Design World - Additive Manufacturing Handbook September 2019 PDF

September 2019 www.designworldonline.
com
2019
Additive
Manufacturing
Handbook
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E d i t o r i a l
Additive technology
expands in multiple directions
Welcome to the second annual edition of the Additive Manufacturing
Handbook. This dynamic industry continues to find new ways to make
parts faster, and some of these new methods are included within this
issue. But one of the bigger stories on additive this year is the growth of
service providers. This industry continues to develop new ways to make
objects faster, but which one do you choose for your needs? An excellent
approach is to work with service providers. Not only do they typically have
all the additive technologies you need, they also have “seen it all,” and can
offer excellent advice and guidance so that you get the part you want.
Another big story involves the funding developers of additive
technology are getting. For example, Carbon announced it raised more
than $260 million in growth funding a few months ago. This latest round
brought its total fundraising to more than $680 million.
Markforged in Massachusetts announced earlier in the year that it
closed an $82 million Series D round of funding led by Summit Partners
with participation from existing strategic and financial partners.
And Essentium, Inc., a provider and innovator of 3D printing solutions
for industrial additive manufacturing, closed $22.2 million in Series A
funding.
Service providers are growing through funding as well. One example
is Fast Radius in Chicago with its recent announcement of $48 million in a
Series B funding round led by UPS, with strong insider participation from
Drive Capital.
This handbook will help sort through all the developments and changes.
Among these pages you’ll find information that describes how many of the
additive technologies work. You’ll also read stories on applications, both
popular and unique. In addition, you’ll read what various industries leaders
have to say about this technology and how they plan to make additive
technology more useful for manufacturing.
Given the dynamism of the industry, changes will continue to come.
And we will continue to keep you informed of those changes.
Leslie Langnau | Managing Editor

llangnau@wtwhmedia.com
On Twitter @ DW_3Dprinting
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9 • 2019 • designworldonline.com
Contents
04 _3D SYSTEMS 28 _MARKFORGED

Engine manufacturer validates Advancing the use of desktop metal
designs with SLS 3D printing 3D printing
08 _BIGREP 32 _NANO DIMENSIONS

When size matters How 3D printing can produce a

10 _CARBON
functional RF circuit
Company
How additive manufacturing
addresses automotive
34 _RENISHAW
Profiles
Take the stress out of metal
manufacturing challenges
additive parts 50-54
14 _DESKTOP METAL
38 _RIZE
Post processing options for
metal additive parts 3D printing jigs and fixtures
with zero post processing
18 _EOS
40 _STRATASYS
Shaping the future of
manufacturing Building a better 3D printer
20 _FORMLABS 46 _ULTIMAKER
Low force stereolithography Streamlining manufacturing
delivers better surface finish with 3D printing
22 _GE ADDITIVE
Additive manufacturing delivers
the scaffolding for growth
24 _HP ADDITIVE
3D printed anatomical models
make surgeries easier and faster
DESIGN WORLD www.designworldonline.com September 2019 3
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User stories
Engine manufacturer
validates designs with
SLS 3D printing
The Rapid Prototyping Center at Briggs & The SLS prototyping applications
Stratton has been using Selective Laser Sintering include prototyping blower housings
A version of this (SLS) 3D printing since 2015 when it acquired and fuel injector systems, cyclonic
V-twin intake a 3D Systems’ SLS printer. Prior to bringing air cleaning systems, mufflers and
manifold success- SLS in-house, the products manufacturer used intake manifolds, just to name a
fully underwent machining, external services, and other in-house
few. In addition to proof-of-concept
2000 hours of testing prototyping for nearly all parts,
on wide-open throttle.
printing technologies to meet its prototyping
Briggs & Stratton designers include
needs. Buying an SLS printer introduced new
certain SLS parts on engine fit-
levels of throughput, durability, and accuracy, ups for early insights into design
as well as cost savings to Briggs & Stratton’s performance, assembly, and
prototyping capabilities. interferences.
4

3DSystems.9.19.Vs3.LL.indd 4 9/13/19 8:51 AM

The company’s designers Citing an extreme application in an ABS plastic or glass-filled nylon,
unanimously agree that the greatest example, Dorna says he received however designer Brian Holzman also
advantage of the SLS technology a part request for an SLS printed reports great success using SLS to
is speed. “The quicker we can get and epoxy-sealed intake manifold: prototype sheet metal parts. “A lot
a design in our hands, the sooner “The next thing I knew I had an of the sheet metal parts are 0.8 - 1
we can take next steps,” says Matt order for six more,” he says. “I mm thick, and the DuraForm material
Martinek, New Product Development, found out these SLS parts are used does an awesome job on those,” he
Briggs & Stratton. “We SLS print just to qualify the design, which means says. “It’s durable and flexible, so it’s
about every part we come up with a they’re being run on an air-cooled conducive to thin parts.”
new design for.” engine for 2000 hours at wide open Mechanical designer Jonathan
The ability to stack parts within throttle. That’s a brutal environment, Tyznik works in Briggs & Stratton’s
the build enables higher throughput, and these parts are holding up.” Research & Development group and
making it possible to build more Briggs & Stratton currently uses estimates that depending on where
parts at once and keep up with the DuraForm® ProX® PA across all of its he is in development he requests an
continual demand for parts. prototyping applications. DuraForm average of 1 - 2 to 12 - 15 SLS parts
Michael Dorna, manager of Briggs & ProX PA is a durable polyamide 12 a week. Designer Casey Groh says:
Stratton’s Rapid Prototyping Center, nylon material with resolution and “I’ve easily requested a hundred parts
estimates that 30-40% of SLS part mechanical properties for complex or more for the current project I’m
orders are tested for function. “With parts with thin walls or snap fit working on.”
SLS, we get the benefit of tough, requirements. Many of the parts that According to Bob Johnson, a
durable parts that can also be are functionally prototyped using Briggs & Stratton designer for more
detailed,” says Dorna. SLS are ultimately injection molded than 30 years, a coat of spray paint
is all it takes to give the SLS parts
a close resemblance to their final
molded counterparts, and the SLS
parts perform similarly as well.
To ensure confidence in final
production materials, Briggs & Stratton
does not exclusively rely on SLS
parts for final pre-production testing,
but Johnson says using SLS for
certain testing, such as performance
¾-scale V-twin that turns with
the crank handle; printed as an and airflow, allows the company to
assembly with only the pushrods accelerate its validation process.
printed separately.
3D Systems | www.3dsystems.com
This SLS printed cam tensioner lever

spent 500 hours inside a running engine.

User stories
COMPANY MACHINE NAME BUILD ENVELOPE BUILD MATERIALS LAYER BUILD SPEED
(MM; W X D X H) THICKNESS
3D SYSTEMS FABPRO 1000 ENTRY-LEVEL 125 X 70 X 120 MM (5 X FABPRO TOUGH BLK, PROTO GRY, JEWEL- 0.03 TO 0.1 MM UP TO 21 MM/HR VER-
INDUSTRIAL 3D PRINTER 2.75 X 4.7 IN. ) CAST GRN, ELASTIC BLK AND SELECTED TICAL BUILD SPEED
NEXTDENT DENTAL MATERIALS - UV CUR-
ABLE PLASTICS
FIGURE 4 STANDALONE 3D 124.8 X 70.2 X 196 MM (5 FIGURE 4 TOUGH-GRY 10, TOUGH-GRY 15, 0.02 TO 0.1 MM UP TO 104 MM/HR
PRINTER X 2.75 X 7.72 IN.) FLEX-BLK 10, ELAST-BLK 10, JCAST-GRN 10 VERTICAL BUILD
- UV CURABLE PLASTICS SPEED
FIGURE 4 MODULAR 3D 124.8 X 70.2 X 346 MM (5 FIGURE 4 TOUGH-GRY 10, TOUGH-GRY 15, 0.02 MM MIN. UP TO 104 MM/HR
PRINTER X 2.75 X 13.6 IN.) FLEX-BLK 10, ELAST-BLK 10 - UV CURABLE VERTICAL BUILD
PLASTICS SPEED
FIGURE 4 PRODUCTION 3D 124.8 X 70.2 X 346 MM (5 30+ UV CURABLE MATERIALS 0.02 MM MIN. UP TO 104 MM/HR
PRINTER X 2.75 X 13.6 IN.) VERTICAL BUILD
SPEED
NEXTDENT 5100 DENTAL 124.8 X 70.2 X 196 MM (5 BROAD SELECTION OF NEXTDENT DENTAL 0.03 MM MIN.
3D PRINTER X 2.75 X 7.72 IN.) MATERIALS - UV CURABLE PLASTICS
PROJET CJP 260PLUS 236 X 185 X 127 MM (9.3 VISIJET PXL - CMY COLOURS 0.1 MM 20MM/HR MAX. VER-
COLOR 3D PRINTER X 7.3 X 5 IN.) TICAL BUILD SPEED
PROJET CJP 360 3D 203 X 254 X 203 MM (8 VISIJET PXL - WHITE (MONOCHROME) 0.1 MM 20MM/HR MAX. VER-
PRINTER X 10 X 8 IN.) TICAL BUILD SPEED
PROJET CJP 460PLUS 203 X 254 X 203 MM (8 VISIJET PXL - CMY COLOURS 0.1 MM 23MM/HR MAX. VER-
COLOR 3D PRINTER X 10 X 8 IN.) TICAL BUILD SPEED
PROJET CJP 660PRO 254 X 381 X 203 MM (10 VISIJET PXL - FULL CMYK COLOURS 0.1MM 28MM/HR MAX. VER-
COLOR 3D PRINTER X 15 X 8 IN.) TICAL BUILD SPEED
PROJET CJP 860PRO 508 X 381 X 229 MM (20 VISIJET PXL - FULL CMYK COLOURS 0.1 MM 5-15MM/HR MAX.
COLOR 3D PRINTER X 15 X 9 IN.) VERTICAL BUILD
SPEED
PROJET MJP 2500 PLASTIC 295 X 211 X 142 MM (11.6 VISIJET M2R-WT, M2R-BK RIGID PLASTICS, 32μ
3D PRINTER X 8.3 X 5.6 IN.) VISIJET PROFLEX M2G-DUR ENGINEERING
PLASTIC; MELT AWAY SUPPORT
PROJET MJP 2500 PLUS 295 X 211 X 142 MM (11.6 VISIJET PROFLEX M2G-DUR, ARMOR M2G- 32μ
PLASTIC 3D PRINTER X 8.3 X 5.6 IN.) CL ENGINEERING PLASTICS
VISIJET M2R-WT, M2R-BK, M2R-CL, M2R-
GRY, M2R-TN RIGID PLASTICS
VISIJET M2 EBK, M2 ENT ELASTOMERIC
MATERIALS
MELT AWAY SUPPORT
PROJET MJP 2500W REAL- 294 X 211 X 144 MM (11.6 VISIJET M2 CAST - WAX MATERIAL 16μ
WAX 3D PRINTER X 8.3 X 5.6 IN.)
PROJET MJP 2500 IC REAL- 294 X 211 X 144 MM (11.6 VISIJET M2 ICAST - WAX MATERIAL 42μ
WAX 3D PRINTER X 8.3 X 5.6 IN.)
PROJET MJP 3600 PLASTIC UP TO 298 X 185 X 203 VISIJET M3-X, BLACK, CRYSTAL, PRO- 16μ TO 32μ
3D PRINTER MM (11.7 X 7.3 X 8 IN.) PLAST, NAVY, TECHPLAST, PROCAST - UV
CURABLE PLASTICS
PROJET MJP 3600 MAX UP TO 298 X 185 X 203 VISIJET M3-X, BLACK, CRYSTAL, PRO- 16μ TO 32μ
PLASTIC 3D PRINTER MM (11.7 X 7.3 X 8 IN.) PLAST, NAVY, TECHPLAST, PROCAST - UV
CURABLE PLASTICS
PROJET MJP 3600W REAL- UP TO 298 X 183 X 203 VISIJET M3 CAST, M3 HI-CAST - WAX 16μ TO 32μ
WAX 3D PRINTER MM (11.7 X 7.3 X 8 IN.) MATERIAL
PROJET MJP 3600W MAX UP TO 298 X 183 X 203 VISIJET M3 CAST, M3 HI-CAST - WAX 16μ TO 32μ
REALWAX 3D PRINTER MM (11.7 X 7.3 X 8 IN.) MATERIAL
PROJET MJP 3600 DENTAL 284 X 185 X 203 MM (11 VISIJET M3 DENTCAST, PEARLSTONE, 29μ TO 32μ
3D PRINTER X 7 8 IN.) STONEPLAST - DENTAL UV CURABLE
PLASTICS
PROJET MJP 5600 MULTI- 518 X 381 X 300 MM VISIJET CR-CL 200, CR-WT 200, CR-BK; CE- 13μ TO 16μ
MATERIAL 3D PRINTER (20.4 X 15 X 11.8 IN.) BK, CE-NT COMPOSITE MULTI-MATERIAL
PRINTING
6


