<p id="isPasted">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.</p><h2 data-counter-attr="value0"><strong>What is Infill in 3D Printing?</strong></h2><p>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.</p><h2 data-counter-attr="value1"><strong>What is the Purpose of Infill in 3D Printing?</strong></h2><p>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.</p><h2 data-counter-attr="value2"><strong>What Are the Key Elements of Infill in 3D Printing?</strong></h2><p>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.</p><h2 data-counter-attr="value3"><strong>What Are the Different Types of Infill in 3D Printing?</strong></h2><p>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:</p><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"><strong>Concentric Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Concentric infill</span></span></span></p><h3 data-counter-attr="value5" id="isPasted"><strong>Grid Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Grid infill</span></span></span></p><h3 data-counter-attr="value6" id="isPasted"><strong>Line Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Line infill</span></span></span></p><h3 data-counter-attr="value7" id="isPasted"><strong>Gyroid Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Gyroid infill</span></span></span></p><h3 data-counter-attr="value8" id="isPasted"><strong>Octet Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Octlet infill</span></span></span></p><h3 data-counter-attr="value9" id="isPasted"><strong>Lightning Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Lightning infill</span></span></span></p><h3 data-counter-attr="value10" id="isPasted"><strong>Triangular Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Triangular infill</span></span></span></p><h3 data-counter-attr="value11" id="isPasted"><strong>Tri-Hexagon Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Tri hexagon infill</span></span></span></p><h3 data-counter-attr="value12" id="isPasted"><strong>Cubic Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Cubic infill</span></span></span></p><h3 data-counter-attr="value13" id="isPasted"><strong>Cross Infill Pattern</strong></h3><p>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.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><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"><span class="fr-inner">Cross infill</span></span></span></p><h3 data-counter-attr="value14" id="isPasted"><strong>What is an Optimal Infill Density?</strong></h3><p>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.</p><h3 data-counter-attr="value15"><strong>How Does Infill Pattern Choice Affect the Overall Aesthetics of a 3D Printed Part?</strong></h3><p>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.</p><h3 data-counter-attr="value16"><strong>What Are the Infill Patterns That Maximize the Strength of the Part?</strong></h3><p>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.</p><p>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.</p><h2 data-counter-attr="value17"><strong>How to Choose the Best Infill</strong> Pattern</h2><p>The process of selecting the optimal infill pattern involves several steps:</p><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><p>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.</p><h2 data-counter-attr="value18"><strong>Is Infill Important for 3D Printing?</strong></h2><p>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.</p><h2 data-counter-attr="value19"><strong>Conclusion</strong></h2><p>The article covers the significance of infill in 3D printing, outlines various types of infill patterns available, and offers guidance on pattern selection.</p><p>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.</p>

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

<p dir="ltr" id="isPasted">Selective laser sintering (SLS) 3D printing is considered one of the most reliable and productive forms of additive manufacturing.<sup id="isPasted">[1]</sup> Recently, advances in hardware are improving SLS printing even further, enabling even better surface finish quality and achievable level of fine details.&nbsp;</p><p dir="ltr">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.</p><h2 dir="ltr">The Science of Laser Spot Size</h2><p dir="ltr">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. <sup>[2]</sup></p><p dir="ltr">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. <sup>[3]</sup></p><p dir="ltr">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 <sup>[4]</sup></p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU3Mjc2OTk1LVNjcmVlbnNob3QgMjAyNC0wNC0yNCAxMzE0MTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><sup>&nbsp;</sup></p><p dir="ltr" id="isPasted">Where:</p><p dir="ltr"><em>Eₛ</em> is the laser energy density (J/cm^2)</p><p dir="ltr"><em>P</em> is the incident laser power (Watts)</p><p dir="ltr"><em>v</em> is the laser scan speed (cm/s)</p><p dir="ltr"><em>δ&nbsp;</em>is the laser beam spot size (cm)</p><p dir="ltr" id="isPasted">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. <sup>[5]</sup></p><p>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 <sup>[6]</sup></p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU3NTExMjE0LVNjcmVlbnNob3QgMjAyNC0wNC0yNCAxMzE4MjMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted">Where:</p><p dir="ltr"><em>f</em> is the focal length.</p><p dir="ltr"><em>Wf&nbsp;</em>is the beam radius focal length (i.e., spot size)</p><p dir="ltr">λ is the laser wavelength</p><p dir="ltr"><em>w</em>₀ is the beam waist</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714132304695-o.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 1: The propagation of a laser along its axis.</span></span></span></p><p dir="ltr" id="isPasted">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.</p><h2 dir="ltr">Impact of Laser Spot Size on Print Quality</h2><p dir="ltr">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. <sup>[7]</sup></p><p dir="ltr">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. <sup>[8]&nbsp;</sup></p><p dir="ltr">Research has found that smaller laser spot sizes markedly enhance the geometrical accuracy of printed tracks. <sup>[9]</sup> 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;</p><p dir="ltr">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;</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU1ODQ4MTcxLTVfRXNjaGJhbF9TTFNDb21wb25lbnQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 dir="ltr" id="isPasted">Sintratec’s Unique Selling Proposition (USP)</h2><p dir="ltr">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;</p><p dir="ltr">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:</p><table style="width: 100%;"><tbody><tr><td style="width: 50.0000%;"><strong>SLS 3D Printer</strong><br></td><td style="width: 50.0000%;"><strong>Laser Spot Size (μm)</strong><br></td></tr><tr><td style="width: 50.0000%;">Sintratec S3 and S2<br></td><td style="width: 50.0000%;">145 μm <sup>[10]</sup><br></td></tr><tr><td style="width: 50.0000%;">Prodways Promaker P1000<br></td><td style="width: 50.0000%;">450 μm <sup>[11]</sup><br></td></tr><tr><td style="width: 50.0000%;">Sinterit Lisa X<br></td><td style="width: 50.0000%;">650 μm <sup>[12]</sup><br></td></tr><tr><td style="width: 50.0000%;">Formlabs Fuse 1<br></td><td style="width: 50.0000%;">200 μm <sup>[13]</sup><br></td></tr></tbody></table><h2 dir="ltr" id="isPasted">Real-World Applications and Benefits</h2><p dir="ltr">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.</p><p dir="ltr"><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.”</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEzOTU2MDE1NjA3LTZfS29udGFrdFNpbW9uX1NMU0NvbXBvbmVudC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted">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;</p><p>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.</p><h2 dir="ltr" id="isPasted">Conclusion</h2><p dir="ltr">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;</p><h2 dir="ltr" id="isPasted">References</h2><p dir="ltr">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.</p><p>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.</p><p>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/ISFA2012-7232</p><p>4. 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_5</p><p>5. 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).</p><p>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)</p><p>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>.</p><p>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></p><p>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.</p><p>10. <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank">https://sintratec.com/sls-3d-printer/amp/sintratec-s2/</a></p><p>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></p><p dir="ltr">12. https://www.3d-printer.com/3D_Printers/Sinterit_Printers/lisa-x</p><p>13. https://formlabs.com/3d-printers/fuse-1/tech-specs/</p>

