<p id="isPasted">What if items in a room could "talk" to each other wirelessly — without any configuration, batteries, or contact? What if instead of having to wait in line at the supermarket, you could just checkout by walking out the front door? Or the next time you misplace your keys, they could tell you where they were located? RFID is a technology that can do all this and more.</p><p>Radio Frequency Identification (commonly known as RFID) is a technology that leverages wireless communication over radio waves to both transfer data and locate objects. Many of us use RFID as part of our everyday life without noticing it, whether it be entry keycards, contactless payments, or toll road transponders on vehicles. While RFID has been streamlining processes for decades, there has been an explosion in the applications of RFID in recent years.</p><p>Retail businesses have started using RFID to speed up the checkout process and improve customer experience. Some countries have begun using RFID to augment their passports with additional information to verify an individual’s identity. RFID is even used in healthcare, with the FDA certifying the use of RFID to track donated blood, including using RFID tags to track the origin, type, and date of donation for blood [1].</p><p>So what’s the catch? &nbsp;Well, with nearly 28 billion RFID tags sold in 2021 and a yearly growth of 36% [2], the sheer volume of these tags will result in significant environmental challenges, due to the wasteful and resource intensive nature of current production methods. In addition, current RFID tags leverage aging material technology that is quickly being supplanted in performance and cost by novel approaches, namely nano copper inks, like&nbsp;<a href="https://www.copprint.com/wp-content/uploads/2021/12/TDS-LF-301-Beta-22-08-21.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Copprint LF-301</a>.</p><p>Nano copper inks offer several advantages over existing materials used in RFID production. &nbsp;The most common way tags are made today is by etching aluminum, a subtractive process similar to how PCBs are made. A laminate of aluminum foil and PET is put through a chemical process where excess aluminum is subtracted to form the final tag pattern. In contrast, nano copper inks use additive processes where conductor material is deposited onto a substrate in the desired pattern. This results in no copper waste, or toxic chemical byproducts from the production process. What’s more, with an ink like Copprint LF-301 the tag can be made right on a paper substrate such that the RFID tag is compostable, a big change compared to non-recyclable and non-compostable etched aluminum tags.</p><p>We set out to create an RFID tag using this innovative ink by&nbsp;<a href="https://www.copprint.com/" target="_blank">Copprint</a>. Specifically, we designed, printed, assembled and tested an UHF (ultra-high frequency) RFID tag. This sort of tag is commonly used in asset-tracking applications, like logistics and consumer retail. Using industry-standard design and simulation software, a high-performance UHF RFID tag was designed, but as with everything, you don’t know how something really works until you make your first prototype.</p><p>Fortunately, getting up to speed with a new ink and substrate is a breeze with&nbsp;<a href="https://www.voltera.io/nova" target="_blank">NOVA</a>. Using the Smart Dispenser, combined with the built-in ink calibration workflow, we were able to tune an ink profile to use with Copprint LF-301. What’s more, NOVA’s Vacuum Table module made it a breeze working with paper substrates. After placing the paper on the Vacuum Table, it is held in place until the print is complete. Once the ink was dialed in, and paper substrate was in place, we were ready to print — no upfront costs or time waiting for custom screens to print our prototype pattern: just NOVA, Copprint LF-301, and cardstock paper.</p><p>With NOVA set up, we printed the RFID antenna pattern which was based on the Modified Half-Dipole antenna topology which is commonly used in this sort of application. From beginning to end, including surface-mapping with the Smart Probe, it took less than 15 minutes to produce one RFID tag antenna print. &nbsp;</p><p>Once printed, we followed the sintering instructions provided by Copprint; sintering is a critical step for nano copper inks as it transforms the structure of the material, from many disconnected microscopic particles of copper to one continuous bulk. This is the magic of Copprint’s ink, as the sintering process transforms the easy-to-print ink into a high performance copper antenna. &nbsp;This is achieved by using a simple oven and heat press, all within our lab.</p><p>With the antenna printed and processed, all that was left was to bond the RFID transceiver integrated circuit to the antenna itself. This IC controls the antenna and responds to an incoming RFID signal. While these are often bonded using specialized adhesives known as Anisotropic Conductive Adhesives (ACA), we chose to simply solder the IC to the antenna as the sintered ink behaves just like bulk copper on a PCB. And with that, our tag was complete!</p><p>After testing the RFID tag we produced, we were surprised at the performance: this custom tag which was designed and prototyped in-house in a week performed slightly better than the off-the-shelf tag we purchased from a market-volume leader in RFID. This was accomplished with minimal upfront cost, using NOVA to rapidly prototype our design, moreover with the quick production time for each tag, iterations of the design can be rapidly created and tested.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/2COFihlYVos?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p>

Radio Frequency Identification (commonly known as RFID) is a technology that leverages wireless communication over radio waves to both transfer data and locate objects. 

Making an RFID Tag using Revolutionary Copper Ink on Paper

<p id="isPasted">Established in 1906 and headquartered in Italy, Panelli Srl is a leading manufacturer of submersible pumps and motors. Thanks to recent investments in industrial automation and the extensive use of robotized assembly, Panelli can offer various products with high hydraulic characteristics.</p><p>Historically, the company only used a traditional industrial 3D printer for prototyping, but materials costs were high. As a result, Panelli added the UltiMaker Method XL 3D printer, a cost-effective and comparable alternative, allowing the company to successfully achieve the dual goals of cost efficiency and superior quality in their prototypes.</p><h2>Challenge: Prototyping and testing large parts that can withstand high impacts</h2><p>Panelli’s technical department employs 3D printing to prototype its pump components and ensure that all parts are up to specifications. The team currently uses a simple industrial 3D printer and needed to add another one to support its growing design and production needs.</p><p>“We print very often, almost daily,” said Francesco Zamirri, mechanical designer at Panelli. “Especially when we need to improve the hydraulic performance of an existing range or create a new one.”</p><p>However, traditional industrial printers can be rather large and expensive, both to operate and maintain. The team needed something more affordable and that would not require much maintenance.</p><h2>Solution: Integrating Method XL into their processes</h2><p>After consulting with&nbsp;<a href="https://manufat.com/ultimaker-makerbot-method-xl/" target="_blank">Manufat</a>, a local reseller with expertise in 3D printing solutions, Panelli added Method XL, UltiMaker’s latest professional 3D printer. Known for its robust engineering capabilities, Method XL was a cost-effective alternative to expensive industrial machines but still offered industrial-grade features. The heated chamber and heated build plate reduces the risks of warping and improves layer adhesion across the entire print. Method XL also boasts a 305 x 305 x 320 mm build volume and ABS and carbon fiber 3D printing capabilities, allowing Zamirri and his team to continue to prototype large and strong parts with little downtime.</p><p>“We selected Method XL because it can create high-quality, industrial-grade parts in ABS and carbon fiber,” said Zamirri. “Method XL allows us to test prototypes with large dimensions and high pressures. For a desktop 3D printer, the results are exactly as we would get them on our industrial printer. Method XL is also very easy to use, and the materials are much more affordable. We have had a great experience with it so far.”</p><p>The team is using Method XL to print functional prototypes of diffusers and large centrifugal impellers that must withstand high pressure and flow rate. Because they need strong parts that can endure their testing, the prototypes are printed in ABS Carbon Fiber, a composite material known for its ability to withstand high impacts.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxODU0MjM3NjY4LWV6Z2lmLTItNmUzNDRlMDVhNy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></p><p id="isPasted">The team also uses ABS-R for rapid prototyping and parts with complex geometries. ABS-R offers superior printing performance for consistent and repeatable parts. With ABS-R, they can use RapidRinse, UltiMaker’s support material that easily dissolves in tap water. This feature not only enhances operational sustainability but also widens the scope for designing complex parts without compromising on strength.</p><p>“RapidRinse is very helpful. We can have the final part with a super easy workflow and with better quality, compared to the use of breakaway supports,” said Zamirri. “We also don’t have to use any chemical solvent that is always very hard to manage.”</p><h2>Results: Streamlined workflow, and time and cost savings</h2><p>Zamirri and his team continue to use both Method XL and their older industrial 3D printer to accelerate the prototyping process. While one machine prints the impeller, the other is used to print the diffuser, ensuring high efficiency and little downtime.</p><p>“The use of 3D printing lets us save a lot of time and money, compared to the use of CNC machining,” continued Zamirri. “In 24 hours, we can produce an impeller with a very difficult geometry and minimal effort. Impellers always have very complicated shapes, and Method XL helps us a lot.”</p>

Panelli’s technical department employs 3D printing to prototype its pump components and ensure that all parts are up to specifications. The team currently uses a simple industrial 3D printer and needed to add another one to support its growing design and production needs.

Panelli Srl: Accelerating Prototyping and Testing with 3D Printing

Two primary PCB assembly techniques have emerged as the electronics industry standards: Through-Hole Technology (THT) and Surface Mount Technology (SMT). This article delves into the intricacies of THT and SMT, providing a thorough comparison of their advantages, disadvantages, and applications.

