This year has seen an abundance of high quality entries into the TCT Awards 2022. We have received submissions detailing a wide variety of interesting projects with truly ground-breaking developments within 3D technology innovation.
After careful consideration, we are pleased to announce the TCT Award finalists 2022.
Innovations and developments in the aerospace industry are renowned for ultimately benefitting all other engineering industries - from developing new and ground-breaking materials, to advanced electronics and automation. It is therefore unsurprising that the aerospace industry has been a key adopter of 3D technologies, and we are excited to see what pioneering applications have been released this year.
AlbaPod v2 deployer
Tech Lead: CRP Technology
End User: Alba Orbital
Alba Orbital’s 3D printed AlbaPod v2 is currently the only operational, flight-proven PocketQube Deployer on the market. Created with carbon fibre-reinforced composite material from CRP Technology, five AlbaPod deployers released13 PocketQubes in low orbit on the Transporter-3 flight via SpaceX Falcon 9 rocket, Alba Orbital’s biggest cluster to date.
Avionics Heat Exchanger
Tech Lead: Advanced Engineering Solutions
End User: Military Helicopter
Partners: EOS; PTC
Advanced Engineering Solutions developed an innovative compact heat exchanger with Gyroid minimal surfaces that aims to ‘revolutionize the design of helicopter oil coolers.’ 'Utilizing optimized lattices and 3D printed as a single structure without any supports, the avionics heat exchanger offers higher structural strength, and 4x better performance at half the bounding volume of its original design.'
Safran Bizjet Landing Gear
Tech Lead: SLM Solutions
End User: Safran
Safran Landing Systems and SLM Solutions worked together produce a 455 x 295 x 805 mm titanium component of a bizjet nose landing gear. Believed to be a ‘world first for a part of this size’, the part was redesigned for 3D printing on the SLM 800 to achieve a weight saving of around 15%, and reduce lead time from months to days.
We use consumer products every day, often taking for granted their impact on our daily lives. Behind each of those products is a product designer – designing the look, feel, function and production route of these products. The use of 3D technologies in the life of a product designer has increased 10-fold over the past few years, and as the adoption increases, so do the innovations.
Blackland Razors – The Era
Tech Lead: 3DEO
End User: Blackland Razors
The Era from Blackland Razors is the world’s first 3D printed production razor. Created with 3DEO's Intelligent Layering process and CNC machining, The Era benefits from additive-only design features and a tool-less production process which has enabled 11 designs with increased speed and design flexibility.
Cobra Golf Putter
Tech Lead : HP
End User: Cobra Golf
Partners : Parmatech
Cobra Golf worked with HP to 3D print a first of its kind high-performance golf putter featuring a complex lattice structure and hollow body. Designed to ‘completely transform the golf experience,’ the putter enhances a golfer’s ability to control its centre of gravity and features a high moment of inertia (MOI), which is critical to a putter's performance.
Mishima Lounge Chair
Tech Lead: AREVO
End User: Mishima
3D printed using AREVO technology, the Mishima lounge represents new possibilities for customisation in the furniture industry. Unconventional in its design and fabrication, and inspired by the stone chair at Mishima Grand Shrine in Japan, the frame is 3D printed in a continuous carbon fibre pass to form a seamless organic curve, requiring little physical labour, and offers over 180 design combinations.
Tech Lead: AREVO
End User: Superstrata
The fully-customisable Superstrata bike features a unibody frame 3D printed entirely from thermoplastic carbon fibre composites. Created with AREVO technology, each carbon fibre has its directionality engineered by algorithms to optimise riding positions, and accommodate multiple load scenarios. Superstrata also features an unconventional, no-seat-tube design and an in-tube battery for a sleek, aerodynamic ride.
The film, theatre, art, architecture and jewellery industries all have one thing in common – they take a creative vision and turn it into a physical realisation. As such it is one of the most fascinating areas of innovation in 3D technologies. We are excited to see where this industry can push the boundaries in using the technologies in the creative arena.
