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Weird stuff: Moon dust simulant for 3D printing

Crafted from a lunar regolith simulant, Basalt Moon Dust Filamet™ (not a typo) available from The Virtual Foundry closely mirrors the makeup of lunar regolith found in mare regions of the Moon. It enables users with standard fused filament fabrication (FFF) 3D printers to print with unparalleled realism. Try out your ideas before you go for that big space contract, or help your kid get an A on that special science project.
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Make nylon 3D-printed prototypes and parts in the office

The new SLS 300 from 3D Systems is an affordable, turnkey, closed-loop 3D-printing system designed to operate in a smaller-footprint environment. SLS 300 makes selective laser sintering available to a broader range of customers with a high-reliability, affordable solution to produce end-use parts. Users can produce tough, durable parts from a range of production-grade nylon materials. Amazing fill, finishing, and clean-up systems.
Learn more.

Will it erode? 3D-printing materials comparison from Xometry

Which 3D-printed plastics are the toughest? In this "Will it ..." video, Greg Paulsen, Xometry's Director of Application Engineering, 3D printed Benchies (3D test models) using different materials (such as polycarbonate, PLA, polypropylene, ULTEM, and Nylon 11 and 12) and processes (such as FDM, SLS, MJF, SLA, LSPc, Polyjet, and DLS) and then ran several abrasion tests on them. Watch to find out which 3D-printed plastic is truly the toughest of them all!
View Part 1.
View Part 2.

Graphene Handbook: Learn all about this wonder material

Metalgrass LTD has published the 11th edition of its "Graphene Handbook," a comprehensive resource on graphene technology, the industry, and the market for this wonder material made of single layers of atoms of pure carbon. The book includes development history, production methods, current research, an intro to metrology and standardization, and even an investment guide. Under 100 bucks for digital edition. Hard copy available too.
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Who knew? How colorants affect plastic

In plastic injection molding, one aspect of polymer characteristics that doesn't always get the consideration it deserves is the addition of colorant. Believe it or not, there is a whole scientific body of knowledge about the ways in which adding color to plastic can affect its behavioral properties. This short article by Denny Scher of ICO Mold takes a high-level look at some of the different, and surprising, ways colorants can affect plastics.
Read the full article.

Retaining magnets from JW Winco: Universal and clever

JW Winco has expanded its magnet line to support more applications with new materials, shapes, systems, and even raw magnets. Learn about their latest offerings, including retaining magnets designed for corrosive environments (GN 50.8), encapsulated magnets designed for sensitive or painted surfaces (GN 51.8), handle magnets (GN 53.3), and powerful magnets designed to handle challenging environs (GN 52.6).
Learn more.

3D print tool steel with the ease of a plastic

The Virtual Foundry, a pioneer in advanced 3D-printing materials, is excited to announce the launch of their latest innovation: M300 Tool Steel Filamet™ (not a typo). This material answers the demand for FFF 3D-printable Tool Steel, delivering unparalleled strength and versatility. What sets this material apart is its seamless compatibility with various 3D printers, including Creality, Bambu Lab, Ultimaker, and more. The filament prints effortlessly, resembling the ease of working with PLA (plastic).
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Great Resources: Sheet metal design guide

If you're looking for a basic guide to sheet metal design, this one from Xometry will serve your needs well. Follow the design requirements and tolerances in this guide to ensure parts fall closer to design intent. This is the type of information you'll sock away and then refer to again and again.
Read the full article.

Particle foam perfectly distributed thanks to simulation with Ultrasim

BASF's Ultrasim simulation solution now includes Infinergy, an expanded thermoplastic polyurethane (E-TPU) that is used in a wide range of applications to make components with particle foam -- from bicycle tires to the soles on shoes. Identify and solve problems related to pneumatic filling when distributing particle foams in molds, even taking gravity and mold closing into consideration. Avoid those pesky air pockets.
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Premium polymer DLP printer is half the price of its predecessor

Desktop Metal has just launched the ETEC Pro XL -- a premium polymer digital light processing (DLP) printer that enters the market at less than half the price as its predecessor. DLP is regarded by many as a superior polymer 3D-printing technology for speed, surface finish, and accuracy. Ideal for automotive and machine parts, aerospace components, housings, connectors, jigs and fixtures, short-run molds, and more.
Read the full article.

CNC machining case study: One-of-a-kind computer chassis

Learn how Josh Sniffen, the YouTuber behind the popular PC-building channel "Not From Concentrate," trusted Xometry to provide a wide range of manufacturing options, personalized Design for Manufacturing (DFM) feedback, and order management support for his latest creation: the HEXO ATX computer chassis. All in all, Sniffen procured parts using Xometry's CNC machining service, selective laser sintering 3D-printing service, and sheet metal cutting and fabrication services. A neat insider look at the process.
Read this Xometry case study.

Which parts should be 3D printed? AI combs through CAD files to find out

One of the biggest challenges in transitioning to additive manufacturing (AM) is the ability to identify which parts are best suited for the process quickly and easily. Learn how Danfoss, Stanley Engineered Fastening, and even the U.S. military have utilized advanced additive manufacturing software to automate the process, reducing material waste and energy costs, improving part reliability, decreasing lead times, as well as now having the ability to identify part consolidation opportunities through intelligent AM decision-making.
Read the full article.

