Kapsula is an innovative solution designed to provide extreme protection for electronic devices in harsh environments. Utilizing advanced materials like polyphenylene sulfide reinforced with carbon fiber (PPS CF), Kapsula offers unparalleled durability against physical impacts, high temperatures

Kapsula: Extreme Protection for Sensitive Devices

<h2 id="isPasted">Project overview</h2><h3>Purpose</h3>The purpose of this project was to demonstrate the multilayer capability of <a href="https://www.voltera.io/nova">Voltera NOVA</a>. We printed a blue light-emitting pattern — the Voltera logo — on two substrates: paper and PET separately, using electroluminescent ink.<iframe src="https://www.youtube.com/embed/Yc8nEoVnpDY?&amp;wmode=opaque&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" style="width: 640px; height: 450px;">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</iframe><h3 id="isPasted">Design layout</h3>Electroluminescence operates by exciting a phosphor material with an electric field. An inverter is needed to convert the direct current from the power source into alternating current.Based on this mechanism, our design positions a phosphor layer between two conductive layers, incorporating a dielectric ink layer to insulate the phosphor. The printing sequence is as follows:<ul><li>Layer 1: Base conductive layer&nbsp;</li><li>Layer 2: Dielectric layer&nbsp;</li><li>Layer 3: Phosphor layer</li><li>Layer 4: Top conductive layer</li></ul><h3>Layer overview</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492862692-67091c8ba38b9d9305e349bd_67091ae09acab270adbdf20e_Printing-electroluminescent-ink-paper-pet-layer-overview.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Desired outcome</h3>Once connected to an alternating current (140 V, 1.862 kHz), the phosphor layer emits blue light, illuminating the Voltera logo with an even glow across both prints.<h3>Functionality</h3>We determined the Voltera logo would be suitable for this project. It is feasible to incorporate designs into larger electronic applications, including billboards, branded merchandise, and control panels.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492887115-67091c8ca38b9d9305e34a1b_67091b02bdc7f308274e583c_Printing-electroluminescent-ink-paper-pet-functionality.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Final print on paper <h2 id="isPasted">Printing the electroluminescent Voltera logo</h2><h3>Base conductive layer</h3>This layer consists of a Voltera logo pattern (55.5 mm L × 19.75 mm W) and positive and negative traces that connect to power and ground terminals.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492929241-67091c8ba38b9d9305e349c3_67091b1d9aa70f5ad577fd0b_Printing-electroluminescent-ink-base-conductive-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: NOVA settings, base conductive layer <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492948899-67091c8ba38b9d9305e349d2_67091b3ba4c7564aec9fc4c0_Printing-electroluminescent-ink-base-conductive-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on paper, base conductive layer<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492971049-67091c8ca38b9d9305e34a00_67091b566f34a25480b46ae4_Printing-electroluminescent-ink-base-conductive-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on PET, base conductive layer<h3 id="isPasted">Dielectric layer</h3>This layer features a dielectric Voltera logo pattern which measures 23 mm L × 15 mm W and two dielectric pads. These extra pads help ensure the top conductive layer is appropriately insulated.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493165129-67091c8ba38b9d9305e349c0_67091b7716905ac65aa4e290_Printing-electroluminescent-ink-dielectric-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: NOVA settings, dielectric layer<h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493233623-67091c8ba38b9d9305e349cf_67091b9107b512cf5a4ae562_Printing-electroluminescent-ink-dielectric-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on paper, dielectric layer </h3><h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493246956-67091c8ca38b9d9305e34a15_67091bafbdc7f308274eea1a_Printing-electroluminescent-ink-dielectric-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on PET, dielectric layer</h3><h3 id="isPasted">Phosphor layer</h3>This layer contains a Voltera logo pattern, slightly smaller than the dielectric layer (by 0.5 mm each way), printed with blue light-emitting ink.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493315418-67091c8ba38b9d9305e349c9_67091bcf07c69e92aba81f70_Printing-electroluminescent-ink-phosphor-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: NOVA settings, phosphor layer<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493337007-67091c8ba38b9d9305e349d5_67091be50886a22f6b31099d_Printing-electroluminescent-ink-phosphor-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on paper, phosphor layer<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493358134-67091c8ca38b9d9305e34a1e_67091c028b83f4ea5977853c_Printing-electroluminescent-ink-phosphor-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on PET, phosphor layer<h3 id="isPasted">Top conductive layer</h3>Lastly, this layer includes a conductive overlay with an opening at the bottom left to prevent short circuiting. It measures 29.5 mm L × 21.5 mm W and connects to the ground terminal.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493385109-67091c8ba38b9d9305e349db_67091c23c63ef691b7477c26_Printing-electroluminescent-ink-top-conductive-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: NOVA settings, top conductive layer<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493412343-67091c8ca38b9d9305e34a12_67091c394819899b375fb8eb_Printing-electroluminescent-ink-top-conductive-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on paper, top conductive layer<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493430542-67091c8ca38b9d9305e34a18_67091c534ec56a943f81fc4f_Printing-electroluminescent-ink-top-conductive-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Result on PET, top conductive layer<h2 id="isPasted">Challenges and advice for printing multilayer electroluminescent displays</h2><h3>Trapped air</h3>Air bubbles can form in inks that have been left unused for an extended period. These bubbles caused the dielectric layer to break when we cured it in the oven.&nbsp;Mixing the ink with a dual asymmetric centrifugal mixer before printing will eliminate air bubbles. Additionally, it is recommended to allow the dielectric layer to dry naturally at room temperature instead of curing it in an oven.&nbsp;<h3>Uneven glow&nbsp;</h3>During our experiments, some prints exhibited dark areas, leading to an uneven glow. This issue can arise from several factors:&nbsp;<ul><li>The top conductive layer being too thick</li><li>The phosphor layer being too thin or getting scratched off during dispensing of the ink for the top conductive layer</li><li>Irregularities in print height</li></ul>Adding fiducials to each layer helps improve alignment and print quality. In terms of print settings, if the layer is too thick, increasing the print speed, reducing the height (we reduced it to approximately 40 µm), and using a smaller nozzle can be helpful. If the layer is too thin, try to reduce the print speed.&nbsp;Furthermore, in multilayer projects, changes in height can happen drastically when printing over existing traces. Setting a low probe pitch will make the height map more accurate, ensuring the height transition at the edges of features is accurate and reducing the risk of traces being printed off-course.<h2>Conclusion</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493470103-67091c8ca38b9d9305e34a03_67091c71bdc7f308274f8ff7_Printing-electroluminescent-ink-paper-pet-conclusion.webp" style="width: 100%px;" class="fr-fic fr-dib">Image: Electroluminescent logo final printThe paper substrate provided consistent results throughout our experimentation, due to its absorbent nature. Each layer was smoother on paper than on PET, highlighting the potential of using paper as a substrate in EL display applications. &nbsp;On the other hand, PET, being flexible and chemically resistant, offers the advantage of suitability for more demanding use cases. As demonstrated by this project, with careful attention and fine-tuning of the print settings, the results of EL display on PET are equally impressive.EL displays are also intriguing when printed on glass and other non-conductive substrates. As we continue to explore the possibilities of electroluminescent inks, we invite you to view the&nbsp;<a href="https://www.voltera.io/applications">other projects</a> we’ve completed.

Due to their consistent brightness, low cost and high energy efficiency, electroluminescent inks are used in a wide range of electroluminescent display applications. This project is an example of printing an electroluminescent ink on soft and flexible substrates.

