Case Studies Archives | INTAMSYS

Explore the innovative application in the Composite Material 3D printing

INTAMSYS — Thu, 14 Mar 2024 03:17:43 +0000

The burgeoning exploration of composite materials in 3D printing represents a promising trend. It is poised to overcome the constraints of traditional methods, leading to significant cost and time savings within the composite fabrication sector.

Founded in January 2021, the Institute of industrial New Materials (Dezhou) is dedicated to researching, developing, and commercializing technologies related to marine composite materials, 5G communication composites, advanced composite manufacturing processes, and high-end equipment. As a provincial “New-style R&D Institution” in China, the institute partners with INTAMSYS to spearhead two initiatives in applying 3D printing technology for developing and implementing composite product parts.

3D Printing Direct Manufacturing: A Replacement for Traditional Composite Material Molding Processes

Developing intake manifolds for a specific aircraft engine was a significant project at the institute. Intake manifolds, critical components within engine systems, directly impact overall engine performance. However, their complex structure has posed challenges during development, such as difficulties in making molds, high costs, and the time-consuming vibration welding process. This has led to longer lead times and reduced efficiency in product development.

To address these challenges, the institute embarked on its first attempt to directly produce intake manifolds using FFF 3D printing technology. After thoroughly researching and evaluating different brands of FFF 3D printers based on material performance, equipment capabilities, and service support, the institute chose the FUNMAT PRO 610HT 3D printer from INTAMSYS and PEEK-CF composite material for product development and application.

As a high-performance FFF printing equipment, the FUNMAT PRO 610HT is mainly designed for printing high-temperature thermoplastic materials such as PEEK, ULTEM, and PPSU. It can handle a wide range of thermoplastic materials available in the market, including custom ones. Its constant temperature chamber ensures excellent performance when printing high-performance materials. With duel-nozzle heating temperature of up to 500°C and a chamber temperature of 300°C, it can print high-temperature materials without distortion, ensuring wrap-free printing while effectively melting most thermoplastics.

The final 3D printed component measures 218.4×216.4×95.4mm. Developed jointly by experts from the insitute and engineers from INTAMSYS, the design was optimized for manufacturing (DfAM), and printing processes were adjusted for the following improvements:

Reduced Weight by 30%: With the thinnest wall of the printed product measuring only 1.7mm, compared to around 3mm for traditional injection-molded intake manifold products, the weight of the aircraft is significantly reduced.

Dimensional Accuracy: Part dimensions are tightly controlled within ±0.2mm, ensuring accurate installation of the intake manifold.

Enhanced Mechanical Strength by 30%: The product demonstrates a mechanical strength of 100MPa, exceeding that of traditional injection-molded PA66-GF products by over 30%.

High-temperature Resistance: High temperature resistance for a long time, fully meets the customer’s application requirements at 144℃

When considering manufacturing efficiency, if this part were made using traditional injection molding processes, it would require tooling costs of about $27803, with a 45-day lead time for tooling. However, with 3D printing technology, the product can be seamlessly manufactured as a single integrated piece, reducing costs to only one-tenth of traditional methods, and shortening the production lead time to just 4-7 days.

Incorporating 3D Printing into Traditional Processes: A New Paradigm for Composite Material Manufacturing

Apart from directly fabricating composite material components, blending 3D printing with traditional techniques unlocks solutions for challenges that conventional methods struggle with, ensuring optimal performance, cost-efficiency, and time-saving advantages. With this innovative strategy in mind, the institute collaborated with a leading domestic university to develop a robotic composite material manipulator arm.

Initially, the FUNMAT PRO 610HT 3D printer was utilized to seamlessly produce the internal support structure of the manipulator arm using PEEK-CF material. This component is recognized for its large size, curved surfaces, high stiffness-to-weight ratio, and exceptional specific strength. These qualities showcase the printing equipment’s capability to create complex high-performance parts.

Subsequently, the institute applied a pre-impregnated layup method to envelop carbon fiber around the 3D-printed structure. This approach yielded a lightweight, robust composite material manipulator arm swiftly and affordably, circumventing the need for mold tooling while achieving structural strength comparable to aluminum alloys.

Beyond integrating with pre-impregnated layup processes, 3D printing offers extensive potential for merging with various other techniques, including traditional filament winding, automated layup, and compression molding processes.

3D printing has achieved breakthroughs in both the direct manufacturing of product components, as well as in integrating with traditional processes, making significant contributions to enhancing efficiency and reducing costs in the manufacturing of composite material products. Through collaboration with INTAMSYS, the Institute of industrial New Materials has demonstrated its strength in engineering innovation, showcasing the immense potential of 3D printing technology in designing, manufacturing, and developing applications for composite material products.

INTAMSYS is a world-leading high-tech company that provides high-performance 3D printing materials, direct additive manufacturing solutions and software. Co-founded by a team of engineers with years of precision equipment development and high-performance material research, the company is headquartered in Shanghai. Currently, it has established a complete marketing and after-sales service system covering the whole world, with 2 European and American marketing and technical service centers, respectively located in Germany and in the United States. INTAMSYS focuses on aerospace, automotive, electronic manufacturing, consumer products, medical, scientific research and other industries, providing complete additive manufacturing solutions, from functional test prototyping, tooling fixture manufacturing to customized mass production. For further information, contact us at info@intamsys.com.

The post Explore the innovative application in the Composite Material 3D printing appeared first on INTAMSYS.

Innovative Solutions for Automotive Aftermarket: INTAMSYS 3D Printing for Cup Keeper Fixtures

INTAMSYS — Wed, 06 Dec 2023 08:49:38 +0000

Meet Pat, a visionary entrepreneur who revolutionized the automotive aftermarket industry with his innovative creation, the “Cup Keeper Plus.” This ingenious product adapts to hold various beverage containers, including flasks and water bottles, making it a must-have accessory for every car owner. Pat’s success story took an exciting turn when a major U.S. retailer placed a massive order for the Cup Keeper Plus.

