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HDFab 3D Printer Unveiled: Capable of Printing Advanced Materials Using New Pressurized Spray Technology - 3DPrint.com
This has already been a big year within the 3D printing industry. We’ve seen numerous new technologies as well as materials emerge as print speeds increase, prices decrease, and the number of machines sold skyrockets.
One company which is making waves within the space is HotEnd Works, a company who thrives on pushing the limits of advanced materials. They have recently unveiled a new patent pending method of printing called Pressurized Spray Technology (PSD), which is inherent in their soon-to-launch 3D printer, the HDfab. Utilizing this new technique, HotEnd Works is able to rapidly fabricate objects using advanced materials and ceramics such as alumina (AL2O3), zirconia (ZrO2), zluminum nitride (AlN), tungsten carbide (WC), silicon carbide (SiC), boron carbide (B4C), and a variety of ceramic-metal matrices.
“The PSD™ technology was developed from my and my team’s experience with spray technology while working in the industry,” explained Benjamin Becker, Managing Director of the Oberlin, Ohio-based company.
“We had been working on a thermoplastic-based binder system to incorporate powdered advanced materials for extrusion. When we discovered the inherent disadvantages of the extrusion method, such as voids within a component and the ‘stair-stepping’ effect, we drew on our spray technology experience and came up with the jetting nozzle that is used with the PSD™ technology. The idea is that the parent material being jetted, such as an advanced ceramic, has a high enough velocity to embed itself into the previously deposited layer, forming a stronger, more dense part.”
The PSD process, which is explained in greater detail here, works by using two different materials during the fabrication process — a main parent material and then a polymeric binding material. The binding material is pretty much for temporary support and adhesion of the parent material, and it can be removed using a heated finishing process. The majority of materials which have melting points over 250ºC can be used with this process, and the parts which are fabricated with the HDfab 3D printer are incredibly dense.
This means no fillers are required, and the parts are pure. Not only is quality one of the outcomes of this new process, but it can all be done at speeds which seem almost unfathomable within the high-end additive manufacturing space. Becker tells us that his machines can dispense material at a rate of 2.5 cc/min, and would be perfect for numerous industries which rely on the manufacturing of components and prototypes using advanced materials.
“Every industry uses advanced materials,” Becker told 3DPrint.com. “I would say our biggest feedback has been from the Defense, Aerospace, and High Technology sectors. We’ve also worked with consumer goods companies as well as the price to manufacture components using our system is often less than traditional advanced material manufacturing methods, while allowing for more freedom during the design process.”
Becker expects that the HDfab printer will be released early next year at a price of around $55,000 per unit.
The machine, which is the product of years of research and development, will likely be shipped with a build envelope of 8 x 8 x 8 inches, although Becker tells us that the system is incredibly easy to scale, so larger machines are feasible as well.
“I became involved in the 3D printing scene because of the lead times and pricing, specifically within the advanced ceramics industry,” Becker told us. “Some parts the size of a half dollar would cost $500 in large quantities, and we would be waiting 12 weeks. That’s when it hit me that there needed to be an additive manufacturing solution for advanced materials, and that the comfortable, almost collusion-like advanced ceramics market needed a wakeup call. In my now day-to-day world, I like handling the business side of our company, as well as getting my hands dirty in the lab building up our next prototype. I’ve been working with many high-profile customers, many of which I’m unable to disclose, to develop this technology since 2013.
”
The company is currently seeking series A investment funding so that they “can grow within the trillion dollar advanced materials market.” If this machine is capable of what HotEnd Works says it is, investment is not something that will be difficult finding.
Let us know your thoughts on this new 3D printing process and subsequent soon-to-launch printer. Discuss in the HDfab 3D printer forum thread on 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: advanced materials 3d printer • ceramic 3d printer • hdfab • hotend works • Pressurized Spray Technology • psd 3d printer
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3ders.org - HotEnd Works' new HDfab ceramic 3D printer utilizes Pressurized Spray Deposition technology for high resolution prints
Apr. 22, 2015 | By Alec
While a new model FDM 3D printer seems to be released just about once a week, the unveiling of other types of 3D printers are much rarer to find.
That’s why we were very interested to learn about a new approach to ceramic 3D printing that has been developed by Oberlin, Ohio-based high quality 3D printing service provider HotEnd Works (or HeW). As company founder Benjamin Becker explained to 3ders.org, his company has developed a custom ceramic 3D printer called the HDfab™ Advanced Materials 3D Printer, which produces high resolution and high quality components using Pressurized Spray Deposition Technology (or PSD).
