TCT Award Finalists
This year has seen an abundance of extremely high quality entries into the TCT Awards 2019. With the addition of 2 new Inspex categories, we have received submissions detailing a wide variety of interesting projects with truly ground-breaking developments within design to manufacturing innovation.
Please find your 2019 finalist below
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.
Etihad Interior Panel
Tech Lead: BigRep Gmbh
Partners: Etihad Airways Engineering
A full-scale 3D print of an Airbus A320 sidewall has been produced with a unique auto-calibration scanning and printing process utilizing an industrial robotic arm. This proof-of-concept Etihad Aircraft panel features sensors and health monitoring systems 3D printed directly onto the double curved surface of the cabin interior, displaying huge potential in non-planar additive manufacturing with part consolidation and functional integration.
Fixed Wing UAV
Tech Lead: Custom Prototypes
UAV on Demand is a proof-of-concept project to 3D print an entire fixed wing airframe in one piece to create a fully functional UAV with integrated moving control surfaces. This unique project showcases the potential for custom drones to be produced quickly and directly in the field for a particular assignment.
Tech Lead: BigRep Gmbh
End User: Dassault Systèmes
Using design for large-format FFF technology, the retro seat has been developed from an existing framework to create a new seat with customisable cover components and integrated technologies. The retrofitted seat saves 50% of the original seat weight and enables numerous part consolidation leading to added structural integrity and a reduction in assembly time.
Rocket Engine Combustion Chamber
Tech Lead: Frazer-Nash Manufacturing
End User: Skyrora
Using AM as a reliable manufacturing process for the creation of complex cooling channels has allowed a more efficient rocket engine to be designed and produced at lower cost than conventional engines. Efficient engines not only reduce the cost of launching satellites into orbit, but they also reduce the amount of exhaust gases (including CO2) that are released into the atmosphere.
VeriPart Digital Supply Chain
Tech Lead: Moog Inc
End User: Air New Zealand
Partners: Microsoft; ST Engineering
In a world first experiment, Moog’s blockchain enabled VeriPart process was utilised to create a point of use, time of need digital supply chain. The proof of concept had Air New Zealand order a digital aircraft part from Singapore-based ST Engineering. The digital file was immediately sent to an approved printer (Moog) in LA, 3D printed and installed on an Air New Zealand Boeing 777-300 aircraft 30 minutes after landing.
The automotive industry has benefited from additive manufacturing since its birth over 30 years ago. As one of the first industries to adopt 3D technologies, the industry has integrated them into its design and development phases as well as growing their use in the manufacturing phase. We are interested to discover the most recent advancements to this application.
Automated Design of Jigs & Fixtures
Tech Lead: Trinckle
End User: Ford Motor Company
Partners: Ultimaker B.V.
Ford and Trinckle have partnered to enhance the use of AM for the production of labelling jigs and fixtures. Through the development of an internal application using Trinckle’s paramate software, the design of AM jigs has been automated - reducing design time from 2-4 hours to 10 minutes and saving up to 50% of the total costs..
Digitally Manufactured End-Use Parts
Tech Lead: Carbon
End User: Ford Motor Company
Carbon have collaborated with Ford Motor Company to develop Ford’s first digitally manufactured polymer production parts. Each of the three parts developed has a unique reason why AM was the best production route including performance, on-demand manufacturing and economies at low volume.
Tech Lead: Betatype
Partners: Progressive Technology; Renishaw; EOS
The laser powder bed fusion (LPBF) process has been utilised to produce 384 qualified metal LED headlights in a single build. This was achieved through design expertise and Betatype’s unique optimisation technology to design a part with in-built support features to allow for part stacking without undue thermal stress. This translated to reduced part costs from £30 to £3, and lead times from 1 hr to 5 minutes.
