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Printing Single Crystal Nickel with Lasers

July 20, 2022 |

A team of researchers at the National Institute for Materials Science and Osaka University Graduate School of Engineering in Japan, has successfully demonstrated the fabrication of single crystal nickel with additive manufacturing, and they are hoping it finds applications in aerospace. Single crystal metals are highly prized for applications undergoing high stresses and strains and in high temperature environments such as inside a jet engine. They also crack less during manufacturing. Typically they are manufactured with casting. Traditional turbine blades used to be polycrystalline in nature, meaning that the alloy material consists of random crystals formed as the cast blade cools. The interfaces between these random grains are called the grain boundary, and these are a point of weakness in the microstructure of the material. A solution to this problem was found by carefully guiding the crystal seed growth through geometric features inside the mold to guide the solidifying blade…    read more 

How CRP Technology’s Windform materials took flight with 3D printed drones

Selecting the right material for security drones is crucial. This is an area CRP Technology, a provider of 3D printing services and materials, specializes in as it’s long been a player in the 3D printed surveillance drone market. CRP has created a whole range of Windform TOP-LINE fiber-reinforced composites dedicated to selective laser sintering (SLS) technology. The mechanical performances and durability offered by Windform materials improve the operations of premium surveillance UAVs by adding a whole new range of vital capabilities.  The firm also sees a synergistic relationship between industrial additive manufacturing and drone technologies, with both spheres evolving at rapid rates. Product designers are finding 3D printing to be an extremely valuable tool when it comes to fabricating custom end-use drone parts that provide bespoke functionalities for unique scenarios. Windform can provide a whole host of benefits to 3D printed drone products. Image via CRP Technology. The power of…    read more 

Mantis shrimp structures deliver incredible toughness with 3D printing technology

July 17, 2022 |

A team of international researchers has turned towards mother nature in a bid to 3D print ceramic composite materials with bio-inspired toughening characteristics. Ceramics composites with damage-resistant properties are in high demand, as toughness is a key requirement in a wide variety of industrial applications. These materials also tend to offer combinations of chemical and mechanical stability, qualifying them for use in everything from automotive and aerospace to energy systems. Unfortunately, many of today’s conventional ceramic composite processing techniques, such as ice templating or freeze casting, are unable to create parts with complex and custom geometries, owing to limitations in mold manufacturing. The international team is now exploring how the protective structures found in mantis shrimps can be used in conjunction with digital light processing (DLP) 3D printing to create geometrically complex ceramic composite components. The mantis shrimp. Photo via Roy L. Caldwell, University of California, Berkeley. What’s so special…    read more 

Startup Gets Boost to Turn Scrap PLA into Resin

July 17, 2022 |

A team from Washington State University (WSU) has just received funding from the Cougar Cage to develop their process for converting waste PLA into brand new PLA resin for SLA and other photopolymer printers. Cougar Cage, for those curious, is the WSU equivalent of Shark Tank/Dragon’s Den, but for WSU staff, students and faculty. That is, it’s a contest where entrepreneurs pitch to investors to get their ideas off the ground in the style of the TV shows. One team has focused on the chemical recycling of PLA plastics, and for their efforts, they have made it through three rounds of the contest and been awarded with $50,000 of funding which will help the team develop the process to create new PLA resins from scrap. Scrap goes in > Resin comes out. (Image credit: WSU) The focus is to find alternative means of recycling PLA, because as we all know…    read more 

Desktop Metal unveils new expandable foam 3D printing material, FreeFoam

3D printer manufacturer Desktop Metal has debuted FreeFoam, a new 3D printable photopolymer resin family that contains heat-activated foaming agents. Invented by Texas-based materials specialist Adaptive3D, a Desktop Metal subsidiary acquired in 2021, FreeFoam can be programmed to expand anywhere between 2 to 7 times its original printed size without any tooling. The result is the production of tunable and durable closed cell foam parts, which are expected to see extensive use in sectors such as automotive, furniture, sporting goods, footwear, and healthcare. Initially available exclusively on the ETEC Xtreme 8K DLP 3D printer, FreeFoam will be showcased at Foam Expo North America in Michigan from June 28-30. The Expo will feature a 3D printed FreeFoam car seat developed in partnership with Camaco. “FreeFoam is one of the most exciting and commercially significant photopolymer solutions to come to market in the industrial printing space in years,” said Ric Fulop, founder…    read more 

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