Liquid crystal elastomers are a class of soft materials that can change shape in response to stimuli such as light or heat — making them promising for applications in soft robotics, wearable and biomedical devices, smart textiles and more. But designing compositionally uniform elastomers that can change into different shapes in response to just one stimulus has been challenging and has limited the application of these potentially powerful materials.&nbsp;Now, researchers from the&nbsp;<a href="https://seas.harvard.edu/">Harvard John A. Paulson School of Engineering and Applied Sciences</a> (SEAS) have developed a way to program liquid crystal elastomers with the ability to deform in opposite directions just by heating — opening up a range of applications.&nbsp;The research was published in&nbsp;<a href="https://www.science.org/doi/10.1126/science.adq6434" target="_blank">Science</a>.&nbsp;“We have shown that by encoding multiple phase transitions within a single material, we can create scalable, easy to fabricate systems capable of achieving various deformations and shape changes without the need of complex designs or composite materials,” said&nbsp;<a href="https://seas.harvard.edu/person/joanna-aizenberg">Joanna Aizenberg</a>, the Amy Smith Berylson Professor of Materials Science and Professor of Chemistry &amp; Chemical Biology at SEAS and senior author of the paper.&nbsp;The team used an approach that combined theoretical modeling,&nbsp;chemical modifications, and mechanics of polymer-polymer interactions to design the system. They began by orienting liquid crystal monomers, which could be bonded together to form polymer chains, along one direction in a magnetic field. The monomers, which were designed with long molecular tails and long linkers, would dangle at the side of polymer chains — like the pendulum of a clock.When exposed to UV light, the oriented molecules tether together and form polymer chains. The process of polymerization contracts and puts strain on the material, squeezing those aligned monomers into a zig-zag, chevron-like pattern of polymers.&nbsp;The researchers found that when they increased the temperature, those chevron-shaped polymers flattened and stacked into flat layers. If they increased the temperature further, those layers transformed into a randomly coiled state — like a pile of spaghetti. When they lowered the temperature back down, the random polymers reformed into flat layers then back into chevrons.&nbsp;“With soft actuators, we need deformations to be reversible so we can cycle them many, many times,” said Milan Wilborn, a PhD candidate in Aizenberg’s lab and co-first author of the paper. &nbsp;“And we demonstrated that we can switch between these three phases at high frequency, moving quickly between each deformation state.”The researchers also demonstrated that by aligning the molecules in different directions before polymerization, they could encode different shape changes into the material, including flat sheets that move like the fins of stingrays and jellyfish by morphing into saddles and domes. &nbsp;“What is so powerful about this research is we have this single, soft material which can achieve opposite deformations. So at room temperature, the material is flat, then it forms a saddle when the polymers are stacked in flat layers and then transforms into a dome when the polymers become random,” said Wilborn. “We’re really excited about using these materials as soft actuators for bioinspired motions.”These transformations respond to not only temperature, but also light and solvent, making them useful for applications from smart textiles to temperature-regulating robotic skins.&nbsp;This research was co-authored by Yuxing Yao, Baptiste Lemaire, Foteini Trigka, Friedrich Stricker, Alan H. Weible, Shucong Li, Robert K. A. Bennett, Tung Chun Cheung, Alison Grinthal, Mikhail Zhernenkov, Guillaume Freychet, Patryk Wąsik, Boris Kozinsky, Michael M. Lerch and Xiaoguang Wang.It was supported by the US Department of Energy, Office of Science, Basic Energy Sciences and the Harvard University Materials Research Science and Engineering Center (MRSEC).

Researchers encode multiple shapes into simple material

Shape-changing soft material for soft robotics, smart textiles and more

Designing medical parts? Just as there are countless types of medical procedures, there are also countless types of polymers on the market today. Which ones are best for your medical application? Great question. We’ll attempt to provide some guidance in this design tip, but it’s important to start with the following caveat: The term “medical grade” is ambiguous at best. &nbsp;<a href="https://www.protolabs.com/en-gb/industries/medical/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Medical" target="_blank" rel="noopener noreferrer">Medical device</a> manufacturers must understand and comply with a slew of standards, but for the purposes of this discussion, ISO 10993 takes the lead role. It has nearly two dozen parts, of which four pertain specifically to material selection; of these, ISO 10993-13 is probably the most relevant to polymers.&nbsp;Unfortunately, there’s no catalogue or book that lists which polymers meet which standards, or even which polymers are biocompatible. Compounding matters is the sheer number of resins, pellets, powders, and bulk forms like rod and sheet from which to choose, each with multiple manufacturers that may or may not meet the necessary&nbsp;<a href="https://www.protolabs.com/en-gb/resources/design-tips/manufacturing-tool-kit-for-the-medical-industry/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Manufacturing Tool Kit for the Medical Industry" target="_blank" rel="noopener noreferrer">medical device requirements</a>. Where one might provide medical-grade ABS, the other produces ABS suitable for LEGOs and power tool housings. &nbsp;Of course, one blog post can’t cover all you need to know about medical grade plastics, so don’t forget you can look at the stats on our <a href="https://www.protolabs.com/en-gb/materials/comparison-guide/?category=plastic&utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Comparison Guide" data-anchor="?category=plastic" target="_blank" rel="noopener noreferrer">materials comparison page</a>. All that said, here are six essential polymers to keep in mind for your next medical parts project.&nbsp;<h3 id="isPasted">Comparing Plastics for Medical Parts&nbsp;</h3>Generally, medical device designers and manufacturers should look for polymers that are resistant to corrosion, chemical attack, and high temperatures. These should be non-absorbent and inert, and able to withstand repeated sterilisation cycles in an autoclave. Of course, they shouldn’t react with bodily fluids and human tissue, cause irritation, or create skin sensitivities. Did we mention strength and durability? All of this might seem like a very tall order, but the good news is that a healthy handful of polymers check at least most of these boxes. &nbsp;<h5 id="isPasted">PC&nbsp;</h5>Oftentimes, an optically transparent polymer is needed for medical procedures, and polycarbonate is the material of choice. It checks all the usual boxes in terms of toughness, dimensional stability, heat and chemical resistance, and sterilizability. You won't find it inside the human body, but PC is typically used when it's necessary to see blood, drugs, and other fluids flowing through a device. Many of Protolabs' medical customers will 3D-print their designs from PC-like materials such as Acura 5530 or PerFORM, then go on to machined or injection-moulded polycarbonate as production needs increase. &nbsp;<h5 id="isPasted">UHMW-PE&nbsp;</h5>Since we’re discussing orthopedic implants, here’s another important polymer to keep in mind: ultra-high molecular weight polyethylene. If you’ve had a knee or hip replacement, chances are good that you have some of this stuff inside you. UHMW-PE is an extremely dense, low-friction member of the polyethylene family. If you’re looking for some machined medical components (or wear-resistant machinery parts), UHMW-PE has excellent impact strength and abrasion resistance, and here again, is eminently biocompatible. And for slightly less demanding applications, “regular” polyethylene (PE) and high-density polyethylene (HDPE) are good, all-around polymers for a wide range of medical applications, especially for single-use products and the PPE gear that’s become so prevalent over the past few years. &nbsp;<h5 id="isPasted">PEI&nbsp;</h5>Like PEEK, polyetherimide borders on super-polymer territory. Better known by its trade name Ultem, PEI is a rigid, semitransparent, and heat-resistant 180°C polymer that is amber in colour and boasts great tensile strength. Because it also has high dielectric characteristics and resistance to flame, it is widely used in electronic components, medical or otherwise. We machine and injection mould PEI into various shapes, with potential uses including handles for surgical instruments, medical device enclosures, insulators, electrical connectors, and more. Lastly, PEI is readily sterilised via autoclaving and gamma radiation. &nbsp;<h5 id="isPasted">PSU&nbsp;</h5>Another amber-coloured polymer is PSU, short for polysulfone. Recognised for its toughness and rigidity at elevated temperatures, PSU is less strong than PEI but more impact resistant. It might be machined or moulded into filter housings, catheter ports, surgical instrument trays, and sizing devices for use during heart valve replacements. Polysulfone is said to be one of the few polymers able to withstand more than 1,000 cycles of steam sterilisation (as can PEEK and PSU’s even more impact- and heat-resistant cousin, polyphenylsulfone, or PPSU).&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519080624-1734519080624.png" class="fr-fic fr-dib" style="width: 806px;">This medical component from IDEXX Laboratories, Inc. is part of an instrument that veterinarians use to test blood and urine.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519116565-1734519116565.png" style="width: 808px;" class="fr-fic fr-dib">Moluded part manufactured with medical-grade liquid silicone rubber.<h5 id="isPasted">PEEK&nbsp;</h5>Polyetheretherketone is a great place to start. Long considered an “engineering-grade” thermoplastic, PEEK enjoys broad use in the medical industry. Orthopedic surgeons use it for trauma fixation, spinal implants, and replacement joints, while dentists use it in crowns and bridges. PEEK is both lightweight and strong, is radiopaque (meaning it appears on x-rays), and maintains its strength and dimensional stability at high temperatures. And seeing that PEEK is often inserted into the human body for extended periods of time, it goes without saying that it’s biocompatible and sterilisable. Protolabs routinely CNC machines and plastic injection moulds PEEK into mechanical components such as gears, bearing surfaces, and manifolds, as well as a host of medical parts. &nbsp;&nbsp;<h5 id="isPasted">Silicone&nbsp;</h5>The stuff of weatherproofing adhesive and cooking utensils, silicone is also an excellent choice for many medical components. Silicone is available in various hardness levels, from soft and stretchy like a rubber band or rigid like a tire tread. It withstands temperatures from sub-zero to oven hot 55°C to 210°C, is hydrophobic (repels water), resistant to solvents and acids, and has good vapour permeability, making it a favourite for prosthetic devices. Protolabs 3D-prints a variety of medical components, including seals, gaskets, and surgical models, and injection moulds all manner of prototypes and end-use production parts using liquid silicone rubber (LSR). You can even 3D print in silicone, a great option for prototyping parts using this material for complex parts or prior to moving to injection moulding for production quantities. In addition, there’s also an optical grade of liquid silicone rubber, OSLR, which enjoys superior refractive and light transmission properties compared to its PC or PMMA (acrylic) alternatives. It is therefore popular for use in lenses and lighting applications, or anywhere that a clear, non-yellowing, heat- and chemical-resistant biocompatible polymer is needed. &nbsp;&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519177098-1734519177098.png" class="fr-fic fr-dib">An operator removes a silicone part from the LSR press. Due to the elasticity of silicone parts, manual removal is necessary.<h3 id="isPasted">More Options to Consider&nbsp;</h3>Those six medical-grade polymers are just the starting point. We’d be remiss if we didn’t mention PTFE, better known as Teflon, a super-lubricious polymer used in everything from catheters and stents to heart-lung machines. Impact and chemical-resistant acrylonitrile butadiene styrene (ABS) is sometimes used to replace metal structural components in medical equipment, as is acetal (you might know it as Delrin), while polyvinyl chloride (PVC) might be considered a flexible version of polycarbonate in certain applications. Polyethylene terephthalate (PET) resists attacks by microorganisms, making it just as suitable for soft drink containers as it is for wearable sensors. Polypropylene (PP)—although considered a commodity plastic—finds widespread use in specimen bottles, prescription containers, and disposable hypodermic syringes (it’s also a great option for parts that would benefit from a living hinge). &nbsp;As with any manufacturing application, choosing the best material for a medical device comes down to its physical, chemical, and electrical requirements, not to mention its operating environment. There’s also manufacturability to consider and all the design rules that go along with that. And at the end of the design and prototyping process waits the FDA approval ordeal. It can be a confusing landscape to navigate, which is why we encourage you to upload a file, get a quote, and give us a call to discuss your options. We've helped countless others who were once in your shoes. &nbsp;

Safety and longevity are key to this list of medical-grade plastics.

