When it comes to global sustainability, the manufacturing industry is under intense scrutiny to improve its practices. &nbsp;Amidst continuous search for alternatives to greener practices, additive technologies such as <a href="https://www.wevolver.com/article/sls-printing-unlocking-the-potential-of-selective-laser-sintering" target="_blank">Selective Laser Sintering (SLS)</a> has turned out to be a promising technology for the manufacturing industry. It has the potential to transform traditional production lines into eco-friendly models of efficiency. In this article, we will explore how SLS enables manufacturers to meet greener environmental guidelines while maintaining economical efficiency.&nbsp;<h2 dir="ltr">Four Eco-Friendly Benefits of SLS Boosting ROI</h2><h3 dir="ltr">Increased Material Efficiency</h3>SLS enhances material efficiency, unlike the subtractive manufacturing process. It builds objects using only necessary material. Any excess powder not sintered in SLS can be recycled and reused for subsequent prints, reducing waste. If the parts are densely stacked and the software has nesting features to optimize the material usage, the efficiency is further increased. In contrast, subtractive manufacturing starts with a large block, carving away material to form an object. This often results in non-reusable scraps and increased waste.&nbsp;<h3 dir="ltr">Liberty from Tooling Management&nbsp;</h3>Traditional manufacturing methods, whether forging, casting, or injection molding, consistently lean on intricate tooling. These tools – molds, dies, and jigs – come with a heavy overhead. Their production demands substantial financial investment, not to mention the time and energy spent on their design, testing, and refinement. Additionally, the environmental footprint of their fabrication and eventual disposal can't be ignored.With SLS technology, manufacturers <a href="https://utw10945.utweb.utexas.edu/Manuscripts/1991/1991-17-Nutt.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">bypass the entire tooling phase</a>. The complex 3D object springs directly from digital blueprints, without any molds or support structure, streamlining the production pipeline immensely. There's no longer a need for large storage areas for tools or the continual upkeep and repair costs associated with wear and tear. Furthermore, the freedom to transition seamlessly from a digital model to a physical product paves the way for intricate designs previously thought unachievable.<h3 dir="ltr">Prevent Overproduction and Decrease Scrap</h3>Mass production, with its inevitable inventory build-ups, often results in overproduction. Such excess not only ties up resources but also contributes to a significant amount of waste when unsold products become obsolete. However, with the on-demand customized production capability of SLS, manufacturers can prevent overproduction, optimize inventory storage, and decrease scrap with ease.&nbsp;By preventing overproduction, we can reduce the waste and ecological harm stemming from both production and disposal of surplus goods. Additionally, the ability to produce parts locally with SLS further drastically reduces carbon emissions associated with long-distance shipping that eventually increases carbon footprint in the atmosphere.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1697727294303-sintratec-kit-part-4.jpg" style="width: 300px;" class="fr-fic fr-dib">SLS printing enables complex geometries with loewr waste. Image credit: Sinatrec.<h3 dir="ltr">Multi-Use Plastics</h3>Selective Laser Sintering has the potential to pivot the industry from single-use plastics to durable, multi-use options.Traditional manufacturing frequently employs injection molding to create single-use plastic items. This method efficiently produces large quantities of identical products. However, these short-lived items quickly become waste, significantly amplifying the global plastic pollution problem.In contrast to traditional methods, SLS harnesses the power of lasers to sinter polymer powders layer by layer, crafting parts with superior strength and precision. These high-quality polymer parts are inherently more durable, reducing their wear and tear over time, leading to a reduction in the overall generation of plastic waste. Also, <a href="https://www.wevolver.com/article/the-guide-to-selective-laser-sintering-sls-post-processing" target="_blank">SLS post-processing options</a> are eco-friendly and ensure appearance and functionality of the component are top-notch.Moreover, one of the significant hurdles is in sourcing spare parts for outdated machinery, making replacements a daunting task. However, <a href="https://www.wevolver.com/article/3d-printing-obsolete-parts" target="_blank">3D printing</a> can replicate these parts with precision with a wide range of industrial-grade materials, ensuring a seamless fit and high shelf life of the machinery.<h2 dir="ltr">Conclusion</h2>3D printing and SLS are greener manufacturing practices with numerous benefits. Manufacturers can leverage SLS to reduce material waste, eliminate unnecessary tools, meet on-demand production, and promote recycling, without hurting their production line. In the long run, it helps industries position themselves at the forefront of innovation and sustainability, crafting a future for the next generation where efficiency and ecology go hand in hand.

