3D printer leuven

Leuven.AM wants to increase the added value of 3D printing

KU Leuven is a pioneer in three-dimensional printing, and the University has strengthened this reputation in the last three decades. The sector continues to evolve, the technology constantly improves, and the quality of the material increases. Leuven.AM, the KU Leuven Institute for Additive Manufacturing, wants to help shape this evolution.

Leuven.AM may only recently have been recognised as a KU Leuven Institute, but the University has enjoyed an excellent reputation in the field of 3D printing since the 1990s. At the time, Emeritus Professor Jean-Pierre Kruth was, together with Jan Van Humbeeck, one of the founders of the scientific research on what was then a radically innovative technology. It resulted in two successful spin-offs: Materialise and LayerWise, which is now part of 3DSystems.

"The approach to the research has been interdisciplinary since the early years", says Brecht Van Hooreweder, director of Leuven.AM. "There has always been consultation and concerted action between various departments, such as Mechanical Engineering, Materials Engineering, Chemistry and Computer Science. Gradually, other research groups joined as end-users of the 3D printing technology. We want to use the recognition as an Institute to forge even better relationships, especially with University Hospitals Leuven (UZ Leuven) and in the healthcare sector. We are not fully aware yet of each other's capacities and needs."

One layer at a timeIn the past five years, additive manufacturing
activities at KU Leuven have tripled. The
brand-new AM Lab will soon open its doors.

It's Leuven.AM and not Leuven.3D, because in engineering, the term additive manufacturing (AM) is the set expression. "You make a virtual design on the computer, which you then divide into layers", explains Professor Van Hooreweder. "Next, you print those layers with plastic material for example, or metals, such as steel, copper or titanium. We build the object one layer at a time, each time adding something, hence additive."

The 3D printing sector is growing every year, on average by 25 per cent. So more and more products are being 3D printed, but additive manufacturing won't completely replace conventional production techniques, indicates Van Hooreweder. "3D printing offers a lot of design flexibility, and the step from the design to the product is small. On the other hand, the cost price for mass production is usually high. So you have to consider in which cases 3D printing has enough added value."

Leuven.AM will be focusing on healthcare and on a close collaboration with the UZ Leuven colleagues to achieve that added value. "Many clinicians don't know all the possibilities in terms of shapes and materials. The 3D data are in many cases already available through medical scans. That allows us to offer solutions tailored to the patient: think of personalised hip prostheses, spinal or dental implants. The same applies to medical and surgical materials. Even printing personalised medication is possible. Ideally, design and production take place in the hospital itself to limit turnaround time."

Fascinating technology

The sector continues to develop. The same goes for KU Leuven: in the past five years, additive manufacturing activities have tripled. The brand-new AM Lab will soon open its doors. "Our machines are designed and built in-house", says Brecht Van Hooreweder. "That way, we are always one step ahead and can immediately experiment with new materials, techniques and printing processes."

"Through Leuven.AM, we want to reinforce the research, but we also want to make young people enthusiastic about science and engineering. The possibilities of 3D printing are endless: you can give your imagination free rein and design the craziest things. That creativity and freedom make this technology very fascinating."

Leuven, Belgium: The HP Jet Fusion 3D Printer Soon to Arrive at the Materialise Factory - 3DPrint.com

While Materialise is a company we follow often, as they offer us everything from software upgrades and new tools to news regarding their latest expansions, we can actually say again that they have some pretty big news upon the announcement of incoming hardware, in the form of the HP Jet Fusion 3D Printer. The Belgium-headquartered leader in 3D printing software and services will now be using the HP technology at their 3D printing facility in Leuven, Belgium. And of course, formnext was the place to make this announcement, as the company shows off their many wares at the Frankfurt show from booth F28 in Hall 3.1

HP’s Multi Jet Fusion 3D printer is one we’ve certainly been watching since its release, along with the rest of the world—and it’s certainly no surprise that Materialise would want to be one of the first getting in on this machine that offers such new power and versatility.

This will certainly be a strong addition to an already stellar facility, allowing them to offer their customer base special access to the latest 3D printing manufacturing, as well as new software. The goal of HP in creating the Jet Fusion 3D Printer was to ‘reinvent’ the way that the 3D printing industry creates both prototypes and production parts.

