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.

To bring you steel products, we work with pioneering additive manufacturing company ExOne, based near Pittsburgh, PA. Their binder jetting process for metals (and, incidentally, sand) is unique, making them an invaluable partner. You can learn more about how steel is made here.

To achieve faster lead times, Shapeways and ExOne took a deeply collaborative approach to making the highly complex steel production process more efficient. It all started with breaking down each stage to find space for improvement.

When we began, we knew that there were more than a dozen process steps, both before and after printing, that kept lead times longer. So, we dug in, looking for anywhere we could reduce friction. This started with tracking and analyzing how much time each step took. We found that the largest bottleneck was the pre-production process, where 3D files are downloaded, checked, stilted, and entered into the system. We decided to start the improvement efforts here.

We then mapped out the current process in full detail, from the steps a customer takes to place an order to the work Shapeways engineers do to get the files to ExOne. The other team members also did a deep dive on their respective tasks after receiving the files, including order entry and build planning.

From there, we mapped out the dream state, where complications don’t exist. Having that goal in mind led to specific process improvements we were able to make immediately, like setting up an automatic flow of files from Shapeways to ExOne. There are still improvements that will take effect down the road, and this two-day lead time reduction is only part of a journey toward finding the “speed limit” of this manufacturing process. With deep collaborations like those between Shapeways and ExOne, we’ll get there faster than you think.

Special thanks to Katie Lopez of Shapeways’ Supply Chain team for sharing the steel lead time reduction story with us.

The post Faster Steel — And the Innovative Process That Made It Possible appeared first on Shapeways Blog.