Metal F1 Wind tunnel Components
Tech Lead: Additive Industries
End User: Sauber Motorsport AG
Using metal AM parts in F1 wind tunnel tests, Sauber Engineering has significantly improved the design of aerofoil components for their F1 Alfa Romeo Racing team due to the improved stiffness and repeatability achieved from a metal part over the previously used SLA or SLS parts.
PSPM Ball-Joint Exhaust System
Tech Lead: Poly-Shape
End User: Pipo Moteurs
PipoMoteurs and Polyshape have partnered to develop a solution to mechanical failures in the exhaust system in extreme Rally and Rallycross competitions. Utilising DFAM, a brand new ball joint exhaust system has been designed with 2 sliding layers to allow for +/- 10 degrees of movement. Not only has their design solved the problem, it has also produced a more lightweight and compact part.
Series-like Car Dashboard
Tech Lead: BMW Group
BMW have developed a brand new process for validating haptics and assembly forces of a dashboard in the car development process. By replacing the use of prototype and pre-series tooling through the validation phases with the use of SLS lattices with a TPU skin, the quality and reliability of the validation process has been greatly improved whilst reducing overall costs and lead-times.
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. So which application is the most innovative for 2019?
Tech Lead: Luma iD Ltd
End User: Choose Water Ltd
Choose Water have utilised 3d printed moulds to develop an important and timely alternative to single-use plastic bottles. The specialist moulds include thousands of tiny holes to allow paper pulp slurry to be shaped and then water extracted to form a solid product. The use of 3DP in place of 2-part steel and mesh moulds led to a 90% cost and 75% time saving.
Home Appliance Spare Parts
Tech Lead: Spare Parts 3D
End User: Whirlpool EMEA
Whirlpool have partnered with Spare Parts 3D to enhance their aftercare services with the use of AM. The DigiPART software was used to perform a catalogue analysis of over 11000 SKU’s to automatically identify suitability for AM in cases of obsolescence and part shortages. 7% were found to be economical, with the first part now in production.
Precision Diamond Helmet Liner
Tech Lead: Carbon
End User: Riddell
Carbon and Riddell have partnered to produce the first ever digitally printed helmet liner for the SpeedFlex Precision Diamond football helmet. Athlete data from Riddell’s proprietary database of 5 million head impacts was used to create the next-gen head protection precisely contoured to the athlete’s head. Incorporating intricate, bespoke lattice structures with custom energy absorbing materials developed by Carbon.
Titanium Watch Strap
Tech Lead: Betatype
End User: Uniform Wares
In collaboration with Betatype, Uniform Wares explored how metal AM could be used to develop and manufacture a new titanium mesh for their straps and bracelets as part of its 2019 watch collection. Through intelligent design and AM process optimization the results produced a luxury watch strap that embodies the distinction of the Uniform Wares brand with high quality functionality and less material waste
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.
A Dark Tour of the Universe
Tech Lead: BMW Group
End User: European Southern Observatory
An interactive educational show about astronomy has been created that is targeted for people who are blind or visually impaired. The show uses astronomy images, data and computer simulations that have been turned into 3D `tactile’ images and sound. This multi-sensory experience allows participants to engage with astronomy in a completely new way using the senses of touch and sound.
Tech Lead: FIT AG
End User: Pfarrei St Laurentius Altmuhldorf
Partners: Kunstlerduo Empfangshalle Munchen; Studio Tessin
The Retable is an outstanding piece of sacred art which is the highlight of the sanctuary of St. Laurentius in Altmühldorf, in Bavaria, Germany. At a height of 8 meters, the complex 3d lattice piece is entirely 3D-printed in SLS and artistically finished with bronze thermal spraying. The project shows a fascinating convergence of historic and contemporary sacred art.
Met Gala 2019 Fashion Pieces
Tech Lead: Protolabs and GE Additive
End User: Jourdan Dunn, Nina Dobrev, Katie Holmes, Julia Garner, Deepika Padukone
Partners: House of Z
Protolabs, GE Additive and Zac Posen collaborated to create 3D printed fashion pieces for the 2019 Met Gala. Combining conceptual thinking, fashion design techniques, complex CAD and 3D printing, resulted in a range of garments largely unprecedented for the fashion industry. The garments required over a thousand hours of 3D printing.
