EOS PRECIOUS M 080 review

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The thinnest layer height of filament material the 3D printer can print. The thinner the layer height, the more detailed the final result.

11,301,600 – 28,254,000

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The EOS PRECIOUS M 080 is an industrial 3D printer made by the German manufacturer EOS.

The EOS PRECIOUS M 080 is based on the DMLS (Direct Metal Laser Sintering) 3D printing technology developed by EOS. This 3D printing technique uses a fibre laser to melt and fuse fine metal powder. Layer after layer the 3D object is built. This 3D printing method allows to create 3D printed products with complex geometries including elements such as freeform surfaces, hollow sections and/or articulating parts.

The EOS PRECIOUS M 080 was designed and optimized for the jewelry industry. With the EOS PRECIOUS M 080 3D printer, a wide range of precious metal powder alloys can be used, such as gold, silver, platinum and palladium alloys, wire, sheet, tubing, coin blanks and casting grain.

11,301,600 – 28,254,000

200 – 240 V socket or fixed connection, max. 2.5 kW

The EOS PRECIOUS M 080 is an industrial 3D printer made by the German manufacturer EOS. The EOS PRECIOUS M 080 is based on the DMLS (Direct Metal Laser Sintering) 3D printing technology developed by EOS. This 3D printing technique uses a fibre laser to melt and fuse fine metal powder. Layer after layer the 3D object is built. This 3D printing method allows to create 3D printed products with complex geometries including elements such as freeform surfaces, hollow sections and/or articulating parts. The EOS PRECIOUS M 080 was designed and optimized for the jewelry industry. With the EOS PRECIOUS M 080 3D printer, a wide range of precious metal powder alloys can be used, such as gold, silver, platinum and palladium alloys, wire, sheet, tubing, coin blanks and casting grain.

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I3DMFG and Delta P Design will be attending Shot Show 2018.Shot Showhas been running for 40 years and is an annual tradeshow for shooting, hunting, and the firearms industry. Its the biggest event of its type in the world.

This year the show is January 23 26thand will be at the Sands Expo Center in Las Vegas.

The show also has an Education portion. They have the following opportunities:

I3DMFG, Inc. has become the first Additive Contract Manufacturer in North America to put into operation anEOS M400.4.  Along with this announcement is a white paper discussing the disruptive nature of Additive Manufacturing and why this is critical for manufacturers, both additive and subtractive.

An ultra-fast quad-laser system with a large building volume. It provides Additive Manufacturing for high-quality parts and is designed for speed and precision.

Large building volume of 400 x 400 x 400 mm with four 400 watt lasers operating independently

The four precise 400 watt fiber lasers operate in a 250 mm x 250 mm square each with an overlap area of 50 mm

Exceptional beam and power stability provides highest DMLS part quality

All processes running on the EOS M 290 can be transferred to the EOS M 400-4 and deliver equivalent part properties.

New and patented EOS ClearFlow Technology ensures consistent process gas management for ideal build conditions

Extensive monitoring features ensure high process stability and part quality

I3DMFG is happy to announce that they are the first Additive Contract Manufacturer in the U.S. to have the EOS M400.4 in production.

EOS just released a new white paper discussing the disruptive nature of Additive Manufacturing. The white paper discusses how to approach Additive Manufacturing from three different angles.

One quote that stands out in the article is from Gungor Kara, Additive Minds:

Soon, there will only be two kinds of players manufacturers who disrupt the market and those whose business is disrupted.

The paper introduces a best-practice approach to becoming an industrial champion in the decade to come as it relates to additive manufacturing and remaining competitive.

You can find the white paperhere in our resource library.

I3D Manufacturing is the feature story and on the cover of the latest issues ofA2Z Manufacturing Magazine. The story begins on page 26 and can be readright here.

A2Z did an incredible 3-page story highlighting how I3D is leading the way for additive manufacturing as an ITAR registered company and supporting some of the largest aerospace customers with cost-effective, small batch complex and high-value metal parts.

I3D is currently in the process of certifying to AS9100 Rev. D, by Q3 of 2017.

You can find a copy of this entire article here in ourDMLS libraryas well.

DIRECT METAL LASER SINTERING (DMLS) FOR CAVITIES AND CORES

You needed your Injection Mold Tooling when?

The Direct Metal Laser Sintering(DMLS) process has been rapidly gaining recognition as perhaps one of the most powerful technologies available in the additive manufacturing world. The recent material parameter developments coupled with outstanding resolution and speed of fabrication are making DMLS cavity and core inserts a very successful tool that can be used to shorten lead times, reduce costs and push multiple projects through in the same amount of time that one project normally takes. i3D

Manufacturing can print mold cavity and core inserts within days, giving end-use customers competitive advantages in real time-to-market, product development, and small batch production. Our Aluminum, Maraging Tool Steel and Stainless Steel mold tools can be post processed in all of the same ways as cast or machined parts, from polishing to welding to anodizing.

Interchangeable Cavity and Core Insert Blocks

i3D™ owns North Americas firstEOS M290DMLS 3D Printing machine. As an officialMaterial Process Applications (MPA) for EOS, i3D™ prides itself on its DMLS material and 3D print application innovations. Our interchangeable mold tool cavity and core universal base provides injection molders flexibility in switching out cavity and cores in small and medium batch runs at economical tooling and change-over costs.

With the latest, highest quality equipment i3D™  is able to achieve densities at nearly 100%, allowing for any finish requirements to the various 3D printed cavity and cores. Lattice and honeycomb designs specially tailored for optimal part cooling and heating add more value to the mold block design options. Injection molders can offer their clients tool design, manufacture, and part production in as little as 3 weeks. The process is all on-shore, protecting customer designs and avoiding costly tool change expense. Rapid Injection Tooling is often used as a bridge between prototyping and production but, not always. If you have low volume injection molding requirements, rapid tooling could be the answer for you.

