AMUG Newsletter June 2019

President’s Report

I am excited to be the president-elect of AMUG for 2019-2020. We have an excellent and experienced team leading us on the path to the next event.

The recent growth of AMUG has been astounding! This brings many challenges, which I am pleased to say your AMUG Board is being very proactive in addressing. These challenges will require more support and have us engaging more members. Your support and involvement will be critical and a key to keeping this growth manageable.

Our recent strategy meeting had us reviewing the key items for achieving the mission of AMUG while aligning with the vision. All of this builds on the credo “For Users – By Users.” To stay in alignment with this, we will be planning to engage a lot more of our members in all of the activities that happen before and during the annual conference. There are limits to what one can do so we are making these engagement points small enough to be non-intrusive yet engaging enough to make a difference. You may express your interest in becoming involved by emailing our secretary, Leslie Frost, at secretary@amug.com.

We look forward to working with you before and during the event!

Conference Photo Gallery

The 2019 AMUG Conference photo gallery is now live on our website. Head over to our photo gallery to flip through over 700 images taken at the event. The pictures capture everything from Saturday bag stuffing by our fantastic volunteers to the festivities at the closing dinner on Thursday night.

If you see an image you like, you can simply download a high-resolution version (1920 x 1080) to your computer or phone.

Spend a few minutes in the gallery to relive the AMUG experience.

Introducing a New Generation of Large-Format 3D Printing: The STUDIO G2

Building on the success of BigRep’s STUDIO large-format 3D printer, we were excited to announce the new and improved BigRep STUDIO G2 at RAPID+TCT. Offering unmatched speed and resolution in large-format additive, the German engineered and manufactured STUDIO G2 is specially designed for industrial applications.

The STUDIO G2 features:

• New fully enclosed and insulated build envelope of 1000 x 500 x 500 mm
• Fast-heating build platform
• Temperature-controlled filament chamber
• Dual extruder equipped with two 0.6 mm ruby nozzles

The printer is capable of printing large-format parts quickly in ultra-fine detail with engineering-grade materials, such as PA6/66, at layer heights as little as 0.1 mm. Future materials to be released will include other engineering-grade materials like ASA and composite materials with carbon/glass fiber enhancement.

For more information and to request a quote, please visit us online.

The BigRep STUDIO G2 is available to order now.

Product Highlight – HT1001P

Farsoon Technologies’  HT1001P large-scale polymer laser sintering system is the first step towards Farsoon’s CAMS® (Continuous Additive Manufacturing Solution), showcasing increased productivity and automation.

The HT1001P features dual 100W CO₂ lasers and a fully digital 3-axis optical scanning system with a build area of 1000 x 500 x 450 mm (39.4 x 19.7 x 17.7 inches). Combined with an internal conveyor system for automated exchanges from the pre-heat, build, and cooling stations, this allows for increased productivity by optimizing workflow between phases of the build process.

This additive production polymer system adds to Farsoon’s existing line of polymer laser sintering systems that includes the 403P series, 252P series, and the eForm.

Farsoon Technologies’ HT1001P PLS modular system.

Flying to the Finish Line

The America’s Cup, the highest prize in sailing, tests not only sailing prowess but boat design skills as well. To win, competitor American Magic, a partnership between three top racing programs and the New York Yacht Club, knew they needed technology that only 3D printing could provide. That’s why they partnered with Stratasys to produce prototypes and final parts for their boats.

Competitive yachts must be durable but lightweight—a difficult balance to achieve. American Magic is using carbon fiber reinforced FDM Nylon 12CF™ to create resilient prototypes and critical parts like brackets and mounts. 3D printing allows American Magic’s engineers to quickly create as many designs as necessary to make the boat as aerodynamic as possible.

You can read more about American Magic and how they’re using 3D printing in this news release. Find out more about the printer and materials they’re using at the Fortus® 450mc™ and FDM Nylon 12CF™ pages at Stratasys.com.

American Magic is betting on 3D printing to help it vie for the America’s Cup.