Plastics for Medical Devices and Applications

We’ve recently covered the&nbsp;<a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-manufacturing/">benefits of 3D printing in manufacturing</a> where we outlined how in today’s fast-paced manufacturing environment, operational efficiency and adaptability are more critical than ever.Whether you're an operations manager looking to streamline production workflows or an engineer tasked with solving complex design challenges, 3D printing has become a transformative tool in modern manufacturing.This article will explore&nbsp;how 3D printing is being applied across the manufacturing industry, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507534509-0H6A3681-2.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2>Custom Jigs, Fixtures, and Tooling</h2>Across the entire manufacturing landscape, jigs, fixtures, and tooling play a pivotal role in ensuring product quality, assembly accuracy, and production speed. Traditionally, creating these components required time-intensive machining and significant costs, especially for customized solutions. 3D printing allows for a vastly more rapid, efficient, and cost-effective way of producing these parts.Several of our clients such as ERIKS, Volkswagen Autoeuropa, Zeiss, and IME Automation have already implemented 3D printing technology to create various jigs and fixtures to streamline and improve their manufacturing capabilities.Here’s a few examples:<h3>ERIKS - Motor and drill alignment jigs</h3>The implementation of the motor jig, for example, allowed for an easier assembly of the components minimizing the chance of assembly errors while also making the process 3 times faster (assembly time previously took around 3 minutes which was cut down to one).According to ERIKS:<blockquote>For us the primary benefit of 3D printing is speed. How quickly can we get something? And that is where 3D printers are the fastest option you can get. I can turn on a print job at 2 pm one day, and the next morning I come into the office and now I have the tools ready. So that is the main factor why we choose 3D printing over conventional methods, whenever we can. Cost is a side benefit for us.</blockquote><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507587853-1734507587853.png" class="fr-fic fr-dib"><h3 id="isPasted">Volkswagen Autoeuropa - Manufacturing tools</h3><a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa</a> has switched to 3D printing in order to produce the vast majority of tools used in their manufacturing line and has seen tool development time reduced by up to 95% and costs by 91% (saving an estimated $375.000 per year).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507613298-1734507613298.png" class="fr-fic fr-dib"><h3 id="isPasted">Zeiss - Adapter plate and label placement gauge</h3>For&nbsp;<a href="https://ultimaker.com/learn/zeiss-precision-parts-for-serial-production/">Carl Zeiss Optical Components</a>, precision is paramount when manufacturing microscopes, multi-sensoric machines and optical sensors for industrial measurement and quality assurance purposes.Their implementation of <a href="https://ultimaker.com/">UltiMaker’s 3D printing</a> technology not only enabled them to create bespoke adapter plates for each of their microscopes in serial production streamlining the process but also made supporting those parts for their clients a lot easier, as spares could be printed on demand and sent to a client’s location. Previously they had to produce several parts, mount them together, and adjust them which was a more costly and time-consuming process.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507633041-zeiss-adapter-plate-ultimaker-1.webp" style="width: 100%px;" class="fr-fic fr-dib">Taking label placement gauges as another example, previously made out of POM (polyoxymethylene), the sharp corners would lead to breakage if dropped. Adding in the fact that POM is traditionally made by injection molding or extrusion, itself a costly process, would often require CNC machining to create the desired part.In contrast, the new 3D printed gauges allowed products to slide in and out of the tool effortlessly while also being less fragile, more wear-resistant and could be printed to achieve tight tolerances, all while having a print time of just 3 hours at €2.20 per part.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507646971-Zeiss.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">IME Automation - Box folding jig</h3>With a focus on precision, efficiency, and innovation in the field of building custom automated robotics for manufacturers<a href="https://ultimaker.com/learn/3d-printing-for-flexible-manufacturing-with-ime-automation/">&nbsp;IME Automation turned to 3D printing</a> to test and create a wide range of applications to be more agile and flexible in their manufacturing process.One of the most notable examples is the one that started them on the path of using 3D printing technology, their patented box folding jig.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507662261-Copy-of-IME-Sparky-close-up-1.webp" style="width: 100%px;" class="fr-fic fr-dib">Used to erect or fold cartons their customers previously had to either buy an off-the-shelf carton erector or a full-fledged cartoner which were big, cost prohibitive, and offered no flexibility to changes due to the long times required to adapt them.The 3D printed folding box jig IME Automation developed was a game changer as they could iterate a wide variety of shapes and sizes with less than 2-minute part changeover times.<h2>Rapid Prototyping and End-Use Parts Production</h2>As previously hinted, 3D printing allows for direct fabrication of prototypes from CAD models, bypassing the need for complex tooling or molds. This capability significantly shortens development cycles and enables designers to test, modify, and validate designs with a high degree of speed and flexibility.Unlike traditional subtractive manufacturing processes, additive manufacturing allows for the creation of designs with complex geometry, overhangs, and organic shapes at a reduced cost and complexity. This innate feature allows 3D printing to bridge the gap between prototyping and large-scale production, allowing companies to produce end-use parts without the need for expensive and time-consuming tooling. Our clients Sylatech and Snow Business offer some great examples in this regard:<h3>Sylatech - Yacht propeller prototype</h3>An investment casting firm, Sylatech was previously unable to test design functionality without using tooling investment casting, a time-consuming and costly process, typically taking three to four weeks with customers paying £2,000-4,000 per tool. Add in the fact that approximately 30% of tools require some sort of alteration, which can cost up to £900, it’s easy to see why they needed a solution to reduce lead times and costs.Using UltiMaker’s 3D printing technology they were able to reduce the development time of a yacht propeller from four weeks to just three days and brought down the total cost from £17,100 to £15,660 (including casting tooling costs).Taking into account that with 3D printing only 5% of tools needed alteration, Sylatech’s ROI for an UltiMaker 3D printer was less than 3 months.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507676679-yacht-propeller-and-prototype-image.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Snow Business - Snow machine nozzle</h3>With over 35 years of experience in the artificial snow industry for film and TV effects production, Snow Business has leveraged 3D printing to prototype, functionally test and create final parts for their machines. For example, the nozzles on their snow machines could be 3D printed in-house within seven hours at £2.50 each, negating the need for an SLS service which took up seven days with a minimum £125 per order. They estimate that their UltiMaker printer paid for itself within just two weeks.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507691141-snow-business-ROI-calculator.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">On-Demand Spare Parts and Maintenance</h2>In traditional manufacturing, maintaining a stock of spare parts for machinery or production lines often requires significant investment in inventory and storage space. Long lead times for replacement parts can result in costly production delays.3D printing eliminates these challenges by enabling the on-demand production of spare parts directly on location, aside from the greater flexibility and cost efficiency in maintenance operations, manufacturers can leverage 3D printing to also extend the lifespan of existing machinery far beyond the OEM’s support cycle which is an often underreported benefit that directly translates to lower production costs and higher production uptimes.Some of our clients, such as Trivium and Heineken, have integrated UltiMaker’s ecosystem precisely for this reason:<h3>Trivium - Conveyor infeed worm and silicone seals &amp; gaskets</h3>In Trivium’s case, the original packaging machine had worn out and was no longer available from the supplier and manufacturing it via traditional methods such as CNC milling was cost prohibitive and time consuming. 3D printing the part in a low cost material such as ABS allowed them to validate the design and switching to carbon reinforced nylon netted them a durable replacement part that allowed them to keep their production rolling.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507706706-image.webp" style="width: 100%px;" class="fr-fic fr-dib">Similarly, the molds needed for silicone seals and gaskets needed for different machines were either too expensive or, as was the case for the infeed wheel, no longer available.Using ABS printed with a 60 micron layer height, Trivium was able to cleare smooth and accurate molds for silicone which could be reused and reprinted on demand, saving time and money.<h3>Heineken - Stopper tool</h3>After the implementation of 3D printing technology in their Seville plant, Heineken was able to improve their manufacturing process in terms of output, uptime, and safety. We recommend reading further on&nbsp;<a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">how Heinken ensured production continuity with 3D printing</a> for a more comprehensive list of applications, but for this example, we want to showcase their stopper tool.As a custom tool used to loosen or tighten the columns for the guiding wheels that apply bottle labels, the 3D printed version of the tool was 70% cheaper to produce than the previously CNC machined one and done within a single day instead of three.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507722244-heineken-ultimaker-3d-printed-tools-speed-up-maintenance-.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Materials Enabling Versatility in Manufacturing</h2>UltiMaker’s ecosystem of advanced printing solutions provides manufacturers with the flexibility to choose from a wide range of materials tailored to specific applications. From durable industrial plastics to flexible polymers, these materials enable the production of functional parts that can withstand the rigors of industrial environments even replacing traditional materials such as aluminum or steel in certain applications without compromising on part reliability or function.As a reference starting point here are 3 of the materials used in the above examples:<a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerTPLA">UltiMaker Tough PLA</a>:<ul><li>Applications: Strong and impact-resistant parts such as jigs, fixtures, and prototypes.</li><li>Use case: Heineken uses Tough PLA to print durable production line components, including bottle guides and tool organizers, ensuring longevity while maintaining cost-effectiveness</li></ul><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/ULTIMAKERNYLON12CFMETHOD">UltiMaker Nylon CF</a><ul><li>Applications: High-strength, abrasion-resistant parts like gears, bushings, and conveyor belts.</li><li>Use case: Trivium Packaging leverages carbon reinforced nylon for parts like conveyor infeed worms, which must endure high wear and tear in a manufacturing environment</li></ul><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerABS">UltiMaker ABS</a><ul><li>Applications: Durable parts requiring smooth surface finishes, such as molds and protective covers.</li><li>Use case: Zeiss’s adapter plates and label placement gauges are both made from ABS.</li></ul>We recognize that material selection is one of the cornerstones of successful 3D printing applications in manufacturing and with a selection of over 200+ materials on the Marketplace, we’ve recently expanded the possibilities available on a single print with our dual-extrusion&nbsp;<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/">Factor 4 printer</a>:<ul><li>Support Materials: Soluble supports like PVA allow for complex geometries with overhangs or internal structures that would otherwise be impossible to produce through traditional methods.</li><li>Composite Structures: Pairing flexible materials like TPU with rigid materials like nylon creates parts with hybrid properties, such as flexible joints or shock-absorbing elements.</li></ul><h2>IMES3D - The Power of Partnership</h2>For a holistic view of how UltiMaker’s complete ecosystem can help manufacturers and businesses integrate 3D printing technologies into their workflows effectively, we turn to <a href="https://ultimaker.com/learn/imes3d-expert-support-for-industry-level-3d-printing/">IMES3D</a>, one of our clients and partners, as an example of leading the charge in the transformative nature of 3D printing technology.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507740966-imes3d.webp" style="width: 100%px;" class="fr-fic fr-dib">Offering professional support and a full suite of comprehensive services, IMES3D specializes in designing and implementing 3D printing solutions tailored to their customers specific operational needs. From printing parts and support in selecting the right materials they also offer consulting services for companies looking to adopt additive manufacturing and integrate it into existing workflows.In order to support their clientele spanning a wide range of industries, including automotive, food and beverage, military and medical sectors, they rely on UltiMaker’s unique ecosystem to ensure that their 60+ printer fleet is utilized as efficiently as possible.Elaborating on UltiMaker’s ecosystem this is comprised of 3 main parts:Hardware:<ul><li>S Series</li><li>Method Series</li><li>Factor Series</li></ul>Software:<ul><li>Cura</li><li>Digital Factory</li></ul>Materials &amp; Partners:<ul><li>UltiMaker materials</li><li>3rd party partner materials</li></ul>Along with UltiMaker Cura which is a fast and easy-to-use slicer, Digital Factory is used to easily manage all of the printers in the network, and ensure that projects get sent to the right printer and queues are monitored. Additionally, some customers have also started using Digital Factory which enables IMES3D to leverage the software as a key support tool being able to remotely send and queue prints from their facility.Their expertise spans technology, material science, and production optimization, which is why we highly recommend watching our&nbsp;<a href="https://ultimaker.com/learn/how-imes3d-unlocks-industrial-3d-printing-with-the-ultimaker-ecosystem/">recent webinar with IMES3D</a> to get a full picture of how they are advancing industrial 3D printing together with UltiMaker’s ecosystem.But for those interested in a couple of short granular examples of applications we’d like to showcase two that were made possible with the addition of the new UltiMaker Factor 4 printer:<h3>Flexible bumpers for PDA’s</h3>Considering that most PDA manufacturers do not make any protective covers for their devices, resulting in drastically reduced lifespans due to accidental drops or mishandles, IMES3D designed and printed a wide variety of custom bumpers made out of soft TPU filament.The ability to print in a variety of colors also allowed IMES3D to color code the bumpers according to their customer’s specifications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507763014-1734507763014.png" class="fr-fic fr-dib"><h3 id="isPasted">Mold for part injection</h3>The ability to print in UltiMaker’s new PPS CF carbon reinforced filament, opened up the possibility of replacing metal parts with the new composite material. With extreme durability and high-temperature resistance (HDT B of over 230°C printing), IMES3D was able to create a mold connector used for injecting parts for water and air pipes.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734507784011-imes3d-1.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Become an industry leader with UltiMaker</h2>3D printing is not merely a complementary technology, it is reshaping the manufacturing landscape. At the cutting edge, UltiMaker’s Factor 4 empowers companies to innovate rapidly, cut costs, and create complex designs and paves the way for a more agile and efficient future.If you want to know how UltiMaker can help you change the game for your business don’t hesitate to&nbsp;<a href="https://ultimaker.com/quote-request/">contact us</a> and our team of experts would be more than happy to reach out!