Garuda: Acoustic Sculpture
Tech Lead: FIT
End User: Peter Lang
Developed by artist Peter Lang in collaboration with experts from Rosenheim University of Applied Sciences, this world-first sculpture consists of honeycomb-shaped tubes made with a rough material to create a special surface texture that acts as a sound absorber. Working with FIT AG, this 6 x 3 x 1 metre piece was 3D printed using a Kuka robot and biocompatible pellet extrusion materials.
Gravity Industries eSuit
Tech Lead: Ricoh 3D
End User: Gravity Industries
Gravity Industries partnered with Ricoh 3D to bring the next generation of its human flight suit to life. Gravity are working to make their jet pack greener, with a battery-powered electric suit which incorporates 3D printed polypropylene parts which are sufficiently light and durable to withstand the demands of flight, whilst ensuring 90% recyclability.
Tech Lead: Shapeways
End User: Anouk Wipprecht
Partners: Swarvoski; BIOPAC
The 3D printed HeartBeatDress symbolises the mind-body connection with electronics, jewellery, and fashion. A Swarovski crystal is used as a conductive sensor, responding to the wearer’s heartbeat and displaying their emotions. FashionTech designer Anouk Wipprecht collaborated with architect and professor Niccolo Casas and Shapeways to create the two hip pieces using Selective Laser Sintering (SLS).
Imaginarium Diamond Ring
Tech Lead: Imaginarium
End User: The Diamond Store by Chandubhai
Inspired by the Himalayan Camellia flower, a symbol of the perfect balance between a traditional and contemporary form, The Divine - 7801 Brahma Vajra Kamalam achieved the world record for most diamonds set in one ring. Featuring seven different sections, the ring was printed in direct castable resin and cast in gold, and thousands of diamonds were set using a highly precise micro pavé technique.
Tech Lead: Polymaker
End User: Matt Denton
While the aesthetics of this Go-Kart were inspired by the LEGO Technics kits #1972 released in 1985, it was the electrification that required an original solution to a design that was not intended for human transportation. Desktop 3D printing and Polymaker materials were used to create all bricks to assemble the Go-Kart with only a few additional non-3D printed parts, such as motors, brakes, and electronics required.
Tech Lead: Stratasys
End User: BMW
The unique user experience and interaction in the BMW i Vision Circular was made possible by large-scale polyjet 3D printing. Here, the classical instrument panel is turned into a next-generation ‘phygital’ user interface in the form of a hovering, V-shaped sculpture that projects out into the cabin. At its heart is a 3D printed crystal body with nerve-like structures running through it, creating an enthralling lighting effect.
The Hardware awards celebrate the very best of the enabling technologies themselves, and are split into two distinct areas, the first of which is non-polymer systems. This could include metals, ceramics, composites, biomaterials or any other material that is not solely a polymer. We are looking for innovations which push the boundaries of current established systems.
Tech Lead: AlphaLaser
The AL3D product line is revolutionary in its powder handling and operator safety capabilities. The unique cartridge system ensures a closed powder circuit so that the operator doesn’t come into contact with the metal powder during the entire printing process. The system was especially developed for medical, dental and jewellery applications, and offers both an optimum printing accuracy and unrivalled resource-saving powder and gas management.
Dual Wire LMD
Tech Lead: Meltio
Meltio have developed a metal 3d printing head with two integrated material feeders that allow for the fast automatic switching of materials within the printing process. This revolutionary innovation allows material changes to happen quickly and reliably, with no cross-contamination of material type. Ideal for applications where localized material properties are beneficial to the part design.
Tech Lead: Desktop Metal
The Forust process upcycles waste byproducts from wood manufacturing (cellulose dust) and the paper industry (lignin) and re-materializes functional wood parts through high-speed binder jetting 3D Printing, including digital grain throughout the part. This unique innovation offers architects, designers and manufacturers a new path to produce luxurious custom wood pieces with a superior environmental footprint.
