Personalized medicine is one of the most exciting verticals in the 3D printing industry, especially since the technology can seriously impact customized drug development and targeted therapeutics. Ever since the first 3D printed drug received Food and Drug Administration (FDA) approval in 2016, several firms began exploring additive manufacturing technology to help create on-demand pills, reduce costs and make easier-to-swallow drugs for patients. One of them is Craft Health, a Singapore-based research and development stage pharmaceutical and nutritional supplement delivery business that relies on 3D printed solutions to simplify drug dosage.

Focused on solving the challenges of complex medication regimens by streamlining how drugs are delivered to patients, Craft Health revealed its proprietary 3D printer uses a specially designed print head for viscous two-component materials by German firm ViscoTec. Craft Health is leveraging ViscoTec’s vipro-Head 5 print head for 3D printing of nutraceuticals and pharmaceuticals. The solution is ideal for accurate and precise personalized tablet manufacturing since it complies with the regulatory requirements that this type of 3D printed product demands.

The ability to produce small batches of carefully tailored drugs with the dosages, shapes, sizes, and release that each patient needs has tremendous potential. When pharma and 3D printing converge to create a chemical compound that can be easily produced on-demand and on-site (at a hospital, pharmacy, or even remote areas), it’s easy to see the benefits of this healthcare segment. By simply streamlining the production process of drug manufacturing with 3D printing technology, companies can save time, reduce waste, and eventually accelerate the creation of a custom formulation for a patient. As the potential of this healthcare segment emerges, more companies will follow suit.

Funded in 2019, Craft Health is an early-stage startup that uses a proprietary blend of formulations–called Craft Blends–corresponding to different controlled release profiles, all 3D printed into a single tablet using a specialized 3D printer called CraftMake. For their drugs to work, the required active ingredient is simply mixed with the formulation and the desired controlled release profile before 3D printing.

According to Craft Health co-founder and COO Seng Han Lim, the brand’s CraftBlends must be printed in the desired volume or geometry, based on the individual requirements of the active ingredient. But precision and accuracy of dosing during 3D printing is the main challenge due to the compressive nature of paste or semi-solids being used.

In fact, the company’s founding duo, who happen to be two pharmacists, learned early on that formulating the pharmaceutical material for 3D printing was not easy. The first time they set out to try their idea on a 3D printer, the material failed to come out from the print head and shot out from the nozzle tip, causing a mess in the entire machine. This material clogging was subsequently fixed, and today, the company relies on the ViscoTec vipro-Head 5, which allows precise and accurate dosing of the material being 3D printed, and the final product to have high uniformity.

“We are using multiple print heads, and so the Craft Blends containing different active ingredients can also be combined onto a single tablet, depending on the individual’s requirement. Different Craft Blends can also be employed to control the rate of release of active ingredients into the body. Hence, a unique and personalized tablet can be 3D printed for the individual, considering the combination, type, dose, and release profile of active ingredients required. The end product is a personalized tablet for the patient, for both nutraceuticals and pharmaceuticals,” highlighted Lim.

Craft Health 3D Printer for nutraceutical and pharmaceutical applications. Image courtesy of Craft Health.

The ViscoTec print head transports two components separately from each other to the static mixing tube. They are then mixed together in a correct mixing ratio and applied layer by layer. Several advantages of ViscoTec include a stepper motor version in the print head that allows easy integration to already existing gantry systems for 3D printing. Also, the wetted and non-wetted surfaces could be clearly separated and cleaned accordingly.

Always on the lookout for collaborations and partnerships, Craft Health worked with the ViscoTec team in Asia on new ideas to modify the print head to comply with any regulatory requirement for manufacturing of nutraceuticals or pharmaceuticals, said Lim. So to meet Craft Health’s needs, the wetted surfaces of the vipro-Head 5 were customized and refabricated using a low-carbon alloy of stainless steel (SS316L) material to comply with FDA regulations for a non-reactive, non-absorptive print head.

Craft Health 3D printing process of personalized tablets. Image courtesy of Craft Health.

