A common question I hear from my customers is, "What 3D materials are tough and which materials are best suited for certain applications?"  The second question I typically hear is, "What is the print speed?"  While not many new AM technologies are being developed, the same is not true with materials.  With innovations in 3D printing and materials development, entirely new business models are being unlocked.  3D printing is developing fast.  With ever-evolving technologies and materials, the range of addressable applications across industries has never been so varied or offered such huge opportunities.  No material can do everything.

The 3D Systems' Figure 4 DLP technology has been especially transformative.  Innovative new materials open up new production workflows for digital manufacturing.  Plastic printing materials are particularly versatile.  Listed below are industrial materials and applications applicable to the Figure 4 DLP technology.  These materials are a new class of additive materials with industry-leading UV stability.

Figure 4® Rigid 140C Black, Figure 4® Rigid White, Figure 4® Rigid Gray, Figure 4® Tough 60C White, Figure 4® Tough 65C Black, Figure 4® PRO-BLK 10: True production-class material; versatile rigid urethane-like material with an industry-leading combination of speed, accuracy and engineering-grade properties of strength, impact, and heat resistance.
GOOD FOR:  • Rapid prototyping • Functional assemblies • Snap-fit components • Consumer electronic components • Drill/tap applications • Master patterns for vacuum casting

Figure 4® 150C FR Black: 
GOOD FOR: • Aircraft interior parts • Consumer goods and electronics • Components requiring flame retardancy

Figure 4® FLEX-BLK 20 and Figure 4® FLEX-BLK 10: Extremely durable polypropylene-like parts Highest precision prototyping material with UV stability for production applications where mechanical properties fit.
GOOD FOR: • Prototyping • Functional testing • Low-volume production • Master patterns for RTV/silicone molding • Snap-fit assemblies

Figure 4® HI TEMP 300-AMB: High-temperature resistance for use in the harshest environments.
GOOD FOR: • HVAC, consumer appliances, motor enclosures, and other test or end-use components requiring high heat resistance • Low-pressure molding/tooling • Overmolding

Figure 4® RUBBER-BLK 10 and Figure 4® Rubber 65A BLK: High tear strength, malleable material for hard, rubber-like parts.
GOOD FOR: • Functional prototypes with rubber-like properties - Gaskets - Hoses - Seals • Low to mid-volume direct manufacturing of end-use parts • Strain-relief applications

Figure 4® MED-AMB 10 and Figure 4® MED-WHT 10: Materials with biocompatibility and autoclave stability for medical and industrial.
GOOD FOR: • Medical applications, including - Surgical drill guides - Splints - Anatomical or bone models • High-temperature applications

Figure 4® EGGSHELL-AMB 10: A rigid plastic for casting silicones to withstand injection at high temperature and pressure, but easy to break away. 
GOOD FOR: • Silicone castings • Customized end-use silicone parts • Low-volume production of silicone parts

With a better understanding of industrial materials discussed for the 3D Systems' Figure 4 DLP technology, I want to discuss the advancements in print speed.  Figure 4 offers ultra-high print speeds with 3 print modes, enabling up to 100mm/hour printing, some of the faster on the 3D printer market today.  The following is a good example from a service bureau printing aerospace check fixtures.  

• CHALLENGE: Deliver production-grade check fixtures for aerospace customer with a very fast turnaround.
• SOLUTION: Figure 4 with 3D Sprint software and Figure 4 TOUGH-GRY 15 material.
• RESULTS: 
  • 24 parts printed per tray
  • Print set up time - 7 minutes
  • Time to part in-hand - 91 minutes
  • Print time - 31 minutes
  • Post-processing - 60 minutes

To round out the key advancements of the 3D Systems' Figure 4, alongside the materials science and production-grade end-use parts at accelerated speeds, the new high-density part stacking feature of 3D Systems' 3D Sprint software allows efficient part nesting and optimized support generation to enable new efficiency in batch printing and post-processing.  Advantages of High-Density Vertical Stacked Printing over traditional methods 3D printing often leads to fast turnaround times without using expensive tooling.  Additive Manufacturing, AM serves as a great tool for prototyping and low/mid-sized production by using high-density vertical stacked printing.  Key drivers for stacked printing include:

