INNOVATION | 3D PRINTING
Right: Design study in a laser-sintered material from EOS
energy-absorbing ink and heated by infrared radiation,” Monsheimer says. (HSS was invented at Loughborough University in the UK.) Evonik is also investigating the potential of other polyamides for 3DP. It cites PA613, whose relatively high fusion point ensures particularly good heat resistance; in addition, the material has excellent rigidity combined with optimal elonga- tion at break. “As a result, products made from PA613 are extremely strong but not brittle,” says Monsheimer. PA613 has already been successfully tested in motor sport: a ventilation duct with an integrated heat shield in a Lotus racing car with- stood several races with no problem.
Fastest SLS
Below: BASF’s Photo-Resin X004M is suitable for break-resistant parts such as these (post- coloured) electric circuit connectors
Other companies active in sintering technologies have been introducing developments aimed at high-speed production. For example, late last year, EOS introduced its EOS P 500 system, which it says “offers high efficiency for lowest cost-per-part, comes automation ready and can process polymer materials, which require operating temperatures of up to 300°C”. The EOS P 500 builds twice as quickly as the current fastest laser sintering machine (EOS P 396) thanks to a dual-laser system fusing the powder, and a new recoater, which applies a new layer of powder to the building platform with high speed (600mm/s) and maximum adjustability. The new unit can handle such polymers as PA6,
PBT, PET, PPS, PEKK and others. The first high performance polymer available is based on Arkema’s Kepstan PEKK. EOS says it also cooper- ates with Evonik and BASF for developing future polymer materials.
EOS has also begun European distribution of three high-per- formance polymers from its subsidiary ALM, which focuses on providing customised material solutions for the additive manufacturing market.
These are a two PA 11 grades,
one carbon fibre reinforced and one flame retard- ant; and a PA12 containing hollow glass micro- spheres and carbon fibres. 3D Systems, meanwhile, was at Rapid+TCT 2018 in Fort Worth, US, in April to show off its Figure 4 platform, which is says is the fastest, most accurate 3DP technology available (it uses a light-based UV curing process), as well as, for larger parts, the ProX SLS 6100. EOS says the ProX SLS 6100 “enables customers to seamlessly scale from functional prototyping to low volume func- tional production parts.” 3D Systems offers a portfolio of polyamides for the printer, which includes six grades based on PA 11 and 12.
Lots more materials Many materials suppliers are upping their 3DP game, with numerous products debuting at events such as the AMUG Conference, Rapid+TCT, Formnext (in Frankfurt, Germany), and of course NPE2018 in Orlando in May. A lot of the buzz is in materials for fused filament fabrication (FFF), but several polymer suppliers are approaching the market on several fronts. One of them is BASF, which last September set up BASF 3D Printing Solutions. It presented a variety of new filaments branded Ultrafuse at AMUG. Together with Texas-based Essentium Materials, it is also building up a global distribu- tion network for plastic filaments. New products include Ultrafuse Z, described as
an extra strong filament based on BASF materials, further developed by Essentium, and offered in combination with Essentium Materials’ processing technology, FlashFuse. Firat Hizal, Marketing & Sales Manager Plastic Filaments at BASF 3D Printing Solutions, says optimum strength in the z-direction is possible. The partners intend to launch filled and flame-retardant filaments later this year. BASF says Ultrasint PA6 LM X085, based on PA6,
provides a new alternative for PA11 and 12 powders for use in SLS processes. The grey powder melts at about 193°C and is said to be easy to process on most commonly used SLS machines. BASF is targeting customers in automo- tive and consumer goods in particular.
20 INJECTION WORLD | June 2018
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