BMW Group opens its new Additive Manufacturing campus with Desktop Metal’s Participation

The BMW Group has officially opened its new Additive Manufacturing Campus in Munich, Germany. The new centre, which began development in April 2018, is said to bring together the production of metal and plastic prototype and series parts under one roof, as well as research into new AM technologies, and associate training for the global rollout of toolless production. 

The campus is the result of an investment of €15 million and is expected to allow the BMW Group to develop its position as technology leader in the utilisation of Additive Manufacturing in the automotive industry. In 2019, BMW produced about 300,000 parts by AM. The new AM Campus currently employs up to eighty associates and operates about fifty industrial AM machines that work with metals and plastics.

BMW’s Additive Manufacturing campus employs up to eighty associates and operates about fifty industrial AM machines (Courtesy The BMW Group)

Our goal is to industrialise 3D printing methods more and more for automotive production, and to implement new automation concepts in the process chain.

Speaking at the opening ceremony, Milan Nedeljković, BMW AG Board Member for Production, stated, “Additive Manufacturing is already an integral part of our worldwide production system today, and established in our digitalisation strategy. In the future, new technologies of this kind will shorten production times even further and allow us to benefit even more fully from the potential of toolless manufacturing.”

“Our goal is to industrialise 3D printing methods more and more for automotive production, and to implement new automation concepts in the process chain,” added Daniel Schäfer, Senior Vice President for Production Integration and Pilot Plant at the BMW Group. “This will allow us to streamline component manufacturing for series production and speed up development.”

“At the same time, we are collaborating with vehicle development, component production, purchasing and the supplier network,” he continued, “as well as various other areas of the company to systematically integrate the technology and utilise it effectively.”

Cooperating with the AM industry to drive development

The advancement of AM at BMW has been the result of many years of in-house expertise and cooperations to advance the technology. Jens Ertel, Director of the Additive Manufacturing Campus, explained, “Over the last thirty years or so, the BMW Group has developed comprehensive skills, which we’ll continue to enhance on our new campus, which has the latest machines and technologies.”

“In addition, we develop and design components that are faster to produce than by conventional means, offer flexibility in terms of  their form, and are also more functional,” Ertel continued. “We are working hard to mature Additive Manufacturing fully and benefit from it as far as possible throughout the product life-cycle, from the first vehicle concept through to production, aftersales and its use in classic vehicles.”

A part produced using Desktop Metal Additive Manufacturing technology at BMW’s Additive Manufacturing Campus (Courtesy The BMW Group)

Access to the latest technologies is reportedly gained through long-standing partnerships with leading manufacturers and universities, and by scouting for industry newcomers. In 2017, The BMW Group became involved with Desktop Metal’s sinter-based metal AM technologies, and continues to collaborate closely with the company. 

In the same year, BMW I Ventures – the group’s venture capital division – invested in the US start-up Xometry, a platform for on-demand manufacturing, including advanced technologies such as AM.

Its latest investment was in the German start-up ELISE, which allows engineers to produce ‘component DNA’ containing all the technical requirements for the part, from load requirements and manufacturing restrictions to costs and potential optimisation parameters. ELISE then uses this data, along with established development tools, to automatically generate optimised components.

Additive Manufacturing in research and pre-development at BMW Group

The pre-development unit of the Additive Manufacturing Campus optimises new technologies and materials for comprehensive use across the company. The main focus is on automating process chains that have previously required large amounts of manual work, to make AM more economical and viable for use on an industrial scale over the longer term.

For the development of AM processes for use on an industrial scale, research projects are especially important. BMW is involved in several of these projects, such as the Industrialisation and Digitisation of Additive Manufacturing for Automotive Series Production (IDAM) project, supported by the German Ministry of Education and Research. 

One of the Additive Manufacturing Campus’s eighty staff inspects a metal additively manufactured component (Courtesy The BMW Group)

With IDAM, the BMW Group and its twelve project partners hope to pave the way for the integration of AM into series production environments within the automotive industry. At the Additive Manufacturing Campus, a production line is being set up that replicates the entire process chain, from the preparation of digital production through to manufacture and reworking of components. 

The IDAM team is now preparing it for the specific requirements of series, individual and spare-part production. According to the group, production targets confirm the status of this collaborative undertaking as a lighthouse project: output is expected to total at least 50,000 series components a year, with over 10,000 individual and spare parts, all produced to a very high quality.

Applications in series production

The BMW Group first began its Additive Manufacturing of prototype parts in 1991, for concept vehicles. By 2010, both metal Additive Manufacturing and plastic AM processes were being rolled out across the group, initially in smaller series, to produce items such as the additively manufactured water pump wheel in DTM race cars. 

Further series production applications followed from 2012 onward, with a range of components for the Rolls-Royce Phantom, BMW i8 Roadster (2017) and MINI John Cooper Works GP (2020), which contains four AM components as standard.

