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Nearly everyone is being affected by supply chain issues, from obtaining even surprisingly small and inconsequential products to very necessary items on a larger scale. On-demand manufacturing is an advantage that is built into 3D printing technology, offering businesses the opportunity not only to eliminate supply chain problems–but take ordering and production to the next level with streamlined automation.

Many Businesses are Stretched to the Limit with Production Challenges

Supply chain challenges have been jarring for customers, manufacturers, and everyone in between. Rather than humming along smoothly on all cylinders as in the past, an ever-growing number of businesses and consumers are being adversely affected like never before–and in nearly every application–from basic household products to automobiles and necessary parts, and critical supplies for facilities like hospitals. 

In the midst of these struggles, however, a new and unexpected dynamic is also in play as more

consumers than ever have cash to spend, and they are doing so copiously. Unfortunately, with a supply chain process that is currently fragmented, and interrupted at many points, frustration ensues when products don’t arrive as expected or at all. Even as factories overseas continue to try and increase production, there may be breakdowns in both communication and timely deliveries from middlemen. Further, even products that have been manufactured and are ready for delivery are lost in the mix due to overwhelming traffic at ports and at shipping docks.

Disrupted times call for disruptive solutions, with 3D printing leading the way. Although many Shapeways customers have been engaged in on-demand 3D printing for years already, the current supply chain issue now highlights the ease in which businesses can circumvent such problems. While some companies may now want to use 3D printing as a stop-gap measure to manufacture and deliver products more quickly and efficiently, others may change production methods radically upon having their eyes opened to the myriad, positive effects.

Eliminating Stress Over Warehouse Scarcity and Other Positive 3D Printing Impacts

Conversely, for those who are able to get products, warehouse space is now challenging to find in many areas; in fact, businesses with bigger pockets are purchasing warehousing sites before they are even built. For those who aren’t so lucky and are attempting to take possession of large quantities of merchandise, they may struggle to keep product from being left to sit on the shipping dock indefinitely. 

3D printing can offer a quick fix for many companies worried about getting products to their customers faster. On-demand 3D printing allows for rapid manufacturing of customized parts, as well as production in local areas rather than depending on products from overseas that are still being delayed due to supply chain issues. With Shapeways, products can be 3D printed quickly and delivered in customized packaging to manufacturers or their own customers.

Other major advantages include:

• Security in uploading, maintaining, and storing 3D digital inventories, along with preventing other issues like overproduction. Not only is the need for warehouse space decreased or completely eliminated, but extra inventory no longer sits around indefinitely. 
• The ability to 3D print with reduced assemblies to streamline production; in fact, for some larger pieces, part counts can be decreased exponentially and ultimately, the structures are lighter in weight too. The overall result is greater efficiency with higher quality and optimization, combined with less use of resources and energy overall.
• Greater efficiency leading to faster time to market whether in manufacturing high-performance components for critical use, or other types of products too.

In partnering with Shapeways for 3D printing, the supply chain is streamlined and improved, and manufacturers have more control over customization, personalization, and distribution. 

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.

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The Advantages—Where to Begin?

Shapeways offers TPU in off-white for use with Selective Laser Sintering (SLS), using EOS 3D printers, as well as Ultrasint TPU01 material from BASF, available in gray, using Multi Jet Fusion 3D printers. These materials offer multiple benefits over other elastomers, to include:

• Superior tensile strength – Defined by how much 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 that must stand up to rigorous use.
•  Elongation at break – This material characteristic is tested by comparing where a part breaks after being strained, versus its original length. TPU is known for high elongation at break due to its elasticity, making it especially useful in critical applications because it is also so tough.
• Excellent load-bearing capacity – This is an important measurement as it testifies to how much weight a 3D printing material can handle—a factor that could be extremely important in applications requiring high-performance products that are expected to last, including mechanical devices like tubing, hoses, and seals.
• Resistance – TPU is able to stand up to many different factors because of its natural resistance, which is why it is considered such a multi-purpose 3D printing material. This includes resistance to chemicals, oil and grease, harsh weather, heat, and abrasion.