Printing Electroluminescent Ink on Paper and PET

Additive manufacturing and material deposition with inkjet is a rapidly expanding field in which inkjet printheads are used to selectively deposit materials onto substrates. While certain versions of inkjet technology are already being used to deposit low-viscosity inks, new developments are moving the goalposts of what is possible.Thanks to precise droplet control, inkjet technologies are known for their ability to produce fine details and precise coverage quickly and consistently. However, they are limited by their dependence on low-viscosity materials. Thicker fluids — many of which have desirable properties — are difficult to move through tiny channels, descender passages, and nozzles, regardless of the inkjet technology. To date, even the most advanced inkjet printheads have not been able to deposit materials with a viscosity greater than 100 mPa·s (millipascal seconds).Viscosity limitations in inkjet technology have historically seen manufacturers turn to alternative methods like screen printing, flexography, and lithography.&nbsp;But while these technologies can handle high-viscosity inks and fluids, they have shortcomings like material waste, high pressure on substrates, and a high cost of job preparation. In response to this dilemma, inkjet trailblazer Quantica has developed a game-changing solution for the inkjet printing of high-viscosity materials, exploiting the key advantages of inkjet while overcoming its biggest limitation.<h1 dir="ltr">Quantica’s Unique Technology: The NovoJet™ Printhead</h1><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1MzUwNzg3MDEzLUEuIFByaW50aGVhZCBGdWxsIEJhY2tncm91bmQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The Quantica NovoJet™ PrintheadThe central feat of engineering on which Quantica’s catalog of products and services is built is the NovoJet™ Printhead, a 96-nozzle digital printhead capable of jetting materials with a viscosity up to 250 mPa·s at jetting temperature — significantly higher than any other printhead on the market.This unprecedented jetting power comes from a unique actuator design and material recirculation. The novel actuator design produces displacement 100x greater than in a conventional piezo printhead, enabling productive deposition of high-viscosity materials at high frequencies. Meanwhile, high-flow recirculation prevents particle settling, even when dispensing inks and fluids with particle sizes up to 5 µm. This smart printhead design has enabled inkjet deposition of materials with a viscosity of up to 250 mPa·s at jetting temperature and, in one successful trial,&nbsp;a material showing 13,000 mPa·s at room temperature (made possible by a drastically drop in viscosity of such fluid when heated by the printhead). That means the technology can process previously un-jettable materials such as adhesives from Henkel LOCTITE®, paints with very high pigment loading, and industrial coatings.In every respect, the Quantica NovoJet™ printhead is a top-of-the-line inkjet printhead capable of precise droplet control. Following on from a production partnership agreement signed in 2023,&nbsp;pre-production of the devices has started at Xaar, leveraging the British company’s state-of-the-art facilities and printhead production knowledge.The NovoJet™ Printhead at a glance:<ul><li dir="ltr">Nozzle count: 96</li><li dir="ltr">Nozzle pitch: 1.27 mm</li><li dir="ltr">Frequency:&nbsp;8kHz</li><li dir="ltr">Max viscosity (jetting temp): 250 mPa·s</li><li dir="ltr">Max room temp viscosity of a jetted material: 13,000 mPa·s</li><li dir="ltr">Operating temperature: 25–80°C</li></ul><h1 dir="ltr" id="isPasted">Adaptable, Modular, Integrated Technology</h1><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1MzUwODc5NDE1LUNvcHkgb2YgTm92b0pldCBQcmludGVyLTIwMjMxMTA1LUlNR18xOTIwLUVkaXQgKDEpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The Quantica NovoJetTM OPEN PrinterWhile the NovoJet™ Printhead forms the basis of all Quantica technology, the company offers a range of products and services that enable customers and partners to go from initial dropwatching and process development all the way to manufacturing integration.&nbsp;Soon, the NovoJet™ Printhead will&nbsp;be deployed in three different systems, each of which serves a distinct purpose on a customer’s journey from material selection to at-scale manufacturing.Since most customers will never before have had the ability to jet materials with a viscosity of up to 250 mPa·s, Quantica is also offering comprehensive application development services, working with partners to carry out material qualification, jetting trials, and printing trials. This effectively allows companies to fast-forward through independent validation and experimentation, using Quantica’s expertise with its systems to develop a reliable process for the relevant materials.<h2 dir="ltr">NovoJet™ JetPack</h2>The JetPack, which has already begun shipping to customers, is a material testing and development tool that enables users to validate materials for use with the NovoJet™ Printhead and its associated hardware. Designed to work with dropwatching systems like ImageXpert’s JetXpert, the JetPack allows for close analysis of jetting and droplet behavior.&nbsp;<h2 dir="ltr">NovoJet™ OPEN Printer</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1MzUxMTk0NDM5LVAxMTIyNTg5ICgyKS5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 832px;" class="fr-fic fr-dib">Multi-material and multi-color samples printed on NovoJetTM OPEN PrinterOnce customers have validated their materials, they can proceed to application development, multi-material experimentation, and low-volume production with the NovoJet™ OPEN Printer, a benchtop printer that can hold up to seven active printheads. The open system allows for intuitive adjustment of jetting and printing parameters.<h2 dir="ltr">Print Engine</h2>The NovoJet™ Printhead can be integrated directly into production lines using the Quantica Print Engine— currently in development with&nbsp;expected trials in 2025&nbsp;—. These printhead equipped units can form part of an integrated, all-in-one system or an inline unit that can be added to an existing production line, allowing manufacturers to replace inefficient processes&nbsp;like screen printing.<h1 dir="ltr">Material Development Possibilities</h1>Quantica has developed a technology for the inkjet printing of high-viscosity materials. However, it’s up to customers to decide which specific materials they wish to validate and print. Such materials may deliver desirable properties such as durability, conductivity, biocompatibility, or UV resistance.Customers seeking to independently develop and validate materials for inkjet printing via the NovoJet™ Printhead can use the Jetpack material testing tool to try out material configurations, adjusting jetting parameters to optimize fluid behavior and compatibility. Alternatively (or additionally), customers can outsource their material qualification and application development to Quantica, leveraging the company’s expertise in conducting jetting and printing trials. Quantica is currently partnered with Fraunhofer IPA in this area, with further qualification and application development partnerships set to be announced later this year.<h1 dir="ltr">The Transformative Potential of High-Viscosity Inkjet Printing</h1><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1MzUxNTg2MjY3LXF1YW50aWNhLTEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1MzUxNTkzMDk2LXF1YW50aWNhLTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Industrial adhesive selectively printed on different substratesWhile many of these applications can be realized using traditional techniques like dispensing, screen printing, and slot-die coating, those methods lack the droplet-level control of inkjet and suffer from other limitations like slowness, lack of multi-material deposition, and material wastage.Thanks to the wide range of materials that can be successfully jetted using Quantica hardware, some potential applications include:<ul><li dir="ltr">Paints with higher pigment loading</li><li dir="ltr">Industrial coatings</li><li dir="ltr">Adhesive and various epoxies</li><li dir="ltr">Insulating and encapsulating layers</li><li dir="ltr">Packaging and labeling coatings</li><li dir="ltr">PCBs and semiconductors using conductive composites</li><li dir="ltr">Printed electronics</li><li dir="ltr">Digital displays</li><li dir="ltr">Translucent or optical materials</li><li dir="ltr">Biomedical devices - including multi-material dentures&nbsp;</li></ul>The design freedom, non-contact nature, and speed of inkjet printing compared to traditional methods — in addition to its fully digital operation that allows for rapid iteration and refinement — will have a significant impact on productivity, potentially transforming mass production of parts like PCBs and fuel cells.<h1 dir="ltr">Conclusion</h1>Introducing high-viscosity printing capabilities radically transforms the nature of inkjet printing. With users of the technology now able to discover and experiment with previously un-jettable materials, inkjet is becoming a genuine manufacturing technology as much as a printing technology, taking its purview beyond text and image printing to the fabrication of functional, multi-material, multi-layer components.<a href="https://www.q3d.io/contact" target="_blank">Arrange a call with Quantica</a> to see how NovoJet™ can change your business.<h2>References</h2>1. Castrejon-Pita JR, Baxter WR, Morgan J, Temple S, Martin GD, Hutchings IM. Future, opportunities and challenges of inkjet technologies.&nbsp;Atomization and sprays. 2013;23(6).

Inkjet printing innovator Quantica has developed a printhead that can print previously un-jettable materials. The technology has implications for the printing of adhesives, coatings, and functional materials.

Quantica Breaks Through Inkjet's Viscosity Ceiling to Deliver Multi-Material Printing of Novel Materials

How to extend the pot life of silicone to several months without changing its material properties? Ulrich Trog [Ulrich.Trog@joanneum.at | JOANNEUM RESEARCH] explains in this article how this is possibleJOANNEUM RESEARCH offers the formulation of the appropriate compound based on feasibility studies of the silicones used by its customers. Licences for the Supresil™ technology are available.Platinum (Pt)-cured silicones are gaining in popularity, emphasising addition curing over traditional peroxide methods. This process ensures purity and efficacy, resulting in products with increased strength and superior aesthetics. The rise of Pt-curing marks a significant shift in silicone manufacturing techniques, promising unmatched quality and durability in a variety of applications. When crosslinking is initiated, the curing process starts almost immediately and the resulting silicone typically has a pot life limited to a maximum of a few hours at room temperature. This places significant&nbsp;practical and technological limitations on its use:<ul><li style="font-weight: bold;">short processing time</li><li style="font-weight: bold;">anufacturing waste</li><li style="font-weight: bold;">difficult reproducibility</li><li style="font-weight: bold;">inflexible manufacturing process</li></ul>Our patented formulation greatly increases pot life via reversible inhibition of the crosslinking via hydrosilylation. After deposition, the inhibitors evaporate easily. Normal crosslinking occurs at mild temperatures, even below 80 °C, leading to a fast and complete curing.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1MDMxNDE2LVNjcmVlbnNob3QgMjAyNC0wNC0wMyAwODM1MjcuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Join the Future of Electronics RESHAPED event in Boston on 12 &amp; 13 June 2024. Learn more <a href="https://www.techblick.com/electronicsreshapedusa" target="_blank" rel="noopener noreferrer">https://www.techblick.com/electronicsreshapedusa</a>Benefits<ul><li>reduces production costs: the pot life of silicone mixtures can be extended to several months and beyond</li><li>enables (3D) printing: shelf stable, 1-component silicone inks can be formulated for use with a variety of printing processes including processes like dispensing, screen-printing, aerosoljet-printing, inkjet printing and others</li><li>no change in material properties: through the complete and trace-free removal of the inhibitor during the curing process there is no change in the material or its properties</li><li style="font-weight: bold;">applicable to liquid Silicone rubber (LSR) and high consistency rubber (HCR)</li><li>suitable for all Pt-cure resins: no curing at processing temperature and normal curing at curing temperature, orthogonal with other inhibitors</li><li>environmental: reduction in waste generation in production process</li></ul>Application examples<ul><li>LED production: Supresil™ resins reduce the processing efforts and increase the yield of colour conversion materials without changing their optical properties. The Supresil™ inhibited silicones can be mixed with colour conversion phosphors in large batches, increasing the accuracy and consistency of the colour conversion composites through improved wetting and distribution of the dispensed material and a better dispersion of the phosphors.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1MjMxMzE4LXVubmFtZWQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><ul><li>3D printing: Standard LSR formulations are optimised for extrusion and injection moulding machines and are not suitable for 3D printing. By adjusting the rheological behaviour and extending the pot life using JOANNEUM RESEARCH‘s proprietary reversible curing inhibition, 3D printing is now possible.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1MjgxMjMxLXVubmFtZWQgKDEpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">All material properties of the silicones are preserved (through complete and trace-free removal of the inhibitor):<ul><li>physical: shrinkage, Shore hardness, storage modulus</li><li>optical: UV/VIS transmission, no „yellowing“, refractive index</li><li>biocompatibility: relevant for medical grade resins / formulations</li><li>unaltered production: viscosity, reproducibility</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM2MTQzMjU0LXVubmFtZWQgKDYpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Fig. 1: Comparison of curing dynamics of standard silicone resins with SupresilTM inhibited resins<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1ODI4NTM0LVNjcmVlbnNob3QgMjAyNC0wNC0wMyAwODQyNTAuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><a href="https://www.techblick.com/exhibitors-2024-berlin" target="_blank" rel="noopener noreferrer">We are Exhibiting in Berlin!</a> Come and visit our booth<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM1OTA5NzAxLXVubmFtZWQgKDMpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Fig. 2: UV/VIS Transmission of cast silicones (100 µm) for the LED productionJOANNEUM RESEARCH is a publicly owned, Austrian Research and Technology Organisation. It is successful nationally and internationally in the fields of “Information and Production Technologies”, “Human Technologies and Medicine” and “Society and Sustainability”AUTHOR: Ulrich Trog [Ulrich.Trog@joanneum.at |JOANNEUM RESEARCH]&nbsp; <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM2MDU0MjI5LXVubmFtZWQgKDQpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">All images: © JOANNEUM RESEARCH<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMTM2MTA3NzU0LXVubmFtZWQgKDUpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">&nbsp;&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712137051266-Screenshot+2024-04-03+084405.jpg" style="width: 100%px;" class="fr-fic fr-dib">&nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;<a href="https://www.techblick.com/" target="_blank" rel="noopener noreferrer">TechBlick.com</a>