The Business Case for Metal AM

Every year, the additive manufacturing (AM) industry comes together for the Additive Manufacturing Users Group (AMUG) Conference, where attendees gain insight into the latest trends, exciting new applications, and developments in AM technology. Stephen Anderson, additive manufacturing business manager at Renishaw Inc, reflects on this year’s conference by discussing how far the AM industry has come and where it is set to go.

As AMUG 2019 was held in Chicago, USA, this year, Renishaw had the opportunity to host 120 delegates before the conference at its AM Solutions Centre in West Dundee, Chicago. This tour was a highlight, with very positive feedback from attendees. During AMUG 2019, another highlight for Renishaw was a Materials Parameters Development workshop—run by John Laureto and Kevin Brigden, applications engineers for Renishaw Inc—which was so oversubscribed that the organizers requested a third repeat. The session educated attendees on materials, process variables, scan path optimization, and how to conduct a design of experiments (DoE) program for best metallurgy using a laser powder bed fusion process.

Read the full story here.

To learn more about Renishaw’s additive manufacturing systems, visit: www.renishaw.com/additive.

A few of the 120 AMUG delegates experiencing Renishaw’s AM Solutions Centre.

Start Small and Grow with MetalFAB1

At another successful US show, Rapid + TCT 2019, Additive Industries presented how you can ‘Start small and grow’ with the MetalFAB1™ system, the only modular and scalable industrial additive manufacturing system with integrated software.

MetalFAB1 is an open-architecture machine that ensures maximum flexibility and allows configurations of up to 11 modules. When more capacity is needed, it is possible to add more modules in the future. The MetalFAB1™ system can be configured to meet your available floor space and includes several optional modules that automate heat treatment and extend productivity.

Additive Industries continuously improves the system by adding functionality in the modules, which protects your investment as technology advances. The MetalFAB1 has automated the manual steps of conventional powder bed fusion printers to ensure the highest productivity, resulting in the lowest cost per printed part. Please let us know if you are interested to find out what it could mean for your productivity.

Start small and grow with the MetalFAB1

Together, We Print Things Beyond What’s Possible

We’re engineers so we know a part isn’t real until you can touch it and see that it works. So when you partner with GE Additive’s Print Services, we put our equipment and know-how to work to help bring your ideas to life.

We offer large-format printing that allows you to print large metal parts without compromising resolution or quality. And our design-to-print offer is a great solution if you need help with product design and printing. Our experienced engineers will provide guidance around the additive design process and then help you print your part. We’ve been in this business for a while so when you partner with us for your printing needs you’re privy to our extensive additive knowledge, our post-processing equipment, and our materials science expertise.

Find out how to transform your industry at ge.com/additive/printservices.

Let’s build anything together.

GE Additive Print Services provides access to technology and expertise.

Introducing 3D Systems’ Figure 4 Modular

Available this month, 3D Systems’ Figure 4^® Modular is a scalable, cost-effective direct 3D production solution that includes automated materials handling and centralized post-processing. Manufacturers can scale Figure 4 Modular as their production needs expand—including up to 24 print engines. Each engine can run different materials and jobs simultaneously as part of a single, high-throughput line. With a low cost of entry and automation options that include job management and queuing, material delivery, and centralized post processing, manufacturers can reduce demand on manufacturing resources and lower total cost of operation.

The company is also expanding its materials portfolio with immediate availability of Figure 4 FLEX-BLK 10, a flexible material for the production of exceptionally durable propylene-like black parts. This material is ideal for functional assemblies and prototypes, master patterns for RTV/silicone molding, short-run production, and concept and marketing models. Additional materials are planned for release in the coming months.

Figure 4 Modular provides customers with an upgradable, cost-effective 3D production solution that can expand as their production needs expand.