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

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

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">Understanding Rapid Prototyping</h2><p>Rapid prototyping spearheads a shift in manufacturing, enabling the quick transformation of ideas into tangible products. This approach leverages cutting-edge technologies such as 3D printing, CNC machining, and additive manufacturing to facilitate fast-paced development cycles, crucial for staying competitive in today's market.</p><p>At the forefront of this transformation is <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN</a>, a company that's integrating advanced rapid prototyping techniques to offer flexible, cost-effective, and time-efficient solutions. Their services cater to a wide range of businesses, from startups dreaming big to global corporations looking for innovative manufacturing strategies. By reducing the time and cost associated with traditional manufacturing methods, BOEN empowers companies to experiment more freely with their designs, iterate faster, and bring products to market more quickly.</p><p>This shift toward rapid prototyping is not just about speed and efficiency; it's also about the democratization of manufacturing. By lowering the barrier to entry, rapid prototyping enables more creators to bring their visions to life, fostering a new era of innovation in manufacturing.</p><h2>The BOEN Difference</h2><p>BOEN distinguishes itself in the rapid prototyping industry through a blend of proprietary techniques and state-of-the-art technology. Their advanced approach combines:</p><p><strong>Innovative Workflows:</strong> Streamlining the design-to-production cycle, BOEN employs agile methodologies that significantly reduce development time. Their seamless integration of client feedback loops ensures that prototypes meet or exceed expectations with minimal iteration.</p><p><strong>Advanced Hardware:&nbsp;</strong>BOEN's investment in cutting-edge hardware, from 3D printers capable of producing complex geometries to sophisticated CNC machines for high-precision machining, sets a new standard for rapid prototyping. This hardware allows for a wide array of materials to be used, each selected through a rigorous materials science approach that matches the right medium to the project's specific requirements.</p><p>The synergy of these elements positions BOEN as a leader in rapid prototyping, providing unique technical benefits such as reduced lead times, increased precision, and greater flexibility in material selection. Their dedication to pushing the boundaries of what's possible in rapid prototyping not only accelerates product development cycles but also empowers innovation, making them a sought-after partner in the manufacturing sector.</p><h2>Practical Impacts on the Industry</h2><h3>Streamlining the Design to Manufacturing Pipeline</h3><p>Rapid prototyping significantly streamlines the journey from design to production, offering a profound impact on manufacturing efficiency and product quality. By enabling quicker iterations and faster validation of designs, organizations can drastically reduce development cycles and associated costs. BOEN plays a pivotal role in this transformation through its advanced prototyping solutions.</p><p>Leveraging state-of-the-art technologies, BOEN helps industries accelerate their design processes. For instance, the use of 3D printing allows for complex geometries to be created directly from digital models within hours, bypassing the lengthy traditional manufacturing setups. Similarly, CNC machining services offer precision in creating parts from a wide range of materials, further refining the prototype's fidelity to the intended final product.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713185375967-5-Axis-CNC-machining-aluminium-p.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">5-axis CNC machines allow BOEN to deliver rapid prototyping at low volume. Credit: BOEN.</span></span></span></p><p>Moreover, BOEN's emphasis on materials science ensures that each prototype not only meets design specifications but also simulates the functional and aesthetic properties of final products. This holistic approach to prototyping encompasses not just the physical creation of parts but also a rigorous assessment of how materials react under real-world conditions, leading to higher quality outcomes.</p><p>Significantly, BOEN's methodologies foster greater innovation. With reduced time and cost implications, companies are encouraged to explore more ambitious designs, test new concepts, and iterate more frequently. This democratization of high-quality prototyping serves as a catalyst for breakthroughs across numerous sectors, from automotive to medical devices, where the precision and speed of prototyping can mean quicker market entry and competitive advantage.</p><p>In essence, the services provided by BOEN underscore the practical benefits of rapid prototyping in today's fast-paced industry, emphasizing efficiency, quality, and innovation.</p><h3>Opening Doors for Startups and Innovators</h3><p>Rapid prototyping is a game-changer for startups and innovative companies, easing the path from ideation to realization with its cost-efficiency and flexibility. For ambitious projects on tight budgets, this methodology is a beacon, illuminating the route to successful product development without the hefty investment traditionally associated with manufacturing.</p><p>BOEN, understanding the unique landscape startups navigate, offers specialized services that align with the agile, innovative ethos of these ventures. Their approach demystifies the prototyping process, granting access to high-quality resources and expertise that were once the exclusive domain of industry giants.</p><p>The technical benefits provided by rapid prototyping, such as improved design accuracy, the possibility of iterative testing, and the capability to quickly adapt to feedback, are crucial for startups. These benefits enable a swift response to market demands or design challenges, enhancing market responsiveness.</p><p>Furthermore, BOEN’s solutions are not one-size-fits-all but are carefully tailored to meet the distinct needs of innovators. Whether it's selecting the right material for a prototype to test its durability or employing the most suitable prototyping technique to ensure cost-effectiveness, BOEN’s expertise proves invaluable.</p><p>This support empowers startups to tread boldly in competitive markets, making rapid prototyping not just a manufacturing approach, but a strategic asset for driving innovation and securing a foothold in the industry.</p><h2>Beyond Prototyping: The Future with BOEN</h2><h3>From Prototyping to Low-Volume Production</h3><p>The transition from rapid prototyping to low-volume production is a critical phase for any product development process, marking the shift from concept validation to market readiness. This stage involves:</p><p><strong>Detailed Planning:</strong> Establishing a clear roadmap from prototype to production, considering timeframes, budget, and resource allocation.</p><p><strong>Material Selection and Sourcing:</strong> Choosing materials that balance cost, performance, and availability for low-volume runs.</p><p><strong>Manufacturing Technique Adjustment:</strong> Shifting from prototyping methods to those more suitable for small-scale production without compromising quality.</p><p><strong>Quality Control Systems:</strong> Implementing stringent quality control measures adapted for low-volume production to ensure each unit meets the high standards set during prototyping.</p><p><strong>Logistics and Supply Chain Management:</strong> Optimizing logistics to handle the distribution of smaller product quantities, managing supply chain relationships to ensure timely delivery of materials.</p><p>BOEN supports businesses through this transition by leveraging its expertise in both rapid prototyping and small-scale manufacturing. Their support encompasses:</p><p><strong>Consultation and Strategy:&nbsp;</strong>Advising on the best pathways for scaling production in a cost-efficient manner while maintaining product quality.</p><p><strong>Custom Manufacturing Solutions:&nbsp;</strong>Offering tailor-made manufacturing solutions that address the unique challenges of low-volume production.</p><p><strong>Quality Assurance:&nbsp;</strong>Ensuring that the quality established during the prototyping phase is maintained or enhanced as production scales.</p><p><strong>Supply Chain Optimization:&nbsp;</strong>Assisting in creating a responsive and efficient supply chain tailored to the needs of small-scale production.</p><p>Through these services, BOEN helps companies navigate the complexities of scaling their products, enabling a smoother transition from concept prototypes to market-ready products. This comprehensive support is invaluable for businesses looking to capitalize on their innovations with minimal delays and optimal product quality.</p><h2>Empowering Innovation Across Industries</h2><p>Rapid prototyping, especially when leveraged by BOEN's expertise, catalyzes innovation across various industries by providing tailored solutions that meet each sector's unique demands.</p><p>In the aerospace sector, precision and reliability are paramount. Rapid prototyping facilitates the production of lightweight, high-strength components, reducing aircraft weight and improving fuel efficiency. BOEN's adept material selection ensures components withstand extreme conditions, from high temperatures to mechanical stress, crucial for aerospace applications.</p><p>In the medical devices industry, the ability to prototype intricate, biocompatible devices rapidly accelerates the development of lifesaving technologies. BOEN's proficiency in navigating material compatibility and regulatory requirements allows for the swift iteration of designs, from prosthetics to surgical tools, ensuring they meet stringent medical standards. Low-volume manufacturing allows medical device products to be made in small batches, as medical devices, unlike consumer products do not require very large quantities.</p><p>The automotive industry benefits significantly from rapid prototyping by expediting the design process of both functional and aesthetic automotive parts. BOEN's expertise in durable materials and finishing techniques enables the production of prototypes that closely mimic final products, allowing for comprehensive testing and design optimization.</p><p>By overcoming technical challenges through innovative solutions and material expertise, BOEN not only advances product development within these sectors but also empowers companies to push the boundaries of what's possible, leading to groundbreaking innovations that reshape industries.</p><h2>Conclusion</h2><p>The journey through rapid prototyping's capabilities and its transformative impact on various industries has underscored its indispensable role in modern manufacturing. Through the lens of BOEN's innovative practices, we've seen firsthand how technological advancements in rapid prototyping significantly streamline the design-to-manufacturing pipeline, empower startups, and catalyze innovation across sectors like aerospace, automotive, and medical devices.&nbsp;</p><p><a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN</a> stands at the forefront of this revolution, offering expertise and solutions that not only meet the current demands of the market but also pave the way for future advancements. The potential for further innovation in manufacturing, driven by rapid prototyping, is boundless. We invite industry professionals to consider how these advancements could be integrated into their operations, ushering in a new era of efficiency and creativity.&nbsp;</p>

