2024-11-10 19:45:00
The Italian Caracol is introducing a new platform for 3D metal printing of large parts at Formnext: Vipra AM. It combines WAAM or Plasma-arc AM with a robot and its own control software. Shorter lead times, lower costs and less material waste are the key concepts that Caracol places on the Vipra AM platform.
Until now, Caracol has focused on 3D printing of large plastic workpieces. To this end, it combines self-developed robot control technology with its own extruder. At the upcoming edition of Formnext, after years of development, the new robot platform for metal will be unveiled: Vipra AM. It provides a turnkey solution for the Direct Energy Deposition system: hardware, software and automation.
Vipra AM uses Plasma-Arc or arc process
Also for high-quality complex underlay
Vipra AM is available in two versions, one emphasizing productivity, the other on accuracy. Vipra XQ (Extreme Quality) uses a plasma arc process for melting welding wire. According to Caracol, this results in a high degree of finish and accuracy. The system is suitable for multiple alloys, including stainless steel and titanium. Due to its good mechanical properties, the technique is suitable for printing structural parts that are subject to stress. Vipra XP (Extreme Productivity) emphasizes productivity. This version uses an arc welding process, standard in WAAM solutions. Due to the availability of aluminum and nickel-based materials, Caracol sees applications for lightweight components and many parts for which the requirements are less stringent, such as architectural structures.
Experiences with polymer printing are the basis
Francesco De Stefano, CEO, says of the two new systems that Caracol has leveraged its experiences and knowledge of 3D printing with thermoplastics and composites to build an AM system for large metal workpieces. “This proprietary metal platform combines state-of-the-art hardware and software together with advanced monitoring technology for robots and automation to find the balance between productivity and quality. With this we expand the production options available to manufacturers of large, complex parts.” Gianrocco Marinelli, Metal Additive Manufacturing Director at Caracol, adds that these manufacturers are under pressure due to cost pressure, the demand for shorter delivery times and the need to combat waste. “Vipra AM brings new capabilities and complements existing processes and enables new hybrid production models that allow manufacturers to optimize their lines, reduce waste and shorten lead times.” This should contribute to an efficiency improvement of their entire process.
Unveiling on Formnext
Snail unveils the Vipra AM during the first trading day of Formnext at 4 p.m. This will be done, among other things, with a forum discussion about the applications of robot AM systems for the production of large components.
Photo: Last year Caracol presented the polymer printer in Frankfurt, now it is introducing a robot printer for metal.
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**Interview with Francesco De Stefano, CEO of Caracol, on the Introduction of the Vipra AM Platform**
**Interviewer:** Thank you for joining us, Francesco. Exciting times for Caracol with the launch of your Vipra AM platform at Formnext. Can you elaborate on what prompted the shift from plastic to metal printing?
**Francesco De Stefano:** Thank you for having me. Our journey into metal printing really stems from our foundational experience with 3D printing thermoplastics. We recognized a growing demand for larger, more complex metal components across various industries. By leveraging our proprietary robotics technology, we’ve been able to pivot into this new arena while maintaining our commitment to innovation.
**Interviewer:** You mentioned the term “turnkey solution” in relation to the Vipra AM platform. Can you explain what that entails for your users?
**Francesco De Stefano:** Absolutely. A turnkey solution means that we’re providing an all-in-one package that includes not just the hardware, but also custom control software and automation tools. Users won’t have to source different components from multiple suppliers; everything is designed to work seamlessly together, minimizing compatibility issues and streamlining the entire production process.
**Interviewer:** Interesting! Can you tell us more about the two versions of Vipra AM—XQ and XP—and when a customer might choose one over the other?
**Francesco De Stefano:** Of course. The Vipra XQ, or Extreme Quality version, is designed for high precision and finish using a plasma arc process. It’s ideal for structural parts or applications requiring stress-resistant components, such as aerospace or medical applications. On the other hand, the Vipra XP, or Extreme Productivity version, focuses on speed and efficiency using arc welding techniques. This version is especially well-suited for lightweight components and architectural structures, where the stringent quality requirements are less critical.
**Interviewer:** With the addition of metal printing capabilities, how do you foresee the impact on lead times and costs?
**Francesco De Stefano:** Our goal with the Vipra AM is to significantly reduce both lead times and costs. By optimizing our processes and using advanced materials, we can decrease material waste and improve production efficiency. This means our customers can expect quicker turnarounds and lower overall production costs while receiving high-quality components.
**Interviewer:** You’ve developed this technology over several years. What has been the biggest challenge in making this transition into metal printing?
**Francesco De Stefano:** Transitioning into metal printing has certainly had its challenges, not least of which was the technical complexity involved. Developing systems that can achieve the necessary heat and material flow while ensuring precision was critical. However, our team’s dedication and experience in polymer printing provided a strong foundation to build upon. It’s been a valuable learning process.
**Interviewer:** what is your vision for Caracol in the next few years with this new technology?
**Francesco De Stefano:** We envision Caracol becoming a leader in the field of advanced 3D printing solutions, particularly in large-scale metal components. With the introduction of the Vipra AM, we’re paving the way for innovative applications in various industries. We aim to continue pushing the boundaries of what’s possible in additive manufacturing and establish partnerships that will redefine production capabilities.
**Interviewer:** Thank you for your insights, Francesco. We look forward to seeing how the Vipra AM platform shapes the future of 3D metal printing.
**Francesco De Stefano:** Thank you! We’re excited to share our journey with the world.
