Designfax weekly eMagazine

Subscribe Today!

Archives

View Archives

Partners

Manufacturing Center
Product Spotlight

Modern Applications News
Metalworking Ideas For
Today's Job Shops

Tooling and Production
Strategies for large
metalworking plants

Full-color 3D-printing Design Guide from Xometry

With Xometry's PolyJet 3D-printing service, you can order full-color 3D prints easily. Their no-cost design guide will help you learn about different aspects of 3D printing colorful parts, how to create and add color to your models, and best practices to keep in mind when printing in full color. Learn how to take full advantage of the 600,000 unique colors available in this flexible additive process.
Get the Xometry guide.

Next-gen SLA materials rival traditional thermoplastics

Formlabs has announced two new SLA materials that bring 3D printing significantly closer to being a manufacturing method for end-use part production. Tough 1000 Resin and a significantly improved Tough 2000 Resin join Tough 1500 Resin, forming the new Tough Resin family. These resilient engineering materials stand up to harsh environments, impact, and repeated wear, all while delivering a dark, matte surface finish with crisp details when printed on Form 4 Series 3D printers.
Learn more.

Surface inspection: From Army depot to factory floor

Born from U.S. Army requirements for rotorcraft inspection, the GelSight Modulus 3D surface measurement system has surpassed 100 units sold to commercial and Department of Defense customers. The handheld, micron-scale tool with interchangeable probe tips delivers fast, high-res measurements in places traditional tools can't reach.
Read the full article.

What is Cold Metal Fusion?

Cold Metal Fusion is an open industry standard for sinter-based metal additive manufacturing. It combines polymer SLS design freedom with reliable debinding and sintering workflows, enabling complex geometries, lightweighting, lattice structures, conformal cooling channels, and high-precision metal parts with predictable shrink behavior. Now available from TriMech Group, this process offers a faster, cost-effective way to produce strong, high-performance metal parts.
Learn more from TriMech Group.

Metal 3D printing: EOS adds four new materials

Industrial 3D-printing supplier EOS has added four new metal additive manufacturing materials to its portfolio: an iron-nickel alloy that boasts stability under fluctuating temps, a nickel alloy with high strength and extreme corrosion resistance, a low-alloyed steel prized for its high toughness and strength, and an industrial-grade stainless steel. Each has been optimized for EOS Laser Powder Bed Fusion systems.
Get all the details.

New materials and finishes from Quickparts

Quickparts has introduced DuraKor, ThermaKor, and vapor smoothing to expand its production-capable materials and finishing portfolio. The new plastics provide polypropylene-like toughness, chemical resistance, and high-temperature stability, while vapor smoothing improves sealing and surface quality. Together, these capabilities help engineers validate designs, refine performance, and transition efficiently from prototypes to scalable manufacturing.
Learn more.

What's the latest in SLA 3D printing?

Learn about the latest offerings in SLA printing from 3D Systems, including the introduction of SLA 825 Dual, the company's most advanced large-frame Stereolithography printer. Other new products include ArrayCast investment casting software that allows users to effortlessly create customized casting trees (complete with configurable runners, sprues, and end effectors), Accura SbF (the latest SLA casting resin), and Accura Xtreme Black (which delivers low shrinkage, large, functional SLA prototype parts with sharp detail).
Learn about all the new 3D Systems products.

meviy cuts CNC milling lead times to just 4 days

meviy, the on-demand custom parts manufacturing service developed by MISUMI Group, has upgraded its Expedite+ service with improved lead times for CNC Milled parts. Customers can now have their parts shipped in as few as four days through meviy's fastest delivery option. The enhanced service helps manufacturers and engineers stay on schedule when projects are behind or production is interrupted. Supported materials include steels and aluminums. Check out their instant quoting too.
Learn more.

Top Tech Tip: How do you 3D print STL files?

Learn the basics of 3D printing STL files -- the files that serve as the digital foundation for 3D printing -- and a whole lot more from the experts at Xometry. These files have advantages, of course, but did you know they have disadvantages too? Also learn about STL tools and programs, and how to reduce file size or even repair a file you are having trouble with.
Read the Xometry article.

When metals can't survive: Machined ceramics as an alternative

Technical Ceramics are so hard and wear resistant that they cannot be machined with conventional tools -- but they can outlast and outperform other materials in demanding or harsh applications. INSACO's proprietary diamond grinding process and specialized techniques developed over many decades allow the company to produce and document parts to exacting specifications consistently. Learn all about the alternatives you have when metals just can't take it.
Read the INSACO article.

Metal 3D printing: Right at your desktop

From prototyping to tooling or batch production of end-use parts, the Studio System 2 from Desktop Metal brings metal 3D printing to any office, studio, or lab setting. This powder- and laser-free system consists of an easy-to-adopt two-step process: print using pre-bound metal rod feedstock and then sinter. It requires minimal training and operator intervention. Combined with next-gen Separable Supports and a software-controlled workflow, the Studio System makes metal 3D printing simpler than ever. This platform offers more materials than any other metal extrusion 3D-printing system on the market. They include Inconel 625, titanium (Ti64), copper, tool steels, and stainless steels.
View the video and learn more.

