According to the company, the new high-performance electro spindle was designed for precision milling and post-processing of polymer 3D printed parts. It’s made to integrate with Rapid Fusion’s ZEUS 3D robotic systems, which have a 6m by 6m (19.7ft x 19.7ft) footprint.

The company is aiming for £3M in sales with the new tool, targeting the automotive, aerospace and marine industries.

“This CNC milling tool has the potential to be a real game changer for manufacturers and has been designed in partnership with a number of end users to ensure we deliver exactly what they need,” said Martin Jewell, R&D director at Rapid Fusion in a press release.

Jewell says Rapid Fusion’s 3D printing technology can produce polymer molds on its own to near net shape, within 3-4mm. The CNC milling tool is intended for applications requiring greater precision. “We now know we can deliver repeatable quality, and, on one trial project, we reduced the lead time for a mold tool from six to eight weeks to just five days,” he said in the same release.

The CNC milling tool can be swapped out for the company’s 3D printing pellet extruder, which can process glass- and carbon-filled PEI and PEEK polymers. Rapid Fusion is a sister business of EVO 3D and is endeavoring to expand additive manufacturing in the UK.

“Everyone knows the UK is a fantastic breeding ground for ideas and innovation, yet we don’t commercialize enough of the new things we come up with,” Jewell said. “We’re trying to change this and the CNC milling tool will be an important weapon in our product portfolio for achieving that.

“When integrated into our new robotic platform, clients will be able to tap into the best of additive and subtractive manufacturing in one solution, benefitting from a host of time, cost and operational benefits – not to mention significant environmental savings from using less material and energy.”

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The biggest recent development on that last one is probably the 2022 experiment at Lawrence Livermore National Laboratory (LLNL) which saw a successful fusion ignition, but the scientists and engineers working at LLNL aren’t content to stop there.

“Now that we have achieved and repeated fusion ignition,” said Tammy Ma, lead for LLNL’s inertial fusion energy institutional initiative, in a press release, “the Lab is rapidly applying our decades of know-how into solving the core physics and engineering challenges that come with the monumental task of building the fusion ecosystem necessary for a laser fusion power plant. The mass production of ignition-grade targets is one of these, and cutting-edge 3D printing could help get us there.”

The ignition targets Ma refers to are nearly perfect spheres of hollow diamond encasing deuterium and tritium (DT) fusion fuel. These are suspended inside a hohlraum: a cavity with walls in radiative equilibrium with the radiant energy within the cavity. Under exposure to intense laser energy, these hydrogen isotopes fuse and, ideally, produce more energy than needed to start the reaction.

Unfortunately, these targets take months to manufacture, while a functioning fusion energy power plant would require nearly one million targets per day, igniting at a rate of ten times a second. The physical reaction would be similar to the ignition already achieved at LLNL, but the production of targets requires a fundamentally new approach that can work at scale.

Enter 3D printing, with a new LLNL project focusing on constructing a workflow to design, fabricate, characterize and field fully 3D-printed fuel capsules. The project is also developing a first-of-its-kind dual-wavelength, two-photon polymerization (DW-2PP) approach to meet the stringent engineering demands of ignition targets.

“We are focusing on a specific type of wetted-foam capsule, in which liquid DT can be wicked into a uniform foam layer on the inside of the spherical capsule by capillary action,” said Xiaoxing Xia, co-principal investigator and a staff scientist at LLNL. “The current DT ice layering process takes up to a week to complete with extreme meticulousness. It’s possible that 3D printing is the only tool for this kind of complex geometry at scale.”

If successful, this project could address critical bottlenecks towards 3D printing ignition capsules in their entirety.

“Our DW-2PP printer uses two light sources with different wavelengths to selectively print different materials with sub-micron resolution,” explained co-principal investigator James Oakdale in the same press release. “This novel capability gives us exquisite control over the spatial chemistry and densities within both the capsule and inner foam material, which allows us to respond quickly to bespoke or one-off capsule designs.”