Plastic Pedestrian Bridge
Tech Lead: Polymaker
End User: Shanghai Municipal City Government
Partners: Shanghai Construction Group
Shanghai construction group have partnered with Polymaker to produce what they say is the largest single 3D printed plastic object ever created and the first plastic 3D printed bridge. The project involved developing a large scale extrusion system specifically for the construction industry and using a specially developed material to withstand external weathering factors.
Replica Dragon Conservation Project
Tech Lead: 3D Systems
End User: Historic Royal Palaces
Partners: Paul Jewby Master Carver
3D systems used digital scan-to-CAD workflow alongside SLS printing and intricate post processing techniques to produce 72 replicas of ornately carved dragons for Historic Royal Palaces. Missing from a UNESCO World Heritage Site for over 200 years, the replica pieces were a lighter weight, longer lasting alternative to direct replacement of the wooden pieces, and were achieved in a much quicker timescale.
The Green Man Sculpture
Tech Lead: Voxeljet UK
End User: Anthology
Partners: Studio Reckoner; London Bronze Casting
Studio Reckoner, Voxeljet UK and London Bronze Casting have collaborated to produce ‘The Green Man’ – a 2.2m, 200kg statue of a former foundry worker on a site now being redeveloped by Anthology. The project used digital sculpting software to design the piece and was produced using PMMA 3d printed patterns to directly cast the final bronze statue, saving almost £20k and over 4 weeks in lead time.
The Hardware awards celebrate the very best of the enabling technologies themselves, and are split into two distinct areas, the second 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: Anisoprint S.a.r.l
Anisoprint S.a.r.l have developed Continuous Composite Fibre Co-extrusion (CFC) technology which can produce parts which they say are several times stronger, lighter and cheaper than single material metal or polymer parts. The process can use different combinations of polymers and fibres, as well as extrude each filament at different rates to produce local variation in mechanical properties in the printed part.
Freeform Injection Molding
Tech Lead: AddiFab ApS
The FIM process, newly developed by Addifab, produces a sacrificial 3d printed injection mold (IM) tool which can be used with traditional IM equipment. Once filled with the desired IM material (rubber/polymer/metal/ceramic) the sacrificial mold is dissolved to reveal the final part. Aimed at speeding up product development and producing end-use parts from IM materials in complex geometries
HP Metal Jet
Tech Lead: HP Inc
HP’s newest addition to additive manufacturing sees the introduction of HP Metal Jet – a powder based binder jet technology allowing for high volume manufacturing of production-grade metal parts. Promising 50x more productivity than other metal 3D printing methods, the process selectively jets binder onto a layer of metal material to create a strong ‘green’ part, which is then sintered to produce the final piece.
Tech Lead: Optomec
The Lens 860 Hybrid Controlled Atmosphere System is a hermetically sealed 3d printing and milling machine capable of processing reactive metals such as titanium. The technology can perform finish machining on a printed part without the need for re-fixturing. Optomec software enables multi-axis build strategies that combine additive and subtractive operations in a singletool path program.
Sapphire Metal Printer
Tech Lead: Velo 3D
A laser powder bed fusion system, Sapphire uniquely enables the realisation of support-free geometries such as designs with overhangs lower than 10 degrees and large inner diameters up to 40 mm. Coupled with the first ever non-contact recoater and closed-loop meltpool control, Sapphire promises to enable a higher degree of quality assurance for serial manufacturing.
The Hardware awards celebrate the very best of the enabling technologies themselves, and are split into two distinct areas, the first 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: BigRep GmbH
The BigRep PRO is an industrial large format FDM machine that prints engineering-grade materials, and features an enclosed temperature controlled build chamber and filament cabinet. A state-of-the-art Bosch Rexroth CNC motion-control system provides accuracy and closed loop control, and the all new Metering Extruder Technology (MXT) allows ultimate control on material deposition for the highest quality parts.
