<p id="isPasted">The CES UVigo Association, made up of 25 engineering students from the University of Vigo, shared a common goal: to build a solar-powered trimaran for competition that runs exclusively on clean energy. Thanks to the&nbsp;<a href="https://ultimaker.com/3d-printers/s-series/">UltiMaker S5 3D printer</a>, they achieved their objective of creating a more environmentally friendly mode of transportation.</p><h2>The Challenge</h2><p><strong>Building a solar trimaran with components that can withstand demanding environments.</strong></p><p>CES UVigo was founded in 2020 with the aim of competing in international regattas. This goal led to the need to construct a vessel for participation: the Boeiro I. With sponsorship from Sicnova, they adopted additive manufacturing as a key tool for creating the components required to build their solar trimaran.</p><p>Before starting construction of the trimaran, the team created a model of the boat with all control and propulsion systems manufactured using 3D printing. For them, 3D printing is the most viable technique for producing parts with rapid adaptability that can endure highly demanding environments, such as the sea. Additive manufacturing also enabled them to work remotely, allowing them to coordinate schedules and bring the project to fruition.</p><blockquote><blockquote><p>Additive manufacturing is the most viable technique for building lightweight, fuel-efficient boats, as it offers numerous advantages to the marine sector.</p></blockquote><p>-Marcos Pardeiro, President of the CES UVigo Association</p></blockquote><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/l44ds20vFlQ?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" 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" data-gtm-yt-inspected-26="true" id="91259150" title="Embarcaciones más ligeras y eficientes gracias a la impresión 3D | Caso de éxito CES UVigo"></iframe></span><br></p><h2 id="isPasted">The Solution - UltiMaker S5 3D Printer</h2><p>With the integration of the UltiMaker S5 3D printer, the team began designing fully printed systems. Since then, they have developed a wide range of 3D printing applications, from tooling to a custom propeller for their boat. To produce the tooling for the solar battery and the boat's steering wheel, they used PETG filaments, known for their low electrical conductivity. For the safety covers at the edges of the solar panels, they used HIPS material, which is resistant to ultraviolet light and water. Another key benefit of 3D printing was the significant reduction in production time for these components compared to traditional manual manufacturing methods.</p><h2>The Result</h2><p><strong>A lighter trimaran with reduced fuel consumption, built with 3D-printed components.</strong></p><p>With the help of 3D printing, CES UVigo successfully designed and built their solar-powered competition trimaran. The vessel is much lighter and consumes less fuel. Their commitment to creating a more sustainable mode of transportation was made possible thanks to additive manufacturing. This technology has allowed them to minimize production times, work with shorter deadlines, and adapt to changes more efficiently.</p><hr><p><em id="isPasted">Originally published on&nbsp;<a href="https://sicnova3d.com/blog/casos-de-exito/embarcaciones-ligeras-sector-naval-impresion-3d/">sicnova3d.com</a></em></p>

25 engineering students from the University of Vigo shared a common goal: to build a solar-powered trimaran for competition that runs exclusively on clean energy. Thanks to the UltiMaker S5 3D printer, they achieved their objective of creating a more environmentally friendly mode of transportation.

CES UVigo: Lighter and More Efficient Boats Thanks to 3D Printing

<p id="isPasted">Data centers form the backbone of countless digital services, from cloud computing to artificial intelligence (AI). However, as data center infrastructures scale up, they face an increasing number of challenges. First, the rapid adoption of AI is accompanied by significant growth in data volume and increased computing requirements. <a href="https://www.statista.com/statistics/871513/worldwide-data-created/">By 2025, data volume is expected to reach 180 zettabytes</a>, compared to 15 zettabytes in 2015. Additionally, the demand for <a href="https://openai.com/index/ai-and-compute/">computing power has been doubling every 3.4 months since 2012</a> to train cutting-edge AI models. This continuous increase in computational power directly impacts electricity consumption, with AI data centers expected to account for up to 7% of global electricity demand by 2030.</p><p>Another significant challenge related to data center infrastructure is power failure. Power shortages in data centers can lead to costly downtimes, data loss, and even equipment damage. To prevent power failures, ensuring power reliability is a critical concern. In response to the demand for stable power supplies, Infineon has introduced its&nbsp;<a href="https://www.infineon.com/cms/en/applications/solutions/system-diagnostics-analytics/power-supply-health-monitoring/power-system-reliability-modeling/?redirId=274819">Power System Reliability Modeling (PSRM</a>), a comprehensive solution aimed at enhancing power reliability and reducing the likelihood of outages in data centers and telecom infrastructure by empowering customers accessibility to in-field power supply real-time data.</p><p>This article will delve into the importance of PSRM and how it could transform data centers companies interpretation of reliability in power, leading to cost savings, improved sustainability and increased resiliency.</p><h2><strong>The Growing Power Demand and Risk in Data Centers</strong></h2><p>Data centers house thousands of servers, networking devices, and other critical systems, consuming vast amounts of electricity. As technologies like AI, machine learning, and neural networking advance, the demand for more computational power grows exponentially. The increasing power density in data centers amplifies the risk of power interruptions. Even a brief outage can disrupt services, potentially affecting millions of users and costing companies significant amounts of revenue. Power inefficiencies also increase operational costs and elevate the carbon footprint of these facilities.</p><p>Given these risks, the ability to maintain uninterrupted power supply is paramount, and this is where Infineon’s new PSRM comes into play.</p><h2><strong>What is Power System Reliability Modeling?</strong></h2><p>Infineon’s Power System Reliability Modeling is a solution that combines hardware and software to enhance the reliability and efficiency of power supplies in data centers. It provides a comprehensive view of the entire power system and predicts potential points of failure before they occur. The solution strengths lie in its predictive maintenance enablement capabilities, enabling companies to address in-field issues before they lead to a failure or outage. By utilizing real-time monitoring of the mission profile of the power supply unit, it offers a dynamic understanding of the power supply’s current health status and how it effects its long-term reliability.</p><p>The PSRM solution focuses on several core insights:</p><ul><li><strong>Real-time Power Monitoring:</strong> mission profile logging features enable real time tracking of operating conditions of the power systems such as input voltage, output voltage, load current, and temperature. By modelling these parameters with component´s FIT rate, we can assess reliability conditions based on the actual mission profile. This allows to anticipate anomalies or fluctuations that could indicate potential problems.</li><li><strong>Lifetime Estimation:</strong> By analyzing the mission profile over time, one can predict the operational lifespan of different power components, allowing operators to replace parts before they fail and balance the load in redundant systems, secure highly reliable system operations.</li><li><strong>Predictive Maintenance:</strong> The collected modelled data allows data center operators to carry out maintenance tasks and optimize fleet management operations based on actual performance data, rather than fixed schedules. Data-driven decisions can optimize operational efficiency and reduce unnecessary costs.&nbsp;</li></ul><h2><strong>Benefits of Power System Reliability Modeling</strong></h2><h3><strong>Reduced Downtime and Operational Costs</strong></h3><p>One of the most significant advantages of implementing this solution in IT power distribution systems lies in enabling companies to use data to minimize unexpected downtimes and prevent disruptions in operations. Traditional maintenance models rely on reactive or periodic maintenance schedules, where issues are addressed only after they occur, or parts are replaced based on time intervals rather than actual wear and tear. In contrast, <a href="https://www.wevolver.com/article/predictive-maintenance-using-smart-sensors-to-get-the-most-out-of-your-assets">predictive maintenance</a> models use real-time data and advanced analytics to anticipate failures, allowing for interventions based on the actual condition of components. By leveraging real-time data from the power supply units, the solution helps companies to ensure that potential problems are identified early, thus preventing power interruptions.</p><p>This predictive approach results in fewer power outages, lower operational costs, and increased system reliability. Data center operators no longer have to deal with the unpredictability of power-related issues, ensuring smoother operations and higher profitability.</p><h3><strong>Improved Energy Efficiency and Sustainability</strong></h3><p>Power reliability isn't just about preventing outages; it’s also about optimizing power usage. With the insights provided with the help of Infineon’s solution, data center providers can assess and optimize the energy efficiency of their power systems. This is particularly important in the context of sustainability, where data centers are under increasing pressure to reduce their environmental impact.</p><p>Hence, data centers can achieve higher energy efficiency by ensuring that their power systems are operating optimally, reducing waste and unnecessary power consumption. In a long run, lower energy use means lower carbon emissions, helping companies meet their sustainability goals while also cutting operational costs.</p><h3><strong>Enhanced System Reliability&nbsp;</strong></h3><p>Reliability modeling on the system level empowers customers' power supply operation and real-time monitoring capabilities. The solution will shed light on vital insights into the complete system health status and proactively allow optimization of its usage to extend the operational lifetime. By leveraging these capabilities, customers can manage their power supply systems based on system health, ensuring enhanced reliability and prolonged operational continuity for critical infrastructure. The key benefits of enhanced system reliability provided by the solution can be summarized as:</p><ul><li>Real-time system diagnostics to any power supply</li><li>Powerful system reliability-centric value proposition</li><li>Seamless integration into power designs through power controllers.</li><li>Easy usage</li></ul><h3><strong>The Future of Data Center Power Management</strong></h3><p>Infineon’s Power System Reliability Modeling is a crucial innovation at a time when data centers are becoming more integral to global infrastructure. With the rise of AI, cloud services, and the Internet of Things (IoT), the demand for reliable, efficient, and sustainable power systems is greater than ever. Infineon’s solution directly addresses these needs, offering a way to enhance power system resilience while also reducing operational costs and environmental impact.</p><p>The introduction of PSRM underscores Infineon’s commitment to providing cutting-edge solutions that go beyond simple component manufacturing. By integrating hardware and software, the company offers a holistic approach to power system reliability modelling when designing the next gen of power supplies. Hence, it supports the increasingly complex needs of modern data centers manufacturers and users.</p><h2><strong>Conclusion</strong></h2><p>As data centers continue to expand in size and complexity, innovations like <a href="https://www.infineon.com/cms/en/applications/solutions/system-diagnostics-analytics/power-supply-health-monitoring/power-system-reliability-modeling/?redirId=274819">Infineon’s Power System Reliability Modeling</a> will be critical in ensuring that they remain resilient, profitable, and sustainable in the future. The solution enables real-time power supply health monitoring and lifetime estimation, helping to reduce downtime, maximize device usage, lower operational costs, and improve energy efficiency.&nbsp;</p><p>Finally, it should not be overlooked that Infineon offers a comprehensive array of additional <a href="https://www.infineon.com/cms/en/applications/information-communication-technology/hyperscale-computing/">solutions</a> for AI data centers, covering everything from the grid to the core. The innovative technologies represent a significant step forward in addressing the power challenges, and the offered solutions are poised to redefine the way data centers operate.&nbsp;</p>

Infineon’s Power System Reliability Modeling enhances power reliability in data centers by enabling real-time power supply monitoring, predictive maintenance, and lifetime estimation from component to system level. 

Power System Reliability Modeling: A Step Toward Resilient Data Centers

<p id="isPasted">This article will cover the introduction to Electroforming technology, its technical features and advantages for the medical industry, and typical applications in the medical field.</p><h2>introducing Electroforming</h2><p>Electroforming is an Additive&nbsp;Manufacturing process that produces&nbsp;high-precision metal components&nbsp;“atom by atom.” Compared to other traditional metal forming technologies, for example, casting, forging, stamping, or deep drawing, Electroforming can deliver mass volume at superior accuracy and extreme design complexity, due to the fact that it can replicate the shape of the mandrel at extreme accuracy.</p><p>As the world leader in Electroforming technology, Veco is the first in the industry to apply advanced<a href="https://insights.vecoprecision.com/how-to-accelerate-your-lead-time-with-the-laser-direct-imager" rel="noopener" target="_blank">&nbsp;Laser Direct Imaging technology</a> in high-precision metal parts manufacturing. The combination of LDI and our leading Electroforming technology has enabled us to further push the boundaries of the industry with our Advanced Lithographic Electroforming, providing our customers with <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal components</a> of higher quality, at lower cost, and with quicker turnaround.</p><h2><strong>what makes Electroforming the preferred technology for the medical industry</strong></h2><p>Electroforming is an accurate and flexible manufacturing process specialized for the production of <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal parts</a>. Its technological capabilities, including precision, cost-effectiveness, biocompatibility, and design flexibility, make it the preferred technology for the medical sector.</p><ul><li><strong>exceptional precision and tight tolerance.&nbsp;</strong>With Electroforming, tolerances at the micro level of ±1 micron can be&nbsp;achieved. In the medical industry, where components must function reliably in life-critical applications, this level of accuracy is critical.</li><li><strong>intricate and complex geometries.&nbsp;</strong>With Electroforming, extremely delicate and complicated geometries that cannot be&nbsp;accomplished&nbsp;with conventional production techniques can be created. This makes it possible to create complex&nbsp;designs suited to particular requirements.</li><li><strong>ultra-smooth,&nbsp;</strong><strong>bu</strong><strong>rr- a</strong><strong>nd stress-free</strong><strong>&nbsp;surfaces.&nbsp;</strong>The Electroforming process delivers exceptional surface quality characterized by ultra-smooth, burr- and stress-free finishes. It not only eliminates the need for secondary finishing operations but also enhances cleanability and sterilization effectiveness.&nbsp;</li><li>cost efficiency from prototyping to mass production.&nbsp;Electroforming can be scaled efficiently, making it a cost-effective solution for producing high-precision parts from prototyping to&nbsp;large quantities.&nbsp;With Laser Direct Imaging (LDI), which is a maskless photolithography technology that eliminates traditional masks in the procedure, the process not only lowers tooling costs but also speeds up turnaround.</li><li><strong>material properties.&nbsp;</strong>Electroforming technology allows depositing metal alloys to tailor specific material properties like mechanical or thermal characteristics. Veco offers high-precision Electroforming with Nickel, in a variety of unique blends or alloys suitable for particular engineering demands, such as Veco84 Nickel, Sulfamate Nickel, Palladium-Nickel (alloy), HR-Nickel, and Meta-Nickel. These materials provide different options regarding hardness, conductivity, corrosion resistance, and biocompatibility, depending on the application. &nbsp;Bio-compatible materials suitable for medical applications can also be electroplated where needed.<br><br></li></ul><h2>applications of Electroforming in the medical industry</h2><p>Electroforming is extensively used in the production of <a href="https://www.vecoprecision.com/products/micro-nozzle-plates/" rel="noopener" target="_blank">micro nozzle plates</a>, which are often used in medical devices where precise fluid control is needed, such as drug delivery systems, microfluidic devices, and diagnostic tools. The Electroforming technology is particularly well-suited for manufacturing these micro nozzle plates due to its ability to produce micro-scale holes down to ±1 μm, burr- and stress-free edges, ultra-smooth surfaces, and complex patterns. In addition, Electroformed micro nozzle plates are highly durable and resistant, making them reliable in a variety of environments in medical applications. A typical example is <a href="https://www.vecoprecision.com/products/nebulizer-plates/" rel="noopener" target="_blank">nebulizer plate</a>, which is&nbsp;a high precision mesh component in drug delivery devices used for respiratory treatments. In state-of-the-art aerosol drug delivery systems that utilize Vibrating Mesh Technology, Veco's electroformed nebulizer plate features 1000 tapered holes on a 5mm diameter surface. When vibrating at 128,000 times per second, this plate acts as a mini pump, generating a fine particle mist with uniform droplets ranging from 1 to 5 microns in diameter, facilitating effective deep lung penetration.</p><p><img data-fr-image-pasted="true" src="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=1305&amp;height=445&amp;name=nebulizer.png" width="1305" alt="nebulizer" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=653&amp;height=223&amp;name=nebulizer.png 653w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=1305&amp;height=445&amp;name=nebulizer.png 1305w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=1958&amp;height=668&amp;name=nebulizer.png 1958w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=2610&amp;height=890&amp;name=nebulizer.png 2610w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=3263&amp;height=1113&amp;name=nebulizer.png 3263w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/nebulizer.png?width=3915&amp;height=1335&amp;name=nebulizer.png 3915w" sizes="(max-width: 1305px) 100vw, 1305px" class="fr-fic fr-dii" style="width: 822px;"></p><p>In the field of minimally invasive diagnostics, Electroforming is used to produce critical components for endoscopes and imaging systems, such as micro-optical components, light stops, and thin-walled housings. &nbsp;Light stop, for example, is a key component in the illuminated optic part of an endoscope system. It defines the edges of the images that are seen through endoscopes. With Electroforming, sharp, clean edges can be achieved without any burr or stress on the surface. Similarly, Electroforming is also used to manufacture slit plates in optical and imaging systems, such as spectrometers. These plates control the flow of light or particles with micron-level precision, determining the optical resolution and the performance of the system.</p><p>Electroforming is&nbsp;also used in&nbsp;the production of precision filters, meshes, and test sieves for medical applications involving the separation, filtration, or analysis of fluids and particles. Electroformed test sieves, for example,&nbsp;are commonly applied for particle size analysis,&nbsp;which is critical in medical research and quality control processes such as drug formulation and biological sample analysis. Sterile filtration, absolute filtration, critical cell-cell separation, cell deformability testing, cell harvesting, particle sieving (diamonds, seeds, and dust), cacao filtration, flow regulation, and laboratory testing are all typical fields where the micro sieves are utilized.</p><p><span class="fr-img-caption fr-fic fr-dii" style="width: 823px;"><span class="fr-img-wrap"><img data-fr-image-pasted="true" src="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=6016&amp;height=2575&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg" width="6016" alt="13_-_filtration_sieve_original_BAS8102-B-453699-edited" srcset="https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=3008&amp;height=1288&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg 3008w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=6016&amp;height=2575&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg 6016w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=9024&amp;height=3863&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg 9024w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=12032&amp;height=5150&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg 12032w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=15040&amp;height=6438&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg 15040w, https://insights.vecoprecision.com/hs-fs/hubfs/Veco/Images/13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg?width=18048&amp;height=7725&amp;name=13_-_filtration_sieve_original_BAS8102-B-453699-edited.jpg 18048w" sizes="(max-width: 6016px) 100vw, 6016px" class="fr-fic fr-dii" style="width: 822px;"><span class="fr-inner" spellcheck="false">Electroformed test sieve</span></span></span></p><p>Electroforming has revolutionized the medical industry with critical components such as micro nozzle plates, precision filters, endoscope components, and so on. With the growing trend of miniaturization in the medical industry, Electroforming has great potential for advancing the development of next-generation medical devices with its capability to produce lightweight, miniaturized, and high-precision components with micron-level accuracy.&nbsp;</p>

