How to choose the right 3D printing material?

How to choose the right 3D printing material?

by | Oct 4, 2024 | Blog

If you decide to 3D print a design, one of the first questions you need to ask yourself is; which filament am I going to use? There is a wide range of filaments available and as a beginner, it can be overwhelming. This blog will help you choose the right filament for your application, so you can be sure you’re getting started with the right filaments.

Who will use the 3D printer?

One of the first considerations when choosing filament is the user of the 3D printer. This is because not every filament is easy to print. For beginners, we recommend PLA or ABS. PLA is the ultimate entry-level material. A print with PLA can hardly fail. If you use the default settings of our dddrop RAPID ONE, it delivers perfect results. ABS is also suitable for beginners, but it is advisable to gain some experience with PLA first before switching to ABS.
Serial production in 3d printing
Filaments such as PETG and FLEX, on the other hand, are more suitable for experienced users. These materials require precise adjustments, where small adjustments can already have a big impact on the print. We therefore recommend gaining a sufficient understanding of the printing process before working with these more complex filaments.

How warm is the environment in which the design is used?

When printing objects exposed to high temperatures, you need to choose the right material that can withstand heat. Each filament has a specific glass temperature – the point at which the material starts to soften. This is crucial when choosing the right filament.

For applications where your object will encounter heat, such as near a heat source or in direct sunlight, ABS is a good choice. It has a high glass temperature of 110°C, which makes it resistant to boiling water and other heat sources. PETG is slightly lower with a glass point of 90°C and is less able to withstand extreme temperatures. PLA and FLEX are the least heat-resistant, with a glass temperature around 60°C.

What are you going to print?

Ultimately, everything revolves around the application of your printed object. What you will print determines which filament is best to choose. Each material has its own strengths and weaknesses, suitable for different purposes. Below, we briefly discuss three popular filaments.

PLA (Polylactic Acid)

PLA is strong and rigid, allowing it to withstand large forces without stretching. The downside is that PLA can break on impact, just like glass. It is therefore mainly suitable for visual models, but not for mechanical parts. PLA is easy to print, energy-efficient thanks to its low print bed temperature of 60°C, and a perfect choice for visual models.
pla filament 1.75mm 5kg

ABS (Acrylonitrile-Butadiene-Styrene)

ABS is more flexible than PLA and is less likely to break when dropped. It is therefore ideal for functional parts and industrial applications. For example, ABS is widely used in the automotive industry for parts such as dashboards and bumpers. One drawback is that ABS emits an unpleasant odour during printing. For use in office environments or at home, we recommend using a well-ventilated room, or choosing odourless filaments such as PLA or PETG.

abs filament kopen

PETG (Polyethylene Terephthalate Glycol)

PETG is both strong and flexible and can be stretched up to twice its own length without breaking. This unique combination makes it suitable for parts that move repeatedly or are under pressure. PETG is also approved for applications in the food industry, making it perfect for packaging, for example. Moreover, PETG can withstand high pressure without deforming, making it an ideal choice for various functional applications.

Conclusion

Which filament you choose will depend on your experience, the environment in which the object will be used and your print requirements. As a beginner, it is best to start with PLA because of its easy print settings and versatility for sight models. For functional parts or applications where heat resistance is important, ABS is a good choice. PETG offers flexibility and strength, ideal for moving parts or food applications. Want to work with flexible materials? Then choose FLEX, but make sure you have gained enough experience, as printing them requires more precision. This way, you will always have the right filament for your project!
10 tips on designing for additive manufacturing (FDM 3D printing)

10 tips on designing for additive manufacturing (FDM 3D printing)

by | Jul 29, 2024 | Blog

Additive manufacturing, in particular Fused Deposition Modeling (FDM) 3D printing, has transformed the way engineers approach design and production. By allowing for complex geometries and reducing the need for traditional manufacturing limitations, FDM opens up a world of possibilities. However, to use this technology to its full potential, it’s crucial to follow best practices in design. Here are 10 tips to help you optimize your designs for FDM 3D printing.