MACHINE NAME BUILD ENVELOPE BUILD MATERIALS LAYER BUILD SPEED
(MM; W X D X H) THICKNESS
PROJET 6000 HD SLA 3D UP TO 250 X 250 X 250 ACCURA 25, XTREME, XTREME WHITE 200, 0.025 TO 0.125
PRINTER MM (9.8 X 9.8 X 9.8 IN.) ABS BLACK, CLEARVUE, 48HTR, PHOENIX, MM
SAPPHIRE, E-STONE™
PROJET 7000 HD SLA 3D UP TO 380 X 380 X 250 ACCURA 25, XTREME, XTREME WHITE 200, 0.050 TO 0.125
PRINTER MM (14.9 X 14.9 X 9.8 IN.) ABS BLACK, CLEARVUE, 48HTR, PHOENIX, MM
SAPPHIRE, E-STONE™
PROX 800 SLA 3D PRINTER UP TO 650 X 750 X 550 ACCURA PLASTICS AND COMPOSITES 0.05 TO 0.15
MM (25.6 X 29.5 X 21.6 (WIDEST RANGE, SIMULATING ABS, PP MM
IN. ) AND PC, HIGH TEMP., FOR CASTING PAT-
TERNS AND OTHER SPECIALTY MATERI-
ALS)
PROX 950 SLA 3D PRINTER 1500 X 750 X 550 MM ACCURA PLASTICS AND COMPOSITES 0.05 TO 0.15
(59 X 29.5 X 21.6 IN.) (WIDEST RANGE, SIMULATING ABS, PP MM
AND PC, HIGH TEMP., FOR CASTING PAT-
TERNS AND OTHER SPECIALTY MATERI-
ALS)
PROX SLS 6100 3D PRINTER 381 X 330 X 460 MM (15 DURAFORM PROX PLASTICS AND COM- 0.08 TO 0.15 2.7 L/HR VOLUME
X 13 X 18 IN.) POSITES (POWDERS) MM BUILD RATE
SPRO 60 HD-HS SLS PRO- 381 X 330 X 460 MM (15 DURAFORM PLASTICS, ELASTOMERS AND 0.08 TO 0.15 1.8 L/HR VOLUME
DUCTION 3D PRINTER X 13 X 18 IN.) COMPOSITES, CASTFORM PS (POWDERS) MM BUILD RATE
SPRO 140 SLS PRODUCTION 550 X 550 X 460 MM DURAFORM PLASTICS AND COMPOSITES 0.08 TO 0.15 3.0 L/HR VOLUME
3D PRINTER (21.6 X 21.6 X 18 IN.) (POWDERS) MM BUILD RATE
SPRO 230 SLS PRODUC- 550 X 550 X 750 MM DURAFORM PLASTICS AND COMPOSITES 0.08 TO 0.15 3.0 L/HR VOLUME
TION 3D PRINTER (21.6 X 21.6 X 29.5 IN.) (POWDERS) MM BUILD RATE
DMP FLEX 100 PRECISION 100 X 100 X 80 MM* (3.9 READY-TO-RUN LASERFORM COCR (B), 10 μM - 100 μM.
METAL PRINTER X 3.9 X 3.1 IN.) COCR (C), 17-4 (B), 316L (B) METAL ALLOYS PRESET: 30 μM
WITH EXTENSIVELY DEVELOPED PRINT
PARAMETERS. CUSTOM MATERIAL PARAM-
ETER DEVELOPMENT AVAILABLE WITH
OPTIONAL SOFTWARE PACKAGE.
PROX DMP 200 PRECISION 140 X 140 X 100 MM* (5.5 READY-TO-RUN LASERFORM COCR (B), 10 μM - 100 μM.
METAL PRINTER X 5.5 X 3.9 IN.) 17-4 (B), MARAGING STEEL (B), 316L (B), PRESET: 30 μM
NI625 (B) AND ALSI12 (B) WITH EXTEN-
SIVELY DEVELOPED PRINT PARAMETERS.
CUSTOM MATERIAL PARAMETER DEVEL-
OPMENT AVAILABLE WITH OPTIONAL
SOFTWARE PACKAGE.
DMP FLEX 350 AND DMP 275 X 275 X 380 MM* WIDE CHOICE OF READY-TO-RUN METAL 10μM - 100μM
FACTORY 350 (10.8 X 10.8 X 14.9 IN.) ALLOYS WITH EXTENSIVELY DEVELOPED PRESET: 30
PRINT PARAMETERS, INCLUDING LASER- AND 60 μM
FORM TI GR. 1 (A), GR.5 (A) AND GR.23 (A),
COCRF75 (A), 316L (A), NI718 (A), ALSI10MG
(A), ALSI7MG0.6 (A) AND MARAGING STEEL
(A). CUSTOM MATERIAL PARAMETER DE-
VELOPMENT AVAILABLE WITH OPTIONAL
SOFTWARE PACKAGE.
DMP FACTORY 500 SOLU- 500 X 500 X 500 MM LASERFORM MATERIALS ADJUSTABLE,
TION (19.6 X 19.6 X 19.6 IN.) MIN. 2 μM,
MAX.200 μM,
TYP. 30-60-90
μM
* MAXIMUM AVAILABLE PART SIZE USING STANDARD BUILD PLATE

Additive technology
The PRO additive

manufacturing
system.
When size matters

How big can you build and how fast can you build are molten extrusion. This technology takes full
frequent questions from users of additive manufacturing. advantage of the printing materials BigRep, in
BigRep, a global leader in large-scale 3D printing, offers partnership with BASF, develops.
The PRO and EDGE systems have two MXT
answers through its Metering Extruder Technology (MXT)
modular extrusion heads that manage and
and its new PRO and EDGE additive systems. synchronize the extrusion and printing operations.
The PRO and EDGE are next-generation 3D printers that This means that:
help engineers and designers create functional prototypes, · The PRO has printing speeds of >600 millimeters
composite tooling, and end-use parts in small-number per second (mm/s), using the 0.6 mm nozzle. The
serial production capacity. Both printers can print with high- EDGE surpasses that with speeds of 1,000 mm/s
performance materials for applications in industries such as with the 0.6 mm nozzle.
automotive, aerospace, consumer goods, manufacturing · Demonstrated filament throughput rates are 5x
and more. the maximum extrusion rate and 3x the average
Metering Extruder Technology establishes a clear extrusion rate.
separation between filament feeding and melting and
8

BigRep.AM.HBK.9.19.Vs3.LL.indd 8 9/13/19 8:54 AM

Company Machine Name Build Size Build Materials Layer Thickness Build Speed
BigRep BigRep ONE 1005 x 1005x 1005 (mm); BigRep PLA, BigRep ProHT, 0.4 - 0.8 mm standard
39.56 x 39.56 x 39.56 in. BigRep PETG other filaments extruder; 0.15 to 1.4 mm
on request. power extruder
BigRepSTUDIO 500 mm x 1000 mm x BigRep PLA, BigRep PRO HT, 0.1 to 0.4 mm up to 140 mm/s
500 mm BigRep PRO HS, BigRep PETG at layer height
0.1 mm
The PRO handles large-scale

industrial parts with a build envelope
of one cubic meter and a large,
temperature-controlled spool
chamber for continuous printing with
high-performance materials like ASA/
ABS, nylon and more. The insulated,
enclosed metal frame ensures an
optimal even temperature control.
The heated print bed is mounted with
polyimide foil for better adhesion
during the printing process, and an
integrated inductive sensor semi-
automatically levels the bed.
The EDGE has a print bed
measuring 1500 x 800 x 600 mm (59
X 31.5 X 23.6 in.) for end-use parts
and functional prototypes. The heated
build chamber provides a controlled,
high-temperature environment of up
to 200° C in the chamber and 220° C
in the print bed. The EDGE also has
automatic, upward-moving doors and
an easy-to-use graphical interface on
a large screen for full control over all
print settings. Metering Extruder Technology
Extrusion technology has largely establishes a clear separation
between filament feeding and
been unchanged for a quarter-
melting and molten extrusion.
century. But BigRep in partnership
with Bosch Rexroth incorporated
a state-of-art CNC control system
and drives, making the PRO and
EDGE systems IoT-ready with full
connectivity and data.
BigRep | www.BigRep.com/nextgen
The Edge additive

manufacturing system.
BigRep.AM.HBK.9.19.Vs3.LL.indd 9 9/17/19 1:11 PM

User stories
Howadditive manufacturing
addresses automotive
manufacturing challenges
Ford Motor Company recently developed a dedicated additive Initially Ford was working with
manufacturing research program to explore the potential of additive, a pre-release version of Carbon’s
first device to evaluate its ability
not just for the rapid development of functional prototypes but also to produce commercial-quality
to manufacture final parts that will eventually hit the road. “If we can polymeric parts by unlocking
shave months off of production time and get a new model onto the mechanical properties unat-
tainable with other 3D printing
market earlier, we can save millions,” said Ellen Lee, team leader in technology.
additive manufacturing research at Ford.
10

Carbon.AM.HBk.9.19.Vs3.LL.indd 10 9/13/19 8:56 AM

Company Machine Build Size Build Materials Layer Build
Name Thickness Speed
Carbon Rigid Polyurethane Layer-less Variable
Carbon Elastomeric Polyurethane
Carbon Dental Production
Carbon Cyanate Ester
Carbon Flexible Polyurethane
Carbon Medical Polyurethane
M2 189 x 118 x 326 mm Carbon Epoxy
Carbon Carbon Silicone Urethane
Printer (7.4 x 4.6 x 12.8 in.)
Dentca Dentures for Carbon Printers
Dreve FotoDent Indirect Bonding Tray for Carbon Printers
Dreve FotoDent Impression Tray for Carbon Printers
Dreve FotoDent Gingiva for Carbon Printers
WhipMix Surgical Guide for Carbon Printers
Keystone KeySplint Soft™ Clear for Carbon Printers
To date, key challenges have stood in the way

of 3D printing/additive manufacturing becoming
a manufacturing tool for the automaker. The first
issue is a fundamental one — conventional 3D
printing technologies make parts layer-by-layer,
slowly crafting one layer at a time, creating parts
that aren’t nearly as robust as those stamped or
injection molded. While the slow speed of this
process is a drawback, the bigger problem is
that the parts produced are not isotropic and not
durable enough to be used in production vehicles.
In addition, most parts used in vehicles must
withstand temperature extremes from the hottest
desert to the coldest Arctic environments and
still maintain their integrity. With only a handful of
stock materials available for 3D printers, meeting
the automaker’s unique demands has not always
been possible. Most parts used in vehicles must withstand
In 2014, Carbon demonstrated Continuous temperature extremes from the hottest desert to
Liquid Interface Production technology (CLIP) the coldest Arctic environments and still maintain
to Ford’s additive manufacturing group. “It their integrity. With only a handful of stock materials
was exciting to see the resulting mechanical available for 3D printers, meeting the automaker’s
properties. There were a lot of things we saw unique demands has not always been possible.
in the technology that would address the main
challenges, and we decided to investigate,” Lee
said.
The team was eager to join Carbon’s early
access program and begin using one of the
devices. Ford was working with a pre-release
version of Carbon’s first device to evaluate its
ability to produce commercial-quality polymeric
parts by unlocking mechanical properties
unattainable with other 3D printing technology.
Ford has already used the CLIP-based device

cmy
pms
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T 847-286-9953 F 847-286-9974 E usa@renishaw.com
www.renishaw.com
Renishaw_Additive Mfg 9-19_page 12.indd 12 9/13/19 8:21 AM

User stories
to grow elastomer grommets for the opportunity to address the Ford uses Carbon’s CLIP-based
the Focus Electric and test them issue using Carbon’s CLIP based additive technology to grow elastomer
against those made by traditional device. The team was able to grommets for the Focus Electric. The soft
3D printing methods. The soft but rapidly design, prototype and but sturdy grommets protect wiring on
sturdy grommets protect wiring manufacture an oil connector using the inside of the door from damage when
on the inside of the door from rigid polyurethane and elastomer the door opens and closes.
damage when the door opens and materials to access the oil fill tube
closes. The Ford team used CLIP to without needing major redesigns to
produce the grommets in less than several components of the vehicle.
a third of the time and with material When it comes to realizing future vehicle applications.
properties much closer to the final Ford’s ambitions to use additive “Carbon’s CLIP technology is
properties desired for the part. In a manufacturing as a manufacturing allowing our engineers to shorten
similar project, several alternative technology, nothing is more their design iteration time and reach
designs were evaluated for a important than having the right a final-part more quickly, which is
damping bumper part on the Ford materials. Thanks to Carbon’s exciting because it means higher
Transit Connect. The game-changing commitment to polymer quality and more cost effective
manufacturing time of the CLIP chemistry and the advantages products for our customers,”
process allowed engineers to make CLIP technology has to support explained Lee.
design iterations more quickly than a broad range of materials, Ford
with traditional methods. has been able to expand its Carbon | www.carbon3D.com
Most recently, Ford needed own materials research efforts.
to address a major engineering To date, the team has tested
issue that arose after placing several materials, including resins
a V8 engine into a new vehicle reinforced with nano-sized particles
body design. The vehicle’s design and is eager to further investigate
created an unreachable oil filler cap resin modifications for improved
because the engine sat lower and mechanical properties and consider
farther back under the hood. The the creation of thermally and
product engineering team realized electrically conductive materials for

