EnvisionTEC lanches D4K Pro Dental

The highest resolution desktop DLP 3D printer for the dental segment

EnvisionTEC is introducing the new D4K Pro Dental, the highest resolution 4K desktop 3D printer specifically for the dental segment. The D4K Pro from EnvisionTEC includes the fastest print speed for a standard DLP printer (intended as non-continuous). As such it can deliver extremely accurate parts with the finest detail available.

The D4K Pro is built on an industrial 4K DLP projector which ensures stable performance for many years. The D4K Pro is compatible with all EnvisionTEC DLP resins for the dental industry, providing essential solutions for applications from models to full dentures and everything in between.

Designed for chairside and small labs, the D4K Pro is the industry’s newest solution, brought to you by the original inventors of DLP 3D printing technology. EnvisionTEC has been leading the way for dental 3D printing since 2003, with equipment and material innovations that have revolutionized the dental and orthodontic industries.

The company founded by Al Siblani has been serving the dental market since 2008, when Jim Glidewell walked up to an EnvisionTEC trade show booth and asked: “Can you do teeth?”

Glidwell is the owner of Glidewell Laboratories in Newport Beach, CA, one the single largest dental labs in the US. Today, Glidewell 3D prints dental prosthetics on nearly a dozen EnvisionTEC printers, both desktop and production models. “Our Perfactory 3D printer from EnvisionTEC allows us to create highly precise wax patterns at a fraction of the time required for a hand wax-up,” Glidwell said.

And EnvisionTEC offers an industry-leading dental materials portfolio that includes several FDA- and CE-approved materials for long term use in the mouth. These include NextDent C&B MFH, NextDent Denture 3D+, E-Guard, E-Guide Tint, and E-IDB, with more added regularly. These dental materials 3D print a full range of models (dental and orthodontic), castables (crowns, bridges, partial frameworks), restorations (crown, bridge, full roundhouse, as well as complete dentures) and appliances (surgical guides, bite splints, indirect bonding trays).

Please do read the official article by Davide Sher here.

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PostProcess and Empire Group: A Superior Approach to SLA Resin Removal Drives Workflow Gains

SLA GROWING PAINS

As an early adopter of rapid prototyping and the first company in its region to embrace 3D printing,
service bureau Empire Group has been enabling clients with faster prototype delivery times and
increased productivity since 1999. Over the years, the company has expanded its offerings to include industrial design and engineering, rapid prototyping, rapid manufacturing, and graphic design, while continually priding themselves on artistry and craftsmanship. Understanding the nuances of each
material used within their shop, as well as the best finishing techniques, is critical to ensuring high product standards.

However, when it came to finishing Stereolithography (SLA) 3D printed parts, Empire Group faced bottlenecks that prohibited them from finishing parts as quickly as they wished. Though SLA 3D printing is acclaimed for its highly accurate part builds and cost-effectiveness, there is still a myriad of post-printing challenges that this technology produces.

In the case of Empire Group, resin removal with solvents and manual labor escalated into a more critical issue as the company grew. While the workload and number of printers increased, it was obvious that without an automated solution, the amount of time dedicated to post-printing would as well.

To keep their additive workflow moving smoothly, they implemented the automated PostProcess™ DEMI™ resin removal solution with proprietary SLA-formulated detergent. The DEMI utilizes agitation algorithms for software-controlled technology to swiftly remove excess resin, even in the narrowest of channels. This patent-pending technology, Submersed Vortex Cavitation (SVC), ensures consistency and prevents part damage while software controls the process.

Example SLA part

DELIVERING SWIFT RESULTS

Developed specifically for additive manufacturing, PostProcess’s comprehensive solution delivered almost immediate benefits to Empire Group’s bottom line. The longevity of the PostProcess chemistry compared to the previously-used solvent (isopropyl alcohol) resulted in a quick positive ROI.

Empire Group has found the PostProcess DEMI to shine, especially when post-printing intricate parts or high-volume production of small parts. Now that they are able to handle resin removal in a fraction

of the time and spend less downtime on chemistry change-outs, the engineers and technicians at Empire Group can direct their energy on more value-added task such as quoting out orders, performing maintenance, build tray optimization, and more.

PostProcess’s software-driven solution has unlocked improvements across the board for Empire Group, on average reducing their SLA resin removal times by at least 50%, sometimes more.