1. Understand material properties

The first step in designing for FDM is understanding the properties of the materials you’ll be using. Common materials include PLA, ABS, PETG, and TPU, each with its own strengths and weaknesses. For example, PLA is easy to print and biodegradable, but it’s less heat-resistant. ABS is stronger and more heat-resistant but can be prone to warping. Knowing the characteristics of your material can influence your design choices significantly.
Serial production in 3d printing

2. Optimize for layer adhesion

Layer adhesion is a n important factor in FDM printing. Poor adhesion can lead to weak parts and print failures. To improve adhesion:

Increase surface contact: Design flat surfaces that maximize contact between layers.
Avoid overhangs: Where possible, minimize overhangs or design them with support structures in mind.
Adjust infill: Use higher infill densities in critical areas to enhance structural integrity.

3. Conside print orientation

The orientation of your part on the print bed can greatly impact the final strength and surface finish. Parts printed with layers aligned along the direction of stress are typically stronger. Experiment with different orientations to find the best balance between strength, print time, and surface quality.

4. Use appropiate wall thickness

Thin walls can lead to weak and fragile parts, while overly thick walls can result in unnecessary material use and longer print times. A wall thickness of 1.2mm to 3mm is generally effective for most FDM applications, balancing strength and material efficiency.

5. Incorporate support structures wisely

Support structures are often necessary for complex geometries but can be difficult to remove and may affect surface finish. Design with support removal in mind:

Use support-friendly angles: Overhangs of 45 degrees or less typically do not need supports.

6. Optimize overhangs and bridges

Overhangs and bridges can be challenging in FDM printing. To ensure successful printing:

Limit overhang angles: Keep overhangs below 45 degrees when possible.
Use fillets and chamfers: Instead of sharp overhangs, use chamfers and use fillets for corners in the X and Y plane to reduce stress.
Bridge distances: Keep bridges short and ensure your printer settings are optimized for bridging.

7. Account for shrinkage and warping

Different materials have different rates of shrinkage and warping. ABS, for example, has a higher shrinkage rate than PLA. To mitigate these effects:

Use brims and rafts: These can help parts adhere to the bed and reduce warping.
Design compensation: Incorporate allowances in your design for shrinkage, particularly in larger parts.

8. Integrate snap-fit joints and threads

FDM printing allows for the integration of functional components like snap-fit joints and threads directly into your design:

Snap-fits: Design with precise tolerances to ensure a snug fit without causing stress concentrations.
Threads: Use standardized thread designs and consider post-processing like tapping to ensure accuracy.

9. Leverage infill patterns

Infill patterns can significantly impact the strength, weight, and print time of your part. Common infill patterns include honeycomb, grid, and gyroid. Each pattern has its own advantages:

Honeycomb: Good balance of strength and weight.
Grid: Simple and quick, offering decent strength.
Gyroid: Excellent strength and stiffness, but may increase print time.

10. Test and iterate

Finally, always test your designs and iterate based on real-world feedback. Even the best-designed parts can have unforeseen issues when printed. By continually testing and refining your designs, you can achieve optimal performance and reliability.

Conclusion

Designing for FDM 3D printing involves a blend of creativity and technical knowledge. By following these tips, you can create parts that are not only functional and robust but also efficient to produce. Remember, the key to successful additive manufacturing is continuous learning and adaptation.
Get in touch!   Curious about industrial 3D printing? Reach out to one of our team members to learn more!    
In-house 3D printing or outsourcing: which option is best for you?

In-house 3D printing or outsourcing: which option is best for you?

by | Jul 26, 2024 | Blog

3D printing is becoming more and more popular, and businesses everywhere are trying to figure out if they should invest in their own 3D printers or outsource their printing needs. This decision can really affect how your company operates, spends money, and innovates. Let’s dive into the pros and cons of in-house 3D printing versus outsourcing, so you can decide what’s best for you.

1. Cost considerations

Initial Investment: Purchasing your own 3D printer translates to a higher initial investent. Industrial, large-format 3D printers can cost anywhere from $10,000 to $100,000 or more.

Operational Costs: After you purchase the printer, printing in-house often is cheaper per part, especially if you print frequently. Outsourcing, however, means you don’t have to spend a lot of money upfront. Service providers charge based on how complex, big, and numerous your prints are. If you only need to print occasionally or in small quantities, outsourcing might save you money.

 

Serial production in 3d printing

2. Speed and turnaround time

In-House Printing: Having a 3D printer on-site means you can print prototypes and parts quickly. This speed is crucial if getting products to market fast is important for your business. Some companies have cut their product development time by up to 50% with quick in-house prototyping.