Up to 10x Faster than Competitive Offerings; the Strength of an Injection Molded Part from a 3D Printer; and Scale for Large-Volume Production

What does it mean to solve speed, strength, and scale for 3D printing? It means manufacturers don’t have to sacrifice speed for accuracy. It means they can keep their operations running more effectively at capacity because they’ve got a faster way to test first articles. It means making a 20+ day turnaround for a tool a thing of the past. It means manufacturers stop paying more for one-off parts and instead reap savings from the production of many custom parts that would be cost-prohibitive to produce without our 3D platform. And it means unlocking the promise of large-scale additive manufacturing to help manufacturers accelerate their journey to Industry 4.0

The Essentium High Speed Extrusion (HSE) 3D Printer garnered non-stop attention at this year’s Rapid + TCT where visitors to the show saw this breakthrough additive manufacturing innovation in action and experienced how it bridges the gap between 3D printing and traditional manufacturing. The HSE is enabling wide-ranging applications as firms across automotive, aerospace, contract manufacturing, consumer goods, and biomedical industries enter Industry 4.0 to drive greater innovation, efficiency, and sustainability across their product development lifecycles.

Find out more at essentium3d.com.

Essentium High Speed Extrusion (HSE) 3D Printer.

Making the Impossible Possible with New Materials and the Right Partnerships

BASF 3D Printing Solutions continues to focus on the development of new materials with the goal of accelerating the growth of additive manufacturing. We are also making our Innofil3D plastic filaments more accessible to the end-user in the US through our newest distribution agreements with MatterHackers and M. Holland.

On June 12, our vice president, Volker Hammes, supported our partner HP and participated in the grand opening of its 3D Printing and Digital Manufacturing Center of Excellence in Barcelona. Volker highlighted our Ultrasint 3D TPU01 which enables the production of flexible, functional parts and may be used in sports equipment.

Last but not least, we recently announced our collaboration with Impossible Objects whose next-generation 3D printing system, CBAM-2, allows customers to use our Ultrasint PA6 powder to 3D print high-performance carbon fiber-PA6 composite parts on an industrial scale for the first time.

For more information, check out our new website or contact us at 3d-printing@basf-3dps.com.

BASF and Impossible Objects open new possibilities (video).

HP and SmileDirectClub Collaboration Transforms Smiles for Millions of Customers

SmileDirectClub, the pioneer of teledentistry and market leader in doctor-directed, remote clear-aligner therapy, announced it will be deploying 49 HP Jet Fusion 3D printing systems running 24×7, producing more than 50,000 unique mouth molds a day—with the capability to produce nearly 20 million individual 3D printed mouth molds in the next 12 months. HP and SmileDirectClub also announced a new recycling program, in which excess 3D material and already processed plastic mouth molds are recycled by HP and turned into pellets for traditional injection molding, leading to more sustainable production.

Learn more here.

HP and Smile Direct Club collaborate on largest Multi Jet Fusion 3D production factory in the U.S.

SLM Solutions Opens New Application Center in Shanghai to Continue Growth in Asian Market

SLM Solutions celebrates the grand opening of its new expanded office facilities and application center for its head office in China. After establishing Chinese operations in Shanghai in 2015, the new facility will strengthen SLM Solutions’ presence in China and allow local staff to collaborate with customers to foster selective laser melting innovation.

The new facility has four selective laser melting machines installed: one SLM®125, two SLM®280, and one SLM®500 system. The application center also includes equipment to represent the supporting process chain to an SLM build, including post-processing capabilities, a metallurgical lab, and best-practice examples for powder storage and operation. Expanded capacity for calibration equipment, spare part storage, and a growing customer support team will allow the company to continue its growth in the region. Read the full press release here.

Loving Eyes Foundation x Resolution Medical: Preventing Childhood Vision Loss

Loving Eyes Foundation (LEF) recently partnered with Resolution Medical to create customized glasses for children with craniofacial malformations, ultimately discovering that the Carbon Platform provided the perfect solution for building each pair of frames to conform to a child’s unique craniofacial anatomy.

Resolution Medical worked with LEF and helped them to rapidly produce the customized spectacles on the Carbon Platform using RPU 70, which has passed biocompatibility tests for sensitization, irritation, and cytotoxicity. The results are a great pair of glass that fits each child.

