The AM process begins as the first layer is deposited onto the print bed and subsequent layers adhere to each other in forming a solid product. Differences in additive manufacturing technology become apparent, however, when resins, thermoplastics, metal particles, lasers, bonding agents, and a variety of other elements separate techniques.

Shapeways Additive Manufacturing Origins: Beginning with the Marketplace

Today, Shapeways offers over 11 different technologies, providing options for 90 different materials and finishes. Taking a step back though, the history of Shapeways began in 2007, with the launch of the Shapeways Marketplace. 

Serving as a unique platform for designers to create and access 3D models direct to the consumer, the Marketplace offers a unique business model that continues to grow in popularity. Hundreds of thousands of 3D printed products are available in a variety of categories, but the Shapeways Marketplace is especially well-known for jewelry produced via Wax Casting in precious metals like Gold and Platinum.

Industrial Additive Manufacturing Technology

From rapid prototyping to end-use production, manufacturers come to Shapeways for additive manufacturing in the following applications:

• Architecture
• Aerospace
• Automotive
• Consumer goods
• Drones
• Robotics

Shapeways offers the following additive manufacturing technology:

Binder Jetting

Binder Jetting additive manufacturing technology is named for the agents used to bond metal particles together as one layer is deposited onto another in creating complex structures. Support structures are not required as unsintered powder bolsters and stabilizes parts during production.

Binder Jetting materials include:

• Sandstone
• Stainless Steel 316L
• Stainless Steel 17-4 PH
• Steel

Benefits of Binder Jetting include speed, precision, expanded freedom in design, and the ability to manufacture large volumes with reduced material waste. Typical applications include medical devices, tooling, fixtures, branding irons and burners, and automotive parts.

Material Jetting

The Material Jetting (MJ) process is unique, relying on multiple nozzles to spray micro-droplets of resin material onto the print bed for curing via ultraviolet light, layer by layer. Shapeways Material Jetting 3D printers range in build volume from 490 mm x 390 mm x 200 mm to 495 mm x 495 mm x 300 mm, with layer thickness averaging 32 microns for full-size models.

Material Jetting materials include:

• Fine Detail Plastic
• High Definition Full Color

Benefits of Material Jetting include speed and precision, along with the ability to produce impressive colors, textures, and fine details. Typical applications include photorealistic medical models, architectural displays, and table-top gaming miniatures.

Multi Jet Fusion 

The Multi Jet Fusion (MJF) process stands apart due to its capacity for powerful production. Thermal heat melts layers together completely, resulting in faster production, and maximum output. Parts are well-defined with more stable mechanical properties and sophisticated interlocking parts can be printed in one piece without any need for post assembly. While size is limited to the volume of the printer, many different pieces can be printed in each build–nested horizontally and vertically–and then fitted together later if necessary.

Multi Jet Fusion materials include:

• Full Color Nylon 12
• Nylon 12 (MJF Plastic PA12)
• Nylon 12 Glass Beads (MJF Plastic PA12GB)
• Polypropylene (PP)
• Thermoplastic Polyurethane (TPU)

Benefits of Multi Jet Fusion include few limitations in design due to the integrity of technology and materials, accuracy in parts, and faster cooling due to an advanced standalone system that also prevents warping, shrinkage, and failure in parts. Typical applications include drone technology, prosthetics, robotics, and mechanical and electronic devices.

Selective Laser Melting (SLM)

The Selective Laser Melting (SLM) process is a powder-based 3D printing method. A powerful laser melts fine metallic powder particles together layer after layer until the desired structure is complete. SLM additive manufacturing technology produces strong metal parts fast without tooling, relying on Aluminum for stiffness, accuracy, and high thermal conductivity for making functional parts and tools.

Selective Laser Melting materials include:

• Aluminum

Benefits of SLM additive manufacturing technology include the potential for maximum customization, and the ability to build unique complexities into strong yet lightweight parts. Typical applications include automotive technology, drone parts, mechanical components, and tools and fixtures.

Selective Laser Sintering

Selective Laser Sintering (SLS) is also a subcategory of powder-bed fusion. This additive manufacturing technology uses a high-powered laser to trace the cross-section of each 3D design into the material dispersed onto the build area, sintered just below the melting point. Once the desired structure is complete, parts are cooled in the build chamber to avoid warpage and preserve integrity of the prints. Shapeways SLS 3D printers range in build volume 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.  

SLS materials include:

• Nylon 12 [Versatile Plastic]
• Nylon 11 [PA11(SLS)]
• Polypropylene (PP)
• Thermoplastic Elastomer (TPE)
• Thermoplastic Polyurethane (TPU)

Benefits of SLS 3D printing technology include high ductility, making it possible to create flexibility in thinner structures and rigidity for thicker parts. No support structures are required, leading to greater design freedom. SLS 3D printing is capable of printing large parts, as well as creating many different sizes of parts in large volumes. Typical applications include aerospace, architecture, automotive, home and consumer goods, medical, robotics, sports equipment, and more.

Stereolithography

Stereolithography (SLA) is a resin-based technology. Known as the original additive manufacturing technology, created in the 1980s, SLA has stood the test of time and is still respected as one of the most powerful 3D printing processes. As a subcategory of vat polymerization, SLA technology uses liquid resin materials to build parts. Objects are cured and solidified by UV light as each thin layer of material is deposited onto the build platform at the top of the resin tank. During the SLA process, a laser traces or draws the design of the part in each layer. 

SLA materials include: 

• Accura® 60 
• Accura® Xtreme
• Accura® Xtreme 200

Benefits of SLA technology include the ability to 3D print smaller, highly intricate parts with good mechanical qualities and a smooth surface finish. Typical applications include prototypes and display models, mechanical components, and snap-fit assemblies.