Rapid prototyping is significantly contributing to an innovative manufacturing future by enabling swift conversion from conceptual designs to physical models.

Rapid prototyping's transformative role to the future of manufacturing

<h2 id="isPasted">1. excellent surface finishing that enhances optical performance</h2><p>Electroformed optical parts exhibit excellent surface smoothness free from defects and irregularities, which is crucial for achieving high image quality and resolution. The smooth surfaces minimize light scattering and diffraction, resulting in sharper and clearer images. This is particularly important in applications such as high-resolution imaging systems, microscopy, and telescopes, where even the slightest surface imperfections can lead to image degradation.</p><p>Moreover, the high reflectivity of Electroformed metal surfaces contributes to increased light throughput and efficiency in optical systems. With <a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> mirror-like finishing can be achieved that allows for efficient reflection and transmission of light, minimizing losses due to absorption or scattering. This is particularly beneficial in applications where light collection and efficiency are critical, such as in astronomical telescopes, spectrometers, and illumination systems. The increased light throughput and efficiency of electroformed optical parts lead to improved signal-to-noise ratios, higher sensitivity, and better overall performance of the optical system.</p><h2>2. superior durability and resistance that increase product reliability and longevity</h2><p>Electroformed optical parts demonstrate excellent resistance to environmental factors, such as moisture, corrosion, and chemical exposure, which is especially important in applications where the optical parts are exposed to harsh or corrosive environments, such as in marine or industrial settings. The ability of electroformed optical parts to withstand these environmental challenges ensures their long-term reliability and performance stability, which eliminates the need for frequent recalibration or adjustments, reducing downtime and increasing the overall efficiency of the optical system.</p><p>The increased durability and reliability also translate to reduced maintenance and replacement costs over the lifetime of the optical component. Unlike other manufacturing methods that may produce parts with shorter lifespans or require frequent repairs, electroformed optical parts maintain their performance and integrity for extended periods. This longevity is particularly valuable in applications where the optical components are difficult to access or replace, such as in satellite systems or deep-sea instrumentation.</p><h2>3. Precision engineering capabilities that enable advanced optical designs and configurations</h2><p>As an&nbsp;<a href="https://www.vecoprecision.com/electroforming/electroforming-process/" rel="noopener" target="_blank">Additive Manufacturing process</a>, Electroforming technology offers the unique ability to integrate multiple optical functions into a single component. With Electroforming, it is possible to create complex optical structures that combine several optical elements. This simplifies the overall optical system, reduces the number of components required, and improves the alignment and stability of the system.</p><p>Electroforming technology also offers excellent design flexibility. As Electroforming allows for the creation of complex, &nbsp;freeform optical surfaces, it enables the realization of advanced optical designs and configurations that may be challenging or impossible to achieve with traditional manufacturing methods. This design freedom opens up new possibilities for optical engineers to develop innovative and high-performance optical systems.</p><h2>4. Miniaturization and precision features that improve user experience</h2><p>Electroformed optical parts play a crucial role in enhancing the user experience. For example in consumer electronics, particularly in imaging devices such as smartphones, digital cameras, and virtual reality headsets, the high precision and surface quality of electroformed lenses and mirrors enable the capture and display of clearer and sharper images, with reduced distortions and aberrations. Users benefit from improved image quality, higher resolution, and better color reproduction, resulting in a more immersive and satisfying visual experience.</p><p>The miniaturized optical parts enabled by Electroforming also allow for the design of sleeker and more portable consumer devices, further enhancing user convenience and satisfaction. This is particularly valuable in applications where size and weight are critical factors, such as in smartphones, wearable devices, and portable medical instruments. By incorporating high-precision miniaturized optical parts, manufacturers can design devices that are more compact, lightweight, and ergonomic, making them easier to carry and use on the go.</p><p>In conclusion, electroformed optical parts offer a wide range of benefits, making electroformed optical parts a preferred choice for various industries, including consumer electronics, automotive, aerospace, scientific instrumentation, and medical devices.</p>

Electroforming technology has emerged as the most suitable method for manufacturing high-quality optical parts due to its unique combination of high precision, material properties, and design flexibility.  