Now as you might know, ceramic 3D printing typically revolves around a custom FDM 3D printer that extrudes molten ceramic rather than plastic, which requires heating in an oven to harden after printing. But as the team from HotEnd Works explains, PSD technology can perhaps best be seen as a professional version of that approach. ‘Pressurized Spray Deposition technology fills the void between production-quality advanced ceramic components and current solutions requiring a post-fabrication infiltration process,’ they say.
‘PSD builds production-quality parts in quantities ranging between 1 and 500 using the highest performance, engineering-grade materials such as advanced ceramics. PSD is the undisputed leader in high strength ceramic parts in various ceramic materials such as alumina (Al2O3), silicon carbide (SiC), and aluminum nitride (AlN).’
That all sounds impressive, but how does it actually work? Well, as they explain, Pressurized Spray Deposition revolves around depositing two different materials on a printbed simultaneously: the parent material (the high quality ceramic powder) and a polymeric binding materal, that serves as a support material. ‘Powder and binder materials are fed from external hoppers into the dispensing chambers, and are then deposited at the precise X and Y positions as dictated by the part being formed,’ they explain.
These layers are deposited in a process that somewhat resembles FDM printing, but instead of just letting layers dry together, a polymeric matrix is applied at precise points between layers of powder.
‘In order to bond the powder material together and only at the intended area, a precision dispensing mechanism is used for the binding material in conjunction with computer-controlled paths.,’ the HeW team explains. The results are subsequently sintered.
The advantage of this approach is that it creates very dense and very pure ceramic materials (with a density of at least 98%). This means parts will be more precise and have a higher mechanical strength than what can be accomplished with other ceramic processing techniques. Optionally, the ceramic components can be further post processed to reach the optimal mechanical and visual qualities, though this will require grinding and hot isostatic pressing to increase density to 100%.
The HDfab™ Advanced Materials 3D Printer that uses this technology can apply PSD 3D printing to a variety of high quality ceramic powders, including: HotEnd Works Premium Alumina (AL2O3), Zirconia (ZrO2), Silicon Carbide (SiC), and Aluminum Nitride (AlN).
Custom-made ceramic and metal materials can also be incorporated into the production process. The 3D printer itself prints layers at a resolution of 200 microns (deposition rate of 2.5 cc/min), with a maximum build volume of 8 x 8 x 8 inches. All this makes it a very interesting prototyping 3D printer, especially its ability to produce complex and highly detailed ceramic pieces in a single piece and in large qualities.
Now as you can imagine, such a high quality and unique 3D printer isn’t exactly marketed to the garage tinkerer. Expected to be priced at $55,000USD, it will doubtlessly be aimed at manufacturing businesses upon release in early 2016. But for that money, the 3D printer will come with custom control and slicing software, 10 pounds of HotEnd Works Premium Alumina (AL2O3) advanced ceramic material, 10 pounds of post-processing agent and a thermal post processing system as well.
For more information about the HDfab™ Advanced Materials 3D Printer, go to the website of HotEnd Works here.
And if you can’t wait until early 2016, they do already offer PSD 3D printing as a service for users. If you’re looking to try that, you can go here to upload an STL file and be provided with a quote.
Posted in 3D Printers
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Jessica wrote at 5/6/2015 2:43:16 AM:
Yes the screw is a rendering.
This demonstrates the type of prototype one can expect to print once available in 2016.
Jessica wrote at 5/6/2015 2:41:27 AM:
Yes it is a rendering. It was meant to show the type of parts you can expect with this 3D printer once available in 2016.
Larry wrote at 4/22/2015 6:14:59 PM:
That screw looks an awful lot like a rendering to me!
HotEnd Works offers a 3D printer for ceramic sputtering
News
Oberlin, Ohio-based HotEnd Works has announced the development of a new HDfab Advanced Materials 3D Printer for printing ceramic products using the Pressure Spray Deposition (“PSD”) method. Most of the existing developments in ceramic 3D printing are based on the adaptation of FDM printers for clay extrusion and require firing of printed products, as in the usual pottery.
PSD, on the other hand, can be considered a kind of development of inkjet 3D printing, using a polymer binder to selectively bond the particles of a consumable material before completion of construction and subsequent firing.