Additive technology
Post processing
options for
metal additive
parts
In 2019, much attention is on the best ways to post process additively
made parts. Nearly all additively made metal parts need secondary finishing
as these parts tend to have rough surfaces. The layer-by-layer build process
can deliver variations in average roughness (RA) throughout a part. The
surface of the part will vary between top, bottom, and the sides. And if
there are internal channels, they can be difficult to finish.
The technique chosen to finish additive parts depends on the part’s

application. A part for prototype use, for example, may need less
post processing than one for a presentation to customers. In another
example, a prototype part may be needed to examine tolerances.
Desktop Metal recently tested centrifugal disc, centrifugal barrel,
and media blasting techniques on metal parts printed with the Studio
System for surface finish. In general, these finishing methods are
viewed as aggressive because they deliver frequent abrasive contact
to part surfaces, but they offer the advantage of finishing many parts
quickly.
Even though additive and 3D printing technologies continually

make strides at improving build speed, that is not the total picture. In-
clude in your timing estimates how much additional time will be needed
to properly finish a part, especially with parts made from metals.
14

DesktopMetal.AM.HNDBK.9.19.Vs2.LL.indd 14 9/13/19 8:58 AM

Desktop Production System 13 x 13 x 13 in. Alloys, including stainless 50 um 8200 cm3/hr
Metal (330 x 330 x 330 cm) steel, copper, and tool
steels, 17-4PH, 316L,
Inconel 625, H13, AISI 4140
Studio System + 11.4 x 7.4 x 7.4 17-4PH, 316L, AISI 4140, std resolution = Max build rate =
Printer (28.9 x 18.9 x 19.5 cm) H13, Copper, Inconel 625 100-220 um 16 cm3/hr
high resolution =
50 um
DesktopMetal.AM.HNDBK.9.19.Vs2.LL.indd 15 9/13/19 8:58 AM

Additive technology
The surface of the part will vary between

top, bottom, and the sides. And if there are
internal channels, they can be difficult to finish.
Centrifugal disc machines consist

of a large drum with stationary sides
machining, grinding, or sanding) as it
can give parts an overall consistent
• Typical batch size differs
based on the type and size of
and a rotating disc at the bottom of finish. It uses compressed air to blast the equipment. Estimated
the drum. The rotating disc moves a loose, abrasive media through cost-per-part should be
parts and media upward for efficient a nozzle to the surface of a part. calculated before selecting a
de-burring and finishing. A variety Several types of media are available finishing method.
of abrasive media can be used. in multiple shapes and sizes to give
Polishing media can be mixed with a
special liquid compound for tumble-
parts the desired surface quality and
reflectivity, such as aluminum oxide,
• The desired surface finish may
impact design specifications,
finishing of the parts. stainless shot, and glass bead. For so it is important to consider
The amount of time parts spend example, round particles can deliver the finishing method prior to
in these machines can be important high reflectivity; angular particles fabrication. To maintain
as it can affect part definition, give more of a matte finish. required tolerances, parts may
especially at part edges. Different types of media blasting need to be “over-built” or
Centrifugal barrel finishing is equipment include suction, wet- “masked” in some areas to
considered the fastest method of blast, and direct-pressure. Direct allow for removal of material
mass finishing. The machine consists pressure is the most aggressive of during post-processing.
of a horizontal main shaft with a this selection. Typically, only one
circular drive plate that connects
to this shaft and rotates in one
part is blasted at a time.
• There is no one-size-fits-all
solution for metal finishing. For
direction. Octagonal barrels with Additions tips to keep in mind: some applications, visible
media, water, liquid compound,
and the printed parts rotate in the
• Mass finishing works equally
on all sides and edges of the

printing lines are acceptable
and minimal post processing
opposite direction. These actions part, but it affects flat surfaces, is needed. Different finishing
create a centrifugal force that curved surfaces, and edges techniques are better suited for
increases gravitational pull by 15 to differently. applications that require a
20 times. smooth or bright finish (<60 RA)
In general, this machine is
suitable for parts needing longer
• There is a difference between
surface smoothness and shine.

versus those where a rougher
surface finish is acceptable.
run-times for finishing. The average roughness (RA)
Media blasting is a good choice measures the smoothness of a Desktop Metal Inc.
when parts have undergone other part and can be measured www.desktopmetal.com
post-processing methods (such as with a profilometer.
16

DesktopMetal.AM.HNDBK.9.19.Vs2.LL.indd 16 9/16/19 12:53 PM

"Making the Additive Manufacturing
Promise Real"
www.thermwood.com
800-533-6901
Thermwood_Additive Mfg 9-19.indd 17 9/13/19 8:18 AM

Additive Insights
Shaping the future

of manufacturing
With an installed base of nearly 3,500 industrial 3D printing systems, The increasing use of AM in serial
the German family-owned enterprise EOS is a leading supplier of systems production scenarios is accompanied
for additive manufacturing (AM). When founding the company on April by the necessity to integrate this
24, 1989, Dr. Hans J. Langer had a clear vision: produce three-dimensional technology in existing production
objects directly from CAD data using laser technology for what was at the environments. The goal is to achieve
flexible production that optimally
time a new rapid prototyping market.
combines industrial 3D printing
and conventional manufacturing
While the early phase of the enterprise was dominated by stereolithography
technologies in a digital factory.
technology, EOS turned to laser sintering in 1997. The powder-bed
According to Dr. Adrian Keppler,
based process is well suited to today’s rapidly growing market of series
CEO of EOS: “The establishment
applications in terms of quality and reproducibility and the speed and cost
of complete digital production
of part production.
platforms is a major goal that we
EOS offered AM systems for processing both polymers and metals,
aim to achieve in the coming years.
as well as the materials, processes, and software tailored to suit these
It’s not just about providing the right
systems. To support companies in the use of AM technology, EOS founded
3D printing solutions, but about
its consulting unit Additive Minds in 2015. With more than 300 successful
evaluating, planning, setting-up,
customer projects, EOS has a number of experts for AM consulting.
and optimizing AM production cells
to leverage all the advantages and
Shaping the future of manufacturing possibilities of digitalization.”
The potential applications for 3D printing are practically unlimited as it is
capable of producing flexible, light, and stable parts that only use as much The EOS ecosystem
raw material as needed to manufacture the product. EOS technology and Established and expanded over
know-how are used in a variety of industries and areas of life: such as fuel- many years by Dr. Langer, the EOS
saving components in the aviation sector, spare parts on demand for buses Ecosystem is a multi-layered network
and trains, or prostheses individually created to suit each patient. of EOS investments, the company
18

EOS.AM.HDBK.Insights.9.19.Vs.4.LL.indd 18 9/13/19 9:00 AM

COMPANY MACHINE NAME BUILD VOLUME (MM) BUILD MATERIALS LAYER THICKNESS BUILD SPEED
EOS FORMIGA P 110 200 X 250 X 330 MM POLYAMIDE 12 (STANDARD, 0.06 MM, 0.1 MM, 0.12 UP TO 20 MM/H
(7.9 X 9.8 X 13 IN) GLASS BEAD FILLED, FLAME MM (0.0024 IN, 0.0039 (0.79 IN/H)
RETARDANT, ALUMINIUM FILLED, IN, 0.0047 IN)
DENTAL), POLYAMIDE 11,
POLYSTYRENE
EOS P 396 340 X 340 X 600 MM POLYAMIDE 12 (STANDARD, 0.06 MM (0.00236 IN), UP TO 48 MM/H (1.9 IN/H)
(13.4 X 13.4 X 23.6) PRIMEPART, GLASS BEAD FILLED, 0.10 MM (0.00394 IN),
FLAME RETARDANT, BLACK, 0.12 MM (0.00472 IN),
ALUMINUM FILLED, CARBON 0.15 MM (0.00591 IN),
FIBER REINFORCED), POLYAMIDE 0.18 MM (0.00709 IN)
11, POLYSTYRENE, TPE
EOS P 500 500 X 330 400 MM 0.06 MM (0.00236 IN), 40 MM/H (1.6 IN. / H);
(19.7 X 13 X 15.7 IN.) 0.10 MM (0.00394 IN), 6.6L/H MAX
0.12 MM (0.00472 IN),
0.15 MM (0.00591 IN),
0.18 MM (0.00709 IN)
EOS P 770 700 X 380 X 580 MM POLYAMIDE 12 (STANDARD, 0.06 MM (0.00236 IN), UP TO 32 MM/H**
(27.6 X 15 X 22.9 IN) PRIMEPART, GLASS BEAD FILLED, 0.10 MM (0.00394 IN), (1.3 IN/H); UP TO 10.5 L/H
FIRE RETARDANT, ALUMINIUM 0.12 MM (0.00472 IN),
FILLED), POLYAMIDE 11, 0.15 MM (0.00591 IN),
POLYSTYRENE 0.18 MM (0.00709 IN)
EOS P 800 700 MM X 380 MM X EOS PEEK HP 3 AMONG OTHERS TYPICALLY 0.12 MM 7 MM/H (0.3 IN/H)
560 MM (27.6 X 15 X (0.005 IN)
22.05 IN)
EOS P 810 700 MM X 380 MM X HT-23 FROM ADVANCED LASER 120 µM UP TO 10 MM/H (0.4 IN/H);
380 MM (27.6 X 15 X MATERIALS (ALM) UP TO 2,7L/H
15 IN)
EOSINT P 800 700 X 380 X 560 MM POLYARYLETHERKETONE TYPICALLY 0.12 MM 7 MM/H (0.3 IN/H)
(27.6 X 15 X 22.05 IN) (0.005 IN)
EOS M 100 Ø 100 X 95 MM (Ø 3.9 IN COBALT CHROME, STAINLESS 20 - 30µM DEPENDING NA
X 3.7 IN) HEIGHT, INCL. STEEL, TITANIUM ON MATERIAL
BUILD PLATFORM
EOS M 290 250 X 250 X 325 MM MARAGING STEEL, COBALT 20 - 60 µM DEPENDING NA
(9.85 X 9.85 X 12.8 IN) CHROME, TITANIUM, NICKEL ON MATERIAL
ALLOY, ALUMINIUM, STAINLESS
STEEL
EOS M 300-4 300 MM X 300 MM X METALS SCANNIN SPEED: UP TO
400 MM (11.8 X 11.8 X 7.0 M/S (23 FT/S)
15.8 IN)
EOS M 400 400 MM X 400 MM X MARAGING STEEL, COBALT 30 - 90µM DEPENDING SCANNING SPEED: UP TO
400* MM (15.8 X 15.8 X CHROME, TITANIUM, NICKEL ON MATERIAL 7.0 M/S (23 FT/S)
15.8 IN) ALLOY, ALUMINIUM
EOS M 400-4 400 MM X 400 MM X MARAGING STEEL, TITANIUM, 30 - 60µM DEPENDING SCANNING SPEED: UP TO
400* MM (15.8 X 15.8 X NICKEL ALLOY, ALUMINIUM, ON MATERIAL 7.0 M/S (23 FT/S)
15.8 IN) STAINLESS STEEL
PRECIOUS M 080 Ø 80 MM X 95 MM METALS LESS THAN 30 UM SCANNING SPEED: UP TO
(HIGH, INCLUDING 7.0 M/S (23 FT/S)
BUILDING PLATTFORM)
AM Ventures, and external partners that enable further innovation in rocket

support promising start-ups. The cooperation engines.
between the various companies combines Even after 30 years, EOS remains
expertise to enable the implementation of true to its mission statement: Shaping
customer-specific manufacturing solutions the future of manufacturing.
along the entire value chain – from the initial
idea to design and engineering, production, EOS | www.eos.info
post-processing, and ultimately the finished
part. For example, one field of application
with potential is the aerospace industry to
EOS.AM.HDBK.Insights.9.19.Vs.4.LL.indd 19 9/17/19 1:19 PM