Loving Eyes Foundation now wants to expand its work to serve all children that need them by allowing any eye care provider to create a 3D model of children’s heads. The same high-quality production via Resolution Medical on the Carbon Platform will then be used to produce impeccably fitting glasses.

Learn more about LEF’s meaningful work by visiting Carbon3d.com, and click here to donate to the cause.

Unique eyewear for unique children created on the Carbon Platform.

ExOne to Participate in Two Dynamic Shows this Month— Plus BIG Reveal at GIFA!

Just finally catching our breaths from the exciting RAPID + TCT show, and ExOne will be exhibiting at two more shows this month: POWDERMET in Phoenix, AZ, June 23 – 26, and GIFA in Dusseldorf, Germany, June 25 – 29. At POWDERMET, ExOne’s director of R&D, Andrew Klein, will be presenting a technical paper on Monday, June 24, titled, “Fatigue Study of 316L Produced using Binder Jet 3D Printing with Hot Isostatic Pressing.” If you’re attending POWDERMET, stop by Booth #514 to talk with our awesome sales team members and find out what’s new and exciting at ExOne, including our NEW X1 25PRO™ 3D Binder Jet printer. The X1 25PRO™ is tailored for your materials, optimized to reduce costs, and designed for your production scale. Learn more at here.

For those attending GIFA, ExOne will be announcing something BIG on June 25! Stay tuned-in to ExOne’s social media channels for more information on the “big reveal” at GIFA! We’ll be exhibiting in Hall 15, booth A11.

3D Printed Rocket Engines & The Future of Spaceflight

Getting off this planet isn’t easy, even after we’ve spent more than half a century doing it. In that time, the strategy generally involved going big, like the Saturn V. It’s still a viable approach today—just look at SpaceX’s BFR—but as the private-sector space race heats up, aerospace companies are starting to reconsider how they design and manufacture launch vehicles. Metal 3D printing has been one of the principal drivers of this paradigm shift, unlocking new geometries and features that were impossible to make using more conventional manufacturing methods.

“Some of the early adopters, like SpaceX, jumped on this bandwagon way back—it’s probably been almost eight years ago—because they saw the potential and actually advertised it,” explained Scott Killian, business development manager for EOS North America. “There were other companies—like Aerojet and obviously NASA—also looking into this. But I think it was really SpaceX and their model of getting into space quickly that got a lot of visibility for additive in the marketplace.”

Read the full article.

Test firing of the Launcher E-1 rocket engine (article).

Formlabs Debuts Ashley Furniture Case Study: From One Idea to 700 3D Printed Parts in the Factory

Shortly after Ashley Furniture brought in the company’s first Form 2 stereolithography (SLA) 3D printer, one of their production engineers had an idea. Was it possible to replace machined alignment pins with end-use 3D printed parts, avoiding the long lead times and minimum order quantities of outsourcing?

The answer was yes, and it led to more questions that provided answers to some of its continuous improvement needs.

Today, about two years and an additional printer later, there are 700 3D printed parts at work on Ashley Furniture’s factory floor in Arcadia, Wisconsin, right alongside industrial robots and CNC milling workhorses, from assembly to fabrication. In addition to replaceable parts, the printer inspired one of the company’s most creative solutions yet; a universal system for assembly fixtures that uses 3D printed parts to simplify adjustments between product changeovers, completely eliminating the need to spend machine shop resources to build each new fixture from scratch. Read about it here.

The universal assembly fixture uses interchangeable 3D printed parts to adapt to each new SKU.

RAPID + TCT 2019: Our Largest, Most Comprehensive Year Yet

RAPID + TCT 2019 was held May 20-23 in Detroit, MI. Nearly 9,000 manufacturing professionals from around the world joined together for North America’s most influential additive manufacturing event, including 5,200 unique exhibits-only and conference attendees. The RAPID + TCT show floor spanned 112,200 square feet and hosted 434 exhibiting companies, a record high. Countless valuable business connections were made, products were introduced, ideas were born, and visions became reality. View 2019 recap.

• Attendance increased 47% over the 2018 event.
• The exhibitor count increased 27% over the 2018 event.
• The show floor footage increased 28% over the 2018 event.