Tech Lead: Additive Industries
The MetalFABG2 series defines a new category of industrial additive manufacturing equipment in terms of reproducibility, productivity and flexibility. It takes the unique all-in-one concept of the original MetalFAB1 to the next level. It is the only system on the market that has a fully modular architecture, and in its fully automated configuration, is able to run up to 8 jobs autonomously.
NXG XII 600
Tech Lead: SLM Solutions
The NXGII 600 is optimized for large parts and high volume production. With twelve lasers to process its 600mm x 600mm x 600mm build volume, it is twenty times faster than a single laser system. These innovations bring key benefits in productivity and reduced cost per part, and have an unrivalled output of 10,000kg of produced parts per year. This innovation also brings freedom of materials choice, allowing for not only aluminium alloys, but nickel based and steel allows to be processed at these higher rates.
Tech Lead: Prima Additive
The REAL DED Head is an innovative laser head for Direct Energy Deposition, designed to increase efficiency and flexibility. It allows the laser beam to be widened or narrowed in real-time up to 2 times the original size according to production needs, which allows greater speed and greater productivity. The final part of the head and the nozzles are additively manufactured using Powder Bed Fusion technology - additive for the additive!
Tech Lead: WAAM3D
Aimed at the aerospace, defence, energy and research communities, the RoboWAAM is a large scale metal AM innovation capable of processing virtually any material available in the form of wire. The huge 2m x 2m x 2m build envelope is powered by WAAMPlanner software for trajectory generation and process parameters, and WAAM Ctrl for process monitoring, data analysis and quality control.
The Hardware awards celebrate the very best of the enabling technologies themselves, and are split into two distinct areas, the second of which is polymer systems. We are looking for 3D printing or additive manufacturing technologies which push the boundaries of polymer processing, bringing innovative improvements or entirely new technologies to the table.
Tech Lead: Cubicure
The large-scale Cerion 3D printer is based on the Hot Lithography process and uses a mobile printing head and a revolving resin carrier film to produce parts. Layers within the 100 x 28 cm build volume are printed at a typical thickness of 0.1 mm and in less than 90 seconds, enabling unprecedented throughput for a resin-based process.
Tech Lead: Fortify
Digital Composite Manufacturing reinforces resin materials with functional additives and fibres to open a wide range of new material properties. Fortify’s Continuous Kinetic Mixing hardware ensures additives are uniformly distributed so that particles stay in suspension instead of settling out of solution, while additives can be further enhanced via alignment using magnetic fields from its Flux print hardware. This process has enabled materials with dielectric, thermal and ESD properties, opening up tooling and end-use applications.
Tech Lead: E3D
E3D’s Revo ecosystems allows FDM printhead nozzles to be changed at room temperature with a users’ fingers. In as little as 30 seconds. The Revo ecosystem integrates the heatbreak and nozzle into a single factory-sealed, leak-proof assembly which helps to reduce the likelihood of print failure.
Tech Lead: Formlabs
With advanced features like automated temperature control and increased laser power, the Form 3+ can print up to 40% faster than the Form 3, while enhanced light touch support structures help to reduce post-processing times thanks to their easy detachment. The patented Low Force Stereolithography technology, meanwhile, helps to enhance surface finishes and an Adaptive Layer Thickness capability analyses part geometries to assign optimal layer heights and speed up print times.
H350™ - SAF™ technology
Tech Lead: Stratasys
Designed to produce high-volume yields of consistent production-grade parts, the H350 promises exceptional detail and smooth surface finishes of end-use, industrial components. The process architecture of SAF ensures all powder particles experience the same temperature profiles, resulting in a more consistent print process, while its Big Wave powder handling system maintains a thermally stable mould of powder when distributing materials across the bed.