Katie Marzocchi, Marketing Manager at Empire Group, said, “We’ve been in the additive realm for quite a while now, and in just a short time, the DEMI has optimized our workflow in the ways that matter most. From improving our bottom line and enabling scalability within our operation to reducing lead times and passing cost-savings on to our customers, the PostProcess solution is essential in helping us deliver high-quality products and service every time. We look forward to continuing our growth as a cutting-edge product development company, now with the DEMI in our tool belt.”

PostProcess™ DEMI™ Resin Removal Solution

About Empire Group
Empire Group is a full-service product development company located in Attleboro, Massachusetts. For over 20 years, we have been a trusted and dependable partner for our customers. Companies on the East Coast, and across the US, that are in the consumer goods, defense, medical device, aerospace/aviation, automotive, juvenile, and toy industries rely on us for our knowledge, experience, and wide range of services. For more information, visit www.empiregroupusa.com.

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. For more information, visit www.postprocess.com.

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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3D Printing Provides Innovation for Nearly Century Old Manufacturer

Article by: Peter Fretty Jul 15, 2020

As we have covered in recent months, COVID-19 played a pivotal role putting additive manufacturing on the map for manufacturers who otherwise had not taken its potential role seriously. For those willing to explore, additive has been enabled companies to speed up the prototyping process, enabled manufactures to build tooling without traditional delays. Of course, the true wins occur when the maturing technology enables meaningful innovations. And, true innovation often comes from the places you least expect.

Case in point: For more than 90 years, John Zink Hamworthy Combustion has operated on the outskirts of Tulsa, Oklahoma, building emissions control and clean air combustion systems, which production facilities around the world depend on to meet or exceed emissions standards. The company custom engineers burners, gas recovery and vapor control systems for a wide variety of energy, petrochemical and manufacturing customers.John Zink is a globally recognized leader in this space, but 21st century emissions problems require 21st century solutions. To help their customers meet rigorous environmental and efficiency standards, John Zink, a part of Koch Industries, recently invested in metal 3d printing technology from Desktop Metal to create parts that are engineered-to-order and optimized for each customer’s specific application.

“Engineers and designers are now able to create the designs they need to optimize each part’s function. In the past, tooling severely limited — and often strong-armed — design creativity. With 3D printing on our Studio System, designers can now transform their square peg/square hole mentality into free-form configurations and even complex geometries like fluted octagons,” Jonah Myerberg, CTO of Desktop Metal tells IndustryWeek. “This is a game changer for the industry as a whole, allowing companies like John Zink to produce custom, on-demand parts faster, cheaper and often times more optimal than with traditional means.”

After several months of working with the Desktop Metal Studio System, the world’s first office-friendly metal 3D printing system for rapid prototyping and low volume production, the companies today are sharing early results of the new additive manufacturing technology, which include:

  • Quick turnaround aftermarket replacement parts;
  • The ability to test different iterations of prototype designs faster;
  • Eliminating the need for casting tooling, saving both time and money because parts can now be printed in-house; and
  • Freedom of creating part designs that cannot be manufactured by traditional methods and can only be 3D printed.

“Our primary goal at John Zink is to custom engineer new systems that eliminate waste so our customers can operate safely and efficiently,” said Jason Harjo, design manager, John Zink. “Additive manufacturing rewrites the book on what is possible from a design standpoint, and working with Desktop Metal allows us a very low-cost entry point into the technology. The versatility of the Studio System has enabled our engineers and designers to find both applications for the technology as well as design and performance benefits we hadn’t even considered.”

Fuel Atomizer–Cost Savings 75%; Time Savings 37%

As a leader in developing innovative solutions to reduce emissions,John Zink has long understood that using atomizers to improve the fuel-air mix inside burners is one easy way to help customers minimize their environmental footprint. Using the Studio System, the company’s designers and engineers were able to prototype and test a variety of options before ultimately creating a radical new design featuring sweeping, airfoil-like fins. The geometric freedom of 3D printing even allowed them to reconsider the shape of the holes -instead of drilling round holes, the part is built with flat openings to improve atomization and increase burner efficiency. Where the previous design was able to reduce fuel use to 120 kilograms per hour, the new design cut fuel use to just 38 kilograms per hour. With three burners per ship, the environmental impact across an entire fleet can be huge. The savings can be equally significant -per ship, the new atomizer could save companies between $90,000 and $160,000 in fuel costs annually, and can be produced in few days for less than half the cost of a traditionally manufactured fuel atomizer.