Tech Lead: Sisma
The EVERES range of DLP 3d printers use patent pending Zero Tilting Technology (ZTT) which minimises the mechanical stress formation on the printed part. Also featuring the Smart building Platform (SBP, patent pending) which provides self-alignment and self-zeroing, as well as a PTFE VAT bottom which allows for non-degenerative printing all of which results in high dimensional precision and repeatability.
L1 Production System
Tech Lead: Carbon
The L1 is the largest industrial-scale printer to utilize Carbon’s proprietary Digital Light Synthesis (DLS) technology. Its key differentiator is that it can produce large scale parts or many parts simultaneously at unprecedented speeds. This makes the L1 perfect for high-volume production for industrial end-use products in a quicker time to market.
Tech Lead: Multiphoton Optics GmbH
This micro 3D printing platform Innovation provides real 3D capabilities not limited to layer-by-layer fabrication. By using a non-linear optical effect it enables the realization of unique designs with superior surface finish. Printing in ORMOCER glass-like polymer material with properties such as transparency, hardness and temperature stability enables unique applications in the life-sciences, optics and photonics industries.
Low Force Stereolithography
Tech Lead: Formlabs
Formlabs have introduced Low Force Stereolithography (LFS), the technology behind the Form 3 and Form 3L. The LFS process uses a flexible resin tank to drastically reduce peel forces, providing far superior surface finish and detail. The Light Processing Unit (LPU) directs the laser perfectly perpendicular to the print plane ensuring a uniform laser spot to deliver accurate and repeatable parts.
Tech Lead: Makerbot
In what MakerBot says is the first performance machine that bridges the gap between industrial and desktop 3D printers, METHOD is a third of the cost of industrial printers whilst comprising key industrial features such as circulated heated chamber, dual performance extruders, PVA dissolvable supports, dry-sealed materials bays and an ultra-rigid frame.
Tech Lead: Nanofabrica
Micro AM provides an end-to-end solution bespoke to manufacturers requiring micron and sub-micron levels of resolution and surface finish. Nanofabrica's technology allows the repeatable mass manufacture of micro parts and components via additive manufacturing for manufacturers that previously had to rely on disproportionately expensive and non-agile manufacturing technologies such as micro moulding.
Tech Lead: CEL UK
RoboxPRO is said to be the first desktop 3D printer to combine industrial 3D printing capabilities and ease of use that are easily affordable by professionals. The printer also features several industry-first and patented technologies, including needle valve material control, extruder feedback, automatic load and material recognition.
Silicone Additive Manufacturing Technology
Tech Lead: Spectroplast AG
Spectroplast's SAMT enables the direct fabrication of functional biocompatible silicone products at large scale and throughput saving both cost and time. Using high-resolution projectors to solidify an entire layer of silicone at once, this technology makes it possible to form customised silicone parts with mechanical, thermal and medical performance that matches injection moulded silicone.
Tech Lead: Ultimaker
With its larger build volume and optimal settings alignment, the Ultimaker S5 promises to be the ultimate professional solution for printing functional prototypes, manufacturing tools, and end-use parts. The S5 features fully integrated hardware, software and materials configuration, with full geometrical freedom capabilities, industrial-grade material properties, repeatability, and integrated workflow.
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.
Biomimetic Regenerative Scaffold
Tech Lead: Osteopore International Pte Ltd
End User: Queensland University of Technology
Partners: Julius-Maximilians University Wurzburg; Princess Alexandra Hospital, Australia
A 3D printing technique from Osteopore has been used to create a scaffold with the interconnected porous structure of the human cancellous bone using a bioabsorbable polymer to empower natural tissue regeneration. Patients eventually recover without a permanent implant and the overall healthcare costs are reduced, due to reduced likelihood of late complications or infections.