Whether reducing the frequency of medicine intake or combining multiple medicines into one single polypill, Craft Health is on a mission to change the status quo of pharmaceuticals. Today, the company offers customers on-demand personalized medicine production, drug development research, and clinical trials for patient acceptability and taste evaluation. To further extend their work, the company recently moved its operations from Bukit Batok industrial park to the prestigious Singapore Science Park in the country’s south-westernmost area of Queenstown. There, the company has set up its very own R&D laboratory and clean room to produce 3D printed nutraceuticals and pharmaceutical products and remains at the forefront of innovation.

Having previously worked for Bond3D and Admatec, Michiel de Brujicker is now doing something very new and exciting in 3D printing. With Poly Products, he’s printing large-scale structures and parts. Using a massive CEAD 3D printer, the company makes outdoor advertising, pump tracks, parts for submarines and molds for jacuzzis. Large-format polymer 3D printing is very much a novelty in additive manufacturing. In our talk with Michiel, it also seems to very much be a business, as well. But, as Michiel’s open-hearted talk reveals, it is also difficult with heating zones, part deformation, and more issues bedeviling the team. He also talks about what applications he wants to go into, from formwork to bridges and tooling molds. Additionally, Michiel discusses what the ideal large format machines would look like. We loved this look into a new and exciting area for AM.

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AM industry events and webinars are back with a vengeance this week as we move into the busy holiday season and this week’s roundup. Topics include everything from standards in the AM industry, 3D printing mold cores, and surgical innovations to disrupting the casting industry, 3D printed medical device design and heat transfer, and more. Read on for all the details!

RSNA 2021 Radiology Conference

First up, the Radiological Society of North America (RSNA) is holding its 107th scientific assembly and annual meeting, RSNA 2021, at McCormick Place in Chicago November 28th through December 2nd this week. More than 19,000 attendees are expected to attend the educational event in-person, with another 4,000 signing on virtually to attend plenary sessions, industry presentations, exhibitor booths, and a showcase focused on medical imaging AI. Some of the industry companies planning to attend include Materialise, Fovia AI, and Realize Medical.

“Our colleagues have told us that they are excited to experience over 2,000 scientific presentations, 1,500 education exhibits and 300+ educational courses, and to witness the state-of-the-art radiology innovations of more than 500 exhibitors.”

You can register for RSNA 2021 here.

TÜV SÜD on AM Industry Standards

Soon to finish its virtual training course, TÜV SÜD will be holding the second iteration of its “Industry Standards in Additive Manufacturing” class on Monday, November 29th and Tuesday, November 30th, starting at 1 am EST both days. Each paid session is four hours long, and focuses on current AM standards, how they can be applied to your business, and how to follow along with industry standardization developments to minimize risks.

“In all industries, standards ensure that processes do not have to be redefined again and again and that there is an approach that is generally recognized. In additive manufacturing, contrary to widespread assumptions, standardization is already on the right track. DIN committees and the Joint Committee of ISO and ASTM unite a large number of relevant market participants and already provide a good range of standards. The question arises in which areas standardisation is advantageous for whom. Particular focus will be placed on safety-relevant topics.”

You can register for the course here.

Formnext Digital Days

The Formnext trade show was held with great success in Frankfurt, Germany earlier this month, but those who were unable to attend in person, Formnext Digital Days will take place this week, November 30th-December 1st. In fact, Formnext was so successful, the organizers are offering everyone the chance to attend Digital Days for free, using the code FN21DD01 for a 100% discount.

“Formnext is before the Formnext Digital Days. There is hardly any time to take a breather, and that’s a good thing. After all, it is important to all exhibitors and the Formnext team to also give community members the opportunity to innovations, exchange and future developments who were unable to come to Frankfurt. That’s why everyone is now putting their efforts into bringing as much Formnext as possible to your (home) office with the Formnext Digital Days. All exhibitors at Formnext Frankfurt 2021 and more will also be there digitally. And not just until after the Digital Days. The company and product profiles of our exhibitors will remain online until May 2022, providing you with a comprehensive AM industry directory.”

You can redeem that free code and register for Formnext Digital Days here.

Giant Health Event 2021

Also from the 30th to the 1st, held at the Business Design Centre in London, is the GIANT Health Event: a global community of nearly 200,000 people in healthcare innovation. GIANT stands for Global Innovation and New Technology, though the event itself is pretty giant with an anticipated 400 speakers, and the mission-driven organization works hard to improve the health and well-being of people by facilitating healthcare innovation and supporting health-tech entrepreneurs. The event is hybrid, so anyone who can’t make it to England can watch the live broadcast and participate in the multiple conference tracks, including pharmaceuticals, virtual clinical trial solutions, the challenges facing healthcare, and more.