Consumables in this case may vary, including additives from alumina, silicon carbide, aluminum nitride and other components, depending on the required characteristics of the finished products. The most obvious advantage of this method over FDM printing will be the higher print resolution.
Filler and binder are sprayed in controlled proportions as required by the project. The method allows to achieve high density of finished products, reaching 98%. High density, in turn, means high strength and overall quality of workmanship. If necessary, additional processing by means of grinding and hot isostatic pressing is possible. The latter allows you to bring the density of the material to almost 100%. At a minimum, printed products require firing in a conventional pottery kiln.
Among the ceramic mixtures offered by the company are options containing alumina (aluminum oxide), cubic zirconia (zirconium dioxide), silicon carbide and aluminum nitride.
In addition, it is possible to create customized mixtures, including the addition of desired metal particles. The printer provides the application of layers with a thickness of 200 microns with a maximum build size of 203x203x203 mm. The print speed reaches 2.5 cm³/min.
It is clear that the unit is intended for professional use only. This is also indicated by the preliminary cost of the printer, estimated at $ 55,000. It is expected that the finished devices will be supplied complete with proprietary software, a five-kilogram supply of alumina ready for printing, as well as post-processing materials and an oven for firing printed products.
The commercial premiere of the HDfab Advanced Materials 3D Printer is scheduled for early next year, but those who want to get acquainted with the possibilities of the technology can place a 3D printing order on the company's website. You can download the .STL file and get an estimate of the cost of the product here.
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Discovery 3D Printer is a range of industrial 3D printers made in Spain for creating large-sized products and prototypes using FFF/FDM technology.
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FDM 3D Printing of Airbus Parts
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A prototype car bumper is printed, measuring 1800 x 600 x 4500 mm and weighing 12 kg.
Create a chair with large format 3D printing
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3D printed architectural statue
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3D printed rail components
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The front part of a tram for CAF was made in one printing session.
Helicopter seat 3D printing
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3D printed internal combustion engine
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Prototype of an internal combustion engine was created, the dimensions of which were 100 x 60 x 50 cm and the weight was 5.
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3D printed exclusive piece of furniture
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Architectural 3D printed in durable ABS with cellulose
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A street sculpture has been made that fully implements the initial decorative idea of the project.
Window dressing for Dior boutiques
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Huge bottles 3D printed for exclusive display at Dior's flagship stores.
FDM Cap Prototype
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Prototype cap printed at 29 x 19 x 4.5 cm and weighing 146 g.0219 Industry:
A prototype modular toilet is printed, measuring 2200 x 1700 x 1200 mm and weighing 250 kg. At the same time, the weight of the product was reduced by almost 50%.
3D printed marine ventilation grille
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Printed motorcycle part measuring 42.5 x 16.5 x 4.5 cm and weighing 165 g.0218
Prototype printed with support measuring 10 x 9 x 2.5 cm and weighing 18 g.
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3D printed car wheel
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A wheel for a car was made, the diameter of which was 440 mm, and the weight of the product was 5 kg.
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Printed vase in ABS for excellent interlaminar adhesion and minimal warping.
Geometric 3D printing
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Pyramid printed with an 8mm extruder with a smooth surface thanks to the built-in milling system.
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Frequently Asked Questions
Which technology should I choose: the method of fusing granules (FGF) or polymer filaments (FFF / FDM)?
What are the kinematics and mechanics of the Discovery equipment?
In this respect, all Discovery equipment differs from budget additive solutions.
The products are based on the kinematic diagram of a CNC machine. Gears, pulleys, lead screws, no belts. HIVIN rail guides are used. The entire structure is made with European quality from advanced products in the machine tool industry.
What consumables can be used with Discovery products?
Any material (other than PEEK and PEKK) sold in bars or pellets. First of all, thanks to the heating of the table to 175 ° C and vacuum fixation, as well as due to the installed nozzles made of hardened steel.
How is such a large print platform heated?
A matrix of separate equidistant heaters is built into the platform from the bottom side; these modules provide uniform heating of the surface of the printing platform. The maximum recorded temperature difference over the entire area is 3°C.
How to speed up printing on such large dimensions?
There is a special method for properly emptying the internal volume, which you can learn more about from our technical experts.
This procedure will have very little effect on the strength and elasticity of the print object, but will still reduce the time by up to 60%.
It is important to consider that with a large range of large-sized products, it is better to consider Super Discovery 3D Printer or Super Discovery 3D Printer Workstation with a capacity of up to 11 kg / h (depending on the material used).
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