Brain Aneurysm Surgery Aid
Tech Lead: Axial 3D
End User: Tallahassee Memorial Healthcare
With the help of axial3D insight & assure software a successful pipeline stent operation was undertaken to reduce the patient’s risk of a stroke to near zero. Prior to carrying out the operation, a 3D replica of the patients skull was printed to obtain the exact curvature of blood vessels and their proximity to other brain structures in relation to the aneurysm - dramatically decreasing risk, time and cost of surgery.
Isolating Breast Cancer Stem Cells
Tech Lead: BCN3D Technologies
End User: University of Girona
Using the 3D printer BCN3D Sigma, scientists at University of Girona have been able to manufacture three-dimensional scaffolds that recreate those structures found in the tissues and fibres of the body. A huge breakthrough for cancer research, these 3D scaffolds are able to separate breast cancer stem cells (responsible for causing relapses) in order to study them and develop pharmaceutical solutions.
Neuroinfuse Drug Delivery System
Tech Lead: Renishaw plc
End User: North Bristol NHS Trust
Partners: The Harley Street Clinic; Herantis Pharma plc
A 3d printed titanium port has been developed to allow accessibility to the brain as part of a neuroinfuse drug delivery system which allows pharmaceuticals to bypass the blood-brain barrier for ongoing treatment of neuro disorders. The port features a roughened surface below the skin to encourage bone integration, and a polished surface above the skin to discourage bacterial settlement.
Tech Lead: Added Scientific Ltd
Partners: Xaar Plc; AstraZeneca
A project specified by AstraZeneca has proven that inkjet technologies are capable of operating under Good Manufacturing Practice (GMP). A medicine-loaded ink was printed under manufacturing conditions to assess the failure modes. The project determined that inkjet AM technology could be technically and commercially viable in the pharmaceutical manufacturing industry.
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, but which are the most innovative for 2019?
Circular Saw for Gas Turbine Repair
Tech Lead: Markforged
End User: Siemens
When gas turbine housings need repairs, engineers need to efficiently cut into them with a custom circular saw. Previous methods for making them were unscalable and repairs took upwards of three weeks. Using a Markforged industrial composite X7 printer, Siemens was able to print custom circular saws to repair gas turbines in the field in a matter of days, saving $8000 dollars per part.
Crop Spray Nozzle
Tech Lead: Paragon Rapid Technologies
End User: Agrifac
While developing their more compact trailed crop sprayer, Agrifac required a new design of its spray nozzle which needed to be smaller and more reliable than the current product. Working with Paragon Technologies using Carbon’s DLS technology, a new spray nozzle was developed which consolidated the nozzle from 3 parts to 1, and created a smaller, more robust product with the benefits of zero-tool manufacturing
Generatively designed AM Workholding
Tech Lead: Matsuura Machinery Ltd
Partners: Autodesk; HP
Metal based work-holdings for CNC 5 axis metal cutting applications can take many weeks to design & manufacture. Using Autodesk Fusion 360 generative design software and HP 4200 Multi-Jet Fusion the work-holding has been redesigned for plastic 3d printing and manufactured in under 24 hours, delivering faster in-process production and slashing time to market.
Industrial Robot Dough Cutting Knife
Tech Lead: K3D B.V
End User: Kaak Group
Partners: Additive Industries ; Civon Project
An industrial robot dough cutting knife has been redesigned for powder bed fusion leading to a myriad of benefits including part reduction of 20 to 1 and weight reduction of 90%. Unique AM improvements include porous structures for better cleaning as well as an inbuilt bearing, leaf spring and thread. This led to more cuts per hour reducing the need from 8 to 6 robots and saving €120k.