However, with great opportunities come great challenges. The retailer had specific labeling and packaging requirements. They demanded labels of precise size and orientation on each Cup Keeper Plus.

Pat’s distinctive design, marked by its curved and tapered structure, posed a substantial challenge in the manufacturing process. Furthermore, the task of consistently affixing labels to thousands of Cup Keepers proved to be an additional hurdle, amplified by the varying sizes that mandated the use of dedicated fixtures. Meeting these demands required the utilization of high-strength and wear-resistant engineering materials.

Pat was not one to back down from a challenge. He enlisted the help of his talented designer, who embarked on a journey of innovation. Leveraging the power of 3D printing technology from INTAMSYS, the designer created custom tools and fixtures to meet these demanding requirements.

Their collaborative ideation culminated in the creation of the ‘Label Peeler,’ a groundbreaking device automating label application by expertly peeling labels from a spool. Comprising the 3D-printed Label Peeler and Label Spool Hub, this assembly integrates seamlessly into a fixture crafted from wood, as depicted below, forming a comprehensive and functional unit. Additionally, they devised the ‘Cup Fixture Assembly,’ meticulously designed to closely align with the internal geometry of the Cup Keeper Plus, ensuring stability and proper orientation for precise label application by the worker.

INTAMSYS became the technology partner of choice for this project, employing the advanced FUNMAT PRO 310 3D printer to transform ingenious ideas into practical tools. Pat strategically chose INTAMSYS Nylon 12-CF, a material expertly reinforced with carbon fiber. This advanced Nylon variant significantly enhances mechanical stiffness, strength, and thermal properties. Moreover, its exceptional wear resistance becomes a pivotal consideration, especially when specifying materials for precision assembly tooling of this nature.

The printer——FUNMAT PRO 310‘s compatibility with PA12-CF and its built-in drying chamber ensured optimal material performance. Its specialized support materials facilitated easy removal, guaranteeing a high-quality surface finish. With exceptional dimensional accuracy, the printer met the precise requirements for tooling and fixture manufacturing, setting a new standard for advanced 3D printing in precision applications.

With the 3D CAD files expertly converted into STL files, Pat was ready to embark on the printing journey. The INTAMSUITE software transformed digital dreams into tangible realities. The FUNMAT PRO 310 sprang into action, 3D printing each tool and fixture with incredible accuracy and speed.

The outcomes surpassed expectations, showcasing phenomenal results. The “Label Peeler” and “Cup Fixture” assemblies emerged as indispensable tools. Beyond merely printing a set of fixtures, the team faced the challenge of customizing multiple fixture sets tailored to the varied dimensions of Cup Keepers. Additionally, fixtures were tailored for different states, optimizing local usage and streamlining efficiency. With this comprehensive approach, Pat’s team established a highly efficient and reliable labeling process, seamlessly progressing from loading the Cup Keeper Plus onto the alignment fixture to applying labels with remarkable precision.

This success story eloquently showcases the harmonious blend of innovation and technology. INTAMSYS, a pioneer in the 3D printing industry, not only enabled Pat to fulfill the retailer’s packaging demands but also facilitated significant advantages in terms of design flexibility, cost efficiency, and time savings. The ability to enhance design freedom, coupled with the advantages in prototype validation, tooling fixtures, and small-batch production, played a pivotal role in securing additional orders for the Cup Keeper Plus.

For those intrigued by this story and eager to explore the possibilities of 3D printing, INTAMSYS invites you to witness the transformative power of the FUNMAT PRO 310. Dive into the world of 3D printing and revolutionize your manufacturing processes with its key features, including full-size engineering polymer printing and the ability to achieve a more delicate surface finish for complex geometries. Experience the limitless potential of 3D printing with INTAMSYS today!

The post Innovative Solutions for Automotive Aftermarket: INTAMSYS 3D Printing for Cup Keeper Fixtures appeared first on INTAMSYS.

INTAMSYS Fuels Solar Team Eindhoven’s Stella Terra: World’s First Off-Road Solar Powered Car with 3D Printing

INTAMSYS — Thu, 23 Nov 2023 08:48:55 +0000

Ostfildern, Germany – November 14, 2023

In a remarkable partnership, INTAMSYS proudly backs the Solar Team Eindhoven from the Eindhoven University of Technology with industrial FFF 3D printing. The World’s first off-road solar powered car successfully conclude the ultimate test: navigating the challenging terrain from Morocco to the Sahara Desert. It signifies a monumental achievement in sustainable mobility.

Stella Terra (Photo credit: STE/Bart van Overbeeke)

Navigating Challenges: Stella Terra's Unmatched Off-Road Durability and the Thriving Partnership

Stella Terra, road-legal by EU regulations, breaks new ground as the first solar-powered off-road vehicle globally. Its self-sustaining energy source eliminates the need for recharging stations, enabling it to conquer diverse terrains with ease. With a maximum speed of 145 kilometers per hour, a lightweight design at 1200 kilograms, and an impressive range of 710 kilometers on a sunny day, Stella Terra is a testament to the power of solar innovation.

It’s worth noting that creating a solar vehicle like Stella Terra poses unique challenges. Traditional manufacturing processes, typically geared for mass production, prove costly and time-consuming for bespoke projects like this one. This limitation brings to the forefront the pivotal role of 3D printing, especially in the fabrication of custom parts that are integral to the vehicle’s design and performance.

Stella Terra Reveal (Photo Credit: STE/Bart van Overbeeke)

Revolutionary 3D Printing Partnership with INTAMSYS to Empower Student Innovators

In pursuit of unparalleled durability and strength for Stella Terra, Solar Team Eindhoven forged a strategic partnership with INTAMSYS, a globally renowned additive manufacturing company specializing in automotive applications. This collaboration extended beyond the provision of 3D printing equipment, software, and materials. INTAMSYS went the extra mile by offering comprehensive training to the students, empowering them with the skills to proficiently operate 3D printers.