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 Additive Manufacturing Technology appeared first on Shapeways Blog.

With Polypropylene 3D printing, manufacturers have the ability to print as many iterations as necessary, and test rigorously in cases where such action is required during product development. For some designers and engineers that may mean 3D printing several prototypes for evaluations, and for others, they may need to create a hundred or more for intensive inspection, testing, and refining before taking the step to finalize end-use parts. Rapid prototyping with Polypropylene for 3D printing is fast and much more economical than using traditional manufacturing with requirements in lead times and tooling.

What is wonderfully unique about Polypropylene–and certainly convenient in terms of manufacturing–is that this industrial-grade material can be used far beyond rapid prototyping, transitioning into 3D printing of high performing, functional parts too. Highly complex parts can be made for applications which require superior mechanical strength and dependability.

With the demand for advanced materials and technology growing, Shapeways also sees many engineers and designers taking advantage of the intense design freedom Polypropylene delivers, mainly due to the lack of supports required during 3D printing. Designers and engineers are able to innovate like never before, creating products that may have been impossible previously with traditional manufacturing, but also in creating designs freed from the constraints of intricate, attached support structures. There is also the opportunity to redesign, improving more complex geometries for better form and functionality.

Why Polypropylene for 3D Printing?

Shapeways offers High Reusability Polypropylene with Multi Jet Fusion (MJF) technology, and Ultrasint® PP nat 01 for Selective Laser Sintering (SLS). These materials are unique not only because they can be used for both prototypes and functional components, but also because end-use parts are produced with mechanical properties and performance similar to products manufactured via injection molding (IM), offering extreme durability for long-term use, along with the smooth surface finish associated with IM. 

Polypropylene is also easy to process, with high reusability of powder later. This is especially helpful in terms of manufacturing sustainability when Shapeways is 3D printing larger volumes of parts.

Both lightweight and strong, Polypropylene for 3D printing offers the following material characteristics:

• Biocompatibility – Polypropylene meets ISO 10993 and US FDA guidance.

• Chemical resistance – Excellent resistance to chemicals makes this material appealing for use in manufacturing parts that may be exposed to corrosive elements.

• Low moisture absorption – Polypropylene is good for end-use parts that may be routinely exposed to liquids.

• High elongation at break – Measured by the amount of deformation that a product experiences under strain, Polypropylene is not only imbued with high elasticity, but also high elongation at break, listed as 20% for Elongation at Break X and 18% for Elongation at Break Z.

• Tensile strength – Defining how much stress a part can take before it breaks, tensile strength is measured in megapascals (MPa), which are units of pressure. With a good tensile strength like 30 (X and Z) MPa, Polypropylene is a tough material offering long-term durability.

Powder-based technologies like MJF and SLS 3D do not require supports, offering further benefit. Parts are already supported during the 3D printing process with unused powder. As it bunches up around the parts, they are stabilized throughout the process. Without the requirements to factor in intricate supports, engineers have much greater flexibility in the design process. There is also much less chance for damage to the 3D printed parts in post-processing since the hassle of removing supports is eliminated. 

Polypropylene with Multi-Jet Fusion Technology 

Shapeways offers Multi Jet Fusion (MJF) for complex 3D prints, resulting in prototypes and parts that are robust, with strong mechanical properties. This powerful technology is powder-based, but 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, resulting parts are stable, well-defined, and may feature details like interlocking parts that can be manufactured in one piece without any further assembly required later. MJF is beneficial overall due to less chance of warping, shrinking, or failure in 3D printed parts. Customization is further encouraged without the need for supports, and designers are able to make complex parts faster, with less time spent dealing with cooling and post-processing.

Like Polypropylene, MJF 3D printing offers many impressive advantages, making the two a winning combination for industrial strength in product development over a wide range of applications. MJF 3D printing includes highlights such as:

• Consistency in mechanical properties.
• A standalone cooling system which helps eliminate challenges specific to Polypropylene like warping and shrinkage.
• Streamlined production and efficiency in post-processing.
• Improved speed in turnaround for project deadlines

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 19 mm
• Bounding Box Max
  • 280 x 280 x 280 mm

This material is available in a natural gray finish, featuring a matte surface.

Find out more about design guidelines for Polypropylene 3D printing with MJF technology here. 

Polypropylene with SLS 3D Printing Technology 

SLS 3D printing 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. Using Natural Polypropylene (SLS), many different parts can be created with fine features and details–and for complex geometries.

SLS industrial 3D printers can range in build volume size, for example smaller printers can have a build volume of 200 mm x 250 mm x 330 mm to larger printers with 700 x 380 x 580 mm, featuring a layer thickness of 100 to 120 microns. Thousands of parts may be included in one build, boasting higher accuracy and repeatability than most techniques.

3D printing Polypropylene with SLS technology offers the following benefits:

• Strong mechanical properties, to include durability and high plasticity.
• Excellence in manufacturing for serial production and rapid prototypes.
• Compatibility for post-processing like hot plate and vibratory welding.
• Suitable for automotive coolant reservoirs and custom production tools.

Design Guidelines

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

• Bounding Box Min
  • 7 x 7 x 2 mm 
• Bounding Box Max
  • 280 x 280 x 280 mm 

This material is available in a natural, slightly translucent with a light yellowish shade, featuring a matte surface. 

Find out more about design guidelines for Polypropylene 3D printing with SLS technology here.

