3D printing infill refers to the inner framework of a 3D printed component, which can be crafted using a variety of shapes. Its primary objective is to enhance part efficiency in terms of weight, strength, and print duration. There are numerous infill patterns.<h2 data-counter-attr="value0">What is Infill in 3D Printing?</h2>In 3D printing, “infill” denotes the internal structures present within the majority of 3D printed components. Unlike certain manufacturing techniques such as injection moulding, which necessitate either full solidity or complete hollowness, parts produced via fused deposition modelling (FDM) 3D printing offer flexibility in employing diverse structural patterns that partially occupy the interior space enclosed by the outer printed walls.<h2 data-counter-attr="value1">What is the Purpose of Infill in 3D Printing?</h2>In 3D printing, infill serves to economize both printing time and material by establishing a lattice structure within a printed part. Printing parts with full density is often unnecessary, leading to material wastage. Infill can be strategically positioned to reinforce areas where the part experiences the highest loads, with higher infill densities indicating a greater percentage of infill material.<h2 data-counter-attr="value2">What Are the Key Elements of Infill in 3D Printing?</h2>A standard 3D printed part consists of an outer shell with a predetermined thickness. Enclosed within this shell, the infill structure remains unseen upon completion of the print. Infill is evenly dispersed throughout the part and is typically printed at higher speeds than the outer shell to expedite printing. Moreover, the lattice structure of infill is thinner compared to the shell.<h2 data-counter-attr="value3">What Are the Different Types of Infill in 3D Printing?</h2>Various types of 3D printer infill patterns are utilized to achieve the common goal of reducing print time and material consumption. Below are several examples of prevalent 3D printing infill patterns:<ul><li>Concentric</li><li>Grid</li><li>Linear</li><li>Gyroid</li><li>Octet</li><li>Lightening</li><li>Triangular</li><li>Tri-Hexagon</li><li>Cubic</li><li>Cross</li></ul><h3 data-counter-attr="value4">Concentric Infill Pattern</h3>The concentric 3D printing infill stands out as one of the quickest patterns to print, consuming minimal material. However, this efficiency compromises part strength, particularly when subjected to loads in the x or y-directions. Compared to other infill types, the concentric pattern exhibits reduced strength.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055882410-concentric-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Concentric infill<h3 data-counter-attr="value5" id="isPasted">Grid Infill Pattern</h3>The grid stands as one of the most prevalent infill types, characterized by a cubic grid pattern where plastic is deposited, intersecting at 90-degree angles. This pattern is particularly suitable for prints featuring expansive, level surfaces. However, gridded infill patterns may lead to nozzle clogging due to the overlapping lines within the same layer.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055901754-grid-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Grid infill<h3 data-counter-attr="value6" id="isPasted">Line Infill Pattern</h3>Line infill contains multiple parallel lines per layer, intersecting the preceding layer at a 90-degree angle. Unlike some patterns, lines do not intersect on the same layer, enhancing part strength in two dimensions. Line infill is slightly faster than grid and triangular patterns.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055927508-line-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Line infill<h3 data-counter-attr="value7" id="isPasted">Gyroid Infill Pattern</h3>The gyroid 3D printing infill pattern generates alternating wavy lines or curves, contributing to its distinct appearance. Although this pattern requires more time to print compared to others, its unique internal structure offers nearly isotropic mechanical properties. While prints may remain weaker on the z-axis, the gyroid pattern enhances shear strength along the x and y-axes. Additionally, this infill pattern is well-suited for use with flexible materials.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055956169-gyroid-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Gyroid infill<h3 data-counter-attr="value8" id="isPasted">Octet Infill Pattern</h3>The octet 3D printing infill pattern forms tetrahedral (pyramid-like) volumes within the part, making it ideal for components with expansive horizontal surfaces. The tapered nature of these pyramid-like volumes enables smaller gaps between infill walls, reducing the likelihood of material sagging and allowing for shorter span distances. Consequently, improved top surfaces can be attained without necessitating an increase in infill density.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055974469-octlet-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Octlet infill<h3 data-counter-attr="value9" id="isPasted">Lightning Infill Pattern</h3>This distinctive infill type prioritizes the fastest print time, albeit compromising part strength. Supports are incorporated in a lightning bolt structure, strategically positioned solely where essential. Components primarily consist of shells, except in areas requiring support for horizontal features or internal overhangs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055994397-lightning-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Lightning infill<h3 data-counter-attr="value10" id="isPasted">Triangular Infill Pattern</h3>The triangular 3D printing infill pattern deposits plastic in a triangular grid, intersecting at 60-degree angles. It is well-suited for parts featuring extensive, level surfaces and offers performance comparable to the grid pattern. However, the triangular infill may lead to nozzle clogging due to the intersecting lines within the same layer.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056014491-triangular-infill.webp" style="width: 100%px;" class="fr-fic fr-dib">Triangular infill<h3 data-counter-attr="value11" id="isPasted">Tri-Hexagon Infill Pattern</h3>The tri-hexagon infill pattern is renowned for its exceptional strength. Similar to the grid and triangular infill types, it forms a hexagonal pattern interspersed with triangles by crossing over itself. However, the crossing of lines within the same layer often leads to nozzle clogging during printing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056035171-tri-hexagon-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Tri hexagon infill<h3 data-counter-attr="value12" id="isPasted">Cubic Infill Pattern</h3>The cubic infill type innovatively forms cubic volumes within the part by adopting a layered pattern reminiscent of triangular infill. Each subsequent layer is strategically offset to construct enclosed cube-shaped volumes within the part. These cubic volumes are precisely oriented, balanced on a single corner, thereby bolstering structural integrity.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056057177-cubic-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Cubic infill<h3 data-counter-attr="value13" id="isPasted">Cross Infill Pattern</h3>The cross pattern produces multiple cross shapes as infill within the 3D printed part. This infill pattern is well-suited for flexible part shapes, allowing for bending and twisting. However, it may not be optimal for more rigid plastics. Moreover, an alternative 3D version of the cross is available to bolster the part’s strength further.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056075047-cross-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Cross infill<h3 data-counter-attr="value14" id="isPasted">What is an Optimal Infill Density?</h3>Typically, an infill density ranging from 20% to 50% is considered advantageous. Below 20%, parts tend to become flimsy, while exceeding 50% leads to extended printing times and excessive material consumption.<h3 data-counter-attr="value15">How Does Infill Pattern Choice Affect the Overall Aesthetics of a 3D Printed Part?</h3>The choice of infill pattern can significantly impact the visual appearance of a 3D printed part. Some infill patterns, such as grid or concentric, may result in a uniform and aesthetically pleasing internal structure, while others, like gyroid or organic patterns, can create visually intricate and unique textures. Additionally, infill density and pattern can affect the transparency, surface finish, and overall perceived quality of the finished part.<h3 data-counter-attr="value16">What Are the Infill Patterns That Maximize the Strength of the Part?</h3>Several infill patterns are known for maximizing the strength of 3D printed parts. Patterns such as honeycomb, tri-hexagon, and gyroid are popular choices for enhancing structural integrity due to their uniform distribution of material and efficient load-bearing capabilities.But the print orientation also plays a major role in the strength of the part. FDM parts exhibit reduced strength along the z-axis because of weaker interlayer bonding. When a load is applied in the z-direction, the primary factor influencing its tensile strength is the quality of interlayer bonding, with the infill percentage having minimal impact in this scenario.<h2 data-counter-attr="value17">How to Choose the Best Infill Pattern</h2>The process of selecting the optimal infill pattern involves several steps:<ol><li>Evaluate the requirements of the part and determine the necessary infill percentage.</li><li>Consider your available resources, such as material and time per part.</li><li>Narrow down the infill patterns that align with your requirements and resources.</li><li>Choose the most suitable infill pattern for your part.</li></ol>Selecting the ideal infill pattern often involves experimentation. Conducting trial prints on small parts can help determine the best settings. Generally, opting for simpler patterns like grid or line patterns tends to yield satisfactory outcomes.<h2 data-counter-attr="value18">Is Infill Important for 3D Printing?</h2>Yes, infill plays a crucial role in 3D printing. It ensures the viability of printing certain parts by providing support for otherwise unsupported surfaces in the design. Infill also enhances strength where necessary, striking a balance between print time and material usage. While some parts can be printed without infill, such as hollow shells like vases, they are generally unsuitable for structural applications due to their lack of internal support.<h2 data-counter-attr="value19">Conclusion</h2>The article covers the significance of infill in 3D printing, outlines various types of infill patterns available, and offers guidance on pattern selection.Xometry offers extensive manufacturing capabilities, including&nbsp;<a href="https://xometry.eu/en/3d-printing/" target="_blank">3D printing services</a> and value-added options for prototyping and production requirements.&nbsp;<a href="https://get.xometry.eu/?locale=en" target="_blank">Simply upload your CAD file</a> to receive an instant quote for your 3D print.

This article will elucidate the concept of 3D printing infill, explore methods for choosing the appropriate infill pattern and density, and detail the array of available infill patterns.