Tech Lead: Axtra3D
Hybrid PhotoSynthesis harnesses power from two different light sources, with one curing the cross-section of a layer while the other cures the edges. With this method, Axtra3D combines the print speed of DLP with the quality surface of SLA. Meanwhile, its large build area and ultra-fine resolution capability makes it suitable for the development in applications in a wide range of industries.
LSAM Auto Temperature Monitor
Tech Lead: Thermwood
Thermwood’s Thermal Sensor Layer Automation capability precisely maintains the ideal temperature at which the fusion between layers of a polymer occurs. This allows the machine to automatically adjust the speed using ‘Layer Time Control’ to print at the temperature needed and achieve the best possible layer to layer fusion. In turn, this provides superior printed part quality.
Tech Lead: Massivit 3D
This large volume additive manufacturing system shifts the paradigm for large tooling by significantly shortening mold-production time, using Massivit 3D’s Cast-In-Motion (CIM) technology. The tool pattern is created with a sacrificial, UV-curable gel using patented Gel Dispensing Printing Technology (GDP). Once the tool is cast, it is immersed in water where the sacrificial pattern material breaks off, leaving the desired mold, ready to use.
Tech Lead: Dyze Design
This high-flow plastic pellet extruder was designed to enable the printing of parts of one m3+ as quickly and cost-effectively as possible. It can output up to 500 mm3/s and, due to its weight of 7kg, is compatible with many large-scale printers and robotics arms. The Pulsar is also equipped with a patented ‘anti-oozing’ system that enables the extruder to move without the worry of potential leaks.
Tech Lead: Nexa3D
The XiP is Nexa3D’s first desktop 3D printing system, based on the company’s proprietary lubricant sublayer photo-curing technology. It features a modular 4K LCD, collimated light optics and an advanced UV light engine, which enable print speeds up to 18cm per hour and equal exposure across the surface to cure entire layers in a single flash.
Tech Lead: Boston Micro Fabrication
Boston Micro Fabrication’s microArch S230 platform is capable of printing up to five times faster than its previous models in the 2 μm series. Designed to produce micro parts with tight tolerances, the microArch S230 uses active layer levelling, automated laser calibration and has the capacity to handle higher molecular weight materials with viscosities up to 20,000 Cp. This allows for the production of strong, functional parts.
Healthcare is one of the most rewarding industries to be involved with, and the use of 3D technologies in this arena couldn’t be more fitting. The ability to create bespoke, one-off parts from scanned data is perhaps more suited to this industry than any other. With the ever-evolving development of new materials, software and hardware, it is no wonder that this industry grasps the benefits of these technologies – and we can’t wait to see what innovative applications have been launched this year.
ABCD reconstructive solutions
Tech Lead: Apium Additive
End User: Lucid Implants
Partners: Dassault Systemes
Lucid Implants has used 3D printing to produce patient-specific PEEK, titanium and HA-TCP implants to rehabilitate patients suffering from accidents, black fungus, cancer, or deformities. Based on more than 250 cases carried out, there has been a 53% decrease in hospital stay, a 73% decrease in OT time and an 88% decrease in recovery cost.
Equinoxe® Stemless Humeral Cage
Tech Lead: 3D Systems
End User: Exactech
The first stemless shoulder implant thought to be produced with Direct Metal printing, the Equinoxe Stemless Humeral Cage is used to replace a degenerated native humerus. The device has a trabecular-like porous structure to promote long-term biologic fixation and a unique central cage to allow for bone though-growth. Thanks to 3D printing, there is an approximate one-month reduction in total manufacturing lead time and a 10% reduction in cost of goods.
Hemocompatible applicator for cancer treatment
Tech Lead: BURMS
End User: Womed
Partners : Pro3dure
A customised additive manufacturing process based on DLP and a hemocompatible, steam sterilizable medical grade resin was used to develop an applicator for intra-operative tumour treatment of breast cancer. The applicator enables a homogenous dose distribution of x-rays in order to ensure an efficient treatment of tumours and tumour beds after resection.