Applications of Electroforming: why Electroforming is the ideal solution for manufacturing optical parts

<h2 id="isPasted">Iconic PepsiCo Brand Finds Best Alternative to Expensive, Time-Consuming Conventional Metal Tooling</h2><p><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.</p><h2 id="isPasted">The challenge</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MTU1MjQ1LWV6Z2lmLTEtNGZiZjE1OTIxMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p>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.</p><p>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.</p><blockquote id="isPasted"><p>“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.”<strong>Max Rodriguez, Senior Manager of Global Packaging<br id="isPasted">R&amp;D, Advanced Engineering and Design, PepsiCo</strong></p></blockquote><h3 id="isPasted"><strong>The application</strong><strong><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjI2NDE3LVBlcHNpQ28tUGF0ZW50ZWQtM0QtUHJpbnRlZC1IeWJyaWQtTW9sZC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></strong><br></h3><p>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.</p><h3><strong>The advantages</strong></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><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/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></span></p><h2 id="isPasted">More Than 10,000 Bottles at 96% Reduction in Cost</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjY2OTM4LVBlcHNpQ28tUGF0ZW50ZWQtTW9sZC0zRC1QcmludGVkLU5leGEzRC03Njh4NTg5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>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.</p><p>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.</p>

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

<p dir="ltr" id="isPasted">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.</p><h2 dir="ltr">The road to 3D printing adoption</h2><p dir="ltr" id="isPasted">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.</p><p dir="ltr">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.</p><h2 dir="ltr">Unlocking new applications</h2><p dir="ltr">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.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjMzMTE3NjI2LWluc2lkZXdlbGQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Thije van Delft with the UltiMaker S5 ProBundle, and the cobot welding rig in the back.</span></span></span></p><p dir="ltr" id="isPasted">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.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2NzgwMjQ1LWxvdyBpbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">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.</span></span></span></p><p dir="ltr" id="isPasted">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.</p><p dir="ltr" id="isPasted">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.</p><h2 dir="ltr">Why the UltiMaker’s S5 ProBundle?</h2><p dir="ltr">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.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2ODQ0NTY0LWRlZXAgLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Multiple prints can be completed simultaneously in the S5’s large print bed.&nbsp;</span></span></span></p><p dir="ltr" id="isPasted">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.</p><p dir="ltr">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.”</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2OTA5Mjg1LWxvdyByZXMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">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.</span></span></span></p><p dir="ltr" id="isPasted">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.”</p><p dir="ltr">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.</p><h2 dir="ltr">Intuitive 3D printing for traditional manufacturing</h2><p dir="ltr">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>.</p>

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

<p id="isPasted">Mike Simmons, Matthew Kleyn, Joseph Vlach, Liz Josephson; Intellivation LLC</p><p>The demand for high-performance devices with enhanced functionalities continues to grow. Materials, such as graphene and MoS2, exhibit unique electrical and mechanical properties making them ideal for flexible electronic applications. To meet the rising demand and requirements for flexible 2D microelectronics devices manufactured using Roll to Roll technology, we use innovative manufacturing techniques including vacuum coatings in combination with laser technology. Laser patterning of sputtered coatings provides the ability to achieve high-volume production with precision, functionality and efficiency for a wide range of flexible applications.</p><p>Sputter deposition is a widely used technique for depositing thin films onto substrates. For flexible 2D microelectronics, sputtered coatings serve as the foundation for building functional devices. Sputtering involves bombarding a target material with ions to eject atoms or molecules, which then deposit onto a substrate to form a thin film. This process allows for precise control over the thickness and composition of the deposited film, making it a preferred method for creating uniform and reproducible coatings. &nbsp;Sputtered layers were deposited using Intellivation’s R2R Lab system. Sputtering provides an excellent method for depositing coatings uniformly over large areas, while laser patterning can create discrete devices, circuits, and other types of discontinuous features required for manufacturing. &nbsp;Using these two techniques in combination provides unique capabilities, particular during product development. &nbsp; Photolithography requires multiple steps and is time consuming, it also requires geometric commitment of features at early stage of design. &nbsp;Laser patterning offers a direct and efficient way to create and define patterns on sputtered coatings including changes in geometry while providing consistent feature size and edge quality.</p><p>Laser patterning uses a laser beam to selectively remove or modify specific areas of deposited films enabling the generation of intricate patterns with submicron-level precision. &nbsp;Control and precision of the laser is critical and the non-contact nature of laser patterning reduces the risk of contamination and damage to the underlying substrate, ideal for delicate 2D materials. &nbsp;This technique provides the ability to develop and then validate a design and process in small volumes and then easily transfer to large area roll-to-roll production without changes to the laser processing equipment.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTYwNzI0ODg3LVNjcmVlbnNob3QgMjAyNC0wNC0wMyAxNTQwMzkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712209387228-Boston-2024-email.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Join us and Intellivation at TechBlick's Future of Electronics RESHAPED conference and exhibition in Boston | June 2024 https://www.techblick.com/electronicsreshapedusa</span></span></span></p><p>Deposition of the conductive material onto the substrate was done with Intellivation’s R2R thin film vacuum deposition Lab coater , it is then laser patterned or the laser is used to isolate regions to crystallize them for interfacing with subsequent layers. Once the substrate, layer stacks and laser variables are optimized, the next phase is to scale these devices to large area R2R processing.</p><p><br><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTYxMDkyODYyLVNjcmVlbnNob3QgMjAyNC0wNC0wMyAxNTQzMzAuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p>The combination of laser patterning and sputtered coatings has unlocked new possibilities in the high-volume production of flexible 2D microelectronics. This innovative approach addresses the demand for devices with enhanced performance, precision, and scalability. A roll-to-roll approach offers several significant advantages in terms of efficiency, cost and adaptability.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712209445705-660d896c5506c37659840c4f.jpg" style="width: 768px;" class="fr-fic fr-dib"><span class="fr-inner">Intellivation will be exhibiting at TechBlick's Future of Electronics RESHAPED conference and exhibition in Boston | June 2024 https://www.techblick.com/electronicsreshapedusa</span></span></span></p><p><br></p>

R2R Sputtering + Direct Laser Patterning is a great way to create large-area circuits on flexible circuits, even with materials such as graphene or MoS2.  The technology R2R produces high-quality uniform films on large substrates whilst the laser forms precision circuit patterns without photolith.

Flexible Microelectronic Devices produced with Sputtered Coatings and Laser Patterning