Applications for 3D Printing with Polypropylene

This versatile material is ideal for a wide range of applications like:

• Automotive – Manufacturers are able to use Polypropylene to test parts for fit and function in vehicles, as well as using the same material for interior parts or critical, high-performance exterior components. Polypropylene 3D printing is also used in fluid systems for automotive applications.
• Consumer goods like home goods and parts for appliances, and especially products which require resistance from chemicals or water.
• Electrical and sports goods such as health care and orthopedic products.
• Industrial goods such as tubes and piping, and tools, jigs, and fixtures.
• Customized medical devices for patient-specific treatment creating products like prosthetics, orthotics, and even orthodontics.

Polypropylene 3D printing has become widely used in all of the above applications not only due to its versatility but because of its potential for long-term use in products. While this material may be 3D printed to manufacture important car parts, it can also be used to create highly useful, ubiquitous items like living hinges–small hinges that open upward for items like plastic bottle caps.

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 Polypropylene: A Material Guide appeared first on Shapeways Blog.

Simplicity in 3D design helps drones go the distance

Quantum-Systems is a long-time Shapeways partner, headquartered just outside of Munich. While they find that enthusiasts typically have seen drones and even use them, many are still uncertain about the features involved and the technology behind them. As CEO Sebastian Sattler makes clear, however, their goal is not to offer their customers technology that presents massive technological complexities; rather, their design team focuses on total simplicity and efficiency in design. 

Quantum-System drones have demonstrated the ability to simplify processes too, disrupting common methods like delivering medical samples, transporting them by air instead with their Trinity F90 model.

Quantum-Systems has relied on 3D printing since the beginning

Since their founding in 2015, Quantum-Systems has relied on 3D printing services for prototypes and parts, offering expertise in development and operation of small UAVs with an emphasis on quality in design, construction, and production. With an interest in aerial applications that began as far back as age five, Sattler’s destiny seemed charted long ago.

Today, he heads Quantum-Systems with over 50 employees intensively working on combining range and electric efficiency in drones, imbuing them with the power to take off and land without extra equipment. This ties into unique offerings like their E-VTOL system—short for electric vertical take off and landing. The name is quite literal in terms of what it means for drones, allowing them to take off and land vertically just like a full-size plane or helicopter would. Notably, they also take off from a small space and then fly fast, with long endurance. None of this is possible, however, without strength in design and materials, as Sattler talked about extensively in a recent webinar, ‘Soaring High with Drones, and 3D Printing.’

The Quantum-Systems design team is passionate about what they do, and they do it well; however, they often see a divide between what the average lay person thinks drones do and what is happening in reality in terms of true applications. A lot goes on behind the scenes in making sure a drone is suitable for completing its skyward mission, including decking it out with all the necessary accoutrements–depending on the application.

While much is changing and the options are continually expanding for drones and 3D printed drone frames, there are still ongoing challenges like legal complexities regarding where drones can actually fly. Many companies reaching out for drone technology or services, however, are focused on very specific project requirements. This means Quantum-Systems may be using 3D scanning technology, or cameras that include zoom and infrared options. Many different drone parts, including camera casings bear 3D printed accessories, again with a focus on lightweight, super durable materials. 

3D printed drone parts are rigorously tested

Testing is critical for drone technology, and Quantum-System performs a lot of that. Their development team believes in rigorous evaluations of 3D printed parts to back up reliability, and this keeps them busy assessing parts in the lab, as well as flying their drones outside every day.

Wind is a definite concern, and while Quantum-Systems has intelligent flight systems for detecting the wind and measuring whether or not conditions are safe, drones must be built to last in unpredictable conditions–as well as withstanding the inevitable possibility of making a hard landing.

It’s not uncommon for Shapeways customers engaged in R&D to have 3D printers onsite, generally for prototyping purposes. The Quantum-Systems team is no exception, maintaining a handful of desktop printers for fast turnaround in designing and testing parts before they hand them off to Shapeways for refinement.  

Shapeways takes Quantum-Systems designs to the next level

Once Quantum-Systems is serious about a design for a drone part, they work with Shapeways to further refine and then 3D print quality prototypes and parts, as was the case in 3D printing their drone antenna mount. They needed to optimize the accessory for the lightest weight possible, and in working with Shapeways they achieved their goal with a flexible honeycomb design.

“The tolerance is much better with the Shapeways parts,” said Sattler. “It’s much easier to print those difficult shapes in SLS because for a desktop system like FDM so much supports are needed.”

The ultimate goal at Quantum-Systems is to use 3D printed parts that are as lightweight as possible yet optimized for endurance and the ability to carry different payloads. They may spend a month prototyping and testing with Shapeways, using SLS, and then move on to injection molding for larger volume production. Sometimes they may only need one iteration of a part, sometimes more.

“For models like the Vector drone, we definitely optimized a lot of the parts, especially in the fuselage, because something as little as five grams really counts at the end,” said Sattler. 

While there are some components that simply cannot be replaced via additive manufacturing yet, most drone parts can be 3D printed, points out Sattler. It is possible to make countless iterations–and economically so–making the product better every time.

3D printing in aerospace is here to stay

Overall, 3D printing is carving out a long-term niche in the aerospace industry, appealing to industrial engineers who are only too happy to make use of a powerful tool that allows them to make complex structures never before possible–and to create prototypes and change them at will, quickly. The combination of additive manufacturing with lightweight metals is what sets this technology apart, along with the availability of strong yet flexible materials like the ever-popular Nylon 12, in accompaniment to Selective Laser Sintering or Multi Jet Fusion 3D printing.

The benefits which make 3D printing so enticing to the aerospace industry easily transfer to unmanned aerial vehicles (UAVs) as they surge in popularity for a fascinating array of applications, including the many typical hobbyist endeavors, military operations, search and rescue missions, tasks for agriculturalists, surveying and photography for real estate developers, and much more—not to mention the ongoing potential for futuristic delivery of items to homes and businesses.