AlSi12 is our most common DMLS Aluminum powder and is perfect for projects with good thermal and low weight considerations. It is an optimal metal for parts with thin walls and complex geometries

Maraging Tool Steel (MS1)

Our Maraging Steel powder has excellent strength and mechanical properties. MS1 is a pre-alloyed, ultra high strength powder most commonly used for tooling applications. Its chemical composition corresponds to U.S. 18% Ni, Maraging 300, European 1.2709 and German X3NiCoMoTi 18-9-5. After heat treatment, MS1 typically has a 50-53 HRC.

PH1 is a medical grade, sterilisable, corrosion resistant steel. It is primarily used in Medical, Firearms, Energy and Automotive applications. After heat treatment, PH1 hardens to 40-45 HRC. Our Stainless steel equivalents include 15-5, 17-4 and 316. Parts made from EOS Stainless Steel PH1 can be machined, spark eroded, welded, micro shot peened, polished and coated if required.

Why would a new small business opening in The Dalles, Oregon be newsworthy toAerospace Manufacturing and Design Magazine? Aerospace is big in the Pacific Northwest and the UAV/UAS giant Insitu is located 20 minutes from i3D™ Manufacturings Direct Metal Laser Sintering (DMLS) factory. 3D metal printing has emerged as a critical component in aerospace, rocket, and UAV design and manufacturing, but until 2014, there were no Northwest DMLS service providers. Insitu, Boeing, and the like were forced to use services thousands of miles  away, reducing some of the lead time and cost advantages 3D printing is known for. Oregon is defined by innovation and i3D™s 3D printing technology is at the forefront of advanced and additive manufacturing. DMLS moves 3D printing from the prototyping realm into true production parts manufacturing. DMLS parts are used in final assemblies by Boeing, Lockheed Martin, GE, etc. In addition to aerospace, i3D™ also provides parts for medical and dental device applications, firearms accessory manufacturers, the energy and recreational gear industries, and automotive parts users.

In 2013, manufacturing accounted for28% of Oregons economy, over $65 billion in output. So, its not surprising that thePortland TribuneandPortland Business Journalalso featured i3D™ in their Summer 2014 publications. As opposed to traditional, or subtractive manufacturing where parts are carved out of billet, the additive manufacturing process starts with 20-40 micron layers of powdered metal and uses a laser to melt thousands of micro layers together, one layer at a time based on a 3D CAD model adding material only where the model dictates.  The no-waste process enables parts to be built that cannot be traditionally manufactured, including complex geometries, lattice and honeycomb structures, conformal channels, and single part builds of multi-part assemblies. i3D™ prints stock metals including Titanium, Aluminum, Inconel, 15-5 and 17-4 Stainless Steel, and Maraging Tool Steel as well as custom powders created for specific customer applications. The Dalles has a long history of metal manufacturing and gave i3D™ a warm welcome to its community and the Columbia River Gorge region. BothThe Dalles ChronicleandGorge Technology Alliancecelebrated i3D™s headquarters locating in Oregon.

WhenINDUSTRYandTi Cyclesdesigned their entry for theOregon Manifestbike design project, their vision required next generation technology and exotic metals that would then be hand-crafted by artisan bike makers into a premier urban commuter bicycle. Creating a beautiful balance between local artisan and new technology meant designing in a completely different mindset enter,3D printing. Keeping it local, INDUSTRY brought Oregon-based i3D™ Manufacturing on board to 3D print components that simply could not be manufactured using traditional methods. Included in these custom parts were intricate handlebars housing a bluetooth smartphone app called My Bike which monitors bike maintenance and alerts you to when a light needs to be replaced or when something goes wrong with your brakes. Another software, Discover My City, has a series of curated rides from five of Portlands coolest residents, which suggests where to ride, eat and shop. The rider simply gets buzzed with the alerts, keeping them connected as they commute. Ti Cycles signature tubing Titanium frames are the perfect way to make sure no wires interfere with the rider and preserve the aesthetics of the bike design. The curves and junctions of parts of the frame also needed to be 3D printed because the tubing could not be traditionally manufactured to hold the lines properly. i3D™ printed fork crowns, front and rear dropouts, head tubes, bottom brackets, and seat clusters for the bike. The titanium printed part welds showed superior strength and seamlessly integrated with the tubing. 3D printing and phone apps aside, in the end, it was the skill and craftsmanship of Ti Cycles that brought the high tech and custom bike manufacturing together to create a perfect blend of utility and elegance. Go see what all the buzz is about at,Engadget,treehugger,andBike Portland.

i3D™ Manufacturing joinedINDUSTRYandTi Cyclesin creating a 3D printed titanium bicycle as Portlands entry for the 2014Oregon Manifest Bike Designcontest. 3D printing is a perfect solution for those wanting to manufacture a tailor-made product. Whether aesthetics, function, weight reduction, design innovations, or exotic metal cost effectiveness are the goals, additive manufacturing is a game-changer for design and manufacture. Direct Metal Laser Sintering (DMLS) produces functional production parts by fuses 20-40 micron layers of metal powders together from a 3D CAD model. Multiple CAD models can be built on a single run, facilitating cost effective single part production, allowing for multiple versions of the same part to be run simultaneously for evaluation, and reducing lead times from weeks or months to hours and days. Exotic metals like Titanium and Inconel become cost effective because DMLS is a no waste process after the micro lasers are laser melted together, the left over powder is vacuumed back into the machine and reused. Traditional manufacturing of these costly metals often resulted in as much as 70% scrap, making Titanium cost prohibitive despite its perfect match for the bicycle industrys weight and strength property requirements. While working with Titanium proved more difficult than other DMLS metals, i3D MFG™ added supports and geometry adjustments for structural rigidity and thermal dissipation to offset tolerance and creep issues created by mass, height, and stress relief. Custom latticed parts, innovative fork crown geometries, and organic frame lines were all possible using 3D printing. Design-for-3D erases all traditional manufacturing limitations, including minimum order quantities, machine lines, and complex assemblies. Furthermore, the weldability and post process properties of 3D printed parts is generally better than cast parts and comparable to machined parts.  Read3D Print News interviewwith Ti Cycles ordesignbooms articlefor details on this exciting Titanium bicycle project.