Electroforming is an advanced manufacturing process that has become an essential manufacturing technology in the medical industry due to its unique capabilities and advantages over traditional manufacturing methods. 

Electroforming for Medical: miniature components making a significant impact

<p id="isPasted">Used in everything from soda cans and foil wrap to circuit boards and rocket boosters, aluminum is the second-most-produced metal in the world after steel. By the end of this decade, demand is projected to drive up aluminum production by 40 percent worldwide. This steep rise will magnify aluminum’s environmental impacts, including any pollutants that are released with its manufacturing waste.</p><p>MIT engineers have developed a new nanofiltration process to curb the hazardous waste generated from aluminum production. Nanofiltration could potentially be used to process the waste from an aluminum plant and retrieve any aluminum ions that would otherwise have escaped in the effluent stream. The captured aluminum could then be upcycled and added to the bulk of the produced aluminum, increasing yield while simultaneously reducing waste.</p><p>The researchers demonstrated the membrane’s performance in lab-scale experiments using a novel membrane to filter various solutions that were similar in content to the waste streams produced by aluminum plants. They found that the membrane selectively captured more than 99 percent of aluminum ions in these solutions.</p><p>If scaled up and implemented in existing production facilities, the membrane technology could reduce the amount of wasted aluminum and improve the environmental quality of the waste that plants generate.</p><p>“This membrane technology not only cuts down on hazardous waste but also enables a circular economy for aluminum by reducing the need for new mining,” says John Lienhard,&nbsp;the Abdul Latif Jameel Professor of Water in the Department of Mechanical Engineering, and director of the Abdul Latif Jameel Water and Food Systems Lab (J-WAFS) at MIT. “This offers a promising solution to address environmental concerns while meeting the growing demand for aluminum.”</p><p>Lienhard and his colleagues report their results in a study <a href="https://pubs.acs.org/doi/10.1021/acssuschemeng.4c07268" target="_blank">appearing today in the journal <em>ACS Sustainable Chemistry and Engineering</em></a>. The study’s co-authors include MIT mechanical engineering undergraduates Trent Lee and Vinn&nbsp;Nguyen, and Zi&nbsp;Hao&nbsp;Foo SM ’21, PhD ’24, who is a postdoc at the University of California at Berkeley.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736902744774-MIT-Sustain-Aluminum-02-press.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">A schematic representation of the role of nanofiltration (NF) for purifying waste cryolite associated with the production of aluminum. Within a production facility, aluminum ore is converted to molten aluminum via electrolysis, leaving a waste electrolyte that is then passed through a nanofiltration membrane, which further extracts any residual aluminum, which can be added to the bulk molten aluminum, while the purified electrolyte is recycled back into the production process. Credit: Courtesy of the researchers</span></span></span></p><h2><strong>A recycling niche</strong></h2><p>Lienhard’s group at MIT develops membrane and filtration technologies for desalinating seawater and remediating various sources of wastewater. In looking for new areas to apply their work, the team found an unexplored opportunity in aluminum and, in particular, the wastewater generated from the metal’s production.</p><p>As part of aluminum’s production, metal-rich ore, called bauxite, is first mined from open pits, then put through a series of chemical reactions to separate the aluminum from the rest of the mined rock. These reactions ultimately produce aluminum oxide, in a powdery form called alumina. Much of this alumina is then shipped to refineries, where the powder is poured into electrolysis vats containing a molten mineral called cryolite. When a strong electric current is applied, cryolite breaks alumina’s chemical bonds, separating aluminum and oxygen atoms. The pure aluminum then settles in liquid form to the bottom of the vat, where it can be collected and cast into various forms.</p><p>Cryolite electrolyte acts as a solvent, facilitating the separation of alumina during the molten salt electrolysis process. Over time, the cryolite accumulates impurities such as sodium, lithium, and potassium ions — gradually reducing its effectiveness in dissolving alumina. At a certain point, the concentration of these impurities reaches a critical level, at which the electrolyte must be replaced with fresh cryolite to main process efficiency. The spent cryolite, a viscous sludge containing residual aluminum ions and impurities, is then transported away for disposal. &nbsp;&nbsp;</p><p>“We learned that for a traditional aluminum plant, something like 2,800 tons of aluminum are wasted per year,” says lead author Trent Lee, who carried out the new work as part of the MITEI Energy UROP program. “We were looking at ways that the industry can be more efficient, and we found cryolite waste hadn’t been well-researched in terms of recycling some of its waste products.”</p><h2><strong>A charged kick</strong></h2><p>In their new work, the researchers aimed to develop a membrane process to filter cryolite waste and recover aluminum ions that inevitably make it into the waste stream. Specifically, the team looked to capture aluminum while letting through all other ions, especially sodium, which builds up significantly in the cryolite over time.</p><p>The team reasoned that if they could selectively capture aluminum from cryolite waste, the aluminum could be poured back into the electrolysis vat without adding excessive sodium that would further slow the electrolysis process.</p><p>The researchers’ new design is an adaptation of membranes used in conventional water treatment plants. These membranes are typically made from a thin sheet of polymer material that is perforated by tiny, nanometer-scale pores, the size of which is tuned to let through specific ions and molecules.</p><p>The surface of conventional membranes carries a natural, negative charge. As a result, the membranes repel any ions that carry the same negative charge, while they attract positively charged ions to flow through.</p><p>In collaboration with the Japanese membrane company Nitto Denko, the MIT team sought to examine the efficacy of commercially available membranes that could filter through most positively charged ions in cryolite wastewater while repelling and capturing aluminum ions. However, aluminum ions also carry a positive charge, of +3, where sodium and the other cations carry a lesser positive charge of +1.</p><p>Motivated by the group’s recent work investigating membranes for recovering lithium from salt lakes and spent batteries, the team tested a novel Nitto Denko membrane with a thin, positively charged coating covering the membrane. The coating’s charge is just positive enough to strongly repel and retain aluminum while allowing less positively charged ions to flow through.</p><p>“The aluminum is the most positively charged of the ions, so most of it is kicked away from the membrane,” Foo explains.</p><p>The team tested the membrane’s performance by passing through solutions with various balances of ions, similar to what can be found in cryolite waste. They observed that the membrane consistently captured 99.5 percent of aluminum ions while allowing through sodium and the other cations. They also varied the pH of the solutions, and found the membrane maintained its performance even after sitting in highly acidic solution for several weeks.</p><p>“A lot of this cryolite waste stream comes at different levels of acidity,” Foo says. “And we found the membrane works really well, even within the harsh conditions that we would expect.”</p><p>The new experimental membrane is about the size of a playing card. To treat cryolite waste in an industrial-scale aluminum production plant, the researchers envision a scaled-up version of the membrane, similar to what is used in many desalination plants, where a long membrane is rolled up in a spiral configuration, through which water flows.</p><p>“This paper shows the viability of membranes for innovations in circular economies,” Lee says. “This membrane provides the dual benefit of upcycling aluminum while reducing hazardous waste.”</p>

The researchers demonstrated the membrane’s performance in lab-scale experiments, pictured, using a novel membrane to filter various solutions that were similar in content to the waste streams produced by aluminum plants. Photo: Trent Lee

MIT engineers designed a nanofiltration process that could make aluminum production more efficient while reducing hazardous waste.

New filter captures and recycles aluminum from manufacturing waste

<p id="isPasted">In the realm of extreme sports, few events rival the intensity and challenge of the Dakar Rally. Beyond being a mere race, it stands as a testament to human endurance and the resilience of machinery. Originating in 1978, the Dakar Rally has grown into a global phenomenon, spanning over 5,000 miles of unforgiving terrain, from deserts to mountains and savannas.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/pM_aDHaCfq8?&amp;t&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" 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"></iframe></span><br></p><p>Prodrive made its debut in the rally scene in 2020 and has since been a consistent participant in the last three Dakar rallies. They have earned a well-deserved reputation for their adeptness in designing and manufacturing resilient and high-performing race and rally cars. Their track record of success speaks volumes about their proficiency in creating championship-worthy vehicles. A prime example of their prowess is when the Prodrive's Hunter model clinched the top three positions on a Dakar stage, highlighting the company's dedication to engineering excellence.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736821800131-768.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>“We need to monitor the health of our vehicles, particularly the space frames”-Paul Doe, Chief Chassis Engineer.&nbsp;</strong></h2><p>The Dakar Rally stands out as one of the toughest races worldwide, with its challenging terrains and extreme weather conditions. Ensuring the structural integrity of vehicles is paramount to ensure the safety of drivers and co-drivers. Any damage or abnormalities in the frame could jeopardize the vehicle's stability, rendering it unsafe for use.</p><p>The vehicle's frame serves as the foundation of its structure, influencing its overall performance. Compromised frames can impact handling, speed, and reliability – crucial factors in the demanding environment of the Dakar Rally. Regular inspections play a vital role in identifying potential issues early on, allowing for prompt repairs and maintenance. This proactive approach extends the vehicle's lifespan and reduces the risk of unexpected breakdowns or malfunctions during the race.</p><p>Post-rally inspections yield valuable insights into how vehicles have endured the rally's harsh conditions. These insights inform refinements and improvements in the design and manufacturing processes, driving continuous enhancement and innovation in 3D engineering solutions.</p><p>The inspection process of the Dakar frame goes beyond a mere routine check; it is a comprehensive endeavor that underscores safety, enhances performance, promotes longevity, and fuels the relentless pursuit of excellence in motorsport.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736821306934-3.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>Elevating the Frame 3D Data Capturing Process with TrackScan-Sharp</strong></h2><p>For this task, our local partner utilized the Trackscan-Sharp, a state-of-the-art large-scale 3D scanner, renowned for its advanced capabilities:</p><p>1. This tracking 3D scanning system harnesses cutting-edge optical tracking technology and high-resolution cameras to deliver unmatched accuracy and efficiency in scanning large-scale parts and components.</p><p>2. With a measuring volume of 49m3 and a tracking distance of up to 8 meters, the Trackscan-Sharp enabled capturing the front and sides of the vehicle in a single position, minimizing the need for tracker repositioning and thus saving time while reducing the risk of errors.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736821328358-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">The following step involved a comprehensive inspection of the motorsport frame. By comparing the latest scan data with historical records, any structural changes or potential damage were identified. Importing the STL file representing the newly captured 3D mesh of the automotive frame into inspection software facilitated a side-by-side comparison with existing records. This critical analysis allowed for the detection of any deviations or changes in the frame's structure resulting from the stresses endured during the rally.</p><h2><strong>Conclusion</strong></h2><p>The utilization of 3D scanning technology in the realm of motorsport, particularly in race car inspection, represents a significant advancement in efficiency and precision. The integration of cutting-edge tools like the TrackScan-Sharp has revolutionized the inspection process, offering a seamless and accurate experience for continuous improvement and innovation in race car design and manufacturing processes.&nbsp;</p>

This blog introduces Prodrive's venture into the Dakar Rally highlights the critical role of 3D scanning technology in race car inspection. Leveraging TrackScan-Sharp, Prodrive ensures thorough assessments of vehicle frames, vital for maintaining safety and performance in extreme racing conditions.