“Our GIANT 2021 event is an invaluable, cost-effective global hybrid event. Combining both a real world physical trade show and multiple conferences in central London, as well as a sophisticated and engaging virtual event based on GIANT Health’s proprietary Virtual Event Platform.”

You can buy tickets to the GIANT Health Event here.

GE Additive’s Arcam EBM Spectra Platform

Making up for lost time, GE Additive will hold its first of six webinars this week at 7:30 am EST on Tuesday, November 30th about the latest capabilities of its Arcam EBM Spectra platform. Speakers Oscar Angervall, Senior Product Manager, and Markus Ramsperger, Process and Materials Engineer, from GE Additive will tell attendees all about the company’s Arcam EBM Spectra H and Spectra L 3D printers.

“Find out what makes the Spectra L a robust system ideal for repeatably delivering parts at a lower cost. And, hear why the Spectra H is the perfect choice for the advanced processing of highly crack-prone nickel-based superalloys, such as Alloy 247, as well as extremely hard and wear-resistant metal matrix composites (MMC).”

You can register for the webinar here.

GE Additive’s M Line Printing Mold Cores

Just a couple hours later on Tuesday, GE Additive will hold its second webinar, “EROFIO Group and the M Line: Making a Mold Core Using Metal AM,” at 9 am EST. Luís Santos, EROFIO Group’s metal AM leader, and Wolfgang Lauer, GE Additive’s M Line product manager, will discuss the evolution of the M Line, and how EROFIO used the printer to create its first mold core at high speeds out of M300 hot work tool steel, less than three months after the system was installed.

“GE Additive’s Concept Laser M Line is more than a single machine. It is a system created specifically for metal additive production, developed around safety, reliability, repeatability and efficiency. EROFIO Group – founded by a mold maker and an injection molding company –is a long-standing user of GE Additive’s Direct Metal Laser Melting (DMLM) technology. Due to their experience with DMLM, Erofio was selected to test and put the M Line through its paces ahead of its commercial readiness later this year.”

You can register for the webinar here.

GE Additive & Writing Raw Material Specifications

The last GE Additive webinar on the 30th, at 10 am EST, will be “Add To Your Additive Manufacturing Toolkit: How To Write Raw Material Specifications.” GE Additive’s Advanced Lead Engineer Dan Frydryk will discuss raw material specifications, of which there are many for traditional manufacturing methods like castings and forged products, but far less in the AM industry.

“This webinar aims to educate the users of metal additive manufacturing on the creation of an internal raw material (powder) specification with focus areas on why such a document is necessary, how to determine process limits and the methods against which to test, and how to be sure the right process windows are identified without being overly constrained.”

You can register for the webinar here.

Save Time in Orthognathic Surgery with Materialise Standard+

Moving on, Materialise is holding a webinar, “Innovating orthognathic surgery with the S-plate,” at 11:30 am on the 30th. Focusing on condylar positioning issues during an orthognathic mandibular sagittal split osteotomy, the webinar will discuss how you can use the adjustable S-plate from the Materialise Standard+ Solutions range to save time during surgery, and avoid compromising the final occlusion. The speaker, Professor Hervé Bénateau from the Caen University Hospital in France, will discuss how the S-plate can help manage the condylar position and more.

“The S-plate does not require screw manipulation for adjustment and offers proven biomechanical reliability. This unique plate allows rapid millimeter adjustment (length and angle) with dedicated pliers to fine-tune the occlusal result after performing a BSSO in orthognathic surgery. Find out how this feature can help reduce surgical time when the occlusion is not perfect at the release step.”

You can register for the webinar here.

GE Additive Mining Data to Develop Additive Software

Back to GE Additive, the company is holding its fourth webinar this week, “Mining Data to Develop an Additive Software Platform,” at 7 am EST on Wednesday the 1st. Structured geometric data is needed to 3D print any component, but a good data management platform is needed that can collect information and create intelligence, due to how complex machine controls and monitoring are becoming when combined with expanding design and material behavior data. In this webinar, participants will learn why information flow ecosystems for additive should form an easily analyzed database, as well as a smart data entry solution.

