Recent Technological Push for Metal 3D Printing

Two relatively new players in the 3D world have announced similar Metal Printing concepts within last few months. Markforged announced the launch of MetalX in January and then Desktop Metal announced the launching of DM-Studio printer in May this year. Also Desktop-Metal announced the coloration with a North American 3D giant "Stratasys". Both Markforged and Stratasys are accepting orders for the systems to be shipped in near future.

 

Similarities

• Powder metal is encapsulated in a binder,  extruded on to a platform just like normal FDM method.
• Some of the binder is washed at a washing station after printing.
• After washing parts are sintered in a furnace.
• Furnace sintering causes the part to shrink quite a bit, up to 20% depending on the metal. Shrinkage factor is calculated and added by the software at the time of process.
• Markforged’s process is called Atomic Diffusion Additive Manufacturing (ADAM).
• Desktop Metal has developed the Bound Metal Deposition (BDM) approach.
• Both systems are expected to cost around $120k. 

 

 Metal X from Markforged

   

 

DM Studio from DeskTop Metal

 

 

 Desktop Metal production system

 

Observations

• Even though both brands are marketing their systems as suitable for office. Washing process involves chemicals and heat, causing fumes and vapors which need to be exhausted properly.
• Both processes use furnace to sinter metal. The sintering process spew fumes and again need adequate exhaust.
• Inconsistencies in shrinkage factor may cause less accurate parts when compare to other established technologies.
• Print-ability of small features may be limited.
• Printing resolution may be a concern for some users.
• The systems are much more affordable as compare to metal laser sintering processes which can open up possibilities of serving cost conscious industries.
• The process could be a good fit for additive + subtrative combination. Complex shapes can be printed and accurate features can be CNC machined. 

References:
Markforged
Stratasys
        

HP Jumping-in to Reap 3D Printing Market

Hewlett-Packard (HP) is a well known brand in manufacturing of printing machines for decades. It has been in the news for some time that HP is working on building its own line of 3D printing machines. Obviously when a big player like HP coming to the market place to compete, they don't want to be one from the crowd rather they want to bring a fresh idea to address certain need of the market.
After much anticipation HP showcased "HP Multi Jet Fusion" machine at Formnext 2016.

Most of the new technologies are fusion of some of the existing ones. "Multi Jet Fusion" is part "Powder Based" machines Z-Corp has been building for some time and part "Selective Laser Sinteing" SLS technology, obviously with its own advanced ingredients. HP is in to compete with top of line professional and production brands.

Strengths:

• Better Quality: Comparing to most FDM machine
• Higher Speed: In comparison wit FDM and SLS machines
• Cost effective: Better recycling ability of powder materials, almost to 80%. 

 

Technical Specs:

Dimensional accuracy of ±0.2 mm/0.008 inches

Layer thickness 0.1mm/0.004 inches

 

Solutions for Each Segment of the Industry:

• The HP Jet Fusion 3D 3200 Printer is ideal for prototyping, offering improved productivity and the capacity to grow usage at a lower cost per part^.
• The HP Jet Fusion 3D 4200 Printer is designed for prototyping and short-run manufacturing needs, with high productivity to meet same business day demands at the lowest cost per part.

 According to HP  "The new solutions will be sold in the U.S. and Canada, as well as select European countries. Availability will be expanded to include additional European and Asian markets in the second half of 2017. Delivery of the HP Jet Fusion 3D 4200 Printer will come in late 2016. Delivery of the HP Jet Fusion 3D 3200 Printer will come in 2017".

The HP Jet Fusion 3D 3200 Printer starts at $130,000, and the full end-to-end solution (HP Jet Fusion 3D 3200 Printer and Processing Station) is available starting at $155,000.

Lear more about HP Multi Jet Fusion machine HERE

Observations: 

If we look at the Quality, Resolution and Layer thickness of the machine, lot of professional grade FDM machines are in the same range. Price is also not hugely different. One front where it is better for sure is the speed. Choice of materials and color schemes are another big plus for HP.