Navigating Extreme Terrain: Prodrive's Utilization of 3D Scanning Tech in Motorsport

<p><strong>Wearable haptic devices, which provide touch-based feedback, can provide more realistic experiences in virtual reality, assist with rehabilitation, and create new opportunities for silent communication. Currently, most of these devices rely on vibration, as pressure-based haptics have typically required users to wear stiff exoskeletons or other bulky structures.</strong></p><p>Now, researchers at Stanford Engineering have designed a comfortable, flexible knit sleeve, called Haptiknit, that can provide realistic pressure-based haptic feedback. Their design, published Dec. 18 in <em>Science Robotics</em>, shows that pressure may be more effective than vibration for some applications and is the first step toward a new category of haptic devices.</p><p>“A device like this opens up a lot of new possibilities for user interfaces – how we experience virtual environments, how we experience remote communication,” said&nbsp;<a href="https://profiles.stanford.edu/allison-okamura" data-extlink="">Allison Okamura</a>, the Richard W. Weiland Professor of Engineering at Stanford and senior author on the paper. “It’s much more lightweight, wearable, and comfortable.”</p><h2>A knit solution</h2><p>Okamura and her colleagues designed a battery-powered pneumatic system with pressure actuators that were essentially small, inflatable pouches that could be rapidly filled with air. But they needed a way to hold those pouches against the skin without using a clunky exoskeleton.</p><p>“If you put air into a balloon next to your skin but don’t anchor it there, it’s going to expand in all directions,” said Cosima du Pasquier, a postdoctoral researcher at Stanford and first author on the paper. “You’re going to waste most of the inflation potential.”</p><p>Du Pasquier, who makes clothes as a hobby, realized that knit fabric might hold the answer. The researchers designed a soft textile that would be stiff in some areas – creating an inflexible backing to hold the pressure actuators against the skin – and flexible where needed to allow for movement and comfort.</p><p>They worked with a team at MIT’s Self-Assembly Lab to manufacture the Haptiknit sleeve prototype on a knitting machine, with space for eight actuators arranged in two rows. Most of the sleeve was knit from nylon and cotton, but the areas backing each actuator also included a thermoplastic fiber. Once the knitting was done, the researchers used heat to melt the thermoplastic fibers and cause them to harden, stiffening those areas.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/il4lICuOIAc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" 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"></iframe></span><em>Demo video of the “Knit Haptic Pneumatic Sleeve” | Skylar Tibbits, MIT Self-Assembly Lab</em></p><p id="isPasted">“A challenge in the field of soft robotics is how do you stick together something hard and something soft – they tend to delaminate,” Okamura said. “But putting these fibers into knitting makes a totally seamless transition from parts that are hard to parts that are soft, because it’s one continuous fabric.”</p><p>The researchers tested the Haptiknit prototype with 32 users. They found that people could more accurately discern the location of individual touches from the pressure actuators than from a similarly arrayed vibrational device. Okamura and her colleagues also tried inflating the actuators consecutively at different speeds to try to create the feeling of a pleasant stroke, as opposed to discrete touches (or the potentially unpleasant feeling of a spider crawling up one’s arm). In general, participants found faster, more overlapping indentation mimicked the feeling of a continuous stroke – the opposite of what the researchers had found for vibration.</p><p>The third test was to see if participants could recognize six emotions – attention, gratitude, happiness, calming, love, and sadness – conveyed through the pressure signals. The researchers used touch patterns established in previous research and found that participants generally guessed correctly at a higher-than-chance rate, although the gestures for “calming” and “love” were easily confused.</p><h2>More comfortable haptics</h2><p>Overall, participants found the Haptiknit sensations to be equally or more pleasant than those caused by vibrations. They also described the prototype sleeve as comfortable and easy to use, which is promising for more long-term uses.</p><p>“What was particularly interesting was that there was a correlation between whether someone had tried a haptic device before and how highly they rated the comfort of our sleeve,” du Pasquier said. “Essentially, if they had tried out other haptic devices, they scored our sleeves much higher.”</p><p>With more lightweight, comfortable haptic devices, the researchers are envisioning new opportunities for conveying information through touch. Haptiknit could be used to aid in navigation, military communication, and even dog training, du Pasquier said.</p><p>Okamura, du Pasquier, and their colleagues are working on refining and optimizing their knitting patterns, as well as creating larger-scale devices – perhaps even a full suit – for virtual reality interactions. They also hope to incorporate this work into assistive devices that can help people move or aid in rehabilitation.</p><p>“We can use this to start testing how people actually interpret and respond to this type of haptic information,” Okamura said. “Whether the purpose is entertainment, communication, training, or physical assistance, this really brings these wearable devices toward things that people might actually want to use in their everyday lives.”&nbsp;</p><hr><p id="isPasted"><em>Okamura, a professor of mechanical engineering, is a member of</em><a href="http://biox.stanford.edu/" data-extlink=""><em>&nbsp;Stanford Bio-X</em></a><em>, the</em><a href="https://humanperformance.stanford.edu/" data-extlink=""><em>&nbsp;Wu Tsai Human Performance Alliance</em></a><em>&nbsp;and the</em><a href="https://neuroscience.stanford.edu/" data-extlink=""><em>&nbsp;Wu Tsai Neurosciences Institute</em></a><em>, a faculty affiliate of the</em><a href="https://hai.stanford.edu/" data-extlink=""><em>&nbsp;Institute for Human-Centered Artificial Intelligence</em></a><em>, a science fellow at the&nbsp;</em><a href="https://www.hoover.org/" data-extlink=""><em>Hoover Institution</em></a><em>, an executive committee member for the&nbsp;</em><a href="https://src.stanford.edu/" data-extlink=""><em>Stanford Robotics Center</em></a><em>, and a faculty member of the&nbsp;</em><a href="https://centerfordesignresearch.stanford.edu/" data-extlink=""><em>Center for Design Research</em></a><em>.</em></p><p><em>Additional Stanford co-authors of this research are visiting students Ian Scholl and Liana Tilton.</em></p><p><em>Other co-authors of this work are from the Massachusetts Institute of Technology and the University of Houston.</em></p>

Haptiknit sleeve worn on the arm, including the control system on the upper arm. | Susan Williams, MIT Self-Assembly Lab

Researchers at Stanford Engineering have developed a lightweight, comfortable knit sleeve that uses pressure-based haptics to simulate touch, opening up new possibilities for wearable devices.

New knit haptic sleeve simulates realistic touch

Explore 2D sonar mosaic mapping with Deep Trekker ROVs to create detailed underwater views for inspecting dams, canals, and tunnels in low-visibility waters.

2D Sonar Mosaic Mapping: All You Need to Know

<p id="isPasted">Measuring Shore hardness is a widely used technique for assessing the hardness of <a href="https://xometry.pro/en-eu/materials/">materials such as rubber, plastics, and elastomers</a>. Unlike other hardness testing methods like Rockwell or Brinell, which are designed for metals and harder materials, Shore hardness testing specifically measures the resistance of more flexible materials to indentation. This makes it particularly valuable in applications where properties like flexibility, elasticity, and impact resistance are essential.</p><p>The term “hardness” refers to a material’s ability to resist indentation or localized deformation, often quantified using an instrument called a durometer. The Shore hardness scale measures this property, providing a numerical value that indicates how much force is required to create an indentation in the material.&nbsp;</p><h2 data-counter-attr="value0"><strong>Shore Hardness Scales: Shore A, Shore B and Shore OO</strong></h2><p>Shore hardness scales are designed to measure the hardnesses of various materials—typically plastics and rubbers, in compliance with <a href="https://www.iso.org/standard/74969.html" target="_blank" rel="noreferrer noopener">ISO 48-4</a> or <a href="https://www.astm.org/d2240-15r21.html" target="_blank" rel="noreferrer noopener">ASTM D2240</a>. Shore hardness is a versatile technique for measuring hardness, from very soft materials like thermoplastic elastomers (TPEs) and soft rubbers to very hard materials like thermoplastics and thermosets. The two most commonly used durometer scales are Shore A and Shore D. The hardness values in both scales range from 0 to 100 and are empirically based on the indentation depth of the test.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736411376691-EN-shore-hardness.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Though not as commonly used, the Shore OO scale is also a durometer scale used to measure the hardness of materials. The Shore hardness scale to be used depends on the material and is largely dependent on the type of test the user would like to use.</p><h2 data-counter-attr="value1"><strong>Shore A vs. Shore D: What Are the Differences?</strong></h2><p>The primary differences between the Shore A and Shore D scales lie in the type of indenter and applied force used to conduct the tests and the materials intended to measure. These differences are crucial for selecting the appropriate Shore hardness durometer test procedure and scale.</p><table><thead><tr><th>Feature</th><th>Shore A</th><th>Shore D</th></tr></thead><tbody><tr><td>Material type</td><td>Softer, more flexible materials (e.g. rubbers, silicones, soft elastomers, TPEs, TPU)</td><td>Harder, more rigid materials (e.g. rigid plastics like ABS, PC)</td></tr><tr><td>Indenter type</td><td>Conical tip for softer materials</td><td>Sharper point for penetrating harder materials</td></tr><tr><td>Scale range</td><td colspan="2">0 to 100</td></tr><tr><td>Force applied</td><td>Approximately 8 N</td><td>Approximately 44.5 N</td></tr><tr><td>Best use case</td><td>Measuring materials requiring flexibility and elasticity</td><td>Measuring materials requiring rigidity and toughness</td></tr><tr><td>Applications</td><td>Seals, gaskets, shoe soles, flexible consumer products</td><td>Hard hats, garden hoses, rigid plastic components</td></tr></tbody></table><h2 data-counter-attr="value2"><strong>Shore Durometer Conversion Chart</strong></h2><p>There is some overlap between the two scales, where either Shore A or Shore D can be used to determine and report the hardness of a single material. For instance, a material with a hardness of 100 Shore A is equivalent to about 60 Shore D, while a material with a hardness of Shore 10 D is equivalent to about 70 Shore A.</p><p>The table below shows the approximately equivalent values for Shore A and Shore D scales:</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736411413570-durometer-converter-2048x681.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted"><strong>Despite these overlaps, it is important to use the same scale when comparing different materials, to be able to effectively quantify a material’s hardness, performance, and quality.</strong></p><h2 data-counter-attr="value3"><strong>Shore A Hardness Scale</strong></h2><p>Shore A measures the hardness of softer, more flexible materials such as elastomers, silicones, and rubbers. The indenter for Shore A has a conical tip, which is suitable for penetrating softer materials. The Shore A durometer applies an approximate 8 N force onto a material using a 35° conical head.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736411431671-EN-shore-a-hardness-testing.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value4" id="isPasted"><strong>Common Materials Measured with Shore A Hardness</strong></h3><p>Shore A hardness is a measure used to quantify the hardness of flexible and soft materials. It’s especially relevant for materials like rubbers, silicones, thermoplastic elastomers (TPEs), and softer thermoplastics and thermosets.</p><table><thead><tr><th>Type of Material</th><th>Material Example</th><th>Shore A Hardness</th><th>Common Applications</th></tr></thead><tbody><tr><td><strong>Silicone</strong></td><td><a href="https://xometry.pro/en-eu/materials/true-silicone/">True Silicone</a></td><td>20 – 60</td><td>Seals, o-rings, kitchen utensils, medical implants</td></tr><tr><td><strong>Silicone</strong></td><td>Silicone elastomers</td><td>20 – 70</td><td>Automotive applications, food-grade products, medical devices</td></tr><tr><td><strong>Rubber</strong></td><td><a href="https://xometry.pro/en-eu/materials/sil-30/">SIL 30</a></td><td>35</td><td>Automotive gaskets, medical devices, kitchenware, seals</td></tr><tr><td><strong>Rubber</strong></td><td><a href="https://xometry.pro/en-eu/materials/epu-40/">EPU 40</a></td><td>72</td><td>Industrial parts, seals, gaskets</td></tr><tr><td><strong>TPE (Thermoplastic elastomer)</strong></td><td><a href="https://xometry.pro/en-eu/materials/tpu-polyurethane/">TPU (Thermoplastic polyurethane)</a></td><td>85 – 95</td><td>Footwear, hoses, industrial belts, cable jackets, sports equipment</td></tr><tr><td><strong>TPE (Thermoplastic elastomer)</strong></td><td><a href="https://xometry.pro/en-eu/materials/tpv-rubber/">TPV (Thermoplastic vulcanizates)</a></td><td>50 – 80</td><td>Automotive seals, weather strips, soft-touch grips</td></tr><tr><td><strong>Softer Thermoplastic / Thermoset</strong></td><td><a href="https://xometry.pro/en-eu/materials/ldpe/">LDPE (Low-density polyethylene)</a></td><td>95</td><td>Squeeze bottles, plastic bags, tubing</td></tr><tr><td><strong>Softer Thermoplastic / Thermoset</strong></td><td>PVC (Polyvinyl chloride), flexible grade</td><td>50 – 90</td><td>Flexible hoses, inflatable products, cable insulation</td></tr><tr><td><strong>Softer Thermoplastic / Thermoset</strong></td><td>Epoxy resins</td><td>60-85</td><td>Flooring, coatings, adhesives</td></tr></tbody></table><h3 data-counter-attr="value5"><strong>Example of Applications</strong></h3><p>The table below shows the Shore A hardness of some familiar items:</p><table><thead><tr><th>Product</th><th>Shore A Hardness</th></tr></thead><tbody><tr><td>Rubber band</td><td>20 A</td></tr><tr><td>Bottle nipple</td><td>40 A</td></tr><tr><td>Pencil eraser</td><td>55 A</td></tr><tr><td>Shoe sole</td><td>70 A</td></tr><tr><td>Leather belt</td><td>80 A</td></tr><tr><td>Tire tread</td><td>80 A</td></tr><tr><td>Golf ball</td><td>90 A</td></tr></tbody></table><h2 data-counter-attr="value6"><strong>Shore D Hardness Scale</strong></h2><p>Shore D measures the hardness of harder, more rigid materials, including hard plastics and harder elastomers with little flexibility. The indenter for Shore D has a sharper point measured from the horizontal compared to the Shore A indenter, which allows it to penetrate harder materials due to the smaller area over which the force of the indenter is applied. To test for Shore D durometer, a 44.5 N force is applied onto a material using a 30° conical head.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736411452109-%D0%A1%D0%BD%D0%B8%D0%BC%D0%BE%D0%BA-%D1%8D%D0%BA%D1%80%D0%B0%D0%BD%D0%B0-2024-09-04-105402.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value7" id="isPasted"><strong>Common Materials Measured with Shore D Hardness</strong></h3><p>The Shore D scale is often used to measure the hardness of more rigid plastics and elastomers such as vulcanized rubber, hard TPEs, and thermoplastics like ABS, PC, PVC, and more.</p><table><thead><tr><th>Type of Material</th><th>Material Example</th><th>Shore D Hardness</th><th>Common Applications</th></tr></thead><tbody><tr><td><strong>Rigid Plastic</strong></td><td><a href="https://xometry.pro/en-eu/materials/abs/">ABS</a></td><td>70 – 85</td><td>Automotive components, electronic housings, consumer products (e.g., toys like LEGO bricks)</td></tr><tr><td><strong>Rigid Plastic</strong></td><td><a href="https://xometry.pro/en-eu/materials/pc-polycarbonate/">PC (Polycarbonate)</a></td><td>70 – 85</td><td>Eyewear lenses, safety helmets, protective shields</td></tr><tr><td><strong>Rigid Plastic</strong></td><td><a href="https://xometry.pro/en-eu/materials/acrylic/">Acrylic / PMMA</a></td><td>70-80</td><td>Windows, skylights, signage</td></tr><tr><td><strong>Rigid Plastic</strong></td><td><a href="https://xometry.pro/en-eu/materials/pvc/">PVC (Polyvinyl chloride), rigid grade</a></td><td>80-90</td><td>Pipes, fittings, window frames, building materials</td></tr><tr><td><strong>Hard Elastomer</strong></td><td>Vulcanized rubber, hard grade</td><td>50-75</td><td>Automotive tires, belts, industrial seals</td></tr><tr><td><strong>Hard Elastomer</strong></td><td>Hard TPEs</td><td>55-75</td><td>Tool handles, automotive components, caster wheels</td></tr><tr><td><strong>Thermoset Plastic</strong></td><td>Epoxy resins</td><td>75-90</td><td>Coatings, adhesives, electrical encapsulation, composite materials</td></tr><tr><td><strong>Composite Material</strong></td><td>Carbon fiber composites</td><td>80-90</td><td>Aerospace, automotive, sports equipment, high-performance applications</td></tr></tbody></table><h3 data-counter-attr="value8"><strong>Examples of Applications</strong></h3><p>The table below shows the Shore D hardness of some common objects:</p><table><thead><tr><th>Product</th><th>Shore D Hardness</th></tr></thead><tbody><tr><td>Shoe sole</td><td>10 D</td></tr><tr><td>Garden hose</td><td>30 D</td></tr><tr><td>Hard Book cover</td><td>40 D</td></tr><tr><td>Wooden ruler</td><td>70 D</td></tr><tr><td>Hard hat</td><td>80 D</td></tr></tbody></table><h2 data-counter-attr="value9"><strong>How to Measure Shore Hardness?</strong></h2><p>The Shore hardness measurement procedure is described in the four steps below:</p><ol><li>Place the test sample on a hard, flat, or rigid surface. Apply pressure to the <a href="https://xometry.pro/en-eu/articles/shore-hardness-for-plastics-and-rubbers/#durometer">durometer</a> quickly and steadily, avoiding any sudden impacts or shocks.</li><li>Take hardness measurements at specified intervals. Record the readings at 3 seconds and then at 15 seconds.</li><li>Measure the hardness at five different points on the test sample to account for any variations. Calculate and record the average of these measurements.</li><li>If the needle on the durometer has penetrated the plastic to its maximum depth and the device is pressed firmly against the material, the needle will indicate the material’s hardness value on the scale.</li></ol><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736411470775-shore-hardness-indenters.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Illustration of the Shore A and Shore D indenters when measuring the Shore hardness of a plastic part</span></span></span></p><p id="isPasted">The hardness value is displayed on a scale ranging from 0 to 100 and is determined by the amount of pressure needed to form an indentation at a particular depth. Materials with higher Shore hardness values have higher hardnesses. However, it’s important to note that a higher Shore hardness does not necessarily mean a material is more durable or better performing in all applications. Hardness is just one aspect of a material’s properties; other factors like flexibility, impact resistance, and tensile strength also play critical roles in determining overall performance.</p><h2 data-counter-attr="value10"><strong>Troubleshooting Tips for Inaccurate Shore Hardness Readings</strong></h2><p>Achieving accurate and reliable readings is essential for making informed decisions in material selection and product design, but various factors can contribute to inaccurate measurements or material-specific challenges. Here are some troubleshooting tips to help you ensure consistent and precise Shore hardness readings:</p><ul><li><strong>Ensure proper calibration of the Shore hardness durometer:</strong> Regularly calibrate your durometer using a standard reference block to ensure accurate readings, as an improperly calibrated device can lead to misleading hardness values and impact material selection and quality control. Keep the durometer clean and well-maintained; check for wear on the indenter tip and other parts, and replace any worn components promptly to maintain measurement precision.</li><li><strong>Prepare the material surface properly:</strong> Ensure the material’s surface is clean, smooth, and free of contaminants or debris to avoid inaccurate readings. The test sample should be flat and sized according to testing standards (e.g., ASTM D2240-15). If the material has a coating or surface treatment, remove it or choose an area that reflects the material’s true bulk properties to prevent false hardness readings.</li><li><strong>Use the correct shore scale:&nbsp;</strong>Choose the appropriate Shore scale (Shore A or Shore D) for the material being tested to avoid inaccurate readings. Be mindful of materials that fall within overlapping hardness ranges and select the scale that best matches the material’s properties and application requirements.</li><li><strong>Account for material-specific characteristics:</strong> Not all materials are suitable for Shore hardness testing. Extremely hard or soft materials may fall outside the scales’ effective range, and some materials, like soft elastomers, can recover from indentation too quickly, resulting in inconsistent or inaccurate readings. To improve accuracy, take multiple measurements and calculate an average. Additionally, ensure that samples meet the minimum thickness requirements—typically at least 6 mm—to avoid skewed results due to inadequate material thickness for proper indentation.</li><li><strong>Apply proper testing technique:</strong> Apply the durometer with steady, consistent pressure, avoiding sudden impacts or jerky movements that could lead to inaccurate readings. Maintain the correct dwell time (typically 1 to 15 seconds) and record measurements consistently to reduce variability. Test multiple points on the material to account for inconsistencies and natural variability, especially in composites or mixed materials. Averaging these readings will yield a more reliable overall hardness value.</li></ul><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736411497557-sls-tpu-flexible-print-scaled.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 data-counter-attr="value11" id="isPasted"><strong>Hardness Testing Results for Reliable Material Performance</strong></h2><p>Understanding the differences between Shore A and Shore D hardness scales is crucial for selecting the right materials for your specific applications. By mastering Shore hardness testing techniques, choosing the correct scale, and troubleshooting common issues, engineers and designers can ensure optimal material performance, quality, and durability in their products. Remember, Shore hardness is just one piece of the puzzle—consider it alongside other material properties for the best results.</p>