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 components that focus on greater comfort for the driver, like customized headrests and seats. With TPU, textures may range from soft and luxurious, to rigid and functional, depending on the interior part for a vehicle. 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 an item that is pretty much impossible to live without. TPU is also an excellent choice for adding quality and customization to highly functional items used daily like rubber mats and products like handles.

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.

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, offering patients safe, customized devices that are able to stand up to long-term daily use without causing skin irritation.

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, 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.

Get Started with TPU Now

Upload your 3D models now to get started with printing in TPU using industrial SLS technology or in Ultrasint TPU01 using MJF technology.

The post Thermoplastic Polyurethane (TPU): Highly Versatile for Many 3D Printing Applications appeared first on Shapeways Blog.

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

Sustainable Origins: PA11 is Naturally Derived and Environmentally Friendly

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

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

Indisputable Advantages: Strength in Material Properties

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

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

Exceptional Parts for Demanding Applications

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

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

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

In the prosthetics industry, 3D printing is starting to become a viable manufacturing process. Since a high level of quality is required, there are some situations where PLA and other common materials don’t quite cut it. Prosthetics and bionics companies are looking at using more exotic materials so that they can improve their products.

Above all else, prosthetic limbs must be lightweight and comfortable. If a prosthetic is powered either electrically or mechanically, it is considered a bionic prosthetic. It is beneficial for bionic products to be as simple as possible, so flexible parts may be desired to reduce the complexity. Bionic prosthetics can also feature sensory capabilities for user-feedback, so electronics may be required. All of these design criteria can be achieved by using special materials that do a little bit more than just your average PLA.

Carbon Fiber Reinforced Filament

Carbon fiber reinforced (CFR) filament is a 3D printing material that contains short strands of carbon. It is stiffer than most filaments, and it is a great material choice if weight and rigidity need to be optimized. One such application is in the socket for prosthetic legs. The socket is the part that connects the person’s leg to their prosthesis. People with leg amputations need their prosthesis to be both lightweight and rigid, and CFR filament fits both of these criteria.

This material consists of short carbon strands suspended in a plastic such as PLA or Nylon. These plastics are all classified as thermoplastics, which means they can be remelted. This material property can be quite beneficial. Typically, an amputee’s residual limb will change shape slightly over the course of months or years. This can lead to discomfort if their socket does not change shape. If modifications to the socket need to be performed, CFR filament can simply be heated up to soften it and then reshaped.

Carbon fiber composite material is different from CFR filament. It consists of woven carbon sheets glued together with epoxy. It does not soften with heat. This is because epoxy is classified as a thermoset polymer. That means it undergoes a chemical reaction as it cures which causes it to permanently harden.

Prosthetic sockets made from carbon fiber composite are in fact stronger than 3D printed carbon fiber material but they are expensive, hard to manufacture, and difficult to re-shape. This is why some prostheses are now made by 3D printing with CFR filament. With a 3D scan of the amputee’s residual limb, a socket can be 3D printed which very accurately captures every detail. This makes for a more comfortable fit. 3D printing a socket is much quicker and also less expensive than the traditional method of creating a prosthetic socket.

Flexible Filament

Unlike most 3D printing materials, thermoplastic polyurethane (TPU) is soft and flexible. This material is perfect for creating flexible joints, and it sees use in applications like prosthetic fingers and as soft liners for prosthetic sockets.

Prosthetic sockets which are made from rigid materials (such as CFR filament) can become uncomfortable if pressure is not evenly distributed. Introducing a soft inner liner can provide cushioning and support, improving comfort for the user. Because 3D printing can create complex shapes, a mesh-like structure can be printed which allows airflow throughout the socket. This ventilation is very necessary because moisture build-up can cause discomfort.

TPU is also being used in bionic hands as a material for flexible fingers. Instead of using a rigid mechanism, using flexible and compliant mechanisms to transfer forces can result in a more natural motion. Using flexible materials in compliant mechanisms reduces the number of parts, removes the need for lubrication, and greatly speeds up the assembly and manufacturing process.

