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Desktop Metal launches affordable new ExOne S-Max Flex 3D printer: technical specifications and pricing

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Industrial 3D printer manufacturer Desktop Metal (DM) has announced the launch of an accessible new binder jetting system. 

Built using the combined technologies and expertise of Desktop Metal and its subsidiary ExOne, the S-Max Flex is specifically designed to provide foundries with a robust, low-cost means of creating sand tooling for metal casting applications. 

As ExOne’s most affordable unit to-date, the Flex effectively makes S-Max technology available to a wider base, and in doing so, allows more users to rapidly cast complex metal parts for clients, including those operating in the aerospace, automotive and energy sectors, amongst others.

“We designed the all-new S-Max Flex from the ground up leveraging Single Pass Jetting (SPJ) technology with the idea of making premium sand 3D printing accessible to every foundry, so that more companies can take advantage of the benefits of AM 2. 0, such as distributed, local production, and remain competitive for the long-term,” said Ric Fulop, Co-Founder and CEO of Desktop Metal.

“To achieve our vision of Additive Manufacturing 2.0, we need to make production 3D printing practical in terms of speed, cost, and material availability for a broad range of applications.”

Desktop Metal’s expanding portfolio 

Since it was founded in 2015, Desktop Metal has established itself as one of the leaders in the binder jet 3D printing space. One way the firm has managed to achieve this is via the sale of machines fitted with its Single Pass Jetting technology, a process which sees the steps behind binder jetting combined into the pass of a single, integrated carriage.  

Desktop Metal’s current 3D printer portfolio includes the Shop System and Production System, and it continues to expand on their material compatibility as a means of growing its accessible markets. Just last year, the company became the first to qualify 4140 low-alloy steel for use with binder jetting, shortly after launching a sustainable wood 3D printing technology via its Forust subsidiary. 

In the aftermath of Desktop Metal’s SPAC merger in late-2020, it has also sought to accelerate its growth trajectory via a string of acquisitions. This strategy has seen the firm buy recoater system developer Aerosint, acquire hydraulic power specialist Aidro, snap up EnvistionTEC (now ETEC) for $300 million, and most significantly purchase ExOne for $575 million, one of its key binder jetting rivals. 

Having bought ExOne, Desktop Metal has now not only carried out some rebranding, adding the InnoventX, X25Pro and X160Pro to its ‘X-Series,’ but it has now poured the firms’ combined expertise into the design of a new low-cost digital casting solution.  

Desktop Metal’s new ExOne S-Max Flex 3D printer. Photo via Desktop Metal.

Introducing the S-Max Flex 

According to Desktop Metal, foundries are enjoying a period of strong demand for castings, but they’re struggling when it comes to finding labor. Citing data provided by the American Foundry Society, the firm says that 90% of surveyed foundries are therefore seeking to take advantage of this trend, by making capital investments over the next year. 

This is where the S-Max Flex comes in, as by packing SPJ technology into a more affordable architecture, it’s designed to offer a new value proposition to foundries seeking to expand their capabilities. Through teaming an industrial robot with an all-new end effector, the system is able to selectively deposit binder into a 1900 x 1000 x 1000 mm telescoping build box, at a rate of up to 115 liters per hour. 

As a result, just like the more premium S-Max and S-Max Pro models, the Flex offers users the opportunity to reliably churn out parts, while achieving a rapid return on investment. The build box itself is also available in larger volumes up to 4700 x 1000 x 1000 mm in size, in addition to taller 1000 x 2500 x 2400 mm variants, enabling foundries to adopt a machine that’s tailored to meet their specific needs. 

Application-wise, given the system’s large size and ability to jet a variety of powders into parts with a dimensional accuracy of +/- 0.5 mm, Desktop Metal says it could soon address “industries beyond metalcasting.” For now, early adopters of the Flex include Founders Service & Manufacturing Co. and HTCI Co, while Desktop Metal’s Forust brand is also set to use it to print large, cost-effective wooden parts. 

A set of sample parts produced via the ExOne S-Max Flex 3D printer. Photo via Desktop Metal.

Technical specifications and pricing 

Below are the technical specifications for the ExOne S-Max Flex 3D printer. The system is set to debut at the CastExpo 2022 metal casting trade show from April 23-26 in Columbus, Ohio. In the meantime, those interested in acquiring the system can contact Desktop Metal for a quote. 

Binder System Furan 
Job Box 1,900 x 1,000 x 1,000 mm
Build Volume 1,900l
Build Rate Up to 115 l/h
Layer Height 0.28 to 0.5 mm
Dimensional Accuracy +/- 0.5 mm
Exhaust Air26 m³/h
External Dimensions 8.5 x 4.9 x 4.9 m
Weight 5,900 kg

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Featured image shows Desktop Metal’s new ExOne S-Max Flex 3D printer. Photo via Desktop Metal.

Tags aerosint Aidro American Foundry Society CastExpo 2022 Desktop Metal ETEC Exone Forust Founders Service & Manufacturing Co HTCI Co Ric Fulop S-Max Flex

Paul Hanaphy

Paul is a history and journalism graduate with a passion for finding the latest scoop in technology news.