Through Hole vs Surface Mount: Unveiling the Optimal PCB Assembly Technique

<h2 dir="ltr" id="isPasted">The Evolution of Electronics</h2><p dir="ltr">The history of electronics dates back to the late 19th century, with the discovery of electrons and the ability to control the electric current flow between them using vacuum tube devices. Of course, electronics today bear little resemblance to turn-of-the-century electronic systems, and this is due in large part to the emergence of printed circuit boards (PCBs). While the first technology to begin to resemble a PCB was patented in 1903 by German inventor Albert Hanson, the electronic devices, which connect wires in a circuit, would not be widespread until the 1960s, with the integration of printed circuit boards into consumer electronics like televisions and home radios. At the time, PCBs offered a number of benefits over existing circuit boards: they were lighter, smaller, and cheaper to produce.&nbsp;</p><p dir="ltr">Over the next decades, printed circuit boards would continue to evolve, with manufacturers finding ways to make the circuitry even more compact and cost efficient. For example, the ability to create multiple layers within a single PCB opened the door to smaller electronic systems with more capabilities.&nbsp;</p><p dir="ltr">Flexible electronics were also developing over this time, evolving significantly from their earliest iterations in the early 20th century (metal conductors mounted on wax-coated paper). In the 1960s, for example, flexible solar cells made from thin silicon were invented. Following this, the development of conductive polymers and other material advances paved the way for today’s flexible electronics.</p><p dir="ltr">Additive technologies, like 3D printing, are now at the cutting edge of both non-flexible and flexible electronics. This technology involves the deposition of conductive and insulating materials onto a substrate to create a circuit. Additive solutions like <a href="https://hubs.ly/Q029xhJN0" target="_blank">Voltera</a>’s high-resolution printing platform are unlocking more opportunities for rigid and flexible electronics by expanding design possibilities and enabling a greater range of materials. In this article, we will be focusing specifically on additively manufactured flexible electronics, looking at how they are made, what benefits they offer, how they can be used, and more.</p><h2 dir="ltr">What are Flexible Electronics?</h2><p dir="ltr">Flexible electronics are a type of electronic device characterized by their ability to flex, stretch and/or conform. Unlike rigid PCBs, this means they can bend without breaking, expand or stretch and return to their original shape, and adapt to whatever surface they are applied to. In the simplest terms, flexible electronics are achieved by mounting flexible conductive elements onto a flexible substrate, typically made of plastics like polyimide or polyethylene terephthalate (PET), or other flexible materials like paper or metal foil.</p><h3 dir="ltr">Materials and Components</h3><p dir="ltr">Flexible electronics typically utilize a range of specialized materials to achieve their unique properties. The most common substrate material is polyimide, valued for its excellent thermal stability and flexibility. PET is another popular choice, due to its cost effectiveness and good mechanical properties. For the conductive elements, materials like silver, copper, and conductive polymers are widely used as they offer both excellent electrical conductivity and ductility.&nbsp;</p><p dir="ltr">Transparent conductors like indium tin oxide (ITO) or conductive polymers are used for applications requiring transparency, such as in flexible displays. These materials are carefully chosen to ensure that the final electronic device retains its flexibility, durability, and functionality, meeting the demands of various applications in fields like healthcare, consumer electronics, and wearable technology.</p><p dir="ltr">In the manufacture of flexible electronics, printing techniques such as inkjet printing, screen printing, and roll-to-roll printing (R2R) are often employed. Inkjet printing, for example, is a non-contact process that involves jetting tiny ink droplets using an array of nozzles onto a substrate. Some specialized inkjet printers, such as Voltera’s NOVA system based on its direct-ink-write technology, are designed to deposit a wide range of materials, such as conductive inks, with ultra-precise accuracy on various substrates.&nbsp;</p><h2 dir="ltr">Applications of Printed Flexible Electronics</h2><p dir="ltr">While printed flexible electronics are still in their infancy, the potential applications for these devices is vast. Flexible electronics with small footprints are being investigated across many industries, from healthcare, to energy, to consumer goods, to make more efficient and innovative products. Let’s take a look at some application areas for printed flexible electronics.</p><h3 dir="ltr">Wearable Technology</h3><p dir="ltr">Flexible electronics have numerous applications in the field of wearable tech, and have a big impact on how devices fit on our bodies and integrate with our daily lives. For example, fitness trackers made from flexible electronics can be integrated into wearable bands or even clothing that users can wear during exercise or daily activities. The flexibility of these devices ensures they remain unobtrusive, conforming to the body's movements while accurately tracking physical activity and vital signs. For wearable applications, electronics are printed onto a flexible material, which can then be applied directly to the surface of the wearable. In one study, Voltera’s technology was used to print a wearable heater, which was successfully applied to a pair of denim jeans resulting in a functional heating patch.</p><h3 dir="ltr">Medical Devices</h3><p dir="ltr" id="isPasted">The medical field is also increasingly interested in leveraging flexible electronics for the development of advanced medical devices. Wearable health monitors utilize flexible electronic circuits to conform to the contours of the human body, providing continuous, real-time health monitoring without causing discomfort or hindering the wearer's movement. Such wearable monitors can track a variety of health metrics, including heart rate, blood pressure, oxygen saturation, and even electrocardiogram (ECG) readings. The flexibility of these electronics is crucial, as it allows the sensors to maintain close contact with the skin, ensuring accurate and consistent data collection. For example, a researcher at York University recently investigated &nbsp;the use of printed flexible electronics for <a href="https://youtu.be/MEW3q7GKYQA" target="_blank">biomedical tattoos</a>, which conform to the patient’s skin for greater comfort. These could be used to capture ECG readings, to integrate with prosthetics, and more.</p><h3 dir="ltr">Consumer Electronics</h3><p dir="ltr">While still a nascent application area, there is huge potential for flexible electronics in consumer electronics. A striking example is the development of flexible displays used in smartphones, laptops, and televisions. These displays utilize flexible electronic components to create devices that are lighter and thinner than their traditional counterparts and offer new form factors such as foldable or rollable screens. These flexible screens could also be used in cars or in wearables, eliminating previous design restrictions on media and consumer electronics by being more adaptable.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701871597307-LG+display.jpg" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false"></span></span></span></p><figcaption id="isPasted"><em>Smashed phone screens could eventually be a thing of the past thanks to ultra-flexible stretchy display tech.</em></figcaption><p>&nbsp;<cite>Image: LG Display</cite></p><p><br></p><h3 dir="ltr">Robotics and Automation</h3><p dir="ltr">Robotics can also benefit from flexible electronics, as the technology opens up the door for pliant and deformable soft robots that can be integrated directly with sensors or electronics components. These soft robots can interact safely and efficiently with humans and complex environments, and can handle even the most fragile components in production or assembly lines. And that’s just the tip of the iceberg: robots with stretchable bodies could also have exciting applications in healthcare, search and rescue, and more.&nbsp;</p><h3 dir="ltr">Energy</h3><p dir="ltr">Flexible, stretchable, and conformable electronics also have the potential to transform certain applications in energy. For example, the ability to directly print flexible electronics can enable the seamless integration of solar panels onto various surfaces, from architectural designs to portable applications, and offer improved durability and aesthetic adaptability. There is also growing interest in the development of flexible energy storage devices (FESDs), which could be used to power wearable tech and other flexible electronic products without the need for a bulky power source or wiring.</p><h1 dir="ltr">Voltera's NOVA&nbsp;</h1><p dir="ltr">In the rapidly evolving field of printed electronics, Canadian company <a href="https://hubs.ly/Q029xhJN0" target="_blank">Voltera</a> is doing something highly unique. It develops and supplies dispensing systems for the rapid prototyping of printed electronics, from traditional circuit boards to flexible, stretchable, conformable, and biocompatible electronics. Their approach enables users to quickly iterate and test designs, enabling faster design development and a more accessible method for industry experimentation and innovation. Notably, their systems don’t require expert knowledge and they can be used with a broad range of inks and materials enabling unfettered design freedom.&nbsp;</p><h3 dir="ltr">NOVA Printer</h3><p dir="ltr">Voltera’s NOVA printer enables high-resolution printing using a range of functional materials and screen-printable inks. The system works with a wide range of conductive and insulating inks, including copper, silver and carbon-based inks ranging from 1,000 to 1,000,000 cps. NOVA deposits these conductive and insulating inks onto various substrates, including flexible, rigid and heat-resistant materials, with incredible precision (capable of printing a line width of 100 µm and a resolution of up to 17 µm/pixel). In terms of flexible substrates, it is possible to print on materials like paper, polyimide films, PET, and more.</p><p dir="ltr">Used by researchers and product developers to streamline their R&amp;D processes, NOVA enables on-the-fly design changes and immediate feedback on new ideas, significantly accelerating timelines and reducing costs. To date, NOVA has successfully been used to manufacture various printed electronic components, such as RFID tags, ceramic PCBs, strain gauges, electrodes on glass, FSR sensors, and FHE circuits.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 304px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701871678248-splash_NOVA.png" style="width: 302px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">The NOVA modular dispensing system.</span></span></span></p><ul><li dir="ltr"><h3 dir="ltr">Direct-Ink-Write Dispensing</h3></li></ul><p dir="ltr">At the core of the NOVA system is Voltera’s direct-ink-write dispensing technology, which eliminates the need for tooling, waste, and extensive cleanup. This approach results in a 90% faster iteration time and a 96% reduction in material costs, highlighting its efficiency and cost-effectiveness.</p><ul><li dir="ltr"><h3 dir="ltr">High-Resolution and Closed-Loop Dispensing</h3></li></ul><p dir="ltr">NOVA offers high-resolution, closed-loop dispensing, which ensures increased material options due to compatibility with a wide range of viscosities. This feature also reduces risk by allowing for the validation of designs and materials in the lab before transitioning to production. The printer achieves consistent results with integrated closed-loop pressure feedback and temperature-controlled dispensing, offering a line width as fine as 100 µm, depending on material properties and nozzle geometry.</p><ul><li dir="ltr"><h3 dir="ltr">Adaptability</h3></li></ul><p dir="ltr">The printer's large, configurable print area of 220 x 300 mm makes it adaptable to various applications. It can handle both rigid and compliant substrates, with a porous titanium vacuum table ensuring uniform suction for flexible and soft substrates. The mounting grid features allow for the development of application-specific fixturing, further enhancing the printer's adaptability.</p><p dir="ltr">With its advanced features and capabilities, NOVA is poised to be a game-changer in the field of printed electronics, offering unparalleled flexibility, efficiency, and innovation in materials and design.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701871716608-application_flexArduino.webp" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Nova enables streamlined research and development with direct-ink-write dispensing.</span></span></span></p><h3 dir="ltr">Case Study: Robotic Hand and Control Glove</h3><p dir="ltr">To demonstrate NOVA's capabilities for flexible electronics, the Voltera team built a robotic hand and a control glove integrated with printed stretchable strain sensors and LED lights. The strain sensors are designed to light up when the glove’s wearer opens or closes their hand, and the brightness of the lights varies depending on the amount of strain on the sensors as the fingers move (i.e. the lights dim when exposed to increased resistance). These strain sensors were cleverly adapted to function as a control mechanism, using the degree of resistance experienced by the glove’s sensor to control the movements of a Bluetooth-connected robotic hand.</p><p dir="ltr">The glove sensors were made by printing traces of DuPont PE874 stretchable ink on a DuPont TE 11-C TPU substrate, which were then heat-laminated onto the glove using a T-shirt press. Then, wires were attached to the glove traces using MG Chemicals 9400 conductive adhesive. Lastly, the robotic hand was 3D printed and integrated with five servo motors to move the fingers. An Arduino, connected via Bluetooth to the glove, controls the robotic hand’s movements based on the glove’s movements. The whole project took only two months to complete.</p><p dir="ltr">Interestingly, strain gauges can be made by printing flexible conductive ink onto almost any stretchable material. The sensor-integrated glove demonstrates how this technology can be applied to a real-world robotics use case. It is also a fine example of how accessible the NOVA system is and how it can be used to develop new ideas and products on a rapid timeline.</p><p dir="ltr">Check out the full case study <a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/6362829f808f8037c5b5e9d9_NOVA-0094%20-%20Robot%20Glove%20Case%20Study_FINAL%20(4).pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">here</a>. In addition, you can also find more case studies on <a href="https://www.voltera.io/case-studies" target="_blank">Voltera’s website</a>.&nbsp;</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzkzMDM3NzQ4LTE3MDE3OTMwMzc3NDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="587" height="205" class="fr-fic fr-dii"></p></td></tr><tr><td><p dir="ltr">Voltera’s Case Study Robotic Hand and Control Glove. Image credit: <a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/6362829f808f8037c5b5e9d9_NOVA-0094%20-%20Robot%20Glove%20Case%20Study_FINAL%20(4).pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Voltera</a>.</p></td></tr></tbody></table></div><h2 dir="ltr">Future Potential &nbsp;</h2><p dir="ltr">The adaptability, robustness, and versatility of flexible, stretchable, and conformable electronics will positively impact multiple industries, particularly healthcare and wearables.&nbsp;</p><p dir="ltr">Innovative manufacturing approaches, such as Voltera’s NOVA, enable the industry to advance at a pace unprecedented in electronics.&nbsp;</p><h2 dir="ltr">References</h2><ol><li dir="ltr"><h2><p dir="ltr">Zhao, Y., Kim, A., Wan, G. et al., 2019. “<a href="https://nanoconvergencejournal.springeropen.com/articles/10.1186/s40580-019-0195-0#citeas" target="_blank">Design and applications of stretchable and self-healable conductors for soft electronics</a>”</p></h2></li><li dir="ltr"><p dir="ltr">Global Electronic Services. “<a href="https://gesrepair.com/future-of-flexible-electronic/" target="_blank">The Future of Flexible Electronics</a>”</p></li><li dir="ltr"><p dir="ltr">Voltera. “<a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/6362829f808f8037c5b5e9d9_NOVA-0094%20-%20Robot%20Glove%20Case%20Study_FINAL%20(4).pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Case Study: Robotic Hand and Control Glove with Printed Stretchable Strain Sensors</a>”</p></li><li dir="ltr"><p dir="ltr">Cassiano Ferro Moraes, 2023. “<a href="https://www.wevolver.com/article/flexible-and-printed-electronics-breakthroughs-applications-and-challenges" target="_blank">Flexible and Printed Electronics: Breakthroughs, Applications, and Challenges</a>”</p></li><li dir="ltr"><p dir="ltr">Guang Z., Wei Q., Tiejun Z. et al., 2014. “<a href="https://pubs.acs.org/doi/10.1021/nl5005652" target="_blank">Self-Powered, Ultrasensitive, Flexible Tactile Sensors Based on Contact Electrification</a>”</p></li><li dir="ltr"><p dir="ltr">Karsten S., Nils N. and Martin S., 2019. “<a href="https://sci-hub.se/https://www.cambridge.org/core/journals/mrs-communications/article/abs/flexible-stretchable-conformal-electronics-and-smart-textiles-environmental-life-cycle-considerations-for-emerging-applications/9941A32DFC15BDE532DCB830C920AE2E" target="_blank">Flexible, stretchable, conformal electronics, and smart textiles: environmental life cycle considerations for emerging applications</a>”</p></li><li dir="ltr"><p dir="ltr"><a href="https://www.sciencedirect.com/science/article/abs/pii/B9780128126400000056" target="_blank">Qing-Hua Lu, Feng Zheng, 2018. “Polyimides for Electronic Applications</a>”</p></li><li dir="ltr"><p dir="ltr">Corzo D, Tostado-Blázquez G, Baran D. Flexible electronics: status, challenges and opportunities. Frontiers in Electronics. 2020 Sep 30;1:594003.</p></li></ol><p><br></p>