“Join this session as the presenters explore the importance of a closed-loop system to facilitate the processing of data in an additive manufacturing environment and shorten the time to production.”

You can register for the webinar here.

Disrupting the Casting Industry with GE Additive

At 8:30 am the same day, GE Additive is holding “Disrupting the Casting Industry,” a webinar that looks closer at a recent collaboration with GE Aviation. Kelly Brown and Nick Buhr will discuss the partnership, which resulted in four parts typically made with conventional casting being converted to additive and a cost reduction up to 35% in the process.

“This game changing initiative, that took only 10 months from identifying target parts to 3D printing final prototypes, shows that metal additive can go toe-to-toe with conventional castings on price.”

You can register for the webinar here.

3D Systems on Factory-Level AM Productivity, Performance

At the recent Formnext event, 3D Systems unveiled several new systems and solutions that can fabricate accurate, cost-effective, repeatable production parts out of a variety of materials, including thermoplastics, metal alloys, and photopolymers, for applications in industries such as aerospace, service bureaus, medical devices, and more. The company is holding a webinar on the 1st, at 9 am EST, to discuss “Answering the Call for Factory-Level AM Productivity & Performance.” Shell Haffner, the VP of Product Management for 3D Systems, is the speaker for this webinar.

“For decades, manufacturing and design engineering leaders have anticipated the point at which additive manufacturing would be capable of delivering factory-ready plastic and metal components. With recent advances in design-to-part workflow productivity & advanced material chemistry performance, it’s now possible to strategize how to integrate additive manufacturing within the wider factory floor ecosystem.”

You can register for the webinar here.

Advanced Materials in AM with GE Additive

In its last webinar this week, GE Additive will focus on “Where No One Has Gone Before: Advanced Materials in Additive Manufacturing.” At 10:30 am EST on the 1st, Dr. Youping Gao, the founder and president of AM research and development firm Castheon, will explain to attendees how using laser powder bed fusion (LPBF) AM processes—specifically the GE Additive Concept Laser M2 machine—can improve the metallurgical properties of refractory metals, so they can perform in environments that were previously off-limits for 3D printing.

“There are plenty of well-known advantages to additive manufacturing, regardless the industry of discussion: lighter weight, reduced part count, improved performance, more intricate new structures.

“But perhaps there is an underdog worthy of a top spot on the list: the ability to manufacture using new, advanced materials.”

You can register for the webinar here.

3DQue Holding First Live Community Conference

At 7:30 pm EST on Wednesday the 1st, 3DQue Systems is holding its first live community conference, “Automation is the Future of 3D Printing. Let’s Build it Together!” Attendees will be able to hear what’s next for 3D printer automation in 2022, get an early look at the newest features, and have the chance to tell 3DQue what printers it should automate next, in addition to features you’d like to see in the future.

“Join us December 1st for this live virtual event, get a sneak peek of the future of 3DQue, and tell us which printer you want us to automate in 2022. If you’ve been waiting for Quinly automation for your printer, now is your chance. The printers that have the most interest will be next in line for beta, so make sure your voice is heard and join us for this exciting event.”

You can register for the conference here.

3DEXPERIENCE SOLIDWORKS with TriMech

Moving on to Thursday, December 2nd, TriMech is holding a webinar at 10 am EST, “Get to Know 3DEXPERIENCE SOLIDWORKS,” all about the main differences between it and desktop SOLIDWORKS. Elite Application Manager Wayne White will discuss the various functionalities and data management options of each ecosystem and how they can benefit your team, as well as who’s a good fit for 3DEXPERIENCE SOLIDWORKS and why now might be a good time for switching to cloud connectivity for your business. Attendees will also get to hear about some of the latest feature enhancements in SOLIDWORKS 2022.

“The 3DEXPERIENCE Platform continues to expand its capabilities. The Platform offers many critical core design functionality including real-time communication, data sharing, viewing of CAD data, built into the web browser design tools, and much more.”

You can register for the webinar here.