According to LLNL, the work is already showing promise, with 3D printed targets successfully used during two fusion experiments in 2024 and more expected in the year ahead.

Could 2025 finally be the year we achieve fusion power?

Probably not, but at least we’re still making progress.

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In the study, waste powder from selective laser sintering (SLS) systems was recycled by Dressler Group and 3D printed by Fraunhofer IPA at the University of Bayreuth using a VX200 HSS platform from voxeljet. According to voxeljet, the initial results demonstrate that reconditioned PA12 waste powder can be processed effectively using ink- and printhead-based high speed sintering (HSS) technology. Moreover, the company reports that the preliminary test results indicate the material properties of the test units are equal to or may even exceed those of comparable prints with fresh powder.

Normally, unprinted PA12 powder loses its ability to be reused due to high temperature exposure in the build area, which causes the polyamide chains to lengthen after condensation and negatively affects powder flowability and melt viscosity. This makes the material difficult to process again via laser-based technologies, since the energy input from lasers is too short to process the longer molecule chains.

The study aimed to reclaim this used powder by processing it through voxeljet’s VX200 HSS platform, which uses an inkjet-based printhead and infrared heating to allow the polyamide to sinter gradually, enabling its reuse.

“Recycling used PA12 powder can effectively reduce costs and support sustainability efforts in AM.” said Holger Leonards, head of R&D at Dressler Group in a voxeljet press release. “Our expertise in regenerating powder properties and handling of large powder volumes enables companies to reclaim this valuable material.”

“The VX200 HSS technology is an open-source system, allowing us to quickly change and adapt process parameters to any powder,” said Jan Kemnitzer, research team lead at Fraunhofer IPA, in the same release. “We were therefore able to quickly adapt the 3D printer to the material with consistent or improved results in part properties.”

“The results of this study are especially interesting for ink- and printhead-based technologies such as the HSS technology,” said Tobias Grün, global product management at voxeljet. “The future possibility of processing this recycled powder on production platforms like the VX1000HSS will bring immense cost savings. Typically, 50% of running costs are attributable to powder. Thus, this development provides a huge effect on cost effectiveness while boosting a circular material flow and reducing waste.”

voxeljet and Fraunhofer will be demonstrating the results of this study at their respective booths at Formnext 2024 in Frankfurt from November 19^th to 22^nd.

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More specifically, ArcelorMittal has selected HP’s Metal Jet S100 as the basis of its research into new steel powders. The announcement comes almost exactly one year after ArcelorMittal entered the AM market as a steel powder supplier with the construction of an industrial-scale inert gas atomizer in Aviles, Spain.

According to ArcelorMittal, the collaboration will focus on two key pillars:

1. Lowering the cost-per-part of AM, with an eye toward the automotive sector
2. Extending material options by developing new steels

The two companies have committed to bringing new steel solutions to a sufficient Technology Readiness Level before using ArcelorMittal’s research center as an incubator for new applications.

“We are thrilled to collaborate with HP in advancing steel additive manufacturing,” said Aubin Defer, Chief Marketing Officer for ArcelorMittal Powders in a press release. “This collaboration leverages our combined expertise to develop innovative solutions to drive the industry forward. The promising results of our steel powders with HP’s binder jetting technology are a testament to the potential of this partnership.”

“We are excited to join forces with ArcelorMittal to push the boundaries of steel additive manufacturing,” said Alexandre Tartas, global leader of metals sales at HP, in the same release. “This collaboration will enable us to leverage our technical expertise and ArcelorMittal’s leadership in sustainable steel solutions to create groundbreaking advancements in the industry. Combining the steel expertise of ArcelorMittal and HP Additive Manufacturing positioning in high volume production offers a unique value proposition for the manufacturing industry.”

Both companies will be exhibiting at this year’s Formnext, from November 19^th to November 22^nd in Frankfurt, Germany.

