TECHNOLOGY | 3D PRINT COMPOUNDS
Right: Ingeo 3D450 is the latest breaka- way support material from Natureworks
(HIPS). Compared to these soluble supports, it also offers longer and more stable shelf life, reduced moisture sensitivity during printing, and reduces the need for post-processing with its clean breaka- way from a build. The new grade is compatible with large format printers and, as the 3D450 breakaway supports do not require solvent baths for removal, its use avoids the size constraints encountered with needing to submerse a build.
High performance Solvay has entered a research collaboration agreement with Aerosint to develop an economi- cally viable SLS printing process for high perfor- mance polymers such as its KetaSpire polyethere- therketone (PEEK) and Ryton polyphenylene sulphide (PPS). These materials have the potential to open new opportunities for additive manufactur- ing in demanding applications, but their adoption with key powder fusion technologies such as selective laser sintering (SLS) has remained limited. “SLS machines that can process high tempera-
Below: Solvay is working with Stratasys to develop optimised
filaments for its FDM F900 3D printers
ture polymers are carefully designed and assem- bled with sophisticated and expensive compo- nents,” says Edouard Moens, Managing Director of Aerosint. “However, at present, there is a significant operating cost disadvantage during the build, which is the excessive waste of up to 90% of ‘used-but-unfused’ powder. Our patented spatially- selective, multiple-powder deposition system under development incorporates a non-fusible support material in each layer where expensive high performance polymers are not required, thereby reducing material waste to very low levels.” Solvay has been working with Aerosint for more than two years, supporting the development of the technology with advanced material, process and fusion expertise. “As with all innovative, ground- breaking technologies there are many challenges to overcome,” says Brian Alexander, Global Product
and Application Manager for Additive Manufactur- ing at Solvay’s Specialty Polymers global business unit. “One of them is to develop and fully optimise high performance additive manufacturing polymer powders for use at high temperatures alongside non-fusible materials in a multi-powder deposition process. Not only will this technology make 3D printing of high performance polymers more affordable, it also will open up its enormous potential to become a competitive industrial process for AM system manufacturers in the medical, aerospace and automotive sectors.” Solvay is also collaborating with Stratasys to develop high performance additive manufacturing filaments for exclusive use in Stratasys’ FDM F900 3D printers. “Stratasys’ customers have been repeatedly asking for more varied, high perfor- mance materials, while many of Solvay’s customers want our high performance polymers to be enabled for use on Stratasys’ industrial 3D printing systems,” says Christophe Schramm, Business Manager for Additive Manufacturing for Solvay’s Specialty Polymers global business unit. Solvay and Stratasys are currently developing a high performance additive manufacturing filament based on Solvay’s Radel polyphenylsulfone (PPSU) polymer that will meet FAR 25.853 compliance requirements for use in aerospace applications. Both companies aim to commercialise this new filament in 2020.
Carbon innovations Covestro is collaborating with Carbon – the developer of Digital Light Synthesis (DLS) technol- ogy – to offer 3D printing that can provide oppor- tunities to produce three-dimensional, often complex shaped parts in a single step. DLS technology is claimed to be able to accelerate
20 COMPOUNDING WORLD | October 2019
www.compoundingworld.com
PHOTO: STRATSYS
PHOTO: NATUREWORKS
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