<p id="isPasted">In an industry where speed, accuracy, and cost-effectiveness are crucial, <a href="https://yawmanflight.com/" target="_blank">Yawman Flight</a> teamed up with <a href="https://motocilino.com/" target="_blank">MotoCilino Engineering Service</a> firm and Nexa3D to address the challenge of designing and developing a first-of-its-kind handheld controller for flight simulations.The Yawman Arrow is the fusion of a traditional handheld gaming controller and the unique flight controls found on aircraft of all sizes. Designed for precision and versatility, the Arrow brings together a traditional joystick, desktop throttle quadrant, and rudder pedals – and more – all into a handheld form factor.</p><p>The result is a breakthrough in both product innovation and manufacturing efficiency, with <a href="https://nexa3d.com/3d-printers/xip/" target="_blank">XiP Desktop 3D Printer</a> playing a pivotal role in achieving success.</p><h2 id="isPasted">Challenge</h2><h5>Create high-fidelity prototypes quickly and cost-effectively without investing in tooling early on in the development process</h5><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712135865489-creating-high-fidelity-prototype-768x720.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Yawman Flight faced the challenge of creating a unique flight simulator controller under significant time and budget constraints. The primary objectives were to develop a first-of-its-kind handheld flight simulator controller and complete the project rapidly and cost-effectively, without investing in costly injection molding tooling. Additionally, the team required high-quality surface finish and mechanical performance of all of the components so achieving injection molding-like quality quickly and affordably were critical to the success of the project.</p><p>Yawman Flight’s intended customer base is flight simulation enthusiasts and professionals in the aviation industry who demand high-quality, realistic flight simulation experiences. The flight simulation industry requires high-quality products that can meet strict specifications for part tolerances and mechanical performance in order to provide a truly realistic simulation experience.</p><blockquote id="isPasted"><p>“The XiP allowed us to create a final product that exhibits injection molded like qualities in terms of surface finish and performance, but without the costs and long lead times. We would’ve been delayed by as much as a year had we used another manufacturing method during the prototyping phase.”<strong>Thomas Nield, Engineering Lead at Yawman Flight</strong></p></blockquote><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712135927444-1712135927444.png" class="fr-fic fr-dib"></p><h2 id="isPasted">Solution</h2><h5>The XiP proved to be ideal tool for the job due to its accuracy and print speed</h5><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712135943136-flight-controller-3D-printed-XiP-768x769.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Yawman Flight collaborated with MotoCilino Engineering Service firm to develop a unique controller in record time, going through 17 different design iterations before validating the final assembly in just a few weeks. The final prototype controller consists of 36 different components, all of which were printed on the <a href="https://nexa3d.com/3d-printers/xip/" target="_blank">XiP desktop 3D printer</a> using xABS3843 high-performance resin.</p><p>The team at MotoCilino chose to print the components on the XiP due to printer’s reliability and high print quality using <a href="https://nexa3d.com/materials-selection-tool/" target="_blank">performance grade resin</a> that mimic mechanical properties of final production grade ABS. In fact, the finished controller visual aesthetic and mechanical performance was virtually indistinguishable from those components that were molded. “Printing on the XiP allowed us to deliver components to the Yawman team in half the time it would’ve taken us had we used another desktop SLA printer, and the print quality on the XiP is just superior,” said Paul Cilino, Owner of Motocilino.</p><h2 id="isPasted">Benefit</h2><h5>Accelerated time to market by nearly a year and delivered high-fidelity prototypes at a fraction of the cost</h5><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712135957381-36-piece-3D-printed-flight-controller-768x774+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>The team was able to finalize the design and deliver a high quality prototype with injection molding-like surface finish and mechanical performance quickly and cost effectively. The finished assembly included over 36 printed components, all virtually indistinguishable from its injection molded counterparts in both finish and mechanical performance. As a result, the team is now ready to scale to production as they prepare for commercial launch in July, 2023, on the heels of tremendous initial demand received during its beta launch earlier in the year.</p>

Working with engineering experts at MotoCilino, the team commercialized a handheld flight controller in record time

Revolutionizing Flight Simulation with XiP Desktop 3D Printer

<p id="isPasted">How to extend the pot life of silicone to several months without changing its material properties? Ulrich Trog [Ulrich.Trog@joanneum.at | <strong>JOANNEUM RESEARCH</strong>] explains in this article how this is possible</p><p>JOANNEUM RESEARCH offers the <strong>formulation of the appropriate compound</strong> based on feasibility studies of the silicones used by its customers. Licences for the Supresil™ technology are available.</p><p>Platinum (Pt)-cured silicones are gaining in popularity, emphasising addition curing over traditional peroxide methods. This process ensures purity and efficacy, resulting in products with increased strength and superior aesthetics. The rise of Pt-curing marks a significant shift in silicone manufacturing techniques, promising unmatched quality and durability in a variety of applications. When crosslinking is initiated, the curing process starts almost immediately and the resulting silicone typically has a pot life limited to a maximum of a few hours at room temperature. This places significant<strong>&nbsp;practical and technological limitations</strong> on its use:</p><ul><li style="font-weight: bold;"><strong>short processing time</strong></li><li style="font-weight: bold;"><strong>anufacturing waste</strong></li><li style="font-weight: bold;"><strong>difficult reproducibility</strong></li><li style="font-weight: bold;"><strong>inflexible manufacturing process</strong></li></ul><p>Our <strong>patented formulation greatly increases pot life via reversible inhibition of the crosslinking via hydrosilylation</strong>. After deposition, the inhibitors evaporate easily. Normal crosslinking occurs at mild temperatures, even below 80 °C, leading to a fast and complete curing.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1MDMxNDE2LVNjcmVlbnNob3QgMjAyNC0wNC0wMyAwODM1MjcuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Join the Future of Electronics RESHAPED event in Boston on 12 &amp; 13 June 2024. Learn more <a href="https://www.techblick.com/electronicsreshapedusa" target="_blank" rel="noopener noreferrer">https://www.techblick.com/electronicsreshapedusa</a></p><p>Benefits</p><ul><li><strong>reduces production costs</strong>: the pot life of silicone mixtures can be extended to several months and beyond</li><li><strong>enables (3D) printing:</strong> shelf stable, 1-component silicone inks can be formulated for use with a variety of printing processes including processes like dispensing, screen-printing, aerosoljet-printing, inkjet printing and others</li><li><strong>no change in material properties</strong>: through the complete and trace-free removal of the inhibitor during the curing process there is no change in the material or its properties</li><li style="font-weight: bold;"><strong>applicable to liquid Silicone rubber (LSR) and high consistency rubber (HCR)</strong></li><li><strong>suitable for all Pt-cure resins</strong>: no curing at processing temperature and normal curing at curing temperature, orthogonal with other inhibitors</li><li><strong>environmental</strong>: reduction in waste generation in production process</li></ul><p><strong>Application examples</strong></p><ul><li><strong>LED production</strong>: Supresil™ resins reduce the processing efforts and increase the yield of colour conversion materials without changing their optical properties. The Supresil™ inhibited silicones can be mixed with colour conversion phosphors in large batches, increasing the accuracy and consistency of the colour conversion composites through improved wetting and distribution of the dispensed material and a better dispersion of the phosphors.</li></ul><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1MjMxMzE4LXVubmFtZWQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><ul><li><strong>3D printing</strong>: Standard LSR formulations are optimised for extrusion and injection moulding machines and are not suitable for 3D printing. By adjusting the rheological behaviour and extending the pot life using JOANNEUM RESEARCH‘s proprietary reversible curing inhibition, 3D printing is now possible.</li></ul><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1MjgxMjMxLXVubmFtZWQgKDEpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p><strong>All material properties of the silicones are preserved</strong> (through complete and trace-free removal of the inhibitor):</p><ul><li>physical: shrinkage, Shore hardness, storage modulus</li><li>optical: UV/VIS transmission, no „yellowing“, refractive index</li><li>biocompatibility: relevant for medical grade resins / formulations</li><li>unaltered production: viscosity, reproducibility</li></ul><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM2MTQzMjU0LXVubmFtZWQgKDYpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Fig. 1: Comparison of curing dynamics of standard silicone resins with SupresilTM inhibited resins</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1ODI4NTM0LVNjcmVlbnNob3QgMjAyNC0wNC0wMyAwODQyNTAuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p><a href="https://www.techblick.com/exhibitors-2024-berlin" target="_blank" rel="noopener noreferrer">We are Exhibiting in Berlin!</a> <strong>Come and visit our booth</strong></p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1OTA5NzAxLXVubmFtZWQgKDMpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Fig. 2: UV/VIS Transmission of cast silicones (100 µm) for the LED production</p><p id="isPasted"><strong>JOANNEUM RESEARCH</strong> is a publicly owned, Austrian Research and Technology Organisation. It is successful nationally and internationally in the fields of “Information and Production Technologies”, “Human Technologies and Medicine” and “Society and Sustainability”</p><p>AUTHOR: Ulrich Trog [Ulrich.Trog@joanneum.at |JOANNEUM RESEARCH]&nbsp;</p><p><br></p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM2MDU0MjI5LXVubmFtZWQgKDQpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>All images: © JOANNEUM RESEARCH</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM2MTA3NzU0LXVubmFtZWQgKDUpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>&nbsp;&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712137051266-Screenshot+2024-04-03+084405.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>&nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;<a href="https://www.techblick.com/" target="_blank" rel="noopener noreferrer">TechBlick.com</a></p><p><br></p>