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 Printed Drones: Light in Weight, Powerful in Performance appeared first on Shapeways Blog.

• Why use of Smooth MJF Plastic Black PA12 continues to increase in popularity.
• How this advanced material is 3D printed using Multi Jet Fusion technology.
• Its UV stability, and the effects of post-processing, heat, and more.
• How designers are using Smooth MJF Plastic Black PA12 in current applications.

Innovation revolves around all the possibilities, while additive manufacturing is reliant on expertise and quality. And that’s precisely why Shapeways continually adds exciting new material offerings–encouraging excellence in design, production, and functionality. Currently, there are over 90 materials and finishes to choose from, and this includes the trending Smooth Multi Jet Fusion Plastic Black PA12.

With so much interest in Smooth MJF Plastic Black PA12, the experts at Shapeways recently took time out to address the following FAQs:

What is the basic background information on this material?

Smooth MJF Plastic Black PA12 is an HP nylon plastic, popular due to the following features:

• High strength 
• Durability
• Impact resistance
• Professional finish
• Suitability for complex geometries 

How does Multi Jet Fusion technology work?

Offering a host of important benefits, Multi Jet Fusion (MJF) was released by HP in 2016. Developed for powerful additive manufacturing, MJF is a subcategory of powder-bed fusion. The process involves an inkjet array moving back and forth, depositing fusing and detailing agents onto the powder. Thermal heat then melts the layers together until the part is complete.

Support structures are not necessary as unused powder stabilizes parts during printing. This further enhances the level of customization and design freedom available for end-use parts. Fewer limitations in design with MJF due to the integrity of the technology and materials leave designers free to make complex structures that can be produced quickly whether they are prototyping or manufacturing final products.

 What are my options for finishing?

The standard option offers a slightly grainy finish; however, Smooth MJF Plastic Black PA12 is also available in a smooth and slightly glossy finish.

How do MJF Plastic PA12 and Smooth MJF Plastic Black PA12 compare otherwise?

Color: PA12 is available in Gray and Black. Smooth PA12 is only available in Black.

Size: 

Max Bounding Box:

• 284 x 380 x 380 mm (Gray Natural and Black Smooth)
• 210 x 210 x 360 mm (Black Natural)

Min Bounding Box:

• 7.0 x 7.0 x 7.0 mm & X + Y + Z ≥ 9 mm (Natural)
• 10 x 10 x 10 mm (Smooth)

Is it skin safe?

The answer is yes, as these 3D printed parts do not show any sign of cytotoxic effect in accordance with ISO 10993-5, ISO 10993-1 and ISO 10993-12.

Is it UV stable?

MJF PA12 is UV stable, and so is Black Smooth PA12. The smoothing process does not alter a product’s UV stability.

Does this type of finish and post-processing cause dimensional variation?

The smoothing process results in no more than a 0.4% dimensional change.

Is it heat-proof?

The smoothing process does not alter a product’s thermal properties. 

Heat deflection temperature:XY: 95°C/203°F 

Z: 95°C/203°F

(@ 1.82 MPa, 264 psi, ASTM D648 Test Method A)

What applications is Smooth MJF Plastic Black PA12 recommended for?

This material is an excellent choice for end-use parts, including:

• Mechanical and structural components
• Architectural designs and home décor
• Drone parts
• Fixtures
• Eye frames
• Jewelry
• Prosthetics

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 Finishing Trends: Smooth MJF Plastic Black PA12 appeared first on Shapeways Blog.

• What qualities make MJF PA12 outstanding for 3D printed industrial parts.
• Why industrial designers and engineers choose Multi Jet Fusion technology for additive manufacturing.
• Why finishes like MJF Black Smooth PA12 are popular for end-use goods.
• The physio-chemical process Shapeways uses to smooth Black PA12 3D printing materials.

Once a 3D model is perfected in terms of design, the next question is what type of technology and materials to use, along with a suitable finish. Shapeways is always hard at work making sure that customers are able to find a perfect match for every product in terms of specific characteristics and project requirements for 3D printing.

MJF PA12 is Suitable for Durable Industrial Parts

3D printing materials like Multi Jet Fusion Plastic PA12 offer outstanding mechanical properties, and a couple of different choices in terms of color and finish too. This material is a great choice for so many industrial applications, including end-use goods which must offer durability for long-term use. Most recently, Shapeways added a smooth and slightly glossy finish for Black PA12.

Black PA12, 3D printed with HP’s Multi Jet Fusion technology, is used for supporting complex geometries as well as structures with thinner features. MJF Black Smooth PA12 creates smooth, semi-shiny, and watertight surfaces, sealing Multi Jet Fusion Plastic’s typically matte and porous surface. And since the finishing process is non-line of sight, even the internal cavities of complex parts can be smoothed.

Shapeways also offers MJF Plastic PA12 Glass Beads with MJF 3D printing, used in applications requiring even greater strength.

Vapor Smoothing Improves Surface Finish and Performance

Vapor smoothing is the physio-chemical process responsible for smoothing Black PA12.  This is a popular post-processing method using chemical solvents for smoothing parts that are placed in a sealed chamber filled with vapor. The chemicals cause a melting process which improves the surface and the performance of the part—including those with internal cavities—sealing in a soft shine.

Unlike polishing, vapor smoothing removes very little material while smoothing, maintaining each part’s structural integrity. In short, geometric complexity doesn’t have to be sacrificed for a professional finish. With such precision, MJF Black Smooth PA12 is a perfect option for working prototypes, display models, external functional parts, and high-end DIY projects.

