AMUG Newsletter June 2018

President’s Report

The summer is upon us, but your AMUG Board is not resting on the beach quite yet. There is work to be done.

By every measure, the 2018 conference was a great success. Yet, we know there are many things that can, or need to be, improved. Our goal, with the 2019 conference squarely in our sights, is to build upon what worked and fix what did not to best serve the AM user community. Your feedback from our survey, through the AMUG app and from conversation during and after the conference is the springboard for thoughtful deliberation and planning.

The AMUG team is assembling this week for a very intense, 2-and-a-half-day strategy and planning meeting. Using your input, we will begin building the 2019 AMUG Conference and be creating action plans for all of the behind-the-scenes work. We’ll keep you posted on the meeting outcomes and 2019 conference details in future newsletters.

Sponsor Support

We really appreciate all of the support and effort provided by our sponsors this year! We had tremendous growth; yet a lot of interest that couldn’t be accommodated. We also a had a few surprises that needed addressing, but with the help of our volunteers, focused effort by contractors and tireless effort by our board members, it all came together. Not only did we learn a lot about managing our growth, we tried to record the suggestions and recommendations so that we can make 2019 even better!

Now, after being able to take a bit of time to reflect and regroup, we are looking forward to even more interactions with our sponsors over the summer. This dialogue will help us make sure that everyone is able to make the most of the 2019 conference.

As sponsors, please anticipate seeing communications intended to keep us ahead of twelfth-hour rushes for next year. We will be sharing information as we prepare for 2019 year, so please, reach out to us with questions, watch for our updates in the newsletter, and expect to see emails from us with details on all of the exciting things to come.  In the meantime, please make sure to whitelist our email addresses so that you don’t miss any of the information for Chi-town 2019!

Conference Photos

The AMUG website now has 697 photos from the 2018 conference for you to peruse. Want to relive the experience? Pop into a slideshow. Want to see if you were captured from your good side? Take a gander at the galleries. View them all here.

This time around, the photo galleries will let you download high-resolution images for your personal archives. And if you need even higher resolution, just send an email to amadvisor@amug.com, noting the gallery name and image number.

Enjoy.

Daniel Delgado Comacho: Guy E. Bourdeau Scholarship Recipient

The 30^th annual AMUG Conference was an interactive and informative experience. I learned about the current state and challenges in additive manufacturing (AM) in different industries. For example, in the automotive industry, I learned that the BMW Group is moving from prototyping to production of customized and optimized parts. Similarly, the aerospace industry has shifted from using AM for prototyping and tooling to using metal AM for part consolidation and designing for additive manufacturing. Through presentations and conversations, I have come to realize that there is potential to apply in the construction industry (my focus) what we have learned about AM at much smaller scales in other industries.

In addition, during the conference, I was able to network with other users and with the AM experts inside the company that I will be joining once I graduate from UT Austin. I was amazed at how everyone was willing to share ideas with excitement and were open to discussing how to improve their business.

Volunteering prior to and during the conference helped me engage with some of the board members and with other volunteers, either when stuffing bags or at the front desk registering attendees. As a volunteer, I realized the amount of work required to organize a conference, but I also appreciated the fun that comes with it.

I hope I can attend and volunteer at the next AMUG Conference in Chicago and keep learning from other users of AM.

Daniel Delgado Camacho, who is pursuing a master’s degree in structural engineering at the University of Texas at Austin (UT Austin), addresses AMUG Conference attendees.

2018 Conference by the Numbers

The AMUG Conference had yet another record year for attendance with roughly a 10% increase year over year. AMUG was also excited to welcome many for whom the 2018 conference was their first. Nearly 40% of the attendance was by first-timers.

Since the conference is based on sharing of insights and knowledge, we are very pleased that 51% of the conference attendees had 6 years or more of AM experience (see chart below). Those new to the industry (49%) had access to the most experienced…those with 20+ years under their belts (9%).

Siemens and HP are Expanding Innovation for Industrial 3D Printed Parts with Full Color

With the latest releases, Siemens, a leader in digital innovation software, and HP, the global industry leader in 3D printing, will enable users of Siemens’ NX™ software and Solid Edge® software to design and produce full-color 3D-printed parts. HP’s Jet Fusion 3D 300/500 series is the industry’s first 3D printing solution for the production of engineering-grade, functional parts in full color, black or white – with voxel-level control – in a fraction of the time of other solutions. The Jet Fusion 3D 300/500 series also supports the leading color file formats, including 3MF, enabling designers to easily produce the color parts they want with a reliable workflow.

Users taking advantage of NX and Solid Edge for HP’s Multi Jet Fusion technology will have access to 3MF files ready for HP’s entire portfolio of printers including the industrial-grade HP Jet Fusion 4200/4210 and 300/500 solutions.