This article will explore how 3D printing is being applied across the manufacturing industry, from custom tooling and rapid prototyping to on-demand spare parts production, highlighting real-world examples and key benefits for professionals striving to maintain a competitive edge in their operations

Applications of 3D Printing in Manufacturing

Let's start with the Properties of Aluminum AlSi10Mg (3.2382)1. High Strength and Hardness: AlSi10Mg is renowned for its high strength and hardness. The addition of magnesium and silicon enhances its mechanical properties, making it suitable for applications that require both durability and strength.2. Good Thermal Properties: The alloy exhibits excellent thermal conductivity, which is crucial for applications in high-temperature environments. This property makes it effective in managing heat dissipation, especially in components subjected to thermal stresses.3. Good Processability: The presence of silicon in AlSi10Mg improves the viscosity of the melt pool during additive manufacturing. This enhances the alloy's processability compared to pure aluminum, allowing for more precise and efficient 3D printing.4. High Corrosion Resistance: AlSi10Mg offers excellent resistance to corrosion, which is essential for parts exposed to harsh environments. This property ensures the longevity and reliability of components, especially in aerospace and automotive applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734430992551-2-min.jpg" style="width: 100%px;" class="fr-fic fr-dib"> Applications of Aluminum AlSi10Mg (3.2382)1. Aviation and Aerospace: In the aerospace industry, AlSi10Mg is valued for its high strength-to-weight ratio, thermal conductivity, and corrosion resistance. It is commonly used in structural components, engine parts, and other critical applications where performance and reliability are paramount.2. Automotive: The alloy is used in automotive parts where high strength and lightweight properties are essential. It is particularly useful for producing parts that need to withstand stress while contributing to overall vehicle efficiency.3. Prototype Cast Parts: AlSi10Mg is ideal for producing prototype cast parts. Its good processability and mechanical properties make it suitable for creating functional prototypes that can be tested in real-world conditions.4. Serial Parts: The alloy is also used in serial production, where it can be employed to manufacture components in bulk. Its ability to maintain strength and quality over large production runs makes it a popular choice for various serial applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734430973728-1-min.jpg" style="width: 100%px;" class="fr-fic fr-dib"> Physical and Mechanical PropertiesTensile Strength: In its as-built condition, AlSi10Mg exhibits a tensile strength of approximately 400 N/mm². This high strength ensures that parts made from this alloy can endure significant stresses and loads.Heat Treatment: The alloy can undergo a P6 heat treatment process to achieve enhanced ductility. This treatment allows for improved performance in applications where flexibility and resistance to cracking are important. To sum it up..Aluminum alloy AlSi10Mg (3.2382) stands out in metal 3D printing for its high strength, good thermal properties, and excellent processability. Its suitability for aviation, automotive, and prototype applications highlights its versatility and reliability. As industries continue to innovate and push the boundaries of material performance, AlSi10Mg remains a key material, offering a blend of strength, processability, and durability for a wide range of advanced manufacturing needs.

AlSi10Mg (3.2382) is a high-performance material widely used in metal 3D printing for various advanced applications. Let's take an in-depth look at its properties, applications, and mechanical characteristics.