Fuel Atomizer customizing designed and printed with Desktop Metal Studio System
Burner Tip customizing designed and printed with Desktop Metal Studio System

YE-6 Burner Tip–Cost Savings 72%

A key component in the efficient operation of industrial burners, burner tips are used to control the injection of fuel into the combustion chamber, or as atomizers, mixing fuel with an atomizing medium like steam to increase burner efficiency. The burner tip -originally cast and post-processed via CNC machining -was first manufactured 30 years ago, and the tooling used to produce it is no longer available. Because the part is too complex to machine as a single component, manufacturing spare parts using traditional techniques would require large investments in both time and money. Instead, John Zink engineers looked to 3D printing to produce a cost-effective replacement burner tip. Using the original engineering drawings, they modeled the burner tip and printed the part on the Studio System.The finished part was produced in just weeks -as opposed to months -and cost significantly less than a cast part -just a few hundred dollars versus a few thousand dollars.

Laser Gas Nozzle–Impossible Geometry for Traditional Manufacturing

A useful tool found in many machine shops, laser cutters can make precise cuts in a variety of materials.The challenge for John Zink engineers was the cutter’s nozzle could become clogged or slag could build up on the edges of cut parts, requiring labor-intensive post-processing. The solution they found was to use the Studio System to design and print an entirely new nozzle, one that incorporates a series of internal channels to direct high-pressure nitrogen gas across the cuts and blow away slag, preventing clogs and ensuring cleaner cuts. The complex geometry of the new nozzle could only be made using additive technology, and was printed in metal after an earlier version -printed from PLA plastic -melted at higher temperatures. Machine Tool Handles–When Plastic Just Won’t WorkAdditive technology has helped John Zink engineers recreate legacy parts and redesign existing parts, as well as helped them find creative solutions that improve how they manufacture those parts. Designed by a machinist with three decades of experience at John Zink, these handles were created to make it easier to lift and place heavy tools in a lathe, and were printed using the Studio System after the initial parts -printed in plastic -broke. The handles were printed rather than machined to minimize waste -each handle would have to be made from a relatively large piece of metal -and to leave machine shop capacity free for customer jobs.

Safety Shutoff Yoke and Handles–Less Down Time with Huge Savings

A key piece of safety equipment, this shutoff yoke and handles are installed on the USS Blue Ridge (LCC-19), which provides command, control, communications, computers, and intelligence support to the commander and staff of the United States Seventh Fleet. Because no tooling exists for this part, creating them via 3D printing was the most time-and cost-effective option for manufacturing. For customers, the payoff has come in less down time -printed parts can be in their hands and installed in days rather than weeks or months -and significant savings, both in part costs, and in fuel, thanks to innovative new designs that can only be manufactured via 3D printing.

“By eliminating the need for hard tooling with the Studio System,John Zink engineers have been able to produce innovative new parts, reproduce parts for which tooling no longer exists and find creative solutions to improving their workflow,” said Myerberg. “As a result, their team has been able to significantly speed up the design, manufacture and deployment of parts, while saving money and delivering parts faster to customers.”

According to Myerberg, as companies like John Zink look to expand their Additive Manufacturing capabilities, adopting additional technology like the Desktop Metal Shop System will help “broaden their portfolio, taking them from prototyping and aftermarket replacement parts to true mid-volume production runs of complex metal parts. Expanding their product portfolio will open up even more opportunities to provide the right solutions to their customers and further reduce costs.”

Please do read the official article here and you can also download the official E-Book by Desktop Metal here.

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Lino3D will participate in Nanotexnology 2020, 4-11/7 in Thessaloniki

We are proud to announce you that Lino3D will participate in the upcoming Nanotexnology 2020 Conference in Thessaloniki.

We are expecting you in the official Nanotexnology 2020 exhibition from 6th to 10th of July. Come visit us at our booth and learn more about how Nanotexnology and 3D printing are two technologies inextricably linked.

Do not miss our Presentation on Nanotexnology 2020 Virtual Event on Wednesday, 8th of July.

Check the event’s program on https://www.nanotexnology.com/

See you in Thessaloniki!

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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.

Read original article here.

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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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