This article explores different Shore hardness scales, focusing on the differences between Shore A and Shore D, and provides insights on how to select the appropriate scale for measuring plastic, elastomer and rubber hardness in diverse applications.

Shore Hardness for Plastics and Rubbers: Shore A and Shore D

<p dir="ltr" id="isPasted">If you have any fault in the neutral wire, the power won’t be able to exit the circuit, and there’ll be a possibility of surges and over-voltage. The electricity will find different paths to discharge its power - via the ground wire, earth or any other material conductor in contact with the circuit. This can lead to dangerous and unpredictable conditions, increasing the risk of electrical shock and serious equipment damage.</p><h2 dir="ltr">How Your Electrical Circuits Work</h2><p dir="ltr">Control panels, devices and equipment are plugged into the mains power source, which sends the electricity through live wires. These wires carry the electrical load to various locations, where it may be distributed via switches or distribution panels. The live wire carries alternating current (AC) at a high voltage, 230 volts in the UK. For this reason, it’s sometimes called the “hot” wire. As long as it’s hooked up to the power source, the live wire always carries current.</p><p dir="ltr">To work properly in an electrical distribution system, this current must complete a circuit that returns the electrical power to its source. This is the function of the neutral wire, which completes the circuit by conveying the current back safely. This is frequently via a busbar in the switchgear or control panel. While it’s operating as the return route for the power, the neutral wire will carry an electrical current. However, in the interests of safety, it makes sense to assume that the neutral wire will always be electrically charged.</p><p dir="ltr">Ground wires offer extra protection against electrical overloads. Although the neutral wire is able to channel the current to&nbsp;<a title="Ground" href="https://www.electrical101.com/electrical-ground.html" target="_blank" rel="nofollow noopener">some form of ground</a>, you won’t always find a ground wire as well. Older installations won’t have them, but they do act as a useful backup. You won’t normally find any current in a ground wire, but if your wiring insulation is damaged or you have a short circuit, any unstable current will be directed through it to protect your electrical system.</p><h2 dir="ltr">Neutral And Ground Wire Confusion</h2><p dir="ltr">People can sometimes get confused between the functions of neutral and ground wires. It’s important to remember that the neutral wire is necessary to return the current to the source, to complete the electrical circuit. It’s a key component of the live circuit, without which the electrical system won’t function. The neutral wire is also grounded to earth, so it’s capable of diverting excess or unstable current. For additional safety, most equipment will also have a ground wire specifically installed for this purpose.</p><p dir="ltr">In industrial settings, some circuits have four wires, especially in applications with a motor. In this type of system, you’ll have two live wires, as well as a neutral and a ground wire. The neutral wire in these circuits helps to balance the electrical load in a&nbsp;<a title="Three-Phase" href="https://www.rowse.co.uk/blog/post/three-phase-and-single-phase-explained" target="_blank">three-phase system</a>, which is required for motor-driven appliances and running heavy machinery. Four-wire circuits carrying three-phase electrical current are more efficient when dealing with a large electrical demand.</p><p dir="ltr">In the UK, wiring colours were standardised in 2006 to comply with IEC 60446 as well as with BS7671. This made them consistent with European standards and helped to avoid confusion. Under this system, the old black neutral wire became light blue. Earth or ground wires changed from green or green and yellow to plain yellow, and live wires from red to brown.<strong>&nbsp;</strong></p><h2 dir="ltr">Loss Of Neutral</h2><p dir="ltr">Loss of neutral is an electrical fault that can seriously impact your system. In standard electrical equipment, any breakdown of the neutral conductor will probably cause problems with over-voltage. Loss of neutral in a three-phase electrical system is far more serious.</p><p dir="ltr">In a three-phase transformer, the neutral wire is connected to the central point and is grounded. If this connection breaks or becomes otherwise disconnected, you’ll lose neutral. The result of this will be an imbalance in the distribution of current and voltage in the system. You’re likely to experience extremely high voltages and voltage fluctuations, which may damage your electrical equipment and even cause electrical fires.</p><p dir="ltr">Some of the most common ways that you might lose neutral are through severe weather, such as storms and lightning. These produce electrical interference that can damage the circuits, or cause unpredictable accidents like something falling on the wires. External wiring can also be damaged by animals or corrosion. Theft is another issue. Valuable copper wires offer a temptation to thieves, due to their high value.</p><p dir="ltr">To help prevent the risk of losing neutral, you can equip your system with&nbsp;<a title="Commercial Surge Protection" href="https://www.rowse.co.uk/blog/post/why-is-commercial-surge-protection-important" target="_blank">commercial surge protection</a>, which will protect it against temporary over-voltages. This will be in compliance with BS7671: IET Wiring Regulations, which govern the safety of UK electrical installations.</p><h2 dir="ltr">Safety First</h2><p dir="ltr">Electricity is a dangerous commodity and must always be treated with caution. The neutral wire is an integral part of the electrical circuit and helps prevent it from overloading. Electrical current always seeks to revert to its source by any available path. In electrical terms, this is what “completing a circuit” means. As long as you provide it with a neutral wire, the circuit will be completed safely. But remember that electricity will always travel along the road of least resistance. If there’s no neutral wire or exit to the ground, the current will take any available route it can find to get back to its source.</p><p dir="ltr">If you have any fault in your neutral wire, the electrical current could seek a different way back. This might include diverting via water pipes, metal components, or any other conductive materials. This means there will be a danger of serious electric shocks, a safety hazard if anyone comes into contact with the charged material. In the most extreme circumstances, the electricity might use the human body as a route as it attempts to complete its circuit, which could well lead to fatal injury.</p>

Electrical circuits are constructed with at least three different wires: live, neutral and ground. Power flows in via the live wire and out via the neutral wire.

What Is A Neutral Wire, And Why Is It Important?

Explore how PCB drilling forms the backbone of modern electronics by enabling seamless circuit connectivity and ensuring robust device performance. Learn practical insights and expert tips to optimize your manufacturing process.