“Our initial work with HP focused on developing a Build Processor that connects HP’s Multi Jet Fusion technology to our software backbone for 3D Printing,” stated Fried Vancraen, Materialise CEO. “Now that our HP Build Processor Beta is officially certified for the HP Jet Fusion 3D Printers, we found it very important to bring the system to our Factory in order to ensure that both users of the Materialise Magics 3D Print Suite and those partners turning to us for the manufacturing of functional prototypes and final production parts have continued access to premium technologies. The upcoming installation of HP’s Jet Fusion 3D 4200 Printer is of high significance for our business and our customers as it will further differentiate our 3D offering. ”

“3D printing is quickly evolving from prototyping into full-scale manufacturing, and HP is committed to working with industry leaders like Materialise to make the process faster and less expensive,” said Stephen Nigro, President of HP’s 3D printing business. “The installation of the HP Jet Fusion 3D Printing Solution in Materialise’s Factory for 3D Printing will enable the manufacturing and software teams, and Materialise customers, to push the limits of what is possible with the technology. HP looks forward to the best-in-class solutions Materialise will create for industrial 3D Printing across exciting vertical markets such as automotive, consumer goods and healthcare.”

This is a strong partnership indeed as the two companies together offer many decades of expertise in both software development and printer manufacturing, coming together to integrate the Materialise software and the HP Jet Fusion 3D Printing solution.

If you are attending formnext this week, be sure to stop by the Materialise booth. Discuss in the HP Materialise forum at 3DPB.com.

Stay up-to-date on all the latest news from the 3D printing industry and receive information and offers from third party vendors.

Tagged with: belgium • formnext • formnext 2016 • HP Jet Fusion 3D printing technology • HP Multi Jet Fusion • HP multi jet fusion 3d printer • materialise • Materialise 3D printing factory • Multi Jet Fusion 3D printer • Multi Jet Fusion 3D printing technology

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Creation of a radio-frequency filter on a 3D printer

Aerospace industry

Implementation stories

Author: Semyon Popadyuk

2015 and 2016 can be considered a breakthrough for metal 3D printing technology (selective laser melting) in the aerospace industry, since it began to be used not only for the manufacture of prototypes, but also for the production of parts and assemblies of aircraft. During these two years, Airbus Defense and Space, with the support of 3D Systems, has managed to make a truly revolutionary breakthrough. nine0003

The first 3D printed RF filter has been tested and is ready for use on commercial long-range satellites. Funding for the project was provided by the European Space Research Agency.

Metal RF and waveguide filters appeared almost half a century ago with the first space communication systems. By their principle of operation, the filters are reminiscent of traffic controllers: they pass the frequencies of some channels and reject the signals of others. nine0003

There is a general trend in the aerospace industry today towards more beam power per satellite. A high power satellite such as Eutelstat KA-SAT (manufactured by Airbus Defense and Space) has about 500 RF filters and more than 600 waveguides. Many of them are custom-made and designed for specific frequencies.

Compliance with stringent Airbus

requirements

Airbus Defense and Space 3D printed RF filter integrated with satellite payload. Compared to the previous model, the weight of the new filter is halved nine0003

Long-haul satellites are a clear indication of the industry's relentless drive to reduce the weight of equipment, because launching a satellite into geostationary orbit can cost $20,000 per kilogram. Continued innovation and reduced production times are other priorities, as most satellites have a lifespan of 10–15 years.

Given these priorities, long-range satellites are proving to be ideal candidates for metal 3D printing. The 3D Systems ProX® DMP 320 printer used to make an RF filter for Airbus allows you to produce one-piece parts, improve their functionality with shapes and surfaces that can not be obtained with traditional methods, reduce production times and reduce costs for custom orders, as well as reduce the weight of products, while maintaining and even increasing the strength of the material. nine0003

New challenge for proven 3D printer

3D Systems in Leuven, Belgium has been using the 3D Systems ProX DMP 320 printer since it was in beta testing. Successful projects include topological optimization, weight reduction and the creation of one-piece, rather than multi-piece parts designed for space flights, namely brackets and connecting fittings for long-range satellites. For the Airbus Defense and Space project at 3D Systems in Leuven, this was the first time they had to work with RF filters. nine0003

The ProX DMP 320 3D printer is designed to deliver high precision and productivity in harsh environments around the clock. A wide range of LaserForm alloys (titanium, stainless steel, aluminum, nickel-chromium and cobalt-chromium) has been developed and tested specifically for this printer to achieve high product quality and consistent performance.