3D printed bikeAdditive Manufacturingi3D Manufacturingtitanium bicycle

i3D MFG™ is the market leader in additive manufacturing technologies specializing in DMLS (Direct Metal Laser Sintering), Wire EDM, Metal Powder Development, and Blue Light Scanning.

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i3D MFG™ is the market leader in additive manufacturing technologies specializing in DMLS (Direct Metal Laser Sintering), Wire EDM, Metal Powder Development, and Blue Light Scanning.  © 2017i3D MFG™, All right reserved.

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3D Printing News Briefs: November 21, 2017

bySarah SaundersNov 21, 20173D Printers3D Printing3D Printing Materials3D SoftwareBusinessMetal 3D Printing

Today in 3D Printing News Briefs, business is taking the focus. At formnext last week, DyeMansion and EOS announced a strategic partnership, and DSM Somos has partnered with UnionTech for materials distribution. Proto Labs will acquire RAPID Manufacturing Group, while TechShop closes its doors due to bankruptcy. SLM Solutions receives a large order for its new SLM 800 machine at formnext, and 3D Platform hits a major 3D printer milestone.

DyeMansion and EOS Form Strategic Partnership

(L-R) Felix Ewald, CEO DyeMansion; Adrian Keppler, CEO EOS GmbH; and Philipp Kramer, CTO DyeMansion at EOS in Krailling.

At last weeksformnexttrade fair in Frankfurt,EOSexhibited its plastic AM portfolio, including its newEOS P 500, while AM finishing systems leaderDyeMansionshowcased its three-stage Print-to-Product workflow, for depowdering, surfacing, and coloring. Also at the event, the two companies announced that they had entered into a strategic partnership, to offer their customers full polymer AM process chains. EOS will combine the complementary portfolios of both companies for high-value consumer and industrial product chains, implementing DyeMansions workflow equipment at its Krailling, Germany headquarters so its customers can enjoy high-end, quickly colored 3D printed products.

We are proud that EOS has selected DyeMansion as a strategic solution partner. Together we are able to offer the Print-to-Product workflow to the most demanding AM customers worldwide, said Kai Witter, Director Global Sales, DyeMansion. Since the product launch at formnext 2016, DyeMansion has delivered more than 70 systems which proves the great acceptance of their solution portfolio. Now together with EOS, we have a strong partner who will help us serving even more AM customers around the world.

DSM Somos Works on Materials Distribution with UnionTech

Example of Somos Perform in prototype injection molding tooling.

Since 2003, Shanghai Union Technology Corp. (UnionTech) has had an active distribution agreement forDSMs Somos SLA materials. However, because the companyexpanded into the USand European markets last year, it has now augmented its original partnership agreement with DSM Somos to includeglobal distribution of the Somos materials. The new agreement covers all Somos materials that are available for UnionTechsPILOTcommercial series, and its RSPro production product lines. Additionally, UnionTech will also offer its in-house developed PolyDevs software to commercial 3D printing users as a more cost-effective option for PILOT data preparation.

Barry Tsou, UnionTech President, said, We are proud to work very closely with the Somos group, combining our fully open hardware platform technology with their constant innovation in resin development. Working together on open platforms brings huge benefits in developing materials that meet the criteria of our customers needs directly.

Proto Labs to Acquire RAPID Manufacturing Group

With the acquisition of RAPID, Proto Labs expands its manufacturing services to include low-volume sheet metal fabrication. [Image: Proto Labs]Today,Proto Labsannounced that it hasreached a definitive agreementto acquireRAPID Manufacturing Group, a privately-held custom parts supplier in New Hampshire that specializes in CNC machining and quick-turn sheet metal fabrication. By acquiring RAPID for an aggregate purchase price of $120 million ($10 million in stock and $110 million in cash), Proto Labs will expand its services with the addition of quick-turn sheet metal fabrication, which reinforces promises the company has made to its customers to improve supply chain efficiencies and optimize product development. Subject to customary closing conditions, the transaction should close by the end of the year.

We listen to our customers very closely to understand their needs. We continue to look for opportunities to expand our capabilities to serve our existing customers and to expand our customer base. RAPID not only adds quick-turn and e-commerce-enabled sheet metal services to our portfolio, it also expands our machining capabilities to support larger and more complex projects, explained Vicki Holt, CEO of Proto Labs. In addition, RAPIDs culture is highly aligned with that of Proto Labs, with a talented and experienced team that we are very excited to welcome to the Proto Labs family.

Proto Labs will host an analyst day next month, where Holt and other Proto Labs leadership team members will present on the companys business strategies and growth opportunities, including its RAPID acquisition. Starting at 10 AM EST on December 12th, a live webcast of the event will be available on the companys investor relations page, with a webcast replay available shortly after the analyst day is over.

TechShop Closes US Locations, Files for Bankruptcy

In June, open-access makerspaceTechShopmade the decision toclose its Pittsburgh location, as it wasnt meeting its operating expenses in the wake of the membership-based business making an effort to stabilize by reducing cash deficit and improving individual store performances. But recently, TechShop shuttered all 10 of its US locations, and its small corporate group, and declared Chapter 7 bankruptcy; global locations owned by overseas licensees are not affected.

In a notice to members,published in full on the Make: site, TechShop CEO Dan Woods wrote, Im not going to spin this. Weve been operating on exceedingly low cash balances for quite some time now. Until recently, this meant late payment to instructors and vendors, which none of us liked, but at least we were able to pay everyone, albeit several weeks late, and keep the doors open. As I shared with many of you directly, I wasnt happy operating that way. We were trying to do whatever we could to keep the doors open and remain operational so that we could see the light of the next day and hopefully close on a couple of large licensing deals we had been working on. However, this cannot go on any longer. The current cash conditions and the toll they are taking on employees, instructors, and members are entirely unacceptable.