PCB Drilling: Precision Techniques for Modern Electronics

<p dir="ltr" id="isPasted">Annealing PLA is a post-processing step that involves heating 3D printed PLA parts to enhance their mechanical strength and thermal resistance. Compared to untreated PLA, annealed parts exhibit improved durability, making them more resistant to heat deformation and mechanical stress over time.&nbsp;</p><p dir="ltr">This improvement in long-term performance makes annealing an appealing post-processing option for projects that demand reliability under challenging conditions. Particularly relevant for makers, hobbyists, and some engineers, this technique addresses common weaknesses in PLA, such as low heat tolerance and brittleness.</p><p dir="ltr">This article provides detailed insights into how to execute the annealing PLA process effectively, troubleshoot challenges, and maximize results for a variety of projects.</p><h2 dir="ltr">What is PLA?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736158120847-biodegradable_cup_base.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="pla"><span class="fr-inner">PLA is a common thermoplastic material for 3D printing and other processes</span></span></span></p><p dir="ltr">Polylactic Acid (PLA) is a thermoplastic polymer derived from renewable resources like corn starch or sugarcane. It is one of the most popular materials used in 3D printing, particularly for Fused Deposition Modeling (FDM) printers. PLA’s widespread use stems from its ease of printing, low cost, and eco-friendly nature.</p><p dir="ltr">PLA filament is highly favored by beginners and professionals due to its low printing temperature (190–220°C), minimal warping, and ability to produce detailed, smooth prints. Unlike materials such as ABS or PETG, PLA requires neither a heated bed nor an enclosed printer, making it accessible for low-cost desktop 3D printers.[1] Additionally, it is available in a wide variety of colors and composite forms, such as PLA infused with wood, metal, or carbon fiber for aesthetic or functional enhancements.</p><p dir="ltr">One of PLA’s major drawbacks is its low heat resistance. PLA has a glass transition temperature of around 60°C, which means it begins to soften and deform at relatively low temperatures. This limitation arises from its molecular structure, which lacks the crystalline reinforcement seen in materials like ABS or polycarbonate.</p><p dir="ltr">The low heat resistance restricts PLA’s use for functional parts exposed to heat, such as car interiors or outdoor applications in hot climates. For higher thermal performance, heat-treated PLA or PLA blends are available, but these solutions often compromise some of PLA's printability advantages.</p><h2 dir="ltr">What Does Annealing Do to PLA?</h2><p dir="ltr">Annealing 3D printed PLA involves heating the material to a specific temperature (typically 60–100°C) below its melting point and holding it there for a set time. This process alters the molecular structure, increasing crystallinity and improving the material's thermal and mechanical properties.[2]</p><p dir="ltr">In its printed state, PLA often has a mostly amorphous structure due to rapid cooling. Annealing allows polymer chains to realign into more orderly crystalline regions. This increased crystallinity raises the material’s heat deflection temperature (HDT), enabling it to withstand higher temperatures. On a simpler level, the heating of the plastic also creates stronger layer adhesion, as layers begin to blend into one another with fewer internal stresses.</p><p dir="ltr">Dimensional changes, such as shrinkage or warping, can occur during annealing as the internal structure reorganizes. These changes depend on factors like geometry, print settings, and annealing conditions. Parts with uniform infill and consistent wall thickness tend to anneal more predictably. Furthermore, high-temperature PLA variants (HTPLA) may exhibit less warping during annealing.</p><p dir="ltr">By improving heat resistance and strength, annealing makes PLA more suitable for demanding applications like automotive or outdoor use. However, care is needed to prevent deformation during the process.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/pla-melting-point" target="_blank"><em>A Comprehensive Guide to PLA Melting Point and How it Influences 3D Printing</em></a></strong></p><h2 dir="ltr">How to Anneal PLA Prints</h2><p dir="ltr">Annealing PLA can enhance its thermal and mechanical properties by increasing its crystallinity. Follow these steps to anneal PLA prints effectively while minimizing risks of deformation.</p><h3 dir="ltr">Equipment Required</h3><ul><li dir="ltr"><p dir="ltr">3D printed object: Ensure the print is clean and free of debris.</p></li><li dir="ltr"><p dir="ltr">Oven: A conventional or toaster oven capable of maintaining precise temperatures between 60°C and 100°C.</p></li><li dir="ltr"><p dir="ltr">Oven thermometer: To verify and monitor the oven’s temperature, as built-in settings can be inaccurate.</p></li><li dir="ltr"><p dir="ltr">Heat-resistant surface: A flat metal tray, glass dish, or ceramic plate to place the print on.</p></li><li dir="ltr"><p dir="ltr">Support material (optional): Sand, uncooked rice, or silicone molds to support complex geometries and prevent deformation.</p></li><li dir="ltr"><p dir="ltr">Heat-resistant gloves or tongs: For safely handling trays or prints during or after annealing.</p></li><li dir="ltr"><p dir="ltr">Calipers or ruler: To measure the part before and after annealing to assess dimensional changes.</p></li></ul><h3 dir="ltr">1. Prepare Your Print</h3><p dir="ltr">Start with a clean, well-printed object. Uniform wall thickness and consistent infill density help ensure even heat distribution during annealing. If possible, choose PLA formulated for annealing, as some blends are optimized for this process.</p><h3 dir="ltr">2. Preheat the Oven</h3><p dir="ltr">Set your oven to a temperature between 60°C and 100°C. The ideal temperature depends on the PLA blend and the object itself, so it helps to conduct tests before annealing your final part. On the whole, the ideal temperature will be the highest possible temperature before the material begins to deform to an unacceptable level.</p><h3 dir="ltr">3. Place the Print on a Stable Surface</h3><p dir="ltr">Put your print on a flat, heat-resistant surface like a metal tray or glass dish. If deformation is a concern, support complex shapes with sand or uncooked rice, which helps maintain the geometry during heating.</p><h3 dir="ltr">4. Anneal the Print</h3><p dir="ltr">Once the oven reaches the desired temperature, place the tray with your print inside. Leave it in the oven for 15 to 60 minutes, depending on the part's size and thickness. Avoid sudden temperature changes that could cause warping. Alternatives to oven baking the PLA include simply using a heated print bed (and covering the print with a bowl) or using a sous vide immersion heater.</p><h3 dir="ltr">5. Cool Down Gradually</h3><p dir="ltr">Turn off the oven and allow the print to cool to room temperature inside to prevent thermal shock. Rapid cooling can cause cracks or deformation. Once the oven is cool to the touch, remove the print.</p><h3 dir="ltr">6. Inspect the Results</h3><p dir="ltr">After annealing, check for any dimensional changes, such as shrinkage or warping. Measure critical dimensions to ensure they meet your requirements. Keep in mind that some slight deformation is normal, especially for complex geometries.</p><h3 dir="ltr">Tips for Success</h3><ul><li dir="ltr"><p dir="ltr">Use test prints to fine-tune your annealing process.</p></li><li dir="ltr"><p dir="ltr">Avoid convection ovens, as airflow can lead to uneven heating.</p></li><li dir="ltr"><p dir="ltr">Monitor the process closely to prevent overheating, which could melt or deform the part.</p></li></ul><h3 dir="ltr">Annealing Time</h3><p dir="ltr">PLA annealing times typically range from 15 to 60 minutes, depending on the part’s size and thickness. Smaller or thinner parts require less time, while larger or bulkier pieces need more. Monitoring is important to ensure even heat treatment and to prevent overheating, which can cause warping or deformation.</p><h3 dir="ltr">Annealing Temperature</h3><p dir="ltr">Annealing temperatures for PLA typically range between 60°C and 100°C, depending on the filament's composition and other factors. It helps to use an accurate oven thermometer to maintain a consistent temperature. Too low won’t effectively increase crystallinity, while too high risks melting or deforming the print. Manufacturer guidelines can help determine the optimal range.</p><h2 dir="ltr">Shrinkage, Warping &amp; Other Considerations</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1736158136509-3d_printing_measurement.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="measuring"><span class="fr-inner">Always measure the annealed prints to check for dimensional changes</span></span></span></p><p dir="ltr">Shrinkage and warping are common concerns when annealing PLA prints, arising from changes in the material's internal structure. As PLA heats during annealing, its polymer chains reorganize into a more crystalline arrangement. This densification process can cause the material to contract, leading to dimensional changes or shrinkage. Uneven heating or cooling exacerbates the issue, causing some areas to shrink more than others, which results in warping or distortion.</p><p dir="ltr">The degree of shrinkage varies based on PLA composition, print geometry, and annealing conditions. Standard PLA typically shrinks by 1–2% with the aforementioned annealing times and temperatures, but high-crystallinity or annealing-specific PLAs may exhibit less shrinkage. Parts with uneven wall thickness or complex geometries are more prone to warping due to differential stresses during heat treatment.</p><p dir="ltr">To offset these effects, careful preparation is crucial. Supporting the print with sand or uncooked rice during annealing may help stabilize its shape, particularly for intricate designs, though there is debate over the effectiveness of this method.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/the-ultimate-guide-to-3d-printing-post-processing-techniques" target="_blank"><em>The Ultimate Guide to 3D Printing Post-Processing Techniques</em></a></strong></p><h2 dir="ltr">How Do Other Filaments React to Annealing?</h2><p dir="ltr">Many 3D printing filaments, such as ABS, PETG, and nylon, are less suited for annealing because their required temperatures are higher than PLA’s, increasing the risk of warping or deformation. ABS and nylon, for example, require annealing temperatures near or above their heat deflection points, which can destabilize the print.</p><p dir="ltr">While PETG has a less crystalline structure than PLA, annealing can still provide some benefits, such as improving impact strength.[3] However, the process often leads to higher shrinkage rates and thermal stresses, making it challenging to achieve consistent results. These factors limit annealing's practicality for most non-PLA materials.</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Annealing PLA is an effective method to enhance the thermal and mechanical properties of 3D printed PLA parts. By carefully heat treating the material, its crystalline structure improves and layer lines are reduced, resulting in increased temperature resistance and <a href="https://www.wevolver.com/article/how-strong-are-3d-printed-parts" target="_blank">strength</a>.&nbsp;</p><p dir="ltr">While shrinkage and warping are potential challenges, these can be mitigated through proper preparation, controlled heating, and gradual cooling. Compared to other filaments, PLA’s relatively low annealing temperature makes the process accessible and practical for most users.</p><p dir="ltr">With the right approach, annealing transforms PLA prints into durable components suitable for a broader range of applications, extending the versatility of this eco-friendly and widely-used 3D printing material.</p><h2 dir="ltr">Frequently Asked Questions</h2><p dir="ltr"><strong>What is the purpose of annealing PLA prints?</strong></p><p dir="ltr">Annealing PLA prints increases their crystallinity, enhancing their heat resistance, strength, and overall durability. This process makes PLA more suitable for applications requiring higher thermal stability, such as automotive or outdoor components, while maintaining its eco-friendly properties.</p><p dir="ltr"><strong>How do you prevent warping when annealing PLA?</strong></p><p dir="ltr">To prevent warping, ensure uniform wall thickness and infill during printing. Support complex shapes with materials like sand or uncooked rice during annealing. Additionally, gradually cool the print by leaving it in the oven after turning it off, preventing thermal shock.</p><p dir="ltr"><strong>Can all types of PLA be annealed?</strong></p><p dir="ltr">Most PLA filaments can be annealed, but some, particularly blends designed for specific properties, may have limited heat resistance or low crystallization potential. Always check the manufacturer’s guidelines for recommended annealing temperatures and times for the best results.</p><p dir="ltr"><strong>Why isn’t annealing suitable for other 3D printing filaments like ABS or PETG?</strong></p><p dir="ltr">Other filaments like ABS and PETG require much higher annealing temperatures, which can lead to warping or deformation. ABS, for example, has a high heat deflection point that risks destabilizing prints, while PETG’s less crystalline structure means annealing offers little benefit.</p><h1 dir="ltr">References</h1><p dir="ltr">[1] Steenhuis HJ, Pretorius L. <a href="https://www.emerald.com/insight/content/doi/10.1108/jmtm-01-2016-0002/full/html" target="_blank">Consumer additive manufacturing or 3D printing adoption: an exploratory study</a>. Journal of Manufacturing Technology Management. 2016 Sep 5;27(7):990-1012.</p><p dir="ltr">[2] Wach RA, Wolszczak P, Adamus‐Wlodarczyk A. <a href="https://onlinelibrary.wiley.com/doi/abs/10.1002/mame.201800169" target="_blank">Enhancement of mechanical properties of FDM‐PLA parts via thermal annealing</a>. Macromolecular Materials and Engineering. 2018 Sep;303(9):1800169.</p><p dir="ltr">[3] Kumar KS, Soundararajan R, Shanthosh G, Saravanakumar P, Ratteesh M. <a href="https://www.sciencedirect.com/science/article/pii/S2214785320376458" target="_blank">Augmenting effect of infill density and annealing on mechanical properties of PETG and CFPETG composites fabricated by FDM</a>. Materials Today: Proceedings. 2021 Jan 1;45:2186-91.</p>

Annealing PLA improves the strength and heat resistance of your 3D printed parts, making them more durable and functional. Here we look at how and when to anneal PLA.

Annealing PLA to Maximize Strength and Heat Resistance

<h2 id="isPasted">Understand the Future of Metal 3D Printing</h2><p>The <strong>Metal 3D Printing Technology Report</strong> 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.</p><p>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 6 below.&nbsp;</p><h2>Complete this form and get your report in your inbox</h2><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><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"><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><h3 dir="ltr" id="isPasted">Cost</h3><p dir="ltr">One of the limiting factors associated with metal additive manufacturing technologies is the cost of the technology. While AM can offer cost benefits in specific cases, the overall cost of manufacturing metal parts using additive manufacturing compared to conventional production processes remains high. The cost is driven by a few factors, including the cost of hardware, the cost of materials, and the cost of post-processing.&nbsp;</p><p dir="ltr">Powder-based metal AM processes, such as LPBF and DED, require the highest capital expenditure, with industrial hardware costing in the range of $1 million. This is due to the complex nature of the process, requiring advanced energy sources, optics, powder management systems, and gas atmospheres. Metallic powder feedstocks are also costly, with a kilogram of metal powder costing anywhere from five to ten times more than the equivalent bar stock. While extrusion-based metal AM hardware and materials are substantially cheaper, the technology’s applications are currently more limited, and parts require more extensive post processing.&nbsp;</p><p dir="ltr">The high—sometimes prohibitive—cost associated with metal additive manufacturing is being addressed in different ways:</p><ul><li dir="ltr"><p dir="ltr">As adoption grows, economies of scale will increasingly come into play, particularly for metal consumables, as increased production volumes and shared resources will lead to lower costs across the supply chain.</p></li><li dir="ltr"><p dir="ltr">Process optimization and further automation, particularly in metal post-processing, will improve efficiency, leading to faster production times and lower labor costs.&nbsp;</p></li><li dir="ltr"><p dir="ltr">Emergence of industrial metal binder jetting systems is presenting a lower cost, yet scalable, production process, since the systems do not rely on complex optical systems and can use more readily available MIM powder as feedstock.&nbsp;</p></li><li dir="ltr"><p dir="ltr">If the high cost of metal AM systems is a barrier to end users, manufacturing services provide an entry point, giving users access to industrial production processes without having to make a large initial capital expenditure.</p></li></ul><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUxMzY4NTkyLTYgaW5zaWRlLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The high cost of powder materials remains a key challenge to the broader adoption of metal AM.&nbsp;</span></span></span></h3><h3 dir="ltr">Consistency and Qualification</h3><p dir="ltr">Metal additive manufacturing, while nearing its full industrial potential, is still burdened by challenges related to process consistency and qualification. There are many variables that come into play in the metal AM process, from part design and material, to type of manufacturing process, and process parameters. The ultimate aim of an industrialized metal AM technology is to be able to produce parts consistently and reproducibly, not only on a single machine but across different systems and at different production facilities. In short, it should be possible to produce a part with the exact dimensions and properties regardless of where or when the part is being printed. Achieving this reproducibility is vital to advancing the qualification of metal AM technologies and applications.</p><p dir="ltr">There are several avenues that will lead to greater process consistency, reproducibility, and ultimately qualification, such as:</p><ul><li dir="ltr"><p dir="ltr">Development and implementation of standard operating procedures (SOPs) across the metal AM workflow, from machine setup to material handling, to post-processing.</p></li><li dir="ltr"><p dir="ltr">Integrating in-situ monitoring systems capable of detecting and fixing any inconsistencies or deviations in the process. Process data can also inform intelligent process optimization solutions to better predict and solve production problems that may occur.&nbsp;</p></li><li dir="ltr"><p dir="ltr">The emergence of more accessible and scalable quality inspection processes for metal 3D printed parts, such as nonlinear resonance NDT.</p></li><li dir="ltr"><p dir="ltr">Promoting industry collaborations to ensure best practices and SOPs are shared across various platforms for industry-wide consistency and repeatability.</p></li><li dir="ltr"><p dir="ltr">The increased emergence of metal binder jetting is also driving greater scalability, as the technology is both more affordable and faster compared to metal powder bed fusion.&nbsp;</p></li></ul><h3 dir="ltr">Scalability</h3><p dir="ltr">Currently, metal additive manufacturing technologies are largely used for prototyping or low-volume production. While these offer benefits, the next frontier for metal AM, and 3D printing in general, is full-scale production. The current state of the industry must still overcome a number of technical hurdles in order to achieve full scalability. Hurdles related in part to the aforementioned issue of establishing greater reproducibility. That is, in order to scale up the production of metal 3D printed products, it must be possible to print identical parts (in terms of dimensions and properties) on multiple machines and, in many cases, at different production sites.</p><p dir="ltr">Reproducibility is a key challenge to scalability, however there are also other factors that must be addressed, including greater process automation, particularly for post-processing metal 3D prints. The current state of metal post-processing, which is largely reliant labor-intensive methods and multiple, time-consuming steps, is a bottleneck that inhibits metal AM scalability. Printing speed is another challenge to achieving higher throughputs, as is 3D printer build size. Establishing scalable quality control and inspection processes as well as reliable material properties across feedstock batches are also necessary for metal AM to truly attain scalable production volumes that can compete with more conventional metal production methods.&nbsp;</p><p dir="ltr">Metal AM software, material, and hardware suppliers are working towards the next step in the industry’s evolution (i.e. greater scalability) by addressing the aforementioned challenges in the following ways:</p><ul><li dir="ltr"><p dir="ltr">Establishing greater process and output consistency through the development of standardized parameters.</p></li><li dir="ltr"><p dir="ltr">Achieving faster printing speeds through software and hardware upgrades, such as multi-laser configurations for LPBF, and faster scanning and deposition rates. &nbsp;&nbsp;</p></li><li dir="ltr"><p dir="ltr">Developing increasingly automated post-processing solutions for metal AM technologies, including powder removal and management systems, automated support removal, and part identification and sorting.&nbsp;</p></li><li dir="ltr"><p dir="ltr">Streamlining quality control processes through scalable non-destructive testing (NDT) methods as well as advanced in-situ monitoring which can detect subsurface flaws in metal 3D prints based on monitoring data.</p></li><li dir="ltr"><p dir="ltr">Driving down material and hardware costs to facilitate the acquisition of more metal AM systems to build scalable production networks.</p></li><li dir="ltr"><p dir="ltr">Leveraging larger metal AM systems for higher throughput jobs. “The more you can fit on the build bed of a metal AM system, the greater the advantage will be,” Xometry’s Matthew Schmidt says. “Most of the production opportunities we see here are jobs in the range of hundreds of parts.”</p></li></ul><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTU0ODA0ODQ5LTE3MzU1NTQ4MDQ4NDkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" id="isPasted" class="fr-fic fr-dii"></p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><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"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><h2 id="isPasted">Read an excerpt from the chapters here:</h2><h3><a href="https://www.wevolver.com/article/metal-3d-printing-technology-report">Introduction Chapter</a></h3><p><a href="https://www.wevolver.com/article/metal-3d-printing-technology-report"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUzNzExNzM2LTEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></p><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal.</p><p><a href="https://www.wevolver.com/article/metal-3d-printing-technology-report" class="button-main-action">READ THE CHAPTER</a></p><p><a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><strong>Chapter 1</strong></a></p><p><strong><a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUzODI3ODU0LTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></strong></p><p>In the first chapter of our new report, we examine the dominant methods of metal 3D printing—metal laser powder bed fusion (LPBF), directed energy deposition (DED), metal extrusion, and binder jetting—as well as other still-emerging or more niche processes.</p><p><a href="https://www.wevolver.com/article/chapter-1-core-metal-3d-printing-technologies" class="button-main-action">READ THE CHAPTER</a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><strong>Chapter 2</strong></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUzODU2ODcxLTMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></p><p>The metal additive manufacturing market features various feedstock types, with powder being the dominant choice for LPBF, some DED methods, and binder jetting. Metal wire and bound metal filament are also used in specific technologies.</p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-1-core-metal-3d-printing-technologies" class="button-main-action">READ THE CHAPTER</a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><strong>Chapter 3</strong></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUzOTAwNjk0LTQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></p><p>In this chapter, we separate metal AM post-processing into four categories: debinding and sintering, CNC machining and milling, heat treatment, and quality assurance.</p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-3-post-processing-for-metal-am" class="button-main-action">READ THE CHAPTER</a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-4-design-for-metal-3d-printing"><strong>Chapter 4</strong></a></p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-4-design-for-metal-3d-printing"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUzOTIwMjg2LTUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></p><p>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.</p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-4-design-for-metal-3d-printing" class="button-main-action">READ THE CHAPTER</a></p><p><a href="https://www.wevolver.com/article/applications-of-metal-additive-manufacturing"><strong>Chapter 5</strong></a></p><p><a href="https://www.wevolver.com/article/applications-of-metal-additive-manufacturing"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1NTUzOTUwMTY1LTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></p><p>This chapter of the report will lay out and examine the various applications of metal additive manufacturing, with a particular focus on end-use applications in the dominant metal AM adoption industries.</p><p><a href="https://www.wevolver.com/article/applications-of-metal-additive-manufacturing" class="button-main-action">READ THE CHAPTER</a></p><p id="isPasted"><strong>Chapter 6</strong></p><p><strong><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM2MjQ1NTg3OTQxLVVudGl0bGVkIGRlc2lnbiAoOSkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></strong>In this chapter, we will explore some of the challenges facing metal additive manufacturing, how they are impacting the growth of the industry, and how metal AM industry players are addressing the issues.</p><p id="isPasted"><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-7-future-outlook-and-emerging-trends"><strong>Chapter 7</strong></a></p><p><strong><strong><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-7-future-outlook-and-emerging-trends"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM2OTM5MTQ1OTM5LVVudGl0bGVkIGRlc2lnbiAoOSkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></strong></strong>The final chapter of the Wevolver Metal AM Report explores the evolving metal additive manufacturing market, projecting a significant growth with a 29% CAGR by 2028 and focusing on key trends including Process Integration, Sustainable Practices, and Accessibility.</p><p><a href="https://www.wevolver.com/article/the-metal-3d-printing-technology-report-chapter-7-future-outlook-and-emerging-trends" class="button-main-action">READ THE CHAPTER</a></p>

