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.

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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.

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Recognized for accuracy and repeatability in industrial parts with excellent mechanical properties,

SLS 3D printing has continued to evolve–remaining at the top of the additive manufacturing hierarchy due to its sheer power–and versatility. 

What is SLS?

To define Selective Laser Sintering means understanding industrial 3D printing. Serving as a subcategory of powder-bed fusion, SLS 3D printing relies on a laser to trace the cross-section of each 3D design into the material dispersed onto the print bed, and sintered just under 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. After, they are removed for post-processing, to include removal of excess powder and then on to finishing, to include dyeing, vapor smoothing, polishing, and more.

SLS industrial 3D printers are capable of producing large parts, in large volumes. While smaller printers may range in build volume from 200 mm x 250 mm x 330 mm, larger laser 3D printers may range in size 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. These SLS printers are remarkable in that hundreds or even thousands of parts can be 3D printed at one time.

SLS Benefits: Expanding Design Freedom and Production Volume 

Support structures are not required for SLS 3D printing, leading to unique advantages for this technology as well as Multi Jet Fusion (MJF) 3D printing. Unsintered powder bunches around parts as they are 3D printed, stabilizing structures, and eliminating the need for support structures. This leads to much greater design freedom as designers are able to engineer parts without having to compensate for intricate supports. No requirements for supports means less use of materials, reducing the potential for damage in post-processing, and eliminating the need for repeated 3D printing.

Shapeways engineers are able to optimize nesting of parts due to the lack of requirement for intricate support structures that would make smart packing impossible. Smart packing is key to optimization, allowing for parts to be placed correctly and keep machines in good working order by running them consistently with maximum builds for efficiency. Streamlined, dense packing of parts reduces the height of the build platform and saves materials.

“The 3D printing nesting software does the hard thinking for us in terms of whether or not a part fits into the spaces available in a build tray,” said Zach Dillon, User Application Team Lead at Shapeways.

Because of the ability to nest so many 3D printed parts together, Shapeways customers experience a key  advantage of 3D printing: speed in turnaround. Numerous projects can be completed simultaneously, and SLS 3D printing powder is easily recycled, promoting sustainability in additive manufacturing with each job.  

When Shapeways customers print in large volumes, being able to work directly with the User Application team to optimize every aspect of production is a huge benefit. 

“We have to take everything into consideration from how larger 3D printed parts will affect others around them to how they will all be unpacked and cleaned in post-processing,” said Dillon.

SLS 3D Printing Materials

Nylon 11 [PA11(SLS)]

Nylon 11 [PA11(SLS)] is a robust white polyamide offering great tensile strength, durability, impact resistance, and flexibility. Due to its biocompatibility, Nylon 11 [PA11(SLS)] is uniquely suited for manufacturing the following:

• Exterior medical devices
• Automotive parts
• Sports equipment
• Loaded functional prototypes
• Hinges

Explore the design guidelines for Nylon 11 [PA11(SLS)] here.

Nylon 12 [Versatile Plastic]

Nylon 12 [Versatile Plastic] is a strong polyamide relied on worldwide for industrial products. This material lives up to its name, set apart from other 3D printing materials mainly due to high ductility. This refers to the material’s flexibility for thinner structures and moving mechanical parts, but stiffness for substantial, end-use parts. Nylon 12 [Versatile Plastic] is dishwasher safe, heatproof to 163C/325F, skin-friendly, and offers good chemical resistance.

Typical applications include:

• Architecture, to include interior statement pieces
• Automotive
• Drone technology
• Footwear, fashion, and accessories
• Luxury jewelry
• Mechanical components, including interlocking parts
• Medical models
• Robotics

Colors and finishes available for Nylon 12 [Versatile Plastic]:

• Natural: This finish has a slightly rough surface and a matte finish.
• Processed: This finish removes some material to create a smoother surface.
• Premium: Relying on ceramic media tumbling, this finish removes material to create a smooth surface.
• Smooth: This finish has a smooth surface and slight shine, created using a physio-chemical process with vapor.
• Colors: Versatile Plastic is naturally white. Shapeways also offers Black, Pink, Red, Orange, Yellow, Green, Blue, and Purple. Colors other than White are dyed and will wear through over time with handling.