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EOS IN738 is designed to combine high-strength and heat resistance with a tensile strength of 1,265 MPa and 4.5% elongation. EOS claims that, compared to traditionally manufactured superalloys, EOS IN738 withstands higher-temperature environments and shows significantly less deterioration in high-stress applications, such as turbine blades and other energy components.

Winnipeg-based Precision ADM provided an early test case for EOS IN738, producing turbine blades for a Canadian energy customer experiencing the strain of supply chain and spare part inventory shortages. This project was both a test for EOS IN738 as well as what may be the first known use-test of AM in a rotating turbomachinery part.

“Because of EOS technology and EOS IN738 material, we successfully produced a turbine engine blade that achieved 110% of standard running RPM, and withstood up to 1,700 degrees Fahrenheit produced by an active turbine,” said Derek VanDenDreissche, director of medical and industrial sales and business development at Precision ADM, in an EOS press release. “These tests not only showcased the first-ever successful 3D printed turbine engine blade, but that EOS IN738 can withstand the high levels of heat and stress that turbomachinery applications require. Simply put, EOS IN738 was critical to the success of this project.”

EOS K500 was developed at the request of a major space launch organization and is designed to balance strength and moderate thermal conductivity, thereby bridging the performance of nickel-alloys and copper-alloys. According to EOS, this material is ideal for space applications like thrusters and nozzles, as well as chemical processors making pumps and valves, and for maritime applications.

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So, here are four diverse examples of using simulation in additive manufacturing.

1) Simulating energy and material consumption in binder jetting           

One of the first questions engineers ask when presented with a new technology is, “How much is this going to cost?” It’s undoubtedly an important question, but it’s not always the easiest one to answer. For AM, what it really boils down to is the amount of energy and material consumed during the 3D printing process. Xin Xu, a graduate student in the department of mechanical engineering at McGill University, tackled this question head on in a master’s thesis entitled An energy consumption and material efficiency simulation method for additive manufacturing.

The simulation considers part geometry, print orientation, layer thickness and various other process parameters to generate a model of energy and material consumption for the binder jetting process. Created using MATLAB, the simulation was validated experimentally based on the following input parameters and process variables:

Taking this approach, the majority of simulated outputs for material and energy consumption were >90% accurate, demonstrating the usefulness of even relatively simple numerical simulations for AM processes. One important caveat: this approach doesn’t include the energy consumption of post-processing operations or calculations of material waste.

2) Modeling heat transfer, fluid flow and solidification in L-PBF

A much more complex example of simulation in 3D printing comes from an engineer and a materials scientist at Ohio State University and Oak Ridge National Laboratory, respectively. In their paper, published in the journal Additive Manufacturing, Y.S. Lee and W. Zhang discuss their development of a computational framework with mesoscale resolution for laser powder bed fusion (L-PBF) of Inconel 718.

The framework combines a simple powder packing model based on a discrete element method and a 3D transient heat and fluid flow simulation (referred to in the paper as “the molten pool model”). The idea is to use this framework to capture the complex interactions between the laser beam and the powder particles during the L-PBF process. By calculating solidification parameters using thermal gradients and cooling rate data, the researchers were able to assess solidification morphology and grain size using previously established models.

3) High-fidelity modelling of thermal stress in additive manufacturing

Another example of process simulation comes from researchers at the National University of Singapore (NUS). In a paper published in Materials & Design, Fan Chen and Wentao Yan explain how they combined a finite element method (FEM) with computational fluid dynamics (CFD) to create an improved model for predicting thermal stress. While their simulations focused on single tracks, multiple tracks and multiple layers of electron beam melting (EBM), the researchers claim that their approach is applicable to a variety of fusion-based AM processes, including selective laser melting (SLM), directed energy deposition (DED) and wire arc additive manufacturing (WAAM).