Outsourcing: While outsourced services often have advanced equipment and expertise, shipping and handling can slow things down. Depending on the provider and your location, it could take anywhere from a few days to several weeks to get your parts.

3. Flexibility and control

In-House Printing: Owning your own 3D printer gives you complete control over the printing process. You are able to experiment with different materials, designs, and techniques whenever you want, withoutbeing tied to an external schedule. This flexibility often leads to more innovation and faster iterations.

Outsourcing: Outsourcing allows you to scale up or down based on your project needs without worrying about equipment limitations. However, you might have less control over the process and quality, as you’re dependent on the service provider’s standards and practices.

4. Confidentiality and intellectual property

In-House Printing: Printing prototypes and parts in-house minimizes the risk of intellectual property theft or confidentiality breaches. Sensitive designs and proprietary information stay within your company’s secure environment.

Outsourcing: When you outsource, you have to share your designs with third parties, which can pose risks to your intellectual property. Make sure the service provider has strict confidentiality agreements and secure processes.

Conclusion: making the right choice

Deciding between in-house 3D printing and outsourcing depends on your specific business needs, budget, and long-term goals. Here are a few questions to help guide your decision:

  1. How often do you need 3D printed parts?
  2. What’s your budget for initial investment and ongoing costs?
  3. How critical is turnaround time for your projects?
  4. How important is confidentiality and control over the printing process?
If you frequently need 3D printed parts and can afford the investment in equipment and training, in-house printing offers speed, control, and potentially lower long-term costs. On the other hand, if you have occasional needs or a limited budget, outsourcing gives you access to high-quality prints and expert services without a big upfront investment.

Ultimately, the choice between in-house 3D printing and outsourcing is a strategic decision that can drive innovation and efficiency in your operations. By carefully evaluating your needs and resources, you can make an informed decision that aligns with your business goals.

Get in touch!   Curious about industrial 3D printing? Reach out to one of our team members to learn more!    
Your Plastic Solutions – Optimized production with the dddrop RAPID ONE

Your Plastic Solutions – Optimized production with the dddrop RAPID ONE

by | May 2, 2024 | User Story

Who is Your Plastic Solutions?

Located in the Achterhoek, Your Plastic Solutions is a prominent player in the plastic processing industry, focusing on sustainable solutions for various sectors such as logistics, mobility, packaging and construction. As a total partner, Your Plastic Solutions offers an extensive range of manufacturing technologies, including 3D printing, thermoforming and injection molding, as well as assembly and post-processing, giving customers a one-stop-shop experience.

3D Printing in the plastics industry

One of the technologies that has boosted Your Plastic Solutions’ manufacturing efficiency is the dddrop RAPID ONE 3D printer. This advanced printer allows them to produce large parts that are not feasible with smaller 3D printers, allowing them to meet their customers’ specific requirements.

“We use FDM printing because it is inexpensive and quite fast,” says Sander Feuler of Your Plastic Solutions. “With the dddrop RAPID ONE, we do not suffer from high entry costs as with traditional injection molding processes because we can produce immediately without the need for molds.”

Local partner with excellent service

Choosing dddrop as a partner was a logical step for Your Plastic Solutions because of their need for a local partner offering high-quality 3D printing solutions. During the 2.5 years of collaboration, they have experienced the benefits of dddrop’s close cooperation and excellent service. “When we started with the dddrop RAPID ONE, we did not think we would go for a second one after only 1.5 years,” notes Sander. “But that has turned out differently. What our future will hold, we don’t know yet. But if we need a third one, we will gladly come back to dddrop.”

“When we started with the dddrop RAPID ONE, we did not think we would go for a second one after only 1.5 years. If we need a third 3D printer, we will gladly come back to dddrop.”

Sander Feuler, Your Plastic Solutions

With the dddrop RAPID ONE, Your Plastic Solutions has not only increased their production capacity, but also strengthened their competitive position by quickly and cost-effectively delivering high-quality plastic products to their diverse customer base.

Explore more about Your Plastic Solutions at yourplasticsolutions.com.