Multi Jet Fusion 3D Printing Technology is Powerfully Complex

Multi Jet Fusion (MJF) is another powder bed fusion 3D printing process, developed by HP Inc. as a progression from their experience in inkjet technology. As powder is deposited across the build area, both fusing and detailing agents help build the 3D printed structure, with each layer fused together via infrared heat.

Industrial designers and engineers tend to choose MJF because of the ability to produce parts with excellent dimensional accuracy and mechanical properties, as well as enjoying the benefit of greater design freedom without a need for support structures. This is due to the stabilizing nature of unsintered powder that gathers around parts during 3D printing. Because there is no need for support structures which may complicate the packing process during production, large volumes of parts can be nested in each build, leading to much greater efficiency in manufacturing. Streamlined packing of parts reduces the height of the build platform, saves materials, and speeds up production overall.

Explore Other Material Options

To get the perfect look and feel for any 3D printed part, check out the  90+ 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 3D Print with MJF Black Smooth PA12 for Semi-Shiny, Watertight Parts appeared first on Shapeways Blog.

• How 3D printed nylon thermoplastics allow Shapeways customers to achieve their vision.
• Why nylon thermoplastics are useful in both rapid prototyping and 3D printing functional parts.
• Why materials like Nylon 12 [Versatile Plastic] are suitable for so many applications.
• How Shapeways uses Selective Laser Sintering (SLS) and Multi Jet Fusion to 3D print popular, high-quality plastics.

Nylon Plastics Continue to Reign

The history of nylon plastics is a long one, and it begins with traditional manufacturing. Nylon 12 serves as an exemplary model of a polyamide discovered for use in processes like injection molding, with many identical advantages offered when it is used in 3D printing too. This includes durability, flexibility, and incredible versatility, along with more specific features like high tensile strength, abrasion resistance, and thermal stability.

Polyamides like nylon offer a high melting point, along with the ability to create flexible parts with thinner structures, but more rigid pieces with thicker parts. Other materials like PA 12 Glass Beads (PA12GB) are fortified to allow for even greater stiffness and product strength in flat or large parts that may be especially susceptible to warping.

Shapeways has been privileged over the years to collaborate with innovative customers involved in very impressive work. Highlighting materials like Nylon 12 [Versatile Plastic], companies like BeeHero have been able to streamline technology for beekeepers and farmers, 3D printing sensor housings for smart hives created to improve pollination. Companies like Verner Architects have used these materials for unique designs like a six-foot-long bathroom vanity meant to stand the test of time. Tilt Hydrometer has also used Nylon 12 [Versatile Plastic] for both prototyping and 3D printing end-use parts for monitoring the fermentation process in brewing craft beer.

Advanced Technology for Advanced Materials

SLS materials are produced using EOS machines and Multi Jet Fusion materials are produced using HP machines. While the material properties are similar, they are each slightly different, making each more suited for one specific application over another.   

Nylon 3D Printed with Selective Laser Sintering

One of the original 3D printing processes, Selective Laser Sintering (SLS) was created in the ‘80s by Dr. Carl Deckard and Dr. Joe Beaman, associated with both University of Texas at Austin and the Defense Advanced Research Projects Agency (DARPA). And although the 3D printing industry has continued to evolve at a rapid pace—and into an industry valued in the billions—SLS technology still prevails, at the top of the additive manufacturing hierarchy as one of the most powerful processes.  

Shapeways relies on Selective Laser Sintering (SLS) technology to 3D print the following materials:

• Nylon 12 [Versatile Plastic]
• Nylon 11 [PA11(SLS)]
• Nylon 6 Mineral Filled (PA6 MF)

Nylon 12 [Versatile Plastic] is the most widely used 3D printed plastic due to its balanced property profile. These balanced properties, including high strength and good chemical resistance, make it a great multipurpose material suitable for a wide range of functional applications. Machines producing SLS PA12 have the largest build platform, allowing larger parts to be printed.

Several finishes are also available:

• Natural: This finish has a slightly rough surface and a matte finish.
• Processed: This finish removes some material to create a smoother surface.
• Premium: This is a smooth finish with good scratch resistance.
• Smooth: This finish has a smooth surface and slight shine, created using a physio-chemical vapor process.

Colors: Versatile Plastic is naturally white. Shapeways also offer Black, Pink, Red, Orange, Yellow, Green, Blue, and Purple. Note: Colors other than White are dyed and will wear through over time with handling.

Nylon 11 [PA11(SLS)] is the most flexible nylon material due to its much higher elongation at break. It also has slightly higher strength than the other materials. This combination of high strength and good elongation at break makes it the most impact-resistant material of the four choices. Popular applications include sports equipment, orthotics and prosthetics, and hinges, where high ductility is important. PA11 also has higher temperature resistance and is based on renewable resources, therefore making it more environmentally friendly.

A natural white finish is available for this material.

Nylon 6 Mineral Filled (PA6 MF) is a unique material, used in applications requiring high stiffness, strength, and heat stability. Mineral-filled reinforcement offers properties similar to injection molded parts—but without the added time and expense required in using that technology. This material is suitable for applications like automotive, including structural parts and functional prototypes.

Parts printed with Nylon 6 Mineral Filled (PA6 MF) are available in the natural black finish.

Nylon 3D Printed with Multi Jet Fusion

Multi Jet Fusion falls into the powder-based category, but uses an inkjet array to move back and forth depositing adhesive agents onto the powder bed, where the nylon powder particles are then melted with thermal heat.