How to extend the pot life of silicone without change in properties for applications in 3D Printing, LED lighting, LED backlights, and others

Extending the pot life of silicones to several months: LEDs, 3D printing and beyond

<p id="isPasted">Author: <strong>Masoud Mahjouri-Samani, PhD |&nbsp;</strong>NanoPrintek | <a rel="noopener noreferrer" href="mailto:info@nanoprintek.com" target="_blank">info@nanoprintek.com</a></p><p>Modern technology and the move toward the Internet of Things have escalated the demand for innovative and efficient printing techniques, particularly in electronics and functional devices. Traditional ink-based printing methods have long been the standard, but now NanoPrintek’s dry multimaterial printing technology has emerged as a disruptive alternative, offering numerous advantages over its ink-based counterparts. The technology’s on-demand and in-situ nanoparticle generation and real-time sintering capability allow the printing of various electronics and functional devices with pure, multifunctional, hybrid materials printing. This thus opens the path to electronics printing and other applications ranging from energy and health to sensing devices.&nbsp;</p><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519983710-1711519983710.png" alt="" class="fr-fic fr-dii"></div><figcaption>Figure 1: Dry printing process. &nbsp;On-demand/ in-situ nanoparticle generation and real-time laser sintering that enables the printing of various electronics and functional materials and devices</figcaption></figure><p><strong>Unveiling a Universe of Materials Beyond the Limitations of Ink:</strong> Traditional inks can be restrictive regarding the materials they can accommodate. Dry printing, on the other hand, opens doors to a wider range of possibilities. From semiconductors and conductors to insulators and nanocomposites, dry printing can handle a broader spectrum of functional materials rapidly, enabling the creation of more advanced and innovative functional devices.</p><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519984882-1711519984882.png" alt="" class="fr-fic fr-dii"></div><figcaption><strong>Figure 2.&nbsp;</strong>The ability to directly print a wide spectrum of materials</figcaption></figure><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519982775-1711519982775.jpeg" alt="" class="fr-fic fr-dii"></div><figcaption><strong>I will &nbsp;present at the Future of Electronics RESHAPED USA in Boston 12-13 June 2024 --&gt;&nbsp;</strong><a rel="noopener noreferrer" href="https://www.techblick.com/electronicsreshapedusa" target="_blank">https://www.techblick.com/electronicsreshapedusa</a></figcaption></figure><p><strong>Environmental Friendliness</strong>: Ink-based printing often necessitates complex ink formulations, storage, disposal, and cleaning procedures. Solvents and other hazardous materials can pose environmental and health risks. Dry printing, however, bypasses these concerns entirely. By utilizing solid targets as a source for on-demand and in-situ pure nanoparticle generation, dry printing eliminates the need for harmful solvents and additives, leading to a cleaner, more sustainable, and environmentally sustainable manufacturing process.</p><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519984450-1711519984450.png" alt="" class="fr-fic fr-dii"></div><figcaption><strong>Figure 3.&nbsp;</strong>The game-changing advantages of NanoPrintek’s dry printing technology</figcaption></figure><p><strong>Cost Efficiency</strong>: Dry printing technology significantly reduces production costs compared to traditional ink-based techniques. By eliminating the need for timely and costly ink formulation processes as well as consumables like inks and solvents and minimizing waste and downtime associated with cleaning, dry printing offers a more economical solution, leading to tens of thousands of dollars in savings per year.</p><p><strong>Potential Precision and Resolution Enhancement:</strong> Due to the nanoscale size and purity of the dry nanoparticles, dry printing enables higher precision and resolution in the deposition of electronic materials. This opens the possibility of creating intricate circuit patterns and fine features, leading to improved performance and reliability of electronic devices.</p><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519984815-1711519984815.png" alt="" class="fr-fic fr-dii"></div><figcaption><strong>Figure 4.&nbsp;</strong>Example of dry printed lines without sintering (a) and with real-time sintering (b, c).&nbsp;</figcaption></figure><p><strong><em>Compatibility with Diverse Substrates</em></strong>: Unlike ink-based printing, which may have limitations in terms of substrate compatibility, dry printing offers greater flexibility. It can be used on a wide range of substrates, including flexible materials like plastics and paper, as well as rigid surfaces like glass, ceramics, and even FR4 substrates, expanding the possibilities for product design and innovation.</p><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519984945-1711519984945.png" alt="" class="fr-fic fr-dii"></div><figcaption><strong>Figure 5.&nbsp;</strong>Enabling the printing on a wide spectrum of substrates c).&nbsp;</figcaption></figure><p><strong><em>Improved Durability and Longevity</em></strong>: The materials deposited through dry printing electronics often exhibit superior durability and longevity compared to those applied using ink-based methods. This is due to the lack of surfactant and contaminations during the real-time sintering process, which allows better particle-particle fusion and a cleaner interface with the substrate. This results in electronic devices that are more resistant to wear and environmental factors, prolonging their lifespan and enhancing overall performance.</p><p><strong><em>Versatility in Applications</em></strong>: Dry printing electronics offers versatility in its applications across various industries, including consumer electronics, automotive, healthcare, and beyond. Whether manufacturing flexible electronics, RFID tags, sensors, energy devices, or smart packaging, this technology can adapt to diverse needs and requirements.</p><p>In conclusion, the advantages of dry printing electronics over ink-based techniques are indisputable. From cost efficiency and environmental friendliness to enhanced precision and versatility, this disruptive technology is reshaping the landscape of functional devices and electronic manufacturing. As advancements continue to propel the field forward, NanoPrintek's dry printing technology promises to unlock new possibilities and drive innovation across industries.</p><p><a target="_blank" rel="noopener noreferrer" href="https://www.techblick.com/electronicsreshapedusa">We are Exhibiting at the Future of Electronics RESHAPED event in Boston (12 &amp; 13 June 2024) :&nbsp;</a><a rel="noopener noreferrer" href="https://www.techblick.com/electronicsreshapedusa" target="_blank">https://www.techblick.com/electronicsreshapedusa</a></p><figure><div contenteditable="false"><button data-test-resize-image-button="true">Minimize image</button><button data-test-edit-image-button="true">Edit image</button><button data-test-delete-image-button="true">Delete image</button><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711519982835-1711519982835.png" alt="" class="fr-fic fr-dii"></div><figcaption data-placeholder="Add caption for image (optional)"><br></figcaption></figure>

Multi-material printing without inks? The technology’s on-demand and in-situ nanoparticle generation and real-time sintering capability allow the printing of various electronics and functional devices with pure, multifunctional, hybrid materials printing - without inks and with bulk properties!