How to extend the pot life of silicone without change in properties for applications in 3D Printing, LED lighting, LED backlights, and others

Extending the pot life of silicones to several months: LEDs, 3D printing and beyond

This article is a chapter from our comprehensive report on 3D printing with wear-resistant plastics. &nbsp;If you're interested in diving deeper and accessing the full report, we invite you to <a href="https://www.wevolver.com/article/the-engineers-guide-to-3d-printing-with-wear-resistant-plastic-materials/draft" target="_blank" rel="noopener noreferrer"></a>download it for free below. Gain a holistic understanding and benefit from the complete insights we've gathered. Don't miss out!<iframe width="540" height="305" src="https://c8056756.sibforms.com/serve/MUIFAI3PJfiab43rzSudutrE1NSBLWBrIYMuTLjuk7V8EDM15HG0D1C6wjdMHZMiff18ZTqCrBhOkxMaCwPGCk91mWqwuJKESYPi5C21fZjDAFoFa8ZDKmVUuECd05z1jZyX_SNjhMolzGuDIRFD1yvyWVOk7LzkFEgXffPqTznKc-H6-CFw0r9KIcY9W66Oq2bcIK4X1RZRsLl1" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block;margin-left: auto;margin-right: auto;max-width: 100%;" class="fr-draggable"></iframe> <h2>Unlocking the material potential</h2>3D printing has long promised to solve a variety of engineering challenges. With its low startup costs, short lead times, and high level of geometrical freedom, additive manufacturing can help engineers find new and innovative solutions in prototyping and production.Materials play a big role in the identification and execution of these solutions. However, few 3D printing materials are developed to fill a highly specific engineering need. Instead, most materials are designed to suit a range of applications and industries, promising broadly desirable attributes like tensile strength, printability, or flexibility. The few specialty materials on the market include products like ESD-safe powders and flame-retardant filaments.Cologne-based plastics specialist igus is one company making 3D printing materials that solve a genuine engineering challenge. The bearings expert has developed a range of 3D printing filaments, powders, and resins with unique tribological properties. Solid lubricant additives make these materials exceptionally wear-resistant, giving them sliding performance unlike anything else on the additive manufacturing materials market.This article serves as an introduction to 3D printing with wear-resistant plastics for motion and sliding applications, looking at why these products exist, how they can be exploited for maximum advantage, and the different technologies available for printing them.<h2 dir="ltr">Why use wear-resistant 3D printing materials?</h2>In the not-too-distant past, 3D printing was considered first and foremost a prototyping technology. In some contexts, the term “rapid prototyping” was synonymous with 3D printing, with a focus on the speed and low cost-per-unit of the technology in small quantities. Today, additive manufacturing has reached a level of maturity where it is also considered a viable tool for production of end-use parts. This opens up many possibilities for engineers.Several 3D printing materials are suitable for end-use parts. High-performance filaments like PEEK offer exceptional strength, while titanium alloy powders for powder bed fusion have been deployed in aerospace applications. However, in the area of moving parts like bearings, sliders, and rollers, only igus 3D printing materials have the wear resistance and low level of friction that can guarantee high performance over a long period of time. So, if an engineer requires both excellent sliding performance coupled with the inherent advantages of 3D printing — geometrical freedom, short lead times, one-off parts, and more — they require igus tribo-materials.Before the development of igus 3D printing materials, the best options for sliding applications were nylons such as PA6 and PA66. However, the utility of these materials is limited by two factors. First, nylons have a higher coefficient of wear than genuine tribo-materials, giving them a relatively short service life. Second, they have substandard printability due to their hygroscopic nature: highly susceptible to humidity, they can produce printing defects if not fully dried before use. A better plastic for sliding applications is POM, but this material is almost impossible to print and is better suited to CNC machining, in which it does not need to be melted.<h2 dir="ltr">The key benefits of 3D printable tribo-materials</h2>The benefits of 3D printable tribo-materials can be divided into two categories. First and foremost, there are the unique&nbsp;performance&nbsp;advantages of these specialist materials, such as the long service life for motion parts like bearings. Secondly, there are several important&nbsp;process&nbsp;advantages relating to the behavior of the material during the 3D printing process.Performance advantages of igus 3D printable tribo-materials include:<ul><li dir="ltr">Low coefficient of wear: igus materials exhibit up to 50x greater wear resistance than standard materials like ABS or nylon.</li><li dir="ltr">Long service life: due to the exceptional wear resistance of the materials, parts have a long service life</li><li dir="ltr">Performance comparable to molding materials: igus 3D printing materials are suitable for end-use parts or prototypes, offering similar performance to molding materials</li><li dir="ltr">Range of materials: broad range of tribo-materials for different applications, such as iglidur i3-PL for the best price-performance ratio for tribo-parts, igumid P190-PF for structural components, iglidur i150-PF for easy processing, iglidur i8-ESD for sliding parts with antistatic properties, and many more.</li></ul>Process advantages of igus 3D printable tribo-materials include:<ul><li dir="ltr">High machine compatibility: open materials suitable for most 3D printing hardware; many materials even compatible with low-cost machines.</li><li dir="ltr">Printability comparable to standard materials: unlike many high-performance plastics, many igus tribo-materials require standard printing parameters with moderate temperatures.</li><li dir="ltr">Resistance to water absorption: unlike nylon, most igus materials are not hygroscopic, making them resistant to water absorption and unlikely to produce defects even in humid ambient conditions (iglidur A350 requires active drying).</li></ul><h2 dir="ltr">Choosing the right technology and material</h2>3D printing tribo-materials from igus come in three formats for different additive technologies: filaments for fused filament fabrication (FFF), powders for selective laser sintering (SLS), and resins for digital light processing (DLP) and liquid crystal display (LCD). These technologies have their respective advantages and disadvantages when it comes to sliding applications. Depending on the application specifics, budget constraints, and availability of printing hardware, the most efficient solution may be an in-house print or a customized print order from the igus 3D printing service.<h3 dir="ltr">Tribofilaments</h3>igus tribofilaments provide the widest range of end-use applications to the widest range of users, as many igus filaments can be processed on standard FFF machines that cost significantly less than other types of additive manufacturing hardware. Tribofilaments also represent the largest material category in the igus 3D printing product portfolio, numbering 10 unique formulations suitable for a range of applications.<ul><li dir="ltr">For maximum compatibility with low-cost, open-frame 3D printing hardware and standard brass nozzles: iglidur i150 and iglidur i151</li><li dir="ltr">For medium temperature resistance (100 °C) and high dynamic applications: iglidur i180</li><li dir="ltr">For rigorous temperature resistance (170 °C) and flame retardancy: iglidur RW370&nbsp;</li><li dir="ltr">For structural components requiring maximum strength: igumid P150 and igumid P190</li></ul><h3 dir="ltr">Powders</h3>Tribological powders from igus are designed for use on SLS hardware. This technology offers advantages over FFF such as greater design freedom, no support structures, and near-isotropy, with no weakness along the Z-axis. As a result, hardware is more expensive and is typically operated only in industrial environments. Users of SLS hardware can choose between several igus tribological powders to suit their chosen application.<ul><li dir="ltr">For good balance of wear resistance, strength, and processability: iglidur i3.</li><li dir="ltr">For reliable prevention of electrostatic discharge (ESD) and compatibility with widest range of SLS hardware: iglidur i8-ESD and igliduri9-ESD.</li><li dir="ltr">For abrasion resistance and use in worm gears: iglidur i6 and iglidur i6-BLUE.</li></ul><h3 dir="ltr">Resins</h3>Tribological resins from igus can be used on standard DLP 3D printers, which can be purchased at costs almost comparable to FFF. Resin 3D printing can produce exceptionally smooth surface finishes and a very high level of detail — ideal for fine-tooth gears. Furthermore, unlike many standard resins, igus DLP materials provide a high degree of strength and stiffness. Compatible with the majority of DLP and LCD 3D printing hardware, igus’ iglidur i3000 resin is the first to provide wear resistance up to 60x greater than standard 3D printing resins.<hr><h2>The Engineer’s Guide to 3D Printing with Wear-Resistant Plastic Materials</h2>Explore the transformative world of 3D printing as we delve into the intricacies of using wear-resistant plastic materials. This <a href="https://www.wevolver.com/article/the-engineers-guide-to-3d-printing-with-wear-resistant-plastic-materials/draft" target="_blank" rel="noopener noreferrer">guide</a> offers engineers a comprehensive overview of material properties, applications, and best practices. Unlock the potential of durable plastics and revolutionize your manufacturing processes.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk5NjIyNzMxMTEzLU1pdHN1YmlzaGkgQ2hlbWljYWwgR3JvdXAgIEdyb3d0aCBHYXJhZ2UgIE9wZW4gSW5ub3ZhdGlvbiBQcm9ncmFtICg2OTQgeCA0MzIgcHgpICg5MDEgeCA1NjEgcHgpICgyKS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"><iframe width="540" height="305" src="https://c8056756.sibforms.com/serve/MUIFAOZIC-gflW1aLa_orKRn1WfjYZVUNQKFKmuk9iXJZ19VWAzEH6DJ3JP2VfVtDZtxKFQmcQjV-ol_LSYY3sOmTqWIXOeD2vIS23yHmiwCSlblo3zVxSmmhFd1ywbxBaAkyVThOqTwmZEMurS0KRMt4DO56IKBFXOQza3xKLTeby9GZtJbXpMzh8KrzihdxeeGHoc45DdHyjH6" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block;margin-left: auto;margin-right: auto;max-width: 100%;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;&nbsp;</iframe>Customers can try the igus <a href="https://www.igus.eu/info/3d-print-3d-printing-service" target="_blank">3D printing service</a> for rapid fabrication and shipment of wear-resistant parts or shop the range of igus <a href="https://www.igus.eu/3d-print-material/3d-print-material" target="_blank">3D printing materials</a> for in-house printing.