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New Case Study by PostProcess and Splitvision: Building on Manufacturing Expertise with Automated 3D Post-Printing

Splitvision, headquartered in Stockholm, Sweden, found the ideal product development formula by combining its talented design team and deep manufacturing experience to deliver competitive solutions for its customers. However, to continually to deliver on that promise requires a culture that embraces leading-edge manufacturing methods and process. That is what brought Splitvision to PostProcess, as they explored a better way to streamline and maximize its 3D printing with DLP resin removal innovation.

QUESTION: Can you give us some background on Splitvision and how you utilize additive manufacturing?

ANSWER:We have been developing products since 1989. From initially strictly offering industrial design, we have broadened our service portfolio over the years to become a full turnkey solution provider for product realization. We have always made prototypes from Polyurethane (PU) foams or solid plastic materials to evaluate form and ergonomics, which we have traditionally done using hand tools. On more detailed prototypes or models with high cosmetic demands, we used to outsource to either print shops in Sweden, or prototype services in China. In 2019, we decided to invest in a Digital Light Processing (DLP) printer from 3D Systems called Figure 4 to speed up our processes while achieving better mechanical properties and fine feature details. In our experience, this is the only printer that can equip soft parts with Thermoplastic Elastomer (TPE)-like performance.Since many of the products we develop and produce for the hearing aid industry are comprised of a combination of both TPE and hard plastic, this was a deciding factor. We can now evaluate fit and assembly on a detail level before actu-ally making the injection tools, typically saving us from 1-2 iterations of tool tuning. We also design casings for electron-ic products, and by using the Figure 4 printer to make smallseries production of those, it is possible for our customers to do field testing and user studies without investing in mass production tools. Needless to say, the DLP printer has brought massive value not only to our workflow, but to our customers as well.

QUESTION: Before introducing the PostProcess solution, what sort of bottlenecks did you experience in your additive workflow?

ANSWER: The design casings that I mentioned of-ten have lots of intricate crevices like screw towers, small slots, and many ribs. It can be a very tedious job to fully clean the resin off of these features with a traditional solution like isopropyl alcohol (IPA). That excess manual labor makes the unit cost for those parts unnecessarily high. Even if the printer used is efficient and several parts can be manufactured in one run, the unit cost still does not go down much since so much time is needed to clean each part in-dividually.

Example DLP parts from Figure 4 printer

Apart from being time-consuming, the work environment also gets compromised by the strong smell from the IPA. Not to mention, we were always concerned about the fire risk posed by IPA. That is where the PostProcess solution was able to really streamline our post-printing process and improve workplace safety overall.

QUESTION: How did the PostProcess solution fit into your additive workflow, and how has it most significantly improved your efficiencies/work environment?

ANSWER: In January 2020, we got the opportunity to try a resin removal system from PostProcess that utilizes their proprietary Submersed Vortex Cavitation (SVC) technol-ogy. The system uses ultrasonic cleaning, agitation, and controlled temperature for the process. The detergent included with the system has a high flammability point, which means it does not ignite from a spark at the machine’s working temperature. Apart from being more pleasant to work with, the detergent seems to be especially efficient at dissolving the uncured DLP resin. Usually, it removes resin completely in just a matter of minutes. In some cases, with deep narrow features, the cycle time can be a little longer, but we have never had a part require more than 10 minutes of processing time.

As an example, a small electronics case took about 30 minutesper part for rinsing and drying. Previously, it was difficult to see if it was fully clean before drying off the IPA with compressed air. You would have to rewash it in IPA, use a brush where it was not clean, and repeat it a few times until it looked good. Now, running this same part in the PostProcess solution, the total cycle time for consistently complete resin removal is only 4 to 5 minutes for a batch of 10 at once. The benefit here you can see is improving from 30 minutes per part down to all 10 parts in less than 5 minutes.

Thanks to how efficient the PostProcess solution is within our workflow, we can now leave the support structure intact on parts when we need to do UV post-treatment of the DLP resin. This was never pre-viously possible with traditional IPA cleaning because it was extremely difficult to get rid of all uncured resin behind the supports. An added bonus is that we can load printed parts into the PostProcess machine without ever removing them from the build tray, eliminating the need to clean the tray separately, removing another tedious process.

We can now offer printed parts at a reasonable price, especially when printing multiple items in one run. Plus, the nasty bit of the printing process has been eliminated for our staff. After having tried the PostProcess solution, it’s hard to imagine ever going back to using IPA.

About Splitvision

Starting out as a design agency, we have over the years integrated the design process with a manufacturing system that can ensure our customers original idea’s integrity while maintaining control over costs and speed up the time to market. We are designers, engineers, buyers, sourcing specialists, QC specialists, logisticians, project managers and businesspeople who love to make good things. We have offices in Stockholm, Sweden and in Shenzhen, China. With more than 30 years of experience in product development, we strive to direct our talented design team to deliver competitive solutions to our customers using our expertise within; Design Strategy, Product and Transportation Design, HMI / GUI, Advanced 3D Modelling, Mechanical Engineering, and Prototypes.

