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    Additive Manufacturing in 2022: Why Additive, and Why Now?

    Read our new white paper to learn how additive manufacturing has grown in recent years, what today's 3D printers are capable of, and how 3D printing is solving a new set of problems.

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    Introducing Simulation from Markforged

    With Simulation, you can now virtually test the strength and stiffness of your parts right from Eiger. Validate your part’s performance before you hit print.

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    5 Supply Chain Makeovers Powered by 3D Printing

    Learn how 5 organizations are using 3D printing to solve supply chain issues.

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    Markforged to Expand into Mass Production of End-Use Metal Parts Through Digital Metal Acquisition

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    What is Additive Manufacturing? Understanding the Technology and its Impact

    Your 101 guide to understanding the current landscape of additive manufacturing from the ground up.

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    Why Integrate Factory Systems With 3D Printing Software?

    We all have software systems that drive our day to day operations on the shop floor. What problems would it solve to integrate yours with 3D printing software?

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    What are the Benefits of Adopting Metal 3D Printing? Business Side and Technical Benefits

    Metal 3D printing correctly can greatly improve business efficiency and agility — whether through eliminating the need for detail drawings and machine programming, or drastically shortening lead times that bog down product development processes. Learn about the full range of business and technical benefits.

Industrial 3D Printers: Strong Parts. Right Now

A complete line of machines made to create functional parts. Industrial 3D printers that consistently improve with a connected platform and precision construction.

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Flagship Industrial Composite 3D Printer

FX20™

An ULTEM™ filament capable production platform for big, strong, high temp parts — usable from factory floor to flight. The ULTEM™ and 9085 trademarks are used under license from SABIC, its affiliates or subsidiaries.

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Flagship Metal 3D Printer

Metal X™ System

An accessible way to go from design to metal part — the Metal X System is a leading end-to-end additive manufacturing solution.

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Flagship Industrial Composite 3D Printer

X7™

The turnkey industrial 3D printer for many types of functional parts.

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Flagship Industrial Composite 3D Printer

X7™

The turnkey industrial 3D printer for many types of functional parts.

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Industrial Composite 3D Printer

X5™

The industrial 3D printer for Continuous Fiberglass reinforced parts.

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Industrial Composite 3D Printer

X3™

The refined Industrial FFF 3D printer for micro carbon fiber filled nylon parts.

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Desktop Series

Drive innovation right from your desktop. Powerful professional 3D printers designed to maximize the capabilities of high-quality composite printing.

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Flagship Desktop Composite 3D Printer

Mark Two™

The powerful professional Carbon Fiber 3D printer for aluminum-strength parts.

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Desktop Composite 3D Printer

Onyx Pro™

The workhorse professional 3D printer for Continuous Fiberglass-reinforced parts.

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Desktop Composite 3D Printer

Onyx One™

The FFF desktop 3D printer for tough, high quality Onyx parts.

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Strong Parts

Every Markforged industrial 3D printer is built to create strong parts. Period.

Designed for Reliability

Precision design and construction yields predictable, repeatable results.

Platform Connected

Monitored and controlled by a central platform — fabricating functional parts is as easy as pressing print.

1. Design & Slice

Design a part in your chosen CAD platform and export it as an STL. Upload the STL to Eiger and select your material and orientation. The software slices your part, automatically generating a raft, supports where necessary, and a layer of release material between the raft/supports and the part itself.

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2. Print

Metal powder bound in plastic is printed a layer at a time into the shape of your part. Parts are scaled up to compensate for shrinkage during the sintering process.

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3. Wash

After printing, “green” parts are placed into the Wash-1, which uses a debinding fluid to dissolve most of the plastic binding material.

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4. Sinter

Washed “brown” parts are placed in a Markforged furnace, where they are heated with a material-specific profile to remove the remaining binder and solidify metal powder.

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5.

Use

Parts come out of the sintering furnace as fully metallic objects and can be used in manufacturing, tooling, and prototyping operations.

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1. Design & Slice

Using the CAD platform of your choice, design a part. Many different parts can be printed, but following Design for Additive Manufacturing (DFAM) guidelines enables you to fully leverage the unique strength and flexibility of Markforged composite printers. Upload the STL to Eiger and select your base materials and part orientation.

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2. Reinforce

Unique to Markforged composite printers with Continuous Fiber Reinforcement (CFR), Eiger enables you to print with two types of printing media: a Composite Base filament and a Continuous Fiber. Configure the reinforcement to your application, choosing a Continuous Fiber and layers to reinforce.

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3. Print

A Markforged composite printer automatically prints your part layer by layer. Composite Base material is printed through one nozzle, and Continuous Fiber is laid in-layer by a second nozzle and extrusion system.

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4. Use

The resulting composite part consists of a Composite Base and a Continuous Fiber, and can be used in a wide variety of industrial applications.

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Markforged has updated the range of 3D printers for printing metal and composite products

News

of polymer-metal blanks, a software update for Next Day Metal, and also announced a field version of the X7 3D printer that prints continuous-fiber-reinforced thermoplastics.

