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Computer Systems and Software


Fortus machines are based on the principle of fused deposition modelling (FDM) in which thin layers of powdered material are laid down and fused by a laser. Both the 400mc and 900mc systems can produce Ultem parts with a layer thickness of 0.254 mm (0.01 inch), though the 400mc also works in increments of 0.33 mm (0.013 inch) if preferred. In terms of build envelope, the 900mc builds parts as large as 914 x 610 x 914 mm (36 x 24 x 36 inches), while the 400mc’s offers 356 x 254 x 254 mm (14 x 10 x 10 inches). Owners of older 400mc and 900mc models can upgrade their software to build Ultem parts. Even Victrex Peek - one of the highest specification plastics, often used in sterilisable medical components - can now be used in rapid prototyping and rapid manufacturing. The design of the Eosint P800 high-temperature laser sintering machine was adapted from that of the Eosint P730 by EOS of Germany, raising the operating temperature to 385˚C. This means it can make parts using Victrex Peek for the first time - courtesy of the new EOS Peek HP3 powder. EOS reports that products made with this material achieve tensile strengths up to 95 MPa and a tensile modulus of 4400 MPa. An EOS manufacturing partner, FKM Interethnic of Germany, is the first company to buy an Eosint P 800. It sees potential in typical Peek applications such as rotor vanes and tank lids. For more generalist applications, the new Connex350 3D printer from Israeli company Objet Geometries enables designers to create multi-material prototypes combining rigid and flexible characteristics. Developed as an entry-level version of the larger Connex500, this machine has a build tray of 350 x 350 x 200 mm so can print multiple small objects or


single large ones. It prints 16 micron layers by jetting UV- curable polymer with its patented Polyjet Matrix technology. Chris Baker, the UK sales manager, says that the system is aimed at “manufacturers, industrial designers or their suppliers who want to reduce to the cost of product development cycles. Customers want to make more variation of prototypes, which are closer to the end product.” In one interesting non-product application the machine has been used to create medical models in which a transparent material


Fig. 2. Multi-coloured 3D printed models built using Z Corporation’s XP150 have a relatively high ‘green’ strength and can be cured simply by spraying with water and Epsom salt.


represents the ‘flesh’ yet provides a clear view of the white ‘bone’ inside. Objet’s range of ‘digital materials’ can


be mixed on the machine to create different effects - such as varying the hardness of the material. Up to 11 materials can be combined in a single part. Furthermore,


the company recently launched 18 new ‘digital materials’ in its Vero and Tango ranges; Vero materials are hard, while Tango materials are elastomeric. Connex machines can blend these materials, enabling stiffness and flexibility to be combined in a single part. Objet has used the machine to create a one-piece air vent for a car: the main body of the vent is made in a rigid material and the perimeter seal is formed from a flexible material.


Production parts from prototyping machinery


The quest to produce ‘production’ parts from ‘prototyping’ machinery looks set to continue, plus it is creating opportunities for new markets. The latest Wohlers Report, which tracks worldwide developments and trends in these technologies, says that direct part production is now the second most popular application after modelmaking. Terry Wohlers, the report’s principal author, comments: “Methods of additive manufacturing are creating new markets for one-of-a-kind products.” Respondents to Wohlers’ survey said that making parts using these techniques will represent one-third of their business in five years – and just over half within 10 years. Indeed, the market for these prototyping techniques is


expected to double by 2015, despite a recent slowdown: the Wohlers Report says the market for ‘additive manufacturing’ products and services grew to $1.183 billion in 2008 - an annual increase of just 3.6 per cent - which was some way down on the 16 per cent growth of the previous year. Many small companies will be put off by the price


Fig. 3. Instead of a laser, Huntsman’ Digitalis SLA system uses a UV-based ‘micro light switch’ technology to convert the resin to solid.


of conventional prototyping machinery, viewing it as an unaffordable luxury. But, in response, Z Corporation has launched an entry-level machine – the low-cost, monochrome Zprinter 350 – to complement its existing range. The company claims the entry-level machine still provides high-end functionality, with features such as: automatic material loading and recycling; self-monitoring operation; control from either desktop or printer; 20 mm/hour vertical build speed; a build area of 203 x 254 x 203 mm; and the use of office-safe build materials with no liquid waste. The quoted price for a machine is a ‘package price’ and includes training, consumables, software and delivery charges. Whereas a 650 machine would cost around €40 000 ($55 000) the 350 is nearer €17 500 ($24 000).


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