9 key design tips for injection molding

Keep costs down and quality up all while optimizing your injection molded designs with these helpful tips from Xometry. Learn how to build better injection molded parts and products -- using draft angles, ribs and gussets, radii, fillets, and more -- and set expectations for the injection molding process. Good info here.
View the video.

Metal additive manufacturing: Rocket turbopump design

Mixing undergraduate curiosity and real-world engagement, two students from Colorado University Boulder Aerospace Engineering Sciences program, Zachary Lesan and Patrick Watson, started an independent effort on turbopump design and manufacture that is a lesson in determination and industry collaboration. With lots of supplies and advice from industry heavy hitters including Velo3D, CFturbo, SpaceX, and many more, their project has reinforced significant points being made about next-generation rocketry.
Read the full article.

Transparent ceramics for extreme optics

Sapphire is an inherently transparent ceramic material that is resistant to extremes of temperature and environment. Sapphire can be processed to unique and precise shape/form by diamond grinding and polishing to allow full transparency. INSACO is a global leader in this capability -- and working with ultra-hard materials in general.
Learn more.

UAV system components take flight thanks to 3D printing

If you have a chance to go to the Paris Air Show next week (June 17-23), 3D printing juggernaut Stratasys will be there along with a French company called Survey Copter to promote prototype and short-run parts-making using 3D printers.

Survey Copter is using Stratasys 3D printing technology to produce components for mini unmanned aerial vehicle (UAV) systems, also known as drones.

Survey Copter, a subsidiary of the European Aeronautic Defence and Space Company N.V. (EADS), specializes in the design, production, and integration of complete remote systems for surveillance photography and video service applications for UAVs and other airborne craft, as well as for sea and overland vehicles.

Having previously outsourced its prototyping requirements, Survey Copter turned to Stratasys for an in-house solution that could reduce costs and ensure greater efficiency and autonomy, granting the company the means to rapidly produce very small quantities within 24 hr. Via Stratasys' French distributor, CADvision, Survey Copter subsequently installed two 3D printing solutions: a Stratasys Dimension Elite 3D Printer and Stratasys Fortus 400mc 3D Production System, which offers nine production-grade engineering thermoplastics using Stratasys' patented Fused Deposition Modeling (FDM) technology.

"Effectively meeting our 3D printing needs can only be achieved via machines that are capable of producing quality parts with high reliability," says Jean Marc Masenelli, managing director, Survey Copter. "Stratasys' reputation for delivering 3D printers that meet these criteria head-on made them the logical company to partner with."

Spearheading Survey Copter's prototyping and short-run manufacturing activities, the Stratasys Fortus 400mc and Dimension Elite 3D Printers are deployed in the production of component parts for the company's mini UAV systems, including both helicopter and fixed-wing variants weighing up to 30 kg and 10 kg respectively. Ranging from a few millimeters up to parts measuring 40 cm x 10 cm, these components comprise mechanical structures for optical turrets, structural elements of aircraft, battery compartment housings, supporting structures, as well as scale models.

A turret-type camera housing is one of the many component parts printed on a Stratasys 3D printer for Survey Copter's mini-UAVs.

 

 

High-performance materials engineered for aerospace
For Masenelli, the ability to use different materials according to specific application needs offers key advantages for producing durable 3D-printed parts. Such materials include FDM thermoplastics, polycarbonate, ABS, and high-performance ULTEM 9085, which boasts superior strength and lightweight properties, as well as other desirable characteristics including FST (flame, smoke, and toxicity) rating. This safety standard, particularly valued within the aerospace and transportation industries, ensures a material won't promote a fire, release harmful smoke, or emit toxic fumes.

"That we are able to print production-grade materials such as high-performance FDM thermoplastics like ULTEM, which is qualified for aerospace applications, is a definite plus for our operations," says Masenelli.

"The Stratasys 3D Printer can produce parts with complex shapes -- for us, a highly sought-after requirement and a principle differentiator that sets Stratasys' proposition apart from that of other providers," Masenelli adds. "This specific capability enables us to produce parts of wide-ranging dimensions and hollow forms, as well as full honeycomb structures."

Featuring two material bays for maximum uninterrupted production, the Stratasys Fortus 400mc 3D Production System produces accurate, durable, repeatable 3D parts with excellent throughput. It is available in two configurations: the basic system, which builds parts as large as 355 x 254 x 254 mm, and an optionally upgraded system, which builds parts as large as 406 x 355 x 406 mm. With four layer thicknesses to choose from, users can fine-tune their desired balance between FDM's finest possible feature detail and the fastest build.

The Stratasys Dimension Elite 3D Printer features the finest resolution of any Stratasys Design Series Performance 3D Printers and produces nine colors of real ABSplus thermoplastic. When the finest dimension resolution of 0.178 mm is not required, the Dimension Elite allows users to accelerate printing with a layer thickness of 0.33 mm.

Source: Stratasys

Published June 2013

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