On the other hand if we compare it with some of the SLS brands out there. SLS machines are more accurate and can deliver better resolution and layer thickness. SLS machines are mostly higher in price and slower in speed in comparison with HP. 

Overall HP machines could be great bang for the buck for certain segments of the industry if they will be able to deliver the promises with out any hiccups. HP realizes the completion is tough, listen to the tone at the NewYork show in the clip below.

     

References:
www2.hp.com
USA Today, Youtube video

Whats New in 3D Technologies

Eco Rapid Layer Manufacturing Technology

Eco concrete ideas in collaboration with HighCon have developed a new technology that allows you to create previously unfeasible items in concrete. 3PM (3D Printed Mold) is a technology that converts a 3D design file into a proprietary software that is then used to create multilayered paper molds.

Each paper slice is printed separately and then aligned and assembled to create a mold. Concrete is poured in to the mold. Paper mold will be broken away after curing of concrete. 

 

Electron Beam Melting (EBM)

Although it is quite different but it seems like advanced form of  Direct Metal Laser Sintering (DMLS).The Arcam EBM machines utilize a high power electron beam that generates the energy needed for high melting capacity and high productivity. The electron beam is managed by electromagnetic coils providing extremely fast and accurate beam control that allows several melt pools to be maintained simultaneously

The Arcam EBM process takes place in vacuum and at high temperature, resulting in stress relieved components with material properties better than cast and comparable to wrought material.
Learn more about EBM here

MagnetoJet

Father and son company has come a long way to develop Magnetojet. They are ready to launch their very first production machine. Vader machines will be available for purchase soon.

Vader’s patent pending MagnetoJet technology is based on the study of Magneto Hydro Dynamics (MHD), or more simply: the manipulation of liquid metal through magnetism. MagnetoJet’s extraordinary physics are accomplished by depositing Aluminum wire into an 800°C ceramic chamber, where it is influenced into a molten state. This molten media is then electromagnetically pulsed – causing a droplet to form and eject with precision from a carefully crafted ceramic nozzle.

Learn more about Magnetojet here

 

Gel Dispensing Printing 

GDP is a new technology developed by Msssivit. GDP is combining FDM way of deposition of Gel with Polyjet way of curing the gel like material with high power UV light. The major advancement is the printing speed. The brand is focused on Speed and Big size prints. Target industry is advertisement and displays.

GDP is unique to Massivit 3D. There is no other 3D printing company utilizing this technology. Massivit 3D technology was structured to fit the specific needs of printing large objects – that is what makes it unique. At the heart of the GDP process is Massivit’s unique printing gel & smart support.

Massivit 3D solution is very fast, and capable of printing up to 35cm / 1ft per hour. As an example it would take ONLY 5 hours to print a simple sculpture of a standing human being in full size.

References:
Concreteideas.co
Arcam.com
Massivit3d.com
Vadesystems.com

3D Dinner

Although 3D printed food is not a brand new idea, but for the first time a franchise is being established as 3D printing restaurant.

Food Ink is a one-of-a-kind gourmet experience in which all the food, all the utensils and all the furniture are completely produced through 3D-printing in an immersive futuristic space.

FOOD Ink

Food Printer at Home

Soon you will be able to buy a 3D machine to print your Food at home. Columbia university Engineering school is working on developing one.

We’re all accustomed to having appliances on our kitchen counters, from toasters and blenders to coffee makers and microwaves. If Mechanical Engineering Professor Hod Lipson has his way, we’ll soon need to make room for one more—a 3D food printer that could revolutionize the way we think about food and prepare it.

Learn more about the project. 

References:
Columbia University: http://engineering.columbia.edu/news/hod-lipson-3d-food-printing
Food ink.io

3D Scanning Buildings of Historic Significance

Why 3D Scanning.