In this chapter, we will explore some of the challenges facing metal additive manufacturing, how they are impacting the growth of the industry, and how metal AM industry players are addressing the issues.

The Metal 3D Printing Technology Report: Chapter 6: Challenges Facing Metal 3D Printing

This chapter of the report will lay out and examine the various applications of metal additive manufacturing, with a particular focus on end-use applications in the dominant metal AM adoption industries.

The Metal 3D Printing Technology Report: Chapter 5: Applications of Metal Additive Manufacturing

<p id="isPasted">As the global energy industry increasingly shifts towards sustainable and renewable sources, the demand for efficient and reliable power generation equipment, such as hydraulic turbines, continues to grow. In this context, the precision of critical components like the spiral casing is essential. Even minor dimensional deviations in the casing can lead to misalignments, reduced efficiency, and operational failures.</p><p>Traditional measurement methods often fall short in accurately capturing the complex geometry and large scale of these components. <a href="https://www.3d-scantech.com/3d-scanners/" target="_blank"><u>3D scanning</u></a> technology provides a precise, real-time, non-contact solution, enabling manufacturers to accurately capture the full dimensions of the spiral casing.&nbsp;</p><h3><strong>Client Overview</strong></h3><p>The client is a leading manufacturer of hydraulic turbines, specializing in the production of high-efficiency turbine systems for the global hydropower industry. They design and produce a wide range of turbine types and associated equipment, including spiral casings, critical for the turbine's performance.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547433436-1.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Given the complexity and large size of the spiral casings, the client needed a high-precision inspection solution to ensure dimensional accuracy, avoid assembly issues, and meet strict industry standards.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547446299-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">To meet these needs, the client required a solution that could:</p><ul><li>Measure large, complex geometries accurately.</li><li>Detect, address, and prevent deformations or misalignments to ensure proper fit during assembly.</li><li>Provide real-time feedback for continuous quality control and adjustments.</li></ul><h3><strong>Challenges of Traditional Measurement Methods</strong></h3><p>Traditional measurement techniques, such as laser tracking and mechanical gauges, face significant limitations when it comes to accurately inspecting large, complex components like spiral casings. These challenges include:</p><p><strong>Limited Measurement Range</strong>: Conventional methods struggle to measure large-scale components accurately without frequent repositioning, leading to potential errors in data stitching and reduced efficiency.</p><p><strong>Susceptibility to Environmental Factors</strong>: Measurements taken in production environments can be influenced by temperature fluctuations, vibrations, or dust, affecting the accuracy and consistency of results.</p><p><strong>Inability to Capture Complex Geometries</strong>: Traditional tools can only measure discrete points, making it difficult to capture the full, intricate shape of the spiral casing, including curves, angles, and detailed surface features.</p><p><strong>Time-Consuming and Labor-Intensive</strong>: Manual measurements are slow and prone to human error, often requiring multiple iterations and inspections, which delays production and increases costs.</p><p>These challenges highlight the need for a more advanced, efficient, and accurate solution, prompting the client to explore 3D scanning technology for its precision and ability to address these issues.</p><h3><strong>Solution: 3D Scanning for Spiral Casing Inspection</strong></h3><p>To overcome the limitations of traditional measurement methods, the client implemented <a href="https://www.3d-scantech.com/product_category/tracking-3d-scanner/" target="_blank"><u>TrackScan Sharp</u><u>&nbsp;3D scanning system</u></a>, designed for large-volume, high-precision measurements, provided an effective solution for inspecting the spiral casing with several key advantages:</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547468322-3.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted"><strong>Portable and Reliable On-Site Scanning</strong></h3><p>The TrackScan Sharp was ideal for on-site measurement of the spiral casing, which is difficult to move due to its size. The handheld 3D scanning system’s portability allowed the client to conduct precise measurements directly in the workshop, improving operational efficiency.</p><p>Its sturdy design ensured stable performance even in challenging workshop environments, remaining unaffected by vibrations, temperature changes, or noise. Its dynamic tracking further ensured the precise measurement on the vibrant shop floors.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547487791-4.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted"><strong>High</strong><strong>ly</strong><strong>-</strong><strong>Efficient&nbsp;</strong><strong>Measurement</strong></h3><p>Equipped with on-board processor for edge computing, the 3D scanning system’s tracker output 3D coordinates in real time after processing images. It sped up the data transfer and the measurement process.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547503110-5.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Besides, its one-position measurement range is larger than that of traditional measurement method. With a few repositioning, it can efficiently capture the data of large-scale parts and ensure the precision by reducing the times of data alignment. Combined with its high scanning rate, the measurement was completed in just 2 hours.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547515051-6.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted"><strong>Precise Data Capture&nbsp;</strong></p><p>TrackScan Sharp enabled precise capture of the complete geometry of the spiral casing, including complex curves, intricate features, subtle deviations and hole diameters.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547528855-7.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>The advanced algorithms ensured accurate measurement of dimensions and machining allowances. This 3D scanning system allowed the client to obtain precise data and ensured the parts manufactured are of high standards.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547542263-8.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547554736-9.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted"><strong>Detailed Deviation Analysis</strong></p><p>The scanning data was processed to create a detailed <a href="https://www.3d-scantech.com/3d-model/" target="_blank"><u>3D model</u></a> of the spiral casing, which was then compared to the original CAD model. This deviation analysis helped identify discrepancies and provided critical insights for quality control.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547571052-10.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547580166-11.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>The deviation color map allowed the client to identify dimensional deviations promptly, so that they minimized defects and ensured the casing met strict tolerances throughout the manufacturing process. It also highlighted specific machining allowances on the surfaces to be machined, ensuring precise machining. Additionally, the high-precision data, especially precise hole diameters, provided a valuable reference for subsequent assembly.&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1735547594478-12.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">The implementation of the TrackScan Sharp 3D scanning system successfully addressed the client's challenges, providing a comprehensive and precise solution that significantly improved the accuracy, efficiency, and reliability of the inspection process for the spiral casing.</p><h3><strong>The Broader Impact and Future Outlook</strong></h3><p>The integration of TrackScan Sharp 3D scanning system has not only addressed the immediate challenges in the precision inspection of spiral casings but also set a new standard for quality control in large-scale turbine manufacturing. By offering on-site measurement, improving measurement accuracy, reducing inspection time, and providing real-time feedback, the solution ensured the manufacturing of high-quality turbine components for the client’s global customers. Its intuitive feedback help manufacturers to monitor the production processes in real time, allowing them to make timely adjustments to reduce defect rates and achieve greater financial benefits.&nbsp;</p><p>Looking forward, the <a href="https://www.3d-scantech.com/application/" target="_blank">application of 3D scanning</a> technology in turbine manufacturing is expected to continue evolving, with future advancements in scanning precision, speed, and automation. The ability to detect and correct deviations in real time will play a critical role in further streamlining production processes and minimizing defects. As the demand for high-performance, reliable turbine systems grows, especially in the renewable energy sector, the adoption of advanced technologies like TrackScan Sharp will become increasingly vital to maintaining competitiveness and meeting industry standards.</p><p>The widespread adoption of 3D scanning technology will not only enhance product quality but also contribute to greater sustainability, by optimizing production processes, reducing waste, and ensuring longer product lifecycles. As Scantech continues to innovate, our <a href="https://www.3d-scantech.com/3d-solution/" target="_blank">3D&nbsp;solutions</a> are poised to play a pivotal role in shaping the future of manufacturing, helping industries meet the challenges of the modern world with precision, speed, and efficiency.</p>

Scantech's TrackScan Sharp 3D scanning system provides a cutting-edge solution for inspecting spiral casings in turbine manufacturing. By offering high-precision measurements, real-time feedback, and rapid data capture, it enhances production efficiency and ensures the highest quality standards.

How 3D Scanning Technology Revolutionizes Spiral Casing Inspection in Turbine Manufacturing

Material hardness measurement with a Brinell hardness tester (Source: emcotest.com)

This article provides an overview of common hardness testing methods for metals, comparing their applications, benefits, and drawbacks, and includes a comprehensive table to guide method selection.

Hardness Testing of Metals: Rockwell, Brinell, Vickers, Knoop, and Leeb Tests

A Comprehensive Guide to Manufacturing Automation

Building the Factory of Tomorrow

WayKen Rapid Manufacturing Limited-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

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All Digital Additive Manufacturing-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