ICU COVID-19 ventilator valves
Tech Lead: 3D Systems
End User: Lonati
As COVID-19 swept across the north of Italy in March 2020, and the original manufacturers were overwhelmed by sudden demand, the manufacture of ventilator valves was required urgently. Overnight, 3D Systems’ ProX SLS 6100 system additively manufactured 95 valves which were put to use to treat COVID-19 patients within days. Through this project, the design of the part was consolidated from two pieces to one, and 3D Systems exhibited 3D printing’s ability to produce parts with speed and agility.
Lattice dental implant bar
Tech Lead: Renishaw
End User: ADEISS
Partners: Sculich School, Western University
By using Renishaw’s metal additive manufacturing technology, a dental implant bar has been fabricated with a lattice structure that helps to reduce weight, save on material and bring the cost down from $6500 CDN to $258 CDN. The 3D printed implant, which works to support and retain the patient’s denture, also saw the lead time reduced from six weeks to approximately 11 hours.
NHS knee alignment device
Tech Lead: Ricoh 3D
End User: ORLAU
Designed specifically for AM, this knee alignment device boasts improved stability with a larger contact area and an improved fit with a more organic shape that is in line with patient’s anatomy. It also features a reference datum arrow to allow for accurate placement on a patient, which means fitting is simpler and can be reproduced effectively. Using 3D printing, Ricoh 3D took lead times down from weeks to days and also achieved a 50% part consolidation.
Personalised Anticancer Polypills
Tech Lead: FabRx
End User: Institut Gustave Roussy
In collaboration with Gustave Roussy, FabRx is working to develop novel, personalised, mutli-drug dosage forms called Pollypills to treat breast cancer patients. FabRx’s M3DIMAKER 3D printer is to be used in a prospective randomised trial evaluating the efficacy of a personalised hormone therapy pill that incorporates multiple drugs – produced with 3D printing – for patients with early breast cancer. It is the first ever clinical trial for 3D printed polypills with personalised doses.
Tech Lead: Nexa3D
End User: WeMed
Partners: Third; Henkel
The SKOP is the first 3D printed cardiopulmonary auscultation medical device intended for both healthcare professionals and the general public. Designed to enable remote diagnostics, it is financially accessible and connects to tablets, phones, and communication platforms like Zoom and FaceTime. The stethoscope required very fine detail and was developed inside nine months thanks to the speed and flexibility of Nexa3D’s NXE 400 platform.
Industrial products work behind the scenes to keep our industries working. Whether it be factory automation equipment, farming tools or material handling machines, there is little that is not touched by an industrial designer. 3D technologies are being increasingly adopted by this sector to drive unique developments.
ASRS Custom parts trays
Tech Lead: 3D Platform; BCN3D
End User: Applied Cobotics
Applied Cobotics’ Automated Storage and Retrieval System is designed to assist collaborative and automation robots by loading and unloading material dunnage trays. 3D printing technology is sued to create custom parts trays, before thermoforming is used to duplicate the design and create as many as is needed. Using the ASRS, a worker only needs to set up a job once, sidestepping countless hours of downtime and cost.
Bee Hero Smart Hives
Tech Lead: Shapeways
End User: Bee Hero
BeeHero’s smart hive monitoring system is designed to monitor the health and activities of bees within their hives in a bid to achieve more efficient pollination. The sensors are housed in a protective 3D printed case, developed by Shapeways with SLS technology. Using Nylon 12, the 3D printed housing is able to withstand the elements and, as a biocompatible material, poses no threat to the bees.
Tech Lead: COLD PAD
End User: EDF
Partners: ARKEMA; ERPRO
This heavy-duty bonded mechanical fastener is designed for concrete surfaces. To achieve the required anti-seismic performances, the fastener has to accommodate the occurrence of a crack into the concrete. In order to give sufficient flexibility transversely and to achieve a relative high stiffness in tension, a 3D printed intermediate deformation layer is introduced between the metallic fastener and the concrete surface. The 3D pattern/ repetitive micro-structures generate the required macroscopic anisotropy.