Explore the guidelines for Nylon 12 [Versatile Plastic] 3D printing material here.

Polypropylene

Polypropylene is a versatile material offering excellence in mechanical properties, to include durability and high elongation at break. Highly suited for rapid prototyping as well as additive manufacturing of elastic, end-use products, PP is used for important applications like:

• Automotive
• Consumer products
• Electrical casings
• Medical devices
• Toolmaking

This material is available in a slightly translucent off-white, featuring a matte surface.

Explore the design guidelines for Polypropylene here.

Thermoplastic Polyurethane (TPU)

Thermoplastic Polyurethane (TPU) is a rubber-like material (available in white) that offers impact resistance and durability, and works well for 3D printing of interlocking parts. Made for elastic, end-use products, TPU is used for important applications like:

• Automotive
• Medical devices
• Robotics
• Footwear
• Sports equipment

This material is available in standard, featuring a slightly rough surface with a matte finish.

Explore the design guidelines for Thermoplastic Polyurethane (TPU) here.

Customers and Applications:

At Shapeways, SLS 3D printing has revealed itself to be both popular and versatile, whether customers are designing for aerospace and drone technology, architecture, luxury jewelry, or medical models. SLS 3D printing is a stand-out technology for designers and engineers making rapid prototypes or high-performance, functional parts.  

Aerospace

The aerospace industry is a leader in its use of 3D printed parts, allowing engineers to create innovative designs and use lightweight, durable materials with complex geometries. This is especially true for companies like Munich-based Quantum-Systems, specializing in advanced eVTOL (electric vertical take-off and landing) drones. 

Using SLS 3D printing for prototyping and manufacturing of functional parts, Quantum Systems is able to make lightweight parts, while taking advantage of “synergy effects” in reducing part counts and assembly.

“Only because of the fact that we have integrated this manufacturing method into our manufacturing and development process, have we been able to significantly reduce development time. For injection molded parts, we save around 10 weeks by using 3D printed samples to release the CAD data,” said Florian Seibel, CEO of Quantum-Systems.

“The probability that these parts need a second loop of corrections is quite low in this way. For CNC-manufactured parts it is the same. We often just skip the first round of samples with SLS 3D printed parts, which saves us three to four weeks. In general, I would say 3D printing saves us 20 to 50 percent of time, depending on which parts we design.”

Architecture

Verner Architects designed a six-foot bathroom vanity for a luxury remodel on a home in California. Verner worked with Shapeways to 3D print the interior statement piece ensuring that durability and water resistance were top of mind.

Due to the print-bed size of SLS technology that Shapeways offers, the architects at Verner were ‘pleasantly surprised’ at the easy assembly of the six-foot-long vanity. 3D printed with Nylon 12 [Versatile Plastic], the 3D printed statement piece was also coated with polyurethane for waterproofing. Two test prints were performed in-house at Verner Architects, allowing the team to refine the design and final structure.

Luxury Jewelry

Industrial designers and luxury jewelry makers like Groen and Boothman use Shapeways services for rapid prototyping and 3D printing the final parts for luxury jewelry like their custom Creatures design series, featuring unique cuff bracelets. The designers rely on the lightweight quality of Nylon 12 [Versatile Plastic], along with the strength and durability of the material.

“3D printing gives us a chance to explore new avenues and get away from the mass production paradigm,” said Joanna Boothman.

Medical

Uruguay-based Armor Bionics creates intricate 3D designs for medical models that are 3D printed by Shapeways via SLS technology. Surgeons rely on the complex 3D printed medical models for more in-depth diagnosis, training, and treatment. Armor Bionics CEO Bruno Demuro is dedicated to offering medical professionals better solutions for surgical planning:

“We’ve seen the benefits and how much treatment affects the patients,” said Demuro. “It betters the outcome of every single surgery where it is applied.”

Other industrial design firms like Flamingo Works collaborated with Shapeways to 3D print colorful simulators using SLS 3D printing materials like Nylon 12 [Versatile Plastic] to train surgeons in robot-assisted surgeries. Yonatan Assouline, Manager and Co-founder, points out that while 3D printed games designed for learning may look simple, the tasks require practice, medical training, and concentration to excel. This is especially true for surgeons training with robotic grips that shift both forward and reverse to reach objects and complete exercises.