Conductive Filament

3D printing is usually used to produce mechanical components, but certain filaments are electrically conductive and can be used in a variety of interesting electronics applications. Magalie Darnis (M.Eng), made this the topic of their master’s thesis. Magalie used a material known as ETPU to create 3D printed sensors.

ETPU combines carbon powder and TPU to develop a flexible and electrically conductive polymer that can be 3D printed. Although ETPU contains carbon, it is very different from CFR filament. This is because it uses graphene powder instead of short carbon fibers. Graphene easily conducts electricity, but it does not add much mechanical strength. Other types of conductive filaments exist, but they are rigid and sometimes brittle. In other applications, this may be desired, but for bionics, the flexibility that comes with ETPU allows for flexible, form-fitting sensors to be embedded in wearable products.

Currently, 3D printed sensors are only found in bionics prototypes, but ETPU has proven to be effective in applications such as touch sensors in bionic fingertips. To create a touch sensor, two ETPU surfaces are printed with a small air gap between them. These surfaces will move closer together when pressure is applied to the fingertip. When these surfaces make contact, it closes a circuit, and this signal can be used to let the user know when they’ve firmly grasped an object.

This binary (on/off) touch sensor is one of the most basic 3D printed sensors, and it can be modified to make more complex sensors such as deformation sensors, vibration sensors, and force sensors.

One of the main benefits of 3D printing sensors is that it simplifies and speeds up production. With 3D printed sensors, pre-built components do not need to be manually attached to an object. The sensors can instead be part of the printing process itself.

Want to find out how Shapeways can help fulfill your medical industry needs? Contact our team today to get a personalized consultation.

The post Exploring Exotic 3D Printing Materials Used in Prosthetics appeared first on Shapeways Blog.

Does this post-processing cause dimensional variation? 

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

Is it skin safe?

Yes! Parts post processed using the PostPro3D® technology do not show a cytotoxic effect in accordance with ISO 10993-5, ISO 10993-1 and ISO 10993-12. 

Is it UV stable?

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

Is it heatproof?

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’s the difference between PA12 and Smooth PA12? 

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

Finish: PA12 has a matte and grainy finish. Smooth PA12 has a smooth, slightly glossy finish. 

Price: Smooth is ~2x the price of Gray and Black PA12. Minimum price is $15/part.

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)

Now that you know a little more about Smooth Multi Jet Fusion Black PA12’s capabilities, how about seeing it in action? Order your parts in this new finish today and feel the difference!

The post FAQ: Smooth Multi Jet Fusion Plastic Black PA12 appeared first on Shapeways Blog.

One of the first 3D printing technologies developed, Stereolithography (SLA) has been widely used for creating models, prototypes and patterns. To produce parts using SLA systems, a laser selectively cures liquid resin in a resin bath above it, moving up layer by layer until the part is complete. Using large format SLA technology, you will be able to produce much larger parts than other resin-based technologies while achieving similar fantastic surface quality.

Our SLA Plastic launch includes the following three acrylate-based materials:

Accura® 60

This clear plastic produces rigid and durable parts with similar properties to molded Polycarbonate (PC). It has the ability for fine details making it apt for tough, functional prototypes, lighting components, medical instruments and fluid flow and visualization models.

Accura® Xtreme

A material with similar physical properties to polypropylene and ABS, Accura® Xtreme is an ultra-tough grey plastic with outstanding durability, accuracy, moisture and thermal resistance and the ability for great detail. It is ideal for snap fit assemblies, enclosures for consumer and electronic products, master patterns for vacuum casting, and general purpose prototyping.

Accura® Xtreme 200

This white plastic is the toughest SLA material available and can replace CNC-machined polypropylene and ABS articles. It is perfect for projects that must withstand extreme, harsh conditions making it ideal for challenging functional assemblies. It can be applied to similar projects as Accura Xtreme as well projects that demand the highest durability like automotive parts, drill/tap applications, assemblies with self-tapping screws, enclosures for consumer electronic components, general purpose prototyping, and master silicone molding.