L-Series Direct Drive Valve
Tech Lead: Domin Fluid Power
The hydraulic L-Series DDV developed by Domin uses metal laser powder bed fusion to produce one of the main components, leading to a valve that is 25 % smaller and 80% lighter than current competition. The use of AM has led to the reduction of parts of from 87 to 34 and lead time of from 26 to 8 weeks.
ViridiScope Laser Sampling Tool
Tech Lead: Quigley Design
End User: Viridian Consultants
Partners: 3D Systems, Materialise, Arkk, Pro2Pro, 3DPrint-UK
ViridiScope is a laser sampling tool designed as a safer and cleaner alternative to conventional drilling to remove material from a surface for nuclear decommissioning applications. Designed specifically for AM via SLS in Nylon 12 due to the benefits of freedom of form and low-volume production capabilities, the project saved over £150k and 12 months of development costs and time
If you can’t measure it, you can’t make it — a fact that is as true for additive manufacturing and 3D printing as it is for milling, moulding and other conventional manufacturing techniques. The Inspex Application Award seeks to commend the most significant case study in the field of metrology and inspection.
Tech Lead: University of Warwick
End User: Oxford University Museum of Natural History
The use of 3D scanning has rewritten natural history for a number of rare objects within Oxford University Museum of Natural History’s collection. Looking specifically at two case studies the project has proven that 3D scanning can unearth previously unknown findings about the way extinct creatures lived and died on this planet.
Nadcap Accredited 3DSL Measurement
Tech Lead: Physical Digital Ltd
Physical Digital are the first company in the world to offer 3D Structured Light (3DSL) measurement that conforms to the Nadcap standard AC 7130-4 for Measurement and Inspection, the highest calibre of recognition within the field of aerospace dimensional measurement and quality inspection. The environmentally controlled measurement cell controls both lighting and temperature which is fundamental for dimensional metrology.
Non Destructive Imaging in Forensics
Tech Lead: University of Warwick
End User: West Midlands Police
Partners: Crown Prosecution Service; University Hospital Coventry and Warwickshire
Numerous criminal cases have benefited from a range of scanning and multi material 3D printing technologies that have, up until now, not been readily available within the Criminal Justice System. This technology has been used to provide evidence in over 120 Homicide cases for over 14 Police Forces throughout the UK and overseas.
The Coracles of Ironbridge
Tech Lead: The 3D Measurement Company Ltd
End User: Ironbridge Heritage Trust
The Ironbridge Heritage trust have commemorated an important piece of historical engineering by reproducing the Coracle - a unique and historic Shropshire river boat. The coracle has been 3D scanned and reverse engineered by T3DMC for 3D printing to help memorialise it’s imprint on Ironbridge’s history.
Inspection and metrology technologies ensure that parts and products are fit for purpose. Innovation often happens in this space at incremental levels but breakthroughs in ease-of-use, portability and accuracy are constant. This award seeks to commend the quest for absolute accuracy, which comes in many technological guises including 3D scanning, CMMs, and measuring arms.
Tech Lead: Artec
The Artec Micro is a fully-automated desktop 3D scanner that is designed to deliver metrology-grade scans with just one click. Said to be perfect for quality control of small objects, as well as reverse engineering, jewellery, dentistry, design and more, the Artec Micro scans with a point accuracy of up to 10 microns.
FARO® OPTOR™ LAB
Tech Lead: Faro
Optor Lab is a 3D dental scanner that combines all kinds of dental professional needs to support a digital workflow. This all-in-one 3D scanning device with its flexible modules is both an ideal entry-level solution and the most advanced 3D scanning desktop scanner. The flexibility in features and the open structure is built for convenient desktop scanning applications in any dental laboratory.
Ophir BeamWatch AM
Tech Lead: MKS Instruments
Ophir BeamWatch AM is said to be the industry’s first non-contact laser beam monitoring system for additive manufacturing. With an integrated laser measurement system designed to measure critical laser beam parameters for laser-based additive manufacturing systems, real-time performance also allows for measurement of dynamic focal shift during laser startup.