“The training for this technique and the framing of the technology was completely unknown at first,” explained Naty Moskovich, Chief Designer and Co-founder of Flamingo Works. “We were developing 50 to 60 learning tasks at a time, coming up with all sorts of different ideas, and sending them to physicians to see if they liked them or not. 

“We would develop one skill and remove another while prototyping. 3D printing with Shapeways gave us the freedom to try out endless new ideas during the product development phase.”

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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Beginning in the 1980s but greatly lauded in more recent years thanks to a patent filed by Chuck Hull (the founder of 3D Systems) in 1986, 3D printing began as a rapid prototyping tool, relying on stereolithography for printing nearly any object layer by layer, and curing it with UV light. Despite many new techniques created throughout the years—accompanied by a stunning and highly commercialized array of hardware, software, and materials—SLA has continued to be popular with savvy users due to its accuracy and potential for use with advanced materials. Fused deposition modeling (FDM) has become most ubiquitous, although many users rely on other forms of 3D printing like selective laser sintering (SLS), digital light processing (DLP), metal binder jetting, and more.

3D printing is extremely impressive in its versatility, allowing for significant impacts to be made in nearly any area of production, but especially the industrial realm. Here, we are going to examine some of the most critical areas, along with a couple that may surprise you:

Aerospace – Metal 3D printing has begun to dominate digital fabrication within the aerospace industry, as functional parts are being made with a variety of different strong and durable metals (and metal alloys) that result in substantial yet lightweight components. Companies such as Boeing have included hundreds of 3D printed parts in aircraft over the past few years, while NASA continues to use metal for engine parts. Evidence of the faith entrusted in this relatively new technology is inspiring as safety and strength are obvious top priorities in such applications, especially when human lives are involved.

Even more interesting, 3D printing is continually highlighted for new concepts for building space habitats using regolith (space dirt, whether from the Moon or perhaps Mars) and complex robots, as well as being used for designing astronaut suits and gear and other helpful tools. Bioprinting in space has even made headlines as research is performed in zero and microgravity, and methods may become available for astronauts to perform complex first aid on their own, including basic forms of tissue engineering.

Transportation – while the automotive industry has predominantly been a proponent of 3D printing, other industries like railways are beginning to grasp the power of a technology that allows them to 3D scan parts that may be obsolete but can be printed within hours and used in older trains as well as allowing for refinements that may now be necessary, and possible. This saves hours—or even exorbitant amounts of time—that may have previously been necessary for tracking down parts no longer in production and rarely sold anymore.  Engineers designing components for automotive and railways, while using a variety of different polymers for interior parts, tend to lean toward metal 3D printing.

Medical – this is one of the industries where you will see the greatest versatility in uses for 3D printing. Beginning with the use of 3D printed medical models—made from a wide variety of materials, to include brittle textures like sandstone—doctors are able to diagnose what may be complex conditions. For example, a surgeon may be able to explore a brain tumor in much more comprehensive detail, as well as coming up with a patient-specific treatment plan to include surgery.

In some cases, doctors may be performing surgeries that are rare or have never been done before. These models can be used as training devices, as well as guides in the operating room. Beyond that, 3D printed models can offer improved education for patients as well as their families. Medical students are also provided with much greater availability for training, rather than having to wait for cadavers or other materials.

Fashion – for the world of art and design, technology like 3D printing gives users access to a treasure trove full of options. From haute couture to everyday wear—and from high heels to comfortable flats or running shoes, 3D printing has played an interesting role in clothing and footwear. Jewelry makers have received an incredible boon as well, especially in working with polymers, resin, metal, and wax casting. Consumers are able to buy incredibly unique pieces today—even including valuables like wedding rings.

Orthotics and prosthetics – while technically, these types of devices would be considered part of the medical industry, the development of orthotics and especially prosthetics has taken on a life of their own, brining true joy to countless individuals who previously dealt with ongoing pain and continued hassle in finding the right fit for better mobility. 3D printed orthotics allow for customized devices that improve foot health, comfort, and walking. With the ability to create them in just hours, patients now have both access and affordability to patient-specific devices.