Optimising serial production with 3D printers

Optimising serial production with 3D printers

by | Mar 13, 2024 | Blog

In an era when speed and efficiency are the backbone of industrial activities, series production is central to the quest for competitive advantage. The landscape of manufacturing processes is constantly evolving, and one of the most notable innovations driving this revolution is the rise of 3D printing.

Change in the way of serial production.

Traditional methods of serial production were characterised by complex and time-consuming processes, with significant overheads and limitations on design freedom. But 3D printing has broken these conventional boundaries by adding a new dimension of flexibility and speed.

With 3D printing, manufacturers can realise complex geometries with unprecedented precision and reproducibility. This opens the door to new design possibilities previously unthinkable, allowing products to be optimised for performance and functionality.

Serial production in 3d printing

Efficiency as a key point

Efficiency is the backbone of serial production, and 3D printing offers a range of benefits that enhance this efficiency. By eliminating tooling costs and minimising raw material wastage, 3D printing significantly reduces operational costs. Moreover, it enables on-demand production, which can optimise inventory levels and avoid excess inventory.

In addition, 3D printing enables manufacturers to take advantage of digital design and manufacturing processes. Through the use of advanced simulation software, designs can be validated before printing, identifying errors at an early stage and avoiding costly revisions. This reduces development time and accelerates time-to-market, giving companies a competitive advantage.

Quality and consistency

While speed and efficiency are vital, this should not come at the expense of quality and consistency. 3D printing, however, offers a high level of reproducibility, with each printed part being identical to the original. This reduces variability in the production process and ensures consistent quality of final products.

Moreover, the digital nature of 3D printing enables real-time monitoring and control, allowing any deviations to be detected and corrected in a timely manner. This increases the reliability of the production process and ensures consistent results across the entire series production.

Sustainability and environmental friendliness

In addition to operational benefits, 3D printing also contributes to sustainability and environmental friendliness. By minimising waste of raw materials and using recycled materials, 3D printing reduces the ecological footprint of series production. Moreover, local production centres can be set up, reducing transport costs and emissions.

Conclusion

In an era when speed, efficiency and quality are crucial to the success of mass production, 3D printing represents a revolutionary force. By breaking the traditional boundaries of manufacturing processes, 3D printing opens up new opportunities for manufacturers to innovate and excel in a competitive market.

With its ability to realise complex geometries, reduce costs and promote sustainability, 3D printing promises to have a lasting impact on the industry. As manufacturers strive to optimise series production, 3D printing will undoubtedly be an integral part of their strategies for success in the 21st century.
Carbon fiber reinforced filaments: the power behind industrial 3D printing revolution

Carbon fiber reinforced filaments: the power behind industrial 3D printing revolution

by | Aug 22, 2023 | Blog

Incorporating carbon fiber (CF) into filaments results in remarkable improvements in strength and stiffness. The increased strength and stiffness resulting from the addition of CF contribute to an improved strength-to-weight ratio. This performance translates into the creation of components that are not only lighter but also more resilient, all while speeding up the printing process.

Read on below to discover how carbon fiber integration can benefit your manufacturing operation and why the RAPID ONE is a suitable printer for this particular material.

Understanding carbon fiber filaments

Carbon fiber-reinforced plastics (CFRP) amalgamate the commendable traits and performance characteristics of carbon fiber with the host polymer substance they fortify. By integrating carbon fiber content, the printability and user-friendliness of conventional thermoplastics like PLA, ABS, or PET acquire heightened performance attributes.

carbon fiber filmament

Chopped fibers, predominantly employed in both industrial manufacturing and 3D printing, serve as the crux. These carbon fibers are introduced either as a “filler” within thermoplastic materials for injection molding or as dedicated carbon fiber filaments tailored for 3D printers. Their processing closely resembles that of any other thermoplastic substance, albeit with additional prerequisites that will be elaborated upon subsequently.

In the realm of FFF (extrusion-based) 3D printing, chopped carbon fibers take center stage. These diminutive fibers are seamlessly blended into a standard thermoplastic matrix to serve as a reinforcing element.

The significance of carbon fiber 3D printing

Within industrial settings, specific mechanical attributes and meticulous precision often take precedence. In this context, the convergence of robust material capabilities and the myriad benefits of additive manufacturing propels carbon fiber 3D printing to the forefront. This innovative approach bestows exceptional dimensional stability upon sturdy components, accentuated by a refined surface finish and elevated heat deflection temperature. These qualities render it an optimal choice for functional, high-performance applications.

