3D printer pushes prototyping boundaries

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The printer head hovers above the printing plate, connected to 3 arms that kind a triangle. This enables for the printing of exceptionally massive components. Credit: Jacobs University Bremen

Making the development of prototypes extra environment friendly, cost-effective, quicker and versatile—this will probably be attainable with the world’s largest industrial delta 3D printer. The four-meter-high machine was developed by Professor Yilmaz Uygun’s analysis group at Jacobs University Bremen. The challenge reveals promising potential for industrial utility and additional analysis and cooperation alternatives for the college in Bremen-Nord.

In industries similar to spare components administration, prototype building, and mechanical and plant engineering, individualized components are commonly required, which poses a problem for these industries; on one hand the components are advanced in construction however are, however, solely wanted in small portions. Typical manufacturing processes are hardly appropriate for the manufacturing of such particular person components. It’s uneconomical, typically even inconceivable, to supply these mandatory components—relying on their dimension and complexity.

That is the place the challenge of Professor Yilmaz Uygun and his staff at Jacobs University Bremen comes into play. Supported by the Kieserling Basis, the analysis staff led by Serkan Özkan has developed the world’s largest industrially usable delta 3D printer inside a really quick time. This additive manufacturing course of makes it attainable to effectively produce advanced particular person components for prototypes which can be nonetheless within the check section. Which means their design may be flexibly and economically tailored to the check outcomes and renewed as required.

The 3D printer has a top of over 4 meters and provides a printing space of as much as 1.5 meters in radius and a printing top of as much as 2.5 meters—making it one among a sort attributable to its design. The printer head hovers above the printing plate, connected to 3 arms that kind a triangle—a delta. The printer head may be moved in any path by way of the arms. The printing space that outcomes from this permits for the printing of exceptionally massive components.

The printed components are created utilizing the additive manufacturing course of are at present utilized in vertical wind generators as a part of a college challenge. Additional initiatives for varied industries are deliberate. The printing velocity is at present round 5kg per hour—relying on the complexity of the specified printout.

The velocity in addition to the printing materials—at present filament, i.e. strings consisting of typical plastics similar to PLA, PET or ABS—are features the place Uygun nonetheless sees nice potential sooner or later.

Extra materials, which is printed as a assist construction for curved and nice components and subsequently disposed of, may very well be shredded and recycled as pellets: “We are currently developing a pellet extruder to be able to produce pellets and use them as input material instead of filament,” stated Uygun. “This radically reduces the carbon footprint. In addition, we can reduce costs, secure the supply chain and ensure independence from specific suppliers and regions,” defined the Professor of Logistics at Jacobs University.

Uygun and his staff are additionally specializing in additional creating high quality administration in the course of the printing course of. One measure they’re engaged on offers with a camera-based system that screens the printing course of visually. In the long run, “Honeycomb,” because the 3D printer has been named, ought to appropriate itself within the occasion of deviations within the print. “Our goal is to bring Honeycomb directly into production. We have several ideas to speed up printing without sacrificing quality.” The staff is researching the simultaneous use of a number of print heads with nozzle openings of various sizes, which might be used for product geometries of various complexity and at correspondingly totally different speeds. “If this is successful, the system could be used directly in production,” stated Uygun.

They selected the identify Honeycomb as a result of it describes the interior construction of the printed components. The honeycomb construction renders an end result with much less materials and the manufactured piece is gentle and steady. One other contribution to effectivity and sustainability. “There are already several interested parties for pilot projects,” stated Uygun.


New 3D printing process is faster and more precise than conventional methods


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Jacobs University Bremen gGmbH

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3D printer pushes prototyping boundaries (2022, August 24)
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