Read more here.

Siemens’ NX and Solid Edge support design full-color 3D printing with HP’s Jet Fusion.

3D Systems’ New Entry-level Metal 3D Printers

Earlier this month, 3D Systems launched the new DMP Flex 100 and DMP Dental 100 3D printers, introducing superior quality, versatility and throughput for entry-level metal 3D printing and dental applications – bringing industrial-grade metal additive manufacturing to a wider customer base.

Designed to be used flexibly for R&D, application development and production, the DMP Flex 100 provides up to twice the throughput compared to 3D Systems’ previous entry-level metal 3D printer, the ProX DMP 100 – achieving superior accuracy, repeatability and surface finish as fine as Ra 5 μm.

3D Systems is also addressing the unique requirements of dental labs with the new DMP Dental 100 metal 3D printer. This entry-level solution is designed for a maximum price/performance ratio – producing high-quality, metal dental prostheses in a business-boosting digital workflow.

The new DMP Flex 100.

National Dentex Labs and Carbon Partner for Dental Solution

Carbon and National Dentex Labs (NDX) announced a multi-year agreement that will place Carbon’s complete dental solution in NDX labs across the country.

NDX, the largest network of dental labs by revenue in the U.S., relies on 3D printing to fabricate models, casting and implant guides. Increasing demand for these items led them to seek a solution that could meet their growing needs. NDX chose Carbon for several reasons, including efficiency, accuracy, scalability, quality parts, and excellent support and service.

For highly regulated industries like dental where the FDA will increasingly require part-specific data to ensure product performance and patient safety, Carbon’s solution provides important features such as part traceability and serialization through next-gen software design tools. The feature’s unique and digitally traceable part ID can identify the digital historical record of the part, such as specific printers, resin, and post-processing protocols involved in making that part.

To learn more, visit www.carbon3d.com.

Carbon’s dental solution to be placed in NDX labs.

Introducing the New FORMIGA P 110 Velocis

The additive manufacturing process has been further optimized with the release of the new FORMIGA P 110 Velocis system. Already one of the most successful and reliable industrial 3D printers for polymer materials, the new iteration of the FORMIGA P 110 offers up to 20% increased productivity, along with a more homogeneous part quality. Like its predecessor systems, the FORMIGA P 110 Velocis is well suited for companies that would like to get into industrial 3D printing.

“The systems of the FORMIGA family have always been distinguished by reliability and productivity,” said Moritz Kügler, product manager at EOS. “At the same time, the running costs are reduced by being confined to the materials and electricity used – no auxiliary materials are needed, keeping operating costs calculably low. It is precisely for these reasons that our existing customers appreciate this product series.”

Read the full press release.

FORMIGA P 110

BASF and Essentium Build Global Distribution Network for Plastic Filaments

Through collaboration and partnerships, BASF continues its efforts of rapidly bringing new materials for industrial 3D-printing applications. Together with Essentium, we are combining a substantial part of our industrial filament materials under the brand name Ultrafuse. This portfolio will provide customers, all over the world, with high-quality materials based on our expertise in application development and know-how in fused filament fabrication (FFF).

All filaments in the Ultrafuse series will target industrial applications with high-performance materials for FFF technology. For example, Ultrafuse Z, an extra strong filament based on Essentium’s processing technology Flashfuse™, will enable 3D-printed parts to have optimal strength in the z-direction. Our cooperation will also bring to the market filled and flame-retardant filaments.

The positive momentum continues as we all help shape this innovative industry. For more information, please contact us at 3d-printing@basf.com.

To learn more about BASF’s and Essentium’s collaboration, click on the image.

The 3D-printing journey continues for BASF and Essentium.

Ceramic 3D Printing Comes to the Desktop

Internal R&D and fabrication labs at Fortune 500 companies report high demand for ceramic 3D printing. Today, burgeoning solutions exist, often born from academic research projects, but these solutions are prohibitively expensive, with machines costing upwards of $100,000.

With the release of new experimental Ceramic Resin, Formlabs is excited to introduce the first affordable ceramic 3D printing material for the world’s industry-leading desktop 3D printer, enabling more engineers and designers to bring rapid iteration with ceramic in-house.

Learn more about Ceramic Resin and its potential applications.

Fired parts printed in Formlabs Ceramic Resin have high temperature resistance, high thermal and electrical insulation, high resistance to corrosion and wear, and are chemically inert.

Accelerating Growth of Additive Industries North America Inc.

Last year, Additive Industries announced its ambition to grow to a Top 3 position in metal additive manufacturing in 2022. In order to execute on this ambition and to meet the challenges of the most demanding applications, in 2017 Additive Industries opened its new North American Process & Application Development Center within the surging California aerospace and astronautics markets.