The training sessions at the STE office in Eindhoven (Photo credit: STE)

Following these successful training sessions, the Solar Team Eindhoven seamlessly integrated INTAMSYS FUNMAT 3D Printers, into their workflow, complemented by INTAMSYS’ advanced slicing software, INTAMSUITE. This innovative software not only facilitates the preparation of CAD files for the printing phase but also enables the selection of printing materials. Such capabilities empower the students to visualize the outcome before initiating the printing process, adding a layer of precision and efficiency to their additive manufacturing endeavors. This collaboration with INTAMSYS combines cutting-edge technology with hands-on training to elevate the solar-powered car project to new heights.

Solar Team Eindhoven embraced INTAMSYS FUNMAT HT, a desktop FFF 3D Printer, and INTAMSUITE slicing software. The FUNMAT HT, capable of printing not only high-performance polymers like PEEK, but also all traditional engineering materials like PA, PC, ABS, and others, contributed to the rapid development of components crucial for Stella Terra’s success.

The Front Light Housing (Photo Credit: STE)

Key components, such as a side camera cover and attachments for the ventilation/heating system, were swiftly designed, and produced using INTAMSYS technology. The collaboration extended to the FUNMAT PRO 610HT, INTAMSYS’ large build volume printer, crafting Stella Terra’s front light housing with precision using PC-ABS. The printer’s sizable build capacity allows for the creation of large-scale parts tailored to diverse performance requirements. PC and PC-ABS, chosen for their high printing quality, mechanical strength, and heat resistance, cater to specific needs. PC excels in impact strength, while PC-ABS offers a refined surface finish and compatibility with metal plating. This thoughtful material selection ensures optimal functionality for Stella Terra’s components.

INTAMSYS FUNMAT PRO 610HT

The integration of 3D printing, particularly in the partnership with INTAMSYS, not only presented a cost-effective and time-efficient solution compared to traditional mass production methods but also showcased the significant advantages of 3D printing technology in the automotive industry. Beyond its economic and temporal benefits, 3D printing technology stands out for its ability to greatly enhance design flexibility, enabling customized designs. This, coupled with the capacity to reduce vehicle weight while maintaining strength, exemplifies how 3D printing contributes to energy conservation in the automotive sector.

After its public debut in September, Stella Terra embarked on a transformative journey through diverse Moroccan landscapes, covering over a thousand kilometers without recharging. The ultimate test in the Sahara Desert showcased Stella Terra’s capability to pave the way for a sustainable future.

The finish at the Sahara Desert (Photo credit: STE/Rien Boonstoppel)

INTAMSYS remains unwavering in its commitment to supporting students as they embark on a journey of creativity and sustainability, underscoring the company’s broader mission to drive transformative changes through the continuous evolution of 3D printing technology.

Introduction to partners in this case

About Solar Team Eindhoven

Solar Team Eindhoven builds innovative, efficient cars powered by the sun. The team has previously won the World Solar Challenge in Australia four times in a row, competing in the family car class (Cruiser Class). With the Stellas, the team wants to demonstrate that the transition to a sustainable future offers reasons for optimism. And encourage individuals and companies to accelerate the energy transition.

The post INTAMSYS Fuels Solar Team Eindhoven’s Stella Terra: World’s First Off-Road Solar Powered Car with 3D Printing appeared first on INTAMSYS.

Automotive groups see prototype verification speed increase 80-90% with INTAMSYS 3D Printing!

INTAMSYS — Wed, 26 Jul 2023 06:55:35 +0000

In the wave of Industry 4.0, 3D printing continues to change the manufacturing landscape. As an emerging manufacturing technology in the automotive industry, 3D printing has injected new vitality, especially in the aspects of rapid prototype trial production, functional prototype verification, tooling jigs& fixtures. It also assists with the production and application of spare parts for customized, discontinued or small batch vehicles.

3D printing automotive parts

Under the trend of electrification and smart manufacturing for automobiles, along with the desire and product differential consumer upgrades allow, customers are attaching more importance to interior and exterior accessories. This leads to an inevitable trend of diversification, personalization, and customization to meet varied customer demands. With rich experience in the automotive industry, INTAMSYS has widely applied 3D printing technology to automotive interior and exterior accessories, such as customized bumpers, steering wheel test pieces, racing car parts, tail logo fixtures, and more.

ﾠ

Most recently, INTAMSYS has partnered with KEXCELLED to provide their 3D printing solutions for the Automotive Division of SIKA in China; this project has become a significant milestones in the automotive industry.

China Automotive Division, SIKA

Compared with traditional injection molding methods, INTAMSYS 3D printing has helped clients in the automotive industry reduce time and cost by 80% -90% for their prototype development, giving a boost to rapid iterations and significant changes needed to be made with tight timelines.

Automobile models printed using INTAMSYS FUNMAT PRO 41O

As an automotive component supplier capable of providing a complete set of adhesive, shock absorption, sealing, and structural enhancement solutions, SIKA helps OEM clients create vehicles which are lighter, stronger, safer, quieter, and more eco-friendly. During the manufacturing and verification process of the prototype, the components 3D printed by the INTAMSYS’ FUNMAT PRO 410 were bonded with SIKA EVA eco-friendly plastic foam materials. EVA foam materials filled the gaps between the printed components and the bodywork, forming a sturdy structure that not only ensured the required stiffness of the vehicle body, but also provided shockproofing, sound insulation, and noise reduction.

3D-printed components bonded with EVA material

In the selection of 3D printing materials, KEXCELLED PAHT K7 has stood out thanks to its characteristics of high rigidity, high performance, and ease of use. The material has a fracture elongation of 21-25%, with good toughness and excellent impact strength; The elastic modulus ranges from 4600 to 4800Mpa, demonstrating high rigidity and remarkable load-bearing capacity. In addition, it has low creep performance, is not prone to deformation, and maintains good accuracy. Thanks to these characteristics, the 3D-printed parts using KEXCELLED PAHT K7 continuously meet many of the various requirements for automotive components. Looking past the raw print off the build tray, the sound adhesion property of the material allows it to easily form composite structures and components for specific functions with other materials, This enables many of those important attributes mentioned earlier such as sound insulation, noise reduction, and being shockproof.