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Manufacturing

<p dir="ltr" id="isPasted">On the whole, FDM 3D printers are smart pieces of equipment that are capable of doing almost exactly what you tell them to. Sometimes, however, the components of the machine need&nbsp;calibrating&nbsp;so the physical hardware is in sync with the digital instructions being sent to it.</p><p dir="ltr">One essential part of 3D printer calibration is setting the number of&nbsp;E-steps per millimeter&nbsp;on the extruder. In short, E-steps are the incremental movements made by the extruder&nbsp;stepper motor&nbsp;as it rotates, and this rotation translates to&nbsp;linear movement&nbsp;of the extruded filament. When the manufacturer puts together your 3D printer, it programs the extruder to make a certain number of “E-steps” in order to extrude a given length of filament. But the required number of E-steps varies depending on certain factors, and can also change over time or when new components are installed.</p><p dir="ltr">This article goes over the basics of calibrating E-steps. First, we look at what E-steps are and how they affect extrusion. Then we learn how to calibrate E steps using a slicer capable of sending <a href="https://www.wevolver.com/article/your-guide-to-3d-printing-g-code" target="_blank" rel="noopener noreferrer">G-code commands</a>. Finally, we examine the relationship and key differences between E-steps and flow rate.</p><h2 dir="ltr">What Are E-Steps?</h2><p dir="ltr">E-steps is an abbreviation of “extruder steps,” with “steps” referring to the incremental movements made by the extruder’s stepper motor.</p><p dir="ltr">To understand E-steps, we therefore need to understand&nbsp;stepper motors. A stepper motor is a brushless phased electric motor, for which a full rotation is divided into a fixed number of steps, that can be instructed to move and hold at one of these steps without any position sensor. A typical stepper motor can move in steps of around 1.8 degrees, which means it takes about 200 steps to complete a full rotation.[1] Motors that take more steps to complete a full rotation are more accurate.</p><p dir="ltr">3D printer extruders use stepper motors due to their excellent&nbsp;precision&nbsp;and&nbsp;reliability. Each step moves the filament a little way along. But in order for a printer to work properly, we need to know exactly how many steps it takes to extrude a certain amount of filament, otherwise the printer might extrude too much or too little. This value isn’t always consistent, and physical changes to the printer — even in the time between leaving the factory and being installed on your desktop — can change the value. This is where talking about E-steps comes in handy.</p><p dir="ltr">In short, E-steps are an important measurement for your 3D printer firmware, where a value is set that represents how many steps the stepper motor needs in order to extrude 1 mm of filament.[2] The number of required steps can differ depending on hardware and material, and can also change over time. It therefore requires calibration every now and again.</p><h2 dir="ltr">When Is E-Step Calibration Required?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM2OTU0MDMyODk3LTNkX3ByaW50ZXJfZXh0cnVkZXJfY2xvc2V1cC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="stepper"><span class="fr-inner">Installing new stepper motors requires E-step calibration</span></span></span></p><p>E-step calibration is generally required only when installing new hardware, such as an extruder or stepper motor, or when replacing the printer’s control board. These changes can affect the accuracy of filament extrusion, as the steps-per-millimeter value may no longer match the new components. In most cases, once E-steps are correctly calibrated once, no further calibration is necessary unless additional hardware modifications or firmware updates alter the printer's extrusion behavior.</p><p>In summary, perform E-step calibration after:</p><ul><li>Buying a new 3D printer</li><li>Installing a new extruder</li><li>Installing new stepper motors</li><li>Replacing your printer's control board</li></ul><h2 dir="ltr">Issues Caused by Poorly Calibrated E-Steps</h2><p dir="ltr">If the E-steps per millimeter value is not set properly, then the printer is vulnerable to either over-extrusion or under-extrusion, i.e. the extruder pushing too much or too little filament toward the hot end. For instance, if the extruder is programmed to make 100 steps in order to extrude 1 mm of filament, but those 100 steps actually results in the extrusion of 1.5 mm of filament, then the E-steps value needs to be re-calibrated to prevent over-extrusion.</p><p dir="ltr">Knock-on issues can result from a lack of calibration, such as poor first-layer adhesion, inter-layer adhesion, gaps between layers, and <a href="https://www.wevolver.com/article/what-causes-3d-print-warping-and-how-to-prevent-it" target="_blank" rel="noopener noreferrer">warping (under-extrusion)</a>, as well as sagging, nozzle clogging, oozing, and <a href="https://www.wevolver.com/article/3d-printer-stringing" target="_blank" rel="noopener noreferrer">stringing (over-extrusion)</a>.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/under-extrusion" target="_blank" rel="noopener noreferrer"><em>How to fix under extrusion: Maintenance and print settings</em></a></strong></p><h2 dir="ltr">Calibrating E-Steps</h2><p dir="ltr">To calibrate a 3D printer’s E-steps, the following tools are required:</p><ul><li dir="ltr">Computer with slicer that allows for single-line G-code commands, such as Simplify3D or Octoprint</li><li dir="ltr">Spool of filament (non-flexible, e.g. PLA, ABS, or PETG)</li><li dir="ltr">Calipers</li><li dir="ltr">Permanent marker</li></ul><p dir="ltr">The following steps will guide you through E-step calibration. Note that these instructions are for printers with Bowden extruders running Marlin firmware, such as the Creality Ender 3.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU2OTQzNzc2ODM5LTNkX3ByaW50ZXJfc2V0dGluZ3MuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib" alt="LCD interface"><span class="fr-inner">You can calibrate E steps using the printer's LCD interface</span></span></span></p><ol><li dir="ltr">Obtain the printer’s current E-steps settings. Using the printer’s LCD interface, navigate to Control &gt; Motion &gt; E-steps/mm, and note the value. If this is not possible, use the slicer to run an M503 command, and find the value at the end of the line beginning with “echo: M92.”</li><li dir="ltr">Load the non-flexible filament. Preheat the nozzle to the required temperature for the filament and load the spool as usual.</li><li dir="ltr">Set the printer to relative mode. This can be achieved by sending an M83 command to the printer via the slicer. In this mode, all coordinates are interpreted as relative to the last position, rather than being interpreted as absolute values.</li><li dir="ltr">Measure and mark the filament. Using calipers (or a ruler), measure the 120 mm of filament immediately before the entrance to the extruder and mark it precisely using a permanent marker. This extra 20 mm should give us enough leeway to see how many millimeters of inaccuracy there are. (We can’t mark at 100 mm, because if the printer is over-extruding, the pen mark will disappear beyond sight!)</li><li dir="ltr">Extrude 100 mm of filament. There are two ways to do this. On the printer interface, navigate to Prepare &gt; Extruder &gt; Move 10mm, then change the value to 100 with the control dial. Alternatively: in the slicer software, send the command G1 E100 F100. Either method tells the printer to extrude 100 mm of filament (or, more precisely, what it&nbsp;believes&nbsp;to be 100 mm of filament).</li><li dir="ltr">Measure the actual extrusion. Now the extrusion has taken place, the mark you originally made 120 mm from the extruder entrance should — if the extruder is perfectly calibrated — now be exactly 20 mm from the extruder entrance. Measure the actual distance using calipers. If it is more than 20 mm, then the printer has been under-extruding; if it is less than 20 mm, it has been over-extruding. Make a quick calculation of 120 mm minus the distance between the extruder and your pen mark. This is how much filament the printer has actually extruded in its attempt to extrude 100 mm.</li><li dir="ltr">Calculate your new E-steps settings. We can figure out the printer’s current number of E-steps per “100 mm” by taking the value from step one (E-steps/mm) and multiplying it by 100. But what the printer interprets as “100 mm” is not actually 100 mm: we gathered the actual length extruded during step six. Now if we take the steps per “100 mm” and divide it by the actual length extruded, we get a new and accurate E-steps/mm value. (Note, however, that if your new E-steps/mm value differs from the current value by &gt;30%, you may have a clog or some kind of mechanical issue.)</li><li dir="ltr">Apply new E-steps settings. The accurate new E-step value can be implemented in two ways. Using the printer interface, navigate to Control &gt; Motion &gt; E-steps/mm, select “E-steps/mm” and input the new value. Alternatively, use the slicer to send the command M92 E[new value, to one decimal place] followed by the command M500.</li><li dir="ltr">Check that calibration is complete. Turn the printer off and on again, then repeat step one to check that the E-steps/mm has changed. If so, extruder calibration is complete. For total peace of mind, you can repeat steps 4–6 to make sure the printer is extruding exactly 100 mm when told to do so.</li></ol><h2 dir="ltr">What Is a Normal E-Steps Value?</h2><p id="isPasted">E-steps/mm refers to the number of steps the extruder motor takes to push one millimeter of filament through the system. For the most popular hobbyist FFF printer out there, the Creality Ender 3, the default E-steps value is 93 steps/mm. This works well for stock extruders but may need adjustment based on hardware changes or specific extrusion behavior.</p><p>In practice, many users find their calibrated E-steps value to be slightly higher, often ranging from 95 to 110 steps/mm. This increase is commonly due to minor differences in extruder components or slight filament slippage, which affects the actual amount of filament fed into the hotend. While it is better to not have slippage at all, it is often more convenient to account for it during E-steps calibration.</p><p>Values approaching 120 steps/mm can still be acceptable, especially for setups using less efficient extruders or softer filaments. However, if your calibration results in an E-steps value significantly above 120, it’s often a sign of a mechanical issue. Potential causes include a partially clogged nozzle, misaligned Bowden tube, or a damaged extruder gear.</p><h2 dir="ltr">What Is Flow Rate?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM2OTU0MDQxODQ4LTNkX3ByaW50ZXJfY3JlYXRpbmdfZ3JlZW5fb2JqZWN0LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="flow"><span class="fr-inner">Flow rate settings can be used to control extrusion</span></span></span></p><p dir="ltr">Flow rate is an extrusion setting that is closely related to E-steps calibration. Sometimes called an extrusion multiplier (or just “Flow” in Cura), flow rate is a setting that instructs the printer to&nbsp;extrude more or less material. It can be easily adjusted in slicing software, and is useful when dealing with a variety of different filaments: some materials require a much higher flow rate than others. Flow rate is expressed as a&nbsp;percentage, with the default value being 100.</p><p dir="ltr">If flow rate sounds an awful lot like E-steps calibration, that’s because it is. Essentially, adjusting the E-steps per millimeter and adjusting the flow rate achieves the same thing: both settings instruct the extruder stepper motor to make more or fewer steps during extrusion in order to push through more or less material.</p><p dir="ltr">The difference is that adjustment of E-steps is an essential piece of 3D printing calibration that properly sets up the printer for an&nbsp;average&nbsp;spool of filament. Flow rate, on the other hand, is a fast, simple, and temporary way to adjust the default number of E-steps per millimeter in order to accommodate&nbsp;different types&nbsp;of filament (or even just different brands of the same filament, which may behave in different ways). The flow rate is&nbsp;relative&nbsp;to the E-steps per mm value, which is itself absolute.</p><p dir="ltr">So given that E-steps and flow rate settings can achieve the same outcome, how do you know which to change? Generally, you should only need to calibrate your extruder E-steps when setting up the printer for the first time or installing a new extruder. But flow rate might need to be adjusted every time you change filament.</p><p dir="ltr">In its Cura guidelines, Ultimaker defines “Flow” like this:</p><p dir="ltr"><em>The flow is the amount of material that needs to be extruded over a specific amount of time and is based on the filament diameter and print speed. The flow is always set to 100%, which means that the extruded amount of filament will match the calculated amount. This setting is not usually changed, as the calculation is done automatically, but it can be useful when printing with experimental materials.</em>[3]</p><h2 dir="ltr">Setting the Flow Rate</h2><p dir="ltr">In order to extrude the right amount of filament for a given material, you need to set the right flow rate. Slicers like Cura have flow rates for individual materials in their respective material profiles, but it may be necessary to work out a new flow rate for an experimental material or a material that is not producing the right results with the default settings.</p><p dir="ltr">Materials that shrink a lot during extrusion tend to require a higher flow rate, while those that swell a lot require a lower rate. Flow rate can also account for marginal differences in filament diameter, as well as differences in nozzle diameter.</p><ul><li dir="ltr">In Cura, the “Flow” parameter can be found under “Material” settings. It is expressed as a percentage, with 100 the default.</li><li dir="ltr">In Simplify3D, the “extrusion multiplier” parameter can be found within “Edit Process Settings” under the “Extruder” tab. Expressed as a positive number relative to 1, the default value is 1.0.</li></ul><h2 dir="ltr">Conclusion</h2><p dir="ltr">Calibrating your 3D printer’s E-steps is a good way to ensure that the extruder is pushing through roughly the right amount of filament every time it receives an instruction. If the E-steps value is drastically wrong, you may experience issues such as over-extrusion or under-extrusion. It is therefore recommended to calibrate the E-steps per mm when setting up a printer for the first time or when changing extruders.</p><p dir="ltr">That being said, E-steps calibration is not a catch-all solution to extrusion issues. If you’re experiencing a number of printing problems, there may be other technical issues with your setup that need diagnosing independently. Furthermore, if you have gotten used to 3D printing with an uncalibrated extruder, it might take a while to re-tweak your print parameters after the calibration has taken place (by adjusting the flow rate, for example) in order to achieve the desired print quality.</p><p dir="ltr">Once you have calibrated your E-steps, your primary focus should be on adjusting the flow rate or extrusion multiplier in order to fine-tune material extrusion. Flow rate overrides the base E-steps value and is helpful when printing with experimental materials, materials that exhibit unusual shrinkage or expansion, or materials with a nonstandard diameter.</p><h2 dir="ltr">Frequently Asked Questions</h2><p id="isPasted"><strong>What are E-steps?</strong></p><p>E-steps, short for "extruder steps," refer to the number of steps the stepper motor takes to extrude one millimeter of filament. This value ensures accurate extrusion by controlling how much filament is fed into the hotend during printing. Proper E-step calibration is crucial for achieving consistent layer adhesion, precise dimensions, and high-quality prints.</p><p><strong>When is E-step calibration necessary?</strong></p><p>E-step calibration is typically required when you install new hardware, such as a different extruder, stepper motor, or a new control board. It's also necessary if you notice significant under- or over-extrusion, indicating that the current E-step value may no longer be accurate.</p><p><strong>Why does the E-step value change?</strong></p><p>E-step values can change when you replace hardware that affects the extrusion system, such as switching to a geared extruder or upgrading to a different stepper motor. Manufacturing tolerances between components can also cause slight variations in extrusion behavior, making recalibration essential after hardware upgrades.</p><p><strong>Do I recalibrate E-steps for different filaments?</strong></p><p>No, E-step calibration is not required for different filament types. Filament diameter and material properties may affect print quality, but these are typically addressed by adjusting slicer settings, such as flow rate or temperature, rather than recalibrating E-steps.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Athani VV. <a href="https://books.google.co.uk/books?id=0m8NTozFZL8C&printsec=frontcover&redir_esc=y#v=onepage&q&f=false" target="_blank" rel="noopener noreferrer">Stepper motors: fundamentals, applications and design</a>. New Age International; 1997.</p><p dir="ltr">[2] Helmer D, Voigt A, Wagner S, Keller N, Sachsenheimer K, Kotz F, Nargang TM, Rapp BE. <a href="https://publikationen.bibliothek.kit.edu/1000080642" target="_blank" rel="noopener noreferrer">Suspended liquid subtractive lithography: printing three dimensional channels directly into uncured PDMS</a>. InMicrofluidics, BioMEMS, and Medical Microsystems XVI 2018 Feb 19 (Vol. 10491, pp. 84-89). SPIE.</p><p dir="ltr">[3] <a href="https://support.ultimaker.com/hc/en-us/articles/360012610379-Material-settings" target="_blank" rel="noopener noreferrer">Material settings</a> [Internet]. Ultimaker. 2022 [cited 2022 Jul 4].&nbsp;</p>

This article explains the basics of E-step calibration for FFF printers

When setting up your 3D printer for the first time or swapping out components, knowing how to perform E-step calibration is vital for ensuring the right amount of filament gets extruded.

E-Step Calibration: How and When To Do It

ABS creates great prints with the right speed settings

As one of the most durable low-cost filaments, ABS is an essential material for most 3D printer users. But ABS print speed can be a limitation on productivity.

ABS Print Speed Limits and Other Considerations

Poor bed adhesion can lead to issues such as shrinking and warping.

From temperature settings, to print speed, to build surface, here are our suggestions for improving bed adhesion when 3D printing PETG.

