AMUG July 2023

President’s report

Positive energy…this can be a label you might associate with someone you know. You may hear it discussed in conference rooms, classrooms, and maybe even your own living room! Perhaps it’s because there is an abundance of studies aligning positive energy to healthy outcomes. Johns Hopkins reports that people with a family history of heart disease with a positive outlook were one-third less likely to have a heart attack within 5-25 years than those with a more negative outlook. Research suggests that people who are more positive may be better protected against the inflammatory damage of stress.

In the workplace, in our homes, and in our social circles, we will have to overcome negativity, adversity, and challenges. The answer to these is positive energy—optimism, trust, enthusiasm, love, JOY, and passion. When I think of the AMUG Conference each year, I think of positive energy! Every room I walk into has our industry colleagues engaged in conversation, laughter, hugs, education, and cheer! It is beyond inspiring to me; it is downright infectious! And to think, we may be discussing career changes (desired or dealt with), crashed builds, perplexing challenges, unknowns, and uncertainties… and yet, we aren’t curled into a corner of solitude and defeat. We are engaged, we are building, and we are sharing our passions!

This month, the AMUG Board of Directors will gather to review the 2023 AMUG Conference and plan for 2024. We have much to review based on the valuable feedback of members and sponsors. The time you take to complete our surveys and communicate the things you enjoy, as well as the things you might wish to see change, helps to steer our conversations and implementation. We genuinely want this conference to be built for the user community… with each of us being met with success for the investment we make to attend and participate!

We will have so much to share in the coming months, as our aspirations are high, our determination is steadfast, and our positive energy is rampant!

Shannon VanDeren
President
President@amug.com

AMUG Board of Directors update

Following Mark Abshire’s retirement as president, the AMUG Board has appointed Shannon VanDeren, formerly vice president, as president and Ted Anderson as vice president. Additionally, Claire Belson Barnes has been appointed as director of membership. Each will serve the remainder of their position’s terms, concluding on June 30, 2024.

With these appointments, the AMUG Board is:

Officers & Directors

• President: Shannon VanDeren, Layered Manufacturing and Consulting
• Vice President: Ted Anderson, GE Aerospace
• Treasurer: Robin Van Bragt, Eagle Design & Technology, Inc.
• Secretary: Heather Natal, GoEngineer

Directors

• Director at Large: Gary Rabinovitz, Reebok International
• Director of Education & Conference: Ed Graham, Prototek
• Director of Events and Hospitality: Thomas Sorovetz. T. A. Sorovetz, LLC
• Director of Membership: Claire Belson Barnes, LightForce
• Director of Sponsors & Exhibitors: Tim Bell, MELD Manufacturing Corporation

Ex Officio

• Immediate Past President: Carl Dekker, Met-L-Flo
• Immediate Past Treasurer: Vince Anewenter, Milwaukee School of Engineering (MSOE)

Committee chairs announced

For the July 1, 2023, to June 30, 2024, term, the AMUG Board has appointed the following AMUG Members as chairpersons of their respective committees.

Operations Committees

• Executive: Shannon VanDeren, Layered Manufacturing & Consulting
• Finance: Robin Van Bragt, Eagle Design & Technology
• Governance: Heather Natal, GoEngineer
• Collaboration: Gary Rabinovitz, Reebok
• International: Stefan Ritt, Technical University of Luebeck
• Marketing: Kim Killoran, Stratasys
• Membership: Chris Prue, United Performance Materials
• New Member: Nick Licari, GoEngineer
• Nominating: Carl Dekker, Met-L-Flo
• Volunteer: Jamie Cone, BD

The AMUG Board will review the recommendations for committee members at this week’s strategy and planning meeting. Approved members will be posted to AMUG’s Committee Members page.