In hindsight, we invested too many years and too many dollars trying to prop up the wrong business model. What we accomplished over the past ten years, however, has been nothing less than monumental. I encourage our members, employees, partners, and the entire maker community to take something constructive from TechShops experience: the world needs makerspaces.

TechShop explored options to file Chapter 11 bankruptcy instead, which would have allowed the organization to reorganize and restructure its debt, but ultimately did not have the required funds to do so.

SLM Solutions Receives Major 3D Printer Order at formnext

[Image: SLM Solutions via Twitter]Metal 3D printer supplierSLM Solutions Group AGpresented its new large-format SLM 800 machine model at formnext last week, and on the very first dayreceived a major order for 20 of the machines, and oneSLM 280, from an energy sector customer based in Asia, where the company has been working to attain a more noticeable presence since its 2014 IPO. The total volume of the contract is at least €37 million, with the possibility of increasing the order volume with the purchase of additionalSLM 500machines at a later date.

The outstanding quality of build parts that can be achieved on all our machine types, our market-leading multi-laser technology and in particular the large construction chamber of the SLM 800 convinced the customer, said Henner SchÜneborn, board member of SLM Solutions. We are convinced that the new machine model is of great interest to many companies around the world who are planning the use of production-oriented additive manufacturing machines in their manufacturing processes.

The 3D printing systems will be delivered to the customer between 2017 and 2019.

3D Platform Ships 500th Large Format 3D Printer

Illinois-based 3D printer manufacturer3DPlatform(3DP), which develops large format, industrial FFF machines, celebrated a major milestone earlier this month it has nowshipped out 500 large format 3D printersto customers in just three years. The company has worked hard to develop a solution that would work for many different customers, resulting in the WorkSeries and its four base models: the WorkTable, WorkBench Classic, WorkBench Pro, and Workbench Xtreme; the 3D printer line also has several options and upgrades available. Obviously, as the 500th machine shipped earlier this month, 3DPs customers appreciate the companys efforts.

3DPs commitment to our customers has led to a very loyal customer base with many them coming back to purchase another printer, said Mark Huebner, Market Development Manager for 3D Platform. We have multiple customers who own more than 5 printers! They will use them not only for prototyping, but deploy them in production support capacities.

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Discussion related to 3D Printer parts, such as hot ends, extruders, and anything else you may want to discuss related to printer parts, as well as filament, resin, and sintering powder.Inside 3D Printing EventsSingaporeFebruary 6-7, 2018DsseldorfFebruary 21-22, 2018SydneyMay 9-11, 2018SĂŁo PauloJune 11-12, 2018SeoulJune 27-29, 2018New YorkOctober 30-31, 2018TokyoOctober 2018

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Formnext expo sees 3D laser printing innovations

Concept Laser and EOS present new approaches and tools at last weeks Frankfurt show and conference.

At Formnext, Concept Laser presented its smart and robust production approach.Formnext, the international exhibition and conference on additive technologies and tool making, which ran last week in Frankfurt, Germany, gave several developers of laser additive manufacturing systems a good opportunity to showcase their latest innovations in this rapidly-expanding industrial sector.

Concept Laserpresented a new machine and plant architecture. A modular, integrated machine concept called AM Factory of Tomorrow offers modular integration of this machine technology to the manufacturing environment, with what the company calls a radically new approach in the design of process components. After its debut at Formnext, Concept Laser will launch it into the market by the end of 2016.

Dr Florian Bechmann, Head of R&D at Concept Laser, explained Factory of Tomorrow is about splitting up a build jobs preparation, follow-up processing and additive manufacturing in any number of combinable modules. With comparatively large build envelopes, jobs can be carried out with a time delay. Our intention is that this should drastically reduce the downtime associated with previous stand-alone machines. There is plenty of potential here for improving the level of added value in the production chain.

Bechmann said, AM users experience the pressure of traditional manufacturing: demand for space, expansion of the machinery, increasing operating tasks and in particular times. In the new approach from Concept Laser, interesting solutions are offered in this regard: production is decoupled in machine terms from the preparation processes. The time window for AM production is therefore increased to a 24/7 level, meaning that there is higher availability of all components.

Concepts concept: the modular AM Factory of Tomorrow.Modular scenario

Concept Laser argues that by adopting its AM Factory of Tomorrow approach the requirement for build space can be reduced by up to 85% compared to current models. In addition, the laser power per square meter may be increased seven-fold. Build rates have increased enormously thanks to the multilaser technology, said Bechmann. Build envelope sizes have also experienced considerable growth. We now want to use an integrated machine concept to highlight the possible ways that the approaches of Industry 4.0 can change additive manufacturing as the manufacturing strategy of the future.

In an example presented by Concept Laser at Formnext, the laser processing station offers a build envelope of 400 x 400 x>

400 mm3, laser sources, process gas management and filter technology are integrated in the module. This machine solution has a variable focus diameter and will be available optionally with 1, 2 or 4 laser optics with a laser power ranging from 400W to 1kW. Bechmann said, More and more laser sources only increase the expected speeds to a limited extent. But ultimately they also increase the level of complexity and dependencies, which can result in vulnerability, and thus turn the desired positive effect into a negative.

EOS presents holistic approach to 3D printing

Additive manufacturing specialistEOS also used the Formnext expoto demonstrate a new approach and new equipment. The German-headquartered company believes a central concern of this expanding industrial sector is to establish a holistic approach to quality assurance in series production.

EOS at Formnext: It has doubled its installed base over the past three years.Dr. Tobias Abeln, Chief Technical Officer at EOS, stated, Consistent and repeatable part quality is essential for series production applications. With our quality assurance concept, EOS covers the three technological elements of additive manufacturing, which have a direct influence on the quality of an additively manufactured component namely system, material and process. Thanks to the joint development and mutual adjustment of systems, materials and processes, EOS has established the conditions for best possible part properties.