Exploring the transformative journey of flexible electronics and how additive manufacturing is the future.

Beyond Rigidity: The Rise of Flexible Electronics

<p id="isPasted">From this model, 3D objects can be constructed by adding physical materials according to the design specification. As opposed to, say, a machine cutting out or grinding down materials to the required size and shape, 3D printing builds them up. It’s a much more cost-efficient method of production, as nothing is wasted.</p><p>The first industrial uses of 3D printing technology were producing prototypes of a specialised item, or parts in very small batches. While this aspect of 3D printing is still important to industry, its major focus has evolved. 21st-century AM is more interested in the end-use production of new and innovative solutions. Industries like health, energy, automotive and aerospace are looking for more efficient and higher-performing parts. The process is also being incorporated into other manufacturing processes, creating hybrid techniques for conventional processes like injection moulding.</p><h2>3D Printing Trends</h2><p>3D printing has reached a point where it’s likely to be industrialised on a large scale. As the technology evolves, it’s important to take stock of its developments and direction. Some key trends outline the current industrial uses of 3D printing, and what its manufacturers and users hope to do with it in the future. These key trends include:</p><ol><li>Bringing 3D printing in-house</li><li>Stronger focus on designing/printing spare parts</li><li>Using 3D printing with other manufacturing techniques (hybrid manufacturing)</li><li>Improvements in speed and accuracy</li></ol><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701421075788-1701421075788.png" alt="3d Printing Trends" class="fr-fic fr-dii"></p><h3>BRINGING 3D PRINTING IN-HOUSE</h3><p>Rapid prototyping is still one of 3D printing’s most widespread uses. No other technology can match its ability to produce high-quality prototypes, quickly and cost-efficiently. These can serve both visual and functional purposes, like testing and evaluation. Using an in-house 3D printer enables product designers and engineers to generate prototypes from 3D models. You can then comprehensively evaluate and test these prototypes, easily integrating changes and quickly printing new iterations.</p><p>With the agility of 3D printing, your product development methods will be transformed. In-house prototyping can dramatically reduce your production lead times. At the same time, you know that your engineers have modified the design continuously until they’ve achieved the best possible part design. You’ll also save time previously wasted in waiting for third-party manufacturers and shipping.</p><h3>STRONGER FOCUS ON DESIGNING/PRINTING SPARE PARTS</h3><p>Using 3D printing, you can leverage digital inventories to print spare parts on demand. You no longer need to order and store replacement parts, but simply print them when and where you need them. In addition, you can also replicate rare or&nbsp;<a href="https://www.rowse.co.uk/blog/post/3d-printing-obsolete-parts" title="3D Printing Obsolete Parts" target="_blank">obsolete parts</a>, without any necessity to invest in costly tooling. 3D printing will revolutionise your spare parts production, cutting down or entirely eliminating inventory and warehousing costs, long lead times and complex logistics.</p><p>3D printing is also opening up a lot of new industrial applications with its ability to use new and diverse materials. It’s no longer confined to the low-grade plastics that were appropriate for prototyping, You can now expand production viability and versatility with 3D printing of metals, ceramics, industrial-grade plastics, alloys and composites. These materials are critical to discovering new high-performance applications, as they are continuously being developed for specific AM processes.</p><h3>USING 3D PRINTING WITH OTHER MANUFACTURING TECHNIQUES (HYBRID MANUFACTURING)</h3><p>As the technology matures, many manufacturers are beginning to recognise the benefits of combining 3D printing with conventional methods. Each can complement the other, to enhance the overall efficiency of the production process. For example, you can hybridise traditional manufacturing processes like machining with 3D printing. One way is to print your near-net-shape parts, and finish them off with CNC machining to achieve tight tolerances.</p><p>Another innovative hybrid is found in injection moulding, by printing a 3D mould in a soluble material. Once the prototype has been injected and set into the mould, the printed material dissolves, leaving just the finished item. In this way, you can combine the benefits of the two processes into a single, more efficient hybrid. Injection moulding offers high quality, material versatility and minimal post-processing. 3D printing offers greater cost efficiency and design freedom for small-scale production.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1701421075661-1701421075661.png" alt="3D Printing Trends" class="fr-fic fr-dii"></p><h3>IMPROVEMENTS IN SPEED AND ACCURACY</h3><p>The main advantage of AM is that you don’t need any tooling – but 3D printing speed is still an issue. Although it’s usually faster to print a single unit or small batch than making them by traditional methods, the same doesn’t apply for larger-scale operations. Once you start scaling up production volumes, the time it takes for printing is a negative factor. However, system developers are working to improve build times by optimising printing parameters. This means they’re tackling issues like printhead or laser speed, plus altering stacking and print bed orientations. They’re also introducing more automation to post-processing steps, which in the past have been mostly completed by hand. This not only makes them much faster, but more efficient.</p><p>In the past, there has also been some discrepancy in the specifications laid down in the CAD model and the printed result. This is largely because the pinpoint accuracy of the design measurements couldn’t always be materially replicated, particularly on curved surfaces. Advances in AM research have altered the approach to incorporate options like variable layering, to accommodate different material thicknesses. Programmable robots can also prescribe and measure the accuracy of the printing while it’s in progress, and make alterations to correct errors as they occur. A similar idea is Warp-Adapted-Modelling (WAM), which uses data from an initial prototype to identify errors before producing an amended model.</p><h3>NEW MATERIALS AND APPLICATIONS</h3><p>3D printing has expanded considerably since its invention in the 1980s, both in its technologies and its applications. Industry focus today is increasingly on applications that really exploit its capabilities. AM is moving into an area where even large items like bridges and houses can be printed, using fibre-reinforced extrusion or wire-arc technologies. Innovative new materials are being discovered and adapted to the method, and accuracy and speed are improving.</p>

