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Radio Flyer cuts ebike prototype time radically with Fuse X1 large-format SLS 3D printer

Radio Flyer cut prototype lead times for its Flyer Loop cargo ebike frame from two months to two days using Formlabs' new Fuse X1 SLS large-format 3D printer. "We can now print an entire Flyer Loop cargo ebike overnight and be gluing it together the next day," said Agostino LoBello, product development engineer at Radio Flyer. "I can iterate three times as often with nine times less labor." The Fuse X1 delivers production-quality parts with 50% lower costs and triple the throughput of comparable industrial systems, featuring automated powder handling and a compact, easy-to-install design. [Credit: Image courtesy of Formlabs]
View the video.

Compact industrial sand 3D printer

ExOne has launched the S-Print Pro, a compact industrial sand 3D printer that brings production-grade binder jetting to smaller foundries, pattern shops, and print service providers. Aimed at businesses competing on cost and flexibility, it handles low-volume casting, spare parts, and custom components. The system processes furan binder with silica sand, CeraBeads, or silicon carbide.
Learn more about this capable machine.

Fast-cure composite for aero and defense manufacturing

Toray Composite Materials America has launched 3960-FC, a fast-cure variant of its high-performance 3960 prepreg system for mission-critical aerospace and defense applications. This material reduces cure time by up to 45% while maintaining proven mechanical performance, stiffness, and exceptional toughness. It is highly compatible with automated manufacturing technologies like AFP and ATL, as well as traditional processing methods.
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Metal finishing: With rising carbide prices, when cermet makes sense

As critical raw material access tightens, manufacturers are rethinking cutting tool usage. While essential, carbide is often unnecessary for finishing processes. Cermet -- a ceramic-metal composite -- offers an excellent alternative, delivering exceptional fracture and wear resistance for these specific machining stages.
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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.
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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.
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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.
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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.

Heat-resistant camouflage makeup aims to shield Soldiers from bomb blasts

Camouflage face makeup for warfare is undergoing one of the most fundamental changes in thousands of years, as scientists recently described a new face paint that both hides Soldiers from the enemy and shields their faces from the searing heat of bomb blasts. Firefighters also could benefit from the new heat-resistant makeup, according to the report.

Image courtesy: Robert Lochhead]

 

 

It was part of a broader symposium on innovations in ingredients for personal care products held in August during the 244th National Meeting & Exposition of the American Chemical Society, the world's largest scientific society. The meeting included almost 8,600 reports on new discoveries in science and other topics.

Robert Lochhead, Ph.D., who presented the report, explained that Soldiers have used face paint for centuries for one kind of protection to help their skin blend in with the natural environment and shield them from enemies. The new material continues that tradition, but also provides protection from the searing heat of roadside bomb blasts and other explosions that have claimed a terrible toll in Iraq, Afghanistan, and other conflicts.

Video caption: Heat-reflective camouflage makeup made by Bob Lochhead and a team from the University of Southern Mississippi keeps the left-hand strip at below 100 degrees C after 10 sec under a blowtorch, whereas the unprotected strip reaches 400 degrees C.

"The detonation of a roadside bomb or any other powerful explosive produces two dangerous blasts," Lochhead said. "First comes a blast wave of high pressure that spreads out at supersonic speeds and can cause devastating internal injuries. A thermal blast follows almost instantaneously. It is a wave of heat that exceeds 1,112 degrees F. That's as hot as a burning cigarette. The thermal blast lasts only two seconds, but it can literally cook the face, hands and other exposed skin."

In an effort to protect soldiers from this threat, the U.S. Department of Defense has been seeking a solution that Lochhead initially regarded as an impossibility: A material that Soldiers could smear on their faces like suntan lotion, leaving a coating that although thinner than a sheet of paper, could protect against that intense heat. Dr. Paige Buchanan, Kelli Booth, Michelle McClusky, Laura Anderson, and Lochhead were the team that tackled the challenge. Not only did they succeed, but they discovered a formulation that protects in laboratory experiments way beyond the 2-sec heat-wave threat from improvised explosive devices and other bombs.

The new camouflage makeup protects the face and hands for up to 15 sec before its own temperature rises to the point where a first-degree burn, which is a mild burn, might occur. In some tests, the new face paint can protect for up to 60 sec, which could be important in giving Soldiers time to move away from blast-related fires and also for use by civilian firefighters.

The makeup had to meet several key criteria: It had to reflect intense heat; have camouflage colors suitable for day and night use; be easy to apply and remove; be waterproof; and be non-irritating to the eyes, nose, and mouth.

The trickiest part was that the University of Southern Mississippi team had to avoid the use of mineral oil, mineral spirits, fatty substances, and other traditional hydrocarbon makeup ingredients. Hydrocarbons can burn in contact with intense heat in the flame spectrum. The team turned to silicones, which are not as flammable because they absorb radiation at wavelengths outside of the intense heat spectrum. Silicones have been replacing hydrocarbons in many commercial cosmetic makeup products as cosmetics companies improve products to confer better feel properties and transfer resistance.

Another challenge was adding DEET, an insect repellent. The military mandates that all camouflage makeups contain 35% DEET. "DEET also is flammable, so when the Department of Defense asked us to incorporate it, we didn't think we could do it," Lochhead said. But the team successfully included DEET by encapsulating it in a hydrogel substance, a water-rich material that prevented DEET from catching fire.

It already has passed the preliminary laboratory tests needed to determine whether development should continue. Lochhead's team also plans tests of the material on other surfaces to try to protect clothing, tents, and other items from burning, and a colorless version is being developed for firefighters.

Source: ACS

Published September 2012

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