Shapeways, a leader in powering digital manufacturing, continues to disrupt the traditional manufacturing market through end-to-end digitization and automated workflows that lower manufacturing barriers, alleviate critical supply chain bottlenecks and speed delivery of quality products worldwide. The company’s purpose-built software, proven production capabilities and global network of certified printer, materials and manufacturing partners are transforming manufacturing while boosting supply chain resiliency.
“Global supply chains continue to face massive disruptions caused by unforeseen events—from a traffic jam at the Suez Canal to a year-long pandemic that upended sourcing, procurement and production,” said Miko Levy, chief revenue officer of Shapeways. “Digital manufacturing is the key to meeting escalating demands for supply chain resilience with unprecedented agility and flexibility.”
Ford and HP are looking to make 3D printing technology more sustainable. The giants of industry are teaming up to reuse spent 3D printing parts and powders for vehicle parts, minimizing waste in the process.
Ford and HP are testing the process by making injection-molded fuel-line clips for the Ford F-250 Super Duty. According to Ford, the recycled parts are lighter, less expensive, and more resistant that conventional fuel-line clips. Because the project has panned out successfully so far, Ford is looking to bring its innovation to as many as 10 new vehicles.
The push toward going all-in on EVs creates a natural pivot point to leverage industrial 3D printing, also known as additive manufacturing.
In the past year, we’ve seen a drastic shift across the automotive industry and among consumers with a growing appetite for electric vehicles.
General Motors, Ford and other OEMs have made recent announcements signaling they’re pursuing EVs more heavily. President Biden signed an executive order requiring the replacement of the entire fleet of federal vehicles, about 645,000 cars, trucks, and vans, with U.S.-made electrics.
This push toward going all-in on EVs creates a natural pivot point to leverage industrial 3D printing, also known as additive manufacturing (AM). Here’s why:
A dynamically controlled surface with moving metal platforms can cut material usage in 3D printing by reducing the need for “wasteful” printed supports, its developers have said.
Printing times could also be shortened thanks to the new technique, said the researchers from the University of Southern California (USC).
As conventional 3D printers create custom objects layer-by-layer, they often need to print supports to balance the product. These supports are manually removed after printing, which requires finishing by hand and can result in shape inaccuracies or surface roughness. The materials the supports are made from often cannot be reused, so they are discarded and contribute to the growing problem of 3D-printed waste material.
Ultimaker has released its 2021 3D Printing Sentiment Index (3DPSI), showing that awareness and adoption of 3D printing went up during 2020, and that companies used it in a more integrated way. While the study doesn’t delve into the reasons behind these developments, Ultimaker anecdotally linked them to the challenges posed by COVID-19 and a disrupted global supply chain.
The 3DPSI covers three broad categories: sentiment, awareness, and adoption. Awareness covers how much people know about 3D printing, sentiment covers whether people feel 3D printing is or will be useful, and adoption covers how much people are already using it at their workplaces.
This year’s 3DPSI was conducted online by independent research firm Savanta in December 2020. It polled 2,525 professionals across diverse fields like healthcare, manufacturing, architecture and education. These professionals came from twelve “key markets” across the world: the US, Mexico, United Kingdom, Germany, France, Switzerland, Italy, the Netherlands, China, Japan, South Korea and Australia. Both South Korea and Australia were new this year.
Manufacturing system provider Ingersoll Machine Tools has partnered with aviation company Bell to 3D print a 22 foot-long vacuum trim tool – a mold used for the production of helicopter rotor blades.
The project, which resulted in major lead time savings, was completed using Ingersoll’s own large-format hybrid MasterPrint system, a gantry-based 3D printer with integrated 5-axis milling functionality. According to Ingersoll, the MasterPrint is the largest polymer 3D printer in the world. Designed specifically for the production of extra-large production parts, the system can be found at Ingersoll’s headquarters in Rockford, IL.
“We are continuously testing and advancing MasterPrint in our Development Center” said Chip Storie, CEO at Ingersoll. “Among Ingersoll’s short-term objectives is for MasterPrint to 3D print molds for aerospace that preserve the geometrical properties and tolerances, vacuum integrity and autoclave resilience normally obtained with traditional technology, but with the cost and time reduction only additive manufacturing can offer. The relentless progress our MasterPrint process has made in 2020 has finally made this target attainable.”
Swedish aerospace and defense company Saab has successfully conducted a flight test that has shown how additive manufacturing can be used to repair battlefield damage on its Gripen fighters.
The test flight, which took place at Saab’s facilities in Linköping, Sweden on March 19 marks the first time an exterior 3D-printed part has been flown on a Gripen, rather than internal 3D-printed components.
The Gripen was fitted with a replacement hatch that had been 3D-printed using additive manufacturing, using a nylon polymer called PA2200.
The project is a step towards 3D-printed spares being used for rapid repairs to fighter aircraft that have sustained damage while deployed on remote operations, thereby gaining a vital time-saving advantage, said Saab.
Relativity Space has the audacious goal of 3D printing 95 percent of a rocket and sending it to orbit. Getting to space is hard. But completely reinventing how rockets are manufactured at the same time? Harder. Six-year-old upstart Relativity may nail both by the end of this year.
After several years designing, building, and testing their Terran 1 rocket, they’re nearly ready to roll. This week the company gave Ars Technica a progress report—and included a pretty visual.
DNV GL, a global certification and risk management firm, has released a new 3D printing service specification document aimed at supporting additive manufacturing in the oil and gas industry.
Specification DNVGL-SE-0568 defines DNV’s additive manufacturing qualification scheme and provides details on how to obtain and retain a number of the company’s 3D printing-related certificates. This includes certificates that endorse facilities and digital manufacturing services, and certificates that qualify manufacturers, build processes, 3D printers, parts, and personnel.
The document was developed in accordance with industry standard DNVGL-ST-B203, which DNV previously created for metallic components in the energy sector. As such, the specification is ultimately intended to help the industry in adopting metal 3D printing in a safe and efficient manner.
Ford teamed up with HP to reuse spent 3D printed powders and parts, thus closing a supply chain loop and turning them into injection-molded vehicle parts. The recycled materials are being used to manufacture injection-molded fuel-line clips installed first on Super Duty F-250 trucks. The parts have better chemical and moisture resistance than conventional versions, are 7% lighter and cost 10% less. The Ford research team has identified 10 other fuel-line clips on existing vehicles that could benefit from this innovative use of material and are migrating it to future models.
Sustainability is a priority for both companies, which, through joint exploration, led to this unlikely, earth-friendly solution. The resulting injection-molded parts are better for the environment with no compromise in the durability and quality standards Ford and its customers demand.
“Finding new ways to work with sustainable materials, reducing waste and leading the development of the circular economy are passions at Ford,” said Debbie Mielewski, Ford technical fellow, Sustainability.