Using their improved model, the researchers were able to identify the process parameters with the greatest impact on mechanical failures correlating with high-stress regions, such as cracking and porosity.

4) The impact of additive manufacturing on supply chain design

Going beyond the 3D printing process itself, simulation can also be a tool for understanding how implementing additive manufacturing technology can affect supply chains. A team of engineers from the University of Campania in Italy did just that by creating a discrete event simulation model using Excel to compare AM with traditional manufacturing methods for aerospace spare parts.

Their model of a traditional manufacturing supply chain included one supplier, one OEM, two regional distributors and eight local distributors, while the AM supply chain was modeled in two different ways:

• A centralized model with one supplier, two OEMs and eight local distributors
• A decentralized model with one supplier and eight OEMs

The researchers evaluated these three different models on 11 different service level scenarios, ranging from 65% to 95%, and included variables for final customer demand, lead times and travel distances based on industry data attained via literature review. Each model was evaluated in terms of supply chain lead times and customer satisfaction. What they found was that “regardless of the service level, additive manufacturing reports a better result.”

However, it’s worth noting that, “the significant number of machines affects the KPIs linked to the production stage and such aspect could limit the economic feasibility of AM technology.” In other words, if you have enough 3D printers, you can construct a decentralized supply chain that performs better in terms of holding stock, supply chain costs and customer satisfaction.

These are often touted as benefits of AM, but this simulation actually provides evidence to back them up.

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Now, in a joint research project between Sandia and Texas A&M University, engineers and materials scientists have developed a new type of ILMs using shape memory alloys.

“ILMs are poised to redefine joining technologies across a range of applications, much like Velcro did decades ago,” said Ibrahim Karaman, a professor of materials science and engineering at Texas A&M in a press release. “Our research demonstrates that these ILMs can be selectively disengaged and re-engaged on demand while maintaining consistent joint strength and structural integrity.”

In their original formulation, ILMs were passive, requiring force for engagement. However, with 3D printing, the research teams designed and fabricated active ILMs using nickel-titanium shape memory alloys, which recover their original shapes after deformation with the application of heat. Controlling ILMs in this way opens new possibilities for smart, adaptive structures.

“Active ILMs have the potential to revolutionize mechanical joint design in industries requiring precise, repeatable assembly and disassembly,” said Abdelrahman Elsayed, a graduate research assistant at Texas A&M, in the same release.

Potential applications include reconfigurable aerospace components, flexible and adaptable joints for robotics and adjustable biomedical implants and prosthetics. The researchers are hoping that they can build on their initial findings by using the superelasticity of shape memory alloys to create ILMs that can both withstand severe deformation and automatically recover under high stress.

 “Achieving superelasticity in complex 3D-printed ILMs will enable localized control of structural stiffness and facilitate reattachment with high locking forces,” said Karaman. “Additionally, we expect this technology to address longstanding challenges associated with joining techniques in extreme environments. We are highly enthusiastic about the transformative potential of ILM technology.”

The research is published in the journal Materials & Design.

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How to optimize AM material management with simulation

In contrast to subtractive manufacturing processes, AM can drastically reduce material waste since the majority of what’s deposited, polymerized, sintered, etc. ends up in the finished product. Compare this to the old adage in machining: “If you’re not making chips, you’re not making money.” Of course, the specifics of how 3D printing helps manage material usage depend on the particularities of the process and (more significantly) the post-processing involved.

Nevertheless, there are several ways simulation can help optimize material management. For example, simulation can help with designing the complex, conformal lattice structures that reduce material usage without reducing part strength. Simulation can also aid in predicting where porosity is most likely to occur so that (depending on the material) engineers can allow for it in regions where strength is less critical. Of course, the actual material savings in such cases will be minimal.

More significantly, simulation can inform adjustments to infill density and density gradients, once again reducing material use without compromising structural integrity. In the most advanced cases involving multi-material prints, simulation can help AM engineers assign materials based on structural needs to minimize the use of more expensive materials.