Ice Cream Extrusion Nozzle
Tech Lead: Tetra Pak
Partners: Teknologisk Institut
Using powder bed fusion processes, Tetra Pak has developed an ice cream extrusion system which better controls the flow of ice cream. Due to the product architecture, only the forming nozzle needs to be replaced for a new ice cream product, while costs have been reduced by 60%, delivery time shortened from eight weeks to four weeks, and the design consolidated from around 30 parts to three.
Modular Grooving System
Tech Lead: SLM Solutions
End User: Burgmaier AM
Partners: ZCC Cutting Tools
This additively manufactured grooving system has been designed for radial grooving and boasts a specially developed spring tension and innovative cooling system. The medium is fed through the various components of the system to the indexable insert using internal channels, which reduces wear and tear on the cutting edge and extends its service life. Thanks to AM, the replacement of componentry is 40% faster and the weight of the system has been reduced by 45%.
Modular Mold Set
Tech Lead: PepsiCo
Partners: Carbon; Nexa3D; Blow Moulding Technologies; Plastic Technologies Inc
Pepsi’s patented Modular Mold Set comprises a universal aluminium shell which is designed to fit 3D printed inserts for various bottle designs ranging from 200ml to 1L. Using resin-based technologies from Carbon and Nexa3D, Pepsi is now able to create functional prototypes within a week, a significant reduction in lead-time compared to conventional methods, and thus test and validate bottles much quicker. Through a proof of concept exercise, the Modular Mold Set can produce up to 10,000 bottles.
Tech Lead: Luma-ID
End User: Structemp Innovations
In under a year, Luma-ID and Structemp Innovations went from concept to working prototype of a scaffold coupler component, initially using PLA material on a Prusa machine and eventually printing a functional prototype in aluminium on a DMLS system. The coupler component has been designed with no sharp edges on the exterior and a shortened thread that allows users to screw the device to a close in seconds. Though the initial FDM prototype was produced in two components and riveted together, the DMLS version has been printed in a single piece.
3d printing and additive manufacturing processes would not succeed but for the development of appropriate materials for the job. Though often underappreciated, the amount of science and innovation which goes into the development of materials for these processes can be overwhelming. We would like to celebrate advancements any material for additive manufacturing from polymers to metals, ceramics to composites, biomaterials and any other advanced material.
Tech Lead: 4D Biomaterials
Partners: University of Birmingham
This patented range of novel polymeric 3D printing resin-inks enable the printing of complex scaffold designs and other implantable medical devices in fine resolutions for both soft and hard tissue indications. The biocompatible materials promote tissue regeneration, have non-toxic biodegradation, have mechanical properties suited to the host tissue, and good handling properties in a clinical environment.
6K Additive refractory powders
Tech Lead: 6K Additive
End User: Quadrus
Enabled by the UniMelt microwave plasma system, 6K Additive refractory metal powders are highly spherical with no porosity, ensuring the materials are extremely consistent and superior in quality to those produced by atomisation. Refractory metals, such as tungsten, rhenium and niobium, are much sought after in the defence, aerospace and medical industries because of their density, strength and resistance to corrosion, but have traditionally been difficult to process.
Equispheres Aluminum Powder
Tech Lead: Equispheres
End User: Aconity3D
Produced using a patent-pending atomisation technique, Equispheres’ metal powders are designed specifically for additive manufacturing. Its aluminium powders boast sphericity, uniform size and consistent microstructure, as well as smoother surface and thinner oxide layers. This allows parts to be printed with superior mechanical properties and more quickly.
Tech Lead: Fortify
The first photoresin on the market designed for thermal management applications that require electrical insulation, TCDR has a thermal conductivity of up to 2 W/mK and dielectric strengths over 27 kV/mm. Because of its dielectric strength, TCDR can print parts like heat sinks and heat exchangers that are placed directly against electronic equipment such as batteries, printed circuit boards and RF devices.