Secretary’s Introduction

In case we haven’t had a chance to meet, my name is Heather Natal, and thanks to all of you, I am the new secretary of AMUG. When my career moved me from the world of traditional manufacturing (CNC milling, turning, and multi-spindle equipment) to that of AM, I was enamored with all of the additional possibilities it can offer users while improving the world. AMUG is where I’ve been fortunate enough to get a front-row seat to the latest technologies and applications along with meeting some of the greatest, smartest people on the planet. While I am a marketing communications professional by trade, I am most passionate about bringing AM to the forefront of the manufacturing conversation.   

I would like to thank my predecessor, Leslie Frost, for all of her great work and organization over the past few years and for her guidance while I transitioned into the role. She has set me and the AMUG team up for success. I look forward to helping serve the great members of our AMUG organization and am excited about all of the wonderful things the AMUG Board is working on. If you ever have any questions, feedback, or ideas, you’re always welcome to contact me at secretary@amug.com.

See you in Chicago!

Heather Natal
Secretary
secretary@amug.com

Director of membership’s introduction

Greetings from your new director of membership! I am honored to serve in this role for the remainder of the term and to continue my volunteer journey with AMUG. Since my first AMUG Conference in 2016, I have enjoyed the many opportunities to learn, share knowledge, and develop friendships. Receiving the Guy E. Bourdeau Scholarship was one of the major highlights of my AMUG career, and it sparked my interest in giving back to the community.

I have served on the scholarship committee for several years and, more recently, on the registration committee. This move to the AMUG Board aligns perfectly with my desire to see AMUG have an even larger impact on the industry and our community members. The board’s planning session will be helpful in defining go-forward strategies, so be on the lookout for communication from me leading up to the 2024 AMUG Conference.

I am excited to engage with all of you. AMUG members are our best and brightest asset! Feel free to reach out to me at dmembership@amug.com with any questions, feedback, or even just to say “Hi.”

Claire Belson Barnes
Director of Membership
dmembership@amug.com

SPONSOR NEWS

Our very first whitepaper and the xTechInternational Award

Meltio has made its first wire-laser metal 3D printing solution whitepaper available to the AM community. One of the main missions of the Spanish multinational dedicated to manufacturing wire-laser metal 3D printing solutions is to provide knowledge on how our unique technology helps to manufacture and repair metal parts.

In this whitepaper, which is titled “Mold-making with LMD and Dual wire,” you can learn about:

• Current mold and die manufacturing challenges
• The opportunity of AM for mold and die production
• Wire–LMD process
• Materials & mechanical properties
• How to add conformal cooling features
• Dual wire capabilities
• Examples of molds and dies
• Case Study: Conify and modular molds for polymer medical items

Download the whitepaper here. 

In other news, Meltio was honored to receive the xTechInternational Advanced Manufacturing and Materials Award from the US Department of Defense! The third annual international prize competition, organized by the U.S. Army xTech Program, has unveiled its top-five winners. Among the 137 submissions centered around advanced manufacturing and materials, Meltio and its U.S. distributor Phillips Corporation secured fifth place for their exceptional deployable hybrid machine utilizing laser-wire DED AM.

The deployable hybrid technology, which provides subtractive and additive capabilities to world-renowned Haas machines, improves readiness by providing an easy-to-use solution for point-of-need manufacturing. The monetary prize for placing in this competition will help to fund Meltio and Phillips in their research to develop a new generation of deployable hybrids.

Advancing toolpath control and file compatibility: Dyndrite showcases Aconity3D, EOS, Renishaw, and SLM Solutions builds

Dyndrite’s Materials and Process Development for LPBF software puts automated capabilities in the hands of materials scientists and engineers. The company’s robust geometric querying capability and programmatic APIs give production users unprecedented control over how to assign parameters and print parts—dramatically speeding up and lowering the time and cost of new alloys and material parameters.