PostProcess Technologies: Live Solution Experience Tours

On the 2nd, PostProcess Technologies is holding its Live Solution Experience Tours at 10 am and 11 am EST, offering attendees a look into how software-based technology is applied to post-processing for several kinds of 3D printing processes. These real-time group tours of the company’s automated post-printing methods, streamed from the PostProcess labs, will center around the main print technology applications, with the 10 am tour focused on automated support removal and surface finishing for FDM and PolyJet printing, and the 11 am about resin removal and surface finishing for SLA, DLP, and CLIP photopolymer printing.

“Conducted by one of our post-printing experts broadcasting from our lab, you will get a close-up view of how software, hardware, and chemistry work together for transformative end part results. See the solutions running live on the proprietary AUTOMAT3D platform and engage in real-time Q&A.”

You can register for the 10 am tour here, and the 11 am tour here.

Design for 3D Printed Medical Devices with 3DHEALS

At 11 am EST on the 2nd, 3DHEALS will hold its latest webinar, “Design for 3D Printed Medical Devices.” Moderated by Jenny Chen, the 90-minute webinar will feature experienced, knowledgeable educators and designers who will share their work, forecast, and industry insights. The speakers will be Jade Myers, Visiting Scientist/Adjunct Faculty, Rochester Institute of Technology; Matthew Shomper, Director of Engineering at Tangible Solutions; and CEO of MIX Surgical Technologies Nicholas Jacobson, Translational Research Faculty at University of Colorado Anschutz Medical Campus. As always, breakout rooms will be available after for 30 minutes of networking.

“Creativity is arguably the most valuable yet under-valued asset in society. With emerging technology like 3D printing, design is the ultimate barrier to entry regardless of the intended application. As our understanding of additive manufacturing technologies deepens, more and more efforts are put into enabling great designs that don’t just look stunning but provide more functionality and characteristics that did not exist or co-exist before.”

You can register for the webinar here.

Heat Transfer in Medical Device Design

Local tissue heating including cooling effects of blood flow.

Speaking of designing medical devices, “Heat Transfer in Medical Device Design,” sponsored by COMSOL, will be held at 2 pm EST on Thursday the 2nd and focus on applying multiphysics simulation to medical device design. AltaSim Technologies President Kyle Koppenhoefer and Senior Engineer Joshua Thomas will share their experiences using simulations in operating medical device design in a multiphysics environment, and demonstrate an ablation device that heats tissue using high-frequency electromagnetic energy to heat tissue. They will also demonstrate the effects of necrosis on perfusion, and answer questions from attendees at the end.

“Many medical devices operate in a multiphysics environment. One of the physics that many devices rely on is electromagnetism; therefore, it is important to consider how electrical effects interact with the extraordinary complexity of the human body. This energy typically generates heat sources, which medical device engineers seek to control due to the dangerous effects of elevated temperatures on tissue. However, the complexity of the human body often causes challenges for engineers seeking to calculate temperature distribution. Multiphysics simulation helps engineers better understand how their devices will interact with the body and reduces the time needed for physical prototyping.”

You can register for the webinar here.

Using AM to Innovate Electric Vehicles

Also at 2 pm EST on the 2nd, HP is presenting a webinar titled “Innovation in the Electric Vehicle Ecosystem with Additive Manufacturing.” Discussing the EV ecosystem, opportunities with polymers for optimizing EV components, applying 3D printing to electrical distribution, finishing options and production use cases for EV components, and more, will be HP panelists Aaron DeLong, Solutions Architect, HP 3D; Wes Kramer, 3D Application Engineer; Jens Hübner, Application Specialist; and Isabel Sanz, 3D Category Business Manager.

“Major automakers are focusing on electric vehicle (EV) production as they incorporate selling only zero-emission vehicles in their future plans. In parallel, EVs have grown in popularity with recent research predicting explosive global growth in EV demand.”

You can register for the webinar here.

Markforged Metal Xpo Forged Tour Continues

Finally, Markforged is continuing its Metal Xpo Forged Tour, which is heading to multiple cities across North America. This Thursday, December 2nd, at 2 pm PST (5 pm EST), the company is heading to Canada, specifically the Hawk Ridge Systems Showroom in Richmond, BC, to enjoy food and beverages with attendees and answer questions about its metal 3D printing capabilities. If you’re in the area, come and see the company’s technology in action, and sign up to receive a free Mark Two 3D printer, and two seats for the Markforged University Virtual Metal Certification, with the purchase of a Markforged Metal X system.

