How BMW uses binder jetting for serial production

September 20, 2023

At Desktop Metal, we remain steadfast in our commitment to deliver the next generation of Additive Manufacturing 2.0 technologies that will drive 3D printing into serial, volume production.

That’s why we’re all in on #binderjetting — a technology invented at MIT by Desktop Metal co-founder Ely Sachs. We’re not the only ones.

In the links below, you can see a new video that shows how BMW Group is using binder jetting for serial production to virtually eliminate emissions at its Landshut Light Metal Foundry. Next, we have more content that shows how we’re transitioning binder jetting for direct 3D printing of metal parts with customers such as FreeFORM and DSB Technologies.

We truly believe that binder jet 3D printing will help deliver a more sustainable production method for years to come, largely because of its high speed, low waste and cost, as well as material flexibility.

Εκδήλωση 3DENT 9.6.2023, «Τρισδιάστατη εκτύπωση για την παραγωγή εξατομικευμένων κατασκευών στην οδοντιατρική»

June 16, 2023

Η κοινοπραξία του Ερευνητικού έργου 3DENT, με συντονιστή φορέα την ΕΒΕΤΑΜ Α.Ε., οργάνωσε εκδήλωση διάχυσης των αποτελεσμάτων του έργου με θέμα:

«Τρισδιάστατη εκτύπωση για την παραγωγή εξατομικευμένων κατασκευών στην οδοντιατρική». Η εκδήλωση πραγματοποιήθηκε με φυσική παρουσία, στις εγκαταστάσεις του ΕΜΠ την Παρασκευή 09 Ιουνίου 2023.

Το έργο «3DENT-Τρισδιάστατη εκτύπωση για την παραγωγή εξατομικευμένων κατασκευών στην οδοντιατρική», υλοποιείται στο πλαίσιο της Δράσης Εθνικής Εμβέλειας “ΕΡΕΥΝΩ – ΔΗΜΙΟΥΡΓΩ – ΚΑΙΝΟΤΟΜΩ” της Παρέμβασης ΙΙ (Β’ κύκλος)– Συμπράξεις Επιχειρήσεων με Ερευνητικούς Οργανισμούς, η οποία συγχρηματοδοτείται από εθνικούς πόρους (μέσω του Ε.Π. Ανταγωνιστικότητα, Επιχειρηματικότητα & Καινοτομία – ΕΠΑνΕΚ, ΕΣΠΑ 2014-2020) και από κοινοτικούς πόρους (Ευρωπαϊκή Ένωση, Ευρωπαϊκό Ταμείο Περιφερειακής Ανάπτυξης) (κωδικός έργου Τ2ΕΔΚ-04124).

Το συνεργατικό σχήμα του έργου αποτελείται από έναν ερευνητικό φορέα, το Εργαστήριο Μεταλλουργίας της Σχολής Μηχ. Μεταλλείων Μετ/γων του ΕΜΠ, έναν επιχειρηματικό τεχνολογικό φορέα δημοσίου συμφέροντος, την ΕΒΕΤΑΜ Α.Ε., που δραστηριοποιείται στην Εφαρμοσμένη Έρευνα, Τεχνολογική Ανάπτυξη, Πιστοποίηση & Ποιοτικό Έλεγχο ευρέος φάσματος υλικών και βιομηχανικών προϊόντων, και δύο μικρομεσαίες επιχειρήσεις, την εταιρεία LINO 3D που προσφέρει υπηρεσίες 3D εκτύπωσης και την εταιρεία NOVAMIND που δραστηριοποιείται στον χώρο των οδοντιατρικών/οδοντοτεχνικών υλικών και εμφυτευμάτων με 3D εκτύπωση.

Το έργο 3DΕΝΤ καθοδηγούμενο από τις ανάγκες της αγοράς για γρήγορη κατασκευή, εξατομικευμένων, ποιοτικών & υψηλής ακρίβειας οδοντικών αποκαταστάσεων, στοχεύει σε μια νέα προσέγγιση για την ανάπτυξη τους, βασισμένη σε προσθετικές μεθόδους παραγωγής, μελετώντας και συνδυάζοντας 2 κατηγορίες υλικών: μέταλλα- κεραμικά. Στο έργο αναπτύσσονται και μελετώνται με την τεχνική 3D-εκτύπωσης ολοκεραμικές αποκαταστάσεις με βάση τη ζιρκονία και μεταλλοκεραμικές αποκαταστάσεις με μεταλλικό σκελετό κράματος Co-Cr και επικάλυψη οδοντιατρικής πορσελάνης.