Mark your calendars for RAPID + TCT 2020: April 20-23 in Anaheim, CA. Sign up to receive event updates here.

RAPID + TCT 2020: April 20-23 in Anaheim, CA.

3DMP Summer Issue: RAPID Wrap-up, Lincoln Electric Bullish on AM

3D Metal Printing’s summer issue, out in July, tackles the new technology displayed at RAPID + TCT last month, and it details an Israeli machine shop’s entrance into AM via titanium parts printed on 3D Systems equipment. And, 3DMP will profile Lincoln Electric’s new wire-arc additive manufacturing operation.

Also, 3DMP is prepping for its 3D Metal Printing Experience and Tech Tour, August 6-7 in Detroit, MI. Besides speakers offering must-have technology and trend information, the event features visits to Ford’s Advanced Manufacturing Center and Linear AMS to see metal 3D printing in action. See details at 3DMP’s website, www.3dmpmag.com.

The Summer 2019 issue of 3D Metal Printing explores Lincoln Electric’s journey into additive manufacturing via a unique wire-arc process.

AM for Mission-Critical Jet Engine Parts

While news about additive manufacturing’s contributions to the GE9X has been widely reported, GE Aviation has (until now) never identified the seven additively manufactured components in the engine. In this exclusive story, the company shares the list of 3D printed parts that are going into the largest, most fuel-efficient engine it has ever produced. The GE9X is on track to gain final Federal Aviation Administration (FAA) certification later this year, which could provide a blueprint for realizing future AM advances in aerospace.

The GE9X is the first commercial aircraft engine to reach production with significant additive content—seven part numbers totaling more than 300 3D printed pieces in each engine. Learn more.

Natural Resources and National Strategies: How Metal AM is Taking Off in Australia

Australian expertise is today becoming much more commonplace on the international AM scene. From technology and materials suppliers to application developers, companies are growing on the back of world-class research and education facilities, and a business environment where innovation and international trade are rewarded.

Combine this with an abundance of AM-relevant natural resources and, as Alex Kingsbury explains, an environment has been created in which AM is thriving. Read this article online or as a PDF download.

Heading down under? Pick up your copy of Metal AM at APICAM2019, the Asia-Pacific International Conference on Additive Manufacturing, June 30 – July 3, 2019, at RMIT University.

The latest issue presents Australian 3D printing applications, research and development.

Honorees Named in 3D Printing Industry Awards

3D Printing Industry recently celebrated its third annual awards ceremony in London, UK. Celebrating the best 3D printers, most innovative applications, and well-respected names in materials and software, the event saw the attendance of more than 150 guests. Over 60 companies were represented, among them industry leaders such as Protolabs, Ultimaker, GE Additive, and Stratasys.

Decided by informed readers, the 3D Printing Industry Awards is one of the largest surveys of additive manufacturing, this year accruing more than 80,000 individual votes. Among the winners was Dr. Hans Langer, the founder of EOS, who earned the accolade of Outstanding Contribution to 3D Printing for his three decades in the industry. See the complete list of 2019 3D Printing Industry Awards winners here.

The winners of the 2019 3D Printing Industry Award with 3D Printing Industry team.

One Week Left to Enter the TCT Awards!

It’s been a busy few months for the additive manufacturing community, culminating in the recent RAPID + TCT event in Detroit that featured AM updates and application inspiration to boot. Amidst all that, here at TCT we’ve been sifting through the stack of entries we have received for this year’s TCT Awards.

Didn’t get a chance to submit your entry? Worry not, we have now extended the deadline for award submissions for one extra week. You now have until June 25 to enter your most exciting product or application success stories and you could be joining us for our prestigious ceremony on September 25 in Birmingham, UK.

Maybe you launched a new piece of technology this year? Are you using AM in a truly creative way? Or perhaps you know someone who’s got a real game-changing medical or aerospace application? Give them or yourself a nudge and visit tctawards.com.

Winning entries will be honored at the TCT Awards on September 25.