Infill in 3D Printing: Definition, Main Parts, and Different Types

Zeroing in on which of our six&nbsp;<a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="3D Printing" target="_blank" rel="noopener noreferrer">3D printing technologies</a> you want to use is totally \desired aesthetic. Two of our most popular 3D printing services, stereolithography (SLA) and selective laser sintering (SLS) offer engineering-grade options for parts.Before we dive into the options and benefits, let’s look at how each technology works. <h3 id="isPasted">Process Differences Between SLA and SLS</h3><a href="https://www.protolabs.com/en-gb/services/3d-printing/stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="Stereolithography" target="_blank" rel="noopener noreferrer">Stereolithography (SLA)</a>:&nbsp;With SLA, a laser unit bounces an ultraviolet (UV) beam off of a reflective mirror. The machine’s Galvo Motor System steers the focused beam to the design surface. The laser system first draws support structure layers, followed by actual part geometry. The UV laser solidifies and cures the liquid thermoset resin one layer at a time. After solvent processing to remove any additional resin, the support structures are removed manually.<a href="https://www.protolabs.com/en-gb/services/3d-printing/selective-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="Selective Laser Sintering" target="_blank" rel="noopener noreferrer">Selective Laser Sintering (SLS)</a>: SLS is a powder bed fusion additive process. A laser sinters each layer of part geometry using a bed of material-based powder. After each layer, a roller distributes the next layer of powder, and this process is repeated layer-by-layer until the build is complete. Finally, the part is manually removed from the powder and bead blasted in post-processing.How SLA works:<iframe src="https://fast.wistia.net/embed/iframe/1ye1g3wd0u" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>How SLS Works:&nbsp;<iframe src="https://fast.wistia.net/embed/iframe/ranw97cko8" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>&nbsp;<h3 id="isPasted">Analysing Application Needs</h3>Some common applications for parts made via SLA include cosmetic prototypes with a smooth surface finish, parts requiring high dimensional accuracy and intricate detail, and large parts. However, if durability is a key factor, SLS will likely be the more fitting process.SLS builds accurate prototypes and functional product parts, fast. One consideration to keep in mind: With SLS 3D printing, no support structures are required allowing for the option to include multiple parts into a single build; an economical solution when you need a large volume of 3D-printed parts. <h3 id="isPasted">Material Options for SLA and SLS</h3><a href="https://www.protolabs.com/en-gb/resources/design-tips/a-guide-to-stereolithography-3d-printing-materials/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" title="A Guide to Stereolithography 3D Printing Materials" target="_blank" rel="noopener noreferrer">SLA materials</a> are considered photopolymers, or thermoset resins that are in liquid form. SLA boasts the broadest selection of 3D-printable plastics with an impressive range of mechanical properties. Some of our thermoplastic-like materials include:<ul type="disc"><li>ABS-like</li><li>Polypropylene-like</li><li>Polycarbonate-like</li></ul>SLS materials originate as thermoplastic powders. In comparison to SLA materials, SLS material can build durable end-use parts. Some options include:<ul type="disc"><li>General purpose nylons (PA 12 Smooth White)</li><li>Filled materials (PA12 Carbon-filled Smooth Black, PA12 40% Glass-filled Smooth White)</li><li>Specialty materials (TPU 88-A Pure Black)</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU4MTcwMjM5LTE3MTM5NTgxNzAyMzkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"><h3 id="isPasted">SLA vs. SLS Surface Finishes</h3>In general, parts made using SLA offer smoother surface finishes compared to SLS- parts. Here are the options we offer for finished SLA parts:<table border="0" cellspacing="0" cellpadding="0" id="isPasted"><tbody><tr><td>Unfinished</td><td>Dots, or standing"nibs," remain evident on the bottom of the part from the support structure remnants.</td></tr><tr><td>Natural</td><td>Supported surfaces are sanded down to eliminate the support nibs.</td></tr><tr><td>Standard</td><td>Supported surfaces are sanded, and the entire part is finely blasted for a consistent look. Note that the layers are still present. &nbsp;For ABS-Like Black, parts will be painted after support removal; if final blasting is wanted, this must be specified while ordering (external surface will become grey)</td></tr></tbody></table>Surface finishes on SLS parts are typically rougher than SLA or other 3D printing technologies, but this service provides parts that are more durable and better suited for heat or chemical resistance. SLS also works well if flexibility or dimensional stability is needed. <h3 id="isPasted">Final Considerations for Choosing Between SLA and SLS</h3>Certain considerations like durability, resolution, or part size may make the decision for you when deciding between SLA or SLS 3D printing. Refer to the table below to see which process tends to win out over the other based on key factors. &nbsp;&nbsp;Durability and Strength: In general SLS builds more durable, higher strength parts due to the engineering-grade materials available and the fact that they are actual thermoplastics being sintered.Surface Finish:&nbsp;SLA will build parts with high quality, smoother surface finishes that more closely resemble an injection-molded parts.Resolution:&nbsp;SLA provides higher resolution compared to SLS. Our SLA 3D printing service offers three resolution options so you can balance detail and surface finish quality with cost.Tolerances:&nbsp;SLA will be capable of achieving tighter tolerances compared to SLS.Part Size: Our SLA printers have a larger build envelope than our SLS machines.Heat and Chemical Resistance: Thermoplastic SLS materials will have better overall heat and chemical resistance than SLA parts.We’ve covered a lot of ground here. Know that you’re not alone when you’re navigating and deciding which 3D printing process best suits your part needs. Our applications engineers are well-versed at helping you through the process, from design to finished part. Be sure to check out our design tips on <a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" target="_blank" title="Designing for Stereolithography" rel="noopener noreferrer">stereolithography</a> and <a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-selective-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-3dp-0424&utm_content=wevolver-sla-vs-sls-blog-0424" target="_blank" rel="noopener noreferrer">selective laser sintering</a> for more useful tips and tricks. &nbsp;&nbsp;

Learn the key differences between two popular polymer 3D printing processes: Stereolithography(SLA) and Selective Laser Sintering (SLS).