Printed components are bonded to EVA and installed on the vehicle body

It is evident that the KEXCELLED PAHT K7 material, with its outstanding properties, has extremely high requirements for the printing ability of the equipment, which needs to address the water absorption effect of nylon while meeting the printing temperature requirements. As an industrial-grade dual nozzle high-temperature 3D printing equipment, the INTAMSYS FUNMAT PRO 410 features a format printing size of 305 * 305 * 406mm, equipped with wire sealing and drying technology and multi-material coverage ability. It prints PA engineering plastics with extremely high accuracy and quality, producing detailed and high-quality prints which accurately reproduce the design model of automotive components.

INTAMSYS FUNMAT PRO 410

Based on the optimization and strict testing of the KEXCELLED PAHT K7 material process parameters, INTAMSYS has maximized its performance advantages, helping SIKA to quickly and repeatedly verify their design while also changing plans of the BIW cavity noise isolation and structural enhancement components, thus greatly reducing the risk and cost of verifying and changing molds. Most importantly, the 3D-printed components are directly used for prototype verification, shortening both the time for component design modification and the entire vehicle development cycle.

SIKA body in white

The different applications in the automotive industry have also put forward high requirements for materials. INTAMSYS provides 3D printing solutions covering different materials, including many with high-performance attributes used to build fixed devices, gaskets, busbars and other components in racing cars, composite materials used for turbofan engine components, and engineering materials used for air conditioning filter cover plates and steering wheel trial parts. INTAMSYS collaborates closely with customers in the automotive industry chain such as Porsche, Tesla, BMW and Toyota to empower the development of electrification and smart manufacturing in the automotive industry.

INTAMSYS, as a global leading high-tech company providing 3D printing solutions with high-performance materials and industrial direct additive manufacturing solutions, has always dedicated itself to promoting additive manufacturing as an innovative method for industrial creation. In the future, INTAMSYS looks forward to more in-depth partnerships with leading enterprises to jointly explore the potential of 3D printing in a wider range of application scenarios.

Introduction to partners in this case

About SIKA:

SIKA Group was established in 1910 and is headquartered in Switzerland. As a wholly-owned subsidiary of SIKA Group in China, SIKA China offers solutions in concrete, waterproofing, sealing and bonding, roofing, flooring and coatings, repair and reinforcement, and industrial innovation.

About KEXCELLED:

KEXCELLED is committed to providing users with cost-effective FDM/FFF related materials and accessories, with its business covering consumer, professional, and industrial levels. It is known as one of the most comprehensive, high-quality, and innovative brands in the industry.

ﾠ

The post Automotive groups see prototype verification speed increase 80-90% with INTAMSYS 3D Printing! appeared first on INTAMSYS.

Empowering PEEK Implant Surgeries: INTAMSYS 3D Printer Leading the Way

INTAMSYS — Fri, 30 Jun 2023 07:19:13 +0000

The application of PEEK (polyetheretherketone) in 3D printing of human hard tissue substitutes has drawn extensive attention in recent years. With excellent biocompatibility and chemical stability, and density and mechanical properties close to those of human bone, PEEK is an ideal material for bone substitutes and has become a leading candidate material to replace metal implants and prostheses in orthopedic, spinal, and craniomaxillofacial surgeries. Combined with 3D printing technology, PEEK is expected to be widely used in the field of orthopedic implants. The advanced medical application project of PEEK 3D printing conducted by INTAMSYS in collaboration with Tangdu Hospital of Air Force Medical University is a pioneering practice in this field.

PEEK 3D printed implants in the treatment of skull, thoracic ribs and nutcracker syndrome

Skull reconstruction surgery

In conventional skull implant procedures, hard and lightweight titanium mesh is commonly used to repair damage or fill voids. Meanwhile, the medical community is in constant pursuit of new medical implant materials to improve surgical outcomes and post-operative patient experience.

Skull implant protocol

What kind of technique can best meet the surgical requirements?

A patient at Tangdu Hospital of Air Force Medical University had a head tumor and needed skull implant to repair the damaged area. Based on the patient’s CT scan data, the surgeons designed a “tailor-made” skull piece structure using CAD software. They printed customized skull pieces by FDM (fused deposition modeling) using high-performance PEEK material with the help of the 3D printing technology of INTAMSYS. During the surgery, the surgeons successfully repaired the damaged area of the patient’s skull by precisely implanting skull pieces according to the protocol. The postoperative examination showed that the skull pieces fitted perfectly with the patient’s natural bone without artifacts, and the patient recovered well after the operation.

Versatile application in surgical implants

In 2018, the Department of Urology at Tangdu Hospital and the 3D Printing Research Center of the Air Force Medical University jointly performed the world’s first surgery treating nutcracker syndrome with 3D printing technology, adopting PEEK human bionic material to make the human implants.

Nutcracker PEEK implant 3D printed by INTAMSYS equipment

The 3D Printing Research Center of the Air Force Medical University made breakthroughs in several thoracic rib PEEK replacement surgeries by creating new implants with the help of the FDM/FFF 3D printing technology of INTAMSYS.

PEEK thoracic rib implant 3D printed with INTAMSYS FUNMAT PRO 610

Hundreds of PEEK implant procedures have already been performed with the help of 3D printing technology, and the patients recovered well after the operation.

3D printing technology unleashes new potential of PEEK materials

As the medical implant production switches from the conventional standard mass production to patient-specific customized implant production, 3D printing is taking on an increasingly important role in the medical implant manufacturing industry, making it possible to realize batch production of patient-specific and small-scale customized PEEK implants.

FDM/FFF 3D printing technology based on material extrusion process is one of the more economical and efficient production approaches for small-batch production compared with the traditional manufacturing approaches. For example, in the aforementioned skull reconstruction surgery at Tangdu Hospital, the medical team “tailored” PEEK implants for the patient based on the FDM/FFF 3D printing technology of INTAMSYS, and the skull pieces were perfectly embedded with the patient’s natural bone, contributing to quick post-operative recovery.