Additive technology
Low Force
Stereolithography
delivers better surface finish
Thanks to investments made during the recent 3D printing hype cycle, vendors have
introduced new ways to extrude and cure photopolymer resins. For example, Formlabs
recently introduced Low Force Stereolithography (LFS).
LFS is a variation on stereolithography. Like traditional stereolithography, it uses a vat
of photo-reactive resin and an illumination source to cure the resin into three-dimensional
objects. However, there are a few key differences:
• The printer uses a parabolic mirror to create a perpendicular laser spot. This feature
ensures uniformity across the build platform.
• A feature called the flexible tank keeps the need for part supports minimal. The flexible
tank reduces the peel forces needed during printing.
• The Light Processing Unit (LPU) includes a custom enclosed optics engine to build parts
with consistency and accuracy. The laser beam in the LPU passes through a spatial filter
to catch stray light. A galvanometer positions the laser beam in the Y direction. The unit
includes a fold mirror and a parabolic mirror to ensure the laser beam is always
perpendicular to the print plane. Fine details are possible through the linear path the
laser takes.
20

Formlabs.AM.HNDBK.9.19.Vs3.LL.indd 20 9/13/19 9:01 AM

The Light Processing Unit contains a galvanometer that controls the direction of the laser, as the entire
LPU unit moves across the build area. The Form 3 contains 1 LPU unit where the Form 3L contains 2.
FORMLABS FORM 2 14.5 × 14.5 × 17.5 CM PHOTOPOLYMER RESIN 25-300 MICRONS DEPENDENT ON GEOMETRY,
5.7 × 5.7 × 6.9 IN .001-.012 IN IN GENERAL 1-3 CM/HR ALONG
THE Z AXIS WHEN PRINTING
AT 100 MICRONS
FUSE 1 16.5 X 16.5 X 32 CM, NYLON POWDER 199 MICRONS 10 MM/HR

6.5 X 6.5 X 12.6 IN .008 IN
FORM CELL UP TO 10 FORM 2 PHOTOPOLYMER 25-300 MICRONS DEPENDENT ON SETUP

3D PRINTERS OR RESINS .001-.012 IN
FORM WASH UNITS
HOUSED TOGETHER
WITH ROBOTIC
GANTRY ARM
FORM 3 14.5 × 14.5 × 18.5 CM PHOTOPOLYMER 25-300 MICRONS DEPENDENT ON GEOMETRY

5.7 × 5.7 × 7.3 IN RESINS .001-.012 IN AND MATERIAL, BUILD SPEED
WILL BE AVAILABLE AS
MATERIAL SETTINGS SHIP
Low Force Stereolithography

(LFS) is an advanced form of
SLA printing that uses a flexible
tank and linear illumination to
turn liquid resin into flawless
parts.
The laser has a spot size of 85 microns LFS reduces the stresses from this force
and an increase in power at the print plane of by gently peeling the layer away as the build
25%. Stereolithography uses a layer-by-layer platform pulls the part up. Thus, build objects
process to build objects. As in all layer-by- need only minimal support.
layer processes, surface finish is affected by a The print speed is adaptable.ABG
layer’s alignment with the previous layer. With
the flexible tank, the bond formed between Formlabs | www.formlabs.com
the printed part and the tank is gently broken
to prepare for the next layer. For example, an
inverted stereolithography 3D printer tends to
exert a large force on the layers of the part,
resulting in a step appearance on the surface.
Formlabs.AM.HNDBK.9.19.Vs3.LL.indd 21 9/17/19 1:27 PM

User Stories
Additive manufacturing
delivers the scaffolding for growth
A key application of additive manufacturing is in the development of spinal implants. A team at Nexxt Spine
are pioneers in the design and development of spinal fusion implants that incorporate interconnected micro-
lattice architectures with the goal of promoting osteoconduction, osteointegration, and boney fusion. They
found that additive technology not only adds value to their products, it is helping their company grow as well.
“Additive is booming,” says investment in metal additive to commercialization,” Alaedeen

Alaedeen Abu-Mulaweh, director technology was the acquisition of a continues.
of engineering at Nexxt Spine a Concept Laser Mlab 100R in 2017. The investment in Concept
medical device company focused “We used the first Mlab Laser Mlab machines allowed the
on designing, manufacturing and primarily for R&D purposes, but Nexxt Spine team to take ownership
distributing innovative spinal implant we soon realised that further of the entire design, production
solutions. The company designs investment in additive technology and distribution process in-house,
and manufactures 100% of its could add value not only to our eliminating the need for contract
implants exclusively from its facility overall growth strategy, but also manufacturers, thereby accelerating
in Noblesville, Indiana. Abu-Mulaweh at a clinical application level with development and commercialization.
began his additive journey two the ability to develop implants
years ago. with intricate micro-geometries Focus on core science
Established in 2009 and initially that could maximize healing. One of Nexxt Spine’s flagship
producing speciality spinal screws, We have made a seamless jump products, launched in 2017 is its
rods, and plates using conventional from R&D to serial production Nexxt Matrixx System - a collection of
subtractive manufacturing and in doing so have significantly porous titanium spinal fusion implants
techniques, Nexxt Spine’s first accelerated the time from concept that interweave highly differentiated
surface texturing technology with
novel 3D-printed cellular scaffolding.
The Nexxt Matrixx system is a collection of porous titanium spinal
fusion implants that interweave highly differentiated surface texturing However, while other medical
technology with novel 3D printed cellular scaffolding. manufacturers have used additive
22

GE.9.19.Vs5.LL.indd 22 9/17/19 2:18 PM

Company Machine Name Build Size (mm) Build Materials Layer Build Speed
Thickness
GE ADDITIVE MLAB CUSING 50 X 50 X 80 MM (X,Y,Z); 2 X 2 CL 20ES, CL 80CU, CL 92PH, REMA- NA 1-5 CM3/H (DEPENDING
CONCEPT LASER X 3.12 IN. NIUM STAR CL, YELLOW GOLD, ROSE ON MATERIAL)
GOLD*, RED GOLD*, PLATINUM,
SILVER ALLOY
MLAB CUSING R 70 X 70 X 80 MM (X,Y,Z); 2.75 CL 20ES, CL 31AL, CL 4ITI ELI, CL 42TI, NA 1-5 CM3/H (DEPENDING
X 2.75 X 3.12 IN.; 90 X 90 X 80 CL 80CU, CL 92PH, REMANIUM STAR ON MATERIAL)
MM3 (X,Y,Z); CL, REMATITAN CL, YELLOW GOLD,
3.5 BY 3.5 X 3.12 IN. ROSE GOLD*, RED GOLD*, PLATINUM,
SILVER ALLOY
MLAB CUSING 200R 70 X 70 X 80 MM (X,Y,Z); 2.75 CL 20ES*, CL 31AL*, CL 4ITI ELI*, CL NA 1-5 CM3/H (DEPENDING
X 2.75 X 3.12 IN.; 42TI*, CL 80CU*, CL 92PH*, ON MATERIAL)
REMANIUM STAR CL, REMATITAN CL*
50 X 50 X 80 MM3 (X,Y,Z);
2 X 2 X 3.12 IN.
M1 CUSING 250 X 250 X 250 MM (X,Y,Z); CL 20ES, CL 50WS, CL 91RW, CL NA 2-15 CM3/H (DEPENDING
9.84 X 9.84 X 9.84 IN. 92PH, CL 100NB, CL 101NB REMANIUM ON MATERIAL / LASER
STAR CL POWDER)
M2 CUSING 250 X 250 X 280 MM (X,Y,Z); CL 20ES, CL 31AL, CL 4ITI ELI, CL 42TI, NA 2-20 CM3/H (DEPENDING
9.84 X 9.84 X 11 IN. CL 50WS, CL 91RW, CL 92PH, CL ON MATERIAL)
100NB, CL 101NB, CL 110COCR*
REMANIUM STAR CL, REMATITAN CL
M2 CUSING 250 X 250 X 280 MM (X,Y,Z); CL 20ES, CL 31AL, CL 4ITI ELI, CL 42TI, NA 2-35 CM3/H (DEPENDING
MULTILASER 9.84 X 9.84 X 11 IN. CL 50WS, CL 91RW, CL 92PH, CL ON MATERIAL / LASER
100NB, CL 101NB, CL 110COCR* POWDER)
REMANIUM STAR CL, REMATITAN CL
M LINE FACTORY 400 X 400 X UP TO 425 MM CL 20ES*, CL 31AL*, CL 4ITI ELI* NA NOT STATED
(X,Y,Z); 15.75 X 15.75 X 16.73 IN.
X LINE 2000R 800 X 400 X 500 MM (X,Y,Z); CL 20ES*, CL 32AL, CL 4ITI ELI, CL NA UP TO 120 CM3/H (DE-
31.5 X 15.75 X 19.68 IN. 100NB PENDING ON MATERIAL /
GEOMETRY)
manufacturing to develop devices

that directly mimic bone’s trabecular
geometry, Nexxt Spine chose to deviate Some medical manufacturers use additive manufacturing to develop devices
from the status quo and instead blend that directly mimic bone’s trabecular geometry, Nexxt Spine chose to deviate
from this and instead blend cellular porosity, inspired by natural bone biology,
cellular porosity, inspired by natural
with core engineering fundamentals to develop structurally sound devices,
bone biology, with core engineering optimized for fusion.
fundamentals to develop structurally
sound devices, optimized for fusion.
“Titanium – porous or otherwise
- is physically incapable of biological
remodeling, so using additive to mimic the
structural randomness of bone doesn’t
make a whole lot of sense. Nexxt Matrixx
was designed with functionality to fulfil
our vision of actively facilitating the
body’s natural power of cellular healing,”
continues Alaedeen.
“We are seeing ongoing adoption of
additive manufacturing in the orthopaedic
industry and an exciting shift from
research and development to serial
production,” says Stephan Zeidler, senior to serial additive manufacturing excited for what the future holds for
global and key accounts director for the production, Nexxt Spine is well- us,” comments Alaedeen.
medical sector at GE Additive. placed to service and scale, as
needed, to meet the growth in GE Additive | www.ge.com/additive
Additive opens up new frontiers demand for spinal fusion device.
With design, manufacturing and distri- “Like I said, additive is
butions functions in-house, and the shift absolutely booming. We are
GE.9.19.Vs5.LL.indd 23 9/17/19 2:21 PM

User stories
3D printed
anatomical models
make surgeries easier and faster
At Rady Children’s Hospital in San Diego, CA, 3D printed
heart models serve to educate patients and their families
regarding the complicated anatomy of the heart and also
provide surgeons with the opportunity to inspect the patient’s
specific anatomy, develop a surgical plan, and even test the plan
in advance of the actual surgery to ensure accuracy and limit
the chances for complications.
Such models helped Leanne Wilbert with her son’s condition.

“We found out that our son had a heart condition called Surgeons can practice an upcoming surgery
transposition of the great arteries, where the two main arteries with full color models of organs, like this
are switched,” she said. “We knew pretty far in advance that he heart of a young girl with a complex heart
was going to need open-heart surgery.” defect. The heart was printed using HP’s Jet
Fusion 300 / 500 3D printer.
24

HP.AM.HNBK.Vs4.LL.indd 24 9/17/19 2:24 PM

The 3DI Lab at Rady Children’s Hospital in San Diego, CA, uses an HP
Jet Fusion 580 Color 3D printer to help surgeons plan operations and
help explain those operations to patients.
Company Machine Name Build Volume in mm Build Materials Layer Thickness Build Speed
HP HP Jet Fusion 3D 380 x 284 x 380 mm HP 3D High Reusability PA 11 0.08 mm (0.003 in) 4115 cm³/hr (251 in³/hr)
4210/4200/3200 (15 x 11.2 x 15 in) HP 3D High Reusability PA 12
Printing Solutions HP 3D High Reusability PA 12
GB Vestosint 3D Z2773 PA 12
HP Jet Fusion 5200 380 x 284 x 380 mm HP 3D High Reusability PA 11 0.08 mm (0.003 in) 5058 cm³/hr (309 in³/hr)
Series 3D Printing (15 x 11.2 x 15 in) HP 3D High Reusability PA 12
Solution Girbau DY130 Dyeing Solution9
HP Jet Fusion 332 x 190 x 248 mm CB PA 12 material 0.08 mm (0.003 inches) 1,817 cm3/hr (111 in3/hr)
540/340 3D Printer (13.1 x 7.5 x 9.8 inches)
HP Jet Fusion 332 x 190 x 248 mm CB PA 12 material 0.08 mm (0.003 inches) 1,817 cm3/hr (111 in3/hr)
580/380 Color (13.1 x 7.5 x 9.8 inches)
HP Metal Jet 430 x 320 x 200 mm 316L stainless steel MIM 1200 x 1200 dpi address- NA
(16.9 x 12.6 x 7.9 in) powder ability in a layer 50 to
100 microns thick
But obtaining 3D printed turnaround time and enable new

models could be a challenge for innovations in the medical domain.
the physicians. For several years, The decision to bring 3D
the orthopedics department and printing technology in-house came
the cardiology unit either 3D about when Justin Ryan, Ph.D.,
printed anatomical models using joined Rady Children’s to start the
FDM printers or outsourced the hospital’s new 3D Innovations (3DI)
models. Lab (which was launched in July
Outsourcing had its 2018). He developed an interest
drawbacks; projects could take in HP Multi Jet Fusion technology
at least two weeks to complete when the medical staff learned
and often could only be delivered about its ability to produce delicate
during business hours. The costs and resilient structures, which had
of outsourced 3D models were
also a burden for the hospital:
A small FDM model could cost
“3D printed heart models educate patients
between $600 and $700 USD,
and larger models could cost in and their families on the anatomy of
the heart, and allow surgeons to inspect
excess of $1,200 USD. Due to
the lengthy production schedule,
Rady Children’s was only able
to complete about one to two that anatomy before surgery and limit
outsourced projects per month.
Ultimately, these departments complications.”
needed to bring more 3D printing
technology in-house to reduce
HP.AM.HNBK.Vs4.LL.indd 25 9/17/19 1:33 PM