SLA vs. SLS: Comparing Plastic 3D Printing Technologies

Selective laser sintering (SLS) 3D printing is considered one of the most reliable and productive forms of additive manufacturing.[1] Recently, advances in hardware are improving SLS printing even further, enabling even better surface finish quality and achievable level of fine details.&nbsp;At <a href="https://sintratec.com/" target="_blank" rel="noopener noreferrer">Sintratec</a>, a Swiss maker of professional SLS systems, these advances are in the form of high-precision lasers with spot sizes significantly smaller than other entry-level SLS systems. This has enabled Sintratec to achieve unparalleled print resolutions and feature sizes on its SLS platforms. In this article, we look at what laser spot size is, how it influences print resolution, and how Sintratec’s technologies are unlocking new opportunities for SLS users.<h2 dir="ltr">The Science of Laser Spot Size</h2>Selective Laser Sintering is an additive manufacturing technique that fabricates parts by sintering powdered material using a laser. The process begins by depositing a thin layer of polymer powder onto a build platform. A high-powered laser then selectively scans the surface, melting and fusing the powder according to the cross-sectional geometry of the part being built. On the completion of one print layer, the build platform descends incrementally, and a new layer of powder is spread across the surface, repeating the sintering process. This layer-by-layer approach continues until the part is complete. [2]While there are different types of lasers that can be used in the SLS process, one of the most common is Fiber Lasers. These lasers generate light through diodes that pump energy into a fiber optic cable doped with rare-earth elements such as ytterbium. The resulting light typically has a wavelength of about 1,060 nm, which offers high absorption rates in metals and certain polymers. This characteristic makes fiber lasers highly effective for the precision melting of polymer and metal powders. Advantages of fiber lasers in SLS include their excellent beam quality, energy efficiency, and minimal maintenance requirements. [3]When evaluating laser performance in SLS printing, laser spot size is one of the most important specifications. In short, laser spot size (also known as laser beam diameter) is defined as the smallest diameter that a laser can be focused to with a lens. One major reason why laser spot size is so valuable is because it directly influences the laser energy density, which determines the precision and quality of the sintered parts by affecting the melt pool size, depth of penetration into the powder bed, and overall resolution of the final product. Laser energy density is defined as [4]<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU3Mjc2OTk1LVNjcmVlbnNob3QgMjAyNC0wNC0yNCAxMzE0MTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">&nbsp;Where:Eₛ is the laser energy density (J/cm^2)P is the incident laser power (Watts)v is the laser scan speed (cm/s)δ&nbsp;is the laser beam spot size (cm)The laser spot size itself can be defined and calculated in several different ways, but, in the case of SLS printers, spot size is generally defined by the full width at half-maximum (FWHM). Essentially, FWHM quantifies the beam's spread or divergence by measuring the distance between the two points on the intensity profile (a plot of light intensity versus position) at which the intensity falls to half of its peak value. [5]There are many variables that impact the laser beam spot size. Assuming an ideal Gaussian beam, it’s well-defined that the beam width varies as it propagates along its axis. Therefore, the spot size at the focal length is determined by the focal length itself, the smallest radius of the Gaussian beam (i.e., beam waist), and the beam’s wavelength. Based on this, the spot size is mathematically defined as [6]<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU3NTExMjE0LVNjcmVlbnNob3QgMjAyNC0wNC0yNCAxMzE4MjMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Where:f is the focal length.Wf&nbsp;is the beam radius focal length (i.e., spot size)λ is the laser wavelengthw₀ is the beam waist<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU1NzcyMTMyLTI0MDQyMl9KZXNzIGltYWdlLTAxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 790px;" class="fr-fic fr-dib">Figure 1: The propagation of a laser along its axis.Ultimately, the laser spot size is an important factor that influences the resolution of printed components as well as properties like density, strength, and minimum feature size. In essence, the degree of detail an SLS 3D printer can achieve is determined by the laser spot size, and the minimum feature size typically corresponds to the laser spot size.<h2 dir="ltr">Impact of Laser Spot Size on Print Quality</h2>When we talk specifically about resolution in 3D printing, there are two types of resolution to consider: the Z resolution and XY resolution. Z resolution is the vertical resolution that is dependent on the layer thickness of the print (i.e. how finely the recoater can spread each new layer of powder material). XY resolution, for its part, refers to the horizontal resolution of the print and is influenced by both laser spot size and the precision of the laser’s movement. [7]A smaller laser spot size therefore directly corresponds to a higher XY print resolution and enables users to integrate very fine details and intricate features into their 3D prints. SLS 3D printers with smaller laser spots are also better equipped to print parts with superior surface finishes. Smaller laser spot sizes have been shown to decrease layer line height, resulting in less visible layer lines, smoother surfaces, and finer details in the printed objects. [8]&nbsp;Research has found that smaller laser spot sizes markedly enhance the geometrical accuracy of printed tracks. [9] One reason for this is that a small spot size affords precise control over the dimensions of the melt tracks, including their width, height, and depth. As part of this, smaller spot sizes minimize the heat-affected zone around the melt tracks, reducing thermal deformations and residual stresses that can compromise the mechanical integrity of the final product.&nbsp;Adjustments in laser power and scanning speed can significantly influence these parameters, enabling the creation of smoother surfaces and more defined track edges. Precise parameter control helps maintain stable melt pool dynamics, crucial for minimizing defects such as porosity and keyhole formation that degrade print quality.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU1ODQ4MTcxLTVfRXNjaGJhbF9TTFNDb21wb25lbnQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">Sintratec’s Unique Selling Proposition (USP)</h2>Sintratec places an important emphasis on SLS printer laser spot size. The company’s machines boast some of the finest laser spot diameters and resolutions in the SLS 3D printing market today. The company’s newest fusion module for its All-Material Platform, the Sintratec S3, is equipped with a 30-watt fiber laser that is focused down to a spot size of just 145 μm. The S2, fitted with a 10-watt fiber laser, has the same laser spot size.&nbsp;Sintratec’s laser spot diameter is substantially smaller than many other SLS platforms on the market. This opens applications for its technology in industries like aerospace and electronics that require not only high throughput and process consistency but also high resolution and part accuracy. You can find a comparison of some leading SLS systems below:<table style="width: 100%;"><tbody><tr><td style="width: 50.0000%;">SLS 3D Printer </td><td style="width: 50.0000%;">Laser Spot Size (μm) </td></tr><tr><td style="width: 50.0000%;">Sintratec S3 and S2 </td><td style="width: 50.0000%;">145 μm [10] </td></tr><tr><td style="width: 50.0000%;">Prodways Promaker P1000 </td><td style="width: 50.0000%;">450 μm [11] </td></tr><tr><td style="width: 50.0000%;">Sinterit Lisa X </td><td style="width: 50.0000%;">650 μm [12] </td></tr><tr><td style="width: 50.0000%;">Formlabs Fuse 1 </td><td style="width: 50.0000%;">200 μm [13] </td></tr></tbody></table><h2 dir="ltr" id="isPasted">Real-World Applications and Benefits</h2>Adopters in various industries are already reaping the benefits of Sintratec’s high-resolution SLS solutions. Around the globe, its Swiss-made systems are leveraged by product developers, engineers, and researchers to create precise, functional prototypes that not only closely match the exact dimensions and shape of final parts, but also their mechanical properties. This application dramatically speeds up design validation and prototype testing, enabling users to move quickly and confidently into series production.<a href="https://sintratec.com/additive-manufacturing-sparks-innovation/" target="_blank">Kontakt-Simon SA</a>, a major manufacturer of electric installation equipment, has been using the Sintratec S2 since 2022 to create complex, high-precision prototypes for the electrical sector. The accuracy of Sintratec’s fiber laser system has been vital in this application because printed parts are used to validate geometries and assemblies before moving into full-scale production. The high-quality surface finish of Sintratec prints, as well as the ability to produce complex shapes with fine details, has been important to Kontakt-Simon, since electric housings and components must not only fit electrical components of varying geometries within them but also fit perfectly into larger assemblies. When asked about the main benefits of the S2, Thomas Wilk, Head of Kontakt-Simon’s technical department, listed “complex geometries, thin walls, high aesthetics and accuracy, great strength, and homogeneity in each axis of the part.”<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU2MDE1NjA3LTZfS29udGFrdFNpbW9uX1NMU0NvbXBvbmVudC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">Swiss window maker <a href="https://sintratec.com/innovative-window-systems-with-sls-components/" target="_blank">Eschbal</a> has also integrated the Sintratec S2 for a number of end uses, including prototyping, tooling, and small series production parts. Like Kontakt-Simon, the company values the technology’s ability to print parts that closely match the properties of injection molded parts. “With the SLS process, we were especially impressed by the tolerances of up to 0.1 millimeters and the surface quality,” comments Michael Ebnöther, a member of Eschbal’s tech department. For tooling and end-use parts, mechanical properties are paramount. For example, Eschbal optimized a connector component through SLS 3D printing, reducing the weight of the final part by 33%.&nbsp;The case studies represent just a small fraction of the ways that Sintratec’s high-resolution 3D printers are being used. You can find more <a href="https://sintratec.com/stories/" target="_blank">customer stories</a> here.<h2 dir="ltr" id="isPasted">Conclusion</h2>Overall, laser spot size is an important piece of the SLS puzzle, influencing print properties like resolution. By focusing on precision through laser spot size, Sintratec has carved out a position for itself in the broader SLS market that caters to applications that require high print accuracy and fine details. In combination with SLS’ excellent throughput and consistency, the ability to achieve smaller features and ultimately better-quality prints takes the technology to another level.&nbsp;<h2 dir="ltr" id="isPasted">References</h2>1. Awad A, Fina F, Goyanes A, Gaisford S, Basit AW. 3D printing: Principles and pharmaceutical applications of selective laser sintering. Int J Pharm. 2020 Aug 30;586:119594. doi: 10.1016/j.ijpharm.2020.119594. Epub 2020 Jul 2. PMID: 32622811.2. David L. Bourell, Trevor J. Watt, David K. Leigh, Ben Fulcher, Performance Limitations in Polymer Laser Sintering,Physics Procedia, Volume 56, 2014, Pages 147-156, ISSN 1875-3892, https://doi.org/10.1016/j.phpro.2014.08.157.3. Liao, H, Le, MT, &amp; Long, DV. "Optimization on Selective Fiber Laser Sintering of Bimetallic Powder via Design of Experiments Method." Proceedings of the ASME/ISCIE 2012 International Symposium on Flexible Automation. ASME/ISCIE 2012 International Symposium on Flexible Automation. St. Louis, Missouri, USA. June 18–20, 2012. pp. 475-482. ASME. https://doi.org/10.1115/ISFA2012-72324. Lü, L., Fuh, J.Y.H., Wong, Y.S. (2001). Selective Laser Sintering. In: Laser-Induced Materials and Processes for Rapid Prototyping. Springer, Boston, MA. https://doi.org/10.1007/978-1-4615-1469-5_55. J. Chalupský, J. Krzywinski, L. Juha, V. Hájková, J. Cihelka, T. Burian, L. Vyšín, J. Gaudin, A. Gleeson, M. Jurek, A. Khorsand, D. Klinger, H. Wabnitz, R. Sobierajski, M. Störmer, K. Tiedtke, and S. Toleikis, "Spot size characterization of focused non-Gaussian X-ray laser beams," Opt. Express &nbsp;18, 27836-27845 (2010).6. Oz Livneh, Gadi Afek, and Nir Davidson, "Producing an efficient, collimated, and thin annular beam with a binary axicon," Appl. Opt. 57, 3205-3208 (2018)7. Anketa Jandyal, Ikshita Chaturvedi, Ishika Wazir, Ankush Raina, Mir Irfan Ul Haq, 3D printing – A review of processes, materials and applications in industry 4.0, Sustainable Operations and Computers, Volume 3, 2022, Pages 33-42, ISSN 2666 4127, <a href="https://doi.org/10.1016/j.susoc.2021.09.004" target="_blank">https://doi.org/10.1016/j.susoc.2021.09.004</a>.8. M. Launhardt, A. Wörz, A. Loderer, T. Laumer, D. Drummer, T. Hausotte, M. Schmidt, Detecting surface roughness on SLS parts with various measuring techniques, <a href="https://www.sciencedirect.com/science/article/abs/pii/S0142941816302057" target="_blank">https://www.sciencedirect.com/science/article/abs/pii/S0142941816302057</a>9. Vaglio E, De Monte T, Lanzutti A, Totis G, Sortino M, Fedrizzi L. Single tracks data obtained by selective laser melting of Ti6Al4V with a small laser spot diameter. Data Brief. 2020 Oct 22;33:106443. doi: 10.1016/j.dib.2020.106443. PMID: 33195769; PMCID: PMC7642809.10. <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank">https://sintratec.com/sls-3d-printer/amp/sintratec-s2/</a>11. <a href="https://www.prodways.com/wp-content/uploads/2021/09/ProMaker-P1000-Series-EN-V19.08.2021.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">https://www.prodways.com/wp-content/uploads/2021/09/ProMaker-P1000-Series-EN-V19.08.2021.pdf</a>12. https://www.3d-printer.com/3D_Printers/Sinterit_Printers/lisa-x13. https://formlabs.com/3d-printers/fuse-1/tech-specs/

Sintratec's high-precision lasers with smaller spot sizes allow for superior print resolution and finer details in SLS 3D printing.

Sintratec's Laser Spot Size The Key to Superior Print Resolution

This article delves into the fundamentals of EMI gaskets, types, and their critical role in protecting electronic devices and ensuring optimal performance in various engineering applications.