How simulation helps optimize geometry and part design in 3D printing

It’s often said that “complexity comes for free” with 3D printing, in the sense that creating additive parts with highly complex geometries adds far less build time than trying to create an equally complex part with conventional manufacturing. While there is some truth to this platitude, the physics of AM processes still place additional burdens on designers, particularly when it comes to complex components.

Fortunately, simulation can help take advantage of this feature of 3D printing. Topology optimization is a prime example, with simulation tools helping engineers to adjust part geometry so that they can remove unnecessary material from low-stress areas, resulting in faster builds and less material usage. Simulation can also help identify the optimal orientation for a part, minimizing the need for sacrificial supports and making it easier to remove parts from the build plate once finished.

It’s also worth bearing in mind that just because something is free doesn’t mean it’s desirable. Using simulation to identify features that can be simplified or even eliminated without compromising performance can reduce complexity and thereby save both time and materials.

How to enhance thermal and structural control in AM with simulation

Controlling shrinkage, distortions and residual stress is key to success in additive manufacturing, especially when 3D printing metal. In processes such as laser powder bed fusion (L-PBF), there are myriad parameters operating at the micro-, meso- and part scales that can influence the quality of 3D printed part.

Finding the right balance between the forces operating at all three levels is extremely challenging, especially during the printing process itself. This is why conducting careful and comprehensive simulations prior to 3D printing a new part is so important.

In both polymer and metal AM processes, simulations can help predict and adjust for material shrinkage, reducing the risk of parts being out of tolerance and either needing to be further machined or reprinted altogether, both of which increase overall cycle time. By the same token, simulating the thermal distortion of 3D printed parts enables engineers to make the appropriate adjustments – either to the design or the process – and ensure the parts come out right the first time. Residual stress is a well-known challenge for many additive processes, but simulation can help engineers anticipate where it will occur and compensate for it, again via either design or process adjustments.

How simulation improves process efficiency and path planning in 3D printing

For all the differences between subtractive and additive manufacturing processes, there are nevertheless similarities in how they benefit from simulation. For example, simulation can help engineers identify optimal toolpath strategies, whether for cutting tools or print heads. In the latter case, simulating zig-zag versus concentric toolpathing, for example, can help identify when it’s acceptable to use the faster option (zig-zag) or when the slower option (concentric) is worthwhile for greater strength or better surface finish.

Another example that’s more specific to AM involves printing multiple parts in a single setup. In such cases, simulation can identify which, if any, parts need specific parameter adjustments to ensure a successful print. Similar principles apply for simulating parts with variously detailed regions or complex features, where print speeds and deposition rates may need to be reduced.

Finally, simulation can improve 3D printing process efficiency by optimizing energy consumption, particularly in high-energy additive processes such as L-PBF or direct energy deposition (DED). Simulating the energy requirements for different printing strategies can give engineers key insights into the most energy-efficient paths and machine settings, reducing the risks of overheating or material degradation.

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Since its founding in 2017, the company has been pushing large-format additive manufacturing (LFAM) technology in the form of its Heron platform, which uses a six-axis KUKA robot to produce large thermoplastic composite parts via material extrusion.

Now, the company is making a foray into metal 3D printing with Vipra AM, a large-scale direct energy deposition (DED) platform that uses wire arc additive manufacturing (WAAM) to produce metal AM parts.

“At Caracol, we believe that the future of manufacturing lies in combining a strong application focus with advanced innovative technologies that reshape the capabilities of industrial production lines”, said Francesco De Stefano, CEO of Caracol AM in a press release. “With Vipra AM, we’ve leveraged the extensive know-how developed over years working on advanced process control and software for Large Format AM with thermoplastics and composites materials, to develop a proprietary cutting-edge metal platform that combines state-of-the-art hardware and software, with advanced robotic monitoring and automation.”