“Metal 3D printing has changed, and is continuing to change the landscape of manufacturing: Markforged and our partners are hitting the road to show you how.”

You could also register for a virtual ticket to the Metal Xpo livestream on December 1st to learn and be eligible for the discount.

Do you have news to share about any future webinars or virtual and live events? Please let us know!

In this edition of 3D Printing News Briefs, we’re starting with stories from Aleph Farms and Orbex regarding their efforts to keep our planet healthy by, respectively, working towards net zero carbon and making an environmentally friendly rocket with 3D printed parts. Moving on, Additive Assurance has partnered with Volkswagen, and Penn State’s CIMP-3D is expanding its metal AM capabilities. Finally, we’ve got some research on using expandable graphite to modify PLA for FFF 3D printing.

Aleph Farms Introduces Net Zero Carbon Roadmap

Image courtesy of Aleph Farms

Israeli startup Aleph Farms, which grows steaks from non-genetically engineered animal cells, recently introduced its roadmap to achieve net zero carbon in its operations by 2025, and through its supply chain by 2030, thus fulfilling the vow it made last year. The startup created the roadmap with partner Aimee Christensen, a climate change and sustainability strategy expert and the CEO of Christensen Global Strategies, and explains what investments and strategic partnerships will necessary to improve its business bottom line and advance its environmental goals. As part of the roadmap, which includes transitioning renewable energy and optimizing energy efficiency, Aleph Farms signed a Memorandum of Understanding (MoU) with ENGIE‘s sustainability consulting arm ENGIE Impact to ensure that its operations are net-zero compatible, and is also partnering with CE Delft to analyze the life cycle impacts of its production line and supply chain.

“The production of food is one of the largest sources of greenhouse gas emissions on the planet today, and a driving reason why Aleph Farms is making long-term sustainability a top priority. Our roadmap represents significant research that will enable us to fulfill our commitment to total net zero within this decade and we strongly encourage other companies within the agrifood ecosystem to work to eliminate their carbon footprint as soon as possible,” said Dr. Lee Recht, VP of Sustainability at Aleph Farms.

Orbex Developing “World’s Most” Environmentally Friendly Rocket 

Image courtesy of Orbex

UK spaceflight company Orbex is working to launch what it calls the most environmentally friendly space rocket in the world, the 3D printed Orbex Prime. According to a new scientific study by the University of Exeter, the carbon footprint of launching the new Orbex Prime will be up to 96% lower than fossil-fueled alternative space launch programs, and produce up to 86% less emissions, thanks to its reusable design and use of renewable, ultra-low-carbon biofuel. The study shows that the 13.8 tonnes of CO2e emissions from one launch of the Orbex Prime—including direct launch emissions, indirect emissions created by producing necessary propellant fuels, and radiative forcing (RF) effects of non-CO2 emissions at high altitude—is comparable to the annual average emissions created by a single person in the UK, and that the Orbex rocket almost completely eliminates the use of black carbon emissions. As part of its commitment to offset all emissions from the rocket and its launch operations, Orbex plans to launch Prime from Scotland’s carbon-neutral Space Hub Sutherland.

“The UK space industry has a key role to play in combating climate change, for example by launching satellites that can monitor environmental changes on Earth – but such benefits must be weighed against the environmental impact of space launches, which by their nature can be highly carbon intensive. Our study shows that the launch operation planned by Orbex can result in a significantly lower carbon footprint compared to the other launch scenarios considered in our analysis,” explained Dr. Xiaoyu Yan of the Environment and Sustainability Institute at the University of Exeter.

An Executive Summary of the study, “Orbex Holistic Launch Carbon Impact Assessment,” is available upon request.

Additive Assurance and Volkswagen’s Partnership

Moving on, Australia-based Additive Assurance, a Monash University spinout company, is partnering up with Volkswagen to develop an advanced manufacturing system for its production 3D printers, as the automobile manufacturer is actively integrating AM into its workflow and working towards serial production with the technology. Volkswagen plans to install Additive Assurance’s AMiRIS solution for quality verification at its Wolfsburg, Germany AM center, in order to “assure precise replication” of all the components it prints. AMiRIS uses cloud-based machine learning software and inspection hardware, the latter of which observes the layered build process; the software first generates a real-time defect map, then analyzes and feeds the information back to operators. With this solution, Volkswagen should be able to ensure that its 3D printed parts have consistent production quality.