In terms of prosthetics, this can be incredibly valuable to patients, and especially children. Even though prosthetics can improve patients’ quality of life substantially, it can often be challenging to convince patients to wear such devices. Children in particular may be susceptible to worrying about what their peers will say. The use of 3D printing technology enables a wide range of customization features that can be tailored to the preferences of each patient. With a variety of colors and styles available these days, a replacement limb can be made with individual flair (think superhero designs for children or even adults) for added appeal. Most importantly, they can be produced quickly and at a fraction of the price companies charge for conventional devices.

If you are currently working in an industry that is beginning to use 3D printing, or has been enjoying the advantages for years already, find out more about the materials and services available to you through Shapeways whether you are creating prototypes or functional parts. We can help you find the right materials and manufacturing method for your latest project, along with offering instant quotes.

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Aerospace 3D Printing Today

Aerospace is a unique fit for 3D printing, offering a prime application area for many of the benefits of additive manufacturing technologies. Among these benefits are:

• Part consolidation
• Lightweighting
• Complex geometries (“freedom of design”)
• Rapid prototyping
• Low-volume production
• Digital inventory

Leveraging these benefits is proving transformative for aerospace manufacturing as today’s aircraft, rockets, and other commercial, private, and military aerospace builds are increasingly able to perform better than ever before. Fewer, lighter parts mean fewer assembly points that could be a potential weakness as well as a lighter weight structure, enhancing fuel efficiency and load capabilities.

Aerospace has long been a ‘city on a hill’ for additive manufacturing, offering highly visible proof points of the technology’s high-flying potential to very literally fly high.

Like in the automotive industry, many aerospace entities have been using 3D printing internally for years, if not decades. Also like the automotive industry, though, many companies have seen the technology as a competitive advantage best kept somewhat under wraps. This has perhaps benefited these companies’ bottom lines — but it has limited the visibility of these applications.

The GE fuel nozzle — which famously reduced from approximately 20 welded pieces into one 3D printed (and 25% lighter weight) piece — was among one of the highest-profile individual applications to be publicly shared. Such use cases are only ramping up; between 2015 and 2018, for example, GE 3D printed 30,000 of those fuel nozzles. Still, though, these examples are often heard over and over again because many other specific use cases are still seen as proprietary ‘secret sauce’ and not public knowledge.

The cat’s out of the bag by now, though, and it’s almost an assumption that any aerospace company is in some way utilizing 3D printing in its operations.

From SpaceX and NASA to Boeing and Airbus, this is certainly the case. These companies are among the highest-profile in aerospace to share at least some look into their 3D printing usage. Applications range from visible cabin components in passenger airplanes to made-in-space tools on the International Space Station, with both mission critical and aesthetic uses well represented.

The secrecy of ‘secret sauce’ is slowly changing, too, as in addition to broadening adoption of 3D printing, space exploration is becoming privatized.

Organizations like SpaceX certainly have their fair share of trade secrets but are also open about their use of 3D printing in applications from spacecraft to personalized astronaut helmets. 3D printing is often coming into play as well to not only make components of rocket engines, but also in new uses such as at Rocket Crafters for their fuel grains.

Smaller, private companies working in the space industry are celebrating the technologies they use to gain traction in technological advance and out-of-this-world achievements. By highlighting instead of hiding the tech helping them to accelerate toward their own liftoffs, these new entities are contributing directly to a shift in the conversation around aerospace technologies.

Aerospace 3D Printing Tomorrow

When we look ahead, we can see an even brighter future for an aerospace industry making more and better use of additive manufacturing opportunities.

While certainly the technologies will improve, providing natural points of improvement even from those areas already leveraging additive manufacturing, the largest single point of future impact for aerospace overall will simply be wider spread adoption.

While the 3D printing industry has historically been excellent at internally sharing the benefits of the technology (like those bulleted above), a sticking point has been in externalizing this message. Aerospace becoming a more open industry with these new private entities on the rise, and with more participants discussing the advanced technologies they put to use every day, will see industrial additive manufacturing gaining more attention, and more traction, overall.

If the GE fuel nozzle made anyone do a double-take, the next innovations to come — or even those already accomplished and not yet publicized — are sure to be fully head-turning.