Την εκδήλωση χαιρέτησαν δύο προσκεκλημένοι ομιλητές παρουσιάζοντας τις εξελίξεις στον χώρο των οδοντιατρικών υλικών και στον χώρο της προσθετικής κατασκευής. Ο Ομ. Καθηγητής της Οδοντιατρικής σχολής ΕΚΠΑ κος Τριαντάφυλλος Παπαδόπουλος παρουσίασε τις εξελίξεις στο πεδίο των Υλικών και τις προκλήσεις στις οδοντιατρικές κατασκευές. Ο Δρ. Βασίλειος Δρακόπουλος, Διευθυντής Εφαρμογών του ΙΤΕ/ΙΕΧΜΗ και Επιστημονικός υπεύθυνος της ΕΚΕΠΕΚ ΑΕ, του Ελληνικού Κέντρου Προσθετικής Κατασκευής, παρουσίασε τις υπηρεσίες και την καθοριστική συμβολή της ΕΚΕΠΕΚ στην ανάπτυξη νέων τεχνολογιών στην οδοντιατρική και γενικότερα στον τομέα της υγείας.

Εκπρόσωποι των φορέων της κοινοπραξίας παρουσίασαν στην συνέχεια την επιτυχή ανάπτυξη καινοτόμων κεραμικών υλικών για χρήση στις μηχανές εκτύπωσης για οδοντικές αποκαταστάσεις, ενώ επισημάνθηκαν οι δυνατότητες χρήσης τους και σε πολλές άλλες εφαρμογές. Η επιτυχής κλιμάκωση παραγωγής νανοκόνεων ζιρκονίας και διαφόρων υλικών τροφοδοσίας σε μορφή inks/pastes για χρήση στις μηχανές εκτύπωσης από την EBETAM, ανοίγει επίσης νέες προοπτικές στο πεδίο της τρισδιάστατης εκτύπωσης προηγμένων υλικών στην χώρα.

Στο έργο αναδείχθηκε τόσο η δυνατότητα παραγωγής με 3D εκτύπωση υψηλής ποιότητας υλικών για ολοκεραμικές και μεταλλοκεραμικές οδοντικές αποκαταστάσεις, καλύπτοντας τα οδοντιατρικά πρότυπα ελέγχου ποιότητας, όσο και η δυνατότητα της τεχνολογίας για προσφορά εξατομικευμένων λύσεων.

Η Δρ. Κων/να-Ντία Ανδρεούλη, Διευθύντρια Έρευνας & Ανάπτυξης της ΕΒΕΤΑΜ και επιστημονική υπεύθυνη του έργου, επισήμανε την κρισιμότητα της αξιοποίησης των ιδιαίτερα σημαντικών αποτελεσμάτων του έργου από όλους τους φορείς και των ευκαιριών που παρουσιάζονται από το δίκτυο των στρατηγικών συνεργατών των επιχειρήσεων.

Την εκδήλωση παρακολούθησαν μηχανικοί, επιστήμονες υλικών, οδοντίατροι, τεχνολόγοι εκτύπωσης και εκπρόσωπος του φορέα χρηματοδότησης, Υπουργείο Ανάπτυξης και Επενδύσεων-ΕΥΔΕ-ΕΚ.

Visit us at FoamExpo to learn about our tooling-free foam production solution, FreeFoam™

June 16, 2023

Visit us at Foam Expo to see FreeFoam™

Revolutionary, Expandable 3D Printable Resin Designed for Volume Production of Foam Parts

FreeFoam produces durable and dimensionally accurate closed cell foam parts without tooling – delivering all-new benefits for the automotive, furnishing, footwear, sporting goods, health care, consumer goods, and other industries.

Novel FreeFoam photopolymers from Adaptive 3D printed on the ETEC Xtreme 8K eliminate the need for foaming molds and accurately expand from 2 to 7 times the printed component size through a simple, rapid heating process. FreeFoam enables lattice and lightweight designs with a true closed cell foam that maintain tight tolerances without the cost and lead time of traditional manufacturing. Experience a new level of design and engineering freedom with FreeFoam.