As 3D printing continues its trajectory toward broader end-use production, the demand for manufacturing both components and tooling using carbon fiber filaments is on the rise.

From molds and jigs to fixtures, tooling, high-performance race cars, specialized aerospace equipment, and professional cycling gear, the utilization of carbon fiber 3D printer filament empowers the creation of components with remarkable strength. Naturally, as a relatively novel offering in the manufacturing landscape, carbon fiber 3D printing boasts numerous advantages. However, familiarizing yourself with the specific printing requisites is prudent before embarking on your journey.

Applications of CF Filaments

Carbon Fiber 3D printing finds its most promising applications within manufacturing environments, largely attributable to its impressive strength-to-weight ratio and inherent rigidity. Principally, these materials are leveraged for the production of molds, jigs, fixtures, and tooling.

Composite and thermoforming molds

In the industrial realm, the synergy between advanced 3D printing and traditional manufacturing techniques is strikingly evident in the domain of 3D printed molds. These molds amalgamate the swiftness and intricacies of 3D printing with the scalability inherent in mold-based manufacturing. Within the realms of composite molds and thermoforming molds, the performance attributes of CF materials manifest naturally.

Composite molds are pivotal for economically producing large quantities of identical components. Aptly named, they consist of composite materials that can be intricately shaped and endure repetitive utilization, all at a considerably lower cost compared to aluminum or steel molds.

Thermoforming molds employ heat and pressure to mold a flat thermoplastic sheet into a desired form, using various heating methods. Given the requirement for enduring high-temperature cycles, CF materials present an optimal choice for delivering the specific performance capabilities essential for thermoforming molds.

Jigs, fixtures and tooling

Jigs, fixtures, and tooling are often deemed supplementary to manufacturing processes, yet they hold intrinsic significance. These aids facilitate tasks such as milling, drilling, and subtractive operations. Playing a crucial role in holding components securely during various manufacturing stages, they are increasingly being 3D printed on-site. Customizability to specific requirements and the capacity for on-demand reproduction without external reliance or replenishment underscore their prominence.

When fortified with materials like CF filaments, 3D printed jigs, fixtures, and tooling exhibit prolonged durability and heightened performance. This is particularly advantageous in terms of enduring repetitive use and maintaining overall effectiveness.

Automotive and aerospace sectors

The design flexibility afforded by carbon fiber facilitates the realization of intricate geometries that conventional methods might deem cost-prohibitive. This liberty in design expedites iterative processes and, owing to augmented stiffness and thermal stability, enables the creation of more functional prototypes. Enhanced aesthetics, encompassing intricate curvature achieved through 3D printing and improved surface quality via CF filaments, fosters innovation across automotive, aerospace, and related industries.

Advantages of carbon fiber 3D printing

Undoubtedly, one of the most widely acclaimed attributes of carbon fiber 3D printer filament is its exceptional strength, which lies at the core of its performance and allure as a 3D printing medium. Carbon fiber presents a remarkable strength-to-weight ratio, fostering high-performance outcomes while maintaining minimal material density.

Through mitigating the inclination towards part shrinkage, the elevated strength and rigidity of carbon fiber substantiate its exceptional dimensional stability during utilization. This stability stands as a vital attribute for components demanding meticulous dimensions and stringent tolerances.

In tandem with its robustness, the lightweight nature of a carbon fiber 3D printer filament is of paramount significance. The inherent lightness is a central advantage in the realm of 3D printing as a whole. The incorporation of carbon fiber materials into the equation facilitates this reduction in weight without compromising the strength that meets performance standards.

When contrasted with conventional 3D printing materials such as PLA, ABS, and PETG, carbon fiber filaments exhibit notable resilience against elevated temperatures. Carbon fiber composite materials elevate the base material’s heat deflection temperature, thereby augmenting its operational efficacy under high-temperature conditions.

CF filaments effectively minimize the visibility of layer lines, resulting in superior surface quality and tactile feedback. This diminishes the necessity for subsequent post-processing tasks like sanding.

Carbon fiber parts crafted through 3D printing exhibit exceptional form retention even when subjected to significant stress. Unlike alternative materials that compromise durability and strength in pursuit of stiffness, carbon fiber’s rigidity guarantees unwavering structural integrity.