3D printing has made huge advances in the last 40 years. Officially known as additive manufacturing (AM), this technology starts out with a digital 3D model – hence its more common name.

4 3D Printing Trends

<p><em>This is the second article in a new series about FGF 3D Printing.&nbsp;</em><a href="https://www.wevolver.com/article/fused-granulate-fabrication-fgf-unlocking-the-full-potential-of-additive-manufacturing" target="_blank" rel="noopener noreferrer"><em>Read the first article here.</em></a></p><h2 id="isPasted">What is FGF?</h2><p>Fused Granulate Fabrication is an extrusion-based additive manufacturing method that utilizes granular materials (pellets), typically plastics or composites, as the primary feedstock for printing. It uses a heated nozzle to melt and extrude the granules layer by layer, enabling the creation of intricate and customized objects. What sets FGF apart from other 3D printing methods is its versatility, as it can effectively utilize a wide range of commercially available plastic or composite granulates. This feature makes FGF a cost-effective and easily scalable option with numerous applications.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxMDkwNzY2MTI4LTE2OTQ2Nzc5OTM0MTAuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"></p><p id="isPasted">FGF is an emerging technology which stands out with its precise, high-speed plastics extrusion capability compared to fused filament fabrication (FFF). FGF's distinguishing feature lies in its versatility, as it accommodates a wide range of materials. However, this flexibility demands a more intricate printing process, necessitating custom process settings for different materials. This means that material processability requires a deeper technical understanding compared to Fused Filament Fabrication.</p><hr><h2 dir="ltr" id="isPasted">Ready to explore the possibilities of 3D Printing Fused Granulate Fabrication (FGF) for your product or application?</h2><p dir="ltr">The 3D Printing Fused Granulate Fabrication Engineering Challenge invites startups, scaleups and innovative companies to explore the possibilities of 3D Printing with granulates (pellets) and win $25,000 in manufacturing and business support to scale their projects.</p><p dir="ltr"><a href="https://growthgarage.mcgc.com/our-programs/engineering-challenges/3d-printing-fgf-engineering-challenge?utm_source=Wevolver&utm_medium=Engineering+Challenge&utm_campaign=3DP+FGF&utm_content=LP" target="_blank" rel="nofollow" class="button-main-action">LEARN MORE HERE</a></p><p dir="ltr">If you're looking to explore this emerging technology for your part, product, or application, or want to combine it with composites through hybrid manufacturing technologies, the 3D Printing FGF Engineering Challenge presents a great opportunity.&nbsp;</p><hr><h2>The printing process</h2><p>A typical FGF 3DP process comprises a screw and barrel system, akin to those used in traditional extrusion and injection molding. Dry material in pellet form is loaded into a hopper, then conveyed to an extrusion screw. The screw's rotation propels the material through multiple heating zones, gradually heating and melting it (in the extruder) as it approaches the extrusion nozzle. As pressure builds up in the extruder, the material is extruded through the nozzle, conforming to the predefined geometry set in the 3DP software.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxMDkwNzgwOTg3LTE2OTQ2NzgwNDA2NjkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner">Source: MCG Netherlands R&amp;D and 3D printlab</span></span></span></p><h2 id="isPasted">High material flexibility introduces additional process variables</h2><p>To maintain a consistent printing process, it's crucial to control specific factors. For example, pellet size and geometry dictate material flow within the extrusion system. Smaller pellets generally result in smoother extrusion and improved layer adhesion, but overly small pellets may struggle to feed consistently through the extruder. Conversely, pellets of varying sizes and irregular geometry can cause flow variations and uneven extrusion.</p><p>Moisture content in pellets, affecting their dryness, may also impact print quality. Excessive moisture can lead to gas bubble formation during material melting prior to extrusion, disrupting material flow through the nozzle, and causing irregularities in the final part, including structural weaknesses and surface deformities due to poor layer adhesion. Precise control of the gradual heating zones within the extruder is essential to ensure safe and consistent material flow.</p><p>The advantage of using 3D printing with FGF is its ability to produce medium to large sized near net parts which are structurally sound and at significantly high print speeds (compared to filament-based 3D printing).</p><h2>Types of machines for large-scale additive manufacturing (LSAM) with FGF</h2><p>In the industry, there are two primary types of machines used to facilitate LSAM using FGF. a) <strong>Robot based systems</strong> b) <strong>Gantry based systems</strong></p><h3>Robot based systems</h3><p>These systems utilize a freely moving robotic arm to enable larger build sizes, with the build geometry's scope determined by the arm's reach.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxMDkwODE2MjI1LTE2OTQ2Nzk4Mjc4MzUuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner">Source: Autodesk</span></span></span></p><p id="isPasted">A robotic arm setup is more commonly used for printing large scale objects. The advantage of this setup stems from the additional flexibility of motion. This enables it to print large objects such as automotive setup, full-scale furniture, houses and more. Additionally, a robot-based system is well-suited for handling highly complex geometries.</p><p>However, this technology has its own limitations. The setup of a robot 3D printer can be quite costly and demands additional technical expertise and know-how.</p><h3>Gantry based systems</h3><p>In a gantry system, the printing area is fixed within the frame of the rails and drives, and the printer head's motion is guided along this fixed structure. This system excels when dealing with fixed geometries, especially those with a hollow structure.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxMDkwODM3MDM2LTE2OTQ2Nzk4NzQxMTUuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib"><span class="fr-inner">Source: Innotech Europe, ExFlow3D Printer</span></span></span></p><p id="isPasted">The gantry system is the most commonly used type of 3D printer due to its cost-effectiveness in printing compared to a robotic arm. It is also more affordable and easier to set up and maintain, while delivering higher printing speeds and increased accuracy.</p><p>The limitation of a gantry-based system stems out of a restricted freedom of design. It is better suited for printing small to medium-sized objects.</p><p>As evident from the sections above, robotic arm printing offers a significant advantage for printing multi-axial toolpaths. This further leads to a complicated toolpath control software, making it more expensive than gantry printing. For more information, read this <a href="https://ceadgroup.com/large-scale-3d-printing-robot-vs-gantry-systems/" target="_blank" rel="nofollow noopener">article</a> from our 3DP FGF partner CEAD Group.</p><h2>Fused Granulate Fabrication’s (FGF) edge over Fused Filament Fabrication (FFF)</h2><p>FFF or Filament 3D printing is a popular additive manufacturing technique that also employs a hot extrusion of a thin wound filament which is uncoiled and deposited layer by layer on a predefined printing path.</p><p>However, FGF has a distinct advantage over FFF in the versatility of material selection and ability to produce large scale parts. Materials with high stiffness are difficult to be wound on a spool as filament, since bending in coils will eventually break it. In case of flexible materials, the extruders are unable to grip the filament. Filaments below 70 Shore A hardness (More about: <a href="https://www.xometry.com/resources/materials/shore-a-hardness-scale/" target="_blank" rel="nofollow noopener">Shore hardness</a>) are almost impossible to print. However, for pellets with materials of 25 Shore A hardness can also be printed with ease.</p><p>Furthermore, the need for additional process of winding the material in a filament coil is completely eliminated in FGF which lowers the total material cost.</p><h2>In conclusion,</h2><p>FGF is progressively unlocking new possibilities for creating large scale, complex part designs with a high degree of freedom for material selection. This empowers engineers to craft more precise and customized geometries, offering greater design freedom to meet market demands.</p><p id="isPasted">At MCG, we provide FGF material grades suitable for both types of systems. In collaboration with our partners, we offer tailored solutions based on specific requirements.</p><p>Stay tuned for the next article in this series, where we will delve into the different material grades in our portfolio that can elevate your product or part with Fused Granulate Fabrication (FGF).</p><hr><h2 dir="ltr" id="isPasted">Ready to explore the possibilities of 3D Printing Fused Granulate Fabrication (FGF) for your product or application?</h2><p dir="ltr">The 3D Printing Fused Granulate Fabrication Engineering Challenge invites startups, scaleups and innovative companies to explore the possibilities of 3D Printing with granulates (pellets) and win $25,000 in manufacturing and business support to scale their projects.</p><p dir="ltr"><a href="https://growthgarage.mcgc.com/our-programs/engineering-challenges/3d-printing-fgf-engineering-challenge?utm_source=Wevolver&utm_medium=Engineering+Challenge&utm_campaign=3DP+FGF&utm_content=LP" target="_blank" rel="nofollow" class="button-main-action">LEARN MORE HERE</a></p><h2 dir="ltr">Who can enter?</h2><p dir="ltr">We are inviting innovative startups, scaleups, and established companies that are:</p><ul><li dir="ltr"><p dir="ltr"><strong>Inexperienced with 3D Printing</strong> and wish to explore the possibilities with 3D Printing FGF for prototyping or small series production.&nbsp;</p></li><li dir="ltr"><p dir="ltr"><strong>Experienced with 3D Printing (FFF)</strong> and are interested in testing, implementing, and switching to FGF.&nbsp;</p></li><li dir="ltr"><p dir="ltr"><strong>Experienced with 3D Printing&nbsp;</strong>that seek to integrate FGF with hybrid technologies like continuous carbon-fiber-based composites.</p></li></ul>

In the second article of our FGF series we look at the various manufacturing techniques of FGF printing

Fused Granulate Fabrication (FGF): Redefining large scale 3D Printing with a wide range of materials

Interview with Misha Govshteyn, the CEO of MacroFab and 
Brenden Duncombe, the Director of Customer Engineering. 