At Formnext, EOS was showcasing its solutions with the theme Shaping the future of manufacturing. As well as presenting its established portfolio of systems, qualified materials, processes and services, the company introduced a new metal system, a new monitoring solution, and new work material. The EOS M 100 is a compact system that provides a cost-effective entry into Direct Metal Laser Sintering, said the company.

Dr. Adrian Keppler, Chief Marketing Officer at EOS, said, Our company has been pursuing an unparalleled course of growth and success for several years. By October 2015, there were approximately 2,000 EOS systems installed around the world. We were able to double our installed base over the last three years; during the last two years, the number of metal laser sintering systems was doubled from 400 to 800 systems.

New from EOS: the M100 system for Direct Metal Laser Sintering.During the past business year alone, the company sold 400 systems, including 220 metal systems. This underlines EOS leadership role particularly in the metal segment, and the growing interest in this technology particularly in the series production segment. We expect that market demand will continue to rise in the future – not least because leading companies worldwide trust in our technology.

Also during 2015, EOS has increased sales revenues by 53 percent over 2014, to €263 million. All regions exceeded its targets, especially North America delivered a record result with more than $100 million in sales revenues. Today, EOS has 750 employees worldwide, which represents an increase of 38 percent in its global workforce compared to the previous year.

The company says its growth is reflected in the fact that individual locations are also experiencing steady growth. At its Krailling headquarters, EOS recently started the construction of another building, since the technology and customer centre, which started up just last year, is already reaching the limits of its capacities.

Matthew Peach is contributing editor to.

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About EnvisionTEC

EnvisionTEC is a leading global provider of professional-grade 3D printing solutions. Our company invents, develops, manufactures and sells 3D printers and proprietary materials worldwide.

Founded in 2002 with its pioneering commercial DLP printing technology, EnvisionTEC now sells more than 40 printers based on six distinct technologies that build objects from digital design files. The companys premium 3D printers serve a wide variety of medical, professional and industrial markets, and are valued for precision, surface quality, functionality and speed. EnvisionTECs intellectual property includes more than 100 pending and granted patents and 70 proprietary materials.

In 2016, EnvisionTEC had the third largest share of the global industrial additive manufacturing market, according toWohlers Report 2017.

EnvisionTEC has facilities and partners around the world, where we develop 3D printer technologies, materials, manufacture our printers and sell, service and support our products.

We also sell our printers through an experienced and consultative sales team, which includes dealers and resellers, with locations around the world.

Detroit, Michigan North American Headquarters. Business operations, R&D, Service & Support

Gladbeck, Germany International Headquarters. R&D, Production

Los Angeles, California Production, R&D

EnvisionTEC was founded in 2002 by engineer entrepreneur Al Siblani.

Siblani immigrated to the United States from Lebanon to attend college. After earning a bachelors degree in engineering at Lawrence Technological University in Metro Detroit and a masters degree in electrical and computer engineering from Wayne State University, also in Detroit, Siblani entered a 3D printing market still in its infancy. He was 26.

The first rudimentary methods of 3D printing were developed in the early 1980s, and Siblani began working in 1993 for an early 3D printing company, Helisys, that used Laminated Object Manufacturing (LOM) technology to create prototypes for automakers and other commercial customers. Shortly thereafter, he founded Sibco Inc., which provided 3D printing services and materials, often to the Detroit Three automakers.

In 1996, after mastering the 3D printing technologies and materials at that time, Siblani decided to make his own 3D printing machines using a novel idea to cure liquid resins into objects.

His first patent submission, which laid the foundation for EnvisionTEC, was filed in 1999. Sasha Shkolnik, who had worked with Siblani at Helisys, helped to develop the technology with Siblani and has been the Chief Technology Officer of the company since its founding.

EnvisionTECs first 3D printer was a hit in the jewelry market largely because of its ability to deliver incredible precision and surface finish, quickly and the technology spun out to other sectors from there. Customers who manufacture hearing aids, dental prosthetics and other small and smooth parts followed.

Today, as the 3D printing market continues to mature, many different processes are used around the world to 3D print objects from digital design files.

EnvisionTEC now relies on six unique and different processes to 3D print objects from digital design files, and its technology makes parts big and small in a wide range of industry-leading materials, including a growing library of materials certified for medical use.

Digital Light Processing:A vat of liquid photopolymer or resin is cured by a digital light source to build parts.

Scan, Spin & Selectively Photocure (3SP): A laser uses a rapidly spinning mirror to selectively cure liquid resin into parts.

Continuous Digital Light Manufacturing (cDLM): An improvement to the DLP process that relies on continuous motion of the build plate to provide exceptionally fast builds.

Bioprinting: Processing of biomaterial using air or mechanical pressure to a syringe, which can fabricate scaffolds using a wide variety of materials.

Selective Lamination Composite Object Manufacturing (SLCOM): Processes a wide range of woven fibers preimpregnanted with thermoplastics using an ultrasonic cutting blade to create large composite parts.

Robotic Additive Manufacturing (RAM): Through an exclusive strategic partnership with Viridis3D, EnvisionTEC is leading the way with robotic 3D printing, initially using binder jetting technology for sand casting in the foundry industry.

EOS to present industrial 3D printing vision at formnext 2016

additive manufacturing and software systems for the polymer and metal segment, along with many different service and consulting products, at. EOS will showcase industrial 3D printing systems which companies can integrate as a key element in their existing and future manufacturing methods. EOS will be exhibiting in Hall 3.1, Booth G70 under the motto Shaping the future of manufacturing. Formnext takes place from 15 to 18 November 2016.

