it comes to 3D printing with metal. As accelerated market opportunities abound, many different types of materials, hardware, and technologies are becoming available. In metal 3D printing along with SLM, this also includes a variety of other technologies like electron beam melting (EBM), fused deposition modeling (FDM), material jetting, and binder jetting. Shapeways does also offer 3D printing with other metal materials via binder jetting, as well as metal casting for applications like fine jewelry too.

Placing metal 3D printing in the spotlight, Grand View Research shows that the 3D printing metal market size is expected to reach USD 2.36 billion by 2028, expanding at a CAGR of 25.7% over the forecast period.

“Market growth is attributable to the cost-effectiveness of 3D printed parts, reduced lead times, and the development of complex parts during production,” they state. 

And while speed and savings on the bottom line are factored in as some of the most motivating benefits, high costs associated with 3D printing setup still cannot be overlooked for businesses hoping to save precious capital:

“Until very recently, the complexity and high cost of metal 3D printers limited the usage of additive manufacturing to high-volume and low-value parts. SLM and DSLM printer prices start at USD 400,000 and can go beyond USD 1,000,000 and they also require carefully controlled environments and highly skilled workers,” states further data by Grand View Research.

While metal 3D printers–and other printers also–can be extremely expensive, that is part of the beauty in working with Shapeways. Other manufacturers can outsource their 3D printing needs without having to invest in hundreds of thousands of dollars or more in hardware. 

Explore Other Material Options

With over 90 materials and different finishes available, high-quality 3D printing materials are a tremendous source of pride at Shapeways. Great care is taken in choosing all resources, as well as reaching out to new manufacturing partners and suppliers. Each material offering is unique, bearing its own technical specifications too. 

To get the perfect look and feel for any 3D printed part, check out the material options that Shapeways offers. Each material listed notes the available finishing options to ensure that your aesthetic parts look good, and your functional parts perform how you need them to in the end. 

Upload your design and get an instant quote now!

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 Metal 3D Printing: An In-Depth Guide to Aluminum 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.