2023 Autonomous Vehicle Report Interview: The Role of PCB in Shaping Autonomous Vehicle Development

Gerber File Schematic in PCB Manufacturing

This article provides an in-depth view of Gerber files, including their origin, structure, and role in PCB design and manufacturing processes.

What are Gerber Files? Understanding the Blueprint of Electronics Manufacturing

<p id="isPasted">Innovation in manufacturing is a continuous journey, and as <a href="https://www.apsx.com/desktop-injection-molding-machine" target="_blank" rel="noopener noreferrer">APSX-PIM</a> owners, you stand at the forefront of this evolution. Today, we invite you to explore the convergence of traditional injection molding with the cutting-edge realm of Freeform Injection Molding (FIM) using <a href="https://nexa3d.com/digital-tooling/fim-package/" target="_blank" rel="noopener noreferrer">Nexa3D</a> printers, which promises to revolutionize your production capabilities.</p><p><img data-fr-image-pasted="true" src="https://www.apsx.com/images/uploaded/PIM-FIM%20Blog%201.png" alt="APSX-PIM nexa3D FIM " width="750" height="750" class="fr-fic fr-dii"></p><h2><strong>Elevating Precision, Speed, and Complexity</strong></h2><p>Nexa3D printers stand out for their unparalleled precision and ability to produce intricate parts with unparalleled complexity. This technology opens doors to creating molds with finely detailed features, delicate textures, and intricate geometries, previously unattainable using conventional methods.</p><p><img data-fr-image-pasted="true" src="https://www.apsx.com/images/uploaded/PIM-FIM%20Blog%202.png" alt="APSX-PIM FIM package" width="750" height="750" class="fr-fic fr-dii"></p><p><strong>Case Study: Automotive Industry</strong><br>Consider the automotive sector, where the demand for lightweight, intricately designed parts is ever-increasing. With FIM, APSX-PIM owners can swiftly iterate and manufacture complex molds for vehicle components, reducing lead times and enhancing design innovation.</p><h2><strong>Rapid Prototyping and Iteration: Catalyzing Innovation</strong></h2><p>One of the hallmark advantages of integrating Nexa3D printers with APSX-PIM is the ability to accelerate prototyping and iteration cycles. This synergy empowers manufacturers to swiftly test new designs, modify molds in real time, and refine prototypes iteratively.</p><p><img data-fr-image-pasted="true" src="https://www.apsx.com/images/uploaded/PIM-FIM%20Blog%203.png" alt="nexa3D printed molds on the APSX-PIM" width="750" height="750" class="fr-fic fr-dii"></p><p><strong>Case Study: Medical Devices</strong><br>In the medical device industry, speed to market can be critical. FIM allows for rapid prototyping of intricate molds, facilitating the development of medical-grade components with precise specifications, and ensuring compliance and efficacy.</p><h2><strong>Cost-efficiency and Material Optimization</strong></h2><p>FIM with Nexa3D printers offers not just agility but also cost-efficiency. Additive manufacturing capabilities minimize material waste by utilizing only the necessary resources for each mold iteration, aligning with sustainability goals and reducing production costs.</p><p><strong>Case Study: Consumer Electronics</strong><br>In the world of consumer electronics, where design and functionality converge, FIM enables APSX-PIM owners to create molds for intricate casings, connectors, and components, optimizing material usage while ensuring high precision.</p><h2><strong>Seamless Integration: Streamlined Workflow</strong></h2><p>The integration process between Nexa3D printers and APSX-PIM machines is seamless. From designing parts using CAD software to printing molds with Nexa3D and utilizing them in APSX-PIM for injection molding, the workflow is intuitive, enabling a streamlined and efficient manufacturing process.</p><p><strong>Visual Representation of the FIM Process</strong></p><p><img data-fr-image-pasted="true" src="https://www.apsx.com/images/uploaded/PIM-FIM%20Process.png" alt="PIM-FIM Process" width="750" height="375" class="fr-fic fr-dii"></p><h2><strong>Embrace the Future of Manufacturing Today!</strong></h2><p>APSX-PIM owners possess the fundamental tool for precision injection molding. By harnessing the capabilities of Nexa3D printers for FIM, you are poised to expand your manufacturing horizons, unlocking unlimited design possibilities, speed, and efficiency.</p>

We invite you to explore the convergence of traditional injection molding with the cutting-edge realm of Freeform Injection Molding (FIM) using Nexa3D printers, which promises to revolutionize your production capabilities.

Maximizing APSX-PIM Capabilities: Unleashing Freeform Injection Molding (FIM) with Nexa3D Printers

<h2 data-mce-fragment="1" id="isPasted"><strong>3D PROMAKIM</strong></h2><p data-mce-fragment="1">A renowned name in Turkey’s digital production landscape, 3D Promakim offers solutions spanning from Digital Printing to Industrial Additive Manufacturing Systems.</p><p data-mce-fragment="1">&nbsp;3D Promakim isn’t just a reseller; they’re a solution provider. With a diverse clientele including giants like Mercedes Benz, Rocketsan, Bosch, and Turkish Aerospace Industries, they’ve cemented their reputation in sectors ranging from automotive to aerospace.</p><p data-mce-fragment="1">Their mission? To ensure that sectors from automotive to aerospace and&nbsp;defence receive unparalleled technical training, unwavering post-sales support, and a guarantee of impeccable print quality.</p><h2 data-mce-fragment="1"><strong>THE INTRICACIES OF MATERIAL HANDLING</strong></h2><p data-mce-fragment="1">3D Promakim grappled with a complex material management challenge. Each year, over 20 spools of valuable materials were left untouched, primarily because once a spool was opened and not entirely used, it was exposed to ambient conditions. <a href="https://www.wevolver.com/article/hydration-and-drying-challenges-of-nylon-3d-printing-filaments" target="_blank" rel="noopener noreferrer">Even brief exposures to humidity, as short as 15 minutes, could compromise the material’s quality, rendering it virtually unusable for high-quality prints</a>.</p><p data-mce-fragment="1"><span class="fr-img-caption fr-fic fr-dib" style="width: 657px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAwMTU1Mzc3NzI1LVNjcmVlbnNob3QgMjAyMy0xMS0xNiBhdCAxOC4yMi4yOC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 655px;" class="fr-fic fr-dib"><span class="fr-inner">ime it takes for filament of different diameter in different humidity environment e.g. 75% relative humidity vs 50% relative humidity to reach certain moisture level starting from 0.3 w% and how visible are the defects.&nbsp;</span></span></span></p><p data-mce-fragment="1">In their quest to salvage these materials, <a href="https://www.wevolver.com/article/drying-your-fdm-filaments-and-keeping-them-dry-an-overview" target="_blank" rel="noopener noreferrer">3D Promakim explored a plethora of drying solutions</a>. They experimented with various off-the-shelf solutions, from vacuum bags with desiccants to more sophisticated drying techniques. However, these attempts often led to inconsistent results, with the processed material still falling short of the desired quality.</p><p data-mce-fragment="1">Further exacerbating their challenges, the importation of materials to Turkey presented another hurdle. Customs checks often meant that spools were opened for inspection, exposing them to the country’s humid environment. This seemingly routine procedure, had a cascading effect on material quality.</p><p data-mce-fragment="1">The combined financial toll of these import-related losses and in-house wastage amounted to a staggering 12,000 Euros annually. But 3D Promakim wasn’t alone in this struggle. Their clientele, many of whom are leaders of industries where precision is non-negotiable, echoed similar challenges. For these clients, any material exposed to humidity for more than 15 minutes was often deemed a loss, highlighting the critical nature of the material handling issue.</p><h2 data-mce-fragment="1"><strong data-mce-fragment="1">ULTIMATE MATERIAL&nbsp;</strong><strong data-mce-fragment="1">QUALITY CONTROL</strong></h2><p data-mce-fragment="1">3D Promakim’s dedication to delivering unparalleled quality was being tested. As proud distributors of industry leading Markforged printers and materials, the persistent material handling issues were a significant pain point.</p><p data-mce-fragment="1">These challenges aren’t just about in-house costs; they are about upholding their reputation and ensuring that their clients, many of whom also rely on Markforged printers, receive consistent, high-quality results. A single compromised print could have knock-on effects, from financial setbacks to potential damage to their hard-earned reputation.</p><p data-mce-fragment="1">At Formnext 2022 3D Promakim discovered <a href="https://drywise.co/" target="_blank" rel="noopener noreferrer">Drywise</a>. More than just an in-line drying system, Drywise represents a paradigm shift in material quality control. It doesn’t just dry materials; it ensures they are in optimal condition for printing, regardless of their initial humidity exposure.</p><p data-mce-fragment="1"><span class="fr-img-caption fr-fic fr-dib" style="width: 767px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAwMTU1MTgwODAzLVNjcmVlbnNob3QgMjAyMy0xMS0xNiBhdCAxOC4xOS4wNS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 765px;" class="fr-fic fr-dib"><span class="fr-inner">Key concepts how Drywise functions as an in-line intelligent drying solution that monitors material quality while 3D printing.</span></span></span></p><p data-mce-fragment="1">The results of their rigorous testing of six Drywise units were nothing short of transformative.</p><h2 data-mce-fragment="1" id="isPasted"><strong data-mce-fragment="1">THE VALUE&nbsp;</strong><strong data-mce-fragment="1">DRYWISE BROUGHT</strong></h2><p data-mce-fragment="1">With Drywise, 3D Promakim didn’t just find a solution; they found a partner in excellence. It allowed them to uphold their commitment to quality, ensuring that both their in-house operations and the solutions they provided to their clients were of the highest caliber. With Drywise, 3D Promakim achieved:</p><ul data-mce-fragment="1"><li data-mce-fragment="1"><strong data-mce-fragment="1">Zero material waste -&nbsp;</strong>Zero material waste from in-house projects and imports, saving 12,000 Euros annually.</li><li data-mce-fragment="1"><strong data-mce-fragment="1">Saving Time</strong> - 120 hours per year saved on material handling.</li><li data-mce-fragment="1"><strong data-mce-fragment="1">Superior print quality -&nbsp;</strong>Superior print quality with impeccable surface finish and uncompromised mechanical properties.</li><li data-mce-fragment="1"><strong data-mce-fragment="1">Savings on equipment -&nbsp;</strong> Elimination of the need for specialized storage and handling equipment.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 758px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAwMTU1NjgwOTE5LWltYWdlMiBMYXJnZS5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 756px;" class="fr-fic fr-dib"><span class="fr-inner">3D Promakim using Drywise to dry Onyx material for Markforged</span></span></span></p><blockquote><p data-mce-fragment="1">“Before Drywise, material handling was a time- consuming challenge, with off-the-shelf solutions leading to unreliable results. Drywise streamlined our workflows, saved significant costs, and bolstered our confidence in delivering top-tier print projects on schedule. We now are offering Drywise as the go-to solution for every Markforged customer” Tolga Bolo - Business Development Specialist, 3D Promakim</p></blockquote>