HP released Multi Jet Fusion technology in 2016 with great fanfare. Previous to the much-awaited release, there was tremendous buzz about a powerful new 3D printer on the horizon, and one capable of exponentially faster production than anything currently on the market at the time. HP did not miss the mark at all either, bringing forth a printer that took processes like Selective Laser Sintering (SLS) and Binder Jetting one step further, doing away with lasers and binders, and using two different types of liquid agents during the printing process for jobs requiring higher detail and better surface finish.

Shapeways relies on Multi Jet Fusion to 3D print the following materials:

Nylon 12 [MJF Plastic PA12] has very similar properties to Nylon 12 [Versatile Plastic] produced with SLS; however, due to a slightly different printing technology, it has more consistent, isotropic properties throughout parts. MJF PA12 also has a slightly higher elongation at break. Increased elasticity makes this material more resistant to breakages and as a result, it is suitable for 3D printing parts with thinner wires and wall features are able to be produced.

Multi Jet Fusion is printed at a lower layer thickness over SLS PA12 providing better resolution of small details too. Several finishes are available:

• Gray: Medium gray with a matte and slightly grainy surface finish.
• Black: Dyed black with a matte and slightly grainy surface finish.
• Black Smooth: Dyed black with a smooth and slightly glossy surface finish.

Nylon 12 Glass Beads [MJF Plastic PA12GB] is filled with 40% glass bead particles and as a result, is a much stiffer material.  The higher rigidity makes this well-suited for structural parts and housings that will remain stiff and strong over time.  It will hold up better over time, specifically for applications that may be exposed to friction and wear, such as tooling and molds. The following finishes are available:

• Gray: Natural gray finish, blasted with oxide beads and air.
• Dark Gray: Blasted with oxide beads and air, finished with a dark gray color.

With such an abundance of 3D printing materials available today, the key is to recognize the advantages of suitable products and finishes for specific project requirements, and become informed on how different additive manufacturing technology measures up too.

About Shapeways

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.

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.

The post 3D Printing Materials: A Quick Guide to Nylon Plastics appeared first on Shapeways Blog.

Shapeways continues to work with longstanding partners like BASF to make new offerings like Polypropylene (MJF) (HP High Reusability PP)  and Nylon 6 Mineral Filled (Ultrasint® PA6 MF) ) available, striving to give customers swift access to as many 3D printing solutions as possible for accelerating manufacturing and getting products to market as quickly as possible.

Polypropylene (PP) 

Polypropylene (PP) is a versatile material ideal for a wide range of automotive, consumer, industrial and medical applications. With its excellent chemical resistance, low moisture absorption and long-term durability, HP High Reusability PP enabled by BASF is ideal for piping, fluid systems, and containers. The versatility of this PP material enables the production of prototypes and final parts offering the same properties as PP for injection molding.

Shapeways also recommends PP, available in grey with a natural finish, for testing complex structures. Its genuine PP make up allows for prototyping and evaluation of parts in critical areas like automotive, where traditionally manufactured PP is used.

PP  allows for speed and efficiency in manufacturing, machining and tooling can be eliminated, and it is easy to make changes to industrial parts. Other benefits include:

• Excellent chemical resistance
• The ability to weld with injection molded PP
• Low moisture absorption
• Biocompatibility—meets ISO 10993 and US FDA Intact Skin Surface Devices Statements

Multi Jet Fusion with PP

Shapeways relies on Multi Jet Fusion (MJF) to 3D print PP, harnessing the power of HP’s fast technology, which is also capable of enormous output in production.

Recommended for applications requiring tough parts and complex geometries, MJF begins like most other powder-based technologies: a layer of powder is spread onto the print area, and then particles are melted together. The difference with MJF is that lasers are not used; instead, a detailing agent is used to evaporate and cool the printing area, fusing the layers together with uniform strength. Supports are not necessary, due to the bolstering effect of unsintered powder during the printing process, leading to greater design freedom—along with ease in post-processing and the elimination of the potential for damage in removing supports at the end.

Nylon 6 Mineral Filled (PA6 MF)  

Available in black, Nylon 6 Mineral Filled (PA6 MF) is a highly adaptable material, and well-suited for 3D printing as it allows for a transition from metal or alloys to more economical and versatile polymers. Used in highly industrial applications, PA6 MF offers the following benefits:

• High stiffness
• Strength
• Impact resistance
• Heat stability
• Mineral-filled reinforcements offering properties similar to injection molded parts

PA6 Mineral Filled (MF) has, for example, been able to function as a substrate that could endure coating of products along with holding up for long-term as a highly optimized, end-use product. In many cases, PA6 MF is an excellent choice for prototypes of final series parts that require extensive testing for fit and performance. This is especially true in the automotive industry for engine parts, structural parts, and prototypes that must be functional too.

Selective Laser Sintering with PA6 MF

Shapeways 3D prints PA6 MF using Selective Laser Sintering (SLS) technology, another very powerful form of powder-based 3D printing. In this case, lasers are used to cure powder once it is dispersed on the print bed. A computer-controlled C02 laser traces a cross-section of the design in the powder, scans it, and then is responsible for melting all the powder particles together just under the melting point.

SLS 3D printing is also a technology offering greater latitude in design because supports are unnecessary. Up to a thousand parts may be included in one build, yielding high accuracy and repeatability every single time.

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 case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Shapeways Launches Two New Materials appeared first on Shapeways Blog.

Successful manufacturing begins with matching the correct materials and technology to a specific application. Understanding more about materials like MJF Plastic PA12 and MJF Plastic Glass Beads is not only inspiring, but allows designers to take one more step in bringing projects alive successfully. With such an abundance of products available today, the key is to recognize the advantages of suitable materials, finishes, and become informed on how the different 3D printing processes work too. It’s also important to understand the differences between Multi Jet Fusion (MJF) and other similar powder-based technologies like Binder Jetting (BJ) and Selective Laser Sintering (SLS).