But what really makes us unique is our manufacturing experience so when engaging Splitvision for product design, you also get access to significant manufacturing experience as well. We offer manufacturing services within a wide range of techniques and materials through a trusted partner network. The main focus is on injection molded plastic with high functional and cosmetic demands. Our customers range from start-up-brands outsourcing the production of their core product, to large corporations out-sourcing the design and manufacturing of their accessories. Learn more at www.splitvision.com

About PostProcessPostProcess

Technologies is the only provider of automated and intelligent post-printing solutions for 3D printed parts. Founded in 2014 and headquartered in Buffalo, NY, USA, with international operations in Sophia-Antipolis, France, PostPro-cess removes the bottleneck in the third step of 3D printing – post-printing – through patent-pending software, hardware, and chemistry technologies. The company’s solutions automate industrial 3D printing’s most common post-printing pro-cesses with a software-based approach, including support, resin, and powder removal, as well as surface finishing, resulting in “customer-ready” 3D printed parts. Additionally, as an innovator of software-based 3D post-printing, PostProcess solu-tions will enable the full digitization of AM through the post-print step 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 manu-facturing sector.

POSTPROCESS TECHNOLOGIES
2495 Main St., Suite 615, Buffalo NY 14214
1.866.430.5354

POSTPROCESS TECHNOLOGIES INTERNATIONAL
Les Aqueducs B3, 535 Route des Lucioles, 06560 Sophia Antipolis, France
+33 (0)4 22 32 68 13

e-mail: info@postprocess.com
official website: www.postprocess.com

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PRESS RELEASE – Cetim and Desktop Metal Partner to Accelerate the Adoption of Global Metal Additive Manufacturing

Cetim, the Technical Centre for Mechanical Industry, and Desktop Metal, the company committed to making 3D printing accessible to manufacturers and engineers around the world, today announced a partnership to accelerate the global adoption of metal additive manufacturing. Cetim, which works closely with industrial companies to help to identify market opportunities and facilitate innovation and technical progress, will become one of the first adopters of the new Desktop Metal Shop System™, the world’s first metal binder jetting system designed for machine shops and metal job shops.

This announcement builds on the early momentum Cetim is seeing with the installation of the Desktop Metal Studio System™ into its Cluses, France facility. With both the Studio System, for rapid prototyping and low volume production of metal parts, and now the Shop System, Cetim’s customers, which span aerospace, oil and gas, automotive and other industries, will be able to explore new advanced solutions for their manufacturing needs – from low-volume prototyping to mid-volume runs of complex metal parts.

“As the demand for metal AM continues to grow, it is challenging for many of the mechanical industry companies we work with to identify the right solution that meets their needs and then to implement it in an effective and cost efficient way,” said Pierre Chalandon, Chief Operating Officer at Cetim, the Technical Centre for Mechanical Industry based in France.

“Desktop Metal technologies with both the Studio System and new Shop System completes our additive manufacturing machines park. From a general point of view, Metal Binder Jetting Technology is promising for a large part of our clients. Desktop Metal solutions portfolio covers the full metal product lifecycle, which is complementary to our experience on sintered material and finishing Operations,” Chalandon said.

In addition to the implementation of both the Studio System and Shop System, Cetim and Desktop Metal plan to collaborate on a variety of research initiatives leveraging Desktop Metal’s technologies, including design for metal AM processes, post-processing and finishing techniques qualification, workflow optimization and materials development, among others.

The Shop System, launched during Formnext 2019 in Frankfurt, Germany, enables shop owners to leverage affordable, high-quality binder jetting technology to print end-use metal parts with unparalleled speed, print quality, and productivity. Offering the most cost-effective solution in the industry starting at $150,000 USD for the printer, this high-speed, single-pass print engine helps shop owners eliminate many of the constraints previously seen with traditional manufacturing methods like CNC machining and tap into new opportunities to reduce their costs and increase revenue.

The Studio System, the world’s first office-friendly metal 3D printing system for functional prototyping and low volume production, is designed to make metal 3D printing more accessible, enabling design and engineering teams to print metal parts faster, without the need for special facilities, dedicated operators, or expensive tooling. The three-part solution, including printer, debinder and furnace, automates metal 3D printing by tightly integrating through Desktop Metal’s cloud-based software to deliver a seamless workflow for printing complex metal parts in-house – from digital file to sintered part.

“When it comes to empowering industrial companies with the additive manufacturing technologies of the future, Cetim is truly one of the leaders in Europe,” said Ric Fulop, CEO and co-founder, Desktop Metal.

