materials | 3D printing
adhesion for complex parts, and an ABS reinforced with natural fibres that produces a wood-like appearance when used on special 3D printers. Styrenics competitor Ineos Styrolution is also
investing in the development of solutions for 3D printing. “Our goal is to enable our customers to take advantage of their existing styrenic solutions from Ineos Styrolution for either injection moulding or for 3D printing,” says a representative. “This approach will allow customers to embrace 3D printing without going through new major certifications or maybe even new regulatory approval cycles. “In the near future, we do not foresee mass produc-
Above: A Covestro expert observes the manufacture of a small component in Covestro´s new 3D printing laboratory in Leverkusen
Right: Sabic is one of several major materi- als suppliers
extending their offerings for 3D printing (FDM in this case)
thermoplastic polyurethane (TPU) filaments for the FFF process. It also offers TPU powders for SLS. “TPU displays significant advantages over materials com- monly used in SLS, which tend to be less tough and elastic,” the company claims. TPU powders are already used in the industrial production of individualized high-performance soles for shoes, for example. Products are formulated and commercialised by Covestro partner Lehmann & Voss. Covestro has also been developing PUR systems for stereolithography (SLA), digital light process (DLP) and inkjet printing. Numerous other materials suppliers are now launching grade ranges aimed at all types of 3D printing. For example, at the Additive Manufacturing Users Group (AMUG) conference in Chicago this March, DuPont Performance Materials showcased filament forms of Hytrel thermoplastic elastomers, Zytel polyamides, and Surlyn ionomers. In February, Elix Polymers said it was developing additional specialty grades of ABS optimised for 3D printing, in the wake of good interest shown in its initial offering at K 2016 last October. “We got an improved idea of the high potential growth rates of the 3D printing market during the show,” says Fabian Herter, industry manager for automotive. “3D printing fits well with our strategy of focusing in specialty businesses with tailor-made products and services.” The company says it will offer 3D printing grades “that have been optimised after detailed analysis of specific customer needs.” Some new grades for FFF have already been validated at filament producers, 3D printer makers and final part manufac- turers. So far, it has optimised five ABS grades. They include a food contact grade, a grade with improved interlayer
48 INJECTION WORLD | May/June 2017
tion moving to 3D printing. However it will be far more relevant for producing spare parts or small series parts. Therefore it could shorten the supply chain or move the supply chain to other players. It might be that, on a local base, smaller service suppliers will take over the professional printing of spare parts, so that end consumers or garages can order directly there. It might also be that 3D printing enterprises will work as more or less exclusive suppliers for car manufacturers in regards of spare parts, or are even insourced by the OEMs.” In any case, the range of materials available for 3D printing is growing quickly. At the Rapid + TCT show in Pittsburgh in May, Sabic unveiled six new high-perfor- mance filament grades for Stratasys Fortus FDM printers. They are based on Ultem polyetherimide (PEI), Cycolac ABS resin and Lexan polycarbonate, and offer the same composition as the company’s injection moulding grades. Sabic says the new materials solutions directly
address the need for greater options in the industrial filament market and target a broad range of customer requirements. “Both ABS and PC are well-established materials for additive manufacturing of prototypes and end use parts, while Sabic’s Ultem filament is desirable for demanding applications that require high heat resistance, high strength, and low flame, smoke and toxicity,” it says. Topas Advanced Polymers’ cyclic
olefin copolymer (COC) has over the years carved itself a niche in some very specific medical applications, like ‘lab on a chip’ and other microfluidic products for testing and proving new
formulations. Many of these products are injection moulded, but the volumes needed are often quite small, so it is an area ripe for 3D printing. Enter Dolomite, a world leader in microfluidics equipment. Last year, it
www.injectionworld.com
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