Shaping the future with 3D printing

Additive manufacturing, or more popularly known as 3D printing, is a process of creating three dimensional (3D) object of any shape from a digital model. Through the use of a 3D printing machine, virtually any product of any shape can be produced easily and at the shortest time possible.

Since the development of the first 3D printer, the technology has been touted as the most promising and in the plastics industry, the impact of 3D printing cannot be undermined. The technique has been revolutionary and enables the production of various parts in an easy-to-operate machine capable of quick production. For plastic products manufacturers, the simple task of using a design software to create and print using a 3D printer can yield multiple benefits – one of each is that the desired product design is achieved at the shortest time possible.

3D printing essentially makes use of an additive process, where successive layers of raw material are laid down in different shapes. Many developments are taking place in this segment that when talking about 3D printing, one can go beyond prototyping into a broader range of products, such as 3D software printers, raw materials and coatings, printing machines and all other support services.

Simulating polypropylene

Stratasys Ltd. (www.stratasys.com), a leading global provider of 3D printing and additive manufacturing solutions, has introduced Endur, an advanced simulated polypropylene (PP) material for use with all Objet EdenV, Objet Connex, Objet500 Connex3 and Objet 30Pro 3D Printers.

“Beta field trials showed high user satisfaction with Endur for models and prototypes of polypropylene parts,” says Stratasys product director for materials and applications, Fred Fischer. “During Beta testing, customers testing Endur acknowledged its toughness and flexibility, and they believed the material would address future needs. Due to Endur’s excellent simulated polypropylene properties, testing customers were able to address a variety of applications, including moving parts, snap-fit components and small cases and containers.”

As a durable and flexible addition to Stratasys’ growing materials portfolio, Endur offers both high impact resistance and elongation at break, resulting in tough parts. The material also has a heat-deflection temperature up to 129°F or 54°C (HDT @ 0.45MPa per ASTM D-648-06) and has excellent dimensional stability for its material class. These properties make the new material suitable for a wide range of form, fit and assembly applications, including flexible living hinges, moving parts, assembled parts, snap-fit parts such as those used for lids and packaging case applications. In addition, Endur, which is available in bright white, features an excellent surface finish, for a smooth look and feel. This makes the material well-suited for prototyping household appliances, consumer goods, automotive parts and lab equipment.

Stratasys has been credited for launching innovative products in the area of 3D printing. It earlier launched what it claims was the first multi-material full colour 3D printer, the Objet500 Connex3. The colour 3D printer is designed to drastically change design, engineering and manufacturing processes. Objet500 Connex3 Colour Multi-material 3D Printer uses coloured plastic in the traditional inkjet colours of cyan, magenta, and yellow. It is the only 3D Printer that enables colour 3D printing with virtually unlimited combinations of rigid, flexible and transparent materials, as well as digital resources, in a single print run.

The 3D printer makes possible functionally complex models with desirable mechanical properties such as tensile strength, elongation before breaking, and multiple hardness values. For example, the printer is able to print 3D glasses using an "opaque Veroyellow" material for the frame, a rubber-like black "Tangoblackplus" material and a translucent yellow tint for the lenses, all in one print job with no assembly required. This means that one can design a pair of swim goggles, for example, and once the initial design is finished, the goggles can be printed in colour, including the tinted lenses plus flexible parts, without needing to print the parts separately and assemble them later.

Multi-sensory experience in packaging

Trexel, Inc. (www.trexel.com) recently launched worldwide its MuCell? 3D in mould labelling (IML) process for packaging applications. This unique and award winning process creates the look of embossed labeling on the package without any need for additional tooling costs. Instead the “embossed” look comes from the enablement of 3D labels.An application using this process, the Paccor/Unilever 500g polypropylene Margarine Tub with 3D IML, won the DuPont Packaging Silver Award in 2013 as well as the Emerging Technology award in SPI’s International Design Competition at NPE 2012.

The 3D IML combines MuCell technology with IML label technology to offer a unique visual appearance and soft touch effect to packages, providing differentiation without changing the container shape. The 3D in-mould label is processed with an injection-moulded tub made of expanded polypropylene to incorporate selective masking, creating areas without adhesion. The MuCell process controls the introduction of nitrogen into the polymer. Where there is adhesion between the label and the polymer, the nitrogen migrates through both structures. Where there is no adhesion (by design behind the blue lettering), the nitrogen accumulates between the polymer substrate and the label. The process creates bubble patterns or Braille for a multi-sensory experience.

As a result, the Margarine Tub MuCell achievements include a 6% reduction in material, 40% clamp tonnage reduction, 15% cavity pressure reduction and unique 3D IML labelling.

For the moulder this process allows them the possibility to propose embossed containers without extra tooling costs and there are no extra setup costs for the embossing modifications. For the end user the benefits include product differentiation without changing container shape or the printing, additional dimension to the creativity, better visibility on the shelves, sensory effect which is as important as visual effect in purchasing decision, and the possibility to do Braille for the visually impaired

The MuCell process in packaging has enabled injection moulding processing technology providing lighter part to help in meeting sustainability goals. The reduced manufacturing costs are achieved due to less material usage, shorter cycle times and less clamp tonnage. The process also enables dimensionally more stable part; less stress, uniform shrinkage resulting in reduced warpage and fewer mould iterations

From small items to a whole house

The unlimited possibilities of 3D printing has been highlighted in more recent projects. Early this year, a breakthrough machine could 3D print a 2500 sq.ft. house in 24 hours. It was one potential for 3D printing technology that has been widely applauded in a market where construction materials have been constantly being improved and costs are being lowered. But a Chinese company has beaten the record when it reported that it could 3D print 10 houses in a single day.

WinSun Decoration Design Engineering Company is able to print 10 small houses in a span of 24 hours or one day using recycled material. Unlike some 3D printed houses that are small, these were printed in parts and assembled into the final structures. WinSun has used industrial waste and construction materials that were recycled. The printed measures in at 500 feet in length, 20 feet in height, and 33 feet in width. Each printed house, costing about $4,800, measures 200 square meters, and are the by-product of years of research and development. The design also enables quick and easy installation of electrical wirings.

It’s not the first attempt towards 3D printing large items or structures. In California, researchers are also designing a printer that can build a house in 24 hours. A similar project in Amsterdam, a similar project to construct 3D-printed house has begun. The house is made out of plastic bricks that fit together like Lego. It's also being printed onsite.