Aluminum AlSi10Mg (3.2382) in Metal 3D Printing: Key Insights

<section id="isPasted"><h2>What Are Hull Inspections</h2>In the vast expanse of the ocean, where container ships traverse like modern-day superhighways, ensuring uninterrupted global trade relies significantly on the integrity of vessel hulls. The term "hull" encompasses the outer shell of a ship, subjected to constant interaction with water. Hull inspections entail meticulous examinations of this crucial component, vital for maintaining the vessel's structural soundness, operational safety, and efficiency. Whether exposed or covered with a deck, the hull plays a crucial role in the ship's framework, serving as the primary barrier against leaks.Given the extensive expanse of ship hulls and their constant interaction with water, routine hull inspections are critically important. These inspections are essential due to the diverse range of interconnected elements, scenarios, and possible defects, and are instrumental in optimizing vessel performance.</section><section><h2>Significance of Hull Inspections</h2><img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/3YwWuh97P77FJqavh93bXh/2d6802d2691a3e3d77474768018ed118/image6__3_.jpg" alt="DTG3 Ship Inspection -cta" class="fr-fic fr-dii">Hull inspections are crucial for safeguarding maritime safety and operational integrity. By meticulously examining a ship's outer structure, these inspections identify and mitigate vulnerabilities such as corrosion, fractures, and material degradation. This preventive approach not only averts potential leaks and structural failures but also enhances the safety of crew members, passengers, and the marine environment.Furthermore, adherence to regulatory standards, enhanced operational efficiency, and prolonged vessel lifespan reinforce the multifaceted importance of regular hull assessments in sustaining a reliable and environmentally responsible maritime industry.</section><section><h3>Defect Identification and Structural Integrity</h3>The hull acts as the first line of defense against water intrusion. From superficial scrapes to critical fractures, these assessments uncover various anomalies that could compromise the vessel's integrity. By detecting and addressing issues promptly, such as leaks, corrosion, or material weakening, inspectors mitigate the risk of escalating structural concerns that could jeopardize maritime safety and operational efficiency.<h3>Port Security</h3>Beyond structural considerations, hull inspections play a pivotal role in fortifying port security and mitigating potential risks. By scrutinizing the ship's exterior for anomalies, unauthorized alterations, or suspicious items, inspectors uphold security protocols and regulatory compliance. This proactive approach not only safeguards ports and coastal regions from potential threats but also emphasizes the importance of maintaining safety standards and preventing hazardous substances from infiltrating waterways.<h3>Mitigating Ecological Impact</h3>Fouling, the accumulation of marine organisms on a vessel's hull, poses ecological risks, including the introduction of invasive species and ecosystem disturbances. Regular hull inspections and maintenance endeavors are instrumental in mitigating this issue, preserving marine ecosystems, and curbing the proliferation of harmful species. Through proactive measures, such as antifouling paint assessments, operators can minimize ecological impact, uphold operational efficiency, and adhere to environmental stewardship principles.</section><section><h3>Checking Antifouling Paint</h3>Antifouling paint is applied to a ship's hull to prevent the buildup of marine organisms, such as barnacles, mussels, and algae, which can significantly impact the vessel's performance. Regular inspections ensure that the antifouling paint remains effective, preventing excessive fouling that can increase drag, reduce fuel efficiency by up to 40%, and compromise the ship's maneuverability.By examining the condition of the antifouling paint during hull inspections, ship operators can identify any degradation or growth of organisms and take timely measures to maintain optimal performance, reduce operational costs, and minimize the ecological impact on marine ecosystems.</section><section><h2>Challenges Involved in Traditional Hull Inspection Methods</h2>Traditional hull inspection methods present several notable challenges. These methods are often costly and time-consuming, involving manual inspections by divers or technicians, leading to extended downtime for vessels.Additionally, human error, limited accessibility to certain areas, and inconsistent data collection and analysis further compound the drawbacks. The costs associated with labor, equipment, and potential repairs are substantial. To address these issues, there's a growing interest in adopting advanced technologies, such as ROVs, for more efficient and comprehensive hull inspections.<h3>Time intensive procedures</h3>Conventional hull inspections demand considerable time investments. Manual assessments, involving diver or technician intervention, extend the inspection timeline, particularly for larger vessels. Factors such as scheduling diver availability, coordinating with surveyors, and obtaining necessary permits contribute to prolonged downtime for ships, disrupting operational schedules.<h3>Deployment Logistics</h3>Preparing for and deploying inspection teams, equipment, and tools can also be time-consuming. This includes assembling diving gear, positioning boats, and coordinating personnel, and it’s also important to note that ships must be disabled before working. Delays in deployment can further contribute to the overall time required for inspections.<h3>Limited Underwater Visibility</h3><img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/77NtYl6EqyShtw7MEDOMqn/8e5393a946440f848bd83c1f48182854/ROV_Looking_at_Phone.jpg" alt="DTG3 underwater murky waters" class="fr-fic fr-dii">Underwater visibility limitations present significant hurdles to accurate hull assessments. Murky water, sedimentation, and inadequate lighting obscure defect detection, potentially resulting in oversight or misinterpretation of critical issues.Compass navigation can also be difficult in harsh conditions, presenting a challenge to divers and increasing the potential risks involved. Photos and conditions are noted manually, as well, which can be dependent on the weather and prone to human error.<h3>Safety Concerns</h3>Hull inspections come with inherent safety risks, especially when conducted by divers taking on tasks in complex environments. Divers may encounter low visibility, extreme temperatures, strong currents that can make maneuvering difficult and increase the chances of collision with objects or vessels, electrical hazards from equipment, and other dangerous or unpredictable conditions.There is also the potential for accidents, injuries, or health risks associated with prolonged exposure to underwater environments, such as decompression sickness and exposure to dangerous marine life.</section><section><h2>Enhancing Hull Inspections with ROVs</h2>ROVs are revolutionizing the field of hull inspection by offering a transformative approach to assessing the condition of a ship's exterior. These advanced underwater robots are equipped with high definition cameras, sensors, and manipulation tools, allowing them to navigate intricate spaces and gather accurate data without the need for direct human intervention. The integration of ROVs in hull inspections streamlines operations, enhances safety, and facilitates data-driven decision-making, paving the way for a more efficient and sustainable maritime industry.<h3>Target Identification With Sonar</h3><img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/6kjHANIlfEIo4qbGs7LdjK/b80d503170f1d68fa42d0c1fe46db5fc/MP1.png" alt="Advanced Data Capture" class="fr-fic fr-dii">By harnessing sonar capabilities, ROVs empower maritime professionals to navigate complex underwater environments, ensuring comprehensive and accurate data collection during hull inspections. This integration of ROVs with sonar technology can provide a clear perspective in murky, or low visibility conditions, visualize a ship or object from a distance, identify structural areas of interest, and can swiftly and precisely locate potential anomalies, such as cracks or corrosion, even in challenging underwater conditions.This advancement enhances the accuracy and efficiency of inspections by providing detailed real-time imagery and data, enabling maritime experts to make informed decisions about maintenance and repairs. The synergy of ROVs and sonar technology can expedite inspections, minimize downtime, and ultimately contribute to safer, more efficient, and cost-effective maritime operations.<h3>Mitigating Risks for Divers</h3>One of the greatest advantages of utilizing ROVs for hull inspections is the ability to minimize risks to human personnel. The integration of ROVs eliminates the necessity for divers to engage in perilous tasks like deep diving, operating in low visibility, unsafe surroundings, or enduring extreme temperatures. These underwater robots can access challenging or hazardous areas unsuitable for human divers, consequently diminishing the likelihood of accidents and injuries.ROVs also enable real-time monitoring of divers from topside supervisors, meticulous inspections, and data gathering, facilitating precise risk evaluations and well-informed decision-making. Collectively, the incorporation of ROVs into diving operations offers significant promise in enhancing dive safety and safeguarding the welfare of divers.</section><section><h3>Cost and Time Efficiency</h3>By replacing the need for manual, diver-based inspections, ROVs significantly reduce labor costs and operational expenses, don’t require extensive permits and paperwork, and can be deployed in a matter of minutes by a single operator. These underwater robots can also swiftly maneuver through complex structures, access hard-to-reach areas with ease, and conduct inspections in a fraction of the time it would take human divers.The real-time data capture capabilities of ROVs also accelerates the inspection process, enabling timely identification of potential issues. As a result, the integration of ROVs in hull inspection not only enhances accuracy and thoroughness but also delivers substantial savings in both time and resources, ultimately optimizing the overall efficiency of maritime maintenance practices.<h3>Recording Capabilities</h3>Equipped with high-definition cameras and sensors, ROVs facilitate detailed data capture and documentation during hull inspections. Recorded imagery and sensor data serve as comprehensive records, aiding in defect identification and tracking changes over time. This digital record enhances transparency, supports informed decision-making, and fosters effective communication among stakeholders, amplifying the precision and reliability of hull inspection processes.</section><section><h2>Hull Inspection Using Deep Trekker ROVs</h2><img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/4M0wQHlOHc0cx0eZllaYxZ/750e73f43ff09cfed1ac8a7b05e02841/deep_trekker_family_of_rovs.webp" alt="Family photo group glamour shot full res" class="fr-fic fr-dii">Deep Trekker leads the industry with innovative solutions designed to prioritize safety, efficiency, and customer satisfaction in hull inspections for the defense and security sector. Our ROVs are at the forefront of underwater inspection technology, offering portability, ease of operation, and affordability. Equipped with state-of-the-art features including 4K cameras and powerful LED floodlights, our ROVs redefine the standards for hull inspections, ensuring comprehensive assessments with unmatched precision and efficiency. Our commitment to excellence is reflected in every aspect of our products and services, guaranteeing unparalleled reliability and performanceTake a look at a couple of our robotic systems for hull inspections in the defense and security industry:<h3>REVOLUTION ROV</h3><img data-fr-image-pasted="true" src="https://downloads.ctfassets.net/kzewhs8e6cvu/4H4NjDluiIL0HzoHj9U7RF/0aaf965ab8e7fe2b67793651ffd272ac/REV_Standalone.png" alt="REVOLUTION at Pier" class="fr-fic fr-dii">The <a href="https://www.deeptrekker.com/products/underwater-rov/deep-trekker-revolution" target="_blank" rel="noopener">REVOLUTION</a> stands out as an exceptionally user-friendly and stable ROV for intricate underwater missions, powered by field-swappable lithium-ion batteries for extended portable usage. Driven by six powerful vectored thrusters, it offers unparalleled control and precise station holding capabilities. Additionally, it boasts an enhanced 4K camera for identifying smaller defects, featuring an expansive 260° field of view, a depth rating of 305 meters (1000 feet), and exceptionally bright LED floodlights.With tether options up to 500 meters (1,640 feet), the REVOLUTION ensures extensive operational range. It also harnesses the power of BRIDGE technology and effortlessly integrates with an extensive range of add-ons and sensors, including sonar and visualization systems for up-close inspections in murky conditions, stability and positioning systems, thickness gauge integration for structural inspections, and many more industry-specific tools, guaranteeing seamless mission execution.<h3>Expert Guidance for Your Projects</h3>Our team of seasoned industry professionals stands ready to offer <a href="https://www.deeptrekker.com/contact-us" target="_blank" rel="noopener">expert guidance and support</a> to seamlessly integrate Deep Trekker ROVs into your projects. From initial consultation to customized solutions tailored to your specific requirements, we are dedicated to ensuring the success of your underwater inspection endeavors. Contact us today to embark on your journey with Deep Trekker.</section>

Ship hull with biofouling during an inspection with a Deep Trekker ROV

Discover how ROVs revolutionize defense and security missions, ensuring vessel hull safety and integrity. Explore cutting-edge robotic technology.

ROVs for Defense and Security Hull Inspection

Optical LSR is a transparent and flexible thermoset material that is increasingly replacing glass in various optical applications. Discover more about it in this Insight video.

What is Optical Liquid Silicone Rubber (LSR) ?

Diode Symbols: A Comprehensive Guide to Understanding Circuit Diagrams

In this guide, we cover all the different types of polymer FDM 3D printing filament, from standard grades like PLA and ABS to advanced high-performance filaments like PEEK and fiber-reinforced materials.