Interchangeable construction material compartments provide a wide range of applications and reduce non-productive time when changing from one material to another. Thanks to a controlled vacuum build chamber, each product is manufactured with the desired properties, density and chemical purity of the material. nine0003

Innovative design

The RF filter project for Airbus Defense and Space shows that 3D printing technology can be used to find innovative technical solutions for components for the aerospace industry, an area that has not seen any significant changes for decades.

RF filters are usually designed using sets of standard elements such as rectangular resonators and waveguide cross-sections with perpendicular taps. Shapes and connections are dictated by standard manufacturing processes such as milling and EDM. As a result, RF filter resonators usually have to be made from two halves that are bolted together. This increases the weight of the product, adds another step to the manufacturing process and requires additional quality control. nine0003

Designing elements for 3D printing has given Airbus Defense and Space the ability to explore complex geometries without additional production costs.

The RF filters for 3D printing were developed using the standard CST MWS electromagnetic 3D modeling program with a little optimization. The use of 3D printing has increased technological flexibility and made possible the appearance of a design with a concave superellipsoidal resonator shape. This unique shape made it possible to conduct high frequency currents and to find the optimal ratio between the quality factor (a measure of the efficiency of a waveguide based on energy losses) and the suppression of signals out of range. nine0003

“An innovative breakthrough is that the design of equipment is now determined by pure functionality, and not by the ability to manufacture,” says Koen Huybrechts, design engineer at 3D Systems in Leuven. “This project is a classic example of form as a derivative of function.”

“The main benefits of the monolithic design made possible by 3D printing are the reduction in weight, cost and time,” says Paul Booth, RF Engineer at Airbus Defense and Space in Stevenage, UK ). – The mass was reduced due to the fact that there was no need to use fasteners. 3D printing with metals also, without any additional costs, provides such an advantage as a tighter fit of the outer profile to the inner one, so exactly as much metal is consumed as really needed. The time and cost savings come from the reduction in assembly and post-processing steps.” nine0003

Surface Topology Solution

The internal structure of an RF filter printed on a 3D Systems printer

At first, the developers thought that differences in the topology of the surfaces of parts printed on a 3D printer would create a problem, but after numerous tests, Airbus Defense and Space specialists removed all concerns.

“Machined surfaces have sharp ridges and notches,” Booth explains, “whereas the surface of 3D printed parts is fused ellipsoids, so it’s smoother.” nine0003

“The spherical shape of the metal powder particles used for 3D printing results in some waviness and lack of sharp transitions,” notes Huybrechts, “but the ability to shape the part to more effectively filter the signal more than overcomes any concerns associated with surface topology.”

“We are very pleased with the work that 3D Systems has done for us. Many Airbus experts noted the high quality of the surface, Bout noted. “We did an X-ray inspection and were impressed with the density of the material and the overall surface quality.” nine0003

Intensive testing

Airbus Defense and Space at its Stevenage plant tested three aluminum samples printed on a ProX DMP 320 printer with different types of processing. The tests reproduced the conditions that products will be subjected to during launch and in orbit, including vibration, shock and thermal loads (temperature changes and vacuum). All three samples either met or exceeded the requirements, with the best results being the filter with a silver-plated surface obtained by electrolysis. nine0003

In addition to 3D printing, collaboration with 3D Systems has brought other important benefits for this type of project, including the assistance of certified specialists in working with metal powder, process control to ensure high material density, post-processing and reliable quality control.