EMI Gaskets: The Unsung Heroes of Electromagnetic Interference Shielding

Microtunneling is a trenchless construction method using a remotely controlled, steerable tunnel-boring machine for underground pipeline installation. It minimizes surface disruption, making it ideal for urban and sensitive areas. This technique ensures precise pipeline alignment and involves simultaneous excavation and pipe installation, enhancing safety and efficiency. Widely used for utilities, microtunneling's precision and reduced environmental impact make it a preferred choice for constructing water, sewage, and other infrastructure systems in congested settings.This article highlights the progress a young engineering student team from Switzerland has made with its self-developed micro tunnel boring machine. It describes the project on its way to revolutionizing the tunneling industry with specific regard to its innovative 3D-printing-like tunneling mechanism.<h2 dir="ltr">The Journey of Swissloop Tunneling</h2><a href="https://swisslooptunneling.ch/" target="_blank">Swissloop Tunneling</a> is a student group from ETH Zurich that focuses on developing innovative tunneling technologies. This team, composed of students, works on designing and testing tunnel boring machines that incorporate advanced technologies and methods. Their efforts aim to enhance the efficiency and reduce the costs of tunneling processes, contributing to the broader goal of revolutionizing tunneling to facilitate ambitious infrastructure projects, including proposed systems like the Hyperloop transportation system.Further reading:&nbsp;<a href="https://www.wevolver.com/article/swissloop-tunneling-revolutionizing-the-tunneling-industry" target="_blank">Swissloop Tunneling: Revolutionizing the Tunneling Industry</a>Throughout the last 3 years, over 100 Swissloop Tunneling members have made contributions to a common goal: unleashing the potential of time-, cost-, and resource-efficient tunneling. In this regard, innovation is needed to accelerate the infrastructural progress to benefit society by supporting the rapid expansion of connected underground systems. Therefore, Swissloop Tunneling aims to contribute to advancements in technology, demonstrated by its two iterations of prototypical tunnel boring machines since its founding in 2020.&nbsp;Building upon its first model named Groundhog Alpha, the team has maintained the first machine components’ strengths while further extending it with technological add-ons, designing certain subsystems from scratch, conducting tests, and optimizing for higher reliability. Those efforts have now led to the current model Groundhog Beta.<h2 dir="ltr">The Groundhog Beta</h2>The current model of the association’s (micro) tunnel boring machine named Groundhog Beta consists, among others, of these functions:<h2 dir="ltr">Erosion</h2>Extracts and processes the underground material during the boring phase. At the front of the machine, where the cutterhead is placed, a special soil-conditioning foam is used to help decompose the sticky clay ground in Bastrop (TX), where the prototype was being tested. The erosion subsystem can further handle small to medium-sized rocks by crushing them into smaller pieces. A suctioning mechanism then transports the eroded material through and out of the machine. At this point, an external sedimentation system is ensuring a constant circulation of used water and the removal of the extracted material.<grammarly-extension data-grammarly-shadow-root="true" style="position: absolute; top: 0px; left: 0px; pointer-events: none;" class="dnXmp"></grammarly-extension><grammarly-extension data-grammarly-shadow-root="true" style="position: absolute; top: 0px; left: 0px; pointer-events: none;" class="dnXmp"></grammarly-extension><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzNzExOTM0NDY1LXguanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib" alt="groundhog-beta-soil-conditioning-foam">Fig. 1: Groundhog Beta tackling clay using soil conditioning foam<h2 dir="ltr">Navigation</h2>Consists of a two-component system. The steering component allows for angled digging and enables withholding stronger vibrations. It consists of a comprehensive sensory system to achieve an accurate autonomous movement of the machine. The propulsion component gets the machine moving forward by coordinated gripper plates that push the machine forward through the tunnel wall.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzNzEyMDA4NjA4LURTQzA1MDk5ICgxKS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="groundhog-beta-hydraulic-powered-propulsion">Fig. 2: Swissloop Tunneling's hydraulics-powered propulsion component<h2 dir="ltr">Starting platform</h2>Placed in the launching area or on the surface, the starting platform enables the machine to launch from various angles.<h2 dir="ltr">Tunnel liner</h2>One of the most innovative aspects of Groundhog Beta is its tunnel lining mechanism. The liner mechanism simultaneously builds the interior tunnel wall while continuously moving forward with the tunnel boring machine, acting like a 3D printer. As it stands right now, a mechanism of this type has not been tested in tunneling yet and provides an ecologically sustainable solution regarding the reusability of the wall material. By using a pneumatic system, a polypropylene granulate to later build the tunnel wall gets transported into the machine. It then gets extruded by melting it and steering the viscous material into the right shape, finally being cooled down to achieve its intended tunnel wall structure. This mechanism has been optimized since last year - especially in terms of reliability. Additionally, an external testing system was designed to make isolated testing of this subsystem’s functionality possible. In the end, a 15mm thick tunnel wall is produced, being able to withhold the intense forces of machine and earth pressure.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzNzExOTc1MDE2LURTQzA2NDY1LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="groundhog-beta-tunnel-lining">Fig. 3: Polymer starting to come out of the tunnel lining component on the right<h2 dir="ltr">Achievements Over the Years</h2>In addition to refining the engineering processes, the Swissloop Tunneling team has consistently participated in every Not-a-Boring Competition an event aimed at fostering innovation in tunneling technologies. Not-a-Boring Competition is organized each year in the USA by The Boring Company, founded by Elon Musk.<iframe width="640" height="360" src="https://www.youtube.com/embed/OJ0tIHHXuS4??si=AofBJ4PDGhPfTxmg&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">&nbsp;</iframe><iframe width="640" height="360" src="https://www.youtube.com/embed/osnFHy8KeYI?&amp;ab_channel=SwissloopTunneling&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"></iframe> The team has exhibited its excellence by winning awards for innovation and design at the first two competitions, held in Las Vegas (NV) in 2021 and Bastrop (TX) in 2023. Ahead of the 2024 competition in Bastrop, the team dedicated significant efforts to optimizing their machine and making key adaptations. These efforts paid off spectacularly at the Not-a-Boring Competition 2024, where Swissloop Tunneling triumphed by winning 1st Place Overall and the Champion Award.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzNzEyMDY1NjgyLURTQzA2MDg4LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="swissloop-tunneling-team-picture">Fig. 4: The Swissloop Tunneling TeamWith these achievements, the team remains committed to pushing the boundaries of innovation. Swissloop Tunneling will continue to enhance and refine its machinery, further developing its capabilities to fully realize the remarkable potential of advanced tunneling technology.<h2 dir="ltr">Conclusion</h2>The advancements in tunneling technology showcased by the recent developments of the micro tunnel boring machines are reshaping the landscape of construction and infrastructure. By integrating innovative 3D-printing-like methods for tunnel lining, these machines are setting new benchmarks for efficiency, cost-effectiveness, and environmental sustainability in tunnel construction.&nbsp;Such technological breakthroughs promise to revolutionize urban development and the future of transportation, making the once-distant dreams of projects like the Hyperloop increasingly attainable.

Innovative micro tunnel boring technologies are revolutionizing underground construction, setting new standards in efficiency and sustainability, and paving the way for future transformative infrastructure projects like the Hyperloop.

Transforming Underground Construction with Swissloop Tunneling

This article delves into the various types of printed circuit boards, their fundamental concepts, structures, manufacturing processes, and advanced PCB technologies, highlighting their advantages, limitations, and typical applications.

Types of Printed Circuit Boards: A Comprehensive Guide

For engineers working on soft robotics or wearable devices, keeping things light is a constant challenge: heavier materials require more energy to move around, and – in the case of wearables or prostheses – cause discomfort. Elastomers are synthetic polymers that can be manufactured with a range of mechanical properties, from stiff to stretchy, making them a popular material for such applications. But manufacturing elastomers that can be shaped into complex 3D structures that go from rigid to rubbery has been unfeasible until now.“Elastomers are usually cast so that their composition cannot be changed in all three dimensions over short length scales. To overcome this problem, we developed DNGEs: 3D-printable double network granular elastomers that can vary their mechanical properties to an unprecedented degree,” says Esther Amstad, head of the <a href="https://www.epfl.ch/labs/smal/" target="_blank">Soft Materials Laboratory</a> in EPFL’s School of Engineering.Eva Baur, a PhD student in Amstad’s lab, used DNGEs to print a prototype ‘finger’, complete with rigid ‘bones’ surrounded by flexible ‘flesh’. The finger was printed to deform in a pre-defined way, demonstrating the technology’s potential to manufacture devices that are sufficiently supple to bend and stretch, while remaining firm enough to manipulate objects.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713431737943-2048x1152.jpg" style="width: 100%px;" class="fr-fic fr-dib">The lab's DNGE prototype ‘finger’ with rigid ‘bones’ surrounded by flexible ‘flesh’ © Adrian AlberolaWith these advantages, the researchers believe that DNGEs could facilitate the design of soft actuators, sensors, and wearables free of heavy, bulky mechanical joints. The research has been published in the journal <a href="https://onlinelibrary.wiley.com/doi/10.1002/adma.202313189" target="_blank" rel="noopener">Advanced Materials</a>.<h2>Two elastomeric networks; twice as versatile</h2>The key to the DNGEs’ versatility lies in engineering two elastomeric networks. First, elastomer microparticles are produced from oil-in-water emulsion drops. These microparticles are placed in a precursor solution, where they absorb elastomer compounds and swell up. The swollen microparticles are then used to make a 3D printable ink, which is loaded into a bioprinter to create a desired structure. The precursor is polymerized within the 3D-printed structure, creating a second elastomeric network that rigidifies the entire object.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713431770492-3840x2159+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib">Example of DNGEs (3D-printable double network granular elastomers) © Titouan VeuilletWhile the composition of the first network determines the structure’s stiffness, the second determines its fracture toughness, meaning that the two networks can be fine-tuned independently to achieve a combination of stiffness, toughness, and fatigue resistance. The use of elastomers over hydrogels – the material used in state-of-the-art approaches – has the added advantage of creating structures that are water-free, making them more stable over time. To top it off, DNGEs can be printed using commercially available 3D printers.“The beauty of our approach is that anyone with a standard bioprinter can use it,” Amstad emphasizes.One exciting potential application of DNGEs is in devices for motion-guided rehabilitation, where the ability to support movement in one direction while restricting it in another could be highly useful. Further development of DNGE technology could result in prosthetics, or even motion guides to assist surgeons. Sensing remote movements, for example in robot-assisted crop harvesting or underwater exploration, is another area of application.Amstad says that the Soft Materials Lab is already working on the next steps toward developing such applications by integrating active elements – such as responsive materials and electrical connections – into DNGE structures.<hr>ReferencesE. Baur, B. Tiberghien, E. Amstad, 3D Printing of Double Network Granular Elastomers with Locally Varying Mechanical Properties. Adv. Mater. 2024, 2313189.&nbsp;<a href="https://doi.org/10.1002/adma.202313189" target="_blank" rel="noopener">https://doi.org/10.1002/adma.202313189</a>

Example of DNGEs (3D-printable double network granular elastomers) © Titouan Veuillet

EPFL researchers are targeting the next generation of soft actuators and robots with an elastomer-based ink for 3D printing objects with locally changing mechanical properties, eliminating the need for cumbersome mechanical joints.