3D Promakim using Drywise to dry Onyx material for Markforged

3D Promakim’s Journey with Drywise and how they save €12,000 per year

Achieving Zero Material Waste in 3D Printing

<p id="isPasted">With 3D inkjet printing systems, engineers can fabricate hybrid structures that have soft and rigid components, like robotic grippers that are strong enough to grasp heavy objects but soft enough to interact safely with humans.</p><p>These multimaterial 3D printing systems utilize thousands of nozzles to deposit tiny droplets of resin, which are smoothed with a scraper or roller and cured with UV light. But the smoothing process could squish or smear resins that cure slowly, limiting the types of materials that can be used.&nbsp;</p><p>Researchers from MIT, the MIT spinout Inkbit, and ETH Zurich have developed a new 3D inkjet printing system that works with a much wider range of materials. Their printer utilizes computer vision to automatically scan the 3D printing surface and adjust the amount of resin each nozzle deposits in real-time to ensure no areas have too much or too little material.</p><p>Since it does not require mechanical parts to smooth the resin, this contactless system works with materials that cure more slowly than the acrylates which are traditionally used in 3D printing. Some slower-curing material chemistries can offer improved performance over acrylates, such as greater elasticity, durability, or longevity.</p><p>In addition, the automatic system makes adjustments without stopping or slowing the printing process, making this production-grade printer about 660 times faster than a comparable 3D inkjet printing system.</p><p>The researchers used this printer to create complex, robotic devices that combine soft and rigid materials. For example, they made a completely 3D-printed robotic gripper shaped like a human hand and controlled by a set of reinforced, yet flexible, tendons.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/mw9hYHoD46o?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-9="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><p id="isPasted">“Our key insight here was to develop a machine-vision system and completely active feedback loop. This is almost like endowing a printer with a set of eyes and a brain, where the eyes observe what is being printed, and then the brain of the machine directs it as to what should be printed next,” says co-corresponding author Wojciech Matusik, a professor of electrical engineering and computer science at MIT who leads the Computational Design and Fabrication Group within the MIT Computer Science and Artificial Intelligence Laboratory (CSAIL).</p><p>He is joined on the paper by lead author Thomas Buchner, a doctoral student at ETH Zurich, co-corresponding author Robert Katzschmann PhD ’18, assistant professor of robotics who leads the Soft Robotics Laboratory at ETH Zurich; as well as others at ETH Zurich and Inkbit. The research appears today in <em>Nature</em>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700105845585-MIT-VisionJetting-02-press.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">The researchers used their printing system to create complex, robotic devices that combine soft and rigid materials. Since the printer has 16,000 nozzles, the system can control fine details of the device being fabricated. This rendering shows objects that have been halfway built by the printer. Credit: Courtesy of the researchers</span></span></span></p><h2><strong>Contact free</strong></h2><p>This paper builds off a low-cost, multimaterial 3D printer known as <a href="https://news.mit.edu/2015/multifab-3-d-print-10-materials-0824" target="_blank">MultiFab</a> that the researchers introduced in 2015. By utilizing thousands of nozzles to deposit tiny droplets of resin that are UV-cured, MultiFab enabled high-resolution 3D printing with up to 10 materials at once.</p><p>With this new project, the researchers sought a contactless process that would expand the range of materials they could use to fabricate more complex devices.</p><p>They developed a technique, known as vision-controlled jetting, which utilizes four high-frame-rate cameras and two lasers that rapidly and continuously scan the print surface. The cameras capture images as thousands of nozzles deposit tiny droplets of resin.</p><p>The computer vision system converts the image into a high-resolution depth map, a computation that takes less than a second to perform. It compares the depth map to the CAD (computer-aided design) model of the part being fabricated, and adjusts the amount of resin being deposited to keep the object on target with the final structure.</p><p>The automated system can make adjustments to any individual nozzle. Since the printer has 16,000 nozzles, the system can control fine details of the device being fabricated.</p><p>“Geometrically, it can print almost anything you want made of multiple materials. There are almost no limitations in terms of what you can send to the printer, and what you get is truly functional and long-lasting,” says Katzschmann.</p><p>The level of control afforded by the system enables it to print very precisely with wax, which is used as a support material to create cavities or intricate networks of channels inside an object. The wax is printed below the structure as the device is fabricated. After it is complete, the object is heated so the wax melts and drains out, leaving open channels throughout the object.</p><p>Because it can automatically and rapidly adjust the amount of material being deposited by each of the nozzles in real time, the system doesn’t need to drag a mechanical part across the print surface to keep it level. This enables the printer to use materials that cure more gradually, and would be smeared by a scraper.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700105876641-MIT-VisionJetting-05-press.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">A photograph shows a variety of 3D-printed objects in white, displayed on a tray. The objects are: a robotic hand, cubes made of lattice structures, a biological heart, and a walking robot. Credit: Courtesy of the researchers</span></span></span></p><h2><strong>Superior materials</strong></h2><p>The researchers used the system to print with thiol-based materials, which are slower-curing than the traditional acrylic materials used in 3D printing. However, thiol-based materials are more elastic and don’t break as easily as acrylates. They also tend to be more stable over a wider range of temperatures and don’t degrade as quickly when exposed to sunlight.</p><p>“These are very important properties when you want to fabricate robots or systems that need to interact with a real-world environment,” says Katzschmann.</p><p>The researchers used thiol-based materials and wax to fabricate several complex devices that would otherwise be nearly impossible to make with existing 3D printing systems. For one, they produced a functional, tendon-driven robotic hand that has 19 independently actuatable tendons, soft fingers with sensor pads, and rigid, load-bearing bones.</p><p>“We also produced a six-legged walking robot that can sense objects and grasp them, which was possible due to the system’s ability to create airtight interfaces of soft and rigid materials, as well as complex channels inside the structure,” says Buchner.</p><p>The team also showcased the technology through a heart-like pump with integrated ventricles and artificial heart valves, as well as metamaterials that can be programmed to have non-linear material properties.</p><p>“This is just the start. There is an amazing number of new types of materials you can add to this technology. This allows us to bring in whole new material families that couldn’t be used in 3D printing before,” Matusik says.</p><p>The researchers are now looking at using the system to print with hydrogels, which are used in tissue-engineering applications, as well as silicon materials, epoxies, and special types of durable polymers.</p><p>They also want to explore new application areas, such as printing customizable medical devices, semiconductor polishing pads, and even more complex robots.</p>

This rendering shows a robot being built layer-by-layer using the new process. The black spheres represent the material that the printer uses. The material is then cured by UV light, represented in blue. At the top of the image are the cameras that scan the procedure and adjust accordingly. Image: Moritz Hocher

Computer vision enables contact-free 3D printing, letting engineers print with high-performance materials they couldn’t use before.