• Productivity and Efficiency: by utilizing the full build height (350 mm) and stacking parts, more parts can be printed.  With 3D Systems' additive manufacturing workflow software, 3D Sprint, stacks can be easily generated and supported to maximize packing density, reduce post-processing, and decrease labor times.
• Strut Array Generation:  Quickly generate and replicate strut supports throughout a stack within 3D Sprint.  The open, sparse strut network maximizes solvent washing, air drying, and post-cure process effectiveness for batch manufacturing.
• Overnight Printing and Cadence: For manufacturers that do not work around the clock, there is a lot of wasted time at night that could be used for printing parts.  Prints can be planned more efficiently to improve throughput in a single day by printing less frequently, but with a larger yield.  If build times are too short, technicians would get overwhelmed from replacing builds for many printers.
• Automation Compatible: Another method for improving the efficiency of the entire workflow is by using automation.  With pinpoint contact strut supports allowing for quick removal of supports, automation can be used to clean, dry, and cure stacks of parts without human labor.  Multiple wash stations can be used for cleaning parts.

If you want to know more about the advancements of vertical stacking with the 3D Systems solutions please click the following: 3D Systems Application Brief - Industrial Stacking

If you want more information in general, feel free to visit us at www.mastergraphics.com or contact me directly at barb.miller-webb@mastergraphics.com

Whatever the 3D print technique is, some kind of post-processing will be needed to make the part complete. Whether it be removing supports, using ultraviolet light to make a part strong, removing excess powder, or making a part smoother. I would like to review the optimal methods that MJF and SLS printing use to complete the Additive Manufacturing process. The methods (especially those automated) can increase productivity, create higher cost-efficiency, improve component performance, and faster implementation.  

After the unpacking process, the first step in post-processing is CLEANING, removing the excess powder in MJF/SLS printing. 

Media blasting systems need significant airflow to work properly to remove the unsintered loose powder, which can be accomplished with a sandblaster. 

There is an extensive list of sandblasters that are on the market and these machines can be classified into four categories:

• Benchtop media blasters
• Floor top media blasters
• Tumbling blast cabinets
• SLS/MJF-specific depowdering blast cabinets

Benchtop blasters are recommended for users on a budget, typically with small to medium-sized print volumes and pricing up to around $1,000.  

Floor top blasters are generally over $1,000 and offer a larger working space and are considered industrial quality.

This question should be asked in various business initiatives.  However, I want to ask this question as it relates to additive manufacturing especially in smaller manufacturing companies that have yet to adopt additive manufacturing. 

When just beginning something—be it a journey for improvement or an initiative to ensure you are prepared, I always suggest starting small.  Companies that want to dip their toes into 3D printing have a couple of choices; own their own AM equipment or rely on service bureaus.  Times are also changing.  And those old production processes mean you could be losing your competitive edge by missing out on LARGE cost savings.  

Additive manufacturing can provide significant ROI to small manufacturers by helping:

• Improve their industrial tooling processes
• Produce more high-value, complex, low-run parts
• Create highly customized products for their industry and their customers

Start with a basic step process for additive manufacturing:

1. It starts with an organizational shift.  Generate an additive manufacturing mindset within the organization.
2. Create a roadmap.  Pilot a targeted small area and then scale up.
3. Develop a business case.  Examine impacts of parts from your supply chain and or product life cycle with the use of additive manufacturing.
4. Identify challenges and evaluate whether additive manufacturing fits in your company.

You have to get started with additive manufacturing/3D printing - doing nothing gets you nothing!

Historically most machine shops have been job shops, which makes the business dependent on constantly obtaining new customers with new machining needs.  3D printers can enable a machine shop to create its own new products and gain more independence.  

Let us review why it makes sense to adopt 3D printers in machine shops today.  