Users, materials scientists, and engineers can:

• Develop new materials, alloys, and multi-materials
• Control layer heights and define print strategies
• Tailor parameters for intricate geometries, small features, thin walls, domes, and cantilevers
• Ensure material homogeneity
• Control surface roughness
• Determine angle-based print support requirements

Supported LPBF machines:

• Aconity3D – Support through open formats (CLI/CLI+/ILT, OVF)
• EOS – Native file support via EOS job and task files through the EOSPRINT SDK
• Renishaw – Native .MTT Renishaw files through the QuantAM API
• SLM Solutions- Native SLM support, including large multi-optic systems like the 12 laser NGX 600

Choosing the right 3D printing technology for automotive manufacturing

The auto industry is understandably surrounded by many regulations and safety standards. Don’t let these stifle your innovation and creativity. With five game-changing polymer technologies, the team at Stratasys has a solution for endless applications ranging from fluid flow analysis and wind tunnel testing to jigs and fixtures for the assembly line. The technology provided by Stratasys is ready to take on your biggest challenges.

We invite you to explore the 3D Printer Solution Guide for Automotive to discover ways to shorten your development time, reduce costs, and improve your designs by adding 3D printing to your floor.

Explore your options here.

Cost Simulator tool is now available

Nexa3D recently introduced a Cost Simulator tool for its ultrafast resin 3D printers: XiP, XiP Pro, and NXE 400Pro. The free web app allows users to effortlessly estimate both the time and material costs of their print jobs. Users simply upload their STL files and select the preferred material and Nexa3D printer to receive a free print simulation report within minutes. The report includes a comprehensive pricing and print time analysis on the selected resin, as well as a broad range of other resin options for ultimate flexibility and transparency.

The app is available immediately and is free to all. Try it out today.

Peugeot drives car interior design revolution

Global automotive manufacturer, Peugeot, has integrated Stratasys’ 3DFashion™ technology into the interior of its new Inception concept car, incorporating design described by the company as ‘revolutionary’ and featuring advanced materials produced exclusively using Stratasys J850™ TechStyle™ 3D printers.

“At Peugeot, we always like to combine function with aesthetics,” said Maud Rondot, CMF designer, Advanced Design Team at Peugeot.

“Although we have access to relatively flat designs with current embellishment methods, it is not possible to build thickness and height…it is thanks to the company’s exclusive 3DFashion technology that we could 3D print directly onto the flexible material,” she added. “Often, there is a delta between what we imagine and what we can obtain, so it was quite magical to see our idea arrive precisely as envisaged and with a remarkable quality of execution.”

Read the full customer story.

DMG MORI is redefining the footprint of AM

The demand for additive technologies in the U.S. is growing, and the all New LASERTEC 30 SLM US machine is designed, developed, and manufactured all here in the U.S. at DMG MORI Manufacturing USA Inc. in Davis, California. This reduces supply chain concerns while keeping spare parts and service support all within North America.

Ensuring advanced technology of the machine and several key advancements delivers the success users require. First is the Adaptive Beam Control enabling dynamic changes to laser power, laser speed, and laser beam profile. Next, the system offers discrete powder tracking for critical industries so manufacturers can track the lot of material used and the amount of time the material has been cycled. Additionally, the LASERTEC 30 SLM US features best-in-industry production cost by using an optional innovative hybrid toolpath strategy that dynamically changes between laser beam profiles using a 1 x 1,200W programmable laser.

Follow the link to learn more about how manufacturers are advancing their part production.

How big is your 3D-printed part’s carbon footprint?

Understanding the financial factors contributing to your application’s cost-per-part (CPP) is an important step when scaling your AM production. Sustainability within production is a growing factor, as well, oftentimes perceived as a more costly aspect of the process. Responsible manufacturing is both an EOS passion and a key benefit of using AM technology.

To gain insights and drive sustainability, the EOS Additive Minds consulting team has created a powerful cost and sustainability analysis tool, the Additive Manufacturing Cost and Carbon Calculator. This tool helps you uncover and assess all notable factors driving CPP and other cost-related key performance indicators (KPIs) while calculating the emissions from various greenhouse gases (CO2 equivalents). Follow along as we break down the key features, benefits, and inner workings of utilizing the AM Cost and Carbon Calculator in our new EOS blog post.

Read more about the EOS cost and carbon calculator.