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Metal X Gen 2

The first novelty is the second generation of a specialized Metal X FDM system designed for the additive production of polymer-metal blanks. After 3D printing, the binder polymer is removed and the workpieces are sintered into high-density all-metal products.

The second generation Metal X 3D printer is an upgraded version with a number of small but useful improvements, including a new seven-inch on-board touch screen, door sensors for improved operational safety, and additional thermal insulation of the workspace. nine0003

In response to the age-old question “why is this necessary?” the company cites the example of Angus 3D Solutions, a Scottish 3D printing firm serving the local oil and gas sector, among other things. This team was commissioned to manufacture several specialized wrenches to the smallest tolerances and in the shortest possible time - so short that prototyping and production by traditional methods would not meet the allotted time, or at least would fly into a huge amount. The bureau printed a functional prototype in a couple of days instead of a couple of weeks and completed the order on time, at the same time saving about twenty-five thousand dollars due to localized production - including transportation costs, since otherwise you would have to pay for direct shipping to meet deadlines by air. nine0003

Next Day Metal

Users of the original version will not be left out. In addition to hardware upgrades, the company has also been working on software: the Next Day Metal software has also received an update, and now users of the original systems will be able to print faster without the need for hardware upgrades. The increase in productivity comes purely from the increase in positioning and extrusion speed without compromising the resolution of 3D printing.

“We decided to experiment with speeds to test our old assumptions about speed versus quality. As it turned out, the speed can still be increased without reducing the quality of the surfaces. With this update, Metal X users will simply get increased performance without any pitfalls,” says Polina Bako, Head of Public Relations at Markforged.

X7 FE

The latest innovation is not even an upgrade, but an accessory for the flagship X7 system. These 3D printers are powered by the hybrid technology that has earned Markforged its place in the sun. The technology consists in combining FDM 3D printing with polymers or composite materials (usually nylon) with the laying of a continuous reinforcing fiber - carbon, Kevlar or glass. That is, this is the same direction that is being developed with different variations, for example, by the Russian-Luxembourg company Anisoprint, the Russian Stereotech and the sworn enemy of Markforged represented by another Massachusetts company called Desktop Metal, with which Markforged managed to wrestle in court for intellectual property rights. own. The upgrade consists in a protective box, because of which this version of the X7 system received the designation X7 FE, that is, Field Edition or “Field version”. nine0003

In a new protective case, the X7 3D printer withstands the harshest transport conditions: bumps, airdrops, even delivery by Russian Post. About landing, we mean in the most direct sense. The fact is that the US Marine Corps became interested in 3D printers from Markforged, developing a program of rapid response fab lab workshops under the XFAB code and having managed to test X7 systems in the field. The US military is generally very fond of Peli-branded shipping containers, and the plastic box in the photo above allegedly provides enough protection for air transport (presumably even a parachute drop), after which the 3D printer can be debugged and up and running within a couple of minutes. nine0003

Metal X Gen 2 3D printers and updated Next Day Metal software are now available, with the X7 FE scheduled to ship this fall. Additional information about Markforged's offers is available on the official website.

Do you have interesting news? Share your developments with us, and we will tell the whole world about them! We are waiting for your ideas at news@3Dtoday. ru.

Metal X X7 Next Day Metal F.E.

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Copper 3D Printing - Complete Guide

Copper is one of the newest and most promising areas of metal 3D printing for everything from electric motors to heat sinks.

Previously, copper 3D printing was a challenge due to the metal's reflectivity and high thermal conductivity, but advances in printers and materials have largely resolved these early problems. Today, 3D printed copper propulsion systems send rockets into space, 3D printed copper heatsinks cool processors, and 3D printed copper coils boost the performance of electric motors. nine0003


3D printed copper parts (Source: Trumpf)

Why 3D print copper?

Copper has always been a very useful metal due to its ability to conduct heat and electricity, resist corrosion and even kill bacteria and viruses. Demand for complex copper parts is on the rise as 3D printing opens up even more uses and possibilities for this metal.

3D printing (also known as additive manufacturing) allows the creation of exceptionally complex shapes, fine details, internal structures and lattice inserts that are not possible with any other form of metal fabrication. These capabilities reduce weight, increase efficiency, and reduce fabrication and assembly times, as multi-component assemblies can be 3D printed as a single unit. nine0003

Additive Metallurgy

3D printing also allows this relatively expensive metal to be produced more efficiently, reducing waste by using only the amount of material needed to make each part. For companies interested in copper 3D printing, reducing raw material costs is critical.

If you already produce custom copper parts, 3D printing can significantly reduce your production costs while optimizing part performance. nine0003

Markforged 3D printed copper heatsink (Source: Markforged)

Although there aren't many 3D printers that can print copper, there is still a wide variety of printing technologies and prices.