Looking forward to meeting you at Foam Expo

• When: June 20 – 22

• Where: Suburban Collection Showplace, Novi, MI

• Adaptive 3D Booth: 2036

Desktop Metal – Changing manufacturability: Go ahead, get creative

March 21, 2023

PRODUCE COMPLEX PARTS WITH EASE

The Shop System enables design freedom to optimize parts and simplify the design change process.

Metal 3D printing on the Desktop Metal Shop System™ eliminates the need for tooling. Complex parts with features like internal channels, lattices, and assembly consolidations that would be difficult – if not outright impossible – to create via traditional approaches are now possible.

Binder jetting creates complex features with ease, and can reduce production processes or make parts more affordable to produce. While lighweighting features typically increase the cost of traditionally-manufactured parts, they actually reduce the cost of 3D printing parts because they use less material.

Besides the freedom to optimize parts to precise needs, the Shop System dramatically simplifies design changes or part iterations. Rather than investing time and money for new tooling, refining a design is as simple as updating the CAD file and sending the new part to the printer.

The Shop System is already allowing companies around the world to develop complex new parts for a wide range of applications – what can you create?

Desktop Metal – Three New Metals for More Flexibility

March 16, 2023

With qualifications of Copper Alloy C18150 and Titanium Alloy Ti64 on Production System™ and 304L Stainless Steel on the Shop System™, Desktop Metal has a market-leading 23 metal binder jet materials.

Titanium Alloy Ti64 on the Production System™

In collaboration with Detroit-based TriTech Titanium Parts LLC, Ti64 has been customer-qualified for binder jet 3D printing on the Production System.

Binder jetting of Ti64 simplifies production of complex titanium parts, which can be challenging and expensive to fabricate using traditional manufacturing methods. Production System P-1 customers interested in working with titanium should consult their Desktop Metal sales representative on hardware and binder requirements.

Mobile 3D scanning of Museum Artefacts

February 20, 2023

Museums collect valuable artefacts of human history. Its is a window to the past. A large amount of statues, sculpture and and other historical objects present what is long gone. The preservation of the past and reverse engineering processes become possible with 3D scanning technology. Get insights into a scan of a historical statue here.

The goal: a precise scan for the replica of the statue Nike

The War Museum in Greece is the largest museum of military history in the country and one of the largest in Southeastern Europe. It collects relicts of Greek history from all wartime periods. In honor of approx. 1600 Philhellenes who offered their services and often even their lives for the liberation of Greece, a monument is planned at the war museum.

For the Monument of Philhellenes the corrected statue of the well-known Nike (Goddess of Victory) needs to be replicated. The replica will be embossed in the center of the monument (Fig. 1).

For this project, a 3D scan of the original statue is created in this application example. The data collected will later be used to produce the marble duplicate using a CNC cutting machine.

The challenge of scanning

The challenge of the application is the creation of an exact scan and later duplicate of the statue.

The work here is complicated at first by the application environment. The confined space as well as the mounting of the statue on the wall makes scan data collection tricky.

With measurements of 1,2 m by 0,60 m the statue is a fairly large object to scan. Besides that, the original is characterized by the numerous details which should be maintained as best as possible. In order to achieve a realistic replica of the statue all details need to be collected accurately and reliably.

Both requirements have to be taken into consideration when scanning the Victory of Goddess.

The scan data must be as exact as possible since the statue is cut out of a marble block using a CNC marble cutting machine.

The digitized statue was the missing puzzle piece for the following replication.

In order to scan as fast and precise as possible, GOM Scan 1 was used. Due to the fringe projection (stereo camera approach) and the blue light technology, the 3D scanner provides detailed and accurate meshes.

The light weight and compact shape of the GOM Scan 1 turned out to be particularly suitable for confined spaces of a museum. The measuring volume furthermore allowed the collection of fine and small details as well as the digitization of the medium-sized part.

Lino Integrated Printing Solutions executed this task. As a long-standing partner in our network, Lino is experienced in the use of 3D scan technology. Based on years long experience, they chose the GOM Scan 1.

Michalis Bratsolias from Lino Integrated Printing Solutions reported that using the fringe projection technology, it was even possible to scan the whole statue almost without reference points.