“We are excited to partner with Cetim as one of the first customers for our ground-breaking Shop System and are eager to collaborate with Cetim on our shared efforts to change the way that companies manufacture around the globe.”

Cetim is one of the French leaders in metal additive manufacturing development, with different platforms and associated partners, covering almost all the direct and indirect technologies including LPBF, WAAM and MBJ dedicated to the transfer to industrials. Cetim is also strongly involved in international normalization of metal additive manufacturing. Cetim coordinates AFH, the initiative Additive Factory Hub which aims to innovate, develop and integrate additive manufacturing to address the key industrial and economic challenges.

Cetim has been involved in additive manufacturing for more than 15 years and has been developing specifically the Metal Binder Jetting technology for five years, from the design, the process, the characterization to the finishing steps. MBJ technology is opening new opportunities, increasing the production capacities, decreasing the global cost and allowing new materials.

About CETIM

As the leading French player in the fields of mechanical engineering innovation and R&D, Cetim has built up a wide network of partners. Its engineers and technicians operate in more than 30 countries each year. R&D function is carried out either within specific sectors or cutting across sector boundaries, and within either a national or an international context. It embraces a range of complementary aspects, including prospective studies in conjunction with international scientific communities, R&D concerning all areas of mechanical engineering, industry-specific studies and projects, and the large-scale federative technological projects. Cetim provides a comprehensive array of services to the mechanical engineering industry from consulting to testing and from engineering to training in new skills. Cetim is labelled Carnot institute, member of the Réseau CTI and of the Alliance Industrie du futur. www.Cetim.fr.

About Desktop Metal

Desktop Metal, Inc., based in Burlington, Massachusetts, is accelerating the transformation of manufacturing with end-to-end 3D printing solutions. Founded in 2015 by leaders in advanced manufacturing, metallurgy, and robotics, the company is addressing the unmet challenges of speed, cost, and quality to make 3D printing an essential tool for engineers and manufacturers around the world. Desktop Metal was selected as one of the world’s 30 most promising Technology Pioneers by the World Economic Forum; named to MIT Technology Review’s list of 50 Smartest Companies; and recognized among the most important innovations in engineering in Popular Science’s “Best of What’s New.” For more information, visit www.desktopmetal.com.

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Ceramic Applications with XJet – XJet Blog June 2020

Can AM unlock some of ceramic’s lesser known material properties?

Dror Danai, CBO, XJet

Working with many ceramics manufacturers over the last few years I’ve noticed there are a few ‘go to’ material properties – hardness, durability, heat resistance and insulation – that are generally associated with ceramics. However, when I look at some of the developments coming out of ceramic additive manufacturing (AM), the ‘hero’ material characteristics that make new trailblazing applications possible are often those that are rarely mentioned – such as being nonmagnetic or chemically inert, or the material’s unique dielectric constant.

Non-magnetic cryotherapy prove for use on an MRI

A new hero in town?

Take for instance Marvel Medtech’s cryotherapy probe. The intent of the device is to treat early stage breast lesions suspected of being or becoming cancerous with cryoablation before a diagnosis is even made. The device works on an MRI, so if lesions are detected, cryoablation can be used to treat the area immediately, using the MRI to guide the probe. This preventative treatment is expected to have a huge impact in preventing the recurrence and spreading of the disease, which is the most common cancer for women across the world. The result will be more lives saved, improved quality of life, and lower healthcare costs.

Marvel MedTech’s cryotherapy probe for 100% removal of breast cancer lesions

The University of Delaware’s Passive Beam Steering antenna tells a similar story. UDEL (University of Delaware) set about developing an antenna in response to the challenge of rolling out the 5G network; whilst 5G signals deliver data 10-20 times faster than 4G, they are also more sensitive to interference, requiring a vast increase in antenna number to provide reliable signal. UDEL’s design delivered the small, lightweight, cost-effective antennae needed to meet the volume increase but also required smooth, accurate inner channels to retain wave direction, with the right dielectric constant so signals would not be absorbed and weakened. In this case, the dielectric constant of ceramic was the hero characteristic, which was once again unlocked by the complex geometries enabled by AM.

Exact dielectric constant for creating a perfect Passive Beam Steering antenna
University of Delaware’s Passive Beam Steering antenna is potentially a game-changer in the roll-out of 5G

A third notable application is earbuds, another device produced with XJet ceramic additive manufacturing. Like the 5G antenna, smooth, accurate internal channels are essential to provide an elevated acoustic experience. In addition, whilst the vast majority of earbuds on the market today are constructed from plastic and metal components with gel cups and rubber for comfort, an issue with these materials is that they generally break down over time due to exposure to the liquids and wax that are naturally found in our ears. When components are made from chemically inert ceramics, the earbuds typically have a much longer lifespan, as luxury lifestyle brands are discovering.