Further parts consolidation, lightweighting, and other means of taking advantage of the freedoms that DfAM (design for additive manufacturing) enables have the potential to see massive advances in aircraft and spacecraft manufacture.

By optimizing every part of an aircraft, completely rethinking and redesigning the whole, a manufacturer might see unprecedented capabilities emerge. In an industry where every ounce of structural weight matters and lessening any possible point of failure is a must, industrial 3D printing is an obvious fit.

The technology will only continue to make headway into the aerospace industry going forward, and with that larger general footprint will come more significant discrete advances. The future of aerospace and 3D printing is a relationship that will be ever more tightly intertwined.

The post The Future Of Aerospace 3D Printing appeared first on Shapeways Blog.

Let’s dive in to find out just why the aircraft industry is using 3D printing.

A Fit For 3D Printing

Aerospace is a unique fit for many of the most-touted benefits of 3D printing:

• Part consolidation
• Lightweighting
• Complex geometries (“freedom of design”)
• Rapid prototyping
• Low-volume production
• Digital inventory

Let’s look at each of these areas to see how the production of aircraft can make use of these benefits.

Part Consolidation

The weakest point in an assembly is where it has been, well, assembled. When it comes to aircraft, such a weakness could become a point of critical failure, endangering human lives.

By consolidating multiple components of a part into a single 3D printed build, the number of assembly points is necessarily reduced. The unique geometries possible with 3D printing can reduce a part that typically has dozens or hundreds of parts to few — or to one single part. With no welding, riveting, or other fastening needed to keep the part together, not only are SKUs reduced, but so too are potential points of failure.

Lightweighting

Every ounce of weight matters when it comes to equipment meant to fly. Lighter-weight parts means less fuel, improving not only the carbon footprint of a flight but also the cost to fly.

Materials innovations in 3D printing are seeing constant improvements in different metals and polymers approved for use in different equipment. Many of these engineering-grade materials are familiar to those who have worked with them in traditional manufacturing — translating these formulations into 3D printable materials is bringing their capabilities together with part consolidation and other time- and material-reducing benefits to create altogether lighter final parts.

Freedom of Design

Many working with design for additive manufacturing (DfAM) like to proclaim that the technology offers great “freedom of design,” as complex geometries impossible to make with other manufacturing processes are for the first time possible.

Design methods like topology optimization and generative design are developing new shapes never before dreamed of that can be created only by 3D printing. These complex, often lattice-like designs not only reduce weight by including material only where necessary, but are often stronger than legacy designs. While certain constraints of course still exist, and may vary by 3D printing technology and material used, these are in many ways significantly reduced from those seen in traditional, subtractive manufacturing processes. New interior and exterior aircraft components can be designed to replace stodgy original parts, adding both design finesse and extreme functionality.

Rapid Prototyping

The earliest use of 3D printing is also its original nomenclature: rapid prototyping.

Quickly going from a napkin sketch idea to a CAD design to a first prototype — and then a second, third, and so on — speeds up the time-to-market for new products. While traditional manufacturing may require multiple iterations to be sent back and forth over weeks or months, the fast-paced aircraft industry can see much faster turnaround when designs can be created and finalized within days or weeks.

Low-Volume Production

As large as the aerospace industry is, by total volume the sheer number of aircraft produced is relatively small compared to, say, automotive or appliance production.

High-value, low-volume production is a perfect fit for 3D printing. Whereas many traditional manufacturing processes require expensive tooling and molding to be made, creating economies of scale for mass production, no molding is necessary for additive manufacturing. One or a few pieces may be made at a time — including different designs on the same build plate — with no additional molding or tooling costs. The point of inflection for additive versus traditional manufacturing typically requires hundreds or thousands of parts to be made before traditional techniques are more cost-effective — and while that may ultimately reduce costs to pennies per injection molded part, before that crossover point, 3D printing is more cost-effective. This is especially the case when using high-value metal powders, when material savings are imperative; 3D printing eliminates significant waste of material as only the material needed for a given build need be used, and much else can be recycled, rather than cutting away and wasting material from solid blocks in subtractive manufacturing processes.