HP released Multi Jet Fusion technology in 2016 with great fanfare. Previous to the much-awaited release, there was tremendous buzz about a powerful new 3D printer on the horizon, and one capable of exponentially faster production than anything currently on the market at the time. HP did not miss the mark at all either, bringing forth a printer that took processes like Selective Laser Sintering (SLS) and Binder Jetting one step further, doing away with lasers and binders, and using two different types of liquid agents during the printing process for jobs requiring higher detail and better surface finish.

How Multi Jet Fusion Technology Works

Multi Jet Fusion falls into the powder-based category, but uses an inkjet array that moves back and forth depositing adhesive agents onto the powder bed, where the nylon powder particles are then melted with thermal heat.

MJF is an undeniably powerful 3D printing technology, leading to improved speed in production and vast output in comparison to other 3D printers. Because it is often also best-suited for applications requiring tough prototypes and parts, MJF results in the manufacturing of many exciting complex geometries not previously possible with traditional methods.

Once 3D models have been designed, Shapeways production engineers nest them together using proprietary, purpose-built software that yields colorful, automated visualization. Like putting a puzzle together, proper arrangement of all the parts to be 3D printed at once is necessary to a successful build, nesting and stacking to make the most efficient use of the entire build volume.

Smart packing is also the secret behind accuracy and repeatability in parts at Shapeways—every single time. With Multi Jet Fusion, supports are not required. Not only does this lead to greater design freedom as supports don’t have to be considered, nesting of hundreds or even thousands of parts is possible in MJF 3D printing.  

The 3D printing process is set into motion as a thin layer of powder is dispersed on the print bed. A fusing agent is then sprayed on the powder to heat the material. The detailing agent is added around the part, evaporating and cooling the area. Due to these abrupt thermal transitions, molten layers fuse together, resulting in the desired solid 3D printed structure. Parts made via MJF 3D printing are uniformly strong due to evenly dispersed temperatures. After cooling, the build is unpacked, and post-processing begins as powder is removed through automated blasting. Afterward, high-resolution parts are ready for use whether as prototypes or for critical applications.

The Benefits of Using Multi Jet Fusion for End-Use 3D Printed Parts

Although there may not be a wide variety of materials to choose from in comparison to other 3D printing technologies and it may be hard to produce more curved geometries in some cases, the drawbacks in using MJF 3D printing are few. The benefits, however, are expansive, including:

• Higher resolution, greater density, and excellent mechanical properties.
• Ability to print in moving and interlocking parts.
• Greater strength over other methods because thermal energy is so deeply absorbed during the 3D printing process.
• Fast turnaround in production because so many pieces can be printed at once.
• Sustainability in manufacturing due to recycling of materials. The mix ratio in MJF is usually around 80 percent re-used powder, and 20 percent virgin.

Multi Jet Fusion Materials Offered at Shapeways

MJF Plastic PA12 – Featuring a slightly grainy finish in gray or black, this versatile material is also available in a natural or smooth and slightly glossy finish. Used for industrial applications due to its low porosity and optimal mechanical properties, strength, durability, and stiffness, MJF PA12 supports complex geometries and parts with thinner features, and is popular for applications like:

• Drone parts 
• Prosthetics
• Mechanical and structural parts
• Mounts and cases
• Technical accessories
• Home décor

Explore technical documents and design guidelines for MJF Plastic PA12 here. This material is also known as HP Multi Jet Fusion PA12, Professional Plastic, HP Nylon Plastic, PA12, and Polyamide.

MJF Plastic PA12 Glass Beads – Available in gray and dark gray, 40% of this unique material is infused with glass beads for added strength and stiffness, while still offering good flexibility. PA12 Glass Beads are also relied on for manufacturing parts that will last over the long term, as well as offering continued accuracy and repeatability in the following applications:

• Tooling
• Robotics
• Drone parts
• Medical braces
• Housings and cases

Explore technical documents and design guidelines for MJF Plastic PA12 Glass Beads here. This material is also known as HP PA12 Glass Beads, PA12 GB, Glass-Filled PA12, PA12 GF, and Nylon 12 GB.

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 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Multi Jet Fusion 3D Printing in Nylon Plastics PA12 and PA12 Glass Beads appeared first on Shapeways Blog.

What is Multi Jet Fusion 3D Printing?

HP launched Multi Jet Fusion technology in 2016–and over the years this powerful technology has continued to gain attention. Falling into the broader powder-based category, HP MJF 3D printing surpasses other traditional and additive methods by eliminating the need for laser and binders; instead, MJF relies on two different liquid agents during the 3D printing process to produce parts that are highly isotropic, meaning they are mechanically consistent throughout each structure. 

Once 3D printing material is deposited onto the print bed via the recoater, the MJF 3D printing process is initialized as a thermal inkjet array moves back and forth, depositing fusing and detailing agents onto the powder bed, where the nylon powder particles are then melted with thermal heat. The detailing agent is also responsible for cooling and helping create smoother surfaces and sharper detail.

Offering a powerful production solution for Shapeways customers, MJF 3D printing is known for efficiency. While much of that is due to high-quality equipment, the ability to 3D print large volumes of parts also accelerates production. A unique feature in MJF 3D printing allows for the build tray to be removed immediately for post-processing, with another inserted at the same time, permitting ongoing production.