Taking the advantages of additive manufacturing/3D printing technology in fabricating complex structures, the bioactivity of PEEK materials can be improved at the design level. For example, 3D printing technology can construct interconnected and integrated porous structures to facilitate osseointegration of PEEK implants, improve x-ray accuracy, and achieve elastic modulus that closely matches human cancellous bone.

PEEK Filament

Challenges of PEEK FDM/FFF 3D printing

The manufacturing equipment and process stability are the prerequisites for the commercialized application of PEEK 3D printed medical implants. Due to its high melting point, PEEK requires high-temperature heat treatment. The combination of elevated processing temperatures and the high crystallization rate of PEEK leads to excessive thermal stress (uneven distribution between printed layers) and may result in thermal cracking, as well as poor interlayer adhesion and warpage in 3D printed PEEK parts. Therefore, PEEK FDM/FFF 3D printing is far more complex and challenging than the processes using engineering and general purpose plastics. In order to develop high-quality PEEK 3D printed parts, specialized manufacturing techniques, as well as FDM 3D printing equipment dedicated to PEEK materials, are required.

In essence, the 3D printing of high performance materials is a thermal processing of polymer materials. The thermal design of the chamber of the 3D printing equipment and the suitable chamber temperature will enhance the bonding strength between layers of polymer materials, while reducing the shrinkage and deformation due to cooling and residual stress. Different materials have different requirements for chamber temperature during the material extrusion 3D printing process, and the chamber temperature required for 3D printing of high-performance PEEK materials should achieve 150-250°C.

Taking INTAMSYS FUNMAT PRO 610HT 3D printing equipment for high-performance materials as an example, it has a fully enclosed molding chamber, the temperature of the 3D printing platform and the chamber can be controlled in a range from room temperature to 300°C, the equipment controls the heating of the chamber through the double-side circulation hot duct while synchronously heating the printing bed, which is equipped with thickened insulation layer externally to reduce heat dissipation. After reaching the preset temperature and stabilizing for a period of time, the temperature field inside the whole chamber is highly homogeneous, with the temperature controlled accurately within the range of 300°C ± 2.5%. Due to its excellent high temperature performance, INTAMSYS FUNMAT PRO 610HT 3D printing equipment is mainly used for additive manufacturing with high value-added materials such as PEEK, ULTEM and PPSU, and meets the 3D printing requirements of most FDM/FFF materials in the market. Unlike ordinary 3D printers that are heated only by the printing platform, FUNMAT PRO 610HT can further ensure that the first layer of 3D printed parts maintains a high-strength adhesion with the printing platform, and the material is heated at a uniform temperature in all parts during the 3D printing process, which facilitates large-size sample molding while preventing warping and other defects, providing a reliable guarantee for high-quality 3D printing of PEEK materials.

Whether it is for the treatment of skull, sternum or nutcracker syndrome, customized implant protocols will be more precise and efficient to provide a better treatment experience and recovery for patients. And the 3D printing technology also keeps on providing more innovations and breakthroughs in other medical areas such as bone reconstruction and prosthesis manufacturing. We firmly believe that the medical world in the future will be witnessing infinite possibilities brought by 3D printing technology.

The post Empowering PEEK Implant Surgeries: INTAMSYS 3D Printer Leading the Way appeared first on INTAMSYS.

Industrial 3D Printing With High Performance Polymers Can Replace Traditionally Made Metal Parts

INTAMSYS — Wed, 08 Feb 2023 07:18:23 +0000

It is certainly no secret that 3D printing is being integrated into more and more sectors. This includes more traditional manufacturing industries, where additive manufacturing is increasingly being adopted as a complementary technology to produce more lightweight yet still strong parts. Or at least that is the case for Société Parisse, a French company based in Bourgogne-Franche-Comté, that has adopted industrial 3D printing with high-performance polymers through their work with INTAMSYS and CADvision.

Société Parisse was founded in 1981 and moved to Donzy in 1985, where the street where it is located now bears the name of the founder, Gerard Parisse. It specializes in mechanical precision engineering, including the creation of special machinery and assembly control.They are well-known for their know-how and high production quality. This has enabled them to work in a variety of sectors including in Formula 1 and motorsport racing, professional cycling, pharmaceuticals and even the aerospace sector, notably providing parts for the Ariane rocket.

he company has a long history of using traditional processes. At its facilities, Société Parisse has four machining centers (2, 3, 5 axes), four CNC lathes (3 and 4 axes), single-spindle and dual-spindle turning, two EDM (Electro Discharge Machining) wire erosion machines, a surface grinder, a cylindrical grinder, conventional turning and milling, a metrology control laboratory, a laser engraver and a design office. Now, they have also decided to move into industrial 3D printing thanks to growing demand from their customers, who are both French and international.

3D Printing With High-Performance Polymers for Production-Grade, Lightweight Parts

But why did Société Parisse turn to additive manufacturing? And how has the company adopted the technology? Well, the answer to the first question is one that we have certainly heard before: the need for more lightweight parts. More specifically, according to Laurent Parisse, the head and owner of the company who bought it from his father Gérard Parisse in 2003, they were interested in making lighter parts, namely those that could no longer be manufactured by machining due to their weight. AM allowed for a greater freedom of shape and design. However, Parisse knew that he needed to keep the original properties of the metal parts even when switching to AM. To achieve this, he turned to INTAMSYS and CADvision, a reseller of AM solutions with 15+ years of experience that is also based in France. transport, and more.

Parisse was searching for a printer with an open material system that could help them to produce high-quality, 3D printed parts. After he searched independently, CADvision’s final recommendation was that the INTAMSYS’ FUNMAT PRO 610HT 3D printer would best suit Société Parisse’s needs. This FFF machine is known for being open-system and its ability to print with high-performance materials and Parisse claims it was the answer to at least 99% of the company’s concerns when adopting 3D printing. This is thanks to a number of features that were especially important for their work. Notably, he pointed towards the chamber which is capable of reaching up to 300˚C, ideal for printing with high-performance “super” polymers like PEEK and PEKK as well as extruders which can reach up to 500°C with an all-metal hot end. Moreover, he mentions the large build space of 610x508x508mm (24x20x20in) which allows for either the printing of very large parts or multiple small parts for low volume production.