EOS Additive Manufacturing technology has proven its worth for numerous customers across a number of industries whether complex lightweight structures, reductions in costs through functional integration, product individualisation or accelerated product development and production. Industrial 3D printing has now reached serial production. This brings with it new customer demands and calls for corresponding solutions. It is not so much a question of where additive can replace conventional manufacturing, but rather its integration in existing production environments and with conventional manufacturing technologies. With new offerings in the fields of High Productivity Platforms, Excellent Processing, Connected Manufacturing as well as Service and Consulting, EOS provides the basis to help achieve the next level of Additive Manufacturing.

Dr Adrian Keppler, Chief Marketing Officer (CMO) at EOS, comments: For more than 25 years, EOS has been instrumental in the development of AM as a technology pioneer and a leading company in the field of Direct Metal Laser Sintering as well as the provider of a key polymer technology. The industry is now at the next big stage of development: integrating AM in existing and future production environments, with the aim of further optimising the flow of parts and data in serial production. The combination of additive and subtractive manufacturing steps plays a key role here. EOS remains a reliable partner and advisor for its customers. Our latest product premieres at formnext will help shape the future of manufacturing by accelerating integration, automation and productivity.

The positive attitude to the future is nurtured by the success of the company so far EOS remains on course for continued growth. The company was able to increase its turnover by 20 per cent over the previous business year to around 315 million euros. Over this period, EOS delivered approximately 450 systems, so that, as per October 2016, around 2400 EOS systems have been installed worldwide.

This business success is also reflected in the continued growth of the company worldwide. In May 2016, EOS extended its presence in the USA and opened a new office in Pflugerville, Texas. The construction of the additional company building is making rapid progress at the headquarters in Krailling, a further location to expand the technology plants will be opened in Maisach, Germany next year.

EOShas further increased its workforce, hiring 250 additional experts since October last year to support the continued growth of the business and AM systems worldwide. This means that by the end of this year EOS will employ 1000 people worldwide. More information about the company can be found at

First Surface Oberflächentechnik GmbH EOS and BESTinCLASS Found Joint Venture for the German-speaking Market

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First Surface Oberflächentechnik GmbH: EOS and BESTinCLASS Found Joint Venture for the German-speaking Market

Todd Grimmposted on November 29, 201110558 views

The MPP process yields smooth finishes on DMLS parts.Source: EOS GmbH

EOS GmbH is setting up a joint venture for the German-speaking market with the Swiss company BESTinCLASS under the name First Surface Oberflchentechnik GmbH in January 2012. The company will have its headquarters in Krailling near Munich Germany.

First Surface will rely on BESTinCLASS Micro-Machining Process (MPP), which improves surface finish of direct metal laser sintering (DMLS) components.

Surfaces can be treated in many ways. But First Surface (FS) is the first supplier on the German market to improve surface roughness in order to increase its performance, explains Dipl.- Ing. Frank Wiermann, managing director of First Surface Oberflchentechnik.

This joint venture is a perfect combination of two future-oriented companies, says Dr. Hans Langer, founder and CEO of EOS. The application spectrum ranges from prototypes to series products. Through the joint venture, we can extend our services to customers beyond design and the manufacturing process to include the surface finishing of laser-sintered components. This gives our customers a huge competitive advantage.

According to the company, the MPP technology not only permits a surface as smooth as glass, it also has further advantages over other polishing methods. These include exact reproducibility and surface homogeneity, maintenance of design style and the ability to control costs.

First Surface aims to replace manual and semi-automatic methods of surface treatment by an industrial, fully automatic process, thus optimizing component surfaces and achieving reproducible results.

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EOS Named a Game Changer Company and Wins a Challengers Award in Germany

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EOS Named a Game Changer Company and Wins a Challengers Award in Germany

(3DPrint.com) EOS E-Manufacturing Solutions has been named the winner of the Challengers category of the Game Changer Awards to honor German companies that are changing their industries with creativity and innovation. Three categories, Challengers, Incumbents, and Focused Players, were created by the sponsoring agencies German business publication Manager Magazine and consulting company Bain & Company. Only companies with headquarters in Germany were considered for the awards. The Challenger award, which had 78 candidates, focused on the disruptive potential of the business model and its impact on customers and competitors.

As the market leader and pioneer of the revolutionary industrial 3D-printing technology, we considered EOS an obvious candidate for the Game Changer Award, said Olaf Koch, chief executive officer of METRO AG and one of the judges who selected the winners. EOS development, since its formation in 1989 to the present, provides impressive proof, as the company progressed from rapid manufacturing of prototypes through small series to series production for larger volumes.

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Industrial 3D-Printing Technology Leader to Establish North American Headquarters In Pflugerville

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Industrial 3D-Printing Technology Leader to Establish North American Headquarters In Pflugerville

Pflugerville Community Development Corporation Recruited and Negotiated Deal Securing EOS of North America, Inc. with 44,680 Square Feet Lease at 130 Commerce Center; 75 Jobs

PFLUGERVILLE, Texas Pflugerville Community Development Corporations (PCDC) Interim Executive Director Amy Madison today announced EOS, a global market leader in industrial 3D- printing technology, will expand business operations and establish North American headquarters at Pflugervilles 130 Commerce Center.

This move is projected to create 75 new jobs in Pflugerville within the next three years. Within the last two weeks the PCDC has successfully signed leases for more than 60,000 square feet of office and light industrial space at Pflugervilles 130 Commerce Center.

Pflugerville offers EOS access to a diverse and talented workforce and major transportation corridors that have made Central Texas a growing hub for high-tech industries in the United States, said PCDC Interim Executive Director Amy Madison. These resources are critical for an innovative technology leader looking to further expand its market share with major aerospace, medical, automotive, tooling, consumer, and industrial organizations. They need a community where they can continue to grow and evolve  Pflugerville is that place.

PCDC recruited EOS and negotiated the deal that will move aspects of regional applications, inventory, and research and development operations from outside Detroit, Michigan, to Pflugerville. Company global headquarters will remain in Germany while Pflugerville will become home to EOS North American headquarters. The Pflugerville City Council approved the deal on Oct. 27.