Digital Inventory

When an aircraft is approaching the end of its useful life, often it can be salvaged through replacing certain parts to keep it flying. This is often done through use of physical warehouses, where these spare parts were stored on shelves until needed. These spare parts, in most cases, were made at the same time as the original mass-produced OEM parts, set aside to await replacement demand for worn parts. If that demand never comes, though, they were a waste of not only the time and cost of producing them, but also of storing them on shelves for however many years. Worse, if that demand comes but spares are out of stock — especially those forever out of production — the lack of a small part may ground a plane.

Rather than physically keeping goods on shelves, digital fabrication methods allow for storage of a design file that can be 3D printed on demand. 3D printing a replacement part allows for only those parts needed to ever be made — again without need for first producing costly molding or tooling. These on-demand spare parts can also be made anywhere with the appropriate technology, rather than awaiting OEM delays that can all too easily run up into weeks or months.

Flying High With 3D Printing

The production of aircraft, from prototype to spare parts, is increasingly benefitting from the use of 3D printing in the supply chain. Decentralized production, new design possibilities, and reductions in time, materials, and costs are offering new ways for aircraft to keep flying high.

The post Why Is The Aircraft Industry Using 3D Printing? appeared first on Shapeways Blog.

The Housewarming Party Heard ‘Round the World

We’ve been making huge advances recently (‘we’ being humans) in printing structures. From bridges to bus shelters, these experiments have been pretty literally laying the foundation of all the 3D printed structures to come. Then, this month, SXSW happened. And during the always-hyped 10-day festival of innovation, music, film, and whatever else the organizers decide, New Story and ICON’s 3D printed house stole the show. Developed to eventually cost $4,000 and take no more than 12-24 hours to print, it’s destined for use in developing areas that need sturdy housing. The quick-drying cement used by Icon’s specially-produced Vulcan printer is stronger than traditional concrete. Plus, the house’s desert-chic aesthetic is so hot right now.

Take the full tour below:

Italian architect Massimiliano Locatelli has been teasing a similar 3D printed showplace to be unveiled during next month’s Milan Salone del Mobile — this time with fancier fixtures. Follow his Instagram for updates and, we hope, unbearably chic instas from the show.

BUILD A BIG IDEA

It’s actually rocket science

Why 3D print a rocket? “Rockets are the lightest-weight, most expensive, largest, difficult-to-make thing, that really 3-D printing is the optimal solution for.” That’s coming from Relativity co-founder Tim Ellis, whose company is using the largest metal 3D printer in the world to construct rocket elements (today) and fully 3D printed spacecraft (tomorrow). The printer is (super-nerdily, super-awesomely) named Stargate. Learn more at Futurism, and watch PBS’s interview with Tim Ellis (and other 3D printing wizards) below.

Put these contacts in with your robot hand

Researchers at Northwestern University worked their butts off to solve the trickiest of challenges: creating smooth, layer-less lenses with our favorite layer-by-layer manufacturing technique. After more than 100 tries, the resulting lenses are low-cost, high-quality, and fast-printing. Said Cheng Sun, whose lab developed the process, “Up until now, we relied heavily on the time-consuming and costly process of polishing lenses. With 3D printing, now you have the freedom to design and customize a lens quickly.” This means custom contact lenses, microscopes on iPhones, better imaging during things like endoscopic surgeries — but probably not better selfies.

But what about this robot hand? It’s actually the first fully 3D printed bionic arm, and thanks to Open Bionics, it will be available in April for purchase. The Hero Arm can be endlessly customized in terms of its appearance and fit, and it’s much, much cheaper than the next-least-expensive bionic arm on the market. The name derives from the fact that the company has custom-made a few prototypes that are based on superhero characters. But, an inexpensive bionic arm is also kind of a hero in and of itself. See it in action (hero mode) below.

Even better than the ugly sneaker trend

The 3D printed shoe proto-trend became even more fun this month when Reebok got into the game with its Liquid Floatride sneaker drop. Adidas, New Balance, and Under Armour have already brought some offerings to market, and now that Reebok’s Liquid Factory (where a proprietary material is responsible for the kicks’ 3D printed elements) is up and running, our 3D print-shod future is looking so, so cool.