Indeed, high-performance polymers were the key to Société Parisse’s adoption of 3D printing. These so-called “super polymers’ include materials like PEEK (polyether ether ketone) and Ultem and are known for their ability to replace even metal thanks to their high strength and rigidity and high heat resistance. Beyond this they are also chemical, corrosion and heat resistant, making them useful in even the most extreme environments. This while all still being much lighter, an ideal especially for Société Parisse. Although the company had actually already used high performance plastics, INTAMSYS allowed them to use them with additive manufacturing in order to take advantage of AM’s many benefits.

How Has Société Parisse Used the INTAMSYS FUNMAT PRO 610 HT?

Of course, one of the ways that Société Parisse has adopted industrial 3D printing has been through prototyping which is often costly and ineffective with CNC Machining. But additive manufacturing is also being used for end-use parts including the production of spare parts but also for direct use in the aeronautic, railway and pharmaceutical industries. One example of a part was a frame made by the company that could be used like a remote to test a wagon that would be part of a train. Although normally to make this part, it is necessary to create 17 separate parts, all of which are u-shaped, thanks to additive manufacturing it was possible to print it entirely in one part.

Speaking about the choice to use the FUNMAT PRO 610 HT 3D printer, Laurent Parisse concludes, “For us everything was a go: the price, the size of the chamber, the features and more. We are always seeking new innovations and avoiding the mainstream and with INTAMSYS and high-temperature polymer 3D printing we have achieved that.” You can find out more in the link HERE or in the video below.

Read the full article here.

The post Industrial 3D Printing With High Performance Polymers Can Replace Traditionally Made Metal Parts appeared first on INTAMSYS.

3 ways the Royal Netherlands Navy is using INTAMSYS 3D printers in 2022

INTAMSYS — Tue, 20 Dec 2022 05:48:45 +0000

3D printing is becoming an increasingly key technology for the Royal Netherlands Navy. With the INTAMSYS 3D printing of parts on frigates, they will be less dependent on complex logistics operations.

They have been using the FUNMAT PRO 410 for parts printing. It supports fire resistance and strong materials, also can withstand temperatures up to 150°C without issue.

This year, the Navy has revealed how it continues to use INTAMSYS printers for a variety of tasks, printing replacement parts in high-performance materials like PEKK-CF. This article looks at three ways the Royal Netherlands Navy deployed the FFF 3D printers to support on-land troops during a military exercise in Suriname.

Amplifier brackets

Most consumer-level FFF 3D printers cannot print brackets capable of supporting exceptionally heavy weights. Common filaments like PLA and ABS are durable enough for prototypes and low-impact applications, but it takes a much stronger material to guarantee high performance in the heat and humidity of Suriname.

During the military exercise in South America, crew members needed brackets to support a 20 kg signal amplifier so it could be mounted near the top of a 25-meter pole. Doing so would reduce the need to use long cables and consequently boost the signal of the antenna on top of the pole. Since the crew didn’t have brackets with them, they used an INTAMSYS printer to make some out of PEKK-CF, a high-performance material that requires a high-temperature 3D printer with extrusion temperatures of at least 350 °C. Weaker materials could buckle under heavy weight and would not be safe to use.

Valve wheels

A naval ship or submarine contains a huge number of valves for regulating pressure and fluid flows. Such valves control the flow of fresh water, ballast water, and liquid for hydraulic systems, among other things. Valves have wheels that allow them to be manually adjusted, and these valve wheels are regularly removed for cleaning and maintenance. However, they sometimes break or get lost, which means ships must carry spares.

Because there are so many different types and sizes of valve wheels, DMI workers have been using their INTAMSYS 3D printers to fabricate wheels on demand rather than carrying a huge number of prefabricated aluminum/steel spares on board. Valve wheels printed in high-strength materials do not overheat and can last a long time; some are even installed permanently.

Orthotics

Ships and machines aren’t the only things that require maintenance on long missions. Crew members can suffer minor and major injuries in the field, and ships aren’t always within reach of a medical center.

The DMI’s additive specialists have been working with the Radboud University Medical Center (part of the Radboud University Nijmegen) on a research project for developing custom orthotics. Using a mobile 3D scanning application developed by Belgian company Spentys, technicians can design and 3D print custom-fit orthotics to treat minor injuries. A variety of materials can be used, including PEKK, ABS, and PP, and the tightness of the devices can be altered over time with adjustable straps as the injury heals.

Watch the full video here: https://youtu.be/miss5ugJfy4

Learn more about the FUNMAT PRO 410

The post 3 ways the Royal Netherlands Navy is using INTAMSYS 3D printers in 2022 appeared first on INTAMSYS.

Solving challenges in the construction industry with innovative architecture and 3D printing

INTAMSYS — Thu, 17 Nov 2022 09:34:21 +0000

Globally, over 50% of waste comes from construction and demolition work. Buildings and construction projects are responsible for 40% of greenhouse gas emissions, with the largest share of this emission coming from manufacturing raw materials, with packaging and transportation following closely.

As a manufacturing company, we at Richter Lighting Technologies GmbH are clear with our responsibilities and have been driving our main innovations, toward sustainable development of industrial solutions to meet the challenges of the construction sector

Bernd and Marion Richter, founders of RiCHTER Lighting Technologies GmbH

These challenges are characterized by the following points:

Reduce the environmental footprint of the construction sector
Holistic consideration of the materials used over entire product cycle (selection of recyclable materials, reduction of materials used).
Reduce construction cost and completion times
Reduce arduous and risky physical labor.