What Material Is Used for 3D Printing? A Guide to Polymer FDM Filaments

<h2 id="isPasted">Electroforming technology overview</h2>Electroforming is a manufacturing process for the production of high-precision metal components. With precision down to 1 micron, this additive manufacturing process enables the production of metal components with complex designs and unmatched accuracy.&nbsp;Veco, the industry leader in&nbsp;Electroforming technology, was the first to use cutting-edge Laser Direct Imaging (LDI) technology in the production of very precise metal parts. With the help of LDI &nbsp;and our industry-leading&nbsp;Advanced Lithographic Electroforming&nbsp;technology, we have been able to further push the boundaries of the industry, giving our customers higher-quality, more affordable, and faster-turnaround high-precision metal components.In addition to its precision and design flexibility, Electroforming technology enables the creation of complex features and 3D structures through multi-layer deposition. With&nbsp;<a href="https://www.vecoprecision.com/electroforming/electroforming-process/" rel="noopener" target="_blank">Electroforming process</a>, additional layers can be&nbsp;“grown”&nbsp;in specific directions, resulting in complex 3D or 2.5D geometries. This capacity creates new opportunities for delicate product design and is especially useful for semiconductor applications that need for the reinforcement of thin parts or delicate structures.<h2>Electroforming for Semiconductor industry</h2>In contrast to conventional machining techniques such as milling, etching, and EDM, Electroforming provides greater capabilities for producing micro-scale features with exceptional accuracy. With Electroforming technology, complex designs with delicate features which traditional machining finds challenging can be easily transformed into high-quality components. Additionally, the approach produces a lot less waste and is more economical from rapid prototyping to large-scale manufacturing. Compared to other high-precision processes such as silicon MEMS, Electroforming offers a wide variety of materials such as nickel, copper, gold, silver, and other alloys (<a href="https://www.vecoprecision.com/electroforming/materials-used-in-electroforming/" rel="noopener" target="_blank">learn more about material possibilities with Electroforming</a>). Electroformed metals also provide mechanical functionalities that are difficult or impossible to achieve with silicon MEMS. For example, metals used in Electroforming are more ductile and elastic than silicon, which is crucial for Semiconductor applications like contact probes, micro-springs, and flexures.Electroforming technology is a crucial production technique in the semiconductor sector, providing benefits in terms of accuracy, cost-effectiveness, and technical capability. The technology's ability to produce complex, precise components makes it a key enabler for semiconductor manufacturing and next-generation research and design.&nbsp; applications in the Semiconductor industry benefiting from Electroforming technology Semiconductor testing and inspection equipment benefit greatly from Electroforming technology. Take&nbsp;<a href="https://www.vecoprecision.com/products/mems-probes/" rel="noopener" target="_blank">MEMS probe</a> as an example, MEMS probes are used to evaluate the performance of electrical devices during the front-end fabrication and wafer testing. Electroforming enables the creation of high-quality MEMS probes with complex requirements. Electroformed vertical probes can provide a highly stable contact resistance as well as outstanding mechanical and electrical properties.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734081420007-1734081420007.png" width="717" height="319" alt="wafer-probes-1" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/wafer-probes-1.webp?width=359&amp;height=160&amp;name=wafer-probes-1.webp 359w, https://insights.vecoprecision.com/hs-fs/hubfs/wafer-probes-1.webp?width=717&amp;height=319&amp;name=wafer-probes-1.webp 717w, https://insights.vecoprecision.com/hs-fs/hubfs/wafer-probes-1.webp?width=1076&amp;height=479&amp;name=wafer-probes-1.webp 1076w, https://insights.vecoprecision.com/hs-fs/hubfs/wafer-probes-1.webp?width=1434&amp;height=638&amp;name=wafer-probes-1.webp 1434w, https://insights.vecoprecision.com/hs-fs/hubfs/wafer-probes-1.webp?width=1793&amp;height=798&amp;name=wafer-probes-1.webp 1793w, https://insights.vecoprecision.com/hs-fs/hubfs/wafer-probes-1.webp?width=2151&amp;height=957&amp;name=wafer-probes-1.webp 2151w" sizes="(max-width: 717px) 100vw, 717px" class="fr-fic fr-dii">Another critical application of Electroforming in the semiconductor industry is the<a href="https://www.vecoprecision.com/products/test-socket-pins/" rel="noopener" target="_blank">&nbsp;test socket pin</a>. These pins serve as the link between the Device under test (DUT) and the testing equipment, where high precision and durability is a must. For a high-performance test socket, the contactors, the pins in the socket, play a very important role in transferring the signal between the device under test (DUT) and the system with the least amount of signal attenuation or degradation. Electroformed test socket pins provide enhanced mechanical and electrical stability, which leads to longer lifespans and better performance. Additionally, different types of test sockets are needed for different testing processes with specialized electrical and mechanical parameters. Design flexibility of Electroforming technology allows for high level of customization and co-development for engineers to tailor to specific testing needs.In semiconductor process equipment, Electroforming technology is also employed to create high-precision parts such as gas distribution plates for deposition systems. These components require precise hole patterns and uniform gas flow characteristics to ensure optimal process performance. The accurate dimensional control of Electroforming makes it an ideal choice. As semiconductor devices continue evolving and downsizing, the use of Electroforming in the production and innovation of vital components is anticipated to increase.&nbsp;<h2>Co-developing with Veco</h2>When it comes to “tailor-made” solutions for semiconductor applications, Veco's expertise in Electroforming technology and collaborative&nbsp;co-development&nbsp;approach make&nbsp;us&nbsp;the&nbsp;partner&nbsp;of industry leaders.&nbsp;Our&nbsp;application engineering and R&amp;D teams&nbsp;work closely with customers to create next-generation products, combining&nbsp;our&nbsp;knowledge and experience to design, prototype, and scale up to industrial production. Veco's Electroforming technology allows for highly flexible, efficient, and economical development, enabling the creation of several variations of a component in a single run. This experimental design approach is particularly valuable for customers in the design and development phase, as it allows them to compare and test different iterations of a part without incurring significant time and cost. By working with Veco, semiconductor manufacturers can leverage&nbsp;our&nbsp;expertise in precision&nbsp;engineering&nbsp;to bring innovative solutions to market faster and more efficiently.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734081420101-1734081420101.png" width="715" height="383" alt="Services - Codevelopment" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Services%20-%20Codevelopment.jpg?width=358&amp;height=192&amp;name=Services%20-%20Codevelopment.jpg 358w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Services%20-%20Codevelopment.jpg?width=715&amp;height=383&amp;name=Services%20-%20Codevelopment.jpg 715w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Services%20-%20Codevelopment.jpg?width=1073&amp;height=575&amp;name=Services%20-%20Codevelopment.jpg 1073w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Services%20-%20Codevelopment.jpg?width=1430&amp;height=766&amp;name=Services%20-%20Codevelopment.jpg 1430w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Services%20-%20Codevelopment.jpg?width=1788&amp;height=958&amp;name=Services%20-%20Codevelopment.jpg 1788w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/Services%20-%20Codevelopment.jpg?width=2145&amp;height=1149&amp;name=Services%20-%20Codevelopment.jpg 2145w" sizes="(max-width: 715px) 100vw, 715px" class="fr-fic fr-dii">

This blog overviews the Electroforming technology, compares its technical advantages to alternative manufacturing methods, and introduces typical applications in the semiconductor industry.

Electroforming for Semiconductor: enabling next-generation innovation through ultimate precision