“Metal Additive Manufacturing is taking the world by storm, but quality is still not at the level it needs to be for important applications. We see a huge opportunity for Additive Manufacturing and are thrilled to be working with a leading company like Volkswagen to transform how they develop their products,” stated Additive Assurance Co-Founder Marten Jurg.

Penn State’s CIMP-3D Expands Metal AM Capabilities

A lot of additive manufacturing research is conducted at Penn State, and the university’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D) recently expanded its metal 3D printing capabilities by installing three new large-format AM systems. The additions of 3D Systems’ DMP Factory 500 powder bed fusion additive manufacturing (PBFAM) system, ABB Inc.‘s wire arc additive manufacturing (WAAM) system, and a cold spray metal 3D printer from SPEE3D are a great complement to the center’s excellent metal AM research, signaling more to come in the future.

The DMP Factory 500 uses multiple lasers to form solid parts out of metal powders, and includes high-speed video, an internal camera, and other custom sensors for build process monitoring, in addition to powder recycling modules. The printer was installed at CIMP-3D to support a program focused on modernizing products for the US Army. A welding arc connected to a robot allows the freestanding ABB Wire Arc Additive Manufacturing system to build large components, as it doesn’t need to manage powders or operate in a contained space. The system is paired with its larger sibling, a laser-based robotic AM printer commissioned two years ago. Finally, the new SPEE3D printer uses supersonic gas jets to propel powders at incredibly high speeds, so it sticks to parts and quickly builds new ones. The system is fast, flexible, and economic, and can be used to repair or manufacture components in the field very quickly.

Modifying PLA with Expandable Graphite for FFF Technology

Prototypes additively manufactured using FFF-type 3D printer fed with: (a) PLA-EG0%, (b) PLA-EG1%, (c) PLA-EG3% and (d) PLA-EG5%.

Finally, a team of Brazilian researchers from Universidade Federal de Ouro Preto, Centro Tecnológico do Exército, and Centro Federal de Educação Tecnológica de Minas Gerais published a paper about their work modifying polylactic acid, or PLA, filament with expandable graphite for Fused Filament Fabrication, or FFF, 3D printing purposes, and the effect of their experiments on the material’s mechanical and thermal properties. According to the researchers, FFF is the most “widespread” of the 3D printing methods, but in order to be used more for automotive and electronics applications, there’s a need for more flame-retardant filaments. The researchers added 1, 3 and 5% (wt.) of expandable graphite to commercial PLA filament, and reprocessed these composite materials into 3D printable filament, using differential scanning calorimetry and thermogravimetric analysis to determine the thermal properties. All the composites with expandable graphite achieved the V-2 rating of UL-94 flammability test, had no strong adhesion promoted between the matrix and filler in thermo-pressed specimens, but the results indicated that the PLA’s flammability was reduced.

“The possibility of printing parts with complex shapes, with the exact amount of raw material, is a great advantage of 3D printing. In this study, composite filaments based on PLA and 1, 3 and 5 wt.% of EG were developed for using in FFF-type 3D printing. The effect of EG on thermal and tensile properties of PLA was investigated. Based on the findings of these analyses, it is likely that expandable graphite needs stronger interfacial adhesion with the PLA matrix. The possibility to impart anti-flammability property to PLA filament by modifying it with expansible graphite was evaluated. All composites reached the classification V-2 in the vertical burning test (UL-94). This was not the expected result, and it’s probably due to the lack of adhesion between phases, as pointed out by the mechanical and thermal assays. The obtained composite filaments kept printable, and prototypes were successfully made from all of them. Further research should involve silane as coupling agent and also a flame co-retardant to work in synergism with expansible graphite,” the researchers concluded.

You can read the full study here.

As we’ve seen in this series, there are a number of clusters of success in 3D printing. Where we can see small, unique, drop-in, disruptive and sidestep parts, we have success. Beyond that, however, we’ve also seen that there are a lot of hopeful searches for 3D printing applications.