An ink for 3D-printing flexible devices without mechanical joints

In the ever-evolving landscape of production and logistics, robotics &amp; automation play an increasingly vital role, driven by the wave of digitization. However, as with any technology, there are also hurdles which have to be overcome, especially when it comes to the production of customized and lightweight parts in a cost-efficient manner. This is where 3D printing steps in. Join us in this blog article as we explore the benefits and diverse applications of 3D printing for robotic parts and learn about the connection of those two technologies.<h2>Understanding 3D Printing</h2>Before exploring their interconnection, let’s understand 3D printing, also known as additive manufacturing. Additive manufacturing enables the conversion of digital designs into tangible objects by building up layers of material. You just need the right design and production can start without any huge production ramp-up. This freedom enables intricate designs, rapid prototyping, and on-demand production of customized parts, offering a level of flexibility and innovation that has redefined the manufacturing landscape.<figure><img width="1024" height="299" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzMjc0NzI1NjAzLTE3MTMyNzQ3MjU2MDMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="3D-Printing-How-it-Works" srcset="https://replique.io/wp-content/uploads/2024/03/3D-Printing-How-it-Works-1024x299.jpg 1024w, https://replique.io/wp-content/uploads/2024/03/3D-Printing-How-it-Works-300x88.jpg 300w, https://replique.io/wp-content/uploads/2024/03/3D-Printing-How-it-Works-768x224.jpg 768w, https://replique.io/wp-content/uploads/2024/03/3D-Printing-How-it-Works-1536x449.jpg 1536w, https://replique.io/wp-content/uploads/2024/03/3D-Printing-How-it-Works.jpg 1900w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">From digital file to printed parts in hours.</figure><h2>Custom Parts with 3D Printing</h2>Robotics is one of the industries, where these benefits of 3D printing can play a crucial role. And there are many reasons for it. One is the possibility to create custom parts of robotics and automation machinery using 3D printing. Traditional manufacturing methods often fall short when it comes to creating parts, such as grippers, tailored to specific tasks without incurring exorbitant costs due to the creation of specialized tools and molds. Thanks to 3D printing, even small players (SMEs), can use 3D printing to create budget-friendly robot parts, as there are no minimum order quantity, meaning they can produce parts starting from lot-size one. <img width="1024" height="768" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzMjc1MDQ2OTM1LTE3MTMyNzUwNDY5MzUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" srcset="https://replique.io/wp-content/uploads/2024/03/3D-printed-caps-robot-automation-1024x768.jpg 1024w, https://replique.io/wp-content/uploads/2024/03/3D-printed-caps-robot-automation-300x225.jpg 300w, https://replique.io/wp-content/uploads/2024/03/3D-printed-caps-robot-automation-768x576.jpg 768w, https://replique.io/wp-content/uploads/2024/03/3D-printed-caps-robot-automation-1536x1152.jpg 1536w, https://replique.io/wp-content/uploads/2024/03/3D-printed-caps-robot-automation.jpg 1900w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii" style="width: 758px;">Robot caps can be cost efficiently produced in small volumes via 3D printing.<h2>Lightweight Parts Thanks to Intricate Designs</h2>Weight is a critical factor in optimizing robotic performance. Traditional manufacturing often results in excess weight due to subtractive processes. 3D printing revolutionizes this by allowing engineers to design intricate, hollow structures, optimizing weight without compromising strength. This newfound agility finds applications in drones, exoskeletons, and various robotic systems.<h2>Part Consolidation and Modulation</h2>3D printing’s technical benefit extends to the consolidation of multiple parts into a single, complex structure. This not only reduces overall weight but also minimizes assembly challenges and inventory complexity. On the other side, 3D printing allows the separation of a single part into distinct components, simplifying modifications if needed.<h2>Quick Prototyping and Design Changes</h2>Compared to traditional methods, 3D printing offers unparalleled agility in prototyping and design alterations. Engineers and designers can swiftly translate conceptual ideas into tangible prototypes. This means they can test a prototype out almost immediately to see if it’s a good fit. And if they want to tweak or change the design, they can easily do that thanks to the flexibility of 3D printing, empowering innovators to adapt and optimize robotic components with unprecedented speed. This not only accelerates the product development cycle and reduces time-to-market considerably, but also fosters a culture of continuous improvement in the ever-evolving field of robotics.<img width="1024" height="768" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzMjc0ODUwNjU0LTE3MTMyNzQ4NTA2NTQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" srcset="https://replique.io/wp-content/uploads/2024/03/3D-printing-prototyping-robotics-1024x768.jpg 1024w, https://replique.io/wp-content/uploads/2024/03/3D-printing-prototyping-robotics-300x225.jpg 300w, https://replique.io/wp-content/uploads/2024/03/3D-printing-prototyping-robotics-768x576.jpg 768w, https://replique.io/wp-content/uploads/2024/03/3D-printing-prototyping-robotics-1536x1152.jpg 1536w, https://replique.io/wp-content/uploads/2024/03/3D-printing-prototyping-robotics.jpg 1900w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">3D printing can be used for prototyping and visualizing products and ideas.<h2>Spare Parts On-Demand</h2>The wear and tear faced by robotics and automation machinery can lead to costly downtime. Traditional methods of obtaining spare parts involve a time-consuming process of ordering, shipping, and, in some cases, custom manufacturing. 3D printing provides a rapid and cost-effective solution for local or even on-site production of spare parts, just on-demand. Instead of waiting for shipments or relying on extensive inventories, robots can be quickly restored to operational status with 3D printed replacements. This capability significantly minimizes downtime, ensuring continuous robot functionality. At an automation fair for example, Replique was able to get needed spare parts of an exhibitor within a day.Learn more about the benefits of <a href="https://replique.io/3d-printed-spare-parts/" target="_blank">3D printing for the production of spare parts.</a><h2>Application examples</h2><h3>Grippers</h3>Especially, grippers, are undergoing a revolution thanks to additive manufacturing. It enables the creation of grippers in small volumes that are not only cost-efficient but also remarkably lightweight and optimized. When the need arises to change grippers, 3D printing facilitates a swift process with short development and production times. This capability translates into faster movements, reduced cycle times, and an overall more agile manufacturing process.<figure><img width="1024" height="768" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzMjc0NzI2Mzc4LTE3MTMyNzQ3MjYzNzgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="3D printing for robotic parts_gripper" srcset="https://replique.io/wp-content/uploads/2024/03/3D-printed-grippers-1024x768.jpg 1024w, https://replique.io/wp-content/uploads/2024/03/3D-printed-grippers-300x225.jpg 300w, https://replique.io/wp-content/uploads/2024/03/3D-printed-grippers-768x576.jpg 768w, https://replique.io/wp-content/uploads/2024/03/3D-printed-grippers-1536x1152.jpg 1536w, https://replique.io/wp-content/uploads/2024/03/3D-printed-grippers.jpg 1900w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">Cobot gripper designed for 3D printing.</figure>In a recent cooperation with struktur.form.design Engineering GmbH for example, we were able to reduce weight of a cobot gripper by 78%, part count by 84% and overall production cost savings by 30%, just via redesigning and producing via additive manufacturing.And the benefits extend beyond industrial automation, making a significant impact on healthcare robotics as well. In surgical robots, for instance, 3D printed grippers can handle specialized instruments and execute delicate tasks.<h3>Embedded sensors and electronic components</h3>Beyond these core connections, the collaboration between 3D printing and robotics unfolds into an expansive canvas of possibilities. For example, embedding sensors and electronic components directly into robotic structures using 3D printing enhances their functionality and streamlines assembly processes.<h3>Soft robotics</h3>For soft robotics – those dealing with flexible and deformable structures – 3D printing opens avenues for the creation of parts that move and adapt like real muscles. Researchers from the Delft University of Technology, for instance, have pioneered the use of <a href="https://pure.tudelft.nl/ws/portalfiles/portal/142950401/s41563_022_01429_5.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">3D printing in manufacturing soft robots with intricate viscoelastic hydrogels</a>. These materials withstand high pressures and open new possibilities in fields like medical prosthetics.<h3>Innovation and Education</h3>Moreover, 3D printing serves as a catalyst for innovation and education in robotics. It fosters creativity among students and researchers, accelerating the learning curve and driving advancements in the development of robotic systems.<h2>Robots as 3D Printers</h2>The marriage of robotics and 3D printing can even extend beyond conventional roles. Here, robots themselves become integral 3D printers, amplifying the scope and scale of additive manufacturing. Especially noteworthy in large-scale 3D printing, robotic arms deposit materials layer by layer to create objects. This facilitates the creation of parts on a scale previously unattainable in 3D printing.<figure><img width="1024" height="576" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzMjc0NzI2MDYxLTE3MTMyNzQ3MjYwNjEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="robots-as-3D-printers" srcset="https://replique.io/wp-content/uploads/2024/03/robots-as-3D-printers-1024x576.jpg 1024w, https://replique.io/wp-content/uploads/2024/03/robots-as-3D-printers-300x169.jpg 300w, https://replique.io/wp-content/uploads/2024/03/robots-as-3D-printers-768x432.jpg 768w, https://replique.io/wp-content/uploads/2024/03/robots-as-3D-printers-1536x864.jpg 1536w, https://replique.io/wp-content/uploads/2024/03/robots-as-3D-printers-1200x675.jpg 1200w, https://replique.io/wp-content/uploads/2024/03/robots-as-3D-printers.jpg 1920w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">Thanks to the use of robots, even houses can now be 3D printed.</figure><h2>Conclusion</h2>The intersection of 3D printing and robotics reshapes how we conceive, design, and build robotic systems. From lightweight components to customized grippers and on-demand spare parts, this collaboration represents a paradigm shift, offering tailored solutions that enhance the efficiency and adaptability of robotic systems.

Explore the benefits of 3D printing for light-weight, customized and on-demand parts.

How to Leverage 3D Printing in Robotics and Automation

ADDITIV Design World is an international virtual event focusing on the latest DfAM trends. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzMjY1NzU2MDk5LTE3MTI1ODkyNzE4OTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"> This international event will take place on May 23rd, from 9:00 AM to 1:00 PM ET (3:00 to 7:00 PM CEST), and will include panel sessions with professionals working in design in 3D printing, workshops to discover leading design solutions for additive manufacturing and networking sessions with innovative companies in the sector.Date: May 23rd, 2024Time: 9:00 AM to 1:00 PM ET (3:00 to 7:00 PM CEST)<a href="https://wevlv.co/add_med_24" rel="noopener noreferrer" target="_blank" class="button-main-action">REGISTER HERE</a>SPEAKERS:<ul><li>Lilach Porges,&nbsp;Founder and Creative Director, PROCODE_DRESS</li><li>Paul Gradl,&nbsp;Principal Engineer, NASA Marshall Space Flight Principal Engineer</li><li>Patrick Pradel,&nbsp;Coordinator, Design for AM Network</li><li>John Lees,&nbsp;Vice President of Engineering, Evolve Additive Solutions</li><li>Alex Kimber,&nbsp;Industrial Designer, AKD</li><li>Jonathan Blutinger,&nbsp;Food Engineer at Combat Feeding Division, U.S. Army DEVCOM Soldier Center</li><li>Adam Wentworth,&nbsp;Senior Engineer, Mayo Clinic</li></ul><a href="https://wevlv.co/add_med_24" target="_blank" rel="noopener noreferrer" class="button-main-action">REGISTER HERE</a>&nbsp;