Chemically inert earbuds with smooth internal channels for a clean sound

Epic opportunity

The recently released SmarTech Analysis 2020 Report predicts that ceramic AM will grow from the $184 million market it was in 2019 to a $4.8 billion opportunity in 2030. I believe the applications I’ve talked about above, made possible with AM, just scratch the surface. Many ‘impossible’ feats will be made possible, unlocked by additive manufacturing, as ceramic material properties and applications are explored further. With that, it’s an attainable prediction and I’m very much looking forward to the ingenuity and invention that is inspired on the journey.

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PostProcess and Great Lakes Dental Case Study

CASE STUDY
IMPLEMENTING ADDITIVE MANUFACTURING TO UNLOCK THE FUTURE OF DENTAL

Great Lakes Dental Technologies started as a small orthodontic laboratory in 1964 and now operates one of North America’s largest orthodontic laboratories, offering more than 4000 products and services. In addition to distribution, on-site education and training, and in-house manufacturing, Great Lakes adopted the use of additive manufacturing over ten years ago.

Dentistry is a field in which additive manufacturing, also known as 3D printing, is expected to see a lot of growth in the coming years. In fact, a 2019 SmarTech Analysis report found that additive manufacturing for the dental industry is projected to grow into a $9 billion market by 2028. Because 3D printing is renowned for its ability to manufacture one-of-a-kind, intricate solutions quickly, it is ideal for the development of retainers, dentures, custom implants, crowns, and more. Without the option of additive manufacturing, most dentistry operations are forced to rely on more labor-intensive subtractive manufacturing
methods, like milling machines, for example.

Enter PostProcess Technologies, a pioneering start-up out of Buffalo founded in 2015 whose automated solutions for the post-printing segment of additive manufacturing are shaking up the market. Their approach of using software to apply intelligence to what is usually a highly manual process with conventional equipment helps companies scale and improve efficiencies. The pairing of these two Western New York companies is a story of well-established and early growth stage businesses with a
shared passion for innovation.

Great Lakes is all-in on additive manufacturing applications for their dental business. They have specifically invested in PolyJet, DLP, and SLS 3D printing in their own facility and as a reseller of Stratasys and 3D Systems solutions. Great Lakes successfully integrated additive manufacturing into its workflow until it came time for the post-printing step. Because dental appliances are manufactured on a case-by-case basis, no two designs are the same. A dental aligner is customized for each patient and features numerous intricate crevices that can be difficult to post-print and to remove excess powder from. The accuracy of these appliances is critical to both comfort and function. It is imperative that dental aligners and similar custom products have a completely smooth exterior, which is only achievable through surface finishing. This presents Great Lakes with the need for not one, but two efficient SLS post-printing techniques – powder removal and surface finishing. Without an automated solution, both techniques require a significant amount of manual labor. While this tedious task isn’t an ideal use of time for technicians, the process also reduces efficiencies and slows down lead times.

SLS 3D Printed Dental Part
DOUBLING DOWN ON A STREAMLINED WORKFLOW WITH POSTPROCESS

When Great Lakes Dental Technologies decided it was time to automate their post-printing process, PostProcess worked collaboratively to identify the best solution for their needs through a series of benchmark tests. Typically, the two different post-printing processes would require two different solutions. However, PostProcess was able to maximize Great Lakes’ ROI by presenting them with a feasible 2-in-1 solution to automate both their powder removal and surface finishing needs for their SLS prints with their RADOR solution.

The patent-pending RADOR utilizes software intelligence, hardware, and advanced vibratory technology to dually remove powder from and burnish printed parts. The secret behind this flexible automated solution is the Suspended Rotational Force (SRF) technology, which employs their AUTOMAT3D software to create an effective friction force and suspend parts in a circulating motion. This movement ensures that every area of each part receives equal exposure to the finishing hardware. The rotary motion is kicked into gear by the machine’s vibratory tub. These vibrations are essential to RADOR’s effective powder removal and surface finishing capabilities.

PostProcess™ RADOR™Surface Finish Solution

It’s worth noting that absolutely no chemical energy is applied to the SLS dental parts. Instead, finishing media serves as the real workhorse in this solution. After taking print materials, product shapes, and finishing requirements into account, PostProcess engineers matched Great Lakes with the ideal media to finish their complex dental designs.


Since having installed PostProcess’s automated post-printing technologies, Great Lakes has experienced a significant decrease in cycle time and manual labor for their SLS printing workflow. “The RADOR has not only improved our efficiencies but has allowed us to produce a superior product while maintaining our valued workforce,” commented James R. Kunkemoeller, President and CEO, Great Lakes Dental Technologies. “Great Lakes’ forward-thinking mentality has always driven us to look for ways to improve business sustainability, competitiveness, and workforce retention.”

About Great Lakes Dental
Beginning as a small orthodontic laboratory in 1964, Great Lakes Dental Technologies now operates as one of North America’s largest orthodontic laboratories, offering more than 4,000 products and services. As a veteran of additive manufacturing for more than ten years now, Great Lakes executes distribution, on-site education and training, and in-house manufacturing of retainers, orthodontic appliances, TMJ splints, sleep appliances and more.