Helios™ PEEK 2005
Tech Lead: Roboze
Roboze’s PEEK 2005 material uses short fibres of a special technical ceramic that are added to the PEEK matrix to develop a high-performance thermoplastic composite. Using chopped ceramic fibres enables the material to print highly complex geometries with thin walls and fine feature details, while also ensuring high temperature stability, and high thermal and electrical insulation.
Tech Lead: Rosswag Engineering
Specialis has been developed for the LBPF and DED processes, promising high temperature strength and high temperature hardness, and modifications preventing micro-cracking issues. It boasts an as-printed hardness of 30-40 HRC and can reach a hardness of above 65 HRC with a heat treatment process. The material can be used up to 550°C for a broad range of tool applications, with machining and polishing helping to achieve the final tool geometry.
The post processing award aims to celebrate the technologies which add the final touches to the 3d printing/additive manufacturing process chain. The often essential processes which impart material properties and surface finishes to a 3D printed or additively manufactured part. We are excited to commend new innovations in post processing technology.
CCP-2 - Clean, Color, Polish
Tech Lead: AM Efficiency
The CCP-2 enables the efficient and automated cleaning, polishing and colouring of parts produced with SLS, MJF, SAF and HSS technologies. With this automated solution, AM Efficiency is removing the costs and time associated with manual post-processing, while also ensuring users don’t come into contact with hazardous toxins.
Tech Lead: Reinforce3D
End User: Airbus; Delbella; Asics; HP
Partners: Eurocat; BeAble Capital
CFIP has been designed to improve the mechanical and lightweighting performance of 3D printed parts by reinforcing them with continuous fibres post-print. With this process, which is suitable for polymer, metal and ceramic 3D printed parts, users can place fibres in all directions, as well as between printing layers. It delivers an ultra-high joining performance and allows the manufacture of large structures according to mechanical requirements, and cost and production targets.
MARS 03 + STAR 02
Tech Lead: Addiblast
Combining the MARS 03 and STAR 02 machines, AddiBlast’s offering encompasses automated de-powdering and powder recovery and conditioning. De-powdering can now be done in minutes, while a closed-loop inert atmosphere with an oxygen level below 2% helps to preserve material properties.
SFP770 - Automated depowdering
Tech Lead: Solukon
The SFP770 integrates a fully automated unpacking station and cleaning station for SLS parts in a single system. Designed to supplement the EOS P 770 machine, the SFP770 removes direct contact with hazardous plastic powder and enables a more efficient post-processing phase for polymer parts of large sizes and volumes. Additionally, a second unpacking process can start simultaneously while the cleaning of the first batch is still running in the cleaning section of the SFP770.
e-Blast surface finishing
Tech Lead: GPAInnova
This technology combines dry electropolishing technology with a jet of fluid composed by a non-conductive liquid and free solid particles to remove roughness from metal surfaces. Recommended for large, heavy parts and pieces with different degrees of roughness or complex geometries, this electropolishing technology is suitable for blind holes, slots, occluded areas and inner channels.
3D technologies are only as good as the software which links them. The development of specialist software to process, validate and control the systems can mean the difference between a fantastic system and a dud. This award celebrates innovations in any software which impacts product development using 3D technologies from the design phase through to manufacture and end of life.
Artec Studio 16
Tech Lead: Artec 3D
Artec Studio is designed to process large volumes of 3D data quickly to allow for the creation of high-accuracy 3D models. The software allows users to combine colour and mesh data, while also providing an uninterrupted scan-to-inspection workflow that allows users to finish a scan, inspect a mesh or run inspection in CX. Projects load 10x faster than in previous software versions and users now no longer need to wait for scans to be fully loaded before working with the data.