Here, opinion often coalesces early around one opinion and this part is then made. The component could save weight and, if it was on a satellite, this would be amazing and it would work. But, outside a few critical environments where mass is a premium, the part will actually not really be as successful as first hoped.

In order to break through in many more cases in which millions of items are 3D printed, we will need to seek success in stacking. Stacking is a case where we keep searching once we’ve found that one application that makes sense. With stacking, we keep looking once we’ve found our dream part for additive. With stacking, we will have many strong clusters of components that we may make successful.

We will then look not just at one advantage that 3D printing can provide, but see if we can make many work together. With stacking, items can break out of the confines of the critical and make sense in many industries. To explain the benefits of stacking, let’s look at one of the biggest and fastest growing areas of 3D printing: orthopedics.

Stacked acetabular cups on a GE EBM system run by Amplify Addictive.

In orthopedics, 3D printing:

1. Is cheaper
2. Is quicker for iterating and developing new products
3. Has seen more solutions tested, tried, and evaluated
4. Is a better product/market fit or better solution
5. Plays well with new software for digital advantage
6. Could make group-specific/niche implants less expensive
7. Has an advantage in osseointegration
8. Can approximate the modulus of bone better
9. Can reduce mass
10. Can make parts that expand, demonstrate wicking, and other positive features, including internal structures that can be adapted to better fit the patient
11. Can lead to geometry-specific IP
12. Could make patient-specific implants
13. Makes optimal use of an expensive material
14. Can be industrialized (expensively)
15. Can be upgraded
16. Can lead to lasting competitive advantage
17. Can result in better OE/less steps
18. Can produce fewer parts

So, these are some, but not all of the advantages 3D printing has when compared to the manufacturing techniques it replaces. Not all have to be present in every single implant, but we can see that, in the case of orthopedics, we have a lot of them. Also, if we look deeper we can see that these can be tactical, but turn out to be long-lasting, company-specific advantages.

So, in orthopedics, there is a first-mover advantage to adopt AM and also long lasting advantages to be gained from mastering AM. In a lot of cases, some of the below advantages may be of import in your industry, but, in orthopedics, all of the following are relatively important.

The Trinity PLUS 2 is a highly porous acetabular cup made with Arcam EBM by the Corin Group.

Cost

Let’s start with the factor that is almost never realized. We’re almost never cheaper. Really and rarely do you find products silly, important, specific or rare enough to be more expensive than a 3D printed variant. In orthopedics, we’re one-tenth of the price of (some) CNC implants because we can make a texture that promotes osseointegration easily. The cost advantage is such that it could in-and-of-itself explain why orthopedics companies are so excited about 3D printing. But, it’s not just a case of them wanting to save money per implant.

Speed and Invention

They also want to be more competitive and with 3D printing they can iterate, test, and develop products more quickly. The quicker pace of iteration leads to faster generation of inventions and geometry-specific IP. But, it also means that the company can invent more shapes and test more shapes to productize the right ones.

By testing things quicker digitally or with the 3D printed part, companies can ascertain, develop, design, test and patent new designs more quickly than others. They can also test more different parts or designs in destructive testing. This will let them find the right solution more often and also eliminate design flaws more readily. This is of crucial import in the orthopedics market where a single design flaw can be incredibly expensive.

Fitting the Application

More testing, more information, more designs and more malleable designs will make for a firm that more quickly develops the right solution for the right application. This can lead to a better solution or a better fit with the market. What’s more, this is important in their industry due to the pace of innovation and quality.

Simulation

3D printing also plays very well with finite element analysis, digital simulation and calculation software. Simulation that can accurately predict stresses, load-bearing capacity and more can be combined with 3D printing. This let’s you more accurately develop products faster than without a combination of simulation, design and AM. New developments such as musculoskeletal modeling will accelerate this trend. At the same time, 3D scanning may play more of a role in error analysis and the redesign of appropriate structures, which will only accelerate this development. We play better with digital tools because we are digital.

Certifications

All in all, this means that it is faster to develop new products with 3D printing in orthopedics than without it. With certification and approvals being costly, it helps that a similar logic, similar data, similar process, and the same material and process can accelerate approvals and make them less expensive.