About PostProcess Technologies
PostProcess Technologies is the only provider of automated and intelligent post-printing solutions for 3D printed parts. Founded in 2014 and headquartered in Buffalo, NY, USA, with international operations in Sophia-Antipolis, France, PostProcess removes the bottleneck in the third step of 3D printing – post-printing – through patent-pending software, hardware, and chemistry technologies. The company’s solutions automate industrial 3D printing’s most common post-printing processes with a software-based approach, including support, resin, and powder removal, as well as surface finishing, resulting in “customer-ready” 3D printed parts. The PostProcess portfolio has been proven across all major industrial 3D printing technologies and is in use daily in every imaginable manufacturing sector.

POSTPROCESS TECHNOLOGIES
2495 Main St., Suite 615, Buffalo NY 14214
1.866.430.5354

POSTPROCESS TECHNOLOGIES INTERNATIONAL
Les Aqueducs B3, 535 Route des Lucioles, 06560 Sophia Antipolis, France
+33 (0)4 22 32 68 13

e-mail: info@postprocess.com
official website: www.postprocess.com

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Unlock AM Live – The Digital Post-Printing Experience with PostProcess Technologies

Welcome to Unlock AM LIVE!

Join us on a week-long virtual experience with PostProcess’s team and solutions to explore the full potential of automated post-printing in propelling additive manufacturing into the future! Unlock AM LIVE is your key to informative Webinar presentations, unique Live Solution Experience tours, and one-on-one Coffee Talk sessions. We’re excited to bring to you the opportunity for networking, information, and collaboration during Unlock AM LIVE – engage below to start your journey!

Please see original post at: https://www.postprocess.com/unlock-am-live/

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Marketiger advances Full Color Mimaki printing with PostProcess Full Stack solution – Application Story

MARKETIGER SETS THE BAR HIGH

Establishing themselves as a rarity in the market, Netherlands-based Marketiger does it all when it comes to full-service 3D printing. While most additive manufacturing companies choose to either specialize in small scale printing or mass production, Marketiger employs innovative technology that enables them to work at both ends of the 3D printing spectrum.

Being a “next level” 3D printing service company begins with intuitive pre-processing, ensuring that every concept designed is suitable for transformation into a full-color 3D model. When it comes time for printing, Marketiger has employed the world’s first photorealistic, full-color 3D printer, the state-of-theart Mimaki 3DUJ-553. With this technology, they are able to create designs that can incorporate over 10 million colors. This spectrum of colors allows for some of the most vividly designed products in the
industry.

While Marketiger’s additive workflow is a unique one, without the right post-printing support removal solution, there is room for bottlenecks to arise in the final step of the process. Because of how intricate many of Marketiger’s Mimaki 3D printed parts are, they require a post-printing solution that is especially sensitive to the individual needs of each design. With the conventional system they had been using, Marketiger saw negative effects like pronounced layer-lines on finished parts. For a company that heavily values product quality and fine attention to detail, these issues were extremely problematic.

REVOLUTIONIZING SUPPORT REMOVAL WITH POSTPROCESS

“One of my customers told me to contact AM Solutions to do some polishing tests. From there, I contacted Bert van den Boogaard from AM Solutions,” commented Maikel de Wit, director from Marketiger. AM Solutions represents PostProcess products in the Benelux area. “The knowledge and expertise of both AM Solutions and PostProcess regarding cleaning 3D printed parts is enormous,” says Maikel de Wit, director from Marketiger. “We were, therefore, able to learn a lot from each other during the entire process and evaluation.”

Thanks to integrated software intelligence, users like Marketiger are able to fine-tune the support removal settings to exact parameters, allowing for precise control over the process. The FORTI’s exclusive additive-formulated detergents, utilized at specified temperatures and in strategized time allotments controlled by the software, ensure consistency and repeatability without part damage or warping.


Thanks to AM Solutions and PostProcess’s automated support removal technologies, Marketiger has been able to streamline their post-printing workflow while maintaining the high product quality standards that they are used to outputting.

PostProcess™ FORTI™ Support Removal Solution

About AM Solutions
AM Solutions, a brand of the Rösler Group, will support you with the development and implementation of innovative, optimized 3D printed products with a unique, highly flexible solutions package covering the entire process chain. AM Solutions consists of two separate business units; 3D post-processing & 3D printing services. 3D post-processing offers equipment solutions for any post-processing challenges irrespective of the print method and the component material. Its cooperation with numerous industrial partners, universities and research facilities ensures the continuous improvement of products and services so that customers can always count on getting the latest technology.