RAPID ONE: the ultimate ally for carbon fiber reinforced filaments

The rapid one 3d printer is excels at printing carbon fiber reinforced filaments. Here are some features of the rapid one that allow it to print these challenging materials with ease:

Integrated filament dryer

A crucial feature that sets the RAPID ONE apart is the integrated filament dryer. This keeps the filament in optimal state for printing at all times, without humidity that can affect the performance and finish of the final product. This contributes to consistent and high-quality results.

Closed print booth

The RAPID ONE features a closed print booth, resulting in a controlled and elevated temperature during the printing process. This minimizes problems such as warping and delamination, which is crucial when printing complex parts with carbon fiber reinforced filaments.

Tungsten nozzle

The ability to install a tungsten nozzle eliminates nozzle wear concerns with abrasive fiber-reinforced materials. The RAPID ONE is prepared for the challenges of these materials and ensures long-term durability and reliability.

Unleash the future of 3D printing

Carbon fiber-reinforced filaments represent a revolution within the 3D printing industry, and the RAPID ONE is the appropriate printer to go along with this revolution. With advanced features such as integrated filament dryer, the ability to install a tungsten nozzle and an enclosed print booth, the RAPID ONE enables users to achieve superior results with ease with these challenging materials.

Whether you are a professional looking to produce high-quality parts or a hobbyist looking to push your creative boundaries, the combination of carbon fiber reinforced filaments and the RAPID ONE 3D printer opens the door to unprecedented possibilities. Discover the power of this technology and take your 3D printing projects to a whole new level.

5 advantages of large print volumes within industrial 3D printing

5 advantages of large print volumes within industrial 3D printing

by | Aug 11, 2023 | Blog

In the exciting world of industrial 3D printing, the technology has made significant advances and the possibilities have grown exponentially in roughly 10 years. One of the key developments that is attracting attention is the emergence of large print volumes in industrial 3D printers. This innovation has the potential to dramatically change the way we produce and manufacture. In this article, we take a closer look at 5 benefits of large print volumes in industrial 3D printing.

1. Increase in scale and efficiency

One of the most obvious advantages of large print volumes is the ability to print larger objects at one time. This offers significant advantages for industrial manufacturing, where efficiently producing large numbers of parts is crucial. With a larger print volume, manufacturers can produce larger components or multiple smaller parts simultaneously, shortening the production cycle and increasing overall efficiency.

2. Complex designs and prototyping

Large print volumes in industrial 3D printers open the door to creating complex and detailed designs that were previously impossible to achieve. This is especially valuable for prototyping, where engineers and designers can experiment with innovative designs without worrying about print volume limitations. This results in faster iterations and shorter time-to-market for new products.

3. Less assembly and material waste

Large print volumes allow manufacturers to print larger parts that might otherwise consist of multiple smaller parts. This leads to a reduction in assembly time because fewer parts need to be assembled manually. It also minimizes the need for intermediate joints or fasteners, resulting in a stronger end product. This ultimately provides a reduction in material and lowers labor costs.

4. Cost savings at scale

Although the initial investment in an industrial 3D printer with a large print volume can be significant, it can lead to significant cost savings in the long run. The ability to print larger parts or multiple parts simultaneously reduces the need for expensive mold manufacturing or CNC machining. This allows companies to streamline their manufacturing processes and save costs on both labor and materials.

5. Diversification of applications

Another advantage of large print volumes is the ability to address a wider range of applications. From large-scale prototyping and industrial components to custom production and even art and architecture. The possibilities are endless. This diversification allows companies to tap new markets and adapt to changing customer needs.

dddrop Rapid One’s scalable frame

The emergence of large print volumes in industrial 3D printing opens new doors for efficiency, complex designs, cost savings and diversification of applications. This technological development has the potential to transform the manufacturing industry and drive innovation on multiple levels.

The dddrop Rapid One is the first industrial 3D printer with a scalable print volume. Are you looking for a printer for large prints, a large batch of parts or complex prints? Request a free quote or contact us for more information!

Embraer: Innovation through Additive Manufacturing

Embraer: Innovation through Additive Manufacturing

by | Nov 10, 2020 | User Story

Embraer: Innovation through Additive Manufacturing

Embraer, the world’s third largest aircraft manufacturer, located in Gavião Peixoto in São Paulo, stands out for its disruptive innovation in additive manufacturing, using dddrop industrial 3D printers. A successful project was carried out, combining creativity and cutting edge manufacturing in composite materials through 3D printing.