MJF 3D printing technology is faster and more efficient due to the lack of requirements for supports which leads to several important benefits:

• Much greater design freedom and flexibility
• Lack of scarring or blemishes at support sites
• Decreased potential for damage to parts in post-processing

Without any requirements for supports, Shapeways 3D printing engineers nest hundreds of small- to mid-size parts in each build. MJF 3D printing also promotes greater sustainability in additive manufacturing due to the ease in recycling powder from one build to another, with a mix ratio around 80% reused powder and 20% virgin powder. MJF PA12 offers UV stability, and skin safety in accordance with ISO standards.

MJF Additive Manufacturing for Industrial Parts

Advantages to using MJF 3D printing for prototypes and high-performance end parts include higher resolution, greater density, and excellence in mechanical structure. It’s easy to 3D print objects with moving or interlocking parts as they typically offer greater strength in comparison to other manufacturing methods due to effective absorption of thermal energy.

MJF 3D printing is a great fit for production of durable parts featuring fine details and sophisticated geometries. Larger-volume orders, available due to economy of scale, are possible due to the efficient technology and the ability to use proprietary software for smart packing. Some of the most popular uses for MJF 3D printing are replacement parts, snap fits, living hinges, air-tight designs, and industrial components for end-use production.

MJF 3D Printing Materials

Multi Jet Fusion Plastic PA12 (MJF PA12) – Commonly relied on for superior strength and elasticity, MJF PA12 is also chemical- and water-resistant, and suitable for highly functional parts. Because of its outstanding flexibility, MJF PA12 is suited for applications like:

• Architectural designs and home decor
• Drone parts
• Eye frames
• Industrial fixtures
• Mechanical and structural components
• Prosthetics

MJF PA12 is available in both gray and black, featuring a standard finish with a matte surface and slightly grainy texture. Shapeways also provides a black finish with a smooth, non-porous surface created through a physio-chemical vapor smoothing process.

Explore the design guidelines for MJF PA12 here.

MJF Plastic PA12 Glass Beads

This unique material is 40% glass-filled which reduces warping during the printing process and over the product’s life, as well as improving product stiffness and structural integrity. MJF PA12GB 3D printing material is great for flat and large parts that are prone to warping in Nylon 12 [Versatile Plastic] or MJF PA12 Plastic, and for functional parts that require high strength and dimensional accuracy. 

Typical uses include:

• Drones
• Housings and cases
• Medical braces
• Robotics
• Tooling

Find out more about the design guidelines for MJF Plastic PA12 Glass Beads here.

Nylon 12 Full Color (MJF)

Offering the ability to 3D print parts in robust color, this material possesses superior mechanical properties, good dimensional stability, and resistance to impact–as well as chemicals like oil and grease. Defined by the capacity to deform under tensile stress, Nylon 12 Full Color (MJF) is flexible for structures with a thinner design but becomes rigid for use with thicker parts, offering durability and density required for end-use parts. 

This nylon 3D printing material is suitable for products like:

• Braces and casts
• Functional prototypes
• Industrial jigs and fixtures 
• Medical models
• Moving and interlocking components
• Structural parts and mounts

Nylon 12 Full Color (MJF) is available in both natural and smooth glossy finishes.

Explore the design guidelines for Nylon 12 Full Color (MJF) here. 

Polypropylene (PP)

This material is offered for 3D printing a wide range of MJF parts due to superior resistance to chemicals, low-moisture absorption, and extreme durability. PP is recommended for applications like:

• Electronic devices
• Medical devices like braces and respirator equipment
• Piping, fluid systems, and containers
• Prototypes for automotive test applications

This material is available in gray, with a natural finish.

Explore the design guidelines for Polypropylene here.

Thermoplastic Polyurethane (TPU)

This high-performance 3D printing material enables production of elastomeric functional parts, obtaining results similar to Injection Molding. Parts 3D printed with TPU are flexible, tough, and present high elongation at break and impact resistance for applications like:

• Ducts
• Flexible tubing
• Footwear
• Protective gear
• Seating systems
• Soft grip systems

TPU for MJF 3D printing is available in both natural and smooth finishes.

Explore the design guidelines for Thermoplastic Polyurethane here.

Quality additive manufacturing requires expertise and sophisticated machinery. A successful foundation must be set first though, matching compatible materials and technology to each 3D model and its corresponding applications. With an abundance of 3D printing technology and materials available, the key is in recognizing the advantages of additive manufacturing vs. traditional manufacturing, comparing 3D printing technologies, and sorting through suitable materials, finishes, and post-processing needs.

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 The Expert Guide to MJF appeared first on Shapeways Blog.

Top Questions Asked

Q. Is PA12 certified non-allergenic?

A. Yes, here is a certification for biocompatability for skin-contact applications, such as jewelry.

Q. Do you have any colored MFJ materials available?

A. Colors for MJF is not in our near-term roadmap, but we will consider this for the future.

Q. I’m curious about the price of printing in this material.

A. Please upload a model through our model upload page, select Multi Jet Fusion Plastic and your desired color and finishing to see the price for your model; or reach out to our sales team and we would be happy to help!

Q. What type of glue is recommended for use with this material?

A. An off-the-shelf epoxy material will work well.

Q. My product has a moveable part. Is PA12 a good material that can withstand constant bending of this moveable part without breakage?

A. PA12 is a good option. PA11 also has great elasticity and may have slightly better long-term wear properties.

More from the Material of the Month Series: PA12

Part One: Material Overview
Part Two: Material Comparison: Nylon Plastics
Part Three: Business Example: PA12 used in the virtual reality industry
Part Four: Tutorial: Post processing PA12

The post Top Questions Answered: Multi Jet Fusion Plastic PA12 appeared first on Shapeways Blog.