About Marketiger
Marketiger combines innovative Mimaki 3D technology with excellent technical & creative knowledge to manufacture the highest available full-color 3D quality in the world. Marketiger introduces the next level of 3D printing with up to 10.000.000 colors and extreme detail levels. Marketiger uses the Mimaki 3DUJ-553 full-color 3D printer and specializes in creative concepting in all of the several stages a concept can be in. Marketiger’s solutions are an excellent improvement and well-developed replacement for existing full-color sandstone Figurine productions. Collaborating with experts from the field such as Scanologics they offer a fully integrated scan & print solution. The extensive experience in implementing the Mimaki full-color 3D printing technology leads to less rejection of detailed models, broken models, degrading colors and long lead-times.

About PostProcess
PostProcess Technologies is the only provider of automated and intelligent post-printing solutions for 3D printed parts. Founded in 2014 and headquartered in Buffalo, NY, USA, with international operations in Sophia-Antipolis, France, PostProcess removes the bottleneck in the third step of 3D printing – post-printing – through patent-pending software, hardware, and chemistry technologies. The company’s solutions automate industrial 3D printing’s most common post-printing processes with a software-based approach, including support, resin, and powder removal, as well as surface finishing, resulting in “customer-ready” 3D printed parts. Additionally, as an innovator of software-based 3D post-printing, PostProcess solutions will enable the full digitization of AM through the post-print step 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 see original post at:

https://tinyurl.com/yatv6w2z

POSTPROCESS TECHNOLOGIES
2495 Main St., Suite 615, Buffalo NY 14214
1.866.430.5354


POSTPROCESS TECHNOLOGIES INTERNATIONAL
Les Aqueducs B3, 535 Route des Lucioles, 06560 Sophia Antipolis, France
+33 (0)4 22 32 68 13


info@postprocess.com
www.postprocess.com

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PostProcess: COVID-19 Response Update

We’re here to assist with efforts in response to the COVID-19 pandemic however we can. Please contact us if you are 3D printing supplies or PPE for first responders and have a bottleneck in your post-printing step – we can help. Additionally, if you are experiencing a shortage of IPA for resin removal due to its use in sanitizers and other disinfecting products, we have an IPA alternative for this process. Contact us for more information.

How We’re Helping
PPE Production at SCAD

We’re proud that our solutions are being put to work in response to the crisis, such as at SCAD (Savannah College of Art & Design). As one of our long time customers, SCAD is utilizing our BASE Automated Support Removal solution for FDM post-printing on face shield components. Their increased production of PPE for local first responders is supported by the ability to stack on the printer build tray and automate support removal of multiple pieces at once.

Justin Cox, Assistant Superintendent at SCAD, commented: “The BASE has been an invaluable part of our workflow. We are able to load the BASE with large numbers of face shields and ear relief straps and wash them all within 2 hours. This allows our team to assemble and package within a day. We are also using the BASE to wash parts that are printed in our other facilities that normally use traditional parts washing tanks which also saves us a lot of time”. Learn more here.

Redirecting our In-house 3D Printers for Local PPE Efforts

PostProcess’ in-house FDM 3D print capacity, typically used for internal testing and sample parts, has been redirected as a part of a joint effort for PPE equipment production in our hometown of Buffalo, NY. We’re teaming with a number of local companies who are also donating materials and funds to produce face shields for local first responders. Our software-driven Support Removal technology allows us to post-print more parts at once with virtually no technician time, therefore increasing the speed of our production. Learn more here.

Support for our Customers Redirecting 3D Printing Operations

A number of PostProcess customers are redirecting their additive operations to support COVID-19 manufacturing efforts. We are committed to deploying our internal Application Engineering resources to support the optimization of their PostProcess solutions to their new 3D printing program.

Please contact us if we can support your efforts to fight COVID-19 with 3D printing.
Additionally, learn more about our day-to-day operations during COVID-19 here.

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EnvisionTEC COVID-19 Efforts

The 2020 COVID-19 pandemic has proven to be an opportunity for 3D printing to assist in finding new, innovative ways for healthcare professionals to provide assistance.  A shortage of the necessary diagnostic and treatment supplies has been discovered, and while many businesses have jumped in to help, it is 3D printing that may be able to provide real answers for how to combat the supply chain crisis.

Working hand-in-hand with healthcare leaders, EnvisionTEC has identified several areas where their specific strengths in biocompatible materials and fast, precise 3D printing equipment can help to provide replenishment of stocks as well as new, alternative solutions.

Learn more about these efforts below and find out where you can help, and how we can help you.

Personal Protection Equipment (PPE)

In order to effectively treat the growing number of COVID-19 patients, healthcare professionals and many other essential workers rely heavily on PPE’s in order to safely maintain their own health. Many mask designs are meant to be single-use, and with the general public adding to the demand for these items, they are becoming increasingly hard to come by. Again, 3D printing is an ideal solution, allowing for portions of face shields to be printed and sterilized. EnvisionTEC has a number of large 3D printers that can quickly and efficiently print these parts in bulk, and many of their customers have been able to answer the call for local needs.