• Diversification - Metal 3D print technologies are the next evolution to the machine shop.  The ability to complement their subtractive with additive manufacturing.  The evolution of adding plastics, carbon, and now metal additive manufacturing to produce tooling, fixturing, and end-use parts.
• Optimize the tooling with metal 3D printing.  Shops can now leverage 3D printing cost-effective plastic parts or metal parts to enhance workflows and projects.  A machine shop can rely on the printer to mitigate errors and improve timelines from pre-production prototyping to creating production tools to printing end-use parts for quick fixes.
• Small-batch production — additive manufacturing technologies provide direct production options for low volume production and bridge manufacturing.  Save on tooling costs with 3D printing directly from a file, and take advantage of speed to market.

Complex geometries are the best use case for metal AM.

Most importantly, metal 3D printing

• Is especially helpful for geometries that are costly, time and labor-intensive processes to produce on a CNC machine.  Designs that leverage metal AM's freedom to generate internal features of the part, intricate geometries such as lattices, and complex forms such as topology-optimized shapes to maximize their performance while minimizing their weight and the total number of components in an assembly.  
• Communication to the machinists to help interpret drawings that have so many call-outs and can be difficult to catch all with complex geometries.  This helps eliminate time and material waste with a CNC job that a call-out may have been missed.  A 3D print can be a valuable tool prior to machined part production.
• To produce parts for test fit and function.  This will shorten the feedback loop in the machine shop with 3D prints in advance of production.  3D printing allows for faster prototypes, setting up prints to run overnight then using parts the next day.

Jigs, fixtures, and other customized production tools are essential for efficient, effective manufacturing.  Tooling is a fixed expense that must be amortized across large quantities of parts. 

• One important capability is an alternative to casting.  Machining lead times can be a hostage to the lead times from foundries delivering cast parts.  With production, metal additive manufacturing in-house, the machine shop can print its own parts as needed, without any lead-time from a supplier. 

In summary, additive manufacturing eliminates the following barriers with tolling-free production:

1. Optimized designs
2. Mass customization
3. Rapid design to production
4. Cost-effective at any scale
5. Digital inventory
6. Low operator burden

To learn more about metal additive manufacturing solutions, please connect with us directly at https://www.mastergraphics.com/desktop-metal

The official definition of Investment casting is an industrial process based on lost-wax casting, one of the oldest known metal-forming techniques.  The term "lost-wax casting" can also refer to modern investment casting processes.

Additive manufacturing technologies are rapidly evolving and their applicability to investment casting grows with it.  Instead of using injection-molded wax patterns companies can now also choose to directly 3D print patterns using Stereolithography (SLA) and MultiJet (MJP) materials.  Using these AM technologies and 3D printer software such as 3D Sprint from 3D Systems, you can streamline your time and labor-intensive process to advance production and reduce expenses.  Today this is referred to by 3D Systems as "digital foundry" which enables foundries to deliver a new level of service to their customers.  There is no need to change anything in the workflow process.  More importantly, they can expect patterns in hours rather than days or weeks.  Foundries that want to compete in this market and maintain a competitive edge should be using additive manufacturing or... be left behind.  

With the new technologies for investment casting, foundries will be able to:

1. Produce low volumes of casted parts from a CAD model in 24-48 hours
2. Reduce the costs of tooling
3. Eliminate the time it takes to produce tooling
4. Reduce costs and space for tooling storage
5. Deliver unmoldable products

Using powerful software such as 3D Sprint from 3D Systems you can apply chemical etching offsets.  Apply scale compensation for metal shrinkage.  Digitally create and position gates and vents.  Create sectioning of large parts and joints.  Prepare and optimize files for printing. 

Print your master pattern by choosing between plastic and wax master patterns.  But how do you determine which type of master pattern?  Let me summarize the differences:

With MultiJet printing (MJP) for wax casting patterns, you use 100% real wax printing technology.  This technology is great for small to medium size parts typically less than 8 inches in X, Y, and Z geometry.  These patterns are significantly lower in cost due to the material costs.  They are produced in less time than traditional patterns production again for low to medium volume prints.  You can expect accuracy and repeatability with wax patterns and fits into the existing investment casting process.  Also, ideal for customized metal components to bridge manufacturing.

With Stereolithography (SLA) for plastic casting patterns, you would use a castable resin material.  This provides you with highly accurate, high yield, large parts, and very complex lightweight master patterns.  They will maintain dimensional stability over years.  Typically, there is less manual finishing and labor expense with SLA processes.   3D Systems uses a QuickCast resin that is 30% lighter weight and provides consistent strength X, Y, Z geometries.