According to Booth, 3D Systems' experience and knowledge played a key role in the successful outcome of the project: "We understand that we owe the success of the project not only to good equipment, but also to excellent understanding of the technological process by 3D Systems specialists." nine0003

Great economic potential

The RF filter developed by Airbus Defense and Space is the combination of two parts into one single piece. The result is a reduction in the overall weight of the product. 3D printing reduces costs and production time

Now that the process has been established and the products have proven to meet the stringent aerospace industry standards of Airbus Defense and Space, the company has begun calculating the ROI potential of metal 3D printing technology. The profitability potential that the project showed could light up any CFO's eyes: reduced production times, reduced production costs and halved the weight! nine0003

“We have been able to reduce the mass without wasting time on optimization,” comments Booth, “and by refining the design, it can be further reduced. The reduction in mass will help save fuel for the rocket engines, as well as reduce the load on the support structures, which, in turn, will further reduce weight.

The success of this project opens the door to closer integration of RF filters with mechanical and thermal elements in order to reduce the number of parts and the overall weight of the equipment. We hope to further expand the functionality of the satellites, for example by including test connectors in filters or directly in the wave paths. We see huge potential in 3D printing in terms of weight reduction, as well as reducing costs and production times.” nine0003

iQB Technologies invites you to order one of the following services: expert advice, 3D training, test 3D printing/3D scanning, visiting your company, diagnostics or ordering 3D equipment.

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Article published on 20. 09..2017 , updated 04/08/2021

3D printing makes diagnostic tests faster and cheaper

05/11/2021 18:38

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Researchers from KU Leuven (Belgium) have developed a technique 3D printing, which will allow faster and cheaper production laboratory tests for self-diagnosis of diseases, as well as will expand the capabilities of these tests, transfer press service of KU Leuven. The new technology is described in detail in the journal nine0083 Advanced Materials.

Self-diagnostic tests – such as the COVID-19 and pregnancy are the so-called lateral flow tests. Sample material is taken through the nose using a swab. Then it dissolved in a solvent and applied to the test kit. The absorbent material in the kit moves the sample downstream and brings it into contact with the antibody. If the virus is present, a colored line appears. The advantage of these tests is that they cheap and do not require any special equipment. nine0003

Sidestream tests are useful when enough get a yes-no answer, but not for tests that require multi-step protocol. That's why the bioengineers from KU Leuven decided to develop a new type of lateral flow test with extended opportunities.

Using a 3D printer, the researchers made a three-dimensional version side flow test. The base is a small block of porous polymer, in which "ink" with certain properties applied in certain places. This is how the network is printed canals and small "locks" that allow flow or block it where and when necessary, without the need for moving parts. During the test, the sample automatically passes various stages of analysis. Thus it will be possible to follow even complex protocols. nine0003

The researchers evaluated their technique by replicating the ELISA test (enzyme-linked immunosorbent assay), which is used to detect immunoglobulin E (IgE). Ig E is measured to diagnose allergies. In the laboratory, this test requires several steps with different rinsing and changing the level of acidity. Research the group was able to start this whole process using a printed a test kit about the size of a thick credit card.

“The great thing about 3D printing is that you can quickly adapt the test design to suit another type of tests: for example, to detect a cancer biomarker. For For a 3D printer, it doesn’t matter how complex the network of channels is.” – note the authors of the work. nine0003

3D printing techniques are also available and scalable. "In our laboratory production of a prototype Ig E test costs about 1.50 dollar, but if we can increase it, it will be less than 1 dollar,” the researchers say. dj. This method offers opportunities for cheaper and faster diagnostics of only in developed countries, but also in countries where medical infrastructure is less accessible and where there is a strong need in available diagnostic tests.

The research team is currently developing own 3D printer, which will be more flexible than commercial model used in the current study. “The optimized printer is a kind of mobile mini-factory, which can quickly produce diagnostics. Then you can create different types of tests just by uploading another one design file and ink. We want to continue our research diagnostic problems and applications with the help of partners”, – says Innovation Manager Bart van Duffel. nine0003

[Illustration: AMELOOT GROUP]

Author Prepared by Tatyana Matveeva

3D printing polymers self-diagnosis tests for the diagnosis of diseases

Source: nieuws.kuleuven.be

Information provided by the Information Agency "Scientific Russia". Mass media registration certificate: IA No. ФС77-62580, issued Federal Service for Supervision of Communications, Information Technology and Mass Communications on July 31, 2015. nine0003

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