<a href="https://xometry.eu/en/injection-moulding/" target="_blank" rel="noreferrer noopener">Injection molding</a> is a very efficient and widely used plastic manufacturing process for producing parts in large quantities. Mold development is a critical aspect of this process, essential for accurately shaping and forming molten plastic with high precision. The creation of molds, as one of the first steps, demands great precision and accuracy to ensure the quality and consistency of the final products.There are various ways to classify molds in injection molding, including by plate type, runner type, cavity design and class. Among these classifications, mold cavity design—single-cavity, multi-cavity, and family molds—plays a pivotal role in determining production efficiency and quality. Single-cavity molds are simpler and offer high-quality parts, ideal for low-volume production and intricate designs. Multi-cavity molds enhance production speed and reduce the cost per part for large volumes, but require precise balancing to avoid defects. Family molds allow for the simultaneous production of different parts, optimizing manufacturing for multi-part products but increasing design complexity and the potential for defects.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989703073-complex-injection-mold-scaled.webp" style="width: 100%px;" class="fr-fic fr-dib"><blockquote><section>When selecting the right mold type, it’s important to consider your immediate production needs but also the long-term performance and durability of the mold. Molds are classified based on how long they’re expected to last. Class 101 molds can handle over a million cycles, so they’re great for really high production levels. On the other hand, Class 105 molds are good for up to 500 cycles, which makes them perfect for prototypes and low-volume production. At Xometry, we typically use molds that last at least 10,000 shots for our injection molding projects.<h4 id="isPasted">Dmitry Romanov, Lead Injection Molding Engineer</h4></section></blockquote><h2 data-counter-attr="value0">What Type of Mold Is Used in Injection Molding?</h2>Injection molds can be categorized in several ways, each affecting various aspects of the production process. Here’s a detailed look at these categories and their significance:<h3 data-counter-attr="value1">Plate Type</h3>The plate type influences the mold’s cost, the finish of the final product, and overall production efficiency.<ul><li>Two-Plate Molds: Consist of two main parts—the cavity and the core. They are simpler and less expensive but may have limitations in complex part designs.</li><li>Three-Plate Molds: Include an additional plate for separating parts from the runners, improving part ejection and quality. They are more versatile but also more costly.</li><li>Stacked Plate Molds: Utilize multiple levels of cavities, doubling the output without increasing the footprint. They are ideal for high-volume production but require precise alignment and complex design.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989693840-two-plate-three-plate-injection-mold.webp" style="width: 100%px;" class="fr-fic fr-dib">Comparison of injection molds: Three plate mold vs two plate mold (Source: plasticmoulds.net/)<h3 data-counter-attr="value2" id="isPasted">Runner Type</h3>The runner type impacts mold design flexibility, material waste, and the amount of post-processing required.<ul><li>Cold-Runner Molds: Use unheated channels to guide the molten plastic into the mold cavities. They are less expensive but require more post-processing to remove the runners from the final product.</li><li>Hot-Runner Molds: Incorporate heated channels, keeping the plastic molten until it reaches the cavities. They reduce waste and post-processing needs but are more complex and expensive.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989725939-cold-hot-runner-injection-mold-1536x961.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value3" id="isPasted">Mold Cavity Design</h3>The mold cavity design plays a crucial role in production efficiency and part quality, directly influencing the speed, cost, and consistency of the manufacturing process.<ul><li>Single-Cavity Molds: Single-cavity molds produce one plastic part per injection cycle. This gives single-cavity models the slowest production times of the three types of molds we are discussing. However, due to their size and relative simplicity, they are quite affordable to produce, making them a good option for small production volumes in which production speed isn’t the biggest factor.</li><li>Multi-Cavity Molds: Multi-cavity molds contain multiple cavities, as the name suggests. These molds produce multiple copies of the same plastic product in each production cycle. They are ideal for mass production purposes, with high production speeds and a low price per part at large production volumes. Multi-cavity molds are complex and expensive to design and produce, however this can be offset when working with large production volumes.</li><li>Family Molds: Family molds are injection molds that produce multiple different parts per production cycle. They are useful for manufacturing multi-part products quickly but are very complex to design and more prone to molding defects.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989750655-injection-molding-mold-1.webp" style="width: 100%px;" class="fr-fic fr-dib">Multi-cavity injection mold designed for high-volume production of identical parts<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989786780-Injection-family-mold-scaled.webp" style="width: 100%px;" class="fr-fic fr-dib">Injection molded parts from a family mold, illustrating the simultaneous production of different componentsAdditionally, the SPI (Society of the Plastics Industry) classifications provide a standardized method (Class 101 to 105) to evaluate mold life expectancy and suitability for different production volumes.<h2 data-counter-attr="value4">Comparing Single-cavity, Multi-cavity and Family Molds</h2>The table below compares the three types of injection molding molds:<table><thead><tr><th>Property</th><th>Single-Cavity Mold</th><th>Multi-Cavity Mold</th><th>Family Mold</th></tr></thead><tbody><tr><td>Applications</td><td>• High-quality plastic products (e.g. containers for which aesthetics matter). • Intricate geometries or designs with precise control over material flow and injection pressure.• Prototypes with design changes and new mold iterations.• Low-volume production in which cost is a more significant factor than production speed.</td><td>• Large production volumes (over 40,000 products per month). • Applications for which price per part is the most important factor.•&nbsp;High-demand products that require short lead times for high volumes (e.g. bottle caps or packaging).</td><td>• Multi-part products, for which all the parts can be manufactured in a single production cycle. • Prototyping with multiple variations of parts being manufactured simultaneously.• Medium to large production volumes with the same part’s material and color.</td></tr><tr><td>Cost</td><td>Low cost, with the simplest design and tooling requirements.</td><td>High, requiring more complex design and tooling.</td><td>Highest, due to being the most complex to design.</td></tr><tr><td>Complexity</td><td>Low, as it doesn’t require balancing of pressures between multiple cavities.</td><td>High, with complex runner, cooling, and gate systems needed.</td><td>Highest, with multiple different cavities requiring careful design to balance injection pressures and uniformity.</td></tr><tr><td>Lead Time</td><td>Lowest, due to the simpler design process.</td><td>High, requiring careful design.</td><td>Highest, with a long design and simulation process.</td></tr><tr><td>Production Speed</td><td>Slowest, limited to one part per injection cycle.</td><td>Fastest, multiple copies of a part can be made simultaneously.</td><td>Fast, multiple different parts can be made in a single injection cycle.</td></tr><tr><td>Surface Quality</td><td>Highest, with minimal post-processing needed.</td><td>High, with some post-processing needed and risk of defects.</td><td>Medium, with the highest risk of unbalanced injection and defects.</td></tr><tr><td>Advantages</td><td>• Lowest risk of molding defects. • The simplest and fastest type of mold to design and manufacture.</td><td>• Fastest production speed of the three mold cavity types.</td><td>• One mold can produce multiple different parts. • Fast production speeds, especially for multi-part products.</td></tr><tr><td>Disadvantages</td><td>• Lowest production efficiency (only one part can be produced at a time). • Highest cost per part at large production volumes.</td><td>• Highly complex to design and manufacture. • Requires higher maintenance than single-cavity molds.• More prone to unbalanced injections and molding defects than single-cavity molds.</td><td>• Very complex to design and manufacture. • Long lead times for new mold designs, due to design complexity.• More post-processing is required than for single- or multi-cavity molds.</td></tr></tbody></table><h2 data-counter-attr="value5">What Are the Components of Injection Molding Molds?</h2>The injection molding mold itself consists of several components, each with its own specific function within the mold.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989825178-two-plate-injection-mold.webp" style="width: 100%px;" class="fr-fic fr-dib">Detailed structure of a two-plate mold with labeled parts (Source: CustomPartNet)The components are:<ul><li>Mold base: The mold base or mold frame is the foundational infrastructure for the mold assembly, providing rigidity and strength against the internal pressure experienced during injection molding.</li><li>Cavity: The cavity, or cavities, shape the external geometry of the part. The cavity and the core form two halves of the final mold cavity in which the molten plastic is injected.</li><li>Core: The core shapes the internal geometry of the part, and mates with the cavity to form the mold cavity. Multi-cavity and family molds will have multiple pairs of cavities and cores for the multiple parts that they produce.</li><li>Inserts:&nbsp;Inserts are separate components that may be inserted into the mold to create specific geometric features. They are separate from the cavity and core but also help form the internal and external geometries.</li><li>Runner system: The runner system distributes molten plastic throughout the mold cavity to ensure an even distribution of material. They are a network of channels that ultimately end in gates, which are the openings into the mold cavities. Good runner system design is vital for ensuring even material distribution and minimizing defects.</li><li>Nozzle &amp; sprue bushing: The nozzle controls how the molten plastic flows into the mold from the feeding system of the injection molding machine. The sprue bushing is a component of the mold that positions the nozzle to ensure it is centered and aligned.</li><li>Ejector pins: They are used to help eject the part from the mold after it has solidified and the mold has been opened. The part can potentially stick to the mold cavity, and ejector pins are used to automatically provide a force that ejects the part from the mold.</li><li>Cooling system: The cooling system helps maintain the temperature of the mold in order to prevent damage and maintain quality of the finished part.&nbsp;</li><li>Venting system:&nbsp;The venting system provides a way for air and gases to escape from the mold during the injection process. This system consists of various channels, pins, and grooves that allow air to escape, but are small enough to keep plastic inside.</li><li>Guides: The guides of the mold are a series of bushings, sleeves, and guiding pins on the two halves of the mold that help with alignment and assembly.</li></ul><h2 data-counter-attr="value6">What is Injection Mold Life Expectancy?</h2>The life expectancy of an injection mold is determined by the number of molding cycles it can perform, with each cycle consisting of the mold opening and closing. Several factors influence this lifespan, including the mold class, operating conditions, environment, maintenance practices, and the materials used.The Society of the Plastics Industry (SPI) categorizes injection molds into five distinct classes, which are independent of the mold cavity classification. Each class is characterized by specific criteria defined by the SPI, ensuring standardized evaluation for mold life expectancy and suitability for various production volumes.The table below compares the 5 injection mold classes:<table><thead><tr><th>Mold Class</th><th>Cycles</th><th>Production Level</th><th>Uses</th><th>Investment</th></tr></thead><tbody><tr><td>Class 101 Mold</td><td>1 million or more</td><td>Extremely high</td><td>Ideal for high-volume production with fast cycles</td><td>Class 101 molds are the most expensive, crafted from top-tier materials</td></tr><tr><td>Class 102 Mold</td><td>Not exceeding 1 million</td><td>Medium to high</td><td>Suitable for parts requiring durable plastic materials and tight tolerances</td><td>Class 102 molds are quite expensive, made with high-quality materials</td></tr><tr><td>Class 103 Mold</td><td>Not exceeding 500,000</td><td>Medium</td><td>Commonly used for low to medium production runs</td><td>Class 103 molds are priced moderately, falling within average price ranges</td></tr><tr><td>Class 104 Mold</td><td>Not exceeding 100,000</td><td>Low</td><td>Best for limited runs with non-abrasive materials</td><td>Class 104 molds are lower in cost, suitable for limited to moderate production runs</td></tr><tr><td>Class 105 Mold</td><td>Not exceeding 500</td><td>Very low</td><td>Used primarily for prototyping</td><td>Class 105 molds are the least expensive, designed for producing a limited number of prototype parts</td></tr></tbody></table><h2 data-counter-attr="value7">Get Injection Molding Services for Your Next Project</h2>Choosing the right mold is just the beginning of the plastic manufacturing process. Once the mold type is selected based on your production needs and SPI classification, the next steps involve finalizing and validating your design. This includes reviewing the CAD file for any necessary adjustments, producing the T1 sample to test and verify the mold’s performance, and making any required modifications to ensure optimal part quality.After validating the mold, you can proceed with full-scale production, ensuring that all parameters are set correctly for consistent, high-quality output. Partnering with experienced manufacturers, like Xometry Europe, provides the <a href="https://xometry.eu/en/injection-moulding/">injection molding expertise</a> and <a href="https://xometry.pro/en-eu/articles/injection-moulding-eu/" target="_blank" rel="noreferrer noopener">resources</a> needed for successful and efficient production. Begin your injection molding project confidently by using our <a href="https://get.xometry.eu/?locale=en"></a><a href="https://get.xometry.eu/?locale=en" target="_blank" rel="noreferrer noopener">Instant Quoting Engine</a> to get a free quote for your next project.

CNC machining can be used to manufacture metal injection molds

This article explores the different types of molds (design cavity, class) used in plastic injection molding, discussing their ideal applications, strengths, weaknesses and lifespan, and design tips for creating effective molds based on one's manufacturing needs.