Radboudumc logo
Embraer’s executive jets are varied to meet the specific and exclusive needs of customers. The interiors of these jets are carefully manufactured from composite materials and special woods. Throughout the manufacturing process, material has to be removed by using machining.
Radboudumc logo
To clean and remove debris from machining, the engineers have invented a creative solution, in which a rotational vacuum suction system was attached to the head of a robotic system. This system rotates dynamically perpendicularly towards the moving tool head. The suction unit had to be installed in a very small area and move dynamically around the Z axis, controlled by a stepper motor and a logic control unit.
Instead of opting for a traditional CNC solution, which would be costly and time consuming, the team opted for a lighter and much less time consuming solution, using the dddrop Evo Twin 3D printer and a carbon fiber nylon filament with a strength-to-weight ratio superior to steel. The result was a success.
Radboudumc logo
“For our project, the dddrop Evo Twin allowed us to use a wide variety of functional filaments ranging from wood to flexible material, soluble support material and materials with high resistance and temperature tolerance”, said José Otavio Savazzi, engineer at Embraer. “Additive manufacturing and the combination of generative design and functional composite materials play an increasingly important role in our design and manufacturing process,” he added.

Learn more about Embraer here.

Learn more about dddrop Brazil here.

Read the original article here.

Radboudumc – Technology Used To Improve Healthcare

Radboudumc – Technology Used To Improve Healthcare

by | Sep 4, 2020 | User Story

Who is Radboudumc?

Radboudumc is an academic medical center that is focused on people and their quality of life. Radboudumc specializes in patient care, scientific research, teaching and training. Their mission is to have a significant impact on health care and aim to be pioneers in shaping the healthcare of the future using personal approach and innovation. 3D printing fits very well with these ideals and is generally emerging in medicine. Radboudumc uses 3D printing for diagnostics, planning, treatment and evaluation in many different fields, such as breast reconstruction, implantology and oncology.

Radboudumc logo

3D Printing in medicine

3D printing technology is on the rise in the medical sector. More and more hospitals are acquiring 3D printers for implementation in their everyday medical practice. Imaging techniques such as computed tomography (CT) and magnetic resonance imaging (MRI) are being used to create models based on the patient’s anatomy and aid in personalized treatment. 3D printing allows far greater possibilities due to the versatility in materials, construction of complex shapes and visualization of theoretical ideas. Radboudumc utilizes 3D printing to create personalized treatment on a daily basis.

Individualized treatment

One of the 3D printing applications at Radboudumc is the electron beam radiotherapy for non-melanoma skin cancer [1]. A dddrop Leader Twin Machine is used to efficiently create a person-specific tissue equivalent material build-up, called a bolus: A CT scan is made and with it, a bolus is designed that ensures proper coverage of the tumor. A shell is created around the bolus and is 3D printed and filled up with silicone rubber afterwards. At last, the shell is removed and the bolus is ready for use during irradiation treatment.

Radboudumc application
By using 3D printing, the process of creating a personalized bolus has greatly improved. It is more time and cost efficient and more patient friendly now. These characteristics are highly desirable for the vulnerable patient group that is commonly referred for radiation therapy for non-melanoma skin cancer. No plaster face cast has to be made anymore, which is extremely time consuming, and no additional CT scans are needed for adapting the cast, which results in a lower radiation dose and less hospital visits for each patient. Overall, 3D printing provides great advantages in the treatment of patients with non-melanoma skin cancer in comparison to the previously used techniques.

Materials

Radboudumc uses PLA for the printing of the shells. PLA is the preferred material, because of its low glass transition temperature, which makes it easy to remove the silicone rubber bolus from the shell. Printing with PLA has the advantage of almost no shrinking upon cooling, which ensures that geometrical integrity is maintained during printing. In addition, PLA is low cost and biodegradable which adds to the other advantages listed above.

Radboudumc and dddrop

Ever since purchasing the dddrop Leader Twin machine in 2016, Radboudumc has kept in close contact with dddrop. They continuously use the dddrop service plan to achieve optimal printing results and get their 3D printing questions answered. dddrop is very pleased to contribute to healthcare in this way and happy to provide the support team with an opportunity to dive into medical applications that improve the lives of many individuals.