This 3D printer can watch itself fabricate objects

<p id="isPasted">3D printing is advancing rapidly, and the range of materials that can be used has expanded considerably. While the technology was previously limited to fast-curing plastics, it has now been made suitable for slow-curing plastics as well. These have decisive advantages as they have enhanced elastic properties and are more durable and robust.</p><p>The use of such polymers is made possible by a new technology developed by researchers at ETH Zurich and a US start-up. As a result, researchers can now 3D print complex, more durable robots from a variety of high-quality materials in one go. This new technology also makes it easy to combine soft, elastic, and rigid materials. The researchers can also use it to create delicate structures and parts with cavities as desired.</p><h2><strong>Materials that return to their original state</strong></h2><p>Using the new technology, researchers at ETH Zurich have succeeded for the first time in printing a robotic hand with bones, ligaments and tendons made of different polymers in one go. “We wouldn’t have been able to make this hand with the fast-curing polyacrylates we’ve been using in 3D printing so far,” explains Thomas Buchner, a doctoral student in the group of ETH Zurich robotics professor Robert Katzschmann and first author of the study. “We’re now using slow-curing thiolene polymers. These have very good elastic properties and return to their original state much faster after bending than polyacrylates.” This makes thiolene polymers ideal for producing the elastic ligaments of the robotic hand.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/54jg4uduIt0?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span><em>(Video: ETH Zurich / Nicole Davidson)</em></p><p id="isPasted">In addition, the stiffness of thiolenes can be fine-tuned very well to meet the requirements of soft robots. “Robots made of soft materials, such as the hand we developed, have advantages over conventional robots made of metal. Because they’re soft, there is less risk of injury when they work with humans, and they are better suited to handling fragile goods,” Katzschmann explains.</p><h2><strong>Scanning instead of scraping</strong></h2><p>3D printers typically produce objects layer by layer: nozzles deposit a given material in viscous form at each point; a UV lamp then cures each layer immediately. Previous methods involved a device that scraped off surface irregularities after each curing step. This works only with fast-curing polyacrylates. Slow-curing polymers such as thiolenes and epoxies would gum up the scraper.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700105394264-image.imageformat.1286.1632000253.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">The robotic hand is printed layer by layer using polymers of varying elasticity (left: schematic, right: computer graphics). (Visualisations: Buchner TJK et al., Nature 2023)</span></span></span></p><p>To accommodate the use of slow-curing polymers, the researchers developed 3D printing further by adding a 3D laser scanner that immediately checks each printed layer for any surface irregularities. “A feedback mechanism compensates for these irregularities when printing the next layer by calculating any necessary adjustments to the amount of material to be printed in real time and with pinpoint accuracy,” explains Wojciech Matusik, a professor at the Massachusetts Institute of Technology (MIT) in the US and co-author of the study. This means that instead of smoothing out uneven layers, the new technology simply takes the unevenness into account when printing the next layer.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1700105413274-image.imageformat.1286.1443377098.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Other examples of 3D-printing include a legged robot and metamaterials. The latter could be used to absorb vibrations. (Photographs: ETH Zurich / Thomas Buchner)</span></span></span></p><p id="isPasted">Inkbit, an MIT spin-off, was responsible for developing the new printing technology. The ETH Zurich researchers developed several robotic applications and helped optimise the printing technology for use with slow-curing polymers. The researchers from Switzerland and the US have now jointly published the technology and their sample applications in the journal <em>Nature</em>.</p><p>At ETH Zurich, Katzschmann’s group will use the technology to explore further possibilities and to design even more sophisticated structures and develop additional applications. Inkbit is planning to use the new technology to offer a 3D printing service to its customers and to sell the new printers.</p><hr><h2 id="isPasted"><strong>Reference</strong></h2><p>Buchner TJK, Rogler S, Weirich S, Armati Y, Cangan BG, Ramos J, Twiddy S, Marini D, Weber A, Chen D, Ellson G, Jacob J, Zengerle W, Katalichenko D, Keny C, Matusik W, Katzschmann RK: Vision-Controlled Jetting for Composite Systems and Robots, Nature, 15. November 2023, doi: <a href="https://doi.org/10.1038/s41586-023-06684-3" target="_blank">external page10.1038/s41586-023-06684-3</a></p>

3D printed in one go: A robotic hand made of varyingly rigid and elastic polymers. (Photograph: ETH Zurich/Thomas Buchner)

For the first time, researchers have succeeded in printing a robotic hand with bones, ligaments and tendons made of different polymers using a new laser scanning technique.

Printed robots with bones, ligaments, and tendons

<p id="isPasted">3D Point, a 3D printing service bureau based right outside of Berlin, Germany, is fast becoming the go-to for many companies needing to produce parts in large volumes. Although still a young company, having been founded in 2020 by Dieter Fischer and Stefan Wenzel, 3D Point has been receiving orders nearly nonstop from local customers as well as manufacturing and industrial companies across Germany, Austria, Switzerland, and beyond. Some of their biggest customers include large manufacturing companies supplying the automotive and railway industries.</p><p>To provide the best service to their customers, Stefan and Dieter employ an army of 60 3D printers, which utilize a mix of FDM, SLA, and SLS technologies. Half of them are the popular UltiMaker S series. The company has a mix of S5 and the recently launched S7 printers.</p><p>“I have been using UltiMaker printers for 10 years, so I know how reliable the machines are,” said Stefan. “When I was at P&amp;G, we used them in the additive manufacturing department to print spare parts for the Gillette production line. We were printing thousands of parts, and the printers really exceeded our expectations.”</p><h2>Keeping productivity high</h2><p>At 3D Point, the team of three use the S series printers for different applications, but primarily replacement parts in series for companies, which vary from 300 to 5,000 pieces per order. 3D Point’s customers have 3D printing in-house, but do not have the capacity to print parts in large quantities. That is when customers outsource their production to the company.</p><p>With orders this large, Stefan needs to ensure that there is little to no down time. A broken printer could mean major delays for his team, and, in turn, for their customers.</p><p>“UltiMaker printers are very user-friendly, and hardly require any maintenance or repairs. The machines have good firmware and the regular updates are efficient,” said Stefan. “At 3D Point, the printers are working almost nonstop. If there is an issue, we get serviced by UltiMaker’s channel partner Igo3D. They are local, fast, reliable, and can get the machine back up and running in no time.” Igo3D is UltiMaker’s channel partner and representative for Germany, Austria &amp; Switzerland.</p><p>The S5’s compact size also allows Stefan to stack them all on shelves against one wall without taking too much space within the print farm, compared to traditional industrial machines or other desktop 3D printers. At the same time, the S5, as well as the S7, offers a large enough build volume that allows 3D Point to keep up with demand or to print larger parts as needed.</p><p>“I am excited about the new S7. We have been using it and have found that the bed leveling has improved and is better and more advanced than the S5. In addition, the PEI coated flex plate is the best I have ever experienced in the market. The first layer sticks to it better with no warping and parts come off the plate easier. The S series overall has been a fantastic product line,” said Stefan.</p><p>“The factors that are important for a service bureau are ensuring that setting up a print job is easy and that each print should be first time right. We are fulfilling orders constantly so any issues that delay us–whether it is iterating on design or having technical issues–will affect our business as a whole,” Stefan continued.</p><h2>Printing in a safe and secure environment</h2><p>An important aspect for 3D Point was the S5’s open materials platform, which provides the team with flexibility to meet the different needs of their customers. While they mostly use UltiMaker materials, sometimes customers have specific materials requirements. As a result, they have the option to utilize the UltiMaker Marketplace, which opens them up to hundreds of third-party materials from which to choose, including BASF Forward AM’s Ultrafuse, PolyTerra™ from Polymaker, Extrudr GreenTEC, and more.</p><p>Although they work in a print farm which already has a strong ventilation system for 60 printers, Stefan notes that the UltiMaker Air Manager is a great added value when it comes to ensuring better air quality in the space. Some materials require a closed system when printing to ensure that the materials print properly. But that means more particulates are swirling in the air. The Air Manager not only keeps the temperature inside the build chamber more consistent, it also helps to filter the air to reduce particulates.</p><p>Data security is also a top priority for the 3D Point team. “Another key reason for using UltiMaker is the security certification ISO/IEC 27001 for its software, an internationally recognized standard for information security management. We prefer a closed system for IT data, which is essential for the protection of intellectual property. There are strict laws in place in The Netherlands as well as the European Union that prevent the misuse and mishandling of data. As a European company, UltiMaker takes the security of its customers’ data seriously. We feel better knowing that our and our customers’ data are protected with UltiMaker,” stated Stefan.</p><p>Headquartered in The Netherlands, UltiMaker is in strict compliance with the European Union General Data Protection Regulation (GDPR), a comprehensive privacy legislation that protects personal data and the movement of data for all European citizens, and the Dutch Personal Data Protection Act, which governs what may or may not be done with personal data.</p><h2>The future of the print farm</h2><p>3D Point is preparing to print metal on the UltiMaker printers. With requests for metal parts coming in, it has been something that Stefan has been working towards.</p><p>“We have the knowledge of printing in-house, we have software and design expertise, we have material knowledge on the Ultrafuse 17-4 and 316L, we have a close relationship with a sinter and debinding company. And on top, we are investing in post-processing, such as polishing (diamant) and laser engraving. We are ready,” Stefan concluded.</p>

3D Point, a 3D printing service bureau based right outside of Berlin, Germany, is fast becoming the go-to for many companies needing to produce parts in large volumes.