Article #1 of The Engineer’s Guide to 3D Printing with Wear-Resistant Plastic Materials. 

Introduction to 3D Printing with Wear-Resistant Plastics

Cavitation dispersion process improves the properties of materials used in additive manufacturing of circuits. You will learn how one can control hydrodynamic cavitation to produce unique dispersions, formulated inks & pastes, high aspect ratio nanoparticle & ‘2D’ filler particle masterbatches. 



Cavitation dispersion process: how it works and how it improves properties of printed materials

Beginners are often confused by the plethora of material options available for 3D Printing. In this article, we explore the different materials available and how their unique properties influence their utility.

The Ultimate Guide to Materials Used in 3D Printing

Inkjet printing technology, first developed in the late 1950s, has revolutionized the printing industry with its capability to produce high-quality, high-resolution images at a low cost. It has found applications across a wide range of industries, including textiles, electronics, packaging, and more. In recent years, the development of new materials and contactless printing applications has introduced new possibilities for inkjet printing across various sectors.Progress in printhead technologies, material science, and manufacturing processes has markedly enhanced the capabilities of inkjet printers. With the increasing number of printable materials, inkjet printing has discovered applications in an expanding variety of industries and processes. At present, inkjet printing technology can be employed to deposit a diverse array of functional materials onto assorted surfaces, further expanding the applicability of inkjet printing in multiple industries.Inkjet printing for solar cell manufacturingInkjet printing has emerged as a promising alternative to screen printing for the application of silver paste. The silver paste can be deposited directly onto the surface of the solar cell through very minuscule openings of a highly efficient, parallel print head, providing a contactless, maskless printing alternative to conventional processes. This printing process provides the PV industry with multifaceted benefits over conventional screen printing, such as increased efficiency and electricity output, reduced metal paste consumption, and significant throughput potential. (<a href="https://1788947.hubspotpreview-na1.com/how-Electroforming-is-empowering-the-photovoltaics-industry-moving-forward" rel="noopener" target="_blank">Learn more about how our technology empowers Inkjet Printing technology to revolutionize the PV industry here:</a> <a href="https://insights.vecoprecision.com/how-Electroforming-is-empowering-the-photovoltaics-industry-moving-forward" target="_blank">https://insights.vecoprecision.com/how-Electroforming-is-empowering-the-photovoltaics-industry-moving-forward</a>)<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgxMzA0OTAwMTcyLTE2ODEzMDQ5MDAxNzIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 756px;" class="fr-fic fr-dib">Inkjet Printing Across Industries: Flexible Electronics, Biomedical Applications, Electronic Displays, and MoreIn addition to the use of silver paste in the&nbsp;<a href="https://1788947.hubspotpreview-na1.com/how-Electroforming-is-empowering-the-photovoltaics-industry-moving-forward" rel="noopener" target="_blank">manufacturing of solar cells</a>, inkjet printing has also been used to deposit other types of functional materials onto various surfaces. For example, conductive inks can be used to print circuitry onto flexible substrates, such as plastic and fabric, to create flexible electronics. Inkjet printing has also been used to deposit materials for use in the biomedical field, such as living cells onto scaffolds to create tissue-engineered constructs for use in regenerative medicine.Another area where inkjet printing has been used is in the production of electronic displays, including the conductive layers, the active matrix, and the organic light-emitting diodes (OLEDs).&nbsp;The Technology Empowering Contactless Printing Breakthroughs Across IndustriesA vital part of the dispensing print head is the&nbsp;<a href="https://www.vecoprecision.com/products/inkjet-nozzle-plates/" rel="noopener" target="_blank">high-precision nozzle plate</a>, produced using&nbsp;<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming, a micro-precision, metal additive manufacturing (AM) process</a> combining lithography and electrodeposition. The nozzle plate is a thin metal part with miniature holes, through which advanced materials can be directly deposited via the nozzles onto versatile surfaces for endless applications across industries.&nbsp; &nbsp; &nbsp;&nbsp;It is the complicated combination of accuracy, precision, material properties, and unique geometries enabled by&nbsp;<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a><a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">&nbsp;</a>that makes the plate an essential part of the dispensing print head. The miniature holes need to be down to several microns and perfectly circular. Traditional cutting and drilling processes might not meet the stringent accuracy and precision requirements, and etching and laser processes could result in thermal stress and microburrs.&nbsp;Electroforming, on the other hand, does not influence metal properties such as hardness, grain structure, or ductility. It allows for the realization of high-precision products that are thermal stress- and microburr-free, providing absolute accuracy and high aspect ratios.Another significant advantage of&nbsp;Electroforming&nbsp;is reproducibility. The process affords a precision of approximately 5 &mu;m. In a plate that has&nbsp;hundreds of&nbsp;miniature nozzles in a straight line, each of those nozzles needs to be the correct size, not only on each plate but on every plate and across different batches of the plate.&nbsp;Electroforming&nbsp;guarantees reproducibility, meaning the same drawing and process setup translates to perfectly uniform and reproducible printing results and the exact same product time and time again.Electroforming&nbsp;can also be used to produce special hole geometries; for example, bell mouth-shaped holes are not achievable using traditional cutting and drilling processes. These holes can effectively reduce blinding/clogging of the plate/nozzles, thus ensuring exceptional paste release performance.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgxMzA0NjgyMTg2LTE2ODEzMDQ2ODIxODYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="inkjet hole shape" width="2003" class="fr-fic fr-dii" style="width: 755px;">A Bright Future for Inkjet Printing Technology Enabled by ElectroformingAs advancements in printhead technologies, material science, and manufacturing processes continue to progress, the potential applications for inkjet printing across various industries will only grow. With its ability to deposit a diverse array of functional materials onto assorted surfaces, inkjet printing has established itself as a groundbreaking technology that can revolutionize not only the printing industry but also endless sectors.The future of inkjet printing technology is promising, and its continued development is likely to further expand its applications and drive innovations across numerous industries. By embracing and leveraging the power of advanced inkjet printing technology and&nbsp;<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">advanced lithographic Electroforming</a> technology, engineers and researchers alike can unlock new possibilities and create cutting-edge solutions to tackle the challenges of tomorrow.Inkjet printing has come a long way since its inception in the 1950s. The development of new materials and contactless printing applications has opened up new possibilities for inkjet printing in various industries. Inkjet printing can now be used to deposit a wide range of functional materials onto various surfaces, including conductive inks for flexible electronics, living cells for tissue engineering, and silver paste for solar cells. As inkjet printing technology continues to evolve, we will likely see even more innovative applications of this technology in the future.To learn more about&nbsp;<a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> and how it can empower your next innovation,&nbsp;<a href="https://1788947.hubspotpreview-na1.com/en/whitepaper-electroforming" rel="noopener" target="_blank">download our whitepaper Electroforming here:&nbsp;</a><a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kGHY_No8Ht4QxjSAvFwc71E5Tj5OQ&pageId=108651819679&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=5e6e53fc-9be4-4a6a-8053-5f655a480961&hsutk=&canon=https%3A%2F%2Finsights.vecoprecision.com%2Ffrom-solar-cells-to-endless-applications-across-industries-inkjet-printing-revolution-enabled-by-electroforming-technology&portal_id=1788947&redirect_url=APefjpEcgqNObbaV8BMI4KFMyYyMOd4yRDPcalEGsvL_DyahUIMNlPeoe2hS7Ew3w5nOSePlFrVkpKWMljbZWjkeuZs7JN8IKfOPByiBLz-OZmcfx_hHncg8MgnrgDT32Vsfhp2d6orZufw0LQUDWxafhzPrcIGIZw" rel="noopener" target="_blank"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjgxMzA0NjcyMzE4LTE2ODEzMDQ2NzIzMTgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a>

Progress in printhead technologies, material science, and manufacturing processes has markedly enhanced the capabilities of inkjet printers. Inkjet printing has now discovered applications in an expanding variety of industries and processes.

From solar cells to endless applications across industries: inkjet printing revolution enabled by Electroforming technology

Caption: Ultrasint® PA11 ESD, printed part. Source: BASF.

Addressing the risks and challenges of electrostatic discharge in manufacturing thanks to innovative 3D printing materials.


How to Scale Manufacturing with ESD-safe 3D Printing?

In this episode, we talk about how researchers have devised a new approach for manufacturing precise microfluidic channels for medical devices using 3D printed ice and a novel approach for embedding sensors into architected materials therefore making them viable for motorized soft robotic applications.&nbsp;<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/40dd78f5-3816-4ee8-b313-9d19c7ffa54b?dark=false" class="fr-draggable" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><hr>This podcast is sponsored by <a href="https://www2.mouser.com/" id="isPasted" rel="nofollow" target="_blank">Mouser Electronics</a>. &nbsp; &nbsp; &nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjYxMjUwMTgyMjQ3LU1vdXNlci1zcG9uc29yLTEtYS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"><hr><h3 id="isPasted">EPISODE NOTES</h3>(2:35) -&nbsp;<a href="https://www.wevolver.com/article/3d-printing-ice" target="_blank">3D Printing Ice</a>🧊🖨(19:00) - Programmable Materials🧱🧑‍💻Episode 84 was brought to you by Mouser Electronics, Farbod &amp; Daniel’s favorite electronics distributor. Click&nbsp;<a href="https://resources.mouser.com/aerospace/the-potential-for-nanotechnology-in-the-aerospace-industry" target="_blank">here</a> to read about the Mouser technical resource discussing additive manufacturing in the aerospace industry!<a href="https://the-next-byte-wevolver.simplecast.com/episodes/2-boom-brings-back-supersonic-using-ai-to-beat-tb-5g-is-messing-up-weather-forecasts" target="_blank">Link</a> to the episode about Boom Supersonic where we talked about how the startup is leveraging additive manufacturing.<a href="https://the-next-byte-wevolver.simplecast.com/episodes/4-a-breakthrough-in-3d-printing-organs-ai-knows-the-music-you-really-like-better-weather-climate-forecasts" target="_blank">Link</a> to the episode about Carnegie Mellon University where we discuss how they are Bioprinting hearts.<hr>As always, you can find these and other interesting &amp; impactful engineering articles on Wevolver.com.To learn more about this show, please visit our<a href="https://www.wevolver.com/profile/the.next.byte" target="_blank">&nbsp;shows page</a>. By following the page, you will get automatic updates by email when a new show is published. Be sure to give us a follow and review on<a href="https://podcasts.apple.com/nl/podcast/the-next-byte/id1548255861?l=en" rel="nofollow" target="_blank">&nbsp;Apple</a> podcasts,<a href="https://open.spotify.com/show/6lPPsRtegnivsRUEsQ09R7?si=IPMiah7xT_apJtPjqvXMlA" rel="nofollow" target="_blank">&nbsp;Spotify</a>, and most of your favorite podcast platforms!