Dry Multimaterial Printing Technology: Unraveling New Realm of Possibilities in Printed Electronics

The global surge in thermoplastics demand has led to increased production and plastic waste, surpassing annual production levels, necessitating the development of sustainable recycling methods and practices throughout the product life cycle to mitigate environmental impacts.

Engineering Thermoplastics Guide. Chapter 6. Sustainability and Recycling of Engineering Thermoplastics

<p><a href="https://www.ifam.fraunhofer.de/en.html" target="_blank" id="isPasted">Fraunhofer IFAM</a> – an institute in the renowned Fraunhofer Society – is a recognized leader in the field of Metal Injection Molding (MIM), and is serving companies in the aerospace, energy, maritime and other demanding industries. To support research into new applications while lowering lead-times and costs, Fraunhofer recently decided to implement the Freeform Injection Molding (FIM) process powered by Nexa3D’s <a href="https://nexa3d.com/3d-printers/xip/" target="_blank">XiP Desktop 3D printer</a> and LSPc® technology. This platform enables manufacturers to quickly and cost-effectively prototype complex injection-molded parts before making investments in conventional metal tooling.</p><h2 id="isPasted">The challenge</h2><h3><em>Tooling for metal injection molding is costly and time-consuming to produce</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1MzUyNzcwLUZyYXVuaG9mZXItRklNLXRvb2wtMTgwMHgxMDEzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>In metal injection molding (MIM), metal powder is mixed with a plastic binder to create a feedstock that is then injected into a metal mold. The abrasive nature of the feedstock places high demand on the quality of the tooling, and the complexity of the MIM process typically results in the need for multiple iterations. Fraunhofer wanted to offer companies a path to quickly and cost-effectively test new concepts and turned to Nexa3D and Freeform Injection Molding to provide a solution.</p><blockquote id="isPasted"><p>“Freeform Injection Molding provides us with the perfect tools to support innovative companies as they test out new concepts and materials.”<strong>– Sebastian Hein, Fraunhofer IFAM</strong></p></blockquote><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1Mzk5NjAzLTE3MTEwMTUzOTk2MDMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"></p><h2 id="isPasted">The solution</h2><h3><em>3D printed injection mold tooling using xMOLD resin and Freeform Injection Molding</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDE0OTY3LUdFLUVuZ2luZS1CcmFja2V0LTE4MDB4MTIwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>Fraunhofer was inspired by other companies using <a href="https://nexa3d.com/digital-tooling/" target="_blank">Freeform Injection Molding</a> and decided to introduce the XiP desktop 3D Printer and the xMOLD resin. This compact platform is the ideal solution for printing molds in the product size range typically encountered in MIM, and the xMOLD tooling resin has a strong track record for the molding of high-performance materials.</p><h2 id="isPasted">The benefits</h2><h3><em>2-week design cycle enabled for complex metal parts</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDM4MDI1LUdFLU1ldGFsLUVuZ2luZS1CcmFja2V0LXYyLTE4MDB4MTIwMC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>By adopting the FIM process using Nexa3D’s XiP 3D printer and xMOLD material, the Fraunhofer IFAM team enables a host of benefits to their clients.</p><p><strong>Rapid Prototyping:</strong> FIM enables Fraunhofer to quickly prototype MIM parts for customer demonstration and validation testing. The material properties of FIM parts have been shown to closely match those produced with conventional steel tools, ensuring accurate performance evaluation.</p><p><strong>Time and Cost Savings:</strong> FIM allows Fraunhofer IFAM to dramatically reduce the time and cost required for pilot tooling production. The XiP printer’s exceptional speed allows for same-day printing and injecting while at the same time enabling cost and time savings exceeding 75% compared with conventional pilot tooling.</p><p><strong>De-risking Development and Innovation:</strong> Fraunhofer IFAM has already demonstrated that FIM is compatible with the gold-standard Catamold feedstocks from BASF, enabling customers to use well-characterized materials for their development and innovation.</p><h2 id="isPasted">Customer Impact</h2><h3><em>Prototype MIM for complex designs demonstrated</em></h3><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE1NDY5NDU4LUlNR18xNzk5LTc2OHg1MTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></em><br></p><p>Metal injection molding has suffered from a scarcity of prototyping options. Conventional AM-based approaches, whether powder – or binder-based, cannot be used to evaluate flow paths, in-mold stress patterns or warpage of molded parts during debinding and sintering. As a consequence, injection molders have had to invest in high-cost pilot tools when wanting to validate part designs and process parameters. Already with the first project – modeled around the GE Jet Engine Bracket – Fraunhofer IFAM demonstrated the simplicity, speed and design freedom unlocked with Freeform Injection Molding.</p><p>The Fraunhofer team decided on a bracket design that would be suited for injection molding, and to use a well-known off-the-shelf Catamold 17-4PH feedstock from BASF as the material. A XiP printer cell was used to print the soluble injection mold tooling, and an Arburg 320 injection molding machine was employed to complete the molding.</p><p>The project confirmed several important aspects of Freeform Injection Molding:</p><ul><li>Mold design time shrinks from days to hours, as molds do not have to incorporate split lines, ejector pins or sliding features.</li><li>The manufacturing of test molds can be done in days instead of weeks.</li><li>Injection Molding can be carried out using standard injection molding machines and feedstocks, and delivering a material quality that rivals that of conventional metal injection molding.</li></ul><p>To learn more about Freeform Injection Molding, download the&nbsp;<a href="https://nexa3d.com/case-studies/fraunhofer-case-study/#3d-printed-tooling" target="_blank">3D Printed Tooling Design Guide</a> or&nbsp;<a href="https://nexa3d.com/contact/" target="_blank">reach out</a> for more information.</p>

Research institute adopts Freeform Injection Molding to provide rapid prototyping of complex metal parts