Additive manufacturing veteran Shane Collins is successfully leading the Center in Camarillo, Southern California, with a growing team of talented metal 3D printing professionals. In order to keep up with the accelerating growth of the installed base of MetalFAB1 industrial metal 3D printing systems, in demanding industries like aerospace, automotive and medical devices, the new Additive Industries North America Inc. Service & Support Center (Detroit, Michigan) will be providing all the support to the customers in the northern part of the United States.

Modular MetalFAB1 system for industrial series production.

Streamline Jig and Fixture Creation

Simplify the production of jigs, fixtures and other manufacturing tooling by streamlining and automating complex part preparation. Jigs and Fixtures for GrabCAD Print software embeds application expertise, automates several complicated and time-consuming processing steps, and eliminates the need for multiple programs within the workflow.

Jigs and Fixtures for GrabCAD Print expands on the capabilities offered in Stratasys Insight to streamline the toolpath planning process. It increases ease of use, reducing time and costs to create jig and fixture parts, and maximizes the value for Stratasys’ Manufacturing solutions.

By accepting native CAD designs, the part’s original design intent is maintained. This eliminates the need for users to convert their CAD design to an STL file, which can result in key information being lost during translation.

Learn more about the Beta Program for Jigs and Fixtures for GrabCAD Print here.

Jigs and Fixtures for GrabCAD Print automates previously complex part preparation tasks.

PSV Closed-Loop Powder Supply Unit

SLM Solutions has expanded on its powder handling options with the PSV closed-loop powder supply unit. Designed to ensure reliable powder supply throughout an entire production process, the PSV features a 90-liter powder tank and an integrated ultrasonic sieve. Powder is supplied to the SLM machine, transported from the build overflows back to the sieve and can also be vacuumed directly from the build chamber back to the sieve after completion of a build. Utilizing vacuum technology, the PSV transports metal powder automatically and is contained in an inert gas atmosphere.

SLM Solutions spoke with Engineering.com at RAPID + TCT to discuss this safe powder handling system during its North American premiere. Watch the video now and see for yourself at IMTS booth 43-2304!

PSV closed-loop powder supply unit.

Spectra H – the Evolution of a Revolution

GE Additive’s latest innovation, the Arcam EBM Spectra H, was released at Rapid+TCT in Texas in May 2018. With an extended build area and capability to produce parts at temperatures exceeding 1,000 °C, Spectra H’s enhanced capacity is opening up new opportunities to produce high-integrity parts larger, and faster, than ever before. As part of a system that simplifies operation and maximizes output, Spectra H is the EBM evolution that’s helping the industry take the next step forward.

Key features:

• 39% larger build volume than previous generation EBM machines:  250mm dia. x 430mm height
• Up to 50% increased build speed
• Closed-loop system maintains powder integrity
• Capable of working with high-temperature, crack-prone materials such as TiAl

www.ge.com/additive

Arcam EBM Spectra H.

ExOne Showcases New Innovent+ at International Expo

The ExOne Company continues to showcase its new Innovent+, most recently at the International Machine Tool Exhibition in Bilbao, Spain (BIEMH). The expo included ADDIT3D, which was dedicated to additive and 3D manufacturing. Bob Wood, ExOne’s director of business development, gave a presentation on binder/powder bed interaction during the additive talks.

ExOne is also exhibiting at POWDERMET 2018 & AMPM 2018 in San Antonio June 17-20. Binder jet processing will be featured in several technical sessions by customers such as GKN Hoeganaes, Kennametal, Oak Ridge National Laboratory, and Global Tungsten and Powders Corporation. ExOne is also presenting “Material Developments in Binder Jet 3D Printing.”

New Innovent+ is equipped with the most advanced powder dispensing system on the market.

Renishaw AM Delivers Fast Parts at Ferrari F1

Why choose Renishaw machines? The answer is tied to the technological potential, to the awareness of the reliability of all Renishaw products and the ability to listen and to find a solution to all issues that inserting new technology entails.

The Scuderia Ferrari team has chosen additive manufacturing machines to make some of its more challenging, metal, engine components. Renishaw additive manufacturing systems use metal powder bed fusion technology to build components directly from CAD files. The parts made at Ferrari have complex geometries and thin-walls and would be very difficult to produce using more traditional methods, such as casting or machining. Unless great care is taken, the quest for extreme light weight could result in weak points and fragility. Read the case study for more details.

Turbine exit (front and rear views) for Ferrari SF15T.