In this episode, we talk about how researchers devised a new approach for manufacturing precise microfluidic channels for medical devices using 3D printed ice and a novel approach for embedding sensors into architected materials therefore making them viable for motorized soft robotic applications.

Podcast: Printing Ice & Sensing Architected Materials

Design freedom is one of the main benefits that 3D printing offers. The technology allows users to create parts with complex structures and internal infill geometries. But there are some limitations to what 3D printing can do. For instance, fused deposition modeling (FDM) 3D printers struggle to print geometries with bridges or overhangs that exceed angles of 45 degrees.[1] But that doesn’t mean people have to avoid printing parts with such features. 3D printed support structures enable complex shapes with overhangs and fine details to be printed without trouble. &nbsp;Supports are typically generated in slicing software and are applied automatically to areas of your <a href="https://www.wevolver.com/article/how-to-make-a-3d-model-for-printing" target="_blank">3D model</a> that require the extra help. In addition to holding certain types of geometries up, supports can also help improve bed adhesion, <a href="https://www.wevolver.com/article/3d-print-warping" target="_blank">reducing the risk of warping</a>.All that said, 3D printed parts with support structures do require some extra post processing. Specifically, it is important to remove the support structures carefully—either manually or using a solvent—to ensure that your 3D print is structurally sound and visually flawless. In this article, we’ll discuss the different types of support structures available for FDM 3D printing and explain the various methods for removing them without damaging your 3D print.&nbsp;<h2 dir="ltr" id="isPasted">Removing support structures</h2>Once you have your supports and model 3D printed, the next step is to remove the supportive structures. The support removal method depends entirely on the type of material you have used for the supports. In general, there are two ways to remove supports: manually or using a solvent.&nbsp;<h3 dir="ltr">Manual Support Removal</h3>If you have a single-extruder 3D printer, you will likely be 3D printing your supports using the same filament that your part is made of. For example, if you are printing a PLA model, the supports will also be made from PLA filament. This means that they must be removed manually.&nbsp;Because most support structures have a low density, it is possible in some cases to simply break them off from your 3D print. This technique does increase the risk of breaking or damaging your 3D printed part. For more precise support removal, you can use a knife, needle-nose pliers or flush cutters to carefully cut and break off the extraneous 3D printed supports. Carefully heating a knife blade can help to seamlessly remove the support from the print surface. The most important thing to keep in mind is to work gently, especially for harder to reach supports.&nbsp;<h4 dir="ltr">Z-Distance and Support Removal</h4>To facilitate the removal of supports, many users turn to Z-distance settings in their slicer programs. The Z-distance refers to the gap between the top and bottom of the supports and the printed model. This distance ensures that the supports are not completely fused to the 3D model for easier removal. In general, a smaller Z-distance (measured in multiples of the layer height) will result in a higher print quality but harder support removal, while a larger Z-distance will make supports easier to remove but may influence the surface quality of the final part.[2]Recommended reading: <a href="https://www.wevolver.com/article/cura-support-settings" target="_blank">Cura support settings, from angles to Z distance</a><h4 dir="ltr">Smoothing parts after support removal</h4>Once you’ve removed or broken off most of the support structures you can then go over the rough spots with some damp sand paper. This will smooth out the surface where structures were attached and polish the printed part. Alternatively, you can use a solvent, such as acetone or nail polish remover, to smooth out any blemishes caused by support removal. These manual finishing techniques can also be used to reduce the appearance of layer lines.Recommended reading: <a href="https://www.wevolver.com/article/pla-smoothing" target="_blank">Smoothing PLA 3D prints with sandpaper, solvents, and more</a>We should point out that safety is important in the support removal process, and protective eyewear and gloves are recommended to shield against the inevitable debris and sharp edges encountered during support removal.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjUzNDAwMjc1NjQ2LTNkX3ByaW50ZWRfb2JqZWN0LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="624" height="489" alt="Orange hulk 3D printed" class="fr-fic fr-dii">With a single extruder 3D printer, supports have to be manually removed from the print.<h3 dir="ltr">Soluble support structures</h3>If you have the chance to work with a dual extrusion 3D printer, support removal can be far easier, requiring little to no manual intervention. This is because you can print with two different types of filament: a classic build material (like PLA or ABS) for your model, and a soluble print material (like PVA or HIPS) for the support structures.&nbsp;With soluble supports, you simply have to take the 3D printed object from the print bed and submerge it in a liquid bath. PVA filaments will dissolve easily in warm water, while HIPS must be placed in a solution of Limonene. In both cases, it is important not to submerge the parts in water that is too hot, as it can warp the actual model. Keeping the water moving while your part is submerged will also help to dissolve the supports faster. If you are in a particular rush, you can let the supports soften for about 10 minutes and then cut the bulk of them off using pliers. Place the part back in the bath to remove the remaining traces of support.[3]A final note about PVA is that if your soluble material of choice: be sure to store the filament in a dry place. If it absorbs too much moisture from the air, the filament can clog up your 3D printer nozzle. When working with soluble supports, it is also important to exercise caution and use proper safety precautions like PPE and good ventilation.Recommended reading: <a href="https://www.wevolver.com/article/how-to-dry-filament" target="_blank">How to Dry Filament</a><h2 dir="ltr">Types of support structures</h2>When it comes to FDM, there are two main types of 3D printing support structures: linear supports and tree supports.&nbsp;<div dir="ltr" align="left"><table><tbody><tr><td>Type of Support</td><td>Characteristics</td><td>Applications</td></tr><tr><td>Linear Supports</td><td>Vertical columns or grids, consistent support</td><td>Ideal for angled and flat overhangs and bridges</td></tr><tr><td>Tree Supports</td><td>Branch-like structure, fewer contact points and support interfaces</td><td>Ideal for complex geometries and angled overhangs</td></tr></tbody></table></div><h3 dir="ltr">Linear Supports</h3>Linear supports, also known as accordion supports or lattice supports, are the most popular style of support structure. Linear supports are characterized by straight vertical columns that grow upwards from the build platform to support overhangs and bridges. This style is popular because it is highly effective at supporting these features.In Cura slicer software, linear supports are called “normal” and users have the option to choose from various support patterns, including grid, triangle, concentric, and line.[2] You can also choose the support density and whether to print supports with a wall—though this is typically only recommended when printing with a soluble support material.&nbsp;While linear supports are the gold standard for supporting overhang features in 3D printed models, they do have a slight downside. Because they support so much of the overhang, they can be tricky to remove, increasing the risk of damaging or marking the final part.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjUzNDAwMjY1MzUzLXN1cHBvcnQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="936" class="fr-fic fr-dii" alt="3D printer in operation">Users can choose to adjust support parameters, like density, in slicer software.<h3 dir="ltr" id="isPasted">Tree Supports</h3><a href="https://www.wevolver.com/article/cura-tree-support" target="_blank">Tree supports</a>, or tree-like supports, are characterized by more organic structures that grow up from the build plate. Named for their similarity to tree branches, tree supports are most effective when printing angled overhangs. Because they have fewer contact points with the supported print, they are not very effective for holding up bridges or flat overhangs. That being said, tree supports are easier to remove than linear supports, since there are fewer touch points.&nbsp;Tree supports are usually hollow, which reduces the amount of material required to print them. Like linear supports, slicer software will automatically generate the structures, so you don’t have to. Users can, however, choose to adjust a number of settings for tree supports, including branch distance (i.e. how far apart the touchpoints are on the 3D printed model), branch diameter, and diameter angle.&nbsp;Recommended reading: <a href="https://www.wevolver.com/article/tree-supports-better-looking-prints-with-less-wasted-material" target="_blank">Tree supports: Better looking prints with less wasted material</a><h2 dir="ltr">How to Minimize 3D Supports</h2>One of the most important steps to facilitate support removal is to minimize the need for supports in the design and pre-printing stages. Designing with support removal in mind can save significant time and effort. Here are some strategies:<ul><li dir="ltr">Optimize Print Orientation: Orient your model to minimize the need for supports. For example, positioning your 3D model on the build platform horizontally rather than vertically can reduce the amount of support material needed.</li><li dir="ltr">Design with Supports in Mind: When designing the model, incorporate features that reduce the need for supports, such as chamfers, fillets, and flat surfaces.</li><li dir="ltr">Use Support Settings in Slicing Software: Adjust support settings in your slicing software to reduce density and improve ease of removal. Consider using tree supports for complex geometries, a technique that has evolved with advances in slicing algorithms.</li></ul><h2 dir="ltr">Conclusion</h2>In the end, supports are essential to 3D printing: they let you create complex geometries with overhangs and bridges that would otherwise be impossible to print using extrusion systems. This means that, whether you’re a beginner maker or an experienced one, support removal is an important step in the 3D printing process. By choosing the proper slicer settings, using the right tools and working carefully, you can significantly enhance the quality of your 3D prints. Implementing these methods not only improves the aesthetics of your prints but also their functional integrity. Remember to plan your support structures carefully, use appropriate removal techniques, and always maintain your tools to achieve the best results.&nbsp;<h2 dir="ltr">Frequently Asked Questions</h2>Q: What is the easiest way to remove supports from 3D prints?A: The easiest way to remove supports from 3D prints is to use a soluble support filament, which can dissolve in water or specific solvent. For those who don’t have access to dual-extrusion 3D printing capabilities, however, the easiest way to remove supports is using good quality cutting tools, like an X-acto knife and needle-nose pliers. &nbsp;Q: What are the best tools for removing supports from 3D prints?A: Precision knives, needle-nose pliers, tweezers, and flush cutters can all be effective tools for removing supports. Each tool should match the size and delicacy of the supports and the print.Q: How does support design influence removal?A: There are two types of support designs: linear and tree. Generally, tree supports are easier to remove because they have fewer contact points with the 3D model, however this type of support can take longer to generate in slicer software and is not ideal for supporting bridges.Q: How can I prevent my 3D print from getting damaged during support removal?A: Using the right tools and working carefully are key to removing supports without damaging the 3D print. It is also possible to use heat tools to soften the support and facilitate removal or to heat the cutting tools directly for a smoother cut.&nbsp;Q: Are there specific materials that make support removal easier?A: Yes, using soluble support materials like PVA or HIPS, which dissolve in water or limonene respectively, can make support removal easier and reduce the risk of damage.Q: How can I minimize the need for supports in my 3D prints?A: Optimize the print orientation, design with supports in mind by incorporating features like chamfers and fillets, and adjust support settings in your slicing software to minimize support material usage.Q: Can heating supports help in their removal?A: Yes, gently heating the supports with a heat gun on a low setting can soften the material, making it easier to remove without harming the print. Alternatively, it is possible to heat your cutting tools just before removing the supports.Q: What is the best way to smooth surfaces after support removal?A: Sanding with progressively finer grits, using precision files for detailed areas, and solvent smoothing techniques like acetone vapor for ABS prints can effectively smooth surfaces.<h2 dir="ltr">References</h2>[1] “What is important to know about 3D printing supports?” [Internet]. &nbsp;Sculpteo, 2024. <a href="https://www.sculpteo.com/en/3d-learning-hub/design-guidelines/understanding-3d-printing-supports/" target="_blank">https://www.sculpteo.com/en/3d-learning-hub/design-guidelines/understanding-3d-printing-supports/</a>[2] “Support Settings” [Internet]. Ultimaker, March 3, 2024. <a href="https://support.ultimaker.com/hc/en-us/articles/360012612779-Support-settings" target="_blank">https://support.ultimaker.com/hc/en-us/articles/360012612779-Support-settings</a>&nbsp;[3] “How to dissolve Ultimaker PVA” [Internet]. Ultimaker, November 8, 2022. <a href="https://support.ultimaker.com/hc/en-us/articles/360011959100-How-to-dissolve-Ultimaker-PVA" target="_blank">https://support.ultimaker.com/hc/en-us/articles/360011959100-How-to-dissolve-Ultimaker-PVA</a>[4] "Tree supports: What are they and how do they work?" [Internet]. &nbsp;Ultimaker, 2024. <a href="https://ultimaker.com/learn/how-to-use-tree-supports" target="_blank">https://ultimaker.com/learn/how-to-use-tree-supports</a>&nbsp;