The scanner operates with the GOM Inspect software. It was extensively used to digitize the statue. Step-by-step it guided the user through the scanning process. Thus, an accurate measuring was possible due to the constant reassurance of the software.

In the museal application, the sensor and GOM Inspect software were simply the perfect duo:

One stop solution to scan, edit, repair and even more.
Michalis Bratsolias

Ready for some behind the scenes footage of the application and the final result of the replica? Keep scrolling to see the GOM Scan 1 in action!

Thank you to Lino Integrated Printing Solutions for sharing the interesting application example, showing the divers uses of the GOM Scan 1.

Improving Commercial Food Equipment with Metal 3D Printing on The Studio System

January 4, 2023

Fish processing systems are transformed with stainless steel 3D printing on the Studio System. The latest Curio filleting machine, the C-2034, features over 100 metal 3D printed parts. On-demand production with office-friendly Bound Metal Deposition (BMD) technology from Desktop Metal was an affordable, easy-to-use solution that reduced time to market by an entire year, enabling the company to unlock new potential from its products.

Desktop Metal BMD technology was key to easy metal 3D printing adoption for Curio’s food processing equipment. Unlike laser-based 3D printers that melt loose metal powder with strict facility requirements, the Studio System extrudes metal rods for office friendly metal additive manufacturing. The two-step process, print and sinter, yielded immediate benefits.

Parts were innovated on-demand to improve performance. By incorporating 3D printed designs in high-quality 316L stainless steel, Curio machines are also increasing the quality and yield of the seafood processed with new benefits integrated into their systems.

“Features like internal cooling channels were not so easy to achieve with
traditional methods, or were too expensive.”

Elliði Hreinsson
Founder of Curio and Gullmolar

PostProcess and EOS Announce Strategic Partnership to Enable More Sustainable Automation Through the Additive Manufacturing Workflow

October 31, 2022

BUFFALO, NY, USA – October 27, 2022 – PostProcess, the leader in automated and intelligent post-processing solutions for 3D printed parts, and EOS, a leading supplier for responsible manufacturing solutions via industrial 3D printing technology, announce a distribution partnership to provide a fully automated and sustainable depowdering solution for EOS customers. Complementing the EOS printer product range, the PostProcess Variable Acoustic Displacement™ (VAD) technology automates gross depowdering for 3D printed parts. This partnership makes it easier for customers to procure post-printing solutions, further enabling end-to-end digitization of the workflow from the part design through 3D printing to post-processing.

Existing methods of powder removal are highly manual or semi-automated and can cause in some cases safety and sustainability issues. This new solution by PostProcess using VAD is thermodynamically controlled with video and infrared monitoring while releasing, transferring, and recovering loose powder particles, hands-free.

The patent-pending VAD technology leverages software intelligence to optimize mechanical energy and intelligent closed-loop thermal and displacement techniques for revolutionary bulk depowdering results, enabling full process chain automation. The powder removal and recovery achieved with VAD technology improves process performance and control, providing customers with enhanced sustainability and employee safety, repeatability and productivity, and lower operating costs. Customers can print highly detailed and complex parts without worrying about breakage in the post-processing step.

“We are proud to solidify this partnership with EOS, a global leader in industrial 3D printing, to help end users more easily adopt the complete workflow of additive manufacturing and scale their operations,” stated Jeff Mize, PostProcess CEO. “EOS stands behind their sustainability objectives and shares in our dedication to ensuring additive manufacturing scales sustainably.”

Speaking to the collaboration Nikolai Zaepernick, Chief Business Officer at EOS, said, “This partnership with PostProcess provides a digital connection that enables traceability and connectivity. We found the perfect match with PostProcess in providing our customers with sustainable automated post-processing for their delicate and complex parts manufactured using the EOS P 500.”

Since it was first introduced in 2020, and as part of the validation process, VAD technology has been operating successfully with large industrial customers, processing hundreds of SLS cakes and thousands of parts in production environments. With its broader commercial launch at the end of this year, a few spots remain available for customers to participate in its Early Access Program. For more information, or to register for this limited VAD program, contact your EOS or PostProcess representative and learn more.

About EOS:
EOS provides responsible manufacturing solutions via industrial 3D printing technology to manufacturers around the world. Connecting high quality production efficiency with its pioneering innovation and sustainable practices, the independent company formed in 1989 will shape the future of manufacturing. Powered by its platform-driven digital value network of machines and a holistic portfolio of services, materials and processes, EOS is deeply committed to fulfilling its customers’ needs and acting responsibly for our planet. www.eos.info.

