Additive Manufacturing

NOV 2018

ADDITIVE MANUFACTURING is the magazine devoted to industrial applications of 3D printing and digital layering technology. We cover the promise and the challenges of this technology for making functional tooling and end-use production parts.

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Page 69 of 75

NOVEMBER 2018 Additive Manufacturing TECH REVIEW 68 Wax 3D Printing System for Investment Casting Designed for investment casting, 3D Systems' ProJet MJP 2500 IC 3D printer produces RealWax patterns faster and at lower cost than traditional pattern production, while also enabling the creation of designs not possible through tradi- tional wax injection molding. The 3D printer is said to provide accurate prints with smooth surface finishes, sharp edges and fine details with high fidelity and repeatability. The digital foundry solution is suitable for production needs ranging from iterative, initial design to bridge man- ufacturing and low-volume production. A digital workflow supports greater design freedom, enabling strategies such as topology optimization, lightweighting and part consolida- tion, the company says. Design files are prepared for 3D printing and managed with 3D Sprint software. Patterns are produced in VisiJet M2 ICast, a 100 percent wax material said to deliver the same melt and burn-out characteristics of standard casting waxes. Plastic 3D Printer Expands Build Chamber Arburg premieres its Freeformer 300-3X, a larger machine that uses the Arburg Plastic Freeforming (APF) process to enable the industrial additive manufacturing of complex, functional parts in resilient, hard/soft combinations with support structures. The machine's 300 designation indicates the area of the part carrier surface in square centimeters, nearly 50 percent larger than the Freeformer 200-3X model. The build chamber enables small-volume batches and wider parts with dimensions ranging to 234 × 134 × 200 mm. The part carrier offers three axes of movement, in the X, Y and Z directions. The printer's two-part build chamber door enables the feed hoppers to be refilled during operation by opening the top half of the door. Automatic door opening and closing as well as optional interfaces enable automation of the additive manufacturing process and integration of the 3D printer in complete production lines, the company says. The 3D printer is compatible with user materials and enables the optimzation of droplet size as well as process control. The Arburg material database documents qualified standard granulates such as ABS, PA10, PC, TPE-U and PP. Special plastics for specific applications can also be used, such as PLLS for medical and PC for aerospace. Generative Design Software Runs on Windows OS Frustum offers a new release of its Generate software for interactive generative design that enables engineers to develop multiple optimized models and identify the best solution within minutes. Artificial intelligence enables the software to deliver a near-real-time interaction with the generative design model. The software generates designs based on functional requirements, and parts produced this way can be lighter and stronger while using less material than those designed with traditional CAD, the company says. The new Windows-based Generate release supports single and multi-body optimizations as well as multiple loads and constraints. Uses can specify functional requirements and the design will be automatically modeled to meet those requirements. Its standard material library can be supple- mented with user-defined materials. The software supports native CAD file import as well as STL export with user- defined resolution. Design output is functional and does not need to be remodeled in CAD. The software's multi- threaded architecture is said to deliver faster output by leveraging both CPU and GPU computing optionally. Built on Frustum's TrueSolid generative engine, Generate couples advanced topology optimization and simulation algorithms with real-time interaction to quickly produce high-performing, ready-to-manufacture mechanical de- signs. It is functionally parametric and facilitates blending of generative geometry with traditional surface-based CAD. The technology is currently being commercially licensed to Siemens PLM software and integrated into Siemens NX and Siemens SolidEdge.

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