User stories
“The HP MultiJet Fusion delivers accuracy, been a challenge with the hospital’s
former binder jetting technology.
Therefore, the 3DI Lab made sure to
the potential for color, good mechanical include the HP Jet Fusion 580 Color
3D printer in its new facility.
properties, and consistency. You can just “The HP Multi Jet Fusion
captures the anatomy very
have one of these elements and sacrifice well,” says Dr. Ryan. “The spatial
resolution and mechanical
other ones, especially for a hospital where properties are great, especially
compared to competing
consistency and accuacy are critical.” technologies.”
For Wilbert’s son, the surgical
team obtained an image of his heart
from a computerized tomography
(CT) scan, and after creating a
computerized 3D version of the
heart, they printed it to scale using
HP Multi Jet Fusion technology and
HP 3D High Reusability CB PA 12
material.
26

HP.AM.HNBK.Vs4.LL.indd 26 9/13/19 9:17 AM

With the 3D anatomical heart haven’t had to do that with HP. This
model in hand, the surgeon was is really due to the ideal mechanical
able to practice surgery and try properties.”
different approaches. In closely With in-house production
inspecting the 3D part, the surgeon capabilities, instead of waiting 4
was even able to identify a second days or more for an anatomical
ventricular septal defect (VSD), also model, the doctors now can
known as a hole in the heart. produce a model for a critical
“We knew [our son] had one patient and have it ready to review
[VSD], but once we had that the following day, or even the same
imaging, we were able to see that day. With HP MJF as an integrated
there was another small one,” point-of-care process, Rady
Wilbert says. Children’s has noticed savings in
“[The surgical team] knew in both time and expenses compared
advance exactly what they were with outsourcing.
going to be facing and exactly what “Operating room time has a
they needed to do to make sure correlation to cost,” says Dr. Ryan.
that it was done smoothly without Mayo Clinic reports that one minute
any complications,” Wilbert added. of their OR time is between 80 and
“We feel that this should be in every 150 USD, so if you can save a few
single hospital; everyone should minutes of operating time by having
have the opportunity to have it a model better educate a surgical
done.” team, that’s going be a great way to
save on resources.”
Benefits to hospitals In addition, the HP Multi Jet
Depending on the ultimate goal, Fusion delivers accuracy, the
computerized 3D models may potential for color, good mechanical
require further refinement. For properties, and consistency:
example, anatomical models for “You can’t just have one of those
surgical planning may need to be elements and sacrifice other ones,”
color-coded or virtually cut to reveal he says, “especially for a hospital
deeper structures, while parts of where consistency and accuracy are
educational models may need to be critical.”
simplified or exemplified to display With HP Multi Jet Fusion, “I have
different types of anatomy or better peace of mind than with our
pathology. other current technologies. It’s been
Notes Dr. Ryan, “Since they great in terms of its consistency,
know very intimately what the and that’s something that I come to
anatomy looks like, they perform expect from the HP name.”
the surgery with greater confidence
and under less time, which has HP | www8.hp.com
incredible implications: If you can
reduce surgical time, you in fact
reduce anesthesia time and bypass
time, which has a direct correlation
on the reduction of complications—
especially stroke events.”
“With some of the other
technologies, we would print
duplicate models knowing that
one might not make it—one or two
might break,” says Dr. Ryan. “We
HP.AM.HNBK.Vs4.LL.indd 27 9/13/19 9:17 AM

Additive Insights
Advancing the use of

desktop metal 3D printing
Desktop metal 3D printing is still a rare technology, but that doesn’t stop one of the leading
vendors in this market from developing products that improve this technology. Jon Reilly, VP of
Product, Markforged, gives us a closer look at these developments.
Q: You recently announced an

AI powered software for
additive processes. How do
you see AI affecting this
and other areas of Additive
Manufacturing?
A: Traditionally, manufacturing
machines have gone through the
same motion of making parts with
no awareness of the actual part they
are making - without intervention
they will happily make thousands
of out of spec parts. With the help
of sensors and AI, a machine can
compare the part it makes to the
CAD intent.
Engineers at a Canadian inte-

grated energy services company
were tasked with creating an
automated handling machine to
load large glass reinforcement
tape pads, which weigh between
115 and 230 lb. The goal was to
reduce changeover time and in-
crease plant throughput. The pad
handling machine consists of 53
unique 3D printed parts.
28

Markforged.AM.HNDBK.9.19.Vs5.LL.indd 28 9/17/19 1:36 PM

Company Machine Build Size Build Materials Layer Thickness Build
Name Speed
Markforged
Desktop Series Onyx One 320 x 132 x 154 mm Chopped carbon only 100 micron NA
(12.6 x 5.2 x 6 in.)
Desktop Series Onyx Pro 320 x 132 x 154 mm Continuous fiberglass 100 micron
(12.6 x 5.2 x 6 in.)
Desktop Series Mark Two 320 x 132 x 154 mm (12.6 All continuous fibers 100 micron NA
x 5.2 x 6 in.)
Industrial X3 330 x 270 x 200 mm Chopped carbon 50 micron NA

Series (12.99 x 10.6 x 7.87 in.)
Industrial X5 330 x 270 x 200 mm Continuous fiberglass 50 micron NA

Series (12.99 x 10.6 x 7.87 in.)
Industrial X7 330 x 270 x 200 mm All continuous fibers 50 micron NA

Series (12.99 x 10.6 x 7.87 in.)
Metal X 250 x 220 x 200 mm Aluminum, inconel, 50 micron NA

(9.8 x 8.6 x 7.8 in.) titanium, stainless
steel, tool steel
Several of the 3D printed parts for the pad handling machine

were reinforced with Kevlar, HSHT fiberglass, and carbon fiber.

Additive Insights
Mechanical designers used their Markforged composite printer to

fabricate tools and fixtures for a pick and place machine.
Blacksmith - the first adaptive

manufacturing AI - allows any
production system that has controls
to self-adjust and get closer to
a perfect part. We are starting
with Additive Manufacturing, but
Metal 3D printing on the desktop is still Adaptive Manufacturing naturally
extends to a variety of existing
a rare technology, but that doesn’t stop manufacturing processes. Take
CNC for example, by inspecting
one of the leading vendors in this market the actual part produced and
automatically modifying the tool
from developing products that improve this path for the next part, we can
tighten tolerances and eliminate
technology.
process drift - all of which improves
yields and reduces out of spec
parts.
Improving yields translates
directly into lower part cost
and reduced scrap and waste.
Blacksmith is better for the
environment, and will help bring
down the cost of a lot of products.
30


Q: What are some of the metal 3D printing is a three-step
challenges of growing metal process that involves printing,
additive manufacturing? washing, and sintering. Taking full
Is it acceptance, education, advantage of the process requires
something else? an understanding of what each step
can do to your part. A part that’s
A: The number one challenge is very tall and skinny, for example,
education. When you introduce a could collapse in a furnace if not
breakthrough, new way to make supported well. Adding tapers or
parts, it’s naturally going to take a flanges to your design will improve
while for everyone to understand its inherent stability in the furnace
the process and how it can be and create a more successful part.
leveraged to improve their business.
With the Metal X system, it’s more Q: Tell me a bit about your flame
affordable and easier than ever retardant Onyx material?
to rapidly prototype metal parts, Some of its properties, best
build tooling and fixtures for digital applications, and so on.
manufacturing lines, and replace
low volume after-market service A: Onyx FR (Flame Retardant)
parts. We have created Markforged is a V0 rated carbon fiber filled
University to help companies Nylon. We introduced it to meet
overcome the education barrier and an incredibly common request
adopt additive manufacturing at from our automotive, aerospace,
scale. and defense customers. In many
of their applications you need an
Q: What are some of the design engineering grade material that
challenges in working with self-extinguishes when exposed
metal and composite to flame. Like all of our plastics,
materials for users? Onyx FR can be reinforced with
continuous strands of carbon fiber
A: Like any manufacturing - unlocking flame-retardant 3D
technique - engineers need to printed parts that are as strong as
design for the process. Being able aluminum at half the weight.
to go through and identify what
sections of a part require specific Markforged
properties, what environment the www.markforged.com
part needs to perform in, and how
the part needs to behave under a
load are all critical to identifying
the best additive solution for the
application.
When you’re designing a part
for composites, continuous strands
of fibers are essential to 3D printing
a strong part. To take full advantage
of the strength of the fibers, you
need to think about how your
design can leverage the strength
of the continuous fibers to increase
the strength of your part. Likewise,
Markforged.AM.HNDBK.9.19.Vs4.LL.indd 31 9/13/19 9:21 AM

Additive technology
How 3D printing can

produce a functional RF circuit
Can a 3D printer be used to make functional radio frequency (RF) circuits?
That’s the question Harris Corporation, a leading technology innovator of
electronic products that connect, inform and protect, set out to answer.
Working with Nano Dimension, a Creating an RF circuit for manufactured with traditional
developer of 3D printers designed conveying information such as methods, Harris used amplifier
to include electronics, the two data, video and voice across measurements that tested for small
companies began a study on long distances is typically a long, signal gain, input return loss, and
the advantages of using additive complex multi-stage process when output return loss.
manufacturing to develop RF using conventional manufacturing The resulting data showed
circuits for wireless systems as part methods. Consequently, achieving similar RF performance between
of a joint project with the Israel optimum performance is an iterative the 3D printed and the baseline
Innovation Authority and Space process: create a design, produce amplifiers, demonstrating the
Florida Foundation, a partnership the RF circuit, test its performance, viability of 3D printing technology
promoting research development improve the design, and repeat the to produce a functional RF circuit
and the commercialization of process until an optimum design with performance comparable to
aerospace and technology projects. is reached. In practice, optimizing those developed using conventional
The project included designing, performance in this manner can be manufacturing techniques.
simulating, and testing a 3D printed expensive and lead times are long. • There was no noticeable
RF amplifier and comparing it with Harris engineers chose the Nano difference in the input or output
the performance of an amplifier Dimension’s DragonFly Pro system return loss response over the
developed with conventional and were able to 3D print functional frequency range from 10 MHz to
manufacturing techniques, using RF circuits. A 101 mm x 38 mm (4 6 GHz.
FR4 substrate material as a baseline. in. x 1.5 in.) x 3 mm thick circuit • No noticeable difference
was 3D printed in 10 hours. Nano was detected in the gain of
Dimension’s silver nanoparticle the 3D printed circuit and the
conductive and dielectric inks conventionally manufactured
were used to create the functional amplifier. The gain difference
electronic parts in a single print and between the 3-D printed
then components were manually circuit and the conventionally
soldered to the PCB. manufactured circuit was less
To assess the quality of the than 1 dB up to 4.7 GHz and less
3D printed RF circuit versus one than 1.3 dB up to 6 GHz.
32

Nano.Dimensions.AMHDBK.9.19.Vs2.LL.indd 32 9/17/19 1:42 PM

Nano Dimensions DragonFly 2020 200 x 200 x 3 mm (7.87 plastics, some metals 0.03 mm 16 cm3/hr
x 7. 87 x 0.1 in.)
DragonFly 2020 Pro Metals (conductive silver
3D Printer nano particle inks) and
polymers (dielectric inks)
The DragonFly 2020 Pro 3D printer

produces PCB prototypes for electronics
applications.
less time than with traditional

methods. Other advantages of
3D printed electronics include the
ability to save time by evaluating
several design variations at one
time, and fabricate complex
electronic systems that cannot
be manufactured by conventional
means.
“The ability to manufacture
RF systems in-house offers an
exciting new means for rapid and
affordable prototyping and volume
manufacturing,” said Dr. Arthur
Paolella, Senior Scientist, Space
With the DragonFly Pro, circuits and with the traditionally manufactured and Intelligence Systems, Harris
systems that have rigid packaging circuits. An added bonus was the Corporation. “The results of the
integrated with flexible circuits ability to use in-house 3D printing study provide substantial motivation
can be produced in a single print to make RF amplifiers. This ability to develop this technology further.”
without the need for cables and drastically reduced the cost and
connectors. time required per iteration so
The performance of the 3D that RF amplifier manufacturers Nano Dimension
printed RF circuits was comparable can iterate several versions in www.nano-di.com
Nano.Dimensions.AMHDBK.9.19.Vs2.LL.indd 33 9/17/19 1:42 PM