To learn more watch, the 3D Systems YouTube video. Understanding How 3D Printed Casting Patterns Work in the Foundry

What is biocompatibility and how is it relevant to 3D printing? 

 “Biocompatibility is a general term describing the property of a material being compatible with living tissue. Biocompatible materials do not produce a toxic or immunological response when exposed to the body or bodily fluids. Biocompatible materials are central for use in medical implants and prosthetics to avoid rejection by the body tissue and to support harmonious biological functioning.”

3D printer materials have advanced in the medical field. So much that once what was impossible to imagine is now occurring. 3D printed technologies and materials have developed to the point that they are replacing traditional methods of bone and joint replacements in the human body. Knee replacements are often now printed in metal to replicate the replacement knee (using a scan to print an exact replica of the damaged knee) versus using the traditional method of machining net near shape knee and then working to make it fit. Let’s discuss a few of many applications specifically in the medical field. 

Biocompatible materials are used for 3D printing in various medical applications, including dental and orthopedic implants(spinal), drug delivery, hearing aids, tissue, craniomaxillofacial (CMF), dental, veterinary, and prosthesis. Common biocompatible 3D printing materials include polymers, metals, ceramics, composites, and carbon compounds. 3D printing facilitates the easy production of orthopedic implants, dental devices, surgical guides, anatomical models, medical tools, prostheses, and custom enclosures. Taking it one step further and not limited to the printing of organs, bone regeneration, and drug release.

Below I am highlighting some key application use cases with medical 3D printing:

• The applications of Anatomic Models is still highly used in 3D printing and Medical image data is the foundation of highly-accurate, patient-specific anatomic models that can be made in a variety of materials to support patient education and surgical planning.  

• A surgical guide is a medical device that is 3D printed based on the DICOM data which is patient specific. It is used for the accurate placement of the implant in the bone structure. It replicates the exact surfaces of the patient’s intraoral situation  
• And in today’s Covid 19 environment we are printing PPE devices such as masks, ventilators, swabs, and more...
• For instance, Align Technology produces transparent dental aligners – 17 million per year. With the help of 3D Systems 3D Printing. Most removable orthodontic appliances, including retainers and positioners, are made from plaster reference models; individual teeth on these models can be manually sectioned and repositioned with wax.
• Surgical implants and prosthesis is advancing due to innovations in the biocompatible 3D printing materials market.

If you are in the medical space, are you keeping up with the medical advancements in 3D printing?

Biocompatible 3D printing technology is being increasingly used for tissue regeneration in vascular tissue engineering applications. Players operating in the biocompatible 3D printing materials market use the technology to produce patient-specific devices in the biomedical field. 3D printing serves as a resource for the production of devices and systems in biomaterials, and in the field of tissue engineering.  

There are Major Challenges for Biocompatible 3D Printing Materials Market – Why?

Currently, only a few biocompatible materials are widely employed in the healthcare industry. The U.S. FDA (United States Food & Drug Administration) has not yet approved the research in the development of some biocompatible materials. This is restraining the global biocompatible 3d printing materials market.

With 3D printing, the possibility of making health not only accessible but also individually customizable. Each day companies are making exciting discoveries and opening new doors for patients and healthcare professionals alike. The medical world is changing rapidly, and 3D printing will continue to revolutionize the path forward.

Click the link below to read the case study by 3D Systems to see how biocompatible and functional microfluidic components for rapid and portable diagnostics testing were developed.  https://www.3dsystems.com/customer-stories/rapid-diagnostics-device-developed-using-figure-4-standalone

Reach out if you want to discuss other case studies or biocompatible solutions. 
barb.miller-webb@mastergraphics.com

When it comes to advancing manufacturing processes, people pick a team on which to play: the additive manufacturing team or the subtractive manufacturing team.  This meant that people used technologies such as MultiJet, SLA, SLS or FFF technologies for additive manufacturing, or CNC machining for subtractive manufacturing.  The result, companies have a divide with both sides feeling threatened and intimidated by the other.

