Computer Solutions and Software
At the same time, the company has developed a new powder for the Zprinter series of multi-colour 3D printers. Parts made from its ZP150 can be cured by water and Epsom salt (a magnesium sulphate) - which is more straightforward than the usual methods. Another advantage is that the part’s ‘green’ strength - the initial strength it has once it is removed from the machine - is around 40 per cent higher than with the company’s previous materials.
SLA machines without lasers
Huntsman’ Digitalis system uses a new laser-free principle to make parts using stereolithography. The machine works on a different principle to other SLA machines in that it still uses focused light beams to cure a liquid chemical into a solid but it does not use a single-beam laser. Instead the Digitalis cures the material with a ‘micro light switch’ (MLS) with 40,000 tiny, simultaneous UV light sources. It is claimed that the ability to focus multiple micron-sized points of light on the surface simultaneously will lead to shorter build times. It is also possible to build multiple parts concurrently. Ole Hangaard, a project manager at Huntsman, explains why the company has developed new materials for the Digitalis: “We think the properties of SLA materials have reached a plateau – so we have decided to develop our own system.” These new materials – designated the Araldite MLS 7000 series and launched at the recent Euromold show in Frankfurt, Germany – are specifically designed for use in the Digitalis system and will not work with other SLA systems. Huntsman has sold two Digitalis machines and previously supplied the customers with specially designed resins. These resins are now available commercially.
instrument panels and interior/exterior automotive parts with no adhesive joints or welded seams. As an alternative to making large components, the system can build thousands of different components at the same time - in a single process. Peter Mischke, head of the rapid prototyping technologies department, says: “We can produce a wider range of component sizes. At the same time, we can influence and actually configure the process much better than we could with conventional sintering systems.” In a similar vein, Materialise’s Mammoth process uses SLA
to create very large single-piece prototypes. The technique - which is said to have gained wide approval in the automotive industry - uses a machine with a build length of more than 2m. Materialise says that the idea of producing large components arose from the increasing demand for extremely fast and large prototypes of superior quality. Materialise’s machine park in Belgium houses ten Mammoth machines. Parts are built using an SLA process with a patented ‘curtain recoating technology’ that ensures there is less dead time between layers - hence production is faster.
Rapid inspection crucial to R&D
Inspection is a crucial part of research and development processes, including reverse engineering. Wenzel Group’s recently introduced exaCT computed tomography (CT) workstation for industrial applications makes contactless 3D measurements of external and internal structures to complement existing co-ordinate measuring machine (CMM) methods. According to Wenzel, it enables non- destructive inspection for processes such as quality control, test engineering and reverse engineering, at a price that is affordable for small and medium-sized companies. The exaCT’s control software optimises image acquisition,
while its reconstruction software enables 3D voxel (volumetric pixel) data to be evaluated. Data analysis is performed with Quartis software from Wenzel Metromec and Pointmaster from Wenzel Knotenpunkt. Accurate free-form surfaces can therefore be generated and processed from the CT data. Currently the exaCT is used to inspect and measure small and medium-sized parts and assemblies made from plastics, composites, ceramics, aluminium or magnesium. There are also plans to develop systems that can inspect larger parts and those made from other materials. Despite the cost-reduction in rapid prototyping and
Fig. 4. Hofmann Innovation claims that its Hofmann Medea 1500 is the world’s largest SLS system for plastics, with a usable volume of up to 1500 x 500 x 500 mm.
The company has also continued with its traditional range of SLA materials, adding Renshape SL7840, a colourless liquid resin that cures to a pearl white appearance. Parts made with the material have a fine PP-like surface, with high elongation strength and flexibility. Another Euromold exhibitor, Hofmann Innovation, says its Hofmann Medea 1500 is the world’s largest SLS system for plastics, with a usable volume of up to 1500 x 500 x 500 mm. This can therefore produce large components such as
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rapid manufacturing, investing in equipment is not always necessary, as there are numerous companies offering bureau services. USA-based 3D Systems has now extended its rapid prototyping and manufacturing service to Europe: 3D proparts, which launched in the USA in October 2009, supplies a wide range of metal and plastic parts made using the company’s SLA and SLS technologies. As part of the European launch, 3D Systems has set up a 3Dproparts website in German and intends to extend this to other European languages in the near future. Greg Elfering, vice president of European sales and
marketing, comments: “We expect the latest generation of Pro systems and materials to provide our European customers with all their design, prototyping and manufacturing needs.” The new service has been launched on the back of several acquisitions, including Acu-Cast Technologies and Advatech
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