 

Learn more about various 3D printing applications at Radboudumc at https://www.radboudumc.nl/en/research/radboud-technology-centers/3d-lab. 

 

[1] Canters, R. A., Lips, I. M., Wendling, M., Kusters, M., van Zeeland, M., Gerritsen, R. M., … Verhoef, C. G. (2016). Clinical implementation of 3D printing in the construction of patient specific bolus for electron beam radiotherapy for non-melanoma skin cancer. Radiotherapy and Oncology, 121(1), 148–153. https://doi.org/10.1016/j.radonc.2016.07.011

VEDDAN – The New Way of Producing Sound

VEDDAN – The New Way of Producing Sound

by | Aug 3, 2020 | User Story

Who is VEDDAN?

Located in the Achterhoek region of the Netherlands, VEDDAN is set out to change the way people listen to music. The company develops and manufactures speakers with patented new technologies, which they believe is the “new way of producing sound”. VEDDAN has been utilizing 3D printing since the beginning of the company as a tool to realize the speaker design, and lately for production of custom made components for the VEDDAN speakers. 

3D Printing in the Music Industry

As 3D printing becomes an accessible and popular production technique, more and more industries turn to it for developments. The music industry is no different. The company founder, Andre Kamperman, envisioned a future where he can apply different principles of acoustics and sound engineering to speaker designs, which will ultimately lead to better sounding speakers and an immersive sound experience. The new, never seen before, sound generating technique had to be visualized from scratch, so naturally the company turned to 3D printing. 3D printing allowed experimentation, design correction, and rapid production of parts. The flexibility and versatility of 3D printing makes it a revolutionary tool in any industry, and allows visionaries from any background to make a change in their respective fields.

Efficient Production

As a start up company that focuses on developing a new product, there is a great emphasis on implementing efficient and reliable production methods in the assembly line. VEDDAN uses a powerful 3D printing unit, consisting of four dddrop EVO Twin machines, that allows cost-efficient rapid production and design iteration. The VEDDAN speakers utilize 3D printing to produce significant parts of the speaker in-house, rather than outsourcing the process. This allows them to oversee the quality of the parts and make quick adjustments if change has to take place, but most importantly save time with quick delivery as shipping and handling time is eliminated. In a matter of hours after finishing the 3D model design, a part can be assembled.

“We had short print runs when starting the business. Luckily, 3D printing is very flexible. You can draw something and have it the next day, so the R&D process is accelerated.”

Andre Kamperman, VEDDAN.

 

Cost also plays an important role in the VEDDAN production. The VEDDAN speakers are a premium product for sound enthusiasts, so naturally it comes with a premium price tag. 3D printing allowed VEDDAN to produce high quality and reliable parts on-demand, leading to lowering the production cost of the speaker and ultimately the retail cost for the customer. Alternatively, methods such CNC milling, press, or injection molding could have been used for these applications, however, the VEDDAN team found 3D printing to be the most cost and time efficient. Pushing production costs down, and revenue margins up.

Materials

VEDDAN put a lot of thought into choosing the right materials to use for the 3D printed parts. After testing different materials, and comparing different results, the team chose to use PET-G as the primary material for internal 3D printed parts. PET-G showed some acoustic advantages over the other materials while maintaining mechanical toughness. VEDDAN took 3D printing one step forward with a clever solution to add strength, weight and sturdiness to the speaker base, which is printed in PET-G. The base is printed with minimum to no infill and liquid epoxy is poured into the print, excelling the construction qualities while maintaining the customization properties of 3D printing. Alternatively, this part would have been CNC machined which would have increased cost and delivery times, a clever solution to a common design challenge.

VEDDAN and dddrop

The dddrop team is working alongside the VEDDAN team and provides assistance and expert input, and is proud to be a part of such an outstanding project. Implementing 3D printing allows innovators to visualize and bring incredible new designs to life that have the potential to change industries, just as the VEDDAN speaker is set to change the way we listen to music.

 Explore more about the VEDDAN speakers at VEDDAN.com

Request a quote

dddrop Rapid One 3D Printer

[contact-form-7 id="18745" title="Pop up"]
×