WÜRTH Additive Group CEO, Aj Strandquist, joins 3D Printing In Auto Collision Task Force

Physical and digital inventory leader Würth Additive Group’s CEO, AJ Strandquist, will join the groundbreaking, internationally recognized 3D Printing in Auto Collision Task Force, announced at the International Bodyshop Industry Symposium (IBIS) Global Summit 2023 in Milan, Italy.

In April 2023, during the International Bodyshop Industry Symposium (IBIS) USA 2023 trade conference in Nashville, Tennessee, IBIS Worldwide announced that it is launching an industry-first 3D Printing in Auto Repair Task Force to be led by Mr. Harold Sears. With an impressive resume in 3D printing and additive in automotive industry leadership, Sears will drive the task force efforts with over 30 years of industry experience, including leading Ford Motor 3D printing solutions for over two decades.

This strategic partnership aims to drive innovation and facilitate the integration of 3D printing technology within the automotive repair industry. By joining the task force and collaborating with the other members, Würth Additive seeks to advance the adoption of 3D printing, ultimately revolutionizing collision repair processes and enabling 3D printed parts via Würth’s advanced digital inventory management program called DIS3DP.

MEDIA SPONSOR NEWS

The May/June edition of 3D ADEPT Mag is out

In AM, the prevailing myth is that it can only print small and complex parts. Yet, those parts are not usually essential when it comes to building parts for the sea, architecture or construction, aerospace, and space industries. The fact is, large-scale AM is a niche that requires one to rethink everything from materials to design process to potential adjustments of one’s production facility.

For those of you who might think it’s also the case for other AM processes, let me tell you this: we’ve found a dozen reasons that justify our argument. The leap from small- to large-format 3D printing comes with a share of challenges that go beyond the technology’s technical capabilities to encompass financial and human resources. These challenges seem to be exacerbated when trying to scale production, emphasizing how this AM holy grail remains of paramount importance irrespective of the technology used. Nevertheless, there is a market for very large 3D printed parts, and this edition of 3D ADEPT Mag attempts to demonstrate how diverse and impactful it is.

Turning 10,000 AM parts into full-scale production at GA-ASI

General Atomics Aeronautical Systems, Inc. (GA-ASI) is a leading designer and manufacturer of remotely piloted aircraft (RPA) systems. In a talk at the 2023 AMUG Conference—one of the most captivating among several great presentations—GA-ASI’s Additive Manufacturing Department manager Steve Fournier revealed exactly how deep GA-ASI’s commitment to AM goes, from polymer (FDM, SLS), to metal (L-PBF, DED-W), to composite tooling (LSAM, BJP).

Over the past decade, GA-ASI has invested in the onboarding of AM technologies, as well as leading the formation and rapid growth of a dedicated department five years ago. Fournier explained that the centralization of AM activities has proven to be a strong catalyst for AM adoption, leading to successful initiatives in AM technology insertion, application industrialization, flight hardware manufacturing, risk reduction for R&D, and knowledge transfer.

The next step is full workflow integration via collaboration with the experts and pioneers at Divergent to implement their DAPS capabilities. “The future of AM,” Fournier said, “is bright.”

You can read the full review of the GA-ASI presentation on VoxelMatters’ newly released VM Focus Aerospace eBook and tons of other great content and insights.

Open source everything: 3D print your assistive device

In this article, 3DPrint.com Executive Editor Joris Peels examines a project by Professor Joshua Pearce and its potential for broader applications. The open-source walker developed by Pearce’s lab could inspire a slew of open-source, 3D-printed assistive devices that could disrupt the sluggish assistive device industry.

Sustainability: special focus issue

The newest Special Focus Issue on Sustainability from Digital Engineering includes a look at how support-free 3D printing can reduce materials waste, as well as articles on sustainable manufacturing, plastics design challenges, EV batteries, and improvements in electronics design related to repairability. You can download the issue here.

Unearthing insights, connecting innovators, and the 3D Printing Industry Awards return

Much like Christmas and birthdays, the always anticipated AMUG Conference only occurs once a year.