Additive Manufacturing (AM) rose in the 1990's.  Companies thought this would replace traditional machining and I injection molds. It was realized AM at that time had limited materials tolerances, lower speeds and higher prices. AM adoption was slower with manufacturing as a result.  Traditional manufacturers were offended that a technology could replace their skill set.  On the flip side, additive manufacturers were not impressed by traditional manufacturers refusing to advance product development with speed or diversity.  This division slowed the acceptance to AM technology.

So what has changed today?  Proven successful applications over the years.  With the advancement of material properties, faster print technology, better resolution/tolerances and lower equipment pricing has companies adopting AM to complement subtractive manufacturing instead of competing.  More case studies are being produced today with successful applications.

What are a few applications we see additive manufacturing used successful within companies today?

• Jigs or fixtures is used to locate, insert or support something.  Also go/no-go gauges.  Traditionally, these items have been machined which involved expense and time to program the work, buy the material and machine the parts.  3D printed parts can be printed overnight for next day needs, ensure repeatability, save scrap costs and lower the cost of production.
• Mold inserts - low volume injection molds such as up to 200 shots are proving out for companies that want to get to market faster.  The divide is coming together with the designers helping design the fixtures for the tool room manager.
• Thermoforming used as direct tools or custom 'inserts' within traditional tools
• Sheet metal forming tools 3d printed will provide an efficient replacement to waterjet and laser.
• Indirect master patterns save weeks and months with 3D printing.

I work with companies to help educate them about additive manufacturing, to help assure companies will not acquire the wrong technology for their application needs.  The real value of AM technology is found when people take time to learn where the complementing technologies and materials make sense.

A traditional manufacturer should embrace additive manufacturing, because it is truly complementary to their existing processes and adds value.

When customers see these technologies their manufacturers, they feel more comfortable that they are working with a progressive manufacture.  Additive manufacturing is no longer considered "hype".  It is here, and it is staying.  One common comment I hear from manufacturers that have implemented AM, "more applications and cost saving were discovered." While it is unclear if AM will ever fully replace subtractive manufacturing technologies, it seems fairly certain that it will, in the long run, become a significant complement to subtractive manufacturing.

Download the jigs and fixtures eBook for further ideas, or contact Barb Miller-Webb at barbara.miller-webb@mastergraphics.com

"The pain of Change could be LESS than the pain of NOT changing"

It's often not easy to change − whether it is a personal change or business change. I work with customers and often the path of least resistance is to stay status quo − not implement any changes or new processes because often it's perceived as the path of least resistance. I hear "We have done it this way for years and it works" but does it?  Often if you step back and analyze your areas of PAIN, the steps to address those challenges are often times easier than not changing. You can relate to this concept on a personal level if you think of eating healthy − or at least I can relate.  Often the initial change in diet is challenging − you don't like the food options − you miss eating past favorite foods and often the easiest thing to do is NOT change.  So often we are not determined to see the change through and give up.  The end result, we gain a few pounds and are not as healthy.  As opposed to going through the pain − changing our diet − and in the end having a healthier self!  The change seemed hard but easier than the bad habits leading up to issues later that are even more difficult to address than the current situation.

So how does this relate to 3D Print/Additive Manufacturing?  Often I work with clients that have a difficult time stepping back and looking at their overall processes and addressing the changes needed to avoid larger pains in the future.  Like eating right − they hear 3D printing is the future but think it does not apply to them.  I can tell you first hand the organizations that challenge themselves to be more innovative and focus in process change become class leading.  This ability to take on short term pain for long term gain makes them industry leaders − they look at any and all technologies to sustain continual improvements.  Needless to say their commitment to process change makes them industry leaders.  Ever look around and wonder how your competitors have implemented a change that you know gave them an advantage? Commitment to process improvement no matter how disruptive it may initially have been.

Let me get back to how you should look to see if 3D print may address some of your current or long term pains.  It starts internally to truly understand your current challenges and be honest within your organization.  The next step is to find a trusted partner you can be vulnerable with and work to outline/map a future to address those pains.  This of course is easier said than done − need I bring up dieting again?