The virtual event dedicated to design for additive manufacturing

EVENT: ADDITIV DESIGN WORLD 2024

XiP and NXE Series 3D Printers

Ultrafast 3D Printing a Design Guide for LSPc Printing

<h2 id="isPasted">Iconic PepsiCo Brand Finds Best Alternative to Expensive, Time-Consuming Conventional Metal Tooling</h2><a href="https://www.pepsico.com/" target="_blank">PepsiCo products</a> are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo generated more than $79 billion in net revenue in 2021, driven by a complementary beverage and convenient foods portfolio that includes Lay’s, Doritos, Cheetos, Gatorade, Pepsi-Cola, Mountain Dew, Quaker, and SodaStream. PepsiCo’s product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.<h2 id="isPasted">The challenge</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MTU1MjQ1LWV6Z2lmLTEtNGZiZjE1OTIxMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">Speed to market has never been more important in the consumer goods sector, as brand owners aim to develop new bottle and package designs to address ever-shifting customer desires. But creating conventional metal tooling for the blow molding of bottles is an expensive and time-consuming proposition. Once a CAD file of the package design is created, it can take up to four weeks to machine a metal tool, and then an additional two weeks to get a trial unit to do the actual blow molding. It also could easily cost up to $10,000 to produce a single metal tool set depending on its complexity, according to Max Rodriguez, senior manager of Global Packaging R&amp;D, Advanced Engineering and Design, at PepsiCo’s Valhalla research center.This has led many to try to apply 3D printing to shorten this process, but previous rapid tooling approaches also had their shortcomings. It would take two to three days to 3D print a single blow molding tool from Digital ABS (an expensive material) on a $250,000 PolyJet 3D printing machine. Even so, the resulting tool lacked durability and could produce only about 100 bottles before the mold began to fail. This prompted Rodriguez and his team to explore using a hybrid approach, combining parts of a conventional metal mold with 3D printed inserts.<blockquote id="isPasted">“Time and cost are obviously important, but more important is to have the ability to have the flexibility to run through a number of different design iterations at a record pace so that we can evaluate performance in all of the downstream activities. That really is what helps us accelerate packaging design and development.”Max Rodriguez, Senior Manager of Global Packaging R&amp;D, Advanced Engineering and Design, PepsiCo</blockquote><h3 id="isPasted">The application<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjI2NDE3LVBlcHNpQ28tUGF0ZW50ZWQtM0QtUHJpbnRlZC1IeWJyaWQtTW9sZC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"> </h3>Applying its patented technology and a hybrid approach, PepsiCo is using additive manufacturing as an enabler in various aspects of bottle development – accelerating and enhancing performance simulation, advanced system analysis and the production of high-quality, functional prototypes.<h3>The advantages</h3><ul><li>Compress prototype tooling development time from 4 weeks to 48 hours</li><li>Slash prototype tooling costs from $10,000 to $350 per mold set</li><li>Create durable tooling that can produce more than 10,000 bottles per mold</li><li>Enable multiple design iterations to allow for timely verification of downstream activities</li></ul><iframe width="640" height="360" src="https://www.youtube.com/embed/k7OiPJ9xfps?&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"></iframe><h2 id="isPasted">More Than 10,000 Bottles at 96% Reduction in Cost</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjY2OTM4LVBlcHNpQ28tUGF0ZW50ZWQtTW9sZC0zRC1QcmludGVkLU5leGEzRC03Njh4NTg5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">PepsiCo chose Nexa3D’s xPEEK147 from Henkel Loctite for the 3D printed tool inserts due to the material’s strength and impressive performance factors, including its very high heat-deflection temperature. While this hybrid approach is machine-agnostic, meaning it can use various types of 3D printers, PepsiCo has found the ultrafast, high-throughput <a href="https://nexa3d.com/3d-printers/nxe400/" target="_blank">Nexa3D NXE 400 3D printer</a> and accompanying material performance to be ideal for producing the mold components it needs.A complete mold set can be made in 12 hours, with 8 hours of 3D printing time and 4 hours of curing. These hybrid-made molds can then successfully be used for more than 10,000 bottles before failure – at up to a 96% reduction of cost compared to traditional metal tooling.

PepsiCo worked with Nexa3D’s partner Dynamism to validate the NXE 400 and the xPEEK147 material as ideal for their blow molding application requiring speed and durability.

CAD to Part in 48 Hours: PepsiCo Slashes Tooling Costs and Cycle Times with the help of NXE 400

Applications for <a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">3D printing</a> are expanding rapidly in response to new materials, technologies and secondary processes announced seemingly daily. We now see additive manufacturing being used for not only prototyping, but also production parts to reduce assemblies and fabricate complex geometries.<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">Injection moulding</a> continues as the workhorse that produces parts globally, without much fanfare. Perfected over decades, moulding remains the go-to service for cost-effective parts at quantities from 50 to over a million.A future where 3D printing replaces injection moulding may be far off, but today the two work beautifully in tandem. While 3D printing is often touted as a go-to service for prototyping, costs are typically prohibitive when scaling up to production volumes, which is where injection moulding can come in.Deciding which service is the right route for you? Let’s start with a look at cost drivers with both manufacturing services.Post processing workBuild time and post-processing are two main cost drivers. Determining ways to streamline your design or do without unnecessary finishes cuts down significantly on expenses.&nbsp;<img border="0" width="394" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDc0LTE3MTI2Njk2NDk0NzQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="DMLS post processing" class="fr-fic fr-dii">3D Printing&nbsp;Build time: Far and away the most significant cost driver for 3D printing, a longer build time means a more expensive part. Take a solid cube, for example. While a simple part, printing the condensed cube layer by layer would take more time than if the cube’s interior used a cross-linked design, which requires less material and subsequently less machine time. Any necessary support structures during the printing process also increases machine time and cost.Material cost: Depending on the technology, 3D printing materials can add expense. While direct metal laser sintering (DMLS) recycles all unused powder, a process like selective laser sintering (SLS) uses a powder-based polymer process that does not allow for recycling, driving up cost.Post-processing: Required with nearly all 3D-printed parts, these processes strengthen parts, improve cosmetic appearance and more, but also require manual work that can be time consuming. Each 3D printing service also comes with necessary post-processing, so researching what is required on the front end will help determine cost. Injection MouldingPart complexity: Several design factors can lead to a more complex part with injection moulding. <a href="https://www.protolabs.com/en-gb/automated-design-analysis/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">Design for manufacturability</a> (DFM) analysis is critical to identify modifications that reduce cost. For example, a small part doesn’t automatically translate to a smaller mould size. If your part design requires an undercut or side action, mould base size (and cost) increases significantly. If a cam or insert is required, your overall mould size can increase by £1,000-£2,000 per component. Design TimeFor engineers under increasing pressure to bring products to market, time is money. Quick iteration is key to shorten the timeline to perfect your design and move from concept to final part. That’s why we see our customers start with 3D printing during the prototyping process before moving to injection moulding once a part is ready for production volumes.Product iteration with 3D printing is faster and less expensive compared to injection moulding. If you identify a design flaw once a part is 3D printed, the CAD file can be easily tweaked and uploaded with another iteration printed and sent your way in days. Injection moulding requires significant expense with each design change due to the reworking of the mould. Furthermore, injection moulding usually requires more upfront design work since creating a mould can be a complex process with many factors to consider.<img border="0" width="461" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDgzLTE3MTI2Njk2NDk0ODMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Worker inspecting moulded part." class="fr-fic fr-dii">&nbsp;Set Up and ToolingSet up and tooling costs are another area where 3D printing is the clear winner, as it does not require investment in either. Injection moulding on the other hand comes with tooling costs and often a set-up fee with each run of moulded parts. As we discussed earlier, DFM analysis will help reduce tooling costs, but a mould may still bring thousands in up-front expense. Piece-Part PriceNow here’s an opportunity for injection moulding to shine. Piece-part price for injection moulding is going to be significantly lower compared to 3D printing once we reach a high volume of parts. While we have discussed the cost of tooling at length, each part that comes off that mould will be more cost-effective once you reach quantities that rationalise the initial investment.Fortunately, our applications engineers are well-versed in helping our customers determine if piece-part price cost savings justify the initial upfront costs of injection moulding.<img border="0" width="408" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDkzLTE3MTI2Njk2NDk0OTMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Black vapor smooth 3D printed parts." class="fr-fic fr-dii">Post-processingRegardless of technology, nearly all 3D-printed parts will require some level of post-processing. Mandatory processes after a part is printed include removing support structures or excess resin, depending on the technology you choose. The emergence of post-processing options, such as <a href="https://www.protolabs.com/en-gb/services/3d-printing/enhanced-surface-quality-for-sls-and-mjf-parts/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" title="Enhanced Surface Quality for SLS and MJF parts" target="_blank">vapour smoothing</a>, improving strength and aesthetics have been critical in expanding the applications of additive manufacturing, but each comes with an additional expense.Injection moulding on the other hand comes with more than 100 thermoplastic and thermoset materials that eject from the mould with high-quality finishes fit for production. Finishing process are available to texture a mould, add threaded inserts, laser engraving and more, but aren’t necessary for the durability and finish of the part. Prototyping vs. On-Demand ManufacturingInjection moulding is still a viable option at the prototyping stage. When prototyping at Protolabs, we use a single-cavity aluminium mould that can produce hundreds of parts and can be typically delivered in a week or less. Our customers often choose prototyping with injection moulding if they need to complete design or material iterations, as well as assess cost or manufacturability trade-offs.Once past the prototyping stage, our customers often move to on-demand manufacturing, producing injection moulded parts at Protolabs speeds. Using a steel mould, part quantities are virtually unlimited. On-demand injection moulding with us allows you to meet inventory needs with no minimum order quantities, and offers supply chain flexibility through bridge tooling, just-in-time production, or dual-sourcing strategies. Subscribe for monthly design tips <a href="https://explore.protolabs.com/design-tips-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-design-tip-subscribe-banner-0424" target="_blank" rel="noopener noreferrer">here.</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5Njc2NTYwLTE3MTI2Njk2NzY1NjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib">

Explore key components such as build time, material cost, and part complexity, which can add or reduce cost to your part.