Caracol claims to have spent years developing projects and scaling parts production with Vipra AM, resulting in two configurations of the platform:

• Vipra XQ (Extreme Quality) uses plasma arc deposition and is designed to produce parts requiring both high strength and high precision. The system can process stainless steels and titanium alloys and is targeted at aerospace and energy applications, such as load-bearing brackets and other structural components, valves, gauges and structural piping connectors.
• Vipra XP (Extreme Productivity) aims for higher throughput in addition to being able to process aluminum and nickel-based materials as well as stainless steels and titanium alloys. The system is targeting transportation industries, including automotive components, aerospace pressure vessels and marine propellers.

“The launch of Vipra AM represents a significant breakthrough for the metal additive manufacturing industry,” said Gianrocco Marinelli, metal additive manufacturing director at Caracol, in the same press release. “In today’s competitive market, manufacturers face mounting challenges, from material waste and long lead times to the pressure of reducing costs while maintaining high performance. Vipra AM introduces cutting-edge capabilities and complements existing processes, enabling hybrid production models that combine legacy techniques with advanced metal deposition to help manufacturers optimize production lines, reducing waste, accelerating lead times, and driving overall efficiency without overhauling their entire operations.”

Vipra AM will be on display at Formnext 2024, with an official unveiling on November 19^th.

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The Wash 400 support non-flammable detergents while the Wash 400F supports flammable detergents, such as isopropyl alcohol. Both are designed to eliminate most of the manual cleaning required for resin-printed parts, incorporating a dual system that allows for “dirty” and “clean” washing workflows, a parts holder for loose parts or full build platforms and a piston lift mechanism for removing parts from detergents. Both systems can accommodate full 400mm build plates but, depending on printer hardware, users may need a separate adapter.

The Cure 400 is designed for UV-curable resins, with a rotary table, full-spectrum LEDs and a 400 mm³ curing volume. It’s compatible with all of the UV photopolymers in the 3D Systems materials portfolio and is built to optimize floor space and user workflows alongside medium-frame 3D printers.

In addition to these new hardware announcements, 3D Systems is also introducing several new materials at this year’s Formnext, starting with Figure 4 Rigid Composite White and Accura AMX Rigid Composite White. Both are intended to leverage the company’s Figure 4, SLA and PSLA technologies to produce high-stiffness parts with excellent surface quality in short turnaround times. Suggested applications include parts for wind tunnel testing, small-format, short-run tools, jigs and fixtures, and parts exposed to fluids.

3D Systems is also introducing the following new materials in support of its SLS 380 selective laser sintering 3D printer:

• DuraForm PA12 Black
• DuraForm TPU 90A
• DuraForm PA CF
• DuraForm FR 106
• DuraForm PA 11 Natural
• DuraForm PA 11 Black

For the ProJet MJP 2500 multijet 3D printer, 3D Systems is introducing VisiJet Armor Max (M2G-JF), a tough, ABS-like clear plastic intended for advanced prototyping, and VisiJet M2P-CST Crystal, a durable, castable resin for jewelry and industrial applications. According to the company, the blended acrylate incorporates wax and other stabilizing elements for added strength and durability, making it suitable for fit test models, prototypes and consumer goods casting.

Finally, 3D Systems has announced a new powder management peripheral for its DMP Flex 200 printer for dental laboratories. Developed by Delfin, the INVAC 3D is a vacuum system designed for the safe extraction and reuse of metal powders based on gas-tight, closed-loop technology.

“Our customers’ ingenuity fuels our innovation,” said Marty Johnson, vice president of product and technical fellow at 3D Systems in a press release. “By collaborating closely with their engineering teams, we’re pushing the boundaries of additive manufacturing. To keep pace with their evolving needs, we’re constantly expanding our solution portfolio. Our latest additions — new accessories and materials — are prime examples of how customer-centric innovation can deliver a competitive edge.”

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