All three of these SLA materials produce rigid, robust parts that resist breakage and are durable enough to create functional parts as well as provide excellent detail and accuracy. SLA Plastics are printed on large format 3D printers which is great for creating more sizable parts for visual prototypes, short-run production and mass customization including specific applications such as:

• Master patterns for vacuum casting
• Shell investment casting patterns for metal casting
• Complex assemblies
• Wind tunnel models
• Rapid production of flow test rigs
• Mass customization production (orthodontic, dental)
• Custom assembly jigs and fixtures

These materials have a larger build volume than standard SLA technology, which means your projects  will have less limitations. We are excited to see what you create!

The post Introducing Three Tough SLA Plastic Materials 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.

HP’s Multi Jet Fusion Plastic PA12 (formerly named “Professional Plastic”) has excellent mechanical properties and can be dyed black for a sleek finish, making it an ideal choice for a wide range of applications.

Since we now offer two Multi Jet Fusion Plastic materials (see new material announcement), PA12 has reclaimed its industrial name to clearly differentiate it from PA12 Glass Beads, which contains 40% glass beads for added stiffness and durability. Both materials use the Multi Jet Fusion technology, a professional-grade 3D printing process that creates high-quality, end-use products.

Ideal Applications Include:

• Drones
• Fixtures
• Home decor
• Eyewear
• Games
• Prosthetics

HP Multi Jet Fusion Technology

PA12 is printed using HP’s Multi Jet Fusion Technology and supports very complex geometries and thin features.

Material

Polyamide

Colors

Features

• Heatproof to 175C/350F
• Good Chemical Resistance
• Skin-Friendly
• Water Tight

.

Technical Documents

Check out the Material Data Sheet and the Material Safety Data Sheet for PA12.

Upload Your File

Ready to get started? Upload your file now for an instant quote.

Grow Your Business

Learn how you can utilize PA12 to expand the manufacturing capabilities of your business.

Upcoming blog posts on Material of the Month: PA12

Part Two: Material Comparison: PA12 vs PA12 Glass Beads
Part Three: Business Example: PA12 used in the virtual reality industry
Part Four: Tutorial: Post processing PA12

The post Material of the Month: PA12 appeared first on Shapeways Blog.

Whether you’re an entrepreneur in the midst of expanding your business or a first-time creator experimenting with a new product, your idea deserves the highest quality materials. While 3D printing is an ever-expanding industry, here at Shapeways we’re committed to staying on top of the latest cutting-edge technologies to ensure you have all you need to innovate your industry. A large part of that pledge is consistently diversifying our range of materials so that we always have the perfect match for your product’s specific needs. Today we’re excited to announce the addition of two new maker materials to the platform: PA12 Glass Beads and TPU (thermoplastic polyurethane). These two new materials are maker materials meaning they will only be available for purchase on own models and not available on the marketplace.

PA12 Glass Beads

PA12 Glass Beads Multi Jet Fusion Plastic

PA12 Glass Beads is a new addition to the material family formerly known as “Professional Plastic” that we’re renaming “Multi Jet Fusion Plastic.” PA12 Glass Beads is a glass-filled nylon printed with HP MJF technology. This material offers high stiffness and high structural integrity. Translation: large and flat products will print with ease, without the concern of warping or distortion. PA12 Glass Bead’s resilience and strength make it an ideal material for projects within the medical, robotics, and drones industries, particularly for applications like flat parts, fixtures, and tooling. It’s currently available in two finishes: Gray and Dark Gray.

TPU (Thermoplastic Polyurethane)

TPU (thermoplastic polyurethane)

Highly flexible and shockingly durable, thermoplastic polyurethane is a vast improvement from our previously offered elastoplastic. TPU’s elasticity and natural resistance to most every day wear make it an excellent candidate for automotive and medical use. It would work wonders as an insole, midsole, or helmet; and for robotics applications, TPU could be used for tubing, hoses, and seals.

We’re so excited to see how these new materials will expand the realm of what’s possible with Shapeways. PA12GB and TPU are now available on our site for your own models. Upload your design, select one of these two exciting materials, and get an instant quote now.

The post Introducing Our Two New Materials! appeared first on Shapeways Blog.