3D Printing Service Bureau Startup Keeps Customers Productivity High with UltiMaker 3D Printers

<p id="isPasted"><a href="https://xometry.eu/en/vacuum-casting/" target="_blank">Vacuum casting</a>, also called urethane casting, is a manufacturing process used to create small quantities of high-quality plastic or metal parts. It involves creating a mould of the desired part and then injecting liquid plastic or metal into the mould under a vacuum. This creates a uniform and detailed part with an excellent surface finish and dimensional accuracy.</p><p>Let’s see what are the fundamentals of vacuum casting, its applications and its limitations.</p><h2><strong>What is vacuum casting?</strong></h2><p>Casting is a manufacturing process in which a liquid material is poured into a mould and allowed to solidify. Vacuum casting involves using a vacuum to remove air from the mould, which helps ensure that the object takes on the desired shape.</p><p>This process is often used for casting plastics and rubber parts. Vacuum casting is often used for prototype projects or small-scale production runs, as it can be faster and less expensive than other methods, such as <a href="https://xometry.eu/en/injection-moulding-technology-overview/" target="_blank">injection moulding</a>.</p><p>The main advantage of vacuum casting is that it allows for high accuracy and repeatability, making it an ideal choice for applications where precise dimensions are critical. It also allows for more intricate designs to be cast. However, vacuum casting is not suitable for all applications. For example, it cannot be used to cast materials that are sensitive to heat or pressure.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699957271237-Urethane-Casting-Opaque-Elastomer-Material_4581-scaled-1-768x512.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Vacuum cast part next to its silicone mould</em></span></span></span></p><h2 id="isPasted"><strong>How does vacuum casting work?</strong></h2><p>Vacuum casting, like conventional injection moulding, needs a mould tool with a cavity shaped like the finished object. In contrast to injection moulding, vacuum casting uses silicone moulds rather than hard metal ones.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699957298656-Vacuum-Casting-Process.webp" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner">Illustration of the vacuum casting process (Source: ProtoZone)</span></span></span></p><h3 id="isPasted"><strong>Step 1: Create a 3D model</strong></h3><p>As with most contemporary manufacturing processes, the first step is to create a 3D model of the desired form. To get the best results, objects intended for vacuum casting should be made following injection moulding principles. Any design software such as AutoCAD, Solidworks, or CATIA can be used for this purpose.</p><h3><strong>Step 2: Create a master pattern</strong></h3><p>The 3D model is then used to draft a high quality master model. Previously, CNC machining was used to make them, but now additive manufacturing can do the job quickly. With the advent of 3D printing technology, the pattern maker’s role has become more practical and affordable. On the other hand, a cast model that can serve as the master pattern can be utilised without any further modification.</p><h3><strong>Step 3: Make the silicone mould</strong></h3><p>Following the development of the master pattern, a mould is cast. The master pattern, complete with casting cores, inserts, and gates, is hung in a casting box. The formed way is placed in a vacuum casting box, and liquid silicone is poured around it, filling in all the details. This is then put into a preheated oven at 40°C for 8-16 hours to cure. Timing is subject to variation based on the dimensions of the silicone mould.</p><p>The box and the risers come out after the silicone has dried and set. To finish, the negative form cavity of the component is exposed by delicately splitting the mould with a knife. Stickiness and surface flaws can be avoided with careful selection and application of the <a href="https://en.wikipedia.org/wiki/Release_agent" target="_blank">mould-release agent.</a></p><h3><strong>Step 4: Mixing</strong></h3><p>Before mixing, polyurethane resins used for casting are typically heated to about 40°C. To use the machine, a two-component casting resin and any desired colourant are combined in precise quantities and poured into a bowl. The mould is then placed back in place, and the pouring gates are attached to the mixing and pouring vessel.&nbsp;</p><p>Vacuum casting resins and colour pigments are thoroughly mixed and deaerated for 50-60 seconds in a vacuum during the auto-pouring process. Next, a vacuum is created in the mould, and the resin is poured inside. By eliminating the air pockets inside the tool, which would otherwise act as an obstacle to flow, vacuum technology makes it possible for gravity to do all the work in filling the mould.</p><h3><strong>Step 5: Demoulding the parts</strong></h3><p>After the resin has been poured into the mould, it is heated in a curing room until hard. Casting can be taken out of the mould when it has hardened. When the casting is complete, the gate and risers can be removed, and any last finishes performed.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/gZnQu3N5SEg?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted"><strong>Technical specifications of vacuum casting</strong></h2><p>Vacuum casting is a process that uses a vacuum to remove the air from the mould. This leaves a smooth surface on the castings and results in minimal defects. It is often used for small parts and thin-walled parts. Some general specifications of the process are the following:</p><figure><table><tbody><tr><td><strong>Materials</strong></td><td>A wide variety of materials can be used (plastic, rubber)</td></tr><tr><td><strong>Lead time</strong></td><td>10-20 days</td></tr><tr><td><strong>Minimum wall thickness</strong></td><td>0.75 mm, but 1.5 mm is recommended</td></tr><tr><td><strong>Quantity</strong></td><td>1-20 per mould</td></tr><tr><td><strong>Surface quality</strong></td><td>Glossy or matt</td></tr></tbody></table></figure><h2><strong>General applications of vacuum casting</strong></h2><p>Vacuum casting is a versatile process with many applications in different industries. The ability of the process to create intricate and precise components makes it an ideal choice for high-quality results.</p><ul><li><strong>Medical implants:</strong> Vacuum casting is widely used in the medical industry to fabricate complex parts and components. It can be used to make implants and prosthetics.</li><li><strong>Automotive industry</strong>: Automotive parts are often manufactured through vacuum casting due to the process’s ability to create highly detailed components. Automobile parts such as intake manifolds, exhaust systems, and body panels can benefit from the superior accuracy and repeatability of silicone vacuum casting.</li><li><strong>Food Industry</strong>: The process is often used to manufacture intricate parts for the food industry. It can create moulds, packaging components, and other complex shapes needed in food production operations.&nbsp;</li><li><strong>Aerospace components</strong>: This process can be used to fabricate precision aerospace components. Due to its superior accuracy, repeatability, and ability to create intricate detail, components such as air ducts, fuel systems, and even some parts of aeroplanes’ exteriors are often created through vacuum casting.&nbsp;</li><li><strong>Consumer goods</strong>: Vacuum casting can manufacture complex consumer goods such as toys and sporting equipment. The process can create highly precise parts that are perfect for consumer use.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699957360970-Copy-of-Xometry_Photos_Parts_UrethaneCasting-768x576.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Vacuum cast black walkie-talkies</em></span></span></span></p><h2 id="isPasted"><strong>Advantages of vacuum casting</strong></h2><p>The vacuum casting process has a wide range of usage in the industry. In industry, it is commonly used for low-volume production of prototypes or production parts. This production process offers several advantages over other methods of <a href="https://xometry.eu/en/rapid-prototyping/" target="_blank">rapid prototyping</a> and manufacturing.</p><ul><li><strong>Fine details</strong>: One advantage of the vacuum casting process is its ability to produce parts with fine details. The mould is formed using the 3D printed master model. The 3D printing process can produce intricate details, which can be replicated in the final cast.</li><li><strong>Low cost</strong>: Another advantage of vacuum casting is its relatively low cost. Vacuum casting is much less expensive than other rapid prototyping methods, such as CNC machining. This is because it requires only a few hours to produce a mould, which can be reused multiple times. CNC machining requires costly tools and materials.</li><li><strong>Dimensional accuracy</strong>: The vacuum casting process produces parts with excellent dimensional accuracy. The parts produced via vacuum casting will fit together perfectly without needing post-processing steps such as sanding or drilling.</li><li><strong>Flexibility</strong>: It provides a high degree of design flexibility. This is because almost any geometry can be created using 3D printing. As a result, parts that would be impossible to produce using other methods can be easily made using vacuum casting.</li></ul><h2><strong>Limitations of vacuum casting</strong></h2><p>Despite all its advantages, this process has several limitations that should be considered before starting a project:</p><ul><li>The process is only suitable for specific materials</li><li>The prototype quality can be affected by the type of mould used</li><li>Shrinkage may cause parts to become too thin or too thick</li><li>The process is relatively slow, so it may not be suitable for large-scale production runs</li><li>The process is not suitable for high-temperature applications.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699957386500-20210428_Edit4_-ISOLAB-TECHNOLOGIES-LLC-Urethane-Cast-Carousel-copy-768x576.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Coloured vacuum cast parts</em></span></span></span></p><h2 id="isPasted"><strong>Vacuum casting vs. injection moulding</strong></h2><p>Vacuum casting is an excellent option if you’re looking for a quick, easy, and cost-effective way to produce high-quality plastic parts. Injection moulding is another popular method for manufacturing plastic parts. Unlike injection moulding, vacuum casting does not require a DFM process, and thus allows to save project time.</p><p>When choosing a manufacturing process, it’s important to consider your volume requirements, tolerance needs, surface finish requirements, and lead time. Vacuum casting is an excellent choice for low-volume production runs with tight tolerances and a smooth surface finish. Injection moulding is best suited for high-volume production runs with less stringent&nbsp;<a href="https://xometry.eu/en/tolerances-in-injection-moulding/" target="_blank">tolerance requirements</a>.</p><h2><strong>Vacuum casting vs. 3D printing</strong></h2><p>The significant advantage of vacuum casting is that it can create highly detailed parts with smooth surfaces. However, the biggest downside is that it can be time-consuming, especially if you need multiple copies of your part.&nbsp;<a href="https://xometry.eu/en/3d-printing/" target="_blank">3D printing processes</a>, on the other hand, build parts layer by layer from powder or liquid plastic. One of the most significant advantages of 3D printing is that it’s much faster than vacuum casting.</p><p>If speed and cost are your top priorities, then 3D printing is likely the better option. But vacuum casting is the way to go if you need high accuracy and detail.</p><h2><strong>Source your vacuum cast parts at Xometry</strong></h2><p><a href="https://xometry.eu/en/vacuum-casting/" target="_blank">Vacuum casting</a> is a versatile and relatively quick process that can create small batches of detailed parts. It is ideal for prototypes, functional models, and marketing purposes such as exhibition pieces or sales samples.</p><p>Do you have any upcoming projects for vacuum cast parts?&nbsp;<a href="https://get.xometry.eu/?locale=en" target="_blank">Upload your CAD files</a> to Xometry’s Instant Quoting Engine and get a quote within 48 hours.</p>

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