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 in these materials in 2 different awards – the first being polymers.
Essentium TPU 74D-Z
Tech Lead: Essentium Inc
Essentium's TPU 74D-Z is an industrial grade semi-rigid material with outstanding impact, chemical, weather, and heat resistance. With their unique multilayer extrusion process, they apply a thin coating of carbon nanotube composite onto the outer layer of the filament to give it a robust ESD-safe coating embedded throughout the entire 3D printed part.
Filamentive ONE PET
Tech Lead: : Fliamentive Ltd
Partners: Tridea; MCPP Netherlands
ONE PET is a 100% recycled plastic filament made from post-consumer PET plastic bottle waste. ONE PET has been extensively tested for 3D printing applications – it is stiff and tough with excellent interlayer adhesion. Where regular PETg has a better impact resistance, ONE PET boasts superior technical properties such as tensile strength.
Formlabs Draft Resin
Tech Lead: Formlabs
Draft Resin is the fastest-printing Formlabs resin, making it ideal for rapid prototyping. Parts printed with Draft Resin print three to four times faster than parts printed with other Formlabs general purpose resins. The print speed of Draft Resin makes it ideal for same-day design iterations and printing bulky, full-build-volume parts.
SABIC’s AMS31F Support Filament
Tech Lead: Sabic
Partners: DM Digital Solutions; RP+M; 3NTR
AMS31F support filament is formulated for use with SABIC’s ULTEM™ AM9085F filament and is one of the few support materials that is processable at high extrusion temperatures (380-420 C). This patent pending material was developed to balance excellent adhesion during printing with the ability to more easily remove the scaffolding at room temperature, reducing post production time.
Tech Lead: CRP Technology
Windform P1 is the inaugural PA material from the new-born P-LINE family of materials for High Speed Sintering (HSS) technology. It is an isotropic PA material with superior mechanical properties, engineered for faster production of small end-use parts in higher volumes at lower cost, with detailed surface resolution.
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 in these materials in 2 different awards – the second being non-polymers – be it metals, ceramics, composites, biomaterials or any other material that is not solely a polymer.
Tech Lead: OxMet Technologies Ltd
OxMet has developed ABD-900AM, a high-strength nickel-based superalloy computationally designed specifically for crack-free AM. ABD-900AM is as printable as alloy 718, but has a temperature capability 200°C higher, enabling for the first time the use of AM for critical parts at the highest temperature regimes, allowing a new unprecedented design freedom in turbomachinery applications.
Vibenite® 480, Cemented Carbide
Tech Lead: VBN Components AB
Partners: Uppsala University
VBN’s uniqueVibenite 480 cemented carbide has an extremely high carbide content of 65%, long-term heat resistance of 750° C, and high hot hardness. Developed specifically for powder bed fusion, it is suitable for applications where traditional cemented carbides are too brittle and the heat resistance of PM-HSS is too low.
XJet S100 Soluble Support
Tech Lead: XJet
XJet S100 is the only 100% soluble support material in the additive manufacturing of stainless-steel that has fully automated support removal. It brings huge advantages to the user in geometric freedom, preservation of fine details & smooth surfaces, as well as huge savings in post processing labour time and cost.
Tech Lead: Z3DLAB SAS
Partners: CNRS LSPM laboratory
ZTi Powder is a titanium material enhanced with nano-yttria stabilised zirconia specifically developed for additive manufacturing. This combination results in increased hardness, higher temperature range and increase compression strength with no loss in ductility when compared to Ti64.
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.
Tech Lead: B9 Creations
The B9Clean transforms the messy post-processing used in resin 3D printing by offering an automated 1 to 10 minute cleaning cycle, customised for part geometry and material. The process uses 75% less IPA than competitors with 50 uses per IPA refill. Crucially, the IPA automatically drains at the end of the cycle (or in the event of a powercut) to prevent over-exposure.