Object printed in laser sintering machine

SLS 3D Printing: An Eco-Friendly 3D manufacturing solution that reduces waste and energy use while enabling on-demand production and quick customization

Selective Laser Sintering: Bridging the Gap to Sustainable Innovations

When 3D printed parts are used in any application, their failure can result in dangerous situations. If a part isn't durable, it might break under pressure, resulting in equipment malfunction or even injuries. Testing is crucial for manufacturers to determine the suitability of different materials for their specific applications. By subjecting the components printed by the Sintratec S2 to rigorous testing, Sintratec can identify their strengths and weaknesses, ensuring that only durable and high-quality 3D-printed parts are released to the market.&nbsp;This article explores the robust testing processes and the impressive resilience displayed by the Sintratec S2 components, which highlights the company's unwavering commitment to delivering superior quality products.<h2>Testing 3D prints</h2>Sintratec, a Swiss startup specializing in Selective Laser Sintering (SLS) 3D printers, has shared the process of testing their new machine, the Sintratec S2. The test demonstrates the strength of Sintratec's PA12 powder and the efficiency of the Sintratec S2 machine in producing durable prints. This article explores the rigorous testing processes and the resilience of components printed by the Sintratec S2.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk2MjcxNTg2Mzc3LVNpbnRyYXRlYy1TMi1Gcm9udC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt=" Sintratec S2">&nbsp;The Sintratec S2 3D printer.&nbsp;In the comprehensive video produced by Sinatrec, we see Andi, a lead engineer at Sintratec, demonstrating the strength and durability of the parts produced by this new machine. The project involves designing a functional electric ducted fan (EDF) driven by an 800-watt RC brushless in-runner motor to see how much power the part could handle without being damaged.<iframe width="640" height="360" src="https://www.youtube.com/embed/BYieQ-PVlQs?&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" data-gtm-yt-inspected-10="true" id="743390312" title="3D printed Electric Ducted Fan TESTED – How strong is SLS?! (EDF Turbine Test)" data-gtm-yt-inspected-24="true">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</iframe>Once the design was completed, the part was printed using <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank" style="border: 5px solid orange;">Sintratec's strong PA12 material (EXTERNAL)</a>. The next step involved balancing the fan with lead balls around the rotation axis to prepare it for testing 3D prints (BAD). The EDF was then tied to a metal cord, mounted on a rail, and clamped to a table for the testing phase. With proper safety measures in place, the engine was started, and the speed was increased gradually.However, the test was aborted at around a quarter to full speed due to concerns about powder emission from the front. Upon investigation, it was found that this resulted from a <a href="https://www.wevolver.com/article/7-design-tips-for-structural-optimization-lightweighting" target="_blank" style="border: 5px solid green;">design flaw (GOOD)</a> where a small inner area was not closed. The initial prototype had a hollow shell, which made the EDF too soft and pliable. The interior walls were reinforced with additional structures to address this, and the part was printed again.<h2 dir="ltr">Testing round two</h2>In the subsequent test, the EDF was fixed onto a more stable workbench, and the power was increased once again. Although an imbalance in the spinner was noticed, it was removed, and the test continued. Smoke was added to visualize the airflow, and the peak power reached about 1,400 watts, a result considered impressive, especially given the motor's nominal power of 800 watts. The EDF sustained the test without any damage, showcasing the strength of Sintratec's PA12 powder and the efficiency of the Sintratec S2 machine in producing durable prints.<h2 dir="ltr">End Thoughts</h2>Testing the durability of 3D printed parts is crucial for multiple reasons such as safety, material understanding, quality control, design optimization, regulatory compliance etc. Moreover, the durability of 3D-printed parts enhances the reputation of the products or services they're associated with.&nbsp;The commendable performance of the Sintratec S2 system in the tests highlights Sintratec's commitment to giving customers the best and most reliable products, reaffirming its reputation in the world of 3D printing technology.&nbsp;<a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank" rel="noopener noreferrer" style="border: 5px solid orange;">Learn more about Sintratec here. (EXTERNAL)</a>

Aircraft turbine wheel printed on metal 3D printer.