Fraunhofer Speeds Up Metal Injection Molding with 3D-Printed Tooling

<p><strong>3D-printed microscopic particles, so small that to the naked eye they look like dust, have applications in drug and vaccine delivery, microelectronics, microfluidics, and abrasives for intricate manufacturing. However, the need for precise coordination between light delivery, stage movement, and resin properties makes scalable fabrication of such custom microscale particles challenging. Now, researchers at Stanford University have introduced a more efficient processing <a href="https://doi.org/10.1038/s41586-024-07061-4" data-extlink="" target="_blank">technique</a> that can print up to 1 million highly detailed and customizable microscale particles a day.</strong></p><p>“We can now create much more complex shapes down to the microscopic scale, at speeds that have not been shown for particle fabrication previously, and out of a wide range of materials,” said <a href="https://profiles.stanford.edu/jason-kronenfeld" data-extlink="" target="_blank">Jason Kronenfeld</a>, PhD candidate in the <a href="https://desimonegroup.stanford.edu/" data-extlink="" target="_blank">DeSimone lab</a> at Stanford and lead author of the paper that details this process, published today in <em>Nature</em>.</p><p>This work builds on a printing technique known as continuous liquid interface production, or CLIP, <a href="https://doi.org/10.1126/science.aaa2397" data-extlink="" target="_blank">introduced in 2015</a> by DeSimone and coworkers. CLIP uses UV light, projected in slices, to cure resin rapidly into the desired shape. The technique relies on an oxygen-permeable window above the UV light projector. This creates a “dead zone” that prevents liquid resin from curing and sticking to the window. As a result, delicate features can be cured without ripping each layer from a window, leading to faster particle printing.</p><p>“Using light to fabricate objects without molds opens up a whole new horizon in the particle world,” said <a href="https://profiles.stanford.edu/joseph-desimone" data-extlink="" target="_blank">Joseph DeSimone,</a> Professor of Chemical Engineering in the <a href="https://engineering.stanford.edu/" target="_blank">School of Engineering</a> and corresponding author of the paper. “And we think doing it in a scalable manner leads to opportunities for using these particles to drive the industries of the future. We’re excited about where this can lead and where others can use these ideas to advance their own aspirations.”</p><h2>Roll to roll</h2><p>The process that these researchers invented for mass producing uniquely shaped particles that are smaller than the width of a human hair is reminiscent of an assembly line. It starts with a film that is carefully tensioned and then sent to the CLIP printer. At the printer, hundreds of shapes are printed at once onto the film and then the assembly line moves along to wash, cure, and remove the shapes – steps that can all be customized based on the shape and material involved. At the end, the empty film is rolled back up, giving the whole process the name roll-to-roll CLIP, or r2rCLIP. Prior to r2rCLIP, a batch of printed particles would need to be manually processed, a slow and labor-intensive process. The automation of r2rCLIP now enables unprecedented fabrication rates of up to 1 million particles per day.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1710891940620-3d_printing_particles_setup-resized_0.png.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The r2rCLIP setup in the DeSimone lab runs from right to left. The printing occurs at the area below the red piece. | Image courtesy of DeSimone Research Group</span></span></span></p><p id="isPasted">If this sounds like a familiar form for manufacturing, that’s intentional.</p><p>“You don’t buy stuff you can’t make,” said DeSimone, who is also the Sanjiv Sam Gambhir Professor in Translational Medicine at Stanford Medicine. “The tools that most researchers use are tools for making prototypes and test beds, and to prove important points. My lab does translational manufacturing science – we develop tools that enable scale. This is one of the great examples of what that focus has meant for us.”</p><p>There are tradeoffs in 3D printing of <a href="https://doi.org/10.1126/sciadv.abq2846" data-extlink="" target="_blank">resolution versus speed</a>. For instance, other 3D printing processes can print much smaller – on the nanometer scale – but are slower. And, of course, macroscopic 3D printing has already gained a foothold (literally) in mass manufacturing, in the form of shoes, household goods, machine parts, football helmets, dentures, hearing aids, and more. This work addresses opportunities in between those worlds.</p><p>“We’re navigating a precise balance between speed and resolution,” said Kronenfeld. “Our approach is distinctively capable of producing high-resolution outputs while preserving the fabrication pace required to meet the particle production volumes that experts consider essential for various applications. Techniques with potential for translational impact must be feasibly adaptable from the research lab scale to that of industrial production.”</p><h2>Hard and soft</h2><p>The researchers hope that the r2rCLIP process sees wide adoption by other researchers and industry. Beyond that, DeSimone believes that 3D printing as a field is quickly evolving past questions about the process and toward ambitions about the possibilities.</p><p>“r2rCLIP is a foundational technology,” said DeSimone. “But I do believe that we’re now entering a world focused on 3D products themselves more so than the process. These processes are becoming clearly valuable and useful. And now the question is: What are the high-value applications?”</p><p>For their part, the researchers have already experimented with producing both hard and soft particles, made of ceramics and of hydrogels. The first could see applications in microelectronics manufacturing and the latter in drug delivery in the body.</p><p>“There’s a wide array of applications, and we’re just beginning to explore them,” said Maria Dulay, senior research scientist in the DeSimone lab and co-author of the paper. “It’s quite extraordinary, where we’re at with this technique.”</p><p><em>Additional co-authors are Lukas Rother, who was a visiting master’s student at the time of this work, and Max Saccone, a postdoctoral scholar in chemical engineering and radiology. DeSimone is also a professor, by courtesy, in chemistry in the&nbsp;</em><a href="https://humsci.stanford.edu/" data-extlink="" target="_blank"><em>School of Humanities and Sciences</em></a><em>, materials science and engineering in the School of Engineering, and operations, information, and technology in the&nbsp;</em><a href="https://www.gsb.stanford.edu/" data-extlink="" target="_blank"><em>Graduate School of Business</em></a><em>. He is a member of&nbsp;</em><a href="http://biox.stanford.edu/" data-extlink="" target="_blank"><em>Stanford Bio-X</em></a><em>, the&nbsp;</em><a href="https://humanperformance.stanford.edu/" data-extlink="" target="_blank"><em>Wu Tsai Human Performance Alliance</em></a><em>, and the&nbsp;</em><a href="http://cancer.stanford.edu/" data-extlink="" target="_blank"><em>Stanford Cancer Institute</em></a><em>, and a faculty fellow of&nbsp;</em><a href="https://chemh.stanford.edu/" data-extlink="" target="_blank"><em>Sarafan ChEM-H</em></a><em>, co-director of the&nbsp;</em><a href="https://canarycenter.stanford.edu/" data-extlink="" target="_blank"><em>Canary Center at Stanford for Cancer Early Detection</em></a><em>, and founding faculty director of the Center for&nbsp;</em><a href="https://stemmteams.stanford.edu/" data-extlink="" target="_blank"><em>STEMM&nbsp;Mentorship</em></a><em>&nbsp;at Stanford.</em></p>

The 3D-printed DeSimone Lab logo, featuring a Buckyball geometry, demonstrates the r2rCLIP system’s ability to produce complex, non-moldable shapes with micron-scale features. | Image courtesy of DeSimone Research Group, SEM courtesy of Stanford Nano Shared Facilities

A new process for microscale 3D printing creates particles of nearly any shape for applications in medicine, manufacturing, research and more – at the pace of up to 1 million particles a day.

New high-speed microscale 3D printing technique

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