RAPID + TCT 2018 Digital Recording Package Now Available

Didn’t have a chance to attend RAPID + TCT 2018? The Digital Recording Package is now available for purchase to get you caught up to speed. The package is also a great option for those that attended the event and would like to revisit the content covered. The package includes recordings of:

• 28 conference presentations
• All Innovation Summit presentations
• Select theater presentations and panel discussions
• The RAPID + TCT Kickoff
• All keynote presentations
• All Smart Manufacturing Hub presentations
• All Technology LaunchPad presentations

Purchase details: The package is available for $200. If you attended RAPID + TCT 2018 and would like to purchase the package, visit your Registration Resource Center and select “upgrade” If you didn’t attend RAPID + TCT 2018, you can purchase the package here.

Digital Recording Package available for RAPID + TCT.

Why Use 3D printing?

Of what use is additive manufacturing and 3D printing really?  It’s a fair question and one that must be answered before this technology gains wider acceptance among designers, engineers, and executives.  Materialise, a noted provider of software and 3D printing services, recently hosted a conference—the Materialise Experience—to offer thought-provoking presentations and industry insights into this technology. And it promoted the use of this technology in a range of fields.

One presentation gave an unexpected reason on why to use 3D printing. The reason was because 3D printing can reduce or eliminate fear.

The presentation was for the medical use of 3D printing, specifically in medical simulation. 3D printing is increasingly being used in this area—a market that is expected to reach $2.5B by 2022, a 14.9% rate of growth from now until 2022.

Read more here.

3D printing is increasingly being used in medical simulation.

A New Way to Manufacture

Online portals are quickly becoming the industry standard for rapid prototyping and manufacturing of parts. Here’s a look at the benefits and when to bring in specialists.

Online portals covered in DE’s latest issue.

How 3D Printing Is Advancing Plastics Manufacturing

3D printing might always be unthinkable for production runs of hundreds of thousands of plastic parts, but there are at least 10 ways that 3D printing is advancing plastics manufacturing today. One example: At the right scale, 3D printing can be a more cost-effective production method for plastic parts than injection molding and may even deliver those parts faster. Another: Metal 3D printing enables injection mold tooling to be built with conformal cooling channels for more efficient cooling, which in turn improves cycle times and quality in the finished parts. More ways that 3D printing is aiding and advancing the plastics industry in this video.

Rendering from Conformal Cooling Solutions shows a conventional cavity and a 3D-printed core with conformal cooling.

3DMP Offers August Tech Tour and More

Be sure to visit the 3DMP website, www.3dmpmag.com, for details on our 3D Metal Printing Experience and Tech Tour,  August 8-9 in Pittsburgh, PA. Presentations include: Metal 3D Printing: An Overview of Trends and Processes; Find Your Diamonds—A Quick Introduction to Part Screening for Additive Manufacturing; Metal-Additive Design and Manufacturing in the Aerospace Industry—Opportunities and Challenges; and more. Also, attendees will tour the GE Additive Customer Experience Center and the Carnegie Mellon NextManufacturing Center.

Out in July, the Summer 2018 issue of 3D Metal Printing details what we saw and heard at AMUG and RAPID + TCT.

www.3dmpmag.com

3D-printed mining drill components feature integrated water channels that would be nearly impossible to produce using other manufacturing processes.

Calling all TCT Show Exhibitors!

The spring show season may well be over, but as we enter the second half of the year, team TCT already has its sights set on our flagship UK show and TCT Awards event taking place in September. The next issue of TCT Europe will feature our annual TCT Show Preview, a sneak peek at what visitors can expect to see on the NEC show floor and across our three conference stages. So, if you’re exhibiting something exciting—a new machine, material, software, unique application, whatever it may be—our editors and readers want to know about it. Drop us an email, and if you haven’t already, subscribe to receive your free print copy of one of our four TCT titles here.

TCT Show preview coming — exhibitors, submit info today.

Additive Construction: From the 3D-Printed House to the 3D-Printed High-Rise

If you read mainstream tech news, it seems like there’s a new 3D-printed house being unveiled almost every week. But how useful or realistic is the use of additive manufacturing for construction? Are 3D-printed houses actually going to become a “thing”? Will we ever see a 3D-printed high rise?

Get your answers here.

The MX3D bridge is near completion. (Image courtesy of MX3D)

Formula 1 Meets Metal Additive Manufacturing

As the new Formula 1 season roared to life in March 2018, additive manufacturing had played a vital role in the development and manufacture of many of the cars on track.

Early this year, Metal AM magazine visited Sauber Motorsport to discover how its partnership with Additive Industries has supported both the development of in-house AM applications and an expansion of Sauber Motorsport’s AM services for third parties.

To read this 11-page report, simply follow this link to view it for free in your browser or as a pdf download.

New 11-page report on AM and Formula 1.