As an example on how I personally work to be a trusted partner, I work with customers to understand their specific pains within their existing manufacturing process and then determine (together) if additive manufacturing or 3D printing can bring value to addressing their challenges.  I need to be candid often when there is no solution available − thus you need trust that a partner isn't just trying to sell you things.  My clients also need to trust in the process and be candid with themselves on the changes they need to make.  Many companies fail to recognize that change is a process that makes improvements to the organization, instead they ignore the problems/pains and continue to do the same thing over and over again.

If together we can't find a compelling reason/need to change the current process, or a personal impact, the change will not happen in the company.  We are conditioned to avoid pain and discomfort.  There's always adversity, fear, uncomfortable sensations, problems, distractions and so on.  We need to address the pain together...

How can trusted partners help customers discover the compelling reason?  The following are a few questions that I ask to help discover their compelling reason and you should make sure your vendor is asking you:

1. What are your current biggest challenges in your manufacturing processes?
2. Can you be more specific? Give me an example?
3. How long has that been a problem?
4. What have you tried to do about that?
5. How much do you think that has cost you?
6. How do you feel about that?
7. Have you given up trying to deal with the problem?

Will the change you are considering:

1. Speed up your time to market with your products?
2. Cut costs in you manufacturing?
3. Reduce your manufacturing downtime with on demand production?

Change will only happen when the pain of staying the same is greater than the pain of change.  I encourage you to take a step back from the whirlwind and really look at what current pains that are worth addressing.

My last note, check out Mark Blumreiter's blog 22 Ways Manufacturers are using 3D print to see if his outline sparks any ideas on areas 3D print can address your pains.

Even if we can't help you I am always up for great business discussions so don't hesitate to reach out if you want to chat on pain.

My work involves working with customers and their application specific needs and trying to determine which materials on the 2500Plus Multi-jet printer are best for specific use cases.  Many once-valid opinions about additive materials are now myths.

The MJP 2500Plus now expands to 10 materials: five rigid class, two engineering grade, two elastomeric and one specialty for high temps.  VisiJet® M2 MultiJet Printing materials are for functional precision plastic and elastomeric parts. The rigid materials offer watertightness for evaluation of fluid flow performance.  Following are highlights and use cases for some of the materials:

VisiJet Armor is a tough, ABS-like impact resistant material.

• Impact-resistant
• ABS-like for snaps & drilling, jigs and fixtures, patterns and molds
• World-class clear finish

VisiJet Rigid Grey

• Primer Gray finish = exceptional feature detail viewing
• Simple visual modeling applications
• Medical Applications

VisiJet ProFlex

• Durable, Polypropylene-like, High Impact Material
• Capable of creating living hinge parts with multiple full actuations
• Exceptional clarity
• Ideal for applications requiring deformable plastic

VisiJet Rigid M2R-CL and WT; VisiJet CR-CL and WT materials are bio-compatible

USP Class VI - Rigid materials for the ProJet MJP 2500 and 5600 have passed USP Class VI biocompatibility certification.

• Short term contact with human skin (30 days)
• Mucosal-membrane (24 hrs)

ISO 10993 - Rigid materials for the ProJet MJP 2500 have passed the following testing criteria:

• ISO 10993-5 - Cytotoxicity
• ISO 10993-10 Sensitization Maximization Irritation
• ISO 10993-10 Intracutaneous Reactivity

VisiJet M2S-HT90

• Heat resistance with high heat deflection temperature at 90°C
• Excellent humidity/moisture resistance
• Rigid and transparent
• Biocompatible
• Molds and dies for rapid tooling applications

  -Under-the-hood components
  -Heated fluids and gasses flow analysis
  -Electronics enclosures/cases

• Medical applications

For a quick look, 3D Systems also created an eBook that provides an overview of the 2500Plus materials portfolio.  In addition to features and material properties, the eBook (http://info.mastergraphics.com/3d-systems-rapid-prototyping-ebook) provides guidance on how to assess additive materials, and what you should be looking for.  
Download the eBook to learn:

• When to prototype, why and how to achieve faster time to market
• How to reduce development cycles, lead-time and engineering effort
• Prototyping for agile manufacturing, and key questions to ask before getting started 
• How to use CAD data for design verification and types of prototyping
• 3D printing technologies for rapid prototyping and choosing the best solution