9 Tips to Improve PETG Bed Adhesion

<p dir="ltr" id="isPasted">It is always discouraging when a 3D print comes off the build platform with visible defects and imperfections. Whether it’s a 3D print that has become unstuck from the print bed and <a href="https://www.wevolver.com/article/3d-print-warping" target="_blank">suffered from warping</a>, or a <a href="https://www.wevolver.com/article/3d-printer-stringing" target="_blank">print with stringing</a> or other surface irregularities: a ruined print amounts to wasted time and material costs. We’ve already addressed <a href="https://www.wevolver.com/article/3d-print-not-sticking-to-print-bed-heres-the-solution" target="_blank">how to fix problems like poor first layer bed adhesion</a>—which can lead to 3D print warping—so in this article we’ll be focusing on another type of defect: 3D print blobs &amp; zits. Keep reading to understand what causes blobs and zits and how to prevent them from happening in the future.</p><h2 dir="ltr">Identifying Blobs &amp; Zits on a 3D Print</h2><p dir="ltr">In 3D printing, blobs (also known as zits) are extrusion irregularities that appear on the surface of a 3D printed part. Blobs and zits are distinguished from other surface defects, like <a href="https://www.wevolver.com/article/z-banding-rooting-out-the-cause-and-fixing-the-3d-printing-defect" target="_blank">Z-banding</a>, by their inconsistency. Whereas Z-banding produces a ribbed pattern on the 3D print, blobs are quite literally bits of oozed filament that stick out from the print’s surface.&nbsp;</p><p dir="ltr">Blobs and zits can significantly degrade the quality of 3D prints, affecting both their appearance and functionality. These imperfections often create visible blemishes, detracting from the overall aesthetic value of the print. Furthermore, they can disrupt the fit and alignment of components, especially in cases where precision is essential, such as mechanical parts or modular designs. They key impacts of blobs and zits are:</p><ul><li dir="ltr"><p dir="ltr">Weakened Structure:</p><ul><li dir="ltr"><p dir="ltr">Blobs and zits can introduce inconsistencies in layer adhesion, reducing the strength and durability of the print.</p></li><li dir="ltr"><p dir="ltr">They can also create stress points, making the print more prone to cracking or breaking under load.</p></li></ul></li><li dir="ltr"><p dir="ltr">Poor Aesthetics:</p><ul><li dir="ltr"><p dir="ltr">Surface imperfections like blobs and zits are especially noticeable on smooth or curved surfaces, diminishing the visual appeal.</p></li><li dir="ltr"><p dir="ltr">These defects often require post-processing to correct, such as sanding, filling, or painting.</p></li></ul></li><li dir="ltr"><p dir="ltr">Potential for Part Failure:</p><ul><li dir="ltr"><p dir="ltr">Blobs and zits may interfere with moving parts, causing mechanical issues.</p></li><li dir="ltr"><p dir="ltr">They can can disrupt tolerances, leading to misalignment or improper functioning of assembled pieces.</p></li></ul></li></ul><h2 dir="ltr">What causes 3D printing blobs and zits?</h2><p dir="ltr">There are a number of potential issues that can be causing blobs and zits, all of which can be fixed by fine tuning printer settings.[1] Below are the leading causes of 3D print blobs and zits.</p><h3 dir="ltr">Over-extrusion</h3><p dir="ltr">3D print blobs &amp; zits are primarily caused by <a href="https://www.wevolver.com/article/over-extrusion" target="_blank">over-extrusion</a> and the motion of the filament extruder. If, for example, you are printing a part with a circular perimeter, blobs can occur when the print head returns to its starting position. The material builds up at this point, which can result in the formation of a filament blob. Similarly, if the 3D printer extruder starts and stops several times over the course of a 3D print job, blobs and zits can also occur.&nbsp;</p><h3 dir="ltr">Retraction</h3><p dir="ltr">Blobs and zits can also be caused by 3D printer nozzle retraction. In the FDM 3D printing process, retraction is a technique in which the hot end briefly pulls filament back instead of extruding it out. This method is used to reduce unwanted material extrusion, like stringing, as the print head moves to a new print location. However, if the <a href="https://www.wevolver.com/article/cura-retraction-settings" target="_blank">retraction settings</a> on your 3D printer are not optimized, the process may actually have a negative effect, causing blobs or zits.</p><h3 dir="ltr">Nozzle Temperature</h3><p dir="ltr">Other 3D printer settings, such as nozzle temperature, can also increase the risk of blobs. For example, if the nozzle temperature is too high, filament can come oozing out too quickly and create defects on the print surface. (On the flip side, if nozzle temperatures are too low, it can cause other issues like clogs, poor layer bonding, poor dimensional accuracy, and structural weaknesses.)</p><h3 dir="ltr">Print Speed</h3><p dir="ltr">Printing speeds can also be a factor if they are too fast and don’t allow for sufficient cooling time between layers. In other words, if new layers are deposited before the underlying layer of filament has had time to adequately solidify, it can be squished and deformed by the weight of the layers above it.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/3d-print-warping" target="_blank">What Causes 3D Print Warping and How to Prevent It</a></strong></p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 692px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjUwOTQ1OTQzOTE0LTNkX3ByaW50aW5nLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="624" height="459" class="fr-fic fr-dii" alt="3D printer nozzle extruding red filament" style="width: 690px;"><span class="fr-inner">If the 3D printer nozzle is too hot it can cause over-extrusion resulting in blobs and zits.</span></span></span></p><h2 dir="ltr" id="isPasted">What can you do to prevent 3D printing blobs?&nbsp;</h2><p dir="ltr">Fortunately, there are a number of ways to minimize the risk of blobs and zits in FDM 3D printing. Below are five key strategies you can try to prevent the 3D printing defects from occurring.</p><h3 dir="ltr">Adjust Retraction Settings</h3><p dir="ltr">In slicer software, you can adjust retraction settings to control how much filament is pulled back into the nozzle and at what point this happens. Finding the right retraction settings can minimize material buildup either at the beginning of the print head’s path along the part perimeter or as it completes a layer and rejoins its starting position (for this, see coasting settings below).</p><p dir="ltr">In general, it is advisable to use a smaller retraction distance (this is the amount of filament pulled back into the nozzle). This is because if too much filament is retracted, air can also be pulled into the nozzle. When the printhead then goes to extrude filament, the air is heated along with the filament, which can cause extrusion inconsistencies, like blobs and bubbles on the print surface. Too little retraction, however, can lead to over-extrusion and defects like stringing and blobs and zits. It’s all about finding the sweet spot, so you might need to try out a few different retraction distance settings. The amount of retraction will also depend on the type of FDM 3D printer: systems with direct drive extruders only require a retraction distance between 0.5 mm to 2 mm. Bowden extruder systems, on the other hand, can require higher retraction values, as much as 15 mm.[2]</p><p dir="ltr">Retraction speed is also worth mentioning. This setting controls how quickly the filament is pulled back into the nozzle. If the retraction speed is too slow, your print may suffer from oozing filament. A standard range for retraction speed is between 20 mm/second and 100 mm/second.</p><h3 dir="ltr">Activate Coasting Settings</h3><p dir="ltr">Coasting is a setting built in to most 3D printing slicer programs, including Simplify3D and Cura. Coasting is often found under retraction settings and controls if the print head stops extruding filament at the end of each layer perimeter. Coasting is therefore helpful in reducing blobs or zits that are caused by filament buildup when the extruder comes back to its starting point.</p><p dir="ltr">When you activate coasting, the slicing program will essentially tell the 3D printer nozzle when to stop extruding filament—usually this will be triggered a fraction of a millimeter before the printhead completes the part’s perimeter. Coasting therefore anticipates that there will be over-extrusion when the printhead stops extruding and stops the buildup of material at these starting/ending locations. Coasting also helps to relieve pressure inside the nozzle that causes over-extrusion. It is advisable to begin with a smaller coasting distance, such as 0.2 mm, and increase the value incrementally until you no longer see blobs appearing on the part’s surface.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 690px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjUwOTQ2MDg3MjYxLTNkX3ByaW50dGVyX3NldHRpbmdzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="624" height="448" class="fr-fic fr-dii" alt="3D printer extruding yellow filament"><span class="fr-inner">Coasting and retraction settings can help to minimize blobs and zits if used properly.</span></span></span></p><h3 dir="ltr">Wiping and Shell Settings</h3><p dir="ltr">Another group of <a href="https://www.wevolver.com/article/ender-3-v2-max-speed" target="_blank">slicer settings</a> that can help minimize blobs and zits are the wipe parameters. With wiping activated, the 3D printer will drag the nozzle at the end of every printed layer along the outer wall of the printed part to remove any material buildup. With this setting, it is common for retraction to happen simultaneously, which can help prevent blobs and zits. A typical wipe distance—the length that the nozzle will wipe along the outer wall—is 0.4 or 0.5 mm. Wiping can also help to reduce the appearance of the z-seam.</p><p dir="ltr">Because 3D print blobs and zits are primarily an aesthetic issue on the outer shell of a part, tuning your 3D printer’s shell parameters can improve the overall print quality by preventing or covering up blobs and zits. For instance, simply activating the “outer before inner wall” setting in your slicer can improve the quality of the part’s outer shell. This setting tells the 3D printer to extrude the outer layers of a part before printing the inner structure and infill. Not only can this reduce the risk of blobs and blemishes, it can also improve the dimensional accuracy of your print.</p><h3 dir="ltr">Adjust Print Temperature and Speed</h3><p dir="ltr">As we saw, a too-hot print head can lead to over-extrusion, and rapid printing speeds can lead to defects like blobs and zits due to lack of cooling. Therefore, lowering the print temperature and print speed can help to reduce the risk of blobs and zits. The temperature of your nozzle will depend on the type of filament you are 3D printing. For example, PLA filament typically requires <a href="https://www.wevolver.com/article/pla-bed-temperature" target="_blank">a nozzle temperature of between 200-210 °C.</a>[3] If blobs are still occurring in this range, try lowering the nozzle temperature in 5°C increments.</p><p dir="ltr">Reducing the print speed can also reduce the occurrence of blobs and zits. In general, a lower printing speed can improve print quality because the nozzle has more time to deposit the filament and the extruded layer has more time to cool before the next layer is applied. Try reducing your print speed by 5 to 10 mm/s to see if that helps minimize the appearance of blobs.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/abs-bed-temperature" target="_blank">ABS print temperature considerations: Nozzle, bed, enclosure</a></strong></p><h3 dir="ltr">Adjust Fan Settings</h3><p dir="ltr">In addition to finding the right print head temperature, you can also reduce the risk of 3D print blobs and zits by increasing your 3D printer’s fan speeds. (Or, if your 3D printer doesn’t have a built-in fan, it can help to integrate one.) A fan helps to regulate the temperature of the 3D printing environment and can help prevent overheating.&nbsp;</p><p dir="ltr">This, in turn, ensures that the layers of melted thermoplastic that are deposited onto the print bed are cooled and solidified at a controlled rate. Because over-extrusion and squished print layers are two potential causes of blobs and zits, increased cooling in the print chamber using fans can promote better quality prints. Of course, over-cooling your print environment can also impact layer adhesion—it’s all about finding a balance.</p><p dir="ltr">Here’s a table summarizing the five aforementioned strategies:</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>Strategy</strong></p></td><td><p dir="ltr"><strong>Description</strong></p></td><td><p dir="ltr"><strong>Adjustment Range/Notes</strong></p></td></tr><tr><td><p dir="ltr"><strong>Adjust Retraction Settings</strong></p></td><td><p dir="ltr">Controls how much filament is pulled back into the nozzle to reduce material buildup.</p></td><td><p dir="ltr">Retraction distance: 0.5 mm to 2 mm for direct drive, and up to 15 mm for Bowden. Retraction speed: 20–100 mm/s.</p></td></tr><tr><td><p dir="ltr"><strong>Activate Coasting Settings</strong></p></td><td><p dir="ltr">Stops filament extrusion slightly before the printhead completes a layer perimeter to reduce buildup.</p></td><td><p dir="ltr">Start with 0.2 mm coasting distance and adjust as needed.</p></td></tr><tr><td><p dir="ltr"><strong>Wiping &amp; Shell Settings</strong></p></td><td><p dir="ltr">Wiping removes excess filament from the nozzle; shell settings help cover blemishes.</p></td><td><p dir="ltr">Wipe distance: 0.4–0.5 mm. Shell before infill for improved finish.</p></td></tr><tr><td><p dir="ltr"><strong>Adjust Print Temperature &amp; Speed</strong></p></td><td><p dir="ltr">Lower temperatures and slower speeds reduce over-extrusion and give filament time to cool.</p></td><td><p dir="ltr">Lower nozzle temperature by 5°C increments. Speed: Reduce by 5–10 mm/s.</p></td></tr><tr><td><p dir="ltr"><strong>Adjust Fan Settings</strong></p></td><td><p dir="ltr">Increased fan speed helps cool the print layers faster, preventing overheating and over-extrusion.</p></td><td><p dir="ltr">Increase fan speed but avoid over-cooling to maintain layer adhesion.</p></td></tr></tbody></table></div><p dir="ltr">Each of these strategies targets specific factors contributing to blobs and zits, improving overall print quality.</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">In the end, the first step to preventing 3D printing defects like blobs and zits is to understand where they come from. Factors like temperature, calibration, and slicer settings can be the cause and solution to blobs and zits. So if you’re experiencing imperfections in your 3D print’s outer shell, be sure to play with your retraction, coasting, and wipe settings, as well as adjust your nozzle print temperature. It may take some time to find the right combination of settings for a given material, so start out with a small test print. The results will be worth it!&nbsp;</p><h2 dir="ltr">Frequently Asked Questions (FAQs)</h2><p dir="ltr"><strong>Q: How can I identify blobs and zits on a 3D print?<br></strong></p><p dir="ltr">A: Blobs and zits appear as small, raised lumps of excess filament on the print's surface, which are often irregular in shape. Look for uneven layers, especially around corners, edges, or smooth surfaces, where the extruder may have released too much material.</p><p dir="ltr"><strong>Q: How do blobs and zits affect the quality of a 3D print?<br></strong></p><p dir="ltr">A: Blobs and zits can weaken the print’s structure by causing poor layer adhesion, making it more prone to cracking or breaking. They also reduce the visual appeal of the print and can interfere with part alignment, potentially leading to mechanical issues or misfit components in assembled designs.</p><p dir="ltr"><strong>Q: What causes blobs and zits in 3D printing?</strong></p><p dir="ltr">A: Blobs and zits in 3D prints are often caused by over-extrusion, improper retraction settings, high nozzle temperature, or excessive print speed. These issues can lead to excess filament being deposited at certain points, causing raised lumps or irregularities on the surface of the print.</p><p dir="ltr"><strong>Q: How does over-extrusion cause blobs and zits?</strong></p><p dir="ltr">A: Over-extrusion happens when too much filament is pushed out during printing, especially at start/stop points or circular perimeters. This results in material building up and forming blobs or zits, particularly when the print head returns to its starting position or moves over areas multiple times.</p><p dir="ltr"><strong>Q: How do retraction settings affect blobs and zits in 3D prints?<br></strong></p><p dir="ltr">A: Incorrect retraction settings can lead to blobs and zits when the nozzle pulls filament back too much or not enough during travel moves. If retraction is not optimized, excess material may be extruded at the wrong time, causing unwanted surface defects.</p><p dir="ltr"><strong>Q: What is coasting, and how can it help prevent blobs and zits?</strong></p><p dir="ltr">A: Coasting is a setting that stops filament extrusion just before the printhead completes a layer. This prevents excess material from building up at the start/stop points of a print, minimizing blobs or zits. Start with a small coasting distance, such as 0.2 mm, and increase it incrementally until the surface imperfections are reduced.</p><p dir="ltr"><strong>Q: How can adjusting print temperature and speed reduce blobs and zits?</strong></p><p dir="ltr">A: Lowering the print temperature and speed can help prevent blobs and zits. If the nozzle is too hot, filament may ooze out too quickly, causing defects. Try reducing the temperature in 5°C increments if blobs persist. Slower print speeds allow the material to cool properly, reducing the risk of squished layers or over-extrusion, both of which contribute to blobs and zits.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] MorCh N. Analysis of the Effects of Basic Printer Settings on PLA 3D Prints (Doctoral dissertation, Massachusetts Institute of Technology).</p><p dir="ltr">[2] Simplify3D, 2022. “Stringing or Oozing.” [Internet] <a href="https://www.simplify3d.com/support/print-quality-troubleshooting/stringing-or-oozing/" target="_blank">https://www.simplify3d.com/support/print-quality-troubleshooting/stringing-or-oozing/</a> [Accessed April 20, 2022].</p><p dir="ltr">[3] Ultimaker, May 28, 2021. “How to Print with Ultimaker PLA.” [Internet] <a href="https://support.ultimaker.com/hc/en-us/articles/360011952740-How-to-print-with-Ultimaker-PLA" target="_blank">https://support.ultimaker.com/hc/en-us/articles/360011952740-How-to-print-with-Ultimaker-PLA</a> [Accessed April 21, 2022]</p>

Prevent 3D print blobs and zits by adjusting temperature and slicer settings.

Surface imperfections on a 3D print can be frustrating but they’re not insurmountable. Here is how to prevent and fix 3D print blobs and zits by adjusting 3D printer and slicer settings.

How to Prevent 3D Print Blobs & Zits

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