Injection Molding Molds: Types, Lifespan and Design Tips

What started out in 1928 as a blacksmith and carriage smithy is now, 94 years later, a modern, customer-focused vehicle manufacturing company in the heart of Switzerland. These days, <a rel="noopener noreferrer" href="https://sutter-fahrzeugbau.ch/" target="_blank">Sutter AG Lungern Fahrzeugbau</a> specializes in the development and manufacture of 3-side tippers of up to 40t, loading bridges for all trucks and vans, box bodies, tipping bodies, quick-change systems, special vehicles, maintenance and repairs of bodies and trailers.Before purchasing the Creaform 3D scanner, engineers at Sutter spent about 5% of their working time manually measuring certain components with complex geometries to fit them to vehicles. These are mainly aluminum covers, underride guards, crane mounting elements, and other vehicle mounted components that are tailored to the requirements of the vehicle or the customer’s wishes. Before, these parts used to be manufactured without the possibility of double-checking them prior to the time of final assembly, as it was not possible to check the geometries on the vehicle itself. Apart from the extended amount of time it took to develop the components, the effort and expense required to have them modified and adapted by qualified metal workers for their final place of use was enormous.<h2>Requirements for a new measuring system and implementation</h2>Sutter often has to deal with large scanning areas, such as truck chassis zones, where the distance between the individual components is important, yet the measurement accuracy must remain high. The crucial requirement in purchasing the measurement system was therefore accuracy.One of the key factors in choosing <a href="https://www.creaform3d.com/en">Creaform Go!SCAN SPARK</a> was the ability to purchase not just a product, but a complete service. This included the purchase of consumables for the use of the scanner, a laptop, support for the work on site, after-sales service in case of maintenance, repairs, and questions.The implementation of Creaform’s 3D measurement solutions was very intuitive, as it did not require a new process to be defined, only for an existing one to be replaced. In practice, the manual measurement process was simply replaced by 3D scanning. This not only provided the design department with more measurement data, but also allowed them to check the actual dimensions and geometries of vehicle components during development (a double-check).Since Sutter AG is a small company, the entire process from 3D scanning to ordering raw materials for manufacturing the components, such as sheet metal, is handled by one of the engineers in the engineering department. A single two-day training session by a Creaform technician made it possible for Sutter to be fully operational and independent right from the start.<h2>Truck add-on parts: Teamwork between Creaform Go!SCAN SPARK, engineering department and workshop</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989230571-dji_0032-scaled.jpg" style="width: 100%px;" class="fr-fic fr-dib">Sutter AG handles a multitude of diverse projects. As an example, we would like to show how the design, manufacture, and assembly of a customized tool box on an existing truck chassis for the transport of construction machinery was created in cooperation between the workshop and the engineering department.Due to current delivery bottlenecks at the vehicle manufacturer, the “construction machine taxi” project was created under tight time constraints. This meant the engineering department had to do a lot of advance preparation using CAD designs. When the vehicle arrived, an advanced design status was achieved very quickly and the workshop itself built some additional attachment holders for tool boxes.Another application Sutter has found for the technology is to ensure traceability in the archive in accordance with the ISO9001 standard. It was therefore decided to scan the additional mounting bracket with the <a href="https://www.creaform3d.com/en">Creaform Go!SCAN SPARK.</a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989245859-sutter_bild1.jpg" style="width: 100%px;" class="fr-fic fr-dib">Area with additional mounting bracket for toolboxes to be scannedAlthough the additional mounting bracket has a wide variety of surface finishes, colors, and geometries, it took very little time to scan and the amount of material required (targets and matting spray) was very low.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989265416-sutter_bild2.png" style="width: 100%px;" class="fr-fic fr-dib">3D scan of the truck chassis with additional elements mounted by Sutter in the VXmodel softwareWith the help of the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" id="isPasted">VXmodel</a> export function, everything could be imported directly into Solidworks and traced very quickly. This was mostly done using the measurement function, the creation of geometry (such as profiles, planes, and cylinders) in VXmodel, and then with the direct transfer of the geometries into Solidworks.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989299882-reverse-engineering.jpg" style="width: 100%px;" class="fr-fic fr-dib">Reverse engineering in SolidworksWhere possible, purchased parts were replaced with 3D data from parts suppliers. However, this does not happen as a rule, since missing 3D models are often replaced by mesh bodies from 3D scans. This method of working also increases the quality and completeness of the company’s own database of purchased parts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989337664-sutter_bild3.png" style="width: 100%px;" class="fr-fic fr-dib">CAD view of the scanned areas with traced toolbox holders and purchased part (hydraulic tank)<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989357772-sutter_bild4.png" style="width: 100%px;" class="fr-fic fr-dib">CAD view with bridge (main design, manufactured by the engineering department), hydraulic tank (from 3D data from parts supplier), and toolboxes (holders built by the workshop and redesigned through reverse engineering<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989372499-sutter_bild5.jpg" style="width: 100%px;" class="fr-fic fr-dib">Finished body<h2 id="isPasted">How the Go!SCAN SPARK with VXmodel has improved processes and practices at Sutter AG</h2>Apart from the main requirement of accuracy already mentioned before, there have been several improvements at a practical level:<ul><li>The space analysis in the planning of bodies, but also of additional units and attachments, has been greatly simplified.</li><li>The accuracy of measurements and the production of raw parts have been increased.</li><li>Quality management has been improved and it is now possible to track completed and similar projects.</li><li>The waste rate of raw parts has been reduced or brought to zero.</li><li>The assembly and adaptation time by the workshop has been reduced, which avoids the need for highly trained employees (the objective is a plug &amp; play strategy).</li></ul>In terms of software, the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module">VXmodel software module</a> used by Sutter enables the data to be scanned, processed, and aligned with the correct coordinate system quickly and easily, and finally exported directly to the Solidworks CAD drawing program. The biggest advantage is definitely the possibility to export the raw data directly into the Solidworks format. There, the data can be used for CAD comparisons or as an aid for designing further parts.All these factors have led to considerable improvements in internal processes and shared practices in the execution of projects.<h2>Future areas of application</h2>Sutter’s central idea is to gradually increase the use of the <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d">Creaform 3D scanner</a> in order to spread the technical and practical benefits across all industries and product types.Burim Shala, Technical Manager at Sutter comments: “Another step we would like to take as a company is to scan purchased standard components for which there are no 3D models, so that we can plan and design our products with even more detail and precision. We would like to use the 3D scanner mainly for preliminary clarifications so that we can design earlier in the manufacturing process. In a nutshell, I would say that Creaform measurement solutions help us keep the focus on the ‘golden triangle’.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989405049-golden-triangle.png" style="width: 100%px;" class="fr-fic fr-dib">Blue triangle. At the top corner is says “Quality,” at the bottom left corner “Time,” at the bottom right corner “Cost.”

The use of the Go!SCAN SPARK and VXmodel leads to significant improvements in the internal processes when carrying out projects at the Swiss company Sutter AG.

Vehicle manufacturing company increases design quality with 3D scanners

<h2 id="isPasted">Understand the Future of Metal 3D Printing</h2>The Metal 3D Printing Technology Report is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.Read the intro to the report <a href="https://www.wevolver.com/article/metal-3d-printing-technology-report">here</a> and an excerpt from chapter 4 below.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355340345-froala_1733828027720-5%2BRising%2BTrends%2Bfor%2BAI%2BAdoption%2Bin%2BManufacturing%2B%281920%2Bx%2B500%2Bpx%29.png" style="width: 100%px;" class="fr-fic fr-dib"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width: 100%; max-width: 100%; height: 690px; border: none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe><h2 dir="ltr">Introduction</h2>Metal 3D printing opens up design opportunities due to its high level of geometrical freedom. However, like all technologies, it requires design for manufacturability (DFM) considerations, taking into account the physical constraints of the equipment and materials. In 3D printing, this design strategy is referred to as design for additive manufacturing (DfAM). Most major CAD software providers provide DfAM tools (as well as 3D printing simulation tools), as 3D printing hardware is now widespread.<h3 dir="ltr">Design opportunities</h3>Compared to other metal manufacturing processes like machining, casting, and forging, 3D printing offers a number of design advantages, including:<ul><li dir="ltr">Design freedom: Designs are unhindered by cutting tool access and other conventional manufacturing constraints; limitations (e.g. support structures to support overhangs) are minimal in comparison.<ul><li dir="ltr">Multi-axis design freedom: Some DED systems offer multi-axis material deposition, enabling printing of unsupported overhangs and further design freedom.</li></ul></li><li dir="ltr">Internal structures: Additive process allows for complex internal geometries and precise density control, giving a high level of control over part strength, weight, flexibility, and other characteristics, as well as allowing for cooling and fluid flow channels.</li><li dir="ltr">Lightweighting: Partly hollow designs allow for lightweighting of parts that would otherwise be conventionally manufactured.</li><li dir="ltr">Organic shapes: Generative design software can create complex, interlocking, or curved parts that mimic organic shapes.</li><li dir="ltr">Part consolidation: Metal 3D printing can be used to consolidate assemblies into simple parts, increasing production efficiency, improving performance, and increasing part service life.</li></ul><h3 dir="ltr">Design limitations</h3>Metal 3D printing offers a high level of design freedom, but it suffers from a handful of limitations. Some of these are technology-specific. For example, design for metal extrusion is governed by the limitations of both polymer extrusion printing and part sintering. Some limitations in metal 3D printing design include:<ul><li dir="ltr">Thermal stresses: Since most metal 3D printing technologies require high temperatures, part design must minimize thermal stresses. This may be achieved by introducing corner radii, avoiding thin sections, etc.</li><li dir="ltr">Shrinkage: Several metal 3D printing technologies require sintering, which results in part shrinkage as voids are removed. This should be factored into design to ensure part dimensions fall within acceptance tolerances.</li><li dir="ltr">Trapped powder: Powder bed processes can result in powder trapped within hollow sections unless design allows the powder to escape.</li><li dir="ltr">Overhangs, bridges, supports: Supports are often required to support overhangs and bridges. Top-heavy or unbalanced designs may sag or deform during sintering or heat treatment.</li><li dir="ltr">Feature size: Processes like extrusion and binder jetting have a limited minimum feature size.</li></ul><h2 dir="ltr">Tools for DfAM</h2>Advanced CAD software may include tools for metal 3D printing design such as design validation, performance analysis, lattice generation, and topology optimization. Simulation tools for validating designs may be incorporated into CAD, CAE, CAM, or distinct process simulation software. Simulation of 3D printing processes typically involves advanced thermal modeling. Research shows that both topology optimization and generative design tools can be adopted at the early stages of 3D printing design to either create a geometry driven by functional requirements or to redesign components to make them lighter and stronger.<h3 dir="ltr">Generative design</h3>Generative design is the use of algorithmic software to create novel designs based on user-defined constraints. It is generally employed during the conceptual design stage. While generative design is not unique to metal 3D printing, metal 3D printing is one of the few processes that can easily realize a broad range of generated designs. Altair Sulis is one example of a DfAM tool that uses generative design to generate AM-optimized designs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733927613980-design+for+metal.png" style="width: 100%px;" class="fr-fic fr-dib">3D Systems company Oqton’s 3DXpert industrial 3D printing software. Image credit:&nbsp;<a href="https://oqton.com/posts/3dxpert-space-exploration/" id="isPasted">Oqton</a><h3 dir="ltr">Topology optimization</h3>Topology optimization is a design strategy for optimizing the structure of a printed part, generally to reduce weight while maintaining strength. Unlike generative design, it is used to optimize specified shapes instead of creating designs from scratch. As with generative design, however, the freeform nature of 3D printing means that most designs can be realized. Software such as 3D Systems 3DXpert provides topology optimization tools for metal printing.<h3 dir="ltr">Lattice generation</h3>Lattice structures are a key feature of metal 3D printing as they serve to maximize strength and minimize mass and cannot easily be produced using other manufacturing processes. Software can be used to automatically generate printable lattice structures within predefined boundaries. Siemens NX CAD is an example of an application that incorporates lattice generation for metal 3D printing design.<h2 dir="ltr">Get your report now</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355363801-froala_1733828027720-5%2BRising%2BTrends%2Bfor%2BAI%2BAdoption%2Bin%2BManufacturing%2B%281920%2Bx%2B500%2Bpx%29.png" style="width: 100%px;" class="fr-fic fr-dib"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width:100%;max-width:100%;height:690px;border:none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe><a href="https://www.wevolver.com/article/metal-3d-printing-technology-report"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355421527-1734355421527.png" class="fr-fic fr-dii"></a> <a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355370353-1734355370353.png" class="fr-fic fr-dii"></a><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355370459-1734355370459.png" class="fr-fic fr-dii"></a><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734355370376-1734355370376.png" class="fr-fic fr-dii"></a>

Metal 3D printing offers significant design opportunities with its high geometrical freedom, but it requires careful design for additive manufacturing (DfAM) to address equipment and material constraints, a process supported by DfAM and 3D printing simulation tools in most major CAD software.