Tech Lead: Hirtenberger Engineered Surfaces
The H6000 offers fully automated post-processing of up to 100 3D printed metal parts using a combination of electrochemical pulse methods, hydrodynamic flow and particle assisted chemical removal with no mechanical processing. The process automatically removes powder cake and support structure whilst achieving a surface roughness of Ra < 1µm including inside cavities and undercuts, whilst retaining edge sharpness.
Tech Lead: Siemens AG
Partners: Solukon Maschinenbau GmbH
Partnering Solukon’s SFM de-powdering technology with Siemens’ software has enabled a unique solution for powder removal of DMLM parts. The parts are rotated in a sequence calculated from the CAD geometry to precisely drain the residual powder from intricate cavities such as conformal cooling channels. This not only saves manual labour time, but also reduces waste powder and scrap parts due to powder residue issues.
Tech Lead: Rösler Oberflächentechnik GmbH
Partners: AM Solutions
A fully automated system for smoothing and polishing metal and plastic 3D printed parts, the M3 offers a digitally networked solution using Industry 4.0. Handled entirely by robots, an optical measuring system records the geometry and surface condition of the physical part, compares it to its digital twin and calculates the process parameters of the vibratory finishing process. Surface roughness of Ra < 0.06µm can be achieved.
SLA Resin Removal Solution
Tech Lead: Post Process Technologies Inc
Post Process have developed an automated resin removal solution for SLA parts. The new detergent PG1.2, when combined with the DEMI system using submersed Vortex Cavitation technology, performs complete resin removal in 5 to 10 minutes. When compared to traditional IPA resin removal the new solution saves 60% process time and increases solution longevity by over four times.
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.
AM Part Identifier
Tech Lead: 3YOURMIND
Partners: Deutsche Bahn; Bosch Group
3YOURMIND have developed the AM Part Identifier software which automatically provides structured analysis of a company’s part inventory to identify AM use cases based on technical and economic factors. Companies can ensure that not only are they focusing on parts that are geometrically viable for AM, but the parts also have a solid business case to provide cost or process advantages over conventional manufacturing.
Tech Lead: Markforged
Markforged have developed a new AI-powered software which introduces ‘adaptive manufacturing’ to automatically adjust the AM build programme to ensure parts are produced as designed. Closing the process loop between inspection and manufacturing , Blacksmith analyses a design, compares it to the scanned part, and automatically adapts the end-to-end process to produce a more accurate part.
Tech Lead: Valuechain Technology Ltd
Partners: Zenith Tecnica Ltd
DNAam is an end-to-end production management platform to enable scalability of additive manufacturing throughout supply chains. DNAam manages from quotation to invoicing; controlling build files, material traceability, machine integration, post-processing, and inventory (including powders) management, to create a digital thread that improves productivity, product quality and resource utilisation
Dyndrite Additive Toolkit
Tech Lead: Dyndrite Corporation
Dyndrite Additive Toolkit, built on the Dyndrite Accelerated Geometry Kernel (AGK), enables the printing of native CAD geometry, without the need to first convert to an STL. Doing so increases flexibility, printing speeds and quality. Complex geometries which lead to huge STL file sizes take up only a few kb with Dyndrite, leading to faster processing speeds and lower storage requirements.
Tech Lead: Desktop Metal
Fab Flow is a fully-integrated prototype ordering and workflow management system for internal additive fabrication shops. The customizable tool empowers shop managers with increased efficiency, visibility and control over their workflows, and design engineers with managed 3D design communication and graphical version tracking of their parts.
Tech Lead: nTopology
nTop Platform is a unified engineering environment for design, simulation and advanced manufacturing processes. It is said to be the only design solution that allows engineers to simultaneously consider function, geometry, and manufacturing within a single computational methodology. Engineers can create lightweight and optimized parts with functional requirements built right in.
* Rising Star Award
Due to the unique nature of this award, there will be no shortlist and the winner will be announced at the awards ceremony on the 25th September 2019.