X-Series | Desktop Metal

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Systems Overview

  • — 01

    InnoventX

    The most compact binder jet 3D printer for the production of metal, ceramic or composite parts. Launched in 2018, this easy-to-use system features Triple ACT and a piezoelectric printhead. It’s suitable for education, research, prototyping, rapid product development, and short-run production of small components.

    InnoventX

    InnoventX

    The most compact binder jet 3D printer for the production of metal, ceramic or composite parts. Launched in 2018, this easy-to-use system features Triple ACT and a piezoelectric printhead. It’s suitable for education, research, prototyping, rapid product development, and short-run production of small components.

    [SPECS]

     

    InnoventX

    Print Technology

    Triple Advanced Compaction Technology™

    Print direction

    Uni-directional

    Build box size

    160 x 65 x 65 mm (6. 3 x 2.5 x 2.5 in)

    Max build rate (65μm layer thickness)

    54 cc/hr

    Binder Systems

    AquaFuse™, CleanFuse™, FluidFuse™, PhenolFuse™

    External dimensions

    1203 x 1016 x 1434 mm (47.4 x 40.0 x 56.5 in)
    Download Spec Sheet

  • — 02

    X25Pro

    This mid-volume advanced binder jet 3D print system is already being used globally for the production of metal, ceramic and composite parts. Launched in 2020, this system features Triple ACT and a piezoelectric printhead. It’s suitable for research, prototyping, rapid product development, short-run production or continuous 24/7 production.

    X25Pro

    X25Pro

    This mid-volume advanced binder jet 3D print system is already being used globally for the production of metal, ceramic and composite parts. Launched in 2020, this system features Triple ACT and a piezoelectric printhead. It’s suitable for research, prototyping, rapid product development, short-run production or continuous 24/7 production.

    [SPECS]

     

    X25Pro

    Print Technology

    Triple Advanced Compaction Technology™

    Print direction

    Uni-directional

    Build box size

    400 x 250 x 250 mm (15. 75 x 9.84 x 9.84 in)

    Max build rate (65μm layer thickness)

    1,200 cc/hr

    Binder Systems

    AquaFuse™, CleanFuse™, FluidFuse™, PhenolFuse™,

    External dimensions

    2300 x 1800 x 2300 mm (90.5 x 70.9 x 90.5 in)
    Download Spec Sheet

  • — 03

    X160Pro

    The world’s largest binder jet 3D printer for the production of metal, ceramic or composite parts. This system features Triple ACT and a piezoelectric printhead. It's designed for continuous 24/7 production, yet supports short-run production, rapid product development, and even research and prototyping

    X160Pro

    X160Pro

    The world’s largest binder jet 3D printer for the production of metal, ceramic or composite parts. This system features Triple ACT and a piezoelectric printhead. It's designed for continuous 24/7 production, yet supports short-run production, rapid product development, and even research and prototyping

    [SPECS]

     

    X160Pro

    Print Technology

    Triple Advanced Compaction Technology™

    Print direction

    Uni-directional

    Build box size

    800 x 500 x 400 mm (31. 5 x 19.7 x 15.8 in)

    Max build rate (65μm layer thickness)

    Up to 3,120 cc/hr

    Binder Systems

    AquaFuse™, CleanFuse™, FluidFuse™, PhenolFuse™,

    External dimensions

    3300 x 3300 x 2700 mm (130 x 130 x 107 in)
    Download Spec Sheet

Applications by Industry

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ExOne 3D printers. 3D printing with sand. Production of sand molds

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ExOne's history dates back to 1995 when Extrude Hone ProMetal was founded to develop metal 3D printers.

In 1998, Extrude Hone released the world's first commercial inkjet metal 3D printing machine, developed at MIT, the ProMetal RTS-300. The system printed with a mixture of metal powder with a binder, which was subsequently melted in a high-temperature furnace and sintered the metal particles together. The first ProMetal RTS-300 system was installed at Motorola.

Read more…

In 2002, Extrude Hone launched a sand 3D printer for 3D printing molds for metal casting. This process is sometimes referred to as "indirect" 3D printing because the printed molds are used to create finished metal products by casting.

In 2013, the company was restructured and changed its name to ExOne Company, in addition, the firm completed a successful initial public offering on the Nasdaq in the same year.

By 2019, ExOne has launched more than 12 models of industrial 3D printers for printing with metals, sand, ceramics and composite materials. About half of the ExOne machines installed worldwide are used for 3D printing of molds for metal casting, the other half are used for direct 3D printing with metal, ceramics and composite materials.

Today ExOne is the undisputed world leader in the production and supply of additive systems using binder jetting inkjet technology. Hundreds of ExOne pieces of equipment have been installed in industrial plants, research centers, medical educational institutions for the production and development of finished products and test prototypes.

One of the main advantages of 3D printing on ExOne equipment is the ability to combine several metal parts into a single product, which is manufactured in one production cycle, previously, when manufacturing a similar product using traditional methods, it was necessary to produce several parts, which were then assembled into a single assembly by fastening, welding and other types of connection.

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