Supports enable 3D printers to produce parts with overhangs and bridges.

Everything you need to know about 3D printing supports and how to facilitate their removal post printing.

How to Remove Supports from 3D Prints

Additive manufacturing, or 3D printing, has brought with it the ability to customize creations in ways never before possible. Shapes, materials, and colors can all be programmatically altered before short production runs of as little as a single unit &mdash; but work at the Massachusetts Institute of Technology is looking to take things a stage further through the use of lenticular lenses.Known to most as the secret behind those &ldquo;3D&rdquo; bookmarks and posters available from at least one stall at every market in the world, lenticular lenses allow for different images to be seen when a surface is viewed from different angles. The MIT team has not only developed a way to print these lenses on a 3D printer, but also created software to make their design as easy as possible &mdash; demonstrating the project&rsquo;s potential with devices ranging from a kettlebell that lets you know when your form is good to secret-message shoes designed to cheer the wearer up.<h1>Multi-image surfaces</h1>Lenticular lenses work by magnifying the surface beneath, making it so different parts of the surface are visible from different angles &mdash; and are typically limited to two-dimensional objects like posters or CD covers.&ldquo;One reason why lenticular prints do not yet exist in the form of 3D objects is that up until recently,&rdquo; the researchers explain, &ldquo;no fabrication process existed that was able to manufacture the lenticular lenses and high resolution color patterns on doubly curved surfaces. However, over the last years, multi-material 3D printers have been developed that can print with a multitude of materials and in high-resolution color.&rdquo;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1651174873349-lenticular4.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="A diagram showing 19 colours circles, themselves arranged in a circle, under a lenticular lens, labeled &quot;color pattern for 19 different viewpoints.&quot; A second image shows a 3D rendering of the lens seen from each of the 19 viewpoints, showing a unique color from each viewpoint.">3D modeling software developed at MIT is capable of designing lenticular lenses good for an impressive 19 unique viewpoints, but the limitations of 3D printing technology mean fewer are possible in reality.Using an off-the-shelf multi-material 3D printer, the team set about creating lenticular lenses which could be printed alongside the rest of the object &mdash; requiring only a little post-processing, in the form of the application of varnish or oil, to increase their light transmission. That, however, was only half the problem solved: The other half was figuring out where the lenses needed to go, and what should be underneath them to produce the desired effect.For this the team developed custom software designed as a plug-in for the Rhino3D modeling tool. Using the plugin, a designer can import the 3D model of any object, add a lens layer, and apply textures with the colors to be seen from each of the possible viewpoints &mdash; up to 19 in theory, the team found through computer modeling, though that number is presently unachievable on commercial 3D printing hardware.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1651174889585-lenticular2.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="Images of a 3D-printed shoe, both real photographs and 3D ray-traced renders from the MIT modeling software. The left-hand images show the show from above, with the message &quot;CHEER UP!&quot; visible on the toe area; the right-hand images show the same show from an angle, with the message no longer visible.">The team&#39;s software calculates the lens layer and the underlying textures ready for printing; a ray-traced render is shown for each viewpoint for confirmation.Using ray-tracing technology, the software simulates the way light travels through the lenses from each of the possible viewpoints in order to allow the object designer to confirm the texture that will be shown. Once confirmed, the data is sent to the printer &mdash; and the whole object, including the lenses, is printed in a single pass.<h1>Functional objects</h1>Lenticular prints are often considered novelties, but the MIT team believes there&rsquo;s a lot more to the technology than at first glimpse. To prove it, the software was used to generate a series of functional objects &mdash; the most functional of which is a kettlebell weight, fitted with a lenticular shell designed and printed using the custom plugin.When the user lifts the kettlebell to the correct exercise position, they&rsquo;ll see a checkmark; fail to lift the kettlebell high enough and they&rsquo;ll see an arrow pointing upwards, providing feedback as to the mistake and how to correct it. If the kettlebell is lifted too high, meanwhile, the symbol shifts into a downward arrow &mdash; and all entirely passively, with no active electronics or sensing devices to be found.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1651174903350-lenticular3.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="Three images of a user holding a kettlebell weight at arm's length. In the first image, the kettlebell is too low; in the second, at the right height; in the third, too high. For each, real photographs and 3D renders of the lenticular kettlebell are shown: when it's too high, a blue up-arrow is visible; at the right height, a green checkmark; too high, a red down-arrow.">Although frequently associated with art and entertainment, lenticular lenses can create functional objects &mdash; like this form-checking kettlebell.Other demonstrations put together by the team include: A lampshade which reads &ldquo;Good Night&rdquo; when the user is lying in bed and &ldquo;Good Day&rdquo; when they are sitting up; an earpod case which shifts through a series of five striped patterns at different angles, as an aesthetic implementation; and a pair of shoes which appear plain to observers but show a colorful &ldquo;Cheer Up&rdquo; message to the wearer.A final demonstration serves as an experiment in switching to cylindrical lens shapes, which are just as compatible with 3D printing as the traditional round lenses used for the other objects. Offering higher spatial resolution with the limitation of only shifting along a single axis, the cylindrical lenses were used to create a container which reveals its contents only when held to eye-level.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1651174918457-lenticular5.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="Two photographs of a container created using cylindrical lenticular lenses. The left-hand image shows stripes to the upper-right of the container with no visible text; the right-hand image, from a different angle, reveals the text &quot;MINIMAL WOODY 3.46 oz.&quot;">While the team&#39;s software currently focuses on round lenses, cylindrical lenses &mdash; which offer a higher resolution &mdash; are also possible.While admitting to limitations in the work&rsquo;s current state &mdash; including the ability for the designer to accidentally create invalid viewing angles, the application of lenses on top of rather than within object geometry adding 3mm (around 0.12&quot;) of thickness to the target surface, the lenses altering the surface texture and haptics of an object &mdash; the team has shown a solid basis for future work, which is to include enhancements to the software and experimentation with dynamic lens sizing.The team&rsquo;s work has been published in the <cite><a href="https://dl.acm.org/doi/10.1145/3472749.3474815" target="_blank">Proceedings of the 34th Annual ACM Symposium on User Interface Software and Technology (UIST &#39;21)</a></cite> under open-access terms.<h1>Reference</h1>Jiani Zeng, Honghao Deng, Yunyi Zhu, Michael Wessely, Axel Kilian, and Stefanie Mueller: <cite>Lenticular Objects: 3D Printed Objects with Lenticular Lens Surfaces That Can Change their Appearance Depending on the Viewpoint, The 34th Annual ACM Symposium on User Interface Software and Technology, Pages 1184&ndash;1196</cite>. DOI <a href="https://doi.org/10.1145/3472749.3474815" target="_blank">10.1145/3472749.3474815</a>.

This lampshade, printed in-place on a commercial multi-material 3D printer, shows what's possible with MIT's lenticular object technology.

Modeled in software before being printed on a commercial 3D printer in a single pass, these "lenticular objects" from MIT show different imagery depending on the angle at which they're viewed — for everything from exercise form feedback to secret messaging.

