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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).
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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.
Learn more.

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.

Army experiments with $699 3D printers

By Carrie E. David, SMDC/ARSTRAT, Redstone Arsenal, AL

The mission of U.S. Army Space and Missile Defense Command/Army Forces Strategic Command, or SMDC, engineers is to seek, develop, and shape technology to benefit the American warfighter, and oftentimes those ideas can be applied to commercial applications as well.

A recent project being worked by SMDC's Future Warfare Center Innovative Ventures Office since mid-September is developing a smaller and cheaper 3D printer for the U.S. Army than those currently available.

The 3D printer used by the U.S. Army Space and Missile Defense Command/Army Forces Strategic Command Future Warfare Center's Innovative Ventures Office is not the first 3D printer in the command, but it is significant because of its small size and greatly reduced cost. [Image: Carrie E. David (SMDCARSTRAT)]

 

 

 

 

"The ability to replicate parts quickly and cheaply is a huge benefit to the warfighter," said D. Shannon Berry, operations research analyst with the Innovative Ventures Office. "Instead of needing a massive manufacturing logistics chain, a device that generates replacement parts is now small and light enough to be easily carried in a backpack or on a truck."

"It's made from easily replicable parts in printed plastic and laser-cut wood, so the entry price is staggeringly low: $695 compared to more than $3,000 for comparable systems," Berry said. "Considering the calibration and attention to detail needed to operate it, I think it's still short of the idea of having one in every home, but that goal is definitely something achievable in the next 10 years."

The printer Berry is talking about is the Printrbot PLUS made by Printrbot. It retails for $699. And it is giving Army engineers lots of ideas about the military creating its own line of inexpensive printers.

Why?

According to Berry, creating low-cost replacement parts was central to the printer's purpose.

"We do a lot of work with space-borne sensors, and we use small airborne platforms as an inexpensive stand-in when we're experimenting," Berry said. "Parts for these systems break frequently, and many of them are produced overseas, so there's a long lead time for replacement parts. The concept was that a 3D printer could replicate those parts with less overhead in terms of time and money."

As with much of the technology developed by government agencies, there are possible commercial applications for the printer as well.

"The impact is even more significant when you look at small businesses that have great concepts for physical systems that could benefit the warfighter, but they do not have the funds or support in the present acquisition environment to make that system a reality," Berry said. "The 3D printer could strongly impact the acquisitions chain, offering the ability of rapid prototyping and low-cost initial operations capability to more development teams."

SMDC's engineers have already used the 3D printer in practical situations.

"We are honestly still working on calibrating and scaling production with our printer," Berry said. "However, to date, we have modeled and manufactured custom sensor housings and custom casings for control boards and other exposed electronics. The machine also has the ability to replicate its own parts, so we've used it to generate spares for itself."

Although this is not the first 3D printer at SMDC, Berry said this one is significant because of its smaller size and reduced cost.

Author's Note: The 3D printer that the Innovative Ventures Office experiments with is the Printrbot+, created by Brook Drumm. For more information on the Printrbot, please visit www.printrbot.com.

Published January 2013

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