Additive technology
Takemetal
the stress
additive parts
out of
Even though additive manufacturing (AM) gives designers more freedom
to design geometrically complex objects, there are some limitations. One of which
is cost. While a designer can create anything from his/her imagination, it may not
be manufacturable. Or, the part may require additional processing steps to ensure
specific mechanical features.
The laser powder-bed fusion additive process, for example, can bring residual
stresses to parts made with this technology. Residual stress occurs because of the
rapid heating and cooling of the laser as it sinters each layer in the build process.
Remember, powder bed fusion is a layer-by-layer build process. Thus, as the laser
moves over a fresh sweep of powder, it melts that layer fusing it to the layer it melted
34

Renishaw.AMHbk.9.19.Vs4.LL.indd 34 9/13/19 9:28 AM

While a designer can create anything from his/her imagination, it may not be manufacturable. Or,
the part may require additional processing steps to ensure specific mechanical features.
COMPANY MACHINE NAME BUILD VOLUME (MM) BUILD MATERIALS
RENAM 500M METAL ADDITIVE

250 X 250 X 350 MM AISI10MG, IN625, IN718, TI6AI4V
MANUFACTURING SYSTEM
RENISHAW AM 400 METAL ADDITIVE AISI10MG, COCR, IN625, IN718,

250 X 250 X 300 MM
MANUFACTURING SYSTEM STAINLESS STEEL 316L, TI6AI4V
THE RENAM 500Q 250 X 250 X 300 MM
Residual stress occurs because

of the rapid heating and cooling
of the laser as it sinters lay-
ers on top of one another in the
build process. Just as quickly
as the laser heats the top layer,
the hot metal begins to cool
and solidify. As that top layer
cools, it contracts. Because
this layer is constrained by the
already built solid layers below
it, the contraction sets up shear
forces between the solidified
layers, which introduces residual
stresses.
Renishaw.AMHbk.9.19.Vs4.LL.indd 35 9/17/19 1:47 PM

Additive technology
One way to reduce residual stress is to include a hatching pattern within the part.
Here are several hatch patterns recommended by Renishaw.
Even though additive manufacturing (AM) gives previously. The laser in effect
creates weld pools which adhere
designers more freedom to design geometrically the layers together. This process
happens in microseconds. But, just
complex objects, there are some limitations. One as quickly as the laser heats up the
of which is cost.
top layer, the hot metal begins to
cool and solidify. As that top layer
cools, it contracts. Because this
layer is constrained by the already
built solid layers below it, the
contraction sets up shear forces
between the solidified layers,
which introduces residual stresses.
Each layer can have residual
stresses, which can eventually
build to the point of distorting the
part. This distortion can take the
form of layers curling up at the
edges or layers pulling away from
supports. In extreme cases, the
stress may exceed the strength
of the material and part design,
leading to cracking, or the part can
be brittle and crumble and break
easily. In other cases, the residual
stress could distort the build plate.
Parts with large cross-sections
tend to experience these effects
the most because the long weld
tracks give shear forces more
distance to act.
36


Tips to reduce residual stress part, so factor that in if tolerances
• One way to reduce residual are important.
stress is to include a hatching
pattern within the part. In Thus, in summary:
hatching, the laser is moved • Design out residual stresses
back and forth in a pattern where possible
that varies the length of the • Avoid large areas of
scan vectors. The following are uninterrupted melt
hatch patterns recommended by • Be careful about changes in
Renishaw. cross-sections
• Use thicker build plates where
• The Meander Hatching Patten stress is likely to be high
creates a 67° rotation after each • Select an appropriate scan
layer. It offers a high build rate strategy
and is suitable for small and thin
features. Renishaw | www.renishaw.com
• The Stripe Hatching Pattern

creates a homogenous
distribution of residual stresses.
This pattern suits large parts.
While a designer can create anything
from his/her imagination, it may not be
• The Chessboard Hatching Patten
divides each layer into 5 by 5 mm manufacturable. Or, the part may require
islands and uses a 67° rotation of
the whole pattern and each island additional processing steps to ensure

after each layer. It too creates a
homogenous distribution of
specific mechanical features.
residual stresses. It is also suitable
for large parts.
• The orientation of scan vectors

can be rotated from one layer to
the next so that stresses are
not all aligned in the same plane.
A rotation of 67 degrees is
typically used between each layer
to ensure that it is many layers
before the scanning direction is
exactly repeated.
• Another technique is to heat the

build plate to reduce residual
stresses. Often, vendors will
recommend that a part be
placed in a furnace or in some
heat treatment to reduce the
effect of residual stress. Such
treatments will tend to shrink the
final dimensions of a

User stories
3D printing jigs and fixtures

with zero post processing
When it comes to the production of jigs, fixtures, and other manufacturing
tooling, 3D printing is proving to be a reliable, capable, and affordable choice
over more traditional methods.
For HMS Industries Inc., in Blairsville, PA, a Previously, HMS built jigs and fixtures from aluminum,
manufacturer of custom metal stamping and costing as much as $1,000 each. This required a specially
industrial tooling, 3D printing solved their search for trained team member to be taken off another job to
a fast and affordable way to produce strong jigs produce the part.
and fixtures that secured parts during production With their Rize One 3D printer, HMS employees
for consistent manufacturing. HMS provides high- design and print parts on demand in one day, freeing
quality manufacturing services, including product and up a team member and saving up to two days per
prototype development, EDM, tool design, tool and die fixture vs. producing aluminum fixtures, and only costing
manufacturing, as well as high-volume stampings and approximately $40.00 per part.
CNC machining, to manufacturers across all industries. Moreover, Rize’s safe and sustainable biocompatible
Consulting with Cimquest Inc., a Rize Authorized materials and process, without any VOCs or post-
Reseller, HMS chose to use the Rize One 3D printer processing, enables the HMS team to operate Rize
from Rize Inc., a Boston based, next-generation One in their tool shop without the need for any special
additive manufacturing company. HMS cited Rize’s ventilation, storage or disposal equipment.
zero-post-processing, isotropic part strength as two of HMS also uses Rize’s 3D printed marking capability
the reasons for the purchase. to indicate, right on the part, the location where the part
38

Rize.AM.HNDBK.9.19.Vs3.LL.indd 38 9/13/19 9:33 AM

A benefit of Rize’s 3D printers is the ability to mark and
indicate, right on the fixture, the location where a part should
be placed and part numbers for identification.
Rize Rize One 300 x 200 x 150 mm Rizium One thermo- 0.25 mm No info available
(12 x 8 x 6 in.) plastic
Even if painted brown, 3D printed placement fixtures

save up to two days per fixture versus producing
aluminum fixtures.
should be placed and part numbers for

identification.
Noting that a digital model cannot tell
the whole story, the HMS team also prints
complex parts to assist in the quoting
process before machining the parts. This
avoids the additional time and high cost of
potentially having to re-machine the parts
and increases customer satisfaction.
“Our first 3D printer, my team was able
to learn how to use Rize One and be up
and running in less than twenty minutes,”
said Barry Aikins, Vice President at HMS
Industries, Inc.
Said Andy Kalambi, President and
CEO of Rize, “We purpose built Rize One
with an appliance user experience to bring
simplicity, safety and speed to industrial 3D
printing and HMS Industries, a first time 3D
printing user, has demonstrated its value
beyond doubt.”
Rize | www.rize3d.com
Rize.AM.HNDBK.9.19.Vs3.LL.indd 39 9/17/19 1:52 PM

Additive Insights
Building a better
3D printer
Additive manufacturing continues to be a dynamic industry. Scott
Sevcik, VP of Manufacturing Solutions, Stratasys takes a look into what
Boom Supersonic is building the
developments you can expect in the near future.
world’s fastest supersonic aircraft
for commercial travel. They signed
Q What can users of extrusion-based 3D printers expect in terms of a 7-year agreement with Strata-
future developments, especially in regards to speed and accuracy?
sys to leverage the full range of
printers for prototypes and end-use
A You’ll see significant advances in speed and accuracy coming from parts.
many different sources. There’s a lot of inefficiency in non-print time
and extrusion today, and that will be eliminated through architectural
changes, software changes, changes to the tool pathing algorithms
among other developments.
40

Stratasys.AM.HNDBK.Insights.9.19.Vs4.LL.indd 40 9/17/19 1:56 PM

Company Technology Printer Build Envelope (mm) Model Material Options Layer thickness (mm)
Stratasys F120 10 x 10 x 10 in. ABS, ASA, SR30 and others 0.013 in.
STRATASYS F170 254 x 254 x 254 (10 x 10 x 10 in.) ABS-M30TM, ASA, PLA Down to 0.127
STRATASYS F270 305 x 254 x 305 (12 x 10 x 12 in.) ABS-M30TM, ASA, PLA Down to 0.127
STRATASYS F370 356 x 254 x 356 (14 x 10 x 14) ABS-M30, ASA, PC-ABS, PLA Down to 0.127
FORTUS 380mc 356 x 305 x 305 (14 x 12 x 12 in.) ABS-M30, ABS-M30i, ABS-ESD7, ASA, PC- Down to 0.127
ISO, PC, PC-ABS, FDM Nylon 12
FORTUS 380mc 355 x 305 x 305 mm (14 x 12 x FDM Nylon 12CF Carbon Fiber and ASA from 0.330 mm to 0.254
material extrusion
Carbon Fiber 12 in.) mm, depending on material
FORTUS 450mc 406 x 356 x 406 (16 x 14 x 16 in.) ABS-M30, ABS-M30i, ABS-ESD7, ASA, PC- Down to 0.127
ISO, PC, PC-ABS, FDM Nylon 12, FDM Nylon
12CF, ST-130, ULTEM 9085 resin, ULTEM 1010
resin
FORTUS 900mc 914 x 610 x 914 mm (36 x 24 x ABS-M30, ABS-M30i, ABS-ESD7, ASA, PC- Down to 0.178
36 in.) ISO, PC, PC-ABS, PPSF, FDM Nylon 12, FDM
Nylon 6, ST-130, ULTEM 9085 resin, ULTEM
1010 resin
Stratasys
OBJET30 PRO 300 x 200 x 150 mm (11.8 x 7.9 x MODEL: Rigid Opaque: VeroWhitePlus, 28 microns , 16 microns for
5.9 in.) VeroGrayTM, VeroBlueTM, VeroBlackTM, Ver- VeroClear Material
oBlackPlusTM, Simulated Polyproylene: Rig-
urTM, Durus, High Temperature
OBJET30 PRIME 300 x 200 x 150 mm (11.8 x 7.9 x MODEL: Rigid Opaque: VeroWhitePlus, 28 microns for TangoTM
5.9 in.) VeroGray, VeroBlue, VeroBlack, VeroBlack- materials 16 microns for all
Plus - Transparent: VeroClear and RGD720 - other materials
Simulated Polypropylene: Rigur, Durus - High
Temperature - Rubberlike: TangoGrayTM and
TangoBlackTM - Biocompatible
OBJET 255 x 252 x 200 mm (10 x 9.9 x MODEL: Rigid Opague: VeroWhitePlus, Ver- Horizontal build layers as
EDEN260VS 7.9 in.) oBlackPlus, VeroGray, VeroBlue - Rubber-like: fine as 16 microns. Accu-
TangoPlusTM, TangoBlackPlusTM, TangoBlack, racy 20-85 microns for
TangoGray - Transparent: VeroClear and freatures below 50mm;
RGD720 - Simulated Polypropylene: Rigur up to 200 microns for full
and Durus - High Temperature - Biocompat- model size
ible
Stratasys OBJET260/350/500 OBJET260: 260 x 260 x 200 mm MODEL: Rigid Opaque: VeroWhitePlus,Vero Horizontal build layers as
CONNEX 3 (10.2 x 10.2 x 7.9 in.) PureWhite, VeroBlackPlus, VeroGray, and fine as 16 microns. Accura-
OBJET350: 350 x 3350 x 200 mm VeroBlue; VeroCyanTM, VeroMagentaTM, cy up to 200 microns for
Polyjet (13.8 x 13.8 x 7.9 in.) VeroYellowTM - Rubber-like: Agilus30, Tango- full model size (rigid models
OBJET500:500 x 400 x 200 mm Plus, Tango BlackPlus, TangoBlack, Tango only)
(19.7 x 15.7 x 7.9 in.) Gray - Transparent: VeroClear and RGD720
- Simulated Polypropylene: Rigur and Durus -
High Temperature - Biocompatible - DIGITAL:
Vibrant blended colours in Rigid Opaque -
Translucent colored tints -Rubber-like materi-
als in a range of Shore A values - Digital ABS
PlusTM for durability, including blends with
rubber - Simulated polypropylene materials
with improved heat resistance
STRATASYS J750 490 x 390 x 200 mm (19.3 x 15.6 MODEL: VeroTM family of opaque materials Horizontal build layers as
x 7.9 in.) including neutral shades and vibrant colors, fine as 14 microns. Accura-
TangoTM family of flexible materials, Trans- cy up to 200 microns for
parent VeroClearTM and RGD720 full model size (rigid models
DIGITAL: Unlimited number of composite ma- only)
terials including over 360,000 colors, Digital
ABS and Digital ABS2TM in ivory and green,
Rubber-like materials in a variety of Shore A
values, Translucent color tints
Material jetting: OB- 1000 x 800 x 500 mm (39.4 x 31.5 MODEL: Transparent rigid: VeroClear - Rub- Horizontal build layers as
JET1000 PLUS x 19.7 in.) ber-like: TangoPlus and TangoBlackPlus - fine as 16 microns. Accura-
Rigid Opaque: Vero family - Simulated Poly- cy up to 600 microns for
propylene: Rigur full model size (for figid
DIGITAL: Transparent shades and patterns models only)
- Rigid Opaque shades - Rubber-like blends
in a range of Shore A values - Simulated
Polypropylene blends in rigid and flexible
options Digital ABS Plus siulates ABS plastics
by combining HT resistance and toughness
Digital ABS matches these to provide en-
hanced dimensional stability in walls thinner
than 1.2 mm - Rigur-based Digital Materials in
a range of Shore A values and shades in rigid continued on page 42
and flexible options
Stratasys.AM.HNDBK.Insights.9.19.Vs4.LL.indd 41 9/13/19 9:37 AM

