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ExOne and Rapidia launch Metal Designlab 3D printer and X1F furnace- technical specifications and pricing

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Binder jetting 3D printer manufacturer ExOne and Canadian metal 3D printing company Rapidia have launched the Metal Designlab system and X1F furnace. 

As part of a new partnership between the firms, ExOne will exclusively market the machines, which feature Rapidia’s proprietary ‘two-step’ 3D printing technology. The technique is predicated on a water-based metal paste, that evaporates during printing, removing the need for any time-consuming polymer debinding steps.

The deal also gives ExOne first refusal over any future acquisition of its Vancouver-based partner, and sees Rapidia’s founder Dan Gelbart join as a ‘technical advisor.’ According to John Hartner, CEO of ExOne, the partnership will enable its clients in the industrial and education sectors to access an accelerated production workflow.

“We are delighted to partner with the visionary Dan Gelbart and the Rapidia team,” said Hartner. “Now researchers, educators, and industrial designers will be able to bypass days of waiting and produce high-quality parts without the limitations faced by parts that require traditional debinding.”

“This technology is a true time-saving innovation that complements ExOne’s portfolio.”

Rapidia’s ‘Two-step’ technology 

Essentially, Rapidia’s proprietary two-step technology involves 3D printing directly onto a mildly-heated glass bed using a water-based metal or ceramic paste called ‘HydroFuse.’ The technique is advantageous because the resulting parts don’t require debinding before sintering, reducing what’s usually a ‘three-step’ process into a ‘two-step’ one.  

Traditionally, three-step approaches have involved 3D printing objects with polymeric binders, but this causes shrinkage once they’ve been burnt off which sometimes limits their applications. By contrast, Rapidia’s pastes replace 98% of the binder with water which evaporates during printing, serving to lift any part thickness limitations and expedite the process. 

Uniquely, Rapidia’s technology also allows for both 3D printed and machined parts to be moistened, stacked on top of one another and combined into a unified structure. By partnering with ExOne, Rapidia will effectively be able to utilize its reseller network, and market its two-step process to a wider audience.

For ExOne, meanwhile, the deal enables it to leverage the technology to broaden its existing metal 3D printing portfolio, as well as bolster its own capabilities. What’s more, given the interest in binder jetting technologies driven by Desktop Metal’s decision to go public, now could be the ideal time to market its new machines.

ExOne’s new machines (pictured) are powered by Rapidia’s ‘two-step’ 3D printing technology. Image via ExOne.

The Metal Designlab and X1F systems 

ExOne’s Metal Designlab 3D printer is based on the technology used within Rapidia’s earlier machines, and it functions using the same two 0.4mm or 0.6mm independent extruders. Similarly, with dimensions of 78 x 70 x 157 cm, the system remains relatively small, and its compatibility with water-soluble binders makes it somewhat ‘office-friendly.’

With regards to build volume, the Designlab is a little bigger than Rapidia’s initial machine at 200 x 280 x 150 mm, and requires 110-125 AC of power to run at a speed of 2.4 inches per hour. The overall system weighs in at 100kg, rising to 120kg once filled with cartridges, and the printer allows four of these to be loaded at one time. 

In terms of materials, the Designlab is currently compatible with the 17-4PH and 316L stainless steels, with the promise of more new alloys and ceramics to come. Each refillable cartridge measures 7 cm x 35 cm, and contains 4-5 kg of ‘HydroFuse’ alloy, that’s designed to allow users to fabricate complex support-free metal parts. 

Understandably, the X1F furnace system weighs a heavier 500kg, but it has the same 235mm x 400mm volume as Rapidia’s earlier machine. The furnace is also controlled by a similar 10-inch touch screen, and because it’s powered by a regular 220-240 AC socket, it doesn’t require any special installation by an engineer either. 

Technical specifications and pricing

Below are the technical specifications for the Metal Designlab 3D printer and X1F furnace. Orders are now being accepted for both machines, with delivery available from Q2 2021 onwards. Readers interested in purchasing the systems can visit the ExOne website for a quote.