Comparing the Cost between Injection Moulding and 3D Printing

In nanomaterials, shape is destiny. That is, the geometry of the particle in the material defines the physical characteristics of the resulting material.“A crystal made of nano-ball bearings will arrange themselves differently than a crystal made of nano-dice and these arrangements will produce very different physical properties,” said Wendy Gu, an assistant professor of mechanical engineering at Stanford University, introducing her latest <a href="https://www.nature.com/articles/s41467-024-46230-x" data-extlink="" target="_blank">paper</a> which appears in the journal Nature Communications. “We’ve used a 3D nanoprinting technique to produce one of the most promising shapes known – Archimedean truncated tetrahedrons. They are micron-scale tetrahedrons with the tips lopped off.”In the paper, Gu and her co-authors describe how they nanoprinted tens of thousands of these challenging nanoparticles, stirred them into a solution, and then watched as they self-assembled into various promising crystal structures. More critically, these materials can shift between states in minutes simply by rearranging the particles into new geometric patterns.This ability to change “phases,” as materials engineers refer to the shapeshifting quality, is similar to the atomic rearrangement that turns iron into tempered steel, or in materials that allow computers to store terabytes of valuable data in digital form.“If we can learn to control these phase shifts in materials made of these Archimedean truncated tetrahedrons it could lead in many promising engineering directions,” she said.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712303729312-quasi-diamondphase_sb20um_0.png.png" style="width: 100%px;" class="fr-fic fr-dib">Confocal images of truncated tetrahedrons forming several quasi-diamond grains (left). Bond order analysis shows different quasi-diamond grains through alternating colors (right). Neighboring tetrahedrons that have alternating colors (i.e., blue and red/brown, or dark blue and yellow) indicate that they have the same grain orientation. Scale bars are 20 um. | Image courtesy of David Doan &amp; John Kulikowski<h2 id="isPasted">Elusive prey</h2>Archimedean truncated tetrahedrons (ATTs) have long been theorized to be among the most desirable of geometries for producing materials that can easily change phase, but until recently were challenging to fabricate – predicted in computer simulations yet difficult to reproduce in the real world.Gu is quick to point out that her team is not the first to produce nanoscale Archimedean truncated tetrahedrons in quantity, but they are among the first, if not the first, to use 3D nanoprinting to do it.“With 3D nanoprinting, we can make almost any shape we want. We can control the particle shape very carefully,” Gu explained. “This particular shape has been predicted by simulations to form very interesting structures. When you can pack them together in various ways they produce valuable physical properties.”ATTs form at least two highly desirable geometric structures. The first is a hexagonal pattern in which the tetrahedrons rest flat on the substrate with their truncated tips pointing upward like a nanoscale mountain range. The second is perhaps even more promising, Gu said. It is a crystalline quasi-diamond structure in which the tetrahedrons alternate in upward- and downward-facing orientations, like eggs resting in an egg carton. The diamond arrangement is considered a “Holy Grail” in the photonics community and could lead in many new and interesting scientific directions.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712303758221-antiphaseboundary_sb25um_0.png.png" style="width: 100%px;" class="fr-fic fr-dib">Optical images of truncated tetrahedrons forming two large hexagonal grains at an anti-phase boundary (left), and transforming into a quasi-diamond phase that initiated at the anti-phase boundary (right). Scale bars are 25 um. | Image courtesy of David Doan &amp; John KulikowskiMost importantly, however, when properly engineered, future materials made of 3D printed particles can be rearranged rapidly, switching easily back and forth between phases with the application of a magnetic field, electric current, heat, or other engineering method.Gu said she can imagine coatings for solar panels that change throughout the day to maximize energy efficiency, new-age hydrophobic films for airplane wings and windows that mean they never fog or ice up, or new types of computer memory. The list goes on and on.“Right now, we’re working on making these particles magnetic to control how they behave,” Gu said of her latest research already underway using Archimedean truncated tetrahedron nanoparticles in new ways. “The possibilities are only beginning to be explored.”Additional co-authors of the work are PhD students David Doan and John Kulikowski. Gu is also a member of&nbsp;<a href="http://biox.stanford.edu/" data-extlink="" target="_blank">Stanford Bio-X</a>.

Optical images of truncated tetrahedrons forming multiple hexagonal grains (top). Bond order analysis shows different hexagonal grains through different colors (bottom). Neighboring tetrahedrons that have the same color indicate that they have the same grain orientation. Scale bar is 20 um. | Image courtesy of David Doan & John Kulikowski

Stanford materials engineers have 3D printed tens of thousands of hard-to-manufacture nanoparticles long predicted to yield promising new materials that change form in an instant.

Elusive 3D printed nanoparticles could lead to new shapeshifting materials

Is there anything better than a good cup of coffee? It's devine when it's hot, and deliciously refreshing when it's iced.&nbsp;…But room-temperature coffee? Not so great.&nbsp;For most adults around the world, brewing a hot cup of coffee is an established part of our morning routine. But when you have a busy day, it’s easy to get preoccupied and neglect your coffee until it cools to an unpleasant temperature.Duru Uluk, a Voltera test engineering intern, set out to find a solution to this problem. Her goal was to create an induction mug heater using in-mold electronics (also known as in-mold structural electronics).In-mold electronics (IME) processes involve printing conductive inks on moldable plastic films, which are then formed into a desired 3D shape. In the full IME process, after thermoforming, the part is passed along to injection molding, where it is molded in plastic and the electronics become part of the entire structure.&nbsp;In IME, the electronics are printed using a standard process of screen-printing traces onto thermoformable plastics, but new innovative materials — like specially formulated functional inks optimized for high single-stretch operation — allow the traces to stretch into the new thermoformed shape and maintain conductivity.&nbsp;This technology is particularly exciting for automotive and aerospace applications, where thousands of feet of copper wire could be replaced with conductive traces integrated directly into the vehicle’s panels to reduce the vehicle’s weight and improve efficiency. Incorporating IME into vehicle construction also presents opportunities for new design concepts, features, and functionality — like the ability to incorporate strain sensors directly into panels to monitor for damage, interactive surfaces in the interior vehicle panels, or to heat and de-ice the wing of an airplane during flight.&nbsp;In the image below, all the red components identify the wire in a vehicle:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283732859-63b49367152a021e60088642_3ZoHWv-Zic4V11X_3xOkWv831wmyc-hbLHIuslxurYTiXj6bsTy7zNxC97dVW-rYkGLgtJeYYhR5KCm91dpma-EpW2wOgcFG4d_InqrlcJFlFDp3zdS57GulmRe_iM-7DsUkP7ZUhs4RA1FXQ5HbMhmn9_Hgoqkd0BlsUhtZOuHgArS5v-Nn0GG6gaZX3.png" style="width: 100%px;" class="fr-fic fr-dib"><ul id="isPasted"><li>One vehicle has 5000 feet of wires = 50 lbs of copper.</li><li>Transporting 50 lbs burns 12 L of gas per year.</li><li>70,000,000 new cars produced per year.</li><li>840,000,000 L of gas is burned to transport copper cables per year.</li></ul>‍In addition to this example of copper wire, IME offers plenty of other opportunities to reduce the mass of many vehicle components, like the headlight assembly, dashboard, center console, and more.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283763549-63b49367f5596f24c741daec_4ZpHDUtkWx5wmeYtb6X6YjGlsuiVxdPXJ3H64MFHHtiDpTG1Bil6Mat9evncEvLP-DsCX7T2TC63nZtB5DzKQI8Vs98V-vE0R6e3Xbh6oy2iLiPHV6t7InCwE-C3-Mv_9XaLvGjKOrAfnppvIszjmAkMSYyGpSKIKpmn1A621NCHPe04dRGFy75i-Om81.png" style="width: 100%px;" class="fr-fic fr-dib"><a href="https://www.idtechex.com/en/research-article/what-does-2023-hold-for-printed-flexible-electronics/28172" target="_blank" id="isPasted">IDTechEx</a> anticipates the mainstream adoption of in-mold electronics in automotive interiors to begin in 2023, and is forecasting that electronics will be printed onto 3D surfaces, like door panels, in 2026.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283778550-63b49367684ec45971bc70ac_9Gf654z1WMdopCZ5ZMfeK0mO-ZCYnQ1bpkpRVMCY4A4crd2KzqLzh6pao8OoT3ACsO7xnDTdqSfhdTUkRLs-flCOWGlTTjWUHQElpJ__YKFBoiHltw43eQPxsSzSt6DFJUnZ7ONaolf9Fv32CugpbDAMtWnRMf7bRfl-XDBMCBhXX--1QKBBwFR8jUAWd.png" style="width: 100%px;" class="fr-fic fr-dib">Roadmap for selected emerging printed/flexible electronics technologies. Source: IDTechExBut let’s get back to Duru’s coffee conundrum.&nbsp;Using&nbsp;<a href="http://voltera.io/nova" target="_blank">NOVA</a>, a&nbsp;<a href="https://mayku.me/formbox" target="_blank">Mayku Formbox</a>, and a&nbsp;<a href="https://formlabs.com/3d-printers/form-2/" target="_blank">Formlabs 3D printer</a>, Duru designed and built a mug heater with in-mold electronics technology.&nbsp;“During my co-op term at Voltera, Matt (Ewertowski, Product Manager) was my supervisor and also just a super cool person to talk to. We had conversations about different applications of NOVA and how flexible substrates open doors to a lot of different project ideas,” Duru recalled. “He suggested the idea of using the Mayku Formbox alongside NOVA for an in-mold electronics project. I did some research about making molds, molded electronic applications, and coil heaters — and from there it seemed feasible enough to continue with a demo.”&nbsp;So, Duru got to work. First, she used the Formlabs Form 2 3D printer to create a resin mold, and then used NOVA to print traces onto the Mayku Formbox substrates. Finding the optimal baking temperature for the Mayku substrates was a bit of a challenge, since they aren’t intended for IME, but with some experimentation and a bit of help from Mayku, she eventually found the right temperature and baking time to avoid substrate deformation. Once the curing temperature was refined, Duru encountered trace breakage during the forming process. Through some trial and error, Duru refined the design of the mold and the traces until she was successful in creating a design that could be thermoformed and maintain conductivity.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283802120-63b49367bedfeccaa9cf2122_18Qk-iwOjIp00g_snsqEE-x33qu6yTIyGZgI7LuwCgRcaZM_MqpFYbKCYiJuFZBouwEXx12yQES8yTL8EyCsHTZdx9tJe3hHoxa_25BT4I0v1AKIbJnATzxzcMlx7Sax3lK_uGQrK_F9idp-Fxa-5rsh0MAJA5HS_IV8y-YJOUrY7bGJacjQY-0kMgNi_.png" style="width: 100%px;" class="fr-fic fr-dib">“It took several iterations to achieve a design that ensured a fully conductive trace with no breaks. When the baked print goes into the Mayku Formbox, the substrate is being heated and deformed,” she explained. “There are so many factors to consider. Will the conductive ink be damaged? Will the substrate be damaged? That required a lot of correspondence with people to get information about melting points and what not, including <a href="https://insulectro.com/" target="_blank" id="isPasted">Insulectro</a>, who supplied us with the ink — they really helped out. But the biggest issue was of course the sharp angle of the mold, causing the trace to be deformed to a point where it is no longer conductive. And that’s why I had to gradually reduce that angle and on the trace edges.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283815611-63b493679710e828f9389688_waXyaVYzojKJhCnZk3L-4449I7fgizrTBOeX5J_OFFrewsSraWdgajH_SZWHidk2TmHiCQQyixG-GXwRC5MjWiTqBm1HuSU0SPIVCTu_nf4hCdQgQfHpeLhQ5nWupJ7h9OA6rmDnQfC3-dykkJzPrYl_hx-uljy8UhHay90NQDdw1DOL--90k-rxEUl0.jpeg" style="width: 100%px;" class="fr-fic fr-dib">Despite the challenges of the project, Duru loved working with <a href="https://www.youtube.com/watch?v=T62cUY8uj8M" target="_blank" id="isPasted">NOVA</a>. “Everyday I was excited to use the NOVA just because of how cool it is. The user interface is super easy to use, the modular design and the way everything magnetically clicked into place, the sounds, the lights, etc.” she noted. “I also love NOVA’s ability to work with various substrates. I worked a lot with flexible substrates during my time at Voltera, so the vacuum feature was being used frequently.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712283834936-63b4936799db03ad4a1aacaf_ZS6BCi4fHe5wPMhX5X845YVFQK8foJ0C90XCCX2Q0EIZFQ_TL2AX2fVH2gvyMzbL3mfu1mFjlED5rciLDX-kYKeIIYwMn4lQYjsoLvpLbzf2P3dVsHL8YTW0Qjss0gFxsrC5DuwivgbeDPpdGys4vfyDzQ2fmShgr4FPqtWeknJUgW3gxonzz5EeLXoV.jpeg" style="width: 100%px;" class="fr-fic fr-dib">In Duru’s eyes, there are so many exciting applications for the technology. “In biomedical applications, for example, you could use in-mold electronics to build medical tools or prosthetics that are ergonomic and accessible, with electronic components integrated through in-mold processes — to easily incorporate electronics into things that have awkward shapes, or have been challenging to design using traditional methods. And in cases like these, being able to use NOVA to build electronics that fit a specific, custom shape may be a great advantage.”&nbsp;The experience of working with NOVA was inspiring for Duru, and piqued her interest in electronics innovation. “During my time working with NOVA I gained a big interest in additive electronics and learned a foundation of knowledge (about conductive inks, substrates, rheology) that I still bring up at every chance I get,” she said. “I also got inspired to tinker more. Having access to benchtop tools like the NOVA would enable people to tinker freely and try new things — which is beneficial to the engineering iteration process.”&nbsp;Working at Voltera also impacted Duru’s career aspirations. “Many of my co-op placements have been R&amp;D specific. During my future career I think I’d like to work in spaces where I have access to tools like NOVA while doing R&amp;D work and product development. My perspective has shifted to appreciate the potential of additive electronics in&nbsp;<a href="https://www.researchgate.net/publication/361717600_Inkjet_and_Extrusion_Printed_Silver_Biomedical_Tattoo_Electrodes" target="_blank">biomedical applications</a> — for example the&nbsp;<a href="https://uploads-ssl.webflow.com/6334888a34bfac03b46aa715/633c55566e5bffe8db61ba27_NOVA-0082%20-%20Insole%20Case%20Study_v2.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">in-sole pressure sensor</a> project I did, or things like wearable biomarker sensors.”And now, thanks to her in-mold mug heater, Duru can iterate for hours and never have to worry about her coffee getting cold.&nbsp;

