INNOVATION | 3D PRINTING
Above: Ultimaker has developed the S5 Pro Bundle, which consists of the Ultimak- er S5, the new Ultimaker S5 Air Manager and Ultimaker S5 Material Station
properties, PC-ABS is a widely-used engineering material for applications that require high impact and heat resistance,” says Broer. “Method X is the only printer in its price class with a heated chamber that reaches up to 110°C on the build plane, making it ideal for printing PC-ABS.” As end use, injection moulded parts are com- monly made of PC-ABS, it is important for engi- neers to prototype their designs with a material as close to their end use part as possible. This is especially critical for functional prototyping to ensure the prototype checks are representative. Combined with Method’s industrial 3D printing features, PC-ABS enables engineers to achieve parts with high dimensional accuracy and repeat- ability. The material can also be printed with SR-30 soluble supports, allowing customers to produce complex geometries with intricate or deep internal cavities or overhangs.
Carbon fibre Method Carbon Fiber has also been introduced by MakerBot. The new Method Carbon Fiber Editions are designed to enable engineers to print stronger and more accurate parts for manufacturing tools, jigs and fixtures, and end-use production, and can be used to print metal replacement parts in some applications. Method Carbon Fiber Editions print carbon fibre reinforced polyamide that is optimised for high strength and heat resistance. The new Method and Method X Carbon Fiber Editions come pre-configured with a new composite extruder to handle abrasive materials. The new extruder, which is also available as an upgrade for the Method and Method X 3D printers, has hardened metal drive gears, a metal filament switch, and an interchange- able hardened steel nozzle. Since Method X has a higher chamber tempera-
ture than Method of up to 110°C on the build plane, it will be able to support a wider range of
28 INJECTION WORLD | June 2020
high-performance composite materials in the future. The Method platform features industrial 3D printing capabilities that make it ideal for printing with advanced, engineering-grade materials. The combination of a heated chamber, ultra-rigid steel frame, sealed material bays, performance extrud- ers, and dissolvable supports enable engineers to print consistently accurate parts. 9T Labs, the Swiss system provider of digital composite production, and Arkema, are collaborat- ing to combine carbon fibre composite materials based on Arkema’s high performance Kepstan 7000 PEKK thermoplastic polymer and 9T Labs’ recently introduced Red Series manufacturing solution, to enable cost competitive series produc- tion of structural composite parts with complex internal fibre orientation. In order to showcase the potential of metal substitution, a helicopter door hinge was manufactured. Using the integrated FEA solution of 9T Labs’ fibrify software, an optimised fibre layup with a true 3D internal fibre orientation was generated and subsequently manufactured using 9T Labs’ Additive Fusion Technology. As a result, the weight of the optimised fibre composite part was reduced by over 75% compared to the metal component. Furthermore, cost-per-part calculations reveal a 22% cost reduction for a series of 1,000 parts, demonstrating the economic viability of the Red Series solution for series production. Ultimaker has developed the S5 Pro Bundle, which consists of the Ultimaker S5, the new Ultimak- er S5 Air Manager and Ultimaker S5 Material Station. The company says that these machines are tested to be left unattended 24/7 and significantly improve the 3D printing workflow and productivity. The company adds that the Ultimaker S5 Air Manager provides a closed, inside-out air flow for the Ultimaker S5, leading to a better controlled environment inside the printer and filters out up to 95% of all ultrafine particles created while printing. This reduction enables a wider range of materials to safely print with and results in a safer work environ- ment as it creates an effective physical barrier that stops anyone touching hot or moving parts. The Ultimaker S5 Material Station allows users to load filament spools – including glass and carbon fibre composites – in six bays that have abrasive- resistant pre-feeders. Constant supervision is no longer needed, and material can easily be upload- ed at the front of the printer in seconds, not minutes. Silica gel extracts moisture and automati- cally regenerates, keeping the fully enclosed chamber below 40% relative humidity – even in outside conditions of up to 70% humidity.
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www.injectionworld.com
IMAGE: ULTIMAKER
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