Additive Insights
continued from page 41
OBJET30 300 x 200 x 150 mm MODEL: VeroDentPlus - Clear Bio-compatible Horizontal build layers
ORTHODESK (11.8 x 7.9 x 5.9 in.) - VeroGlaze down to 28 microns
OBJET30 300 x 200 x 150 mm MODEL: VeroDentPlus - Clear Bio-compatible Layer thickness 16 microns
DENTAL PRIME (11.8 x 7.9 x 5.9 in.) - VeroGlaze
OBJET EDEN-260VS 255 x 252 x 200 mm MODEL: VeroDentPlus - Clear Bio-compatible 16 microns - accuracy
DENTAL ADVAN- (10 x 9.9 x 7.9 in.) - VeroGlaze 0.1mm
TAGE
Polyjet Dental
Systems OBJET 260/500 OBJET260: 255 x 252 x 200 mm MODEL: VeroDent, VeroDentPlus, VeroGlaze, 16 microns
DENTAL SELECTION (19.7 x 15.7 x 7.9 in.) Clear Bio-compatible
OBJET500: 500 x 400 x 200 mm Additional materials include: VeroWhite,
(19.7 x 15.7 x 7.9 in.) VeroMagenta, TangoPlus, TangoBlackPlus,
Digital materials to reproduce gum-like tex-
tures and natural tooth shades
J700 Dental 490 x 390 x 200 mm Proprietary acrylate/dental photopolymers 55 microns
(19.3 x 15.6 x 7.9 in.)
Mojo 127 x 127 x 127 mm (5 x 5 x 5 in.) ABS 0.17 mm
Metal 3D printing LPM (Layered Pow-

der Metallurgy)
SL V650 Flex 20 x 20 x 23 in. Various resins 1000 ips
You’ll also see advances that

decouple the throughput and
accuracy trade-offs with material
extrusion. Right now, you either print
really slow for feature resolution
or you print really fast and do
post machining. What’s needed is
the ability to localize where you
need accuracy without affecting
throughput on the whole part,
especially with the demand from big
parts that are accurate and detailed.
So, in the next few years you’ll see
systems that address the challenge
of being big, being accurate and not
having to wait a week for your parts
to be done.
The next generation will
architecturally enable us to do
more with the software. Right
now, throughout the industry, the
architectures are fairly rigid and I
think you’ll see more dynamic, more
configurable systems to enable us
The Stratasys production-level manufacturing floor machine to do more to break that throughput
and accuracy trade off.
42


This new elastomer material is
being used across manufactur-
ing environments as some of
the most durable, flexible 3D
Printed material for production
parts. It is actively being used
at such customers as Polaris in
Minnesota.
Q Are you able, at this point, to

give any kind of a guesstimate
of the percentage improvement capital equipment venue allows
in speed and accuracy? us to address a broader range
of applications for those capital
A From a speed standpoint you’re equipment customers as well.
going to see 200%, 300%, 500%
improvement; 2X to 5X is what we’ll Q What is the development state
see over the next few years. of the metal additive
manufacturing system
Q Recently Stratasys announced Stratasys has been
a stereolithography system. working on?
What was the reasoning “In the next few years,
behind that? A We started talking last year
A Outside the industry, a lot
about Layered Powder Metallurgy,
or LPM, which is a new metals
you’ll see additive
of people think 3D printing is
all one technology and all the
technology unlike any of the
existing metal printers that are
systems that address
the challenge of being
technologies are interchangeable. out there today. We continue to
The reality is that each of the progress well on the metal projects
nearly dozen additive technologies that have been announced. But
has applications which are better there’s no new announcements to big, accurate, and of
or worse, either technically or share at this time. We believe our
economically. As we’ve built our Layered Powder Metallurgy will be not having to wait a
service business at Stratasys a compelling technology for more
Direct Manufacturing, we got a economical printed metal parts out week for your parts
strong appreciation for where each for production applications, in the
additive technology fits, and we
learned that stereolithography is
near future.
to be done.”
very complimentary to our FDM and Q What are some of the
PolyJet technologies. For example, challenges you see with shifting
you want a multi-color multi-textured additive technology into faster
design model? You’re going to use manufacturing production?
PolyJet. You want an investment
casting pattern, then you’re A There are many challenges
going to use stereolithography. facing additive manufacturing
Adding stereolithography to our production. Speed and economics

Additive Insights
are always the first to be raised, but Q What are some of the
there are other stakes. We focused challenges with additive in
heavily on repeatability over the industries like aerospace?
last few years. Manufacturers need
to trust that they are going to get
A Aerospace is, I would say,
the part they expect every time.
out in the lead with regard to
That’s absolutely fundamental to
most other industries in terms of
manufacturing. We’ve demonstrated
adopting additive. They were the
with FDM levels of repeatability that
first to really pull FDM in particular
are unprecedented, and in some
into tooling. So, there have been
cases are better than traditional
thousands of tools produced by
technologies. And that ability to
aerospace companies to support
demonstrate repeatability, the ability
aircraft production and spacecraft
for our customers to trust the part
production. And now, as we have
quality, that’s now leading to the
focused on repeatability, we work
development of standards. So, we
on material properties. Some of
have a published qualification with
those same early adopters for
the National Institute of Aviation
tooling have been the ones pushing
Research that is moving through the
the boundaries for production.
Society of Automotive Engineers.
We see Lockheed Martin and
It will be called an AMS7100, which
NASA building the alliance phase
is a standard for FDM Additive
leveraging our technology and the
Manufacturing that’s based on our
Antero material that we provide for
ability to hit those very high levels
that. Airbus and Launch Alliance go
repeatedly. Standards, of course,
back several years in terms of using
make adoption easier within the
our technology to put parts on
supply chain. So, reaching high
launch vehicles and the A350. And
levels of repeatability is fundamental
we’re seeing that accelerate now
for any technology to be accepted
with more companies outside of
for adoption.
these big-name industry leaders.
There are other things, of
We’re seeing the supply
course. Tools are vital, so we’ve
chain start to follow suit so we
been working with providers of
know many Tier 1 aircraft interiors
simulation tools like MSC, Siemens,
manufacturers that are qualifying
the Source Systems and CAD tool
the technology and delivering parts
as well to ensure that engineers
to the OEMs or to the airlines. We
have all the tools they are used to
just recently saw Diehl Aerospace
using with traditional technologies.
and the curtain headers that
If you can’t simulate an additive
they’ve printed for installation
part accurately, you’re going to
on A350s. This is growing as
over design that part or you’re
we’ve focused on their needs of
going to be forced to design and
repeatability in parallel with their
test more. So those same tools that
needs for simulation tools.
engineers are using for traditional
technologies, until those are
Stratasys | www.stratasys.com
accurate and useful for additive
technologies, there will continue
to be a bias to use the traditional
technologies that designers are
used to.
44

Stratasys.AM.HNDBK.Insights.9.19.Vs4.LL.indd 44 9/13/19 9:39 AM

Large-Format
Additive
Manufacturing
Solutions
German-engineered for reliability, speed and precision, BigRep machines are made to meet demanding
BigRep’s suite of large-format 3D printers have been manufacturing schedules in industrial environments.
built for 24/7 printing with engineering-grade Experience the power of BigRep 3D printing – larger
materials. and more powerful than ever before.
Visit bigrep.com for more information
BigRep_Additive Mfg 9-19.indd 45 9/17/19 6:55 AM

User stories
Streamlining
manufacturing with 3D printing
At the Ford pilot plant in Cologne, Germany, each new vehicle design
has a trial manufacturing run before it goes into mass production. The pilot plant is
a small-scale manufacturing line where engineers can experiment with design and
manufacturing processes before full production. Lars Bognar, Research Engineer
at Ford’s Research & Advanced Engineering team in Aachen, has been working
on optimizing the workflow to create jigs, tools, and fixtures for the manufacturing
process.
Most car designs require custom tooling specific to one task and one car model.
Creating the tools externally takes time and is expensive. To get tools faster, the
engineering and manufacturing teams at Ford decided to see what 3D printing
could offer.
46

Ultimaker.FORD.AM.HBK.9.19.Vs4.LL.indd 46 9/13/19 9:41 AM

The Ford pilot plant in Cologne, Germany, is a small-scale manufacturing line where engineers can experiment
with design and manufacturing processes before full production of new vehicle designs.
Company Machine Build Volume (mm) Materials Layer Resolution Build Speed
Name
Ultimaker ULTIMAKER 2+ 223 x 223 x 205 mm Open 0.25 mm nozzle: 150 to 60 micron 0.25 nozzle: up to 8 mm³/s
(8.7 x8.7 x 8 in.) material 0.4 mm nozzle: 200 to 20 micron 0.4 nozzle: up to 16 mm³/s
system and 0.6 mm nozzle: 400 to 20 micron 0.6 nozzle: up to 23 mm³/s
Ultimaker 0.8 mm nozzle: 600 to 20 micron 0.8 nozzle: up to 24 mm³/s
optimised
materials
ULTIMAKER 2 223 x 223 x 305 mm Open 0.25 mm nozzle: 150 to 60 micron 0.25 nozzle: up to 8 mm³/s
EXTENDED+ 8.7 x 8.7 x 12 in. ) material 0.40 mm nozzle: 200 to 20 micron 0.40 nozzle: up to 16 mm³/s
system and 0.60 mm nozzle: 400 to 20 micron 0.60 nozzle: up to 23 mm³/s
Ultimaker 0.80 mm nozzle: 600 to 20 micron 0.80 nozzle: up to 24 mm³/s
optimised
materials
ULTIMAKER 3 215 x 215 x 200 mm Open 0.25 mm nozzle: 150 - 60 micron < 24 mm³/s
(8.5 x 8.5 x 7.8 in.) material 0.4 mm nozzle: 200 - 20 micron
system and 0.8 mm nozzle: 600 - 20 micron
Ultimaker
optimised
materials
ULTIMAKER 3 215 x 215 x 300 mm Open 0.4 mm nozzle: 20 - 200 micron 30 - 300 mm/s
EXTENDED (8.5 x 8.5 x 11.8 in.) material
system and
Ultimaker
optimised
materials
ULTIMAKER S5 330 x 240 x 300 mm Open 0.25 mm nozzle: 150 to 60 micron < 24 mm³/s
(13 x 9.4 x 11.8 in.) material 0.40 mm nozzle: 200 to 20 micron
system and 0.60 mm nozzle: 400 to 20 micron
Ultimaker 0.80 mm nozzle: 600 to 20 micron
optimised
materials
Many manufacturing
plants implement 3D
printing to optimize their
manufacturing process.
Ultimaker.FORD.AM.HBK.9.19.Vs4.LL.indd 47 9/17/19 2:03 PM