3D printed in a single pass, these objects demonstrate the potential for lenticular lens surface technology

An update for Ultimaker S-line printers, Firmware 6.5 helps to improve your 3D printing workflow, as we introduce more streamlined troubleshooting and error handling, and the ability to import material profiles from USB. And with this release, Material Station users will enjoy even better material handling, with more reliability.<section>For more on how Firmware 6.5 makes material handling and troubleshooting quicker and easier, watch the video below and scroll down for more on each feature.<iframe src="https://www.youtube.com/embed/WW_L9n5KEgo?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" style="width: 789px; height: 450px;" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2>Import material profiles from USB</h2><section id="isPasted">If you have been 3D printing with 3rd-party materials but haven&rsquo;t installed the material profile to your printer, you can now install them via USB. This is especially useful if you print offline and don&rsquo;t synchronize across your network.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjI1ODI1ODE4ODA1LWV6Z2lmLTYtNGQ5NGM1NTgxMWQ1LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib"><section id="isPasted">To import material profiles to your printer via USB, simply slice your print job in Ultimaker Cura with the third party material profile and save it to USB. If you then select Import Material Profiles from the Settings menu, your printer will scan the USB for unknown material profiles and install them. This makes your printing workflow much easier, as the printer will then automatically recognize these profiles for future prints.<h2>Improved error handling for all users</h2>With the release of Firmware 6.5, we have improved the error handling of ER998. This expands on improvements made in Firmware 6.4, that introduced a Reboot button for errors that required a printer reboot.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjI1ODI1ODYyMTIyLWV6Z2lmLTYtMTViYzFlZDQzODY3LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">Error 998 causes the touchscreen software to freeze &ndash; sometimes during printing. Rebooting the printer solves the problem, but also stops printing. But with this firmware release, you will no longer need to completely reboot your machine. Instead, you can reboot the touchscreen alone by clicking on the Refresh button that will automatically appear.For more information, you can visit the&nbsp;<a href="https://support.ultimaker.com/hc/en-us/articles/360011599420-ER998-An-unspecified-error-has-occurred" target="_blank">ER998 support page</a>.<h2>Optimized material handling for the Ultimaker S5 Pro Bundle and Material Station</h2>A number of improvements have been launched for the Ultimaker S5 Pro Bundle and Material Station:<ul><li>Improved material unloading increases reliability</li><li>More accurate material loading for greater efficiency</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjI1ODI1ODg1MzY0LWV6Z2lmLTYtNTJmMWJjOGFlOWMyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib"><section id="isPasted"><h2>Improvements to the material unloading process</h2>When a print ends or switches materials, the filament is retracted back into the Ultimaker S5 Material Station. This initiates the <a href="https://support.ultimaker.com/hc/en-us/articles/360012412780-What-is-the-prime-deprime-procedure-" target="_blank">deprime process</a>, which ensures that the material has a clean tip with no stringing. With Firmware 6.5, this process is enhanced.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjI1ODI1OTI1Mzk0LWV6Z2lmLTYtYThkNDI5YTVmNjRjLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">The enhanced deprime process has been extended to include more generic materials. This is in addition to improvements made to the (un)loading of Ultimaker materials in Firmware 6.4. Both of these advancements improve the reliability of the Ultimaker S5 Pro Bundle and Material Station by significantly reducing issues caused by filament blockage or friction when loading material.<div id="isPasted"><div>Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/pushing-the-limits-of-fff-together-lifting-a-12-tonne-tank-with-a-plastic-3d-print" rel="noopener noreferrer" target="_blank">Pushing the limits of FFF together: Lifting a 12-tonne tank with a plastic 3D print</a></div></div><h2>Updated material loading procedure</h2>Firmware 6.5 makes the material loading process more efficient for the Ultimaker S5 Pro Bundle and Material Station. How? The Ultimaker S5 contains a flow sensor in the printer&rsquo;s feeders. With the updated loading procedure, these sensors will detect the tip of the filament and calculate its distance from the nozzle. This more efficient material handling decreases the chances of filament grinding and loading errors.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjI1ODI1OTcwMjA3LWV6Z2lmLTYtYjYyYmVmZGU5ZjJiLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib"></section></section></section></section>

An update for Ultimaker S-line printers, Firmware 6.5 helps to improve your 3D printing workflow, as we introduce more streamlined troubleshooting and error handling, and the ability to import material profiles from USB. 

Increase the productivity of your 3D printing workflow with Ultimaker Firmware 6.5

In collaboration with global engineering technologies company <a href="https://www.renishaw.com/en/renishaw-enhancing-efficiency-in-manufacturing-and-healthcare--1030" rel="noopener" target="_blank">Renishaw</a>, this article explores how to overcome this issue and the use of additive manufacturing to produce intricate and complex copper structures for heat exchangers.<h2>Copper 3D Printing Breakthroughs</h2>“Additive manufacturing (AM) is a breakthrough technology that is transforming the manufacturing industry,” explained Kenneth Nai, Principal Engineer at Renishaw. “This digitally-driven process gives engineers the design freedom to create and manufacture parts with complex structures that would never have been possible with traditional machining.”Traditionally, heat exchangers are made from thin sheets of material that are welded together. The complex geometry of heat exchanger designs makes production challenging and time-consuming. AM systems build parts layer-by-layer, only adding material where needed, to produce lightweight yet complex components, making this process attractive for manufacturing heat exchangers.“While its high thermal conductivity makes copper the ideal material for heat exchangers, the properties of the material can create challenges when using an AM system,” continued Nai. “The laser sintering of copper powder with an infra-red laser at a wavelength of 1070 nm is difficult because copper is very reflective at that wavelength. Therefore, only a small amount of the laser energy is absorbed into the powder, and a critical threshold of absorption is required to melt the powder together. Combining the high thermal conductivity of copper and the laser energy required, leads to instability and often results in poor mechanical properties of the finished part.”Renishaw has collaborated with&nbsp;nTopology&nbsp;to demonstrate to manufacturers that, by using the right software and system together, they can reliably additively manufacture intricate structures from copper.“Combining Renishaw’s RenAM 500S AM system and nTopology software demonstrated an easy method for designing intricate structures suitable for use in heat exchangers and how it can be integrated with Renishaw’s build preparation software, QuantAM,” explained Nai. “At New Mills, our headquarters in Gloucestershire, UK, a RenAM 500S system, with a single 500 Watts laser and 70 micron laser spot size, was loaded with 99.9% pure copper powder supplied by Carpenter Additive. The system was optimized to work with this material. The system was able to manufacture thin walls with a thickness of 0.35 mm and solids with a density over 98 percent, prior to heat treatment in 30-micron layers.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559437990-Thin_Wall_Cylinders.png" style="width: 788px;" class="fr-fic fr-dib">Thin Wall Cylinders (Image courtesy of Renishaw)&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559454040-Wall_Thickness_of_Cylinders.png" style="width: 788px;" class="fr-fic fr-dib">Wall Thickness of Cylinders (Image courtesy of Renishaw)&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559470906-10mm_cubes.png" style="width: 788px;" class="fr-fic fr-dib">10mm Cubes (Image courtesy of Renishaw)&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559493429-copper_cube39.jpg" style="width: 788px;" class="fr-fic fr-dib">Polished section of a 10 mm copper cube — measured optical density of 99.3% (Image courtesy of Renishaw)&nbsp;Designing TPMS Structures for Heat ExchangersnTopology software was used to generate Triply Periodic Minimal Surfaces (TPMS) that are ideal for heat exchangers as they generally require maximizing the amount of surface area within a given volume.First, a wall thickness of 0.35 mm and cell sizes of 2 mm and 5 mm was used to design these gyroid TPMS structures. Then, nTopology was used to slice the design into 30-micron layers and exported the boundaries and hatches as CLI files. Finally, the CLI files were imported into Renishaw’s QuantAM software to generate the build file for printing by the machine. CLI files remove the need for the traditional STL file format which has many disadvantages when used to describe complex intricate structures like these.<h3>Generating the TPMS Gyroids</h3>The design process started with using the Walled TPMS Block in nTopology to generate a gyroid with a wall thickness of 0.1 mm and cell sizes of 2 and 5 mm.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559532258-nTop_Walled_TPMS_Block.png" style="width: 788px;" class="fr-fic fr-dib"><h3>The Slicing Step</h3>The Walled TPMS Block&nbsp;was then sliced using the Slice Body Block to give the sliced boundaries of the gyroid. A layer thickness of 0.03 mm is used as that is the layer thickness of the machine.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559559894-nTop_Slice_Body_Block.png" style="width: 788px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559572839-Sliced_Layers_Gyroid.png" style="width: 788px;" class="fr-fic fr-dib">30µm sliced layers of the gyroid showing the boundaries (Image courtesy of Renishaw)&nbsp; The first boundary slice stack was sliced again to give the area between the boundaries, also commonly known as hatching. Generally, when 3D printing a part in layers, the laser would scribe or infill the body of the part for that layer first and then scribe the boundary for the part. &nbsp;An offset of -0.05 mm was used to standoff the hatching from the boundary using the Offset Slice Stack Block.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559610412-nTop_Offset_Slice_Stack_Block.png" style="width: 788px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559592850-Hatching_Area_Layers.png" style="width: 788px;" class="fr-fic fr-dib">Hatching area for the layers (Image courtesy of Renishaw)&nbsp;Exporting to QuantAM and ManufacturingBoth the Sliced Boundary and Hatching Stacks were exported as 2 CLI files for print preparation. The CLI files were imported into Renishaw’s build preparation software, QuantAM.QuantAM adds the machine parameters and generates a file that enables the machine to print the part. Note: Using CLI files removes the need of converting to STL files which are often huge in size and difficult to generate for complex geometries!<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559645705-Single_Layer_QuantAM.png" style="width: 788px;" class="fr-fic fr-dib">Single layer view from QuantAM. &nbsp;Red areas are the Boundaries and Yellow are the Hatching. (Image courtesy of Renishaw)&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559665139-Single_Layer_QuantAM_Close_Up.png" style="width: 788px;" class="fr-fic fr-dib">Close up view from QuantAM. &nbsp;Red areas are the Boundaries and Yellow are the Hatching. (Image courtesy of Renishaw)&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559689374-Test_Sample_2mm_Cell_Size.png" style="width: 788px;" class="fr-fic fr-dib">Test sample with 2 mm cell size (Image courtesy of Renishaw)&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615559709041-Test_Sample_5mm_Cell_Size.png" style="width: 788px;" class="fr-fic fr-dib">Test sample with 5 mm cell size (Image courtesy of Renishaw)&nbsp;<h2><div class="fr-img-space-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1615560002574-gyroid-576x1024+%281%29.jpg" style="width: 788px;" class="fr-fic fr-dib">Final part design (Image courtesy of Renishaw)&nbsp; From test samples to end-products</div></h2>This article outlined the progress in additive manufacturing of commercially pure copper with the Renishaw AM systems. Heat exchanger design is the most prominent application of this new technology. nTopology equips engineers with the right tools to design advanced heat exchangers that greatly outperform traditional designs and meet the demands of high-performance products.<hr>This article was first published on the <a href="https://ntopology.com/blog/2021/02/25/copper-additive-manufacturing-for-heat-exchanger-design/" rel="noopener noreferrer" target="_blank">nTopology blog</a>.