New lightweight compound for structural car parts

Following four years of collaboration with the University of Toronto, Axiom is proud to announce the creation of AX Gratek PP40 -- a groundbreaking lightweight, high-strength alternative to heavy glass-filled 40-60% PP components. This hybrid composite features graphene nanoplatelets with glass fibers. Patent pending, this material has achieved up to 20% improvement in tensile strength while achieving an impressive 18% weight reduction compared to commercial PPGF60% parts.
Learn more.

Print parts in M300 tool steel: Starter kit

Take your 3D printing to the next level with M300 Tool Steel Filamet™ -- a high-strength and wear-resistant material. Virtual Foundry has released a brand-new M300 Tool Steel Kit packed with everything you need to get started, including: 0.5-kg starter filament spool, Filawarmer, 1 kg of steel blend, 0.5 kg of sintering carbon, and an alumina crucible. From the company that brought us 3D-printable lunar regolith simulant.
Learn more, including print instructions.

New laser-weldable PPS plastic

Polyplastics has launched a laser weldable DURAFIDE^® PPS grade with high transmittance. DURAFIDE PPS 1120LW1 (tentative name) utilizes a unique transmittance improvement technology. Although PPS has traditionally been considered difficult to use for laser welding, this new material expands the possibilities for applying laser welding to parts that previously had limitations in terms of heat and chemical resistance. This material is so new you may want to talk to someone at the company.
Learn more.

Expert design tips and tricks for 3D printing

Join Xometry's 3D-printing experts, Greg Paulsen and Matt Schmidt, as they reveal practical strategies to help you optimize your designs, improve print quality, and reduce costs across your 3D-printing projects. Learn about file-prep best practices, how to reduce costs on 3D prints, key design considerations when working on tolerance or resolution, and much more. Lots to learn here.
View the video.

Renishaw introduces metals additive manufacturing systems designed for rapid material changeover

Renishaw's new laser melting additive-metal manufacturing process is capable of producing fully dense metal parts direct from 3D CAD data using a high-powered fiber laser. Parts are built layer by layer, in thicknesses ranging from 20 to 100 microns, using a range of fine metal powders that are fully melted in a tightly controlled atmosphere.

The current range of machines utilizes a third-generation design representing state-of-the-art manufacturing technology. Key features include variable powder delivery, ultra-low oxygen content in the build atmosphere, and an unparalleled safe-change filter system to minimize user contact with materials.

Two systems are available: the AM125 and the AM250. Both feature vacuum technology and low gas consumption. Both utilize "machine tool" engineering in design, operation, and serviceability, emphasizing ruggedness and ease of operation. The touch-screen operator interface includes menu options for machine preparation and clean down. Consumable costs are minimized through features such as the soft re-coater blade that can be rotated several times before replacement, use of low-cost filter elements, and low gas consumption - all of which improve system reliability and cost of ownership.

Renishaw additive-metal systems process a wide variety of materials, including 316L and 17-4PH SS, H13 tool steel, aluminum Al-Si-12, titanium CP, Ti-6Al-4V and 7Nb, cobalt-chrome (ASTM75), and Inconel 718 and 625. Both systems are designed for rapid material changeover, with the AM125 utilizing a cassette-type materials delivery system and the AM250 a removable hopper - particularly useful for materials development or use of a range of materials. To enhance productivity, a valve interlock on the AM250 allows addition of extra powder while the process is running. Safe processing of reactive materials, such as titanium and aluminum, is ensured with features such as a gas knife that clears away reactive, sooty emissions, and a heated build plate.

The AM125 provides a part-build volume of 125 x 125 x 125 mm (X, Y, Z), and the AM250 provides 250 x 250 x 300 mm (X, Y, Z) with Z-axis extendable to 360 mm. Both have build rates of 5 to 20 cubic cm per hour, dependent on the material, part density, and geometry. The AM125 offers a choice of 100- or 200-W laser, and the AM250 a 200- or 400-W laser.

Both the new machines feature a fully welded vacuum chamber, enabling low-pressure evacuation followed by a recharge with high purity argon gas. Gas consumption, after the initial chamber flood, is extremely low, and allows operation at oxygen concentrations below 50 parts per million - crucial when processing reactive materials, and contributing significantly to material integrity and mechanical performance.

All file preparation is completed off-line through a choice of interface, either Marcam Autofab software or Materialise Magics. Once complete, the build file is uploaded to the machine via a secure network or direct connection. Product traceability has been improved by the addition of process data and event logging as standard, with various additional process control options on request.

Source: Renishaw

Published August 2012

Rate this article