About PostProcess Technologies:
PostProcess is the leader in automated and intelligent post-printing solutions for 3D printed and additive manufactured parts. Founded in 2014 and headquartered in Buffalo, NY, USA, with international operations in Mougins, France, PostProcess removes the bottleneck in the final stage of the 3D printing workflow, post-processing, through a combination of patent-pending software, hardware, and chemistry technologies. The company’s solutions automate industrial 3D printing’s most common post-printing processes including support, resin, and powder removal, as well as surface finishing, enabling customer-ready 3D printed parts at scale and complete digitization of additive manufacturing through the workflow for the Industry 4.0 factory floor. The PostProcess portfolio has been proven across all major industrial 3D printing technologies and is in use daily in every imaginable manufacturing sector.

Please do read the official press release here.

Desktop Metal partners with Siemens to accelerate sustainable Additive Manufacturing

October 27, 2022

Desktop Metal, Boston, Massachusetts, USA, and Siemens have partnered to accelerate the adoption of Additive Manufacturing for production applications, with a focus on the world’s largest manufacturers.

This collaboration is expected to offer increased integration of Siemens technology in Desktop Metal’s AM 2.0 systems, including operational technology, information technology, and automation. Desktop Metal solutions will be fully integrated into Siemens simulation and planning tools for machine and factory design. For example, Siemens Digital Twin tools are now used for designing some machines and Siemens Advanta can simulate all levels of the Binder Jetting (BJT) process and global plant planning, enabling fast and reliable decisions for factory planning.

Additionally, the companies will also work on specific industrial-scale projects involving data handling and environmental and health & safety topics. Together, they aim to promote the benefits of AM 2.0 technologies, with a focus on BJT as a key technology solution that can reduce waste, produce more, and build more resilient supply chains.

“Additive Manufacturing plays a crucial role as horizontal technology for many industries on their way to improved material efficiency and decarbonisation,” stated Tim Bell, head of the Siemens Additive Manufacturing business in the United States. “We are very excited about this partnership with Desktop Metal. Combining our digital twin concept for planning and simulation as well as the automation of the production systems with the technology of Desktop Metal will accelerate the transformation to scale. As additive manufacturing continues its path to industrialisation, collaborations like this will drive additive manufacturing to greater levels of quality and throughput only traditional manufacturing methods profit from today.”

Ric Fulop, founder and CEO of Desktop Metal, commented, “We’re proud to partner with Siemens to improve the integration of Desktop Metal solutions into existing trusted Siemens manufacturing infrastructures, which can help manufacturers prove out their manufacturing resources and concepts prior to the purchase of full work cells. Enabling customers to simulate different task-time scenarios for the full Binder Jetting process can help customers plan before they purchase any equipment. As our technology continues to make inroads toward high-volume production, we believe Siemens technology will be of increasing value to our customers.”

Desktop Metal qualifies Inconel 625 on Shop System

September 19, 2022

Desktop Metal, Boston, Massachusetts, USA, has announced that nickel alloy Inconel 625 has been qualified on its Shop System metal binder jet machine. This marks the material’s qualification across Desktop Metal’s entire portfolio, spanning Production System and X-series models, as well as the Studio System.

“Manufacturers looking to produce complex geometries in IN625 now have a one-stop shop for efficient Additive Manufacturing 2.0 production,” stated Ric Fulop, founder and CEO of Desktop Metal. “IN625 is a very difficult material to machine, but our technology truly makes it easy. We are proud of the work our world-leading material and process teams have done ensuring that this popular material can be offered across our portfolio.”

IN625 is a high-performance nickel alloy known for high levels of strength, temperature resistance, and corrosion resistance — making it a popular material choice for applications in the aerospace, chemical processing, and offshore energy industries.

However, IN625’s strength is what makes it a difficult and expensive material to machine into complex shapes. The process typically requires a skilled machinist and special CNC cutting tools, strategies and coolants to shape – and it’s not uncommon for cutting tools to be broken or deformed when milling Inconel stock, or for the material to deform when the outer layer hardens too quickly in response to machining, explains Desktop Metal.

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