Duru Uluk, a Voltera test engineering intern, created an induction mug heater using in-mold electronics (also known as in-mold structural electronics).

Warming Your Coffee with In-Mold Structural Electronics

Since its founding nearly 25 years ago, welding specialist<a href="https://www.elektrolas.com/en/" target="_blank">&nbsp;Elektrolas</a> has evolved from a company that supplies and maintains welding equipment to one that also offers training and quality management services and, most recently, welding automation services. In parallel to this expansion, the Dutch company has also evolved in terms of the technologies it uses. Notably, it has embraced the use of 3D printing (specifically,<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s5/" target="_blank">&nbsp;UltiMaker’s S5 ProBundle</a>), which has enabled it to improve automated welding setups and streamline operations.<h2 dir="ltr">The road to 3D printing adoption</h2>Like many companies familiar with more conventional production techniques, Elektrolas did not immediately recognize the benefits of integrating 3D printing into its processes. It took Thije van Delft, Technical Manager at Elektrolas, to invest in the technology himself and test out how it could be used in a welding context.He says: “I had done some tests in school using 3D printers, and I asked the company owner [Joost van den Hooven] if I could buy one. He said it wasn’t possible, so I said ‘I will buy one myself’ and purchased a very simple 3D printer for a couple hundred euros and started with that. We did some tests and after some time, Joost was convinced”. From there, Elektrolas consulted with the engineering students participating in traineeships at the company (who were familiar with 3D printing through their studies) about which 3D printer hardware they should invest in. After much deliberation, UltiMaker’s S5 ProBundle was chosen.<h2 dir="ltr">Unlocking new applications</h2>The UltiMaker 3D printer has played an important role at the company, particularly as Elektrolas has ramped up its automation department (spearheaded by van Delft), supplying robotic and cobot welding systems to customers in the Netherlands and beyond. To date, the company has sold and installed dozens of cobot welding systems, which empower its customers to accelerate their lead times and achieve consistent quality, all while mitigating labor shortages in the welding sector.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjMzMTE3NjI2LWluc2lkZXdlbGQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Thije van Delft with the UltiMaker S5 ProBundle, and the cobot welding rig in the back.3D printing has come into play in the production of clamps, which are installed on welding cobots to keep things running smoothly and to ensure the freedom of movement of the robotic arm. Van Delft explains: “We have a holder and an arm clamp that attach the torch hose to the robot. This is made up of two parts: one part that clamps to the robot and one part that attaches to the hose. These are fixed with a fixing pin. If you wanted to make that using milling or other conventional processes, it would not be possible.”<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2NzgwMjQ1LWxvdyBpbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">The complex form of the clamp makes it perfect to be 3D printed at a cost and timeframe impossible to replicate in other manufacturing methods. Image credit: Elektrolas.The company has also found it possible to quickly iterate replacement parts for the 3D printed clamps. Made from Tough PLA, it does happen that the clamps break sometimes. “In this case it’s very easy to print a new one and send it the next day to the customer,” van Delft says. “The customer simply sends a picture of what part is broken, we start the printer, and the next day we can send it via DHL to the customer.” This, of course, has the obvious benefit of eliminating the need for large inventories of spare clamps, since they can be printed on demand.Elektrolas has also turned to 3D printing in the production of temporary holders that attach hand welding torches to robotic or cobot systems. In this case, UltiMaker’s solution enabled Elektrolas to meet the needs of one of its customers who wanted to integrate a manual welding torch in an automated system. “We called the supplier of this welding torch, but the automatic version had a delivery time of 10-12 weeks,” van Delft recalls. By designing and 3D printing a holder to attach the welding torch to the robot, Elektrolas was able to offer its customer a stopgap solution while they waited for the final part from the welding torch supplier. This enabled them to keep their automated welding production up and running rather than being setback by system downtimes.<h2 dir="ltr">Why the UltiMaker’s S5 ProBundle?</h2>While both UltiMaker and Elektrolas are based out of the Netherlands, the local appeal was only part of the equation when the welding company started looking for a 3D printing solution to adopt three years ago. UltiMaker’s S5 ProBundle is a professional-grade solution that combines UltiMaker’s reliable dual-extrusion technology with advanced features like automated material management, superior air filtration, and humidity control for filament. The 3D printer also has a sizable print volume (330 x 240 x 300 mm), which was an important factor for Elektrolas as the company often prints large components.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2ODQ0NTY0LWRlZXAgLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Multiple prints can be completed simultaneously in the S5’s large print bed.&nbsp;Ease of use and print quality were also top of mind for van Delft and his team. The UltiMaker S5 ProBundle delivered on both fronts. Elektrolas has achieved consistency from print to print thanks to the ability to save setup and print settings in Cura. As van Delft explains, he and his team are able to design the parts they need in SolidWorks and print them on demand with the touch of a button. This is also thanks to the work of their trainee students, who have pre-programmed print settings, and UltiMaker’s intuitive user interface, which enables one-button printing. “If, for example, a client wants to weld with some special machine but there is no welding torch on the robot, we can take a normal welding torch and sketch a holder in SolidWorks and then print it.” Using this approach, test parts can be delivered the next day.In terms of printing materials, Elektrolas is primarily working with<a href="https://ultimaker.com/materials/s-series-tough-pla/" target="_blank">&nbsp;UltiMaker Tough PLA</a>, a technical PLA filament that offers good toughness (similar to ABS), as well as minimal warping and excellent printability at an affordable cost. While not the most robust material in UltiMaker’s portfolio, Tough PLA does meet the needs of the welding company for the clamps and holders. Even the material’s weaknesses have proven to be a benefit. “I have twice received a request for a new 3D printed clamp because the operator of the robot made a mistake and broke the clamp when the torch hit some corner when the robot was moving,” van Delft elaborates. “Here it is good that the clamp breaks, because it protects the torch from breaking. The clamp is not expensive and easy to replace, the torch is not.”<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2OTA5Mjg1LWxvdyByZXMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">The 3D printed clamps enable the welding hoses to be safely secured. By printing in Tough PLA, the clamps are robust but also quick and affordable to replace when needed.Elektrolas also benefits from other features that come with the S5 ProBundle, including Air Manager, an enclosure that provides closed inside-out airflow and filters up to 95% of ultrafine particles (UFPs) generated in the printing process, and the S5 Material Station. This piece of equipment stores and protects up to six spools of filament and offers end-of-filament detection and automatic spool switching, which facilitates lights-out printing. “If you have a big print, it is maybe 35-45 hours of printing,” van Delft adds. “Since we have big prints, the material station can change the PLA by itself and keep the print going until it’s ready the next day.”For 3D printer maintenance and technical support, Elektrolas turns to <a href="https://www.makerpoint.nl/nl-nl/" target="_blank">MakerPoint</a>, a Dutch supplier of 3D printing systems and maintenance provider based in Arnhem, Best, and Harlingen.<h2 dir="ltr">Intuitive 3D printing for traditional manufacturing</h2>Elektrolas is one of many businesses in the traditional manufacturing sphere that has reaped the benefits of UltiMaker’s professional 3D printing solutions. For example,<a href="https://www.wevolver.com/article/eriks-leveraging-3d-printing-to-improve-manufacturing-processes" target="_blank">&nbsp;industrial supplier ERIKS BV</a> relies on UltiMaker systems for a range of applications, including prototyping, tooling, customized jigs and fixtures, and replacement parts. You can find more<a href="https://www.wevolver.com/profile/team.ultimaker" target="_blank">&nbsp;UltiMaker client stories here</a>.

Dutch welding solutions specialist Elektrolas uses the UltiMaker 
S5 ProBundle to minimize machine downtimes and facilitate cobot welding for its customers.


How UltiMaker 3D Printing Supports Automated Welding

What is 3D printing? This article goes over the basics of 3D printing, otherwise known as additive manufacturing, covering its engineering principles and applications.


What is 3D Printing: A Comprehensive Guide to its Engineering Principles and Applications

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