By 3D scanning of a building, all details of the site can be captured. Scanned data can be turned in to 3 dimensional models and engineering drawings can be produced from it. Buildings of historic significance can be reproduced to exact dimensions and details in case of collapse or demolish.

3D Scanning of Historic part of the Holy mosque in Mecca.

As apart of Expanding Holly Mosque Capacity, the Ottoman Portico's which prepared during the rule of Sultan Suleyman the Magnificent has been demolished. Part of the historic arches have been captured and can be rebuilt whenever and wherever.  

 Watch the video

 

3D Scanning of mosque from 7th century in Kala-Koreysh

Group of engineers from UK traveled to remote part of Daghestan, Russia to document a mosque from 7th century. The area is called Kala-Koreysh. Technique they used for scanning is called photogrammetry. It works very similar to 123d-catch we learned earlier.

The mosque at Kala-Koreysh is thought to have been established by members of the Quraysh clan in the 7th century during the first outpost of Islam in the Northern Caucasus. The significance of the town extends beyond the mosque, being of importance of the Kaitag feudal state, and one in which a number of its rulers were buried.

The following video is an excellent example of how whole process works.

References:
Geotechuae
Factumfoundation.org
3dprintingindustry.com

Marrying Addititive and Subtractive Manufacturing

This is a huge news for me to see two areas of my expertise (CNC Machining and 3D Printing) coming together. Both of them has their own strengths and limitations. Marrying them together will be a real step forward toward next industrial revolution. One of the well known brand (DMG) in CNC machines manufacturing has showcased the concept at European machine show. We know about few different concepts being used for Metal 3D printing. DMG is using Laser Metal Deposition concept.

Laser Metal Deposition

The process involves a laser beam used to form a melt pool on a metallic substrate, into which powder is fed. The powder melts to form a deposit that is fusion bonded to the substrate. Both the laser and nozzle from which the powder is delivered are manipulated using a computer numerical control system.

CNC Machining

CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools. Tools that can be controlled in this manner include lathes, mills, routers, grinders, EDM machine, Laser cutter etc. The CNC in CNC Machining stands for Computer Numerical Control.

 Additive & Subtractive coming together

References:
Metal Powders for Additive Manufacturing
DMG Mori 
Orange Vise Company

Polyjet Technology

So far we have learned about:

• Fused Deposition Modeling
• Selective Laser Sintering
• Direct Metal Laser Sintering
• Stereolithography

Please read through old posts if you want to learn about the upper mentioned technologies.

Today we want to look at another popular one in the high-end additive manufacturing market. It is "Polyjet or Thermojet" technology. Let's first learn how Polyjet works and then we can shed some light on its strengths and weaknesses.


PolyJet 3D printing is similar to inkjet printing in fact this is the only method which has close resemblance to printing the way it works. Instead of jetting drops of ink on the paper, PolyJet 3D Printers jet layers of curable liquid photopolymer onto a build tray.

Polyjet was developed by OBJET which came under the umbrella of Stratasys in 2012.

Production: 

The 3D printer jets and instantly UV-cures tiny droplets of liquid photopolymer. Fine layers accumulate on the build tray to create a precise 3D model or part. Where overhangs or complex shapes require support, the 3D printer jets a removable gel-like support material.

Support removal: 

The user easily removes the support materials by hand or with high pressure water jet.

I am pretty sure you will enjoy the Objet30-pro video

High resolution (28micron layers) printing, robust quality and higher accuracy are strengths of Polyjet. You will be able to print fine detailed and smooth surface finished parts. Even high end FDM machines won't be able to compete polyjet when it comes to surface finish and smaller/fine details. On the other hand Higher material and maintenance cost can hurt your profitability.  

With Objet260-connex1 you can print softer rubber like and Harder material together. Learn more about Objet Connex here

and with  Objet260-connex3 can you can get unlimited shades of colors in your print.

References:

"Stratasys.com"