3D Print Your Robotics Needs

Learn how you can utilize 3D printing for robotics use. Contact us today to let us know how we can help.

ROBOTICS PRINTING SOLUTIONS

The post The Month in 3D Printing: South by Southwest Builds the Dream appeared first on Shapeways Blog.

Shapeways is deeply invested in 3D design and printing education, so we were delighted to find that one of Shapeways Magazine’s contributors, Michael Parker, is just as invested. Here, he tells us about a novel approach to teaching engineering using 3D printers.

This summer, I had the opportunity to teach a three-day workshop, Understanding the Technology of Additive Manufacturing, to students at New York City College of Technology, better known as City Tech, in downtown Brooklyn.

The students, who ranged from first-years to graduating engineers, received a small stipend if they completed my workshop, plus two more workshops: NASA Free-From Fabrication and Additive Manufacturing for Aerospace and Medical Applications. Together, they added up to City Tech’s Summer STEM Research Experience, a program funded by $1.3M in STEM grants from the National Science Foundation (NSF) and NASA, raised by Gaffar Gailani of City Tech’s mechanical engineering and industrial design technology department.

The summer students were probably expecting a dry lecture, but I wouldn’t do that to them. Not only are lectures boring, but they are poor preparation for the realities of working with the kinds of complex mechanical systems they hope to see throughout their careers.

So instead, I decided they would assemble a 3D printer from a kit. A RepRap open-source printer would be a good fit for engineering students. Due to budgetary and time constraints, I went with the HicTop 3DP-11-ATL, a Prusa i3 clone.

The workshop didn’t start smoothly. At the start of day one, only four of the six 3D printer kits had arrived. Still, I was determined to keep my introductory remarks short before launching the students into the build, where they could learn about the technology as they went.

Even engineering students rarely get opportunities to be hands-on with equipment, so I had to teach them to use their hands and eyes. We also used a variety of tools, but sometimes tools can be crutches and you can lean too heavily upon them. A tool can become inaccurate, but your eyes don’t lie. One key was making sure the students took extra care when assembling the aluminum extrusions that they were at 90° angles and flush. If you don’t have a solid base, you will run into a multitude of problems going forward.

By midday, the two wayward 3D printers kits had arrived. We completed the y-axis assembly and much of the z-axis assembly, including the bottom frame, bed carriage and main board installation. And with practice, students were able to see at a glance whether their builds were true or askew.

On Day 2, the students continued to assembling the frame, mounting stepper motors and making sure that the linear bearings were moved easily along the smooth rods. Then came one of the most critical parts: the extruder.

The extruder consists of a stepper motor that drives a gear to propel plastic filament into the hotend. The hotend barrel is meant to keep the filament cool until it reaches the heating block. The heating block melts the filament, which flows out of the nozzle and cools almost immediately. There are also fans to cool both the hotend barrel and the extruded filament.

On the third day, I made my students take apart their extruders that they had worked so diligently on the day before in order to upgrade them. The 3D printed extruder parts that came with the kits weren’t very sturdy, and the benefit of building this type of printer is that you can modify it to your heart’s content. A well-built and calibrated kit printer can rival an out-of-the-box 3D printer costing thousands of dollars more. It just takes elbow grease and persistence.

The students took ownership of their builds by experimenting with how to level the print beds, adjust the auto-level probe, and make test prints. Then came a quiz about additive manufacturing and 3D printer assembly. The four students with the highest scores on the quiz each took a 3D printer home while the other two stayed at City Tech, where any engineering students can use them.

The post Student Engineers Get Hands-on Experience — by Building 3D Printers appeared first on Shapeways Blog.

print in metal

Here’s a rundown of some recent developments in metal 3D printing:

Most state-of-the-art racing bikes are crafted almost entirely from carbon fiber, which is light and strong. However, Chris Froome’s Tour de France-winning bicycle features 3D printed titanium handlebars. The Engineer reports that 3D printing reduced production time for the handlebars by up to 75% compared with a carbon fiber process. No molds were needed, and the custom fit eliminated any need for adjustability, saving up to 17% of the weight of a traditional handlebar assembly while reducing drag.

