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Multi-material 3D printing with Zmorph

20.04.2017

Przemek Jaworski of ZMorph has no doubt that multi-material 3D printing technology of Fused Filament Fabrication will continue to grow in coming years. It’s the least expensive method of 3D printing, and it offers vast material base, that keeps expanding every year. Many of these new challenges will be won by using advanced software, which can be a game-changer, despite technological limitations.

ZMorph are experimenting with this a lot. Recent updates to the Voxelizer software allowed our two-material DUAL PRO extruder not only to blend filaments but also print colorful images on 3D objects, which they call Image Mapping. It gives existing users a completely new functionality and provided a competitive advantage for attracting new clients.

 

ZMorph 4 material printing. Photo via Zmorph.

ZMorph 4 material printing. Photo via Zmorph.

Another upcoming feature is a set of special tools and 3D filters for architectural models production – totally relying on clever algorithms for no-support printing of floorplates for example.

New dedicated software is a factor that can’t be ignored – and will be crucial for pushing the limits of 3D printing, as the hardware in most machines offers similar technical capabilities and is not progressing much more.

Multi-materiality, multitool, and more

First of all, multi-materiality opens new possibilities in rapid prototyping, which still is the most common application of 3D printing. Although it’s already possible to combine materials in two-material extruders or experimental four-material ones, we’re still a few steps before the quality reaches its full potential (also thanks to a dedicated software).

Multi-materiality in desktop 3D printing will thrive once it enables a truly high-quality material blending of various filaments. Creating prototypes that include hard and flexible parts within one print is possible with expensive industrial machines. As it becomes achievable with a desktop 3D printer, the technology gets more accessible and affordable to a greater number of professionals and unlocks their creative powers.

Colour blending and full-color FFF / FDM desktop 3D printing will also improve and become an industry standard. This will only broaden the possibilities and enable new professional applications.

CDG are the UK distributors for Zmorph.

Cimatron signs CDG for UK market

11.04.2017

Dirk Dombert, VP of Sales at Cimatron, 3D Systems, is pleased to announce CDG as the sole partner for Cimatron software in the UK.

CDG will be offering new and existing customers with software licences, support and maintenance. All enquiries should be directed towards Grant Cameron on 01420 88645 or via our support team; Email: support@cdg.uk.com

cimatron software

Cimatron™ software is the leading CADCAM solution for Mould & Die Design including NC programming. Cimatron imports CAD files from all the leading CAD packages, as well as formats such as STL. The core software engine uses a modern parametric model tree for hybrid modelling using B-Reps (fast and interactive boundary representation coding). The tool design is highly automated for maximum productivity.

Cimatron 13 includes many new features and capabilities such as:- • A fully redesigned user interface that is faster to use, and easier to learn and customize; • A broad range of new CAD for tooling functionalities for faster design, including direct modeling, new mesh operations with hybrid modelling capabilities and enhanced assembly functions; • Boosted drafting capabilities including the dynamic creation of multiple views and the ability to create shaded views; • New mold-design applicative tools including gates design for a more streamlined design process and conformal cooling tools for the easy design of Cimatron™ 13 features a new user interface that is faster to use and easier to customize; • Separate environments for progressive- and transfer-dies for quick design of any die type; • Smart electrode mirroring tools and hybrid design environments for accelerated electrode design with automated solid tools; • A new plate machining solution that provides a complete set of capabilities for fast, efficient and automated programming of mold- and die-plates; • New measurement on CNC machines to define the measurement probing cycle in the NC environment, allowing validation of the machining process while the part is on the machine; • New and improved NC programming capabilities for milling and drilling to boost programming automation in rough, finish and 2.5 axis operations; • Concurrent design and manufacturing environment, enabling multiple users to work on the same project simultaneously.

Wing mirror case study for Omni 3D printing

30.03.2017

Wing mirror case weight reduced by 53% thanks to Omni 3D printing!

Mirror caps, air vents – these are just some of the parts printed by OMNI3D for Arrinera Technology S.A. All models are printed at a full scale, mostly with ABS-42 and are used as functional prototypes as well as final parts. In this particular case, the challenge was to reduce the weight of the mirror case.

TECHNOLOGIES COMPARISON ON THE WEIGHT OF THE MIRROR CASE

DESCRIPTION

In the automotive industry weight is one of the most important aspects. The company was looking for the best solution to produce car parts which are durable and at the same time – as light as possible.

SOLUTION

Parts are printed on a 3D printer – Factory 2.0 Production System using ABS, ASA, PC-ABS, PET-G, HIPS filaments depending on the requirements.

‘Parts printed in 3D on Factory 2.0 Production System meet all of our requirements – both in terms of strength, dimensional accuracy, turnaround time and weight loss. Many elements are installed in the car as the final products,’ – Łukasz Tomkiewicz, Managing Director, Arrinera Automotive S.A.

Omni 3D Printer saving time and money

29.03.2017

Thanks to OMNI additive manufacturing, a new customer saved hundreds of thousands of pounds in just a few weeks! 3D printing using the latest technology can bring hugh potential savings: 90% cost reduction and 80% time savings.

The functional prototype of a train seat was printed using FFF technology on the Factory 2.0 industrial 3D printer from OMNI3D. This project was carried out by METRIS3D for POLGAR KFT, the Hungarian manufacturer of parts for the automotive industry.

Creating a functional prototype has never been so cheap, fast and easy.

 

‘Now, preparing the model cost all together about €40,000, before this was over €400,000 [including the cost of the tooling]. It’s just a fraction of the budget! Regarding the time, now it takes only 3 weeks to prepare first prototype, before it took as long as 4 months…,’ – says Miki Thurzo, Senior Engineer from METRIS 3D.