Under terms of the performance agreement, EOS will lease 44,680 square feet of space at the 130 Commerce Center and hire 20 full-time employees making an average yearly wage of $70,000 plus health benefits. The company looks to increase the number of jobs to 75 within three years. It is expected that EOS operations will be in place in Pflugerville by December.

Utilizing groundbreaking and innovative 3D printing, EOS will harness powerful laser technology to design customized products here in Pflugerville, said Pflugerville Mayor Jeff Coleman. During the companys 25 years, theyve been recognized as a world leader with an international reputation in manufacturing systems used in 3D printing, introducing a variety of methods and specialization in precision surface machining. From their first offices in Munich, Germany to Shanghai, China, EOS is a growing company with a great future, and we are proud to have them expand their North American operations with headquarters in Pflugerville.

EOS chose to expand in Pflugerville for the convenience to greater Austin-area amenities, the location on Highway 130, and access to the airport and major shipping centers needed to support EOS business enterprises.

EOS already has a strong technical and management presence in Central Texas and the move to Pflugerville gives us business stability during a time of high growth, said EOS Chief Operating Officer Donald Vanelli. What we most needed was the ability to get our operations concentrated into a good location quickly and efficiently without the time-consuming challenge of having to build and develop from the ground up. The Pflugerville Community Development Corporation was essential to making this move happen and we look forward to expanding our customer services and application support in North America.

EOS develops and markets industrial 3D-printing technology, also referred to as additive manufacturing (AM), used by companies around the world for manufacturing complex geometries unobtainable via conventional manufacturing methods. The process is a manufacturing game changer by which 3D design data is used to build up a component layer by layer. Essentially, EOS provides the infrastructure including the systems, software, materials, material development, consultation, and services to enable a company to utilize industrial 3D printing and AM applications.

EOS opened North America operations in 2001 and recently celebrated its 26thanniversary. The company employs more than 700 employees worldwide, with customers in over 50 countries and close to 3,000 systems installations worldwide.

For more information about the PCDC or to set up an interview with Interim Executive Director Amy Madison, please contact Lindsey Pope at(512) 626-1591or email herhere.

The Pflugerville Community Development Corporation promotes Pflugerville as a desirable place for new businesses to operate. The organization also supports existing businesses by helping to address their needs. PCDC can provide funding for use as an incentive to businesses to begin doing business in Pflugerville. PCDC funds, which are 4B money generated from a half-cent of the citys sales tax revenue, can also be used to construct needed infrastructure such as roads, utilities and drainage projects. Located 16 miles northeast of Austin and just south of Round Rock, Pflugerville is well situated in Central Texas. New state highways 45 and 130 and Interstate Highway 35 all offer direct access to other nearby cities and the regions main airport.

Founded in 1989, EOS is the global technology and quality leader for high-end additive manufacturing (AM) solutions. As the leading pioneer of Direct Metal Laser Sintering (DMLS™) technology, EOS also provides a unique polymer AM portfolio. For these industrial 3D-printing processes, EOS offers a modular solution portfolio including systems, software, materials, technical and consulting services. EOS is the partner of choice for industrial AM production, enabling sustainable solutions for the industry. Customers utilizing EOS AM solutions gain many benefits from the paradigm-shifting technology: lightweight structures, cost reduction based on functional integration, individualization  as well as accelerated product development and production. For more information, visit

Conveniently located near Austin, in the heart of Central Texas, Pflugerville boasts dozens of business incentives and opportunities:

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Under Armour

Under Armour showcases futuristic 3D-printed shoe.

Under Armour announced a partnership this week with EOS, a supplier of industrial 3D printing equipment and consulting services, to ramp up the sportswear companys efforts to bring 3D-printed sneakers to market.

EOSwill provideUnder Armour, which recently announcedits first connected running shoe, with advanced laser sintering technology, an additive manufacturing technique in which a laser builds objects using powdered materials.

This partnership is set to achieve Under Armours goal to industrialize and scale 3D printing of performance footwear, Glynn Fletcher, President of EOS North America, said in a statement. True additive manufacturing has come to Under Armour; no other athletic brand can make this statement.

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In addition to using EOS technology to print powdered-based parts for its footwear, Under Armour and EOSs consulting division, EOS Additive Minds, will work together to develop new polymer-based materials that can be used with EOS laser sintering technology, which may ultimately find their way into Under Armour products.

Upon announcing the partnership, Under Armour showcased UA ArchiTech Futurist footwear (pictured below) that illustrates the kinds of products the two companies are aiming to produce together.

This partnership adds to a slew of efforts Under Armour has taken in recent years to add technology to its existing line of traditional apparel, accessories and footwear.

While 3D printing enables the company to more cost-effectively scale the manufacturing side of its business, Under Armour has also announced a line of direct-to-consumer connected fitness products that assist users during workouts.

Connected fitness is still a tiny portion of Under Armours overall business by revenue, but its quick pace of growth (up 16 percent last quarter compared with an 8 percent decline for apparel) signals a new area of focus for the company centered on using technology to enhance its products and manufacturing process.

3D Printing,additive manufacturing,eos,footwear,Under Armour

Jen is a senior writer at SportTechie covering the many ways technology is disrupting sports. On any given day she may cover a wide variety of stories ranging from the newest virtual reality training tools for the NFL, the rise of eSports leagues and the infiltration of drones in extreme sports. Prior to joining SportTechie, Jen was a technology reporter at MarketWatch, where she covered major Silicon Valley companies, such as Apple, Amazon, Google and Facebook. Jen is a licensed skydiver who jumps out of planes, helicopters and hot air balloons for fun in her spare time. Shes a former NCAA cross country athlete and currently lives in Hoboken, New Jersey.View all posts by Jen Booton

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3D Printings New Materials Part 2 Metal

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3D Printings New Materials, Part 2: Metal

3D Printings New Materials, Part 2: Metal

Posted by:Pamela J. WatermaninPrototype/ManufactureNovember 1, 2014

18k gold watch-case produced for Hoptroff London on the new PRECIOUS M 080 AM system from EOS and Cooksongold. Image courtesy of Hoptroff.