User stories
A dedicated additive
manufacturing team was founded
Initially, the Ford engineer team used selective laser sintering (SLS)
and they began a successful project
technology, but it added to the post processing steps. The design team
using selective laser sintering (SLS)
experimented with extrusion technology from Ultimaker. It delivered a
technology. The results were good,
fast, affordable solution with less hassle.
but the parts needed specific post-
processing. That’s why the team
started using extrusion technology
from Ultimaker. It delivered a fast,
affordable solution with less hassle.
In addition, not only engineers but
local workforces are able to use
“By having a dedicated 3D workshop in these 3D printers to create the tools
they need.
the plant, Ford produces the right tool Many manufacturing plants
implement 3D printing to optimize
design before a new car goes into mass their manufacturing process.
However, by having a dedicated 3D
production. This ability gives engineers workshop in the pilot plant, Ford
produces all the right tool design
more time to iterate the designs of all the before a new car goes into mass
production. This ability gives the
custom tools.”
engineers more time to iterate the
designs of all the custom tools.
The engineers want to create tools
that speed up the manufacturing
time of the vehicles as well as
offer ergonomic benefits for the
workforce.
48


Now, Ford is placing Ultimaker
3D printers in factories all over
Europe, notably in Spain, Italy,
and Romania. The design team in
Germany will supply the designs
electronically, and the tools will be
3D printed and shipped back to
Germany by the next day.
But Ford is also going a step
further. Using Trinckle generative
software Paramate, workers in
these plants can generate jigs
without much experience in 3D
design. The team in Cologne will
create components they can use
for the tools such as handles and The Ford Focus is manufactured using more than 50 custom
magnet holders. The engineer will designed tools, jigs, and fixtures.
load the design of the car, add
handles, an open space where they
need to add a part to the car, and looking to create tools and fixtures,
the software will generate the jig. but also exploring possibilities to
This design can be sent directly to create spare parts and final parts
Ultimaker Cura and printed locally using 3D printing. “We want to
with their onsite Ultimaker S5 design for additive manufacturing
machines. and print production parts for
So far, this pilot project has production vehicles.”
been beneficial to Ford. Per
custom tool, the company has Ultimaker | www.ultimaker.com
saved a considerable amount of
money compared to traditional
manufacturing or outsourcing.
The Ford Focus, for example, is
manufactured using more than 50
custom designed tools, jigs, and
fixtures. Ford is also looking at
spare parts for production machines
from the manufacturing line. By
printing these parts, they increased
the uptime of the machines and
the manufacturing line is no longer
paused for long.
As for the ergonomic benefits,
Ultimaker’s range of materials are
strong enough to replace metal
tools, cutting weight and making the
job easier for assembly personnel.
Ford is expanding their 3D
printing capabilities rapidly. While
optimizing the workflow to create
tools, jigs, and fixtures, they’re
learning more about the possibilities
of 3D printing. Lars is not only

2019 Vendors in the additive industry
3D Systems
3D Systems software delivers the power to take you from prototyping through to 3D production:
Geomagic® 3D scan and inspection software; GibbsCAM® CNC programming solutions; Cimatron®
mold and die design; DICOM-to-print (D2P ) CT scan processing solutions, DfAM manufacturing
TM
software with 3D Sprint and 3DXpert to deliver perfect parts, every time.
TM TM
333 Three D Systems Circle

Rock Hill, SC 29730
United States of America
Phone: 803.326.3900
Fax: 803.326.4069
http://www.3dsystems.com
50

3D Systems_PROFILE_Add Mfg Hbk 2019_V1.indd 50 9/16/19 3:10 PM

HP Multi Jet Fusion

3D Printing Technology
HP Inc. creates technology that makes life better for everyone, everywhere.
Through our portfolio of personal systems, printers, and 3D printing solutions, we
engineer experiences that amaze. More information about HP Inc. is available at
www.hp.com/go/3DPrint.
Products:
• HP Jet Fusion 5200 Series 3D Printer
• HP Jet Fusion 4200 Series 3D Printer
• HP Jet Fusion 500/300 Series 3D Printers
• HP Metal Jet
https://www8.hp.com/us/en/printers/3d-printers.html
HP
1501 Page Mill Road
Palo Alto, California 94304-1100
Phone: 877.468.8369
hp.com/go/3DPrint
HP 3D Printing_PROFILE_Additive Mfg Hbk 2019_V1.indd 51 9/17/19 11:55 AM

Mimaki USA
Mimaki is a global industry leader

of wide-format inkjet printers, cutting
plotters, 3D modeling machines, software,
hardware and associated consumable
items. The company engineers and
manufactures a complete range of
products that provide a total workflow
solution for the sign graphics, textile &
apparel, industrial products and
Mimaki USA
3D markets. Josh Hope
150 Satellite Blvd. NE, Ste. A
Suwanee, GA 30024
Toll Free: 888-530-3988

www.Mimakiusa.com/3D
52

Mimaki_Additive Mfg Hbk 2019_v1.indd 52 9/13/19 2:27 PM

Renishaw
Renishaw is one of the world’s leading
engineering and scientific technology
companies, with expertise in precision
measurement and healthcare. We are
also a leading manufacturer of advanced
metal additive manufacturing systems and
provider of custom tailored solutions. We
offer a total solution for metal additive
manufacturing, from systems, metal
powders, ancillaries and software; all with
expert advice and support. Our advanced
metal additive manufacturing systems are
designed and built by Renishaw to fulfil
a range of industry applications where
durability, customized parts and precision
are key.
Also called 3D printing, AM is a process

used to create three dimensional parts
from a digital file. It usually involves
building up, or solidifying, thin layers
of material to create complete parts.
The technology enables the production
of complex shapes which cannot be
produced by ‘traditional’ techniques
such as casting, forging and machining.
Additive manufacturing (AM) introduces
new design possibilities for metal parts,
including opportunities to combine
multiple components in production,
minimize material use and reduce
tooling costs.
Our expertise in process development and

experience in using the technology in our
own manufacturing operations enable us
to provide turn-key and optimized additive
manufacturing solutions for a broad range
of applications.
Renishaw, Inc.
1001 Wesemann Drive
West Dundee, IL 60118
(847) 286-9953
usa@renishaw.com
www.renishaw.com
Renishaw_Additive Mfg Hbk 2019_v3.indd 53 9/13/19 2:36 PM

THERMWOOD
Thermwood Corporation, located
in Southern Indiana and established
in 1969, manufactures both three &
five axis CNC machining centers and
Large Scale Additive Manufacturing
(LSAM) systems. The LSAM can
perform both the “additive” and
“subtractive” functions on the same
machine. This approach, called “near
net shape”, uses carbon or glass fiber
reinforced thermoplastic material to
quickly create a part that is nearly, but
not exactly, the final net shape. The
“subtractive” function then machines
the part to the exact final net shape.
Thermwood’s LSAM system can
use a variety of materials from low
temperature to high temperature
applications and is used for the
production of large to very large
tools, molds, masters, patterns, plugs
and fixtures. A variety of industries
including aerospace, automotive,
marine, foundry, thermoforming and
more can use the LSAM system.
LSAM can print either horizontally or
vertically, allowing for the printing of
parts as long as the table.
Thermwood is a US based company

with dealers and distributors
worldwide. In addition to machine
manufacturing and software
development, Thermwood has a
technical service organization that
provides support, machine installation,
training, retrofits, custom programming
and production assistance.
Please visit www.thermwood.com, Thermwood Corporation

call 1-800-533-6901 or email 904 Buffaloville Rd
info@thermwood.com for more Dale, IN 47523
information.
Toll-Free 800.533.6901
Telephone 812.937.4476
info@thermwood.com
www.thermwood.com
54

Thermwood_Additive Mfg Hbk 2019_v2.indd 54 9/13/19 2:29 PM

September 2019 www.designworldonline.com
2019
Additive
Manufacturing
Handbook
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AD INDEX SALES
Jami Brownlee Jim Powers

jbrownlee@wtwhmedia.com jpowers@wtwhmedia.com
224.760.1055 312.925.7793
3D Systems .............................................................IFC @jpowers_media
Mike Caruso
Big Rep .......................................................................45 mcaruso@wtwhmedia.com Courtney Nagle
469.855.7344 cseel@wtwhmedia.com
440.523.1685
HP 3D Printing ........................................................ BC Bill Crowley @wtwh_CSeel
bcrowley@wtwhmedia.com
Renishaw............................................................ 12, IBC 610.420.2433
Jim Dempsey LEADERSHIP TEAM

Thermwood ............................................................... 17 jdempsey@wtwhmedia.com
216.387.1916 Publisher
Mike Emich
Michael Ference memich@wtwhmedia.com
mference@wtwhmedia.com 508.446.1823
408.769.1188 @wtwh_memich
@mrference
Managing Director
Mike Francesconi Scott McCafferty
mfrancesconi@wtwhmedia.com smccafferty@wtwhmedia.com
Company Profiles 630.488.9029 310.279.3844
@SMMcCafferty
3D Systems ..............................................................50 David Geltman
dgeltman@wtwhmedia.com EVP
516.510.6514 Marshall Matheson
HP 3D Printing .......................................................... 51 @wtwh_david mmatheson@wtwhmedia.com
805.895.3609
Mimaki ......................................................................... 52 Neel Gleason @mmatheson
ngleason@wtwhmedia.com
312.882.9867
Renishaw....................................................................53 @wtwh_ngleason
Thermwood ..............................................................54
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AD INDEX - ADDITIVE MFG_9-19_Vs1.indd 56 9/17/19 2:53 PM

cmy
pms
Your partner black
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Power your additive manufacturing with

multi-laser productivity
As manufacturers ourselves, we understand the challenges you face. For 45 years, Renishaw has
been creating breakthrough innovations that solve manufacturing problems and move productivity
to new heights. Renishaw multi-laser AM systems open the door to a new world, bringing more
applications within reach of AM technology.
RenAM 500Q has four efficiently applied high power lasers that reduce cost per part, while
advanced sensors and systems ensure unparalleled processing conditions to deliver consistent
Hydraulic block manifold additively
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Renishaw, Inc. 1001 Wesemann Drive, West Dundee IL, 60118

T 847-286-9953 F 847-286-9974 E usa@renishaw.com
www.renishaw.com
Renishaw_Additive Mfg 9-19.indd 1 9/13/19 8:19 AM

Unlock
Manufacturing
Possibilities
Whether you want to create prototypes or ﬁnal parts, we can help you
to produce lightweight parts with optimal mechanical properties, even
at low volumes.
www.hp.com/go/3Dparts
HP 3D Printing_Additive Mfg 9-19.indd 1 9/13/19 8:22 AM

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Our People Know

For prototyping through to production of end use parts,

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Leslie Langnau | Managing Editor

www.designworldonline.com September 2019 1

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EDITORIAL DIGITAL MEDIA/WEB/ EVENTS Director, Audience

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08 _BIGREP 32 _NANO DIMENSIONS

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ADDITIVE.BUYERS.GUIDE.CONTENTS.9.19.Vs2.LL.indd 3 9/16/19 12:36 PM

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This SLS printed cam tensioner lever

DESIGN WORLD www.designworldonline.com September 2019 5

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* MAXIMUM AVAILABLE PART SIZE USING STANDARD BUILD PLATE

DESIGN WORLD www.designworldonline.com September 2019 7

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The PRO additive

When size matters

BigRep.AM.HBK.9.19.Vs3.LL.indd 8 9/13/19 8:54 AM

The PRO handles large-scale

The Edge additive

DESIGN WORLD www.designworldonline.com September 2019 9

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To date, key challenges have stood in the way

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Your partner black

for innovative manufacturing reverse

Power your additive manufacturing with

Renishaw, Inc. 1001 Wesemann Drive, West Dundee IL, 60118

Renishaw_Additive Mfg 9-19_page 12.indd 12 9/13/19 8:21 AM

DESIGN WORLD www.designworldonline.com September 2019 13

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The technique chosen to finish additive parts depends on the part’s

Even though additive and 3D printing technologies continually

DesktopMetal.AM.HNDBK.9.19.Vs2.LL.indd 14 9/13/19 8:58 AM

DESIGN WORLD www.designworldonline.com September 2019 15

DesktopMetal.AM.HNDBK.9.19.Vs2.LL.indd 15 9/13/19 8:58 AM

The surface of the part will vary between

Centrifugal disc machines consist

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Thermwood_Additive Mfg 9-19.indd 17 9/13/19 8:18 AM

Shaping the future

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AM Ventures, and external partners that enable further innovation in rocket

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FUSE 1 16.5 X 16.5 X 32 CM, NYLON POWDER 199 MICRONS 10 MM/HR

FORM CELL UP TO 10 FORM 2 PHOTOPOLYMER 25-300 MICRONS DEPENDENT ON SETUP

FORM 3 14.5 × 14.5 × 18.5 CM PHOTOPOLYMER 25-300 MICRONS DEPENDENT ON GEOMETRY

Low Force Stereolithography

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“Additive is booming,” says investment in metal additive to commercialization,” Alaedeen

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