As we await the occasion (March 2024), 3DPI remains active and connected within the realm of additive technology. Our executive interview series offers rich perspectives from AM trailblazers spanning the ecosystem. Moreover, our editor-in-chief embarked on a recent expedition to Las Vegas in a quest to understand how Hexagon is tackling the AM space in a groundbreaking alliance with Nvidia, the most recent addition to the illustrious trillion-dollar club.

Do you have an innovative AM leader on your radar that we should feature? Or perhaps a pivotal event in the industry that demands coverage? Don’t hesitate to reach out; we are eager to hear from you.

Mark your calendar: The 3D Printing Industry Awards are making a grand return to London on the 30th of November, 2023. You heard it here first!

The Summer 2023 issue of Metal AM magazine is out now

This 196-page issue features industry news highlights from the last quarter and includes the following deep-dive articles:

• Kennametal: The story of the successful commercialization of AM hard metal and steel solutions
• General Atomics Aeronautical on metal AM’s place at the centre of the digital manufacturing revolution
• Adrian Keppler on AM: An insider’s assessment from the outside
• AMPOWER on metal AM’s journey to industrialization: Are we there yet—and what does the destination even look like?
• A stronger future, layer by layer: How next-generation software will drive adoption of metal AM
• Volkmann: Making the case for the complete automation of powder handling in AM
• Metal AM on an industrial scale: GKN Additive draws on decades of sintering expertise to commercialize Binder Jetting
• International Conference on Electron Beam Additive Manufacturing: Highlights from EBAM 2023

Get your free PDF here. Or, visit this link to read the issue in your browser.

How is 3D printing being used in advertising?

Did you know that big brands such as Coca-Cola, Dior, McDonald’s, Louis Vuitton, and Volkswagen use 3D printing in their advertising strategies? The rise of the technology in recent years highlights the advantages it offers in all kinds of applications in marketing. In particular, the freedom of design, speed of production, and ability to create large parts locally make this manufacturing option very attractive for communication departments within large corporations.

We took a closer look at some of the existing projects and uses. Read the story here.

Original AM insights inside TCT Magazine

If you’re already a subscriber to TCT, you’ll know our magazine is uniquely dedicated to showcasing original AM content written by our editorial team.

In our most recent issue, we went through the doors at two major AM sites in the U.S. and the UK. Sam Davies got an exclusive look at GE Aerospace’s AM journey, application by application, while closer to home, I visited Renishaw’s Miskin facility to meet with Director of AM Louise Callanan about next-gen AM.

In our next issue, we will bring you a behind-the-scenes look at the Natural History Museum’s 3D visualization lab alongside heavy industry applications from Lincoln Electric, Seurat, and more. We’ll also bring you a practical look at one of AM’s biggest talking points: sustainability.

By subscribing to TCT Magazine, you will gain early access to exclusive editorial insights, as well as interviews, in-depth features, and the latest industry trends—all completely free.

More 3D printing stories and a special announcement

In case you missed it, Make Parts Fast (a Design World resource) covered 3D printing for aerospace applications in last month’s issue. Design World also discussed holistic approaches to digital transformation with experts from Festo, Kollmorgen, Emerson, and more. And for the Digital Manufacturing feature, we shared insights from Renishaw on how actionable data can be a manufacturer’s best friend.

Our new July issue includes a section on how 3D printing can transform fastener production. We also announce our special October supplement, Engineering Diversity and Inclusion, which celebrates underrepresented communities in engineering. We encourage our readers to contact us and suggest colleagues who elevate design teams and represent our wonderfully diverse engineering community.

Read and download the July digital issue here.

DNV leading quality assurance provider joins AM Conclave as Knowledge Partner

AM Conclave, an initiative to promote the AM ecosystem in the Middle East, is pleased to announce the addition of DNV as its knowledge partner. DNV’s collaboration with AM Conclave emphasizes their shared commitment to fostering knowledge sharing of AM across various sectors.

Read the full story.