RiCHTER USE CASES

Discover Richter Lighting Technologies GmbH; their project use cases range from creating parts that combine profiles into complex shapes to hold fabrics in our ceiling systems, to using 3D-printed parts to integrate into standardized architectural structures while maintaining the overall strength of the entire structure.

SUSPENDED CEILING SYSTEMS

An example is their most recently completed project was the suspended ceiling systems in the lobbies of the 50 Hudson Yards building in New York City. They drew from their expertise in multiple fields, their experience from past projects, and leveraged some of the most innovative technologies to meet clients’ requirements.

For this project, RiCHTER’s team needed to create complex components to combine multiple profiles for architectural structures and to hold their fabrics in the ceiling systems. To achieve this goal, they needed a material with specific properties, and a 3D printer that can get the best out of the materials.

The material that had the required properties was the ULTEM 9085 filament, a polyetherimide (PEI) plastic and the 3D printer used to achieve this task was the INTAMSYS FUNMAT PRO 610HT. It also has a controlled heated chamber, that was set to about 200 °C, which is necessary in order to achieve strong layer bonding for the ULTEM 9085 filament because of its glass transition temperature of 186° C. The printer has a nozzle temperature that goes up to 500 °C, adequate for this material because of its high melting point.

The result was:

Very complex integrable shapes, that the concept of milling could not even be considered.
Very durable components with strong layer bonding.
Lightweight and highly flame-retardant components.
Reduced materials with infill structure.

3D printed parts with
ULTEM 9085 for architectural use.

UNIQUE ARCHITECTURAL COMPONENT

Another example is when they use the BASF Ultrafuse® PC/ABS FR for their high-end architectural projects.

The major challenge for some projects was achieving a combination of different materials, assembled as a single piece, and shipped for easy, on-site installation.

This component had to have the following requirements:

Remain invisible
Excellent surface quality to act as a frame for fabric systems.
High durability & flame retardant

They achieved this unique architectural component using innovative technologies like (3D printing, 3D engineering, etc.) and thanks to the philosophy at Richter Lighting Technologies GmbH.

3D printed parts with
BASF Ultrafuse® PC/ABS FR for architectural use.

RICHTER PHILOSOPHY

Richter Lighting Technologies GmbH, now a global manufacturer and supplier of modular lighting and acoustic ceiling systems, uses a philosophy – the 90-10 philosophy – which at the highest level is that RLT does 90% of the work and clients do 10%.

The 90-10 philosophy consists of carefully curated synergetic elements that enable RLT to provide ‘clear cost, clear lead-time, clear quality throughout the lifecycle of a project.

Some of these key elements are:

A team with very diverse skills, experience, ages, and cultures from over 30 different countries.
A growing knowledge base and set of reusable technical parts derived from decades of experience and over 250 successfully completed projects.
A preplanned, predefined kit premanufactured with industrial precision that the customer assembles to an integrated product customized for him.
Assembled, packaged, and shipped in a numbered order for easy on-site installation that can be done by any professional.
A custom plenum space that can be implemented on demand and anywhere within the entire system to meet the customers’ needs

This philosophy is implemented primarily to

1) understand the challenges of the customer and the respective project during planning and construction and

2) develop and provide clients with the best solution that perfectly fits their needs and requirements

Richter lighting technologies GmbH

Address: Im Morgen 1

D-73540 Heubach

Website: https://richter-lt.de/
Phone: +49 (0)7173 71440 0
Mail: info@richter-lt.de
LinkedIn: https://www.linkedin.com/company/richter-lt/
Facebook: https://www.facebook.com/Richter-lighting-technologies-GmbH

The post Solving challenges in the construction industry with innovative architecture and 3D printing appeared first on INTAMSYS.

Discover the story of WEERG, a leading 3D Printing and CNC machining online service company

INTAMSYS — Tue, 20 Sep 2022 07:13:24 +0000

Learn how and why they adopted 3D printing to bring their business to another level

Located in the surroundings of Venice, Italy, WEERG was established in November 2015.
The company is the result of its owner’s dream, Matteo Rigamonti, and has become over the years a leader printing service bureau and one of the most popular online quote estimators. Discover WEERG’ journey and their collaboration with INTAMSYS.

The company started with CNC machining services. Indeed, not such a long time ago, getting CNC parts delivered as well as getting a quote for CNC parts were exhaustive processes. Matteo decided to establish a company that would answer his needs.

The company’s goals are to offer – easy, – online quotations through their website and – fast delivery of the parts (within 3 days), putting back the client’s satisfaction first.

They receive on average up to 20,000 quotes a day!
It is so popular that many companies even use their quote system to make their own benchmark. Thus, WEERG never sleeps.

What about 3D printing?

When the company started in 2016, “volume production” was still not so ready for the 3D printing industry. WEERG did not believe in 3D printing mass production alone at that time for generating enough profit, thus they started with CNC machines mainly.

3D Printing volume production at WEERG started with the investment in a fleet of HP Jet Fusion 5210. They saw potential, a good cost/product quality, and they considered HP as an honest partner. Adding 3D printing allowed them to offer PA11, PA12, PP, and even PA12 + GlassBeads for their customers’ applications. An average of 24 to 25,000 pieces a day are being printed on these printers.

Having CNC, 5-axis continuous milling machines, and Jet Fusion 3D Printers that work 24/7 allows them to offer 3 choices of aluminum, 3 types of steel, and polymers like nylons. The business grew fast and with more than half of the sales turnover coming from overseas.

Why go for a high-performance FFF 3D printer?

Demand kept on growing and more and more requests came from industrial companies asking for polymer parts. Polymers parts that have different properties like:

Flame retardancy
High chemical resistance
High-temperature resistance
High stiffness at high temperature
High electrical insulation
Hydrolysis resistance
Etc.

Fabio Trotti, 3D R&D Manager explained, “our clients are really curious about high-performance materials and about how they can use them in their company. The innovation of AM is stimulating Product Designers that work with us to develop in a new way driving innovation forward.”

Though WEERG already had some resign printers to tackle medical and model-making business, completing their portfolio with high-temperature 3D printers capable to print polymers like PEEK, PEEK-CF, PEEK-GF, etc. became a need.