Final part design (Image courtesy of Renishaw)

Commercially pure copper is a highly desirable material for heat exchangers and electrical components due to its excellent thermal and electrical properties. While these properties are beneficial for the application, they also turn the process of using copper in AM into a challenge.

Copper Additive Manufacturing for Heat Exchanger Design

“Toughness” is a combination of an object’s strength (how easily it breaks) and ductility (how easily it deforms). In this way, toughness and impact resistance are one and the same – especially in material science, as toughness is a measure for how easily your part breaks upon impact.<section><h2>Why are toughness and impact resistance important?</h2>Next to strength, toughness is often the most important mechanical property. A tough part will deform before it shatters or breaks, and will also be able to better withstand impact.<h2>Common uses of tough and impact-resistant materials</h2>Tough and impact-resistant materials are often used in jigs, fixtures, and tools in production lines and in the manufacturing industry. <a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing" target="_blank">Heineken</a>, for example, creates parts that are durable enough for everyday use in its manufacturing plants. At its pilot plant in Cologne, Germany, <a href="https://ultimaker.com/learn/ford-reinventing-efficient-manufacturing-using-3d-printing" target="_blank">Ford</a> also uses tough and impact-resistant jigs, tools, and fixtures that must be able to survive intensive use by human operators and on assembly lines. Additionally, <a href="https://ultimaker.com/learn/schubert-a-digital-warehouse-for-on-demand-manufacturing" target="_blank">Gerhard Schubert GmbH</a> uses tough materials to create parts for its multipurpose top-loading packaging machines.<h2>What else should you know?</h2><ul><li><a href="https://ultimaker.com/materials" target="_blank">Ultimaker’s portfolio</a> of tough and impact-resistant materials include Ultimaker Tough PLA, Nylon, TPU 95A and ABS</li><li>Nylon and TPU materials are often used for extreme toughness, with Tough PLA, ABS, CPE+, PP and PC (black and white) used for reasonable toughness</li><li>Materials that are not tough (brittle) are PLA, CPE and PC transparent</li><li>Carbon fiber materials are also often not tough, as they are stiff and therefore brittle, while glass fiber materials are more beneficial for impact resistance &nbsp;</li><li>Flexible materials are often tough, as they are resistant to breaking</li></ul><h2>Our tough and impact-resistant material partners</h2><h3>Lubrizol</h3><a href="https://ultimaker.com/materials/estane-3d-tpu-f70d" target="_blank">Estane® 3D TPU F70D</a> is a semi-rigid Shore D 70 polyether based TPU (thermoplastic polyurethane) at low temperatures while providing UV stability with high transparency.<a href="https://ultimaker.com/materials/estane-3d-tpu-f98a" target="_blank">Estane® 3D TPU F98A</a> is a high-clarity fast printing Shore A 98 polycaprolactone-based TPU (thermoplastic polyurethane) delivering excellent mechanical properties with low warpage and shrinkage.“Lubrizol Estane® 3D F70D which has excellent toughness even at cold temperatures where other materials already become brittle, making it very practical for outdoor exposed applications or parts in freezing environments,” Miguel Navarro, Application Development Engineer for Lubrizol Engineered Polymers, said. “Lubrizol also provides a solution when repetitive impacts are present: Lubrizol Estane® 3D F98A is a flexible material used in applications such as footwear or in automated production lines because of its high elongation at break, which allows it to absorb and dissipate the energy from impacts, thus protecting other materials or objects.”&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611652779397-EstaneTPU-F98A-030_CR_HC_PL.webp" style="width: 788px;" class="fr-fic fr-dib">A part printed with Lubrizol Estane® 3D TPU F98A&nbsp;&nbsp;<h3>Jabil Engineered Materials</h3><a href="https://marketplace.ultimaker.com/app/cura/materials/Eric_Johnson/Jabil_SEBS95A_2019" target="_blank">TPE SEBS 1300 95 A</a> is a modified styrene block copolymer elastomer with a unique set of properties, including very high elongation at break on the XY axis (&gt;780%), which translates into excellent impact strength and abrasion resistance. These attributes, along with a rubber-like feel makes TPE SEBS 95 A a great option to add a soft-touch grip for end of arm tooling (EOAT), material holding nests, boots, and strain reliefs. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611652861839-jabil-tpe-sebs-1300-95.webp" style="width: 788px;" class="fr-fic fr-dib">A part printed with Jabil TPE SEBS 1300 95A&nbsp;"TPE SEBS 95A is also unique as it's an easy to print filament that does not absorb moisture, unlike other elastomers. This translates to easier printability, fewer failed prints and exceptional layer-to-layer adhesion," Matt Torosian, Director of Product Management and Additive Manufacturing at Jabil, said.<h3>Arkema</h3><a href="https://ultimaker.com/materials/arkema-3dxflex-tm-tpe" target="_blank">3DXFLEX™ TPE</a> is an easy to print material with excellent layer adhesion. It's made from Arkema's Pebax® Polyether block amide elastomer, which is highly regarded for lightness, unmatched energy return, and cold temperature durability."Pebax® resin, from which 3DXFlex TPE is created, is a world famous material in tough applications like running and cleated shoes,” Steve Serpe, Market Manager at Arkema, said. “These require a demanding service life and take a phenomenal beating of flex cycles and impacts. We tried hard, but failed to break 3DXFlex TPE during impact testing, even in Z axis at -40 C! This extreme performance is now possible for FFF parts."<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611652923495-ARKEMA-3DFLEX-TPE.webp" style="width: 788px;" class="fr-fic fr-dib">Parts printed with Arkema 3DXFLEX™ TPE&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611652956739-Arkema-Pebax-part-1d.webp" style="width: 788px;" class="fr-fic fr-dib"><h3>BASF 3D Printing Solutions</h3><a href="https://ultimaker.com/materials/owens-corning-xstrand-gf30-pa6" target="_blank">XSTRAND® GF30-PA6</a> is a reinforced PA6 nylon filament with 30% glass fiber, making it up to 250% stronger than neat ABS or nylon.<a href="https://ultimaker.com/materials/owens-corning-xstrand-r-gf30-pp" target="_blank">XSTRAND® GF30-PP</a> is a reinforced polypropylene filament with 30% glass fiber content. GF30-PP delivers superior strength and chemical and UV resistance. With low moisture absorption, this filament is perfect for sports and leisure applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611652987400-OC_XSTRAND_GF30-PA6.webp" style="width: 788px;" class="fr-fic fr-dib">A part printed with XSTRAND® GF30-PA6&nbsp;<div class="fr-img-space-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611653002946-OC-XSTRAND-GF30-PP.webp" style="width: 788px;" class="fr-fic fr-dib">A part printed with XSTRAND® GF30-PP&nbsp;"XSTRAND®  GF30 PA &amp; GF30 PP is a class of unique glass fiber-reinforced engineering filaments that offer users an ideal combination of high stiffness, toughness, and chemical resistance,” Roger Sijlbing, Head of Sales Additive Extrusion Solutions (AES) at BASF Forward AM, said. “With these materials, you can increase your efficiency by 3D printing tools on-demand that are able to withstand high loads in tough environments. Industrial end-users will also be able to explore new applications and business models with XSTRAND®  filaments.”<h3>Mitsubishi Chemical</h3>With excellent weathering, UV stability, impact performance, and stiffness, <a href="https://ultimaker.com/materials/mitsubishi-chemical-3diakon" target="_blank">3Diakon™</a> is an ideal material of choice for outdoor applications and uses and for casting processes where a clean burn to ensure low ash residue is critical to performance. <div class="fr-img-space-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611653029886-daikon.webp" style="width: 788px;" class="fr-fic fr-dib">A part printed with Mitsubishi Chemical 3Diakon™&nbsp;<a href="https://ultimaker.com/materials/mitsubishi-chemical-durabio" target="_blank">DURABIO™</a> is a bio-based, BPA-free engineering 3D printing material developed by Mitsubishi Chemical. With high transparency, similar to Polymethylmethacrylate (PMMA), but better impact behavior and improved heat resistance, DURABIO™ closes the gap between Polycarbonate (PC) and PMMA.&nbsp; <div class="fr-img-space-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1611653054792-a-vehicle-Grill---mitsubishi-durabio.webp" style="width: 788px;" class="fr-fic fr-dib">A part printed with Mitsubishi Chemical DURABIO™&nbsp;"DURABIO™ combines most of the advantageous properties of Polycarbonate (PC) and those of PMMA," Stefano Bertani, Sales &amp; Marketing at Mitsubishi Chemical, said. “In addition to good impact resistance, UV and scratch resistance are key features that explain why DURABIO™ is being used in many MIC (mold in color), high-gloss applications. DURABIO™ beats the well-known inferior properties of PC in regards to scratch resistance, hardness, and chemical resistance.”Ready to get started? You can explore Ultimaker’s range of 3D printers that are compatible with tough and impact-resistant materials.</div></div></div></section>

Schubert uses tough and impact-resistant materials to create parts for its top-loading packaging machines

“Toughness” is a combination of an object’s strength (how easily it breaks) and ductility (how easily it deforms). In this way, toughness and impact resistance are one and the same – especially in material science, as toughness is a measure for how easily your part breaks upon impact.

multi material 3d printing

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