3D Printing Materials

FormNext 2024 in Frankfurt recorded more than 34,000 visitors and saw new product introductions amid an increasingly consolidated additive manufacturing market. PowderMonkeys, a brand of Launhardt GmbH that specializes in polymer powders for powder bed fusion (PBF) processes, presented two new materials designed to improve performance and sustainability in 3D printing. PowderMonkeys, established in 2021 and a regular exhibitor at FormNext, supplies both desktop and industrial-scale systems. The portfolio is known for materials compatible with selective laser sintering (SLS) and high-speed sintering (HSS) platforms developed by companies such as Voxeljet AG, a provider of large-format 3D printing technology. Existing offerings include Monkey TPU 50, a thermoplastic elastomer with UV resistance, biocompatibility, and variable Shore hardness levels. According to technical data, Monkey TPU 50 exhibits a low refreshing rate of around 20% and a spherical powder shape contributing to stable 3D print processes. Monkey TPU 50, PowderMonkeys’ flagship thermoplastic elastomer. Photo…    read more 

Engineers from the University of New Mexico (UNM), a public research institution recognized for its work in advanced construction materials, have patented a bendable concrete designed for 3D printing. Researchers in the Gerald May Department of Civil, Construction, and Environmental Engineering aimed to address brittleness, high labor costs, and dangers associated with traditional building methods. This new composite, classified as self-reinforced ultra-ductile cementitious material, may herald more resilient infrastructure while reducing dependence on steel bars and heavy machinery. Traditional concrete is renowned for its strength under compression but is inherently brittle, leading to frequent cracks and the need for regular maintenance in infrastructure such as sidewalks and bridges. Maryam Hojati, assistant professor in UNM’s Gerald May Department, highlighted this limitation as a primary motivation for their research. “Concrete by itself does not show any tensile properties,” Hojati explained. To address this, the team incorporated short polymer fibers into the concrete…    read more 

UK-based metal 3D printing powder manufacturer Metalysis installed three new Gen 1 units at its Discovery Centre in Catcliffe, Rotherham, increasing its first-stage research capabilities by a third.  These Gen 1 R&D systems are used in the first step of Metalysis’ Fray, Farthing, and Chen (FFC) Cambridge electrolysis method for producing 3D printable metal alloy powders. The process is scaled across the company’s Gen 1-4 units, with material output increasing from grams per machine run with the Gen 1, to tens of tonnes per annum via the Gen 4.  Metalysis’ new systems, which bring its total suite of Gen 1 units to 12, have been added in response to “unprecedented” demand from the high entropy alloy (HEA) and commercial space sectors. They will be used to develop novel materials for advanced applications in hypersonics, defense, clean energy, and space  “We are delighted to be expanding Metalysis’ development capabilities by increasing…    read more 

Renishaw, a leading engineering technology company, has partnered with Cookson Industrial, a UK-based specialist in precious metal additive manufacturing (AM), to reduce the costs associated with 3D printing platinum-rhodium. This collaboration leverages Renishaw’s RenAM 500S Flex AM system, enabling Cookson Industrial to produce high-temperature corrosion-resistant components with improved material efficiency. The advancement is particularly significant for industries such as glass fibre manufacturing, where the viability of using platinum rhodium in additive manufacturing has been enhanced. Cookson Industrial, a division of Cooksongold and a subsidiary of HM Precious Metals, brings over three decades of expertise in designing and producing precious metal alloys. Faced with platinum rhodium prices averaging £80,000 per kilo, minimizing material waste was essential to make production economically feasible. To address this challenge, Cookson Industrial selected Renishaw’s RenAM 500S Flex, a laser powder bed fusion system designed for research and development in additive manufacturing. RenAM 500S Flex installed at…    read more 

Airtech Advanced Materials Group, a leader in high-performance materials for additive manufacturing, has qualified its Dahltram® Resins for use with KraussMaffei Technologies GmbH’s powerPrint Large-Format Additive Manufacturing platforms. This partnership represents a significant advancement in large-scale 3D printing for industrial applications, enabling more precise and reliable production processes. KraussMaffei Technologies, renowned for its expertise in injection molding and extrusion, has been at the forefront of large-format additive manufacturing. The company’s Additive division specializes in extrusion-based 3D printing technology, with the powerPrint system being a key component. This gantry-based platform is designed for industrial-scale production, offering high precision and consistency in part manufacturing. Recently, KraussMaffei has expanded its offerings to include industrial robot-based systems and standalone extrusion solutions, further solidifying its position in the additive manufacturing sector. KraussMaffei powerPrint system interior setup for large-scale additive manufacturing. Photo via Airtech Advanced Materials Group. “We are excited to collaborate with KraussMaffei to bring…    read more