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A team of students at TU/Eindhoven have utilized 3D printing to build an electric vehicle that, among other ecologically friendly measures, captures more CO2 than it produces. The passenger-carrying EV is named “Zem” and has been designed and constructed by the student’s TU/ecomotive team at the Dutch university. The team used multiple production methods to ensure that CO2 emissions were kept down during manufacturing, contributing to the overall low carbon philosophy behind the design. The “Zem” with printed monocoque and panels. (Image credit: TU Eindhoven) This included 3D printing the body panels and monocoque structure, which were designed and manufactured in collaboration with CEAD and Royal3D. Both companies are based in the Netherlands and focus on large format polymer additive manufacturing. The printed parts have been made with recycled thermoplastics, which can in turn be shredded and recycled again further downstream after the car’s disposal. Utilizing AM has allowed the…    read more 

The Department of Energy (DOE) has awarded $3 million in funding to two companies aiming to decarbonize manufacturing with robust, 3D printed resin tooling. Resin-manufacturer polySpectra and composite material specialist Fortify, along with National Renewable Energy Laboratory, MPI Systems, RePliForm Inc, and ORNL have been funded to develop direct additive automotive tooling with polySpectra’s Cyclic Olefin Resin-based resins. COR Alpha resin. Good for tooling. (Image credit: polySpectra) “Olefin-based thermoset composites have been used for many decades in extremely demanding applications such as wind turbine blades and fuel cell components, because they are among the most durable materials on the planet,” said Raymond Weitekamp, polySpectra founder. “Under this research grant, we will leverage Nobel-winning chemistry to directly 3D-print these robust composite Cyclic Olefin Resins. The goal of the DOE project is to bring unprecedented materials durability to additive manufacturing, which will provide the industry with immense leverage for the decarbonization and…    read more 

Just recently we saw how the USS Essex took to the oceans with their own metal printer for fabricating and repairing components while out to sea. This week, it’s the turn of the US Marines who have been testing their own Factory in a Box concept that will allow accurate metrology and advanced plastic and composite manufacturing out in the field. The so-called Expeditionary Fabrication Shop is a portable solution to enable manufacturing and repairs in hard to reach locales and areas without infrastructure. The project is being trialed at a Marine base in Okinawa by the III Marine Expeditionary Force. One of the mini-factory units at Camp Kinser. (Image credit: Stars and Stripes) “The intent is to supplement the supply chain and return whatever piece of equipment it is back into the fight as fast as possible,” said Gunnery Sgt. Quincy Reynolds, who is NCO in charge of the…    read more