FDM printers using copper-filled plastic filament can produce copper jewelry, decorative items, and other parts that are almost 100% copper. While for more advanced production, 3D printers using copper powder, rods or copper polymer slurry produce industrial parts with excellent mechanical and conductive properties, which can meet international standards such as IACS (International Annealed Copper Standard). nine0003

Let's look at what types of printers can work with copper today. Trumpf TruPrint 1000 Green Edition 3D Printer several equipment manufacturers have recently included copper in their material list. Since copper is highly reflective, laser processing of the powder has been a hurdle for manufacturers. However, this technology and materials have evolved to solve this problem. nine0003

3D printer manufacturer Trumpf, for example, has developed an industrial green laser that can 3D print materials such as copper, copper alloys, and precious metals that are difficult to process with infrared waves.

Two powder layer technologies for metal 3D printing, DMLS (Direct Metal Laser Sintering) and EBM (Electron Beam Melting), work by depositing a thin layer of copper powder onto a platform inside the printer. The powder heats up while lasers or electron beams draw the first layer of the part. When the particles in the layer fuse, the platform is lowered slightly into the assembly chamber, and fresh powder is poured on top, and the process is repeated. Some of the copper powder left over from the process can be recycled for use in the next print. nine0003

Copper additive manufacturing powder from GNK Powder Metallurgy (Source: GNK)

Copper-bonded 3D inkjet printers

Copper powder bonded with a liquid binder and sintered in a furnace is a 3D printing technique known as binder inkjet printing that allows parts to be obtained without the use of an auxiliary material. Bond jetting is a no-heat process in which a bonding layer is sprayed between each layer of metal; the binder is then removed during the sintering process. nine0003

Binder blasting is a popular additive manufacturing method for high volume metal parts.

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Metal-on-Copper FDM Blasting Bet

Metal-on-Copper FDM 3D Printers

The most economical approach to 3D printing copper parts is to use machines that extrude the filament. Metal filament for printing metal parts consists of a plastic base with metal particles evenly interspersed in it. Copper interspersed filament for copper parts is a unique type of composite filament that, when used correctly, produces strong, chemically resistant, and near-solid metal parts. nine0003

Virtually any Fused Deposition Modeling (FDM) printer can print near-solid metal parts using a polymer filament filled with copper powder. Currently, there is only one option on the market - from the manufacturer of threads The Virtual Foundry. The company claims that its copper filament is suitable for printing on any filament 3D printer with a hardened nozzle and a hot end that can reach temperatures of up to 225ºC. However, the parts do not become metal immediately after printing and require additional post-printing steps to melt the resin binder and leave only the metal. nine0003

Other types of copper thread contain enough real copper particles to be polished and given a metal-like weight, but are for decorative purposes.

A company in Chile called Copper3D produces a copper-filled filament that produces parts that do not have metal parts, but parts that have the antibacterial and antimicrobial properties of copper. NASA is even testing the filament for use in "interplanetary microbial contamination," according to the company. nine0003

In addition to the mainstream FDM printers, two other filament-extruding printers also offer copper, but they use their own proprietary materials. Desktop Metal uses a bonded metal filament, while Markforged uses a similar metal powder bonded into a plastic matrix. The printers from these manufacturers produce all-metal parts designed for industrial use, such as machine tools, induction coils, heat sinks, and functional prototypes. nine0003

Cold spray and DED copper 3D printers

WarpSpee3D cold spray 3D printer (Source: Spee3D)

Although these two metal 3D printing methods are not usually combined together, we are combining them here due to their general application for coating metal parts with another metal and for layering metal parts with metal powder.

Directed Energy Deposition (DED) is a system developed by Optomec of New Mexico to create, improve and repair metal parts. Like SLS, in DED, high-power lasers build up 3D structures in layers, creating parts with high density and strength, ideal for mechanical applications. In 2019Optomec developed a new copper DED process to produce heat exchangers for use in the aerospace, chemical and other industries.

Spee3D's WarpSpee3D process is unique in its use of supersonic 3D deposition to produce parts from a range of metal powder materials, including copper and aluminum.

Cold spray is an additive manufacturing technique in which metal powder is injected into a supersonic pressurized gas stream. Instead of melting the metal, cold spraying holds it together in a process called plastic deformation. Companies such as Spee3D are using cold spray technology to apply an antimicrobial copper coating to doors, handrails and touch panels intended for use in hospitals, schools and other public places. nine0003

Cold spray is also the fastest metal 3D printing method. Spee3D printed a 17.9kg (17.9kg) pure copper aerospace rocket nozzle lining (pictured below) on WarpSpee3D in about three hours at a cost of just $716, according to the company. Parts like this are usually made from solid forged copper, which takes weeks and costs tens of thousands of dollars.

One of the disadvantages of DED and cold spray is that they are limited in the production of complex geometries. nine0003

Rocket nozzle copper plating, engineer spark-free copper hammer and copper cable clip, 3D printed by Spee3D (Source: Spee3D)

Photopolymerization Holo)

Metal DLP 3D printing is similar to resin 3D printing in that it uses UV light projected onto a photosensitive slurry to cure layer by layer.

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