Sintratec, a Swiss startup specializing in Selective Laser Sintering (SLS) 3D printers, is in the process of testing their new machine, the Sintratec S2.  

Testing the Durability of 3D Printed Parts

The Norwegian start-up Renasys has made it its mission to transform water filtration and wastewater treatment. A newly developed, innovative filtration system removes 99% of dirt particles and suspended matter over 5 microns in size from the water.80% of the world&rsquo;s wastewater is released into the environment untreated, polluting our rivers, seas and oceans (source: <a href="https://www.unesco.org/en/wwap/wwdr#2017" target="_blank">UN WWDR 2017</a>). One consequence of this is that some 4.5 billion people around the world use contaminated, unclean water (source: <a href="https://www.iea.org/commentaries/the-energy-sector-should-care-about-wastewater" target="_blank">IEA</a>). This significantly increases the risk of serious health problems. For example, diseases such as dysentery, typhus, cholera and polio are far more common in countries with poor drinking water quality than in those with clean drinking water. It would cost 8.2 trillion US dollars to modernise and sustainably restructure the global water infrastructure (source: <a href="https://www.oecd.org/env/cc/g20-climate/Technical-note-estimates-of-infrastructure-investment-needs.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">OECD&nbsp;</a>).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695018966303-1695018966303.png" style="width: 707px;" class="fr-fic fr-dib">With the global population continually growing, industrial expansion progressing and laws becoming ever tighter, wastewater treatment plants and their operators are compelled to improve their water treatment systems. The start-up&nbsp;<a href="https://www.renasys.com/" target="_blank">Renasys</a> is based in Norway, where it also focuses its work: after all, Norway&rsquo;s plan alone of further developing and modernising the existing water infrastructure between 2021 and 2040 will require some 17.6 million US dollars of investment. The country currently has around 2,000 wastewater treatment plants (source:&nbsp;<a href="https://295965-www.web.tornado-node.net/wp-content/uploads/Rapport259.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Norsk Vann</a>), 93% of which are purely municipal treatment systems, i.e. systems that are only used locally in one place and are not connected to the central water supply systems. In addition, 55% of Norwegian wastewater treatment plants no longer meet the more stringent legal regulations and requirements (source:&nbsp;<a href="https://295965-www.web.tornado-node.net/wp-content/uploads/Rapport259.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Norsk Vann</a>).Renasys&rsquo;s mission is to preserve, protect and defend the world&rsquo;s most valuable resource. As part of their joint &lsquo;Mission Zero&rsquo;, Renasys and Haver &amp; Boecker have come together as strategic partners and developed a filtration system that removes 99% of wastewater particles over 5 microns in size. This system enables the start-up to achieve a far higher filtration and separation level than legally required in Norway. As a result, the solution is more than promising and can also be transferred to other sectors and areas of use. For example, even today, the innovative Renasys system is not only successfully used in wastewater treatment plants but also in aqua farms. It could also potentially help transform wastewater treatment in the agricultural and shipping sectors as well as in the textile industry and industrial consumer goods production.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695018981341-1695018981341.png" style="width: 747px;" class="fr-fic fr-dib">Renasys&rsquo;s work is helping achieve a sustainable circular economy in the water industry and preparing current infrastructures for the future. Furthermore, existing wastewater treatment plants could act as energy suppliers as the filtered particles could be converted into energy and heat through the use of biogas systems, for example. As the primary energy required to do this is already found in the wastewater, no additional energy input would be needed. The amount of energy potentially generated would more than cover the wastewater treatment plants&rsquo; needs and the excess energy could be used elsewhere. The CO2 equivalent emissions would therefore be zero, making the wastewater treatment plants climate neutral or even climate positive. At present, Europe&rsquo;s wastewater treatment plants alone use the same amount of energy as 55 million people, equating to around 12.3% of the continent&rsquo;s population (source:&nbsp;<a href="https://www.destatis.de/Europa/DE/Thema/Basistabelle/Bevoelkerung.html" target="_blank">German Statistical Office</a>). The CO2e savings therefore play an important role in decarbonising the water and wastewater sector. Energy-producing wastewater treatment plants also reduce the dependency on fossil fuels.But how exactly does the Renasys system work and how can it filter so many more particles from the water?