Read part 1 of this article, 3D Printings New Materials: Plastics, Ceramics, Composites and More.

When it comes to making parts out of metal, additive, subtractive and hybrid technologies may all offer a solution that meets your needs. Mindful of the old adage, what the customer really wants is a hole, not a drill, system manufacturers and supporting businesses continually work to supply a tool that simply gets the end-job done. That need is increasingly being addressed by additive manufacturing (AM), sometimes combined with subtractive (traditional) processes.

AM is gaining acceptance across an ever-widening range of industries. Tim Caffrey, senior consultant at Wohlers Associates, reports that unit sales of metal AM systems increased 75% from 2012 to 2013, growing faster than the rest of the industry. He notes that while medical applications form a large segment of this market, aerospace is definitely growing, referring to GE Aviations 2013 acquisition of Morris Technologies with its EOS direct metal laser sintering (DMLS) technology.

The GE Aviation fuel nozzle project is going forward a little bit slower than we thought, but as far as I know, there is no Plan B, Caffrey says. He adds that Airbus has been fairly visible about working with AM, along with Rolls Royce and Pratt & Whitney. Aerojet Rocketdyne is also working on 3D-printed rocket-engine components.

In this second article of a two-part series on the world of AM materials (see 3D Printings New Plastics, Ceramics, Composites and More,Desktop EngineeringOctober 2014),DEreviews developments in metals by longtime players and newer entries in the field, activity with standards organizations, technology resources, and market implications behind these processes.

Titanium alloys, nickel alloys, cobalt chrome and several stainless steels are the most common materials used for AM processing, but years of behind-the-scenes development are paying off with even more options. The following companies represent just a few of the metal AM systems; these all work with powder-bed formats, but create parts through different technologies.

Thermal management device made of copper and aluminum ultrasonically bonded on a Fabrisonic SonicLayer 7200 system. Image courtesy of Fabrisonic.

In mid-September, EOS announced it has partnered with Cooksongold (a UK-based supplier of fabricated precious metals) to launch the PRECIOUS M 080 DMLS system. Equipped with a 100-watt fiber laser whose small spot-size allows extremely fine resolution, the PRECIOUS M 080 has a build volume of 80mm diameter by 95mm high, including the build platform. The system currently operates with a variety of gold alloys targeted to luxury watches and jewelry; additional materials are planned. Earlier this year, EOS announced a new corrosion-resistant grade of titanium TI64ELI and a highly ductile SS316L good for medical instruments and watch cases, bringing its own material count to 13.

3D Systems never stands still. In September, it acquired LayerWise of Belgium, whose laser-sintering approach adds another direct metal AM process in-house. Rachael Dalton-Taggart, 3D Systems director of marketing communications, professional products, says, The LayerWise acquisition brings new technologies, tools and services to our portfolio. Commenting on the companys expanding metal capabilities, she adds, Our three ProX metals printers are a direct development from the technology acquired from Phenix Systems last year. ProX systems currently support more than 11 materials, including bronze, aluminum and Inconel 718. Dalton-Taggart says that 3D Systems is testing molybdenum, Inconel 625, pure copper, tungsten and other stainless/tool steels. Using ProX equipment, customers such as Metal Technology Inc. (MTI) are developing additional materials, including C-103, a niobium-based alloy widely used in space applications.

Nickel-based alloys are desirable for their resistance to heat and corrosion. Arcam, with its Electron Beam Melting systems, has added nickel-based Inconel 718 to its material list, joining EOS, 3D Systems, Concept Laser, Renishaw and SLM Solutions, among others, in offering this material for sintering/melting.

Taking a very different approach to producing fully dense AM nickel parts, ExOne, with its jetted-binder-on-powder technology, introduced Inconel Alloy 625 in May; parts display an impressive 99% density. This achievement brings the company a big step toward its goal of single-metal 3D-printed parts (compared to its stainless steel/bronze-infiltrated process).

ExOne continues to put extensive effort into materials development, saying its ExMAL group is on track to qualify a new industrial material every six months. Its also working with the University of Pittsburgh and Magnesium Elektron Powders on magnesium and iron-based alloys for biomed applications.

Fusing a bed of powdered metal represents one approach to metals AM. Another technique, direct-metal-deposition (DMD), involves injecting raw material into a heated melt-pool and either fusing it onto an existing part or free-forming it directly on a build-platform. DM3D Technology (previously POM) and Optomec have employed variations on DMD systems for a decade or more; RPM Innovations and Sciaky are more recent entrants in this field; and NASAs Jet Propulsion Laboratory has its own related research program.

SonicLayer 7200 Ultrasonic Additive Manufacturing (UAM) system from Fabrisonic. Ultrasonic welding process creates a solid-state bond between layers of similar or dissimilar metals. Image courtesy of Fabrisonic.

Wohlers Associates Caffrey says only DMD offers highly desired, multi-material options for metals. Bhaskar Dutta, COO at DM3D Technology, notes that it takes a team of design, material and process engineers to define the best approach to building such parts; his company has extensive experience with customizing blended microstructures offering dual- and quad-hopper systems for combining materials such as metals and ceramics.

• AMPM2015 (Additive Manufacturing with Powder Metallurgy 2015 Conference, San Diego, May 17-19, ) A Whos Who of worldwide metal AM industry experts headlined last years inaugural conference, sponsored by the Metal Powder Industries Federation (MPIF.org), a not-for-profit federation of related trade associations that has dealt with powdered metals since 1944. Greg Morris of GE Aviation and Joseph Strauss of HJE Co