2024-03-22 09:58:54
Scientists from KIT in Karlsruhe have developed an alternative 3D printing technology that can process continuous fiber reinforced thermoplastic composites (CFRTP) at high speed. This is possible with a resonant microwave applicator as a print head. KIT will present the technology in April during the Hannover Messe. They are not the only ones presenting the theme of 3D printing with fiber-reinforced plastics at the fair.
This year, 3D printing is once once more a theme that will receive plenty of attention at the Hannover Messe. Manufacturers such as Ultimaker (will the light industrial printer be presented in Hannover?); Formlabs, Markforged and others are exhibiting there this year. It is mainly the knowledge institutes that deliver innovations with AM.
Ten times faster 3D printing
Like the KIT. A technology has been developed at the Institute for Pulsed Power and Microwave Technology (IHM) of this research institution in Karlsruhe to to print continuous fibers, something that has not really gotten off the ground so far. The limitation is often in the diameter of the filament, the printing speed and the volume content of fibers. The German researchers think they can eliminate these limitations with microwave technology. A pre-impregnated filament, in which the continuous fiber is incorporated, is passed through a coaxial resonator. As the fiber reinforced filament moves through the resonator, it is heated over the entire volume cross-section by microwave radiation. The result is that the speed at which CFTRP composite structures can be printed is, according to KIT, a factor of 10 higher than what is currently common.
Endless Industries: total solution
More news in the field of 3D printing with continuous fibers can be seen at the Hannover Messe. The German startup Endless Industries not only develops filament with carbon fibers, it also demonstrates a new patented print head for this at the fair. In combination with the software for placing the fibers, Endless Industries says it offers a solution for 3D printing strong parts that are certainly as strong as aluminum. An alternative to the more expensive milling of components? The company was founded by Stephan Körber, Mathias Czasny and Moritz Ebeling-Rump. They aim to reshape the composite manufacturing industry through the technology developed during Czasny’s PhD research at the Technical University of Berlin. One of the startup’s patents concerns cutting the continuous fiber. This happens directly in the hotend. Because the plastic is then liquid, it is not cut, only the carbon fiber is cut. This allows you to print with thicker filament for higher productivity. Endless Industries is not developing a new 3D printer, but wants to upgrade good existing filament printers with the print head, material and software.
Aerosol printhead
KIT also demonstrates a new concept for one Aerosol jet print head. In this new print head, the carriers of the liquid, which is only mixed with air in the print head to create the aerosol, are cheap disposable parts. At this time, the aerosol is usually generated outside the print head. This means that the pipes must be cleaned when the material is changed. That takes time and can sometimes be complex. With the new print head from the German research institute, this cleaning can be omitted. During 3D printing, a piezo element can switch the head on and off without the need for additional collection of the printing material. The Aerosol print Jet technology is used, among other things, for 3D printing of electronics.
Calculate lifespan
Igus will demonstrate, among other things, the calculator in iglidur Designer with which one can calculate the lifespan of a 3D printed part. The calculation is based on approximately 11,000 closing tests that igus carries out every year with the self-lubricating plastics. According to the manufacturer, the lifespan of the special iglidur polymers is up to 50 times longer than that of other materials for 3D printing. It is available as filament as well as SLS powder and resin for DLP printing.
Other novelties
Schubert Additive Solutions, the 3D printing subsidiary of the packaging machine manufacturer, is also demonstrating the Partbox that it has developed so that customers can print their own packaging-specific grippers. You can read more regarding Schubert here. Xact Metal, the American manufacturer of 3D metal printers, announced this week that it is adding a new tool steel from Uddeholm to its portfolio of metal powders. In Hannover they are showing the XM200G metal printer for SME manufacturing companies.
In addition, there are daily lectures on 3D printing, spread over the various seminars and conferences.
Hannover tradefair takes place this year from April 22 – 26. Here you will find more information.
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