Ship Technology reports that the Port of Rotterdam’s Additive Manufacturing Fieldlab (RAMLAB) teamed with Autodesk to develop a 3D printed nautical propeller. Their hybrid manufacturing process combined wire and arc additive manufacturing with industrial robot arms, subtractive machining (CNC), and grinding. The new process will help the port provide quick replacement propellers for ships.

[Credit: Michael A. Parker]

Spaceships are also increasingly relying on metal 3D printing. NASA has 3D printed entire rocket engines. Scientists at NASA’s Jet Propulsion Laboratory (JPL) created a 3D printed metal fabric to protect both astronauts and spacecraft from micrometeors. As 3DPrint.com reports, the chainmail-like textile, which is printed in one piece, reflects sunlight, provides thermal insulation, is foldable, and has high tensile strength.

Facial reconstructive surgery has benefitted from 3D metal printing. According to Additive Manufacturing, 3D printed titanium can be customized to the individual patient and aid in bone regrowth and stability. 3D Printing Industry reports that British manufacturing company Renishaw partnered with Western University to create a $5 million Additive Design in Surgical Solutions (ADEISS) center in Ontario, Canada, to produce metal additive manufactured medical tools and implants.

[Credit: NASA]

The Vader Systems MK1 Experimental desktop metal 3D printer, meanwhile, uses their MagnetoJet technology to propel liquified aluminum from an electromagnetic-field-encased 1,200° C chamber through inkjet-like print nozzles. Using wire feedstock instead of powders, it reduces costs and dramatically speeds up printing. The production model launches in 2018.

Shapeways’ interlocking precious metals are perfect for creating unique jewelry. Lead times for 3D printed steel were reduced by two days so you can create functional parts quickly. With the benefits of strength, durability, beautiful finishes, and a myriad of material choices, isn’t it time you took a dip into the white-hot 3D printed metal space?

try it yourself

The post From Aerospace to Jewelry, Metal 3D Printing Is Hot appeared first on Shapeways Blog.

How’d you link your passion for space with 3D design?
To answer your question, the link was not just with 3D printing but rather between space and modeling.

Since childhood (December 1968 actually with the flight of Apollo 8, the first men to orbit the moon) I have always been interested by the exploration of space; the 60’s and 70’s being my favorite years with the culmination of the Apollo flights to the moon. I started building space models when I was a kid and I have continued this hobby until now.

In the 60’s and 70’s there were a few space models available like the Gemini, Vostok or Apollo spacecraft, but if you wanted to build something different (for instance a lunar rover or a large lunar module) you had to scratchbuild these models. I eventually became quite good at it, having now a couple of models displayed in museums. A large part of scratchbuilding is research to design parts with paper, wood or styrene. When 3D printing appeared, I said to myself that maybe all this available research could be used in designing parts in 3D and printing them.

Meens’ A10-FUD-Descent Stage for a 1/32 model of the Lunar Module

Seems like you’ve been very successful with the 3D printing approach to your models.
Scratchbuilding requires a lot of research to find the good measurements but it also takes time. Imagine you designed a tiny thruster which take you about half an hour to build and you have 16 of them. 3D printing comes as a very interesting tool, not only your part will be more precise but you can also reproduce it. It also saves time and frustration if you lose a part.

Your models have been displayed in museums, tell us how that came about.
Monogram released many years ago a model of the Apollo spacecraft at 1/32. Unfortunately the lunar module was never released at that scale. Having previously built a large 1/24 lunar module (scratchbuilt) I used my research to design the missing 1/32 LM. I knew this would certainly be a hit among space modelers and it was, being largely promoted on space modeling fora and on my web site where I explained all the intricacies of this model built. As of today it is the only 1/32 lunar module plastic model available.

For the 1/32 lunar module I already designed a few years earlier a 1/24 model which I gave to a museum. All the research was already done and it was just a matter to design it in 3D and print it. Not only it was fun and quicker to build than the 1/24 one but I could offer it to other space enthusiasts.

Designer Vincent Meens of Space Models

We encourage you to check out Vincent’s Shapeways shop here, he has detailed instructions on assembling his model on his website for any of the models you’re interested in building.

The post Designer Spotlight: Vincent Meens – Space Models appeared first on Shapeways Blog.