3D Print Face Shields on Envision One
Order EnvisionTEC Custom-Made Masks

The links below can be used to assist in 3D printing and assembling face shields for interested parties.

Please do not download any files before you have read, acknowledged and agreed to the following Release Waiver

Build files for face shields (8) on the Envision One

Database of PET Film Suppliers

Build files and instructions for 3D printing face shields

Please email your requirements to covid19@envisiontec.com in North America and covid19@envisiontec.de in the rest of the world.

Minimum order quantity: 2000

Lead time: 2 weeks

$13/each

Add $1/filter

Face Shields
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Mask File Photo
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Completed Face Shield
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Filter Mask 1
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Filter Mask 2
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Nasopharyngeal (NP) Swabs

Perhaps the biggest immediate need in the fight against COVID-19 is simply identifying those who have been infected as early as possible.  Testing kit availability has been vastly inadequate, and the medical community has been working tirelessly with the 3D printing community to find a solution to mass-producing the nasopharyngeal collection swabs to alleviate the shortage quickly. EnvisionTEC has been working closely with the Harvard Microbiology Lab within a larger group dedicated to connecting academia with the manufacturing industry to combat this shortage.

To this end, EnvisionTEC engineers have designed a collection tip for a flexible nasal swab.  Brian Nilson, of Nilson Laboratories, 3D printed the final design for testing.  He was able to print 400 of the swabs in E-Guide Soft material on his Envision One cDLM in two hours.  The testing process is comprised of a ten stage mechanical testing, a two part absorption test, a biological/chemical testing procedure to ensure the swab absorbs viral RNA particles and does not interfere with PCA/reagents, and a sample collection testing procedure.  To pass, a sample needed to use a material that is approved as chemically safe, would bend 180 degrees without breaking, and the design needed to be able to safely collect enough virus particles from the nasal passage to effectively test.

E-Guide Soft has passed some of these tests and is awaiting final IRB testing and approval. Under FDA regulations, an IRB group that has been formally designated to review and monitor biomedical research involving human subjects has the authority to determine that E-Guide Soft is suitable for the mass production of the NP swabs for COVID-19 testing.  EnvisionTEC has been working with Beth Israel Deaconess Medical Center (BIDMC) of Boston’s Biomedical Laboratory, to obtain the IRB approval. EnvisionTEC has long been committed to providing solutions to their customers and is now preparing to take on the call to action of helping to equip medical professionals with the tools needed to help combat this global pandemic.  With a vast network of thousands of customers eager to help, EnvisionTEC is proud to offer the capability of producing quantities of up to half a million of the swab per day.

Print NP Swabs
Order NP Swabs

These NP swabs are a Class 1 medical device.  In order to print these for use by medical professionals, you must first be registered with the FDA and the swabs must be added to your medical device listing with the FDA.

Click here for instructions regarding this registration and listing.

Once this is done, please email covid19@envisiontec.com in North America and covid19@envisiontec.de in the rest of the world to be added to the list of available manufacturing partners. The protocols being developed for the NP swabs require an Envision One cDLM and a PCA 2000 curing unit.

NP swabs are available to order. Please email us at covid19@envisiontec.com in North America and covid19@envisiontec.de in the rest of the world for pricing and lead times.

NP Swab FDA Listings

Applicator, Absorbent Tipped, Sterile, Product Code KXG
 
Applicator, Absorbent Tipped, Non-Sterile, Product Code KXF
Swab
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Printed Swabs in EnvisionONE
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Self Sealed Sterilizable Pouch
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Close up of Swabs
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Printed Swabs in EnvisionONE
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Flexing Swab
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Swabs
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Ventilator Splitter

Individual ICU ventilators are critical in the treatment of patients in severe respiratory failure, a symptom of severe cases of COVID-19. It has been determined that the demand for these ventilators will far exceed the current stock on hand.  Manufacturing giants such as Ford and GM have been tapped to assist in the production of these machines, but even with the increased manufacturing capabilities, the process to get these machines ordered and in the hands of the medical professionals who need them could cause delays.  Al Siblani has been working with local hospitals in the Metro Detroit area to provide a functional ventilation splitter that could be 3D printed in a Class 1 material such as EnvisionTEC’s E-Guide. EnvisionTEC is working with the FDA to authorize the use of 3D printed splitters as an emergency solution to allow for multiple patients to receive oxygen from the same ventilator by adjusting the pressure controls on the ventilators to allow for dual-patient use.  By using 3D printing for these accessories, production could be scaled up in locations close to where the need is greatest, allowing for fast reaction to the growing problem and more than double the capacity of current ventilator stock.

To place an order, please email covid19@envisiontec.com in North America and covid19@envisiontec.de in the rest of the world.

Splitter
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Printed Ventilators on platform
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