After a thorough search, several benchmarks, and contacts made with local and international printer manufacturers, the supplier choice was INTAMSYS.

“We were looking for printers that can print high-performance materials and which could run 24/7 on our production floor. We look meticulously for suppliers that can help us deliver functional industrial parts to our clients.”, said Matteo, WEERG’s founder, and CEO.

INTAMSYS offered one single solution that got it all:

a robust printer with a nice esthetic finish with a heated chamber, dual heated nozzles, and heated filament chamber.
a free and user-friendly software with incorporated printing settings (Click and Print experience) on a wide range of materials (from PA12-CF to PEEK),
a reliable support and what we like most at WEERG, honesty and a true partnership

Discover WEERG’s journey with INTAMSYS’ printers

PEEK part – Prototype gear for testing and validation – Quick turnarounds are key in the prototyping phase to allow for easy iteration before finalizing the geometry.

PEEK annealed part – Carter/sump for a small high-performance engine – Lighter than its metal machined counterpart, can fulfill its duties thanks to the high mechanical and thermal properties of PEEK.

PA12-CF part – GoPro helmet mounting bracket. Very light weight, rigid and high performance to reduce fatigue and unnecessary weight on the rider.

“The INTAMSYS FUNMAT PRO 410 has been a performant and reliable tool since day one. It allows us to process high-performance polymers that enable our customers to innovate with them in highly loaded, thermally challenging, and metal replacement applications. It gives us the confidence that is needed to print 24/7 unattended with long print jobs of 100+ hours. It redefines what can be achieved with FDM technology”, stated Fabio.

The story has just begun!

WEERG S.r.l
Via Campocroce, 14
30037 Scorzè (VE) Italy
info@weerg.com

Website: https://www.weerg.com/en/global/home
Facebook: https://www.facebook.com/weerg.it
LinkedIn: https://www.linkedin.com/company/weerg/
Twitter: https://twitter.com/Weerg9

The post Discover the story of WEERG, a leading 3D Printing and CNC machining online service company appeared first on INTAMSYS.

4D Concepts, 3D printing service company, expands its portfolio to better answer high-performance prototype demands

INTAMSYS — Mon, 25 Jul 2022 01:58:11 +0000

4D Concepts GmbH is now a more than 25 years-old well-established 3D printing service company located on the outskirt of Frankfurt in Gross-Gerau, Germany. To pally the demand for high-performance prototypes made from modern high-performance thermoplastics, they added the INTAMSYS FUNMAT PRO 610HT to their portfolio.

4D Concepts’ focus is on prototyping and model construction services in the 4^th Dimension-Time. They combine 3D printing with conventional component processing methods. In this way, they can quickly realize the customer’s ideas and manufacture prototypes, models, or exhibits in all sizes. Even small series production is not a problem.

3D printing is an important part of their service offering. They also own and have expertise in many technologies like ColorJet Printing (CJP), Selective Laser Sintering (SLS), Stereolithography (SLA), PolyJet Printing, MultiJet Printing (MJP), Multi Jet Fusion (MJF), and Fused Filament Fabrication (FFF).

And since 1998, they are also an official reseller of 3D Systems printers which they also use for themselves.

“We accompany our customers in a professional manner throughout the entire project - from planning and design to the prototype or the production of a complete series. Combining our 3D printing processes with conventional component processing, post-processing and surface refinement of the prototypes, small series or even a trade fair exhibit is our daily business. Since the company was founded in 1995, our experienced team in Gross-Gerau has made a name for itself well beyond the borders of the Rhine-Main area. We are one of the leading service providers for everything to do with 3D printing and have more than satisfied customers from a wide variety of industries - from the automotive and consumer goods industries to mechanical engineering and companies from the medical technology sector”

Alex Di Maglie, Managing Director, said

4D Concepts Customer's Experience

With growing demand from aerospace, automotive, food, and medical sectors, and despite the wide variety of 3D printing technologies they owned already, they were missing a printer capable to print super polymers like PEEK, PEKK, PPSU, PPS, or ULTEM. 4D Concepts wanted to expand its offering and materials portfolio to product developers and designers.

They had a look on the market at printers capable to print high-performance polymers (FFF) technologies. They first turned to the most known names, but they couldn’t find exactly what they were looking for.

They were looking for a large build volume (to be able to print all sizes from small to big parts), an open material system (capable to go beyond for the customer’s application and leaving room to experiment and do filament research), and the right price/value.

They went for INTAMSYS and received their FUNMAT PRO 610HT in June 2021. Since the purchase of the printer, they have printed many prototypes, some end-use parts, and from time to time jigs/fixtures and tooling parts.

As the printer has a high chamber temperature (up to 300°C), it also means that all temperatures in between are covered too. 4D Concepts has printed out parts of many plastic types; from PLA, ABS, PC, to PAEK, PEEK, PEI 9085/1010.

4D Concepts – prototype of a temperature-resistant pulley made of glass-fiber reinforced PEEK (PEEK-GF).

Tom Neumann, Application Engineer at 4D Concepts for FFF Technology, shared, “The most important features are to me the automatic reloading system in the filament chambers (when the spool is empty it goes automatically to the next chamber), the high-performance dual nozzles (500°C) and that the printer is an Open System. It allows us to choose the right material for our customers’ applications.”

The application of high-end filaments made of high-performance plastics such as ULTEM is not new to the field of 3D Printing. However, it requires both, a wide range of skills (materials and production) and the appropriate machinery.

Thanks to its large-format 3D printer from INTAMSYS, 4D Concepts can now process a wide range of high-end plastics with excellent thermal and mechanical properties for prototyping. Parts are out of ULTEM9085.

4D Concepts GmbH

Frankfurter Strasse 74

64521 Gross-Gerau

Telefon +49 6152 92310

E-Mail mail@4dconcepts.de

The post 4D Concepts, 3D printing service company, expands its portfolio to better answer high-performance prototype demands appeared first on INTAMSYS.