&nbsp;At the heart of the filtration system is a very special metal filter mesh. Here at Haver &amp; Boecker, we have been working with Renasys on new technologies for water and liquid filtration since 2018 within the scope of our strategic partnership. The technical solution centres on our patented <a href="https://www.haverboecker.com/en/product-solutions/filter-mesh/rpd-hiflo-s/" target="_blank">MINIMESH&reg; RPD HIFLO-S</a> filter weave. This special filter weave has an innovative three-dimensional mesh structure and pore geometry, which significantly increases the porosity within the same area and enables double the flow rate of standard weaves with the same pore size. In cooperation with Renasys, an innovative, closed-loop wastewater filtration solution was therefore developed that is both efficient and scalable.&nbsp;<img border="0" width="517" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1695018990309-1695018990309.jpeg" alt="[Translate to English:] MINIMESH® RPD HIFLO-S-Tressen " class="fr-fic fr-dii">In addition to the aforementioned properties, the three-dimensional, high-performance metal filter mesh is also characterised by higher stability and durability. This is where the MINIMESH&reg; RPD HIFLO-S weave&rsquo;s outstanding separation performance and dirt absorption capacity come in as these promote longer filter service lives and usage intervals. As the filter mesh&rsquo;s underlying structure prevents it from becoming blocked as quickly, longer and more efficient filtration phases are possible between the cleaning and backwashing intervals.In addition, the RPD HIFLO-S filter weaves can be made from comparatively thick wires despite being fine pored. This not only has a positive impact on the costs with regard to the standard stainless steel alloys but also makes it possible to use highly corrosion and temperature-resistant special materials, such as duplex/super duplex, Alloy 310 S, Inconel 600, Hasteloy C22 or titanium, which would otherwise not be suitable for use for creating such fine pores.As a further benefit, the pore sizes of the MINIMESH&reg; RPD-HIFLO-S filter weaves can be precisely varied between 5 and 40 microns depending on the application. This enables the desired filtration processes to occur reliably, efficiently and precisely every time. The filter elements used also impress with excellent long-term stability and a long service life.In cooperation with Renasys...&nbsp;we&rsquo;ve taken the first step towards sustainable, closed-loop water treatment. Our advanced Renasys water treatment systems not only enable us to make an important contribution to global climate and water protection, but also show that, as a global community, we can use knowledge, technical innovation and passion to face the greatest challenges of the upcoming climate transformation.At Haver &amp; Boecker, we are proud to work with partners like Renasys to actively shape the road to a more sustainable future with our innovative wire mesh and filter solutions.We invite youOn our website, in addition to an overview of clever solutions in water management, you will find comprehensive technical articles on selected areas of application:&nbsp;<ul><li>Microplastics filtration</li><li>Wastewater filtration and treatment</li><li>Ballast water treatment</li></ul>Click <a href="https://www.haverboecker.com/en/industries/energy-and-the-environment/#c5717?lso=wevolver-wasserfiltration-beitrag&utm_campaign=wasserfiltration&utm_source=wevolver&utm_medium=beitrag&utm_content=_092023" target="_blank" rel="noopener noreferrer">here</a> to visit our website and read our professional articles. We look forward to your visit and invite you to contact us directly if you have any questions about our product solutions or your specific requirements - even beyond the areas mentioned.

The Norwegian start-up Renasys has made it its mission to transform water filtration and wastewater treatment. A newly developed, innovative filtration system removes 99% of dirt particles and suspended matter over 5 microns in size from the water.

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Selective Laser Sintering: Bridging the Gap to Sustainable Innovations

Testing the Durability of 3D Printed Parts

Achieving "Mission Zero" through wastewater?

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