POLGAR KFT needed the prototype to verify the design of a train seat. There are always some critical points in a design that should be double checked, preferably in real scale.

‘The great thing about having a functional prototype is that we could really test the model. Before, this was impossible due to very long lead time. Now, thanks to 3D printing, we could change the design soon after we made the first 3D prints. It turned out, for example, that some of the movable parts (like trashcans and holders) could not been moved, which was missed in the CAD file,’ adds METRIS 3D.

OMNI3D presents some of the technical specifications of the print performed on the Factory 2.0 Production System:

  • Model: 2 train seats and platform
  • Number of elements: 37
  • Print time: 500 hrs
  • Size of the biggest element: 480 x 210 x 370 mm
  • Size of the smallest element: 70 x 70 x 20 mm
  • Filaments: model ABS-42, support HIPS-20
  • Filaments weight: 10 kg (70% of ABS-42)

Factory 2.0 has one of the largest working platforms with the heated and closed chamber available on the market. Thanks to this, 3D printing specialists from OMNI3D could minimalise the number of the printed parts, which was very important to get the highest strength of the final model.

‘In the case of large models, most challenging is the size of the biggest element, the dimensional accuracy and print time. Factory 2.0 enabled us to print large parts of even 500 mm along each axis with very high accuracy. Thanks to numerous machines available in OMNI3D’s print room, timing is also not a problem. The printing process took us about 2 weeks,’ adds Krzysztof Kardach, Chief of Technologies at OMNI3D – responsible for the printing process.

3D scanning is always the best verification of the 3D printed part.

​​‘We scanned the biggest print (480 x 210 x 370 mm) on our professional 3D scanner – RPS EVO6 – to verify the dimensional accuracy. The results were impressive. The accuracy obtained enabled us to get a perfect fit with the metal seat frame prepared before,’ explains Miki.

New Wax printer for Jewellery & Industrial Investment Casting

22.03.2017

3D Systems announced new products and capabilities to accelerate additive manufacturing in the growing investment casting, jewellery and dental markets, while extending its leadership in precision metal production for healthcare and aerospace.

Among the announcements is expansion of the company’s industry-leading MultiJet Wax family with the new ProJet® MJP 2500W and VisiJet® M2 CAST RealWax™ material, for applications in jewellery and industrial casting. The new wax system combines the precision of the successful MJP 2500 platform with a next-generation 100% real wax material to deliver precise, durable, high-resolution patterns.

CDG are selling the ProJet 2500 Wax printer in the UK.

 

ProJet 2500 Wax 3D Printer

 

 

Supercar with 3D printed parts from OMNI3D

16.02.2017

Poland's first supercar, Arrinera Hussarya, contains 3D printed parts from OMNI3D

Feb 15, 2017 | By Tess

Polish sports car manufacturer Arrinera Technology has teamed up with local industrial 3D printer manufacturer OMNI3D to additively manufacture parts for the Arrinera Hussarya, Poland’s first supercar. OMNI3D, known for its industrial and large-format FFF 3D printing solutions, says it helped to manufacture functional prototypes for the supercar, as well as final parts.

The Arrinera Hussarya supercar, which was first unveiled as a concept back in 2012, has been put into production, and, to a degree, we have 3D printing to thank. Like in other industries, additive manufacturing technologies were leveraged by Arrinera to speed up the prototyping and production process without sacrificing or compromising on quality or optimal design.

As one can imagine, designing a car, especially a supercar, is a rigorous process that involves continuous changes and adjustments to designs, so having the ability to make changes to prototypes on the fly, test them, and tweak them some more, is invaluable. OMNI3D provided Arrinera Technology with this capacity, with the added bonus of manufacturing large-scale, complexly structured parts for the car. The companies have been working together for over a year.

3D printed parts for Arrinera Technology

“Detail production on a 3D printer significantly accelerates the work of our R&D team and reduces production time and costs,” commented Łukasz Tomkiewicz, president of Arrinera Technology S.A. “Frequent changes to a model’s shape–the diameter or length–are not as problematic as they used to be. A new model can be printed in just over twelve hours.”

OMNI3D, perhaps best known for its Factory Production System 2.0, a large-scale (500 x 500 x 500 mm) FFF 3D printer, has been offering on-demand 3D printing services for the past year through its Printroom. The service came about through a necessity to demonstrate OMNI3D’s manufacturing technology to potential clients, as well as to provide an option to companies that aren’t prepared to invest in their own 3D printer.

As Krzysztof Kardach, Chief Technologist at OMNI3D, explains, “We opened the Printroom as a result of observing market needs. Many of our customers before making a final purchase decision about Factory 2.0, ask us for test prints. Others, like Arrinera don’t want to invest in their own machine, but still need professional 3D prints. There are also companies that have big needs for 3D printing, but prefer to trust experienced 3D printing technologists from our company.”

OMNI3D Factory 2.0 3D printer

Not only does OMNI3D’s Printroom offer relatively large-scale 3D printing, its FFF technology can also accommodate high-quality and durable thermoplastics such as ABS-42, ASA-39, PC-ABS- 47, PET-G- 32, and HIPS-20. For the Arrinera Hussarya supercar, mirror caps, air vents, and other important components were 3D printed primarily using ABS-42.

Evidently very happy with the supercar’s 3D printed parts, Tomkiewicz added, “Parts printed in 3D on Factory 2.0 Production System meet all of our requirements...in terms of strength, dimensional accuracy, and turnaround time. Some elements, such as air vents, are even installed in the car as the final product.”

 

 

 

Posted in 3D Printing Application

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