Metal Designlab 3D printer
Print Technology Extrusion of water-based paste
Build Volume 200 x 280 x 150 mm
Resolution 0. 6mm and 0.4mm nozzles
Print SpeedOver 40 cc (2.4 cubic inch) per hour
Print SheetFlexible stainless steel, reusable
Computer InterfaceUSB 
Dimensions 78 cm (W) x 70 cm (D) x 157 cm (H)
Weight 100 kg, 120 kg with four full cartridges

 X1F furnace
Atmosphere Forming gas (3% h3 in Ar)
Max Temperature1400 °C 
Inside Dimensions235 mm (D) x 400 mm (L)
Outside Dimesions78 cm (W) x 105 cm (D) x 188 cm (H)
Weight 500kg
Power220-240 VAC, 50/60 Hz
VentilationSingle ½” plastic tubing vented to outside
Control10” touch screen

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Featured image shows a concept image of ExOne’s new Designlab 3D printer and X1F furnace. Image via ExOne.

Tags Designlab 3D printer Desktop Metal Exone John Hartner Rapidia X1F furnace

Paul Hanaphy

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

New ExOne S-Max Flex sand binder jetting system to debut at CastExpo

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The most affordable sand 3D printer ever offered by binder jetting pioneer ExOne, the all-new S-Max Flex, will debut at CastExpo 2022 in Columbus, Ohio, on April 23. The new machine has been designed from the ground up as a robotic 3D printing system that combines industry-leading binder jetting expertise from ExOne and Desktop Metal (and possibly ETEC Viridis as well). It features Single Pass Jetting technology and will enable more foundries than ever to enjoy the benefits of sand 3D printing technology.

Targeted at the growing number of foundries and pattern shops looking to step into the next era of metal casting, the ExOne S-Max Flex is a simple and easy-to-use sand printing system with a quick payback. By pairing an industrial robot (similar to the one used by Viridis, also part of the Desktop Metal group now), with an all-new printhead and recoater design worthy of the trusted S-Max name, ExOne — in partnership with new owner Desktop Metal —  created an Additive Manufacturing 2.0 system designed to democratize sand 3D printing for the foundry industry.

The combination of multiple sand binder jetting technologies into one company is “bound” to bring significant benefits in terms of leveraging best practices and more efficiently targeting the foundry segment. The benefits of sand binder jetting AM in large foundry core, patterns and mold production has been amply demonstrated as reported in 3dpbm Research’s report on the Ceramic AM market. The new system’s debut at CastExpo 2022 will help drive greater awareness.

The robotic sand binder jetting system developed by Viridis, a company later acquired by EnvisionTEC, now rebranded ETEC and part of the Desktop Metal group.

With a giant build volume of 1900 x 1000 x 1000 mm (39.4 x 74.8 x 39.4 in), and build rate up to 115 l/h, this new turnkey system was developed to help smaller foundry businesses both survive and thrive into the future. The S-Max Flex allows its owners to offer quick turnaround times on high-quality sand molds and cores regardless of complexity – eliminating the need for traditional core production and assembly, and all the labor, scrap, and complication that comes with it. The S-Max Flex is intended to keep foundries competitive by enabling same-day castings of the complex cores becoming increasingly common as manufacturers consolidate and lightweight metal parts for electric cars and a new future. What’s more, this system enables foundries to operate more efficiently, despite labor shortages and supply chain challenges.

The system on display at CastExpo 2022 will also feature an all-new kinematic Single Pass Jetting printhead and recoater assembly designed by Desktop Metal and tested with input from ExOne’s experienced sand 3D printing team It will be combined with a proven industrial robot enabling a flexible layout and ease of access for routine service and maintenance. Desktop Metal’s easy-to-use Fabricate MFG integration will automatically nest parts within the job box for the highest accessibility.

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