Carbon Design Engine™
Tech Lead: Carbon
Design Engine has been developed to save design engineers significant time and effort by automating the creation of complex geometric structures like lattices and meshes. This helps users to integrate mechanical performance enhancements beyond those that can be produced with traditional production methods. The software has been utilised in projects with Adidas, Riddell, Specialized and more.
Tech Lead: ELISE
End User: EDAG Engineering
Based on intelligent algorithms, Elise’s software allows users to digitally model products, execute the additive manufacture of the components and then systematically reuse the information for new variants or projects. Within this one environment, users can access CAD, FE simulation, topology optimisation, support generation, process simulation, nesting, slicing, cost calculation and CO2 footprint calculation. It can also seamlessly integrate with other software platforms.
Tech Lead: Fixie
Specifically developed for architects, Fixie allows users to upload digital exports, specify the product details and instantly see project costs and feasibility. Since architectural 3D files are typically made for visualisation, they tend to require manipulation before being processable on a 3D printer. While this usually requires specialised skills and expensive software, Fixie is now allowing smaller architectural firms without the resources utilise 3D printed models.
Tech Lead: Teton Simulation
Designed as a plug-in for slicing software platforms like Cura, Smart Slice is able to predict the stiffness and strength of a part while considering variable like build orientation, material and print settings. The foundation of the software is Finite Element Analysis which has been developed specifically for FDM 3D printing technology and allows users to move away from build-break prototyping cycles in the evaluation of designs.
Tech Lead: TOffeeAM
End User: Rolls Royce
TOffeeAM’s software leans on artificial intelligence to solve engineering problems by describing the physics of a problems and performing simulation-driven optimisation create suitable geometries for each specific application. It has been designed to automatically design complex components for engines, aircraft and cars that have previously not been possible with human-driven design approaches.
As one of the first industries to adopt 3D technologies, the transport industry has embraced additive technologies at all stages of design, development and manufacturing. We are interested to discover the most recent advancements to this application within the automotive, rail or marine based transportation industries.
Automotive after-market components
Tech Lead: Aira Technology
End User: Induction Technology Group
Leveraging Selective Laser Sintering technology and a polypropylene material, Aira Technology and Induction Technology Group has successfully produced after-market automotive parts with tooling costs eliminated and time to market decreased significantly. By using SLS, the partners have recorded cost savings of 35% in comparison to other suitable 3D printing methods and are able to make parts available in a week as opposed to two months with traditional processes.
Chaos Ultracar - Ceramic Piston
Tech Lead: Xjet
End User: Spyros Panopoulos Automotive
Partners: Lino 3D
Unable to be manufactured any other way, the 3D printed ‘anadiaplasi’ piston helps the Ultracar Chaos reach over 500 km/hr and accelerate from 0-100km/hr in 1.55 seconds. The piston was printed in alumina and designed using the anadiaplasi method, in which a component takes its shape based on the forces acting on it. The resulting part is an organic complex shape which is light, strong and can withstand the temperatures and pressures generated by the car’s engine.
Lightweighted Brake Manifold
Tech Lead: SLM Solutions
End User: Wabtec
Combining the SLM 800 metal additive manufacturing system with AlSi10Mg, Wabtec has recorded a 70% reduction in lead time and 50% reduction in weight during the production of a brake manifold – a safety critical train component. Considered a gatekeeper to future metal AM projects within Wabtec, the part was consolidated from multiple pieces into one, which will ensure less maintenance in the future, and passed dynamic, field and functional testing.
VW Tiguan tooling nozzle
Tech Lead: Additive Industries
End User: Volkswagen
Volkswagen deployed the Additive Industries MetalFAB metal 3D printing system to achieve a 650% cost reduction in the manufacture of a tooling nozzle used for the automated deposition of a rope in the chassis flange of the VW Tiguan. This part, which helps prevent flange corrosion, was manufactured in a single piece in 316L stainless steel. Previously, the component was made up of two pieces and produced in a more expensive Ti-alloy.