The Metal 3D Printing Technology Report: Chapter 4: Design for Metal 3D printing

The two day <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven?creative=713450062759&keyword=hexagon%20live%20eindhoven&matchtype=e&network=g&device=c&gad_source=1&gclid=Cj0KCQjw99e4BhDiARIsAISE7P-jq9--x4A0TeKGXvQPXSR46iJ28I8bV7tNL3-yyfjZcLlvv_LBpE4aAsuEEALw_wcB">Hexagon LIVE event</a> at the Brainport Industries Campus in Eindhoven was an unforgettable convergence of technology, engineering, and innovation, showcasing cutting-edge solutions driving the future of manufacturing. This year’s conference, themed around accelerating smarter manufacturing, brought together experts to discuss transformative solutions in digital workflows, sustainability, and precision engineering. The event emphasized how innovation can meet the demands of modern industries, bridging cutting-edge technologies with practical applications across sectors.Throughout the event, Wevolver was reporting live on our social media channels from the center of the action on Day 1, which saw an engineering marvel in the form of Max Verstappen’s 2021 championship-winning car, showcased by Oracle Red Bull Racing and the grand opening of Hexagon's brand new 400 square meters Experience Center. We also spoke to Jan Klingen, VP EMEA North of Hexagon's Manufacturing Intelligence Divison about how to reach the younger generation of engineers and Erik Josefsson, CEO of R-evolution, Hexagon's sustainable innovation and green-tech investment subsidiary about how their Green Cubes can accelerate biodiversity and rainforest conservation worldwide.&nbsp;If you missed tuning in on the day or you would like to rewatch the interviews, they are now available on-demand in our curated YouTube playlist, offer insights into key discussions, live demonstrations, and interviews with experts. For those who missed the action, don’t miss your chance to catch up on the industry-shaping innovations revealed at Hexagon LIVE!<iframe src="https://www.youtube.com/embed/videoseries?si=Lhd341sSJ5qxATtE&amp;list=PLnGQIAOr1q_N-g5DgT-VhKJGS8PLEpEfr&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" title="YouTube video player" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 560px; height: 450px;">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</iframe><h2 dir="ltr" id="isPasted">A Decade of Collaboration: How Hexagon’s technologies underpin Red Bull Racing’s success</h2>For over a decade, <a href="https://www.redbullracing.com/int-en" target="_blank" rel="noopener noreferrer">Oracle Red Bull Racing</a> has collaborated with Hexagon to revolutionize their engineering processes. Wevolver spoke with Morgan Maia, Senior Technical Partnership Manager at Oracle Red Bull Racing about the partnership and how Hexagon’s technologies underpin Red Bull’s success both on and off the track.<h2 dir="ltr">Inauguration of Hexagon’s New Experience Center</h2>Day 1 of Hexagon LIVE marked the grand opening of Hexagon’s state-of-the-art Experience Center. This 400-square-meter space is a hub of manufacturing innovation, offering visitors hands-on demonstrations of the latest technologies and direct access to industry experts. As the first of its kind in Europe, the center is designed to inspire and educate, showcasing solutions ranging from digital workflows to cutting-edge automation tools, emphasizing Hexagon’s commitment to shaping the future of manufacturing. Wevolver spoke to Jan Klingen, VP EMEA North of Hexagon's Manufacturing Intelligence Divison and Stephen Chadwick, President of EMEA North of Hexagon's Manufacturing Intelligence Divison about the significance of this grand opening.<h2 dir="ltr">A R-evolutionizing Approach to Rainforest Conservation</h2><a href="https://r-evolution.com/" target="_blank" rel="noopener noreferrer">R-evolution</a>, Hexagon's sustainable innovation and green-tech investment subsidiary had a significant launch of their own with their new initiative of Green Cubes, an innovative solution leveraging digital technology for rainforest conservation. These Green Cubes are a cutting-edge platform combining Hexagon's expertise in sensor technology, data analytics, and AI to monitor and protect critical ecosystems in real time. Wevolver spoke to Erik Josefsson, CEO and Stina Langenius, Business Designer how these cubes can contribute to preserving one of the planet's most vital resources.&nbsp;

Wevolver was at the center of action during the Hexagon LIVE in Eindhoven, reporting live on cutting-edge tech and smarter manufacturing solutions, interviewing experts and exploring innovation in digital workflows, sustainability, and precision engineering. Watch the livestream on demand here!

Highlights from Hexagon LIVE 2024: Watch the livestream on demand

Even the smallest design flaw or mold imperfection can lead to big quality issues in injection molding—warping, sink marks, or weak structural integrity. High-quality parts require more than just a well-thought-out design; they demand a proactive approach to ensure manufacturability. This is where Mold Flow Analysis (MFA) steps in, providing critical insights to refine designs, reduce defects, and pave the way for efficient production.<h2 dir="ltr">What Is Mold Flow Analysis?</h2>Mold Flow Analysis is a simulation technique that predicts the flow of molten material within a mold cavity during injection molding. Using advanced software tools, it evaluates critical parameters such as flow patterns, cooling efficiency, pressure distribution, and potential defects like warping or sink marks. This process helps engineers optimize designs and material selection, significantly reducing the need for physical prototypes and minimizing risks during production.<h2 dir="ltr">When Should Mold Flow Analysis Be Used?</h2>For projects requiring precision or complex geometries, Mold Flow Analysis is highly recommended. It provides crucial insights to ensure the design is manufacturable, minimizes defects, and helps save time and costs in the long run. By identifying potential issues early, it reduces trial-and-error cycles, ensuring smoother production and better-quality parts.<h2 dir="ltr">How Mold Flow Analysis Supports Design for Manufacturability (DFM)</h2>Mold Flow Analysis plays a pivotal role in optimizing the design and manufacturing process by addressing potential challenges early. Here are keyways MFA contributes to&nbsp;Design for Manufacturability (DFM):<ul><li dir="ltr"><h3>Refining Gate Placement</h3></li></ul>Proper gate placement is critical for ensuring a smooth and consistent material flow within the mold. By simulating different gate positions, MFA identifies the optimal placement to minimize weld lines, air traps, and other flow-related defects. This not only improves part quality but also enhances the structural integrity and appearance of the final product. For example, poor gate placement can lead to uneven filling, which may weaken specific areas of the part or result in visible imperfections.<ul><li dir="ltr" style="font-weight: bold;">Balancing Material Distribution</li></ul>Mold Flow Analysis evaluates how material fills the mold cavity, identifying regions where uneven distribution might occur. If one section fills faster than another, it can lead to defects like overpacking or underfilling. MFA allows engineers to adjust runner and gate designs to balance the flow, ensuring the material is distributed evenly throughout the cavity. This step is essential for achieving consistent wall thickness, preventing sink marks, and reducing the risk of part failure under stress.<ul><li dir="ltr" style="font-weight: bold;">Improving Cooling Strategies</li></ul>The cooling phase is one of the most critical stages in injection molding, as uneven cooling can lead to warping or dimensional inaccuracies. MFA simulates cooling patterns, helping engineers design efficient cooling channels that ensure uniform temperature distribution. By reducing cooling-related defects, MFA not only enhances part quality but also shortens the overall cycle time, improving production efficiency and lowering costs.<ul><li dir="ltr" style="font-weight: bold;">Predicting Shrinkage and Warpage</li></ul>Different materials shrink at different rates during cooling, which can distort the final part dimensions. Mold Flow Analysis predicts these shrinkage patterns and highlights areas where warpage might occur. By accounting for these factors in the design phase, engineers can make necessary adjustments, such as altering the mold dimensions or modifying material choices, to ensure parts meet exact specifications.<ul><li dir="ltr" style="font-weight: bold;">Reducing Cycle Times</li></ul>By analyzing filling, packing, and cooling phases, MFA provides insights into optimizing the entire molding process. For instance, it can identify opportunities to speed up material flow without causing defects or to streamline cooling times by improving channel designs. These optimizations not only increase production speed but also lower manufacturing costs, making the process more efficient.By incorporating Mold Flow Analysis early in the design process, manufacturers can significantly enhance the manufacturability of their parts, ensuring smoother production, higher quality, and fewer delays caused by defects or design inefficiencies. This proactive approach is a key driver of successful injection molding projects.<h2 dir="ltr">RPWORLD: Comprehensive Injection Molding Solutions</h2>At RPWORLD, we go beyond Mold Flow Analysis to offer a full range of injection molding services tailored to your needs:<ul><li dir="ltr">Lead Times as Fast as 7 Days:&nbsp;Delivering production-ready parts quickly to accelerate your product to market.</li><li dir="ltr">100+ Material Options:&nbsp;From engineering-grade plastics to specialized materials such as medical-grade materials, food-grade materials and more, we provide flexibility to meet diverse application requirements.</li><li dir="ltr">In-House Mold Design &amp; Fabrication:&nbsp;Expertly designed molds to match your project specifications, reducing lead times and improving precision.</li><li dir="ltr">Rigorous Quality Assurance:&nbsp;Advanced inspection tools combining with stringent quality controls ensure every part meets exact specifications, from first article inspection to final quality checks.</li><li dir="ltr">Extensive Finishing Options:&nbsp;Choose from surface finishing, painting, texturing, and more to achieve the perfect part appearance and functionality.</li></ul><hr><h3 dir="ltr">Ready to Optimize Your Injection Molding Project?</h3>With over 20 years of experience, RPWORLD delivers customized manufacturing solutions from prototyping and production, helping you achieve consistent high-quality parts within fastest time, launching products to markets soon.<a href="https://www.rpworld.com/en/get-a-quote/">&nbsp;Contact Us</a> for a free consultation and discover how our advanced injection molding services, including Mold Flow Analysis, can bring your designs to life!

Mold Flow Analysis is a simulation technique that predicts the flow of molten material within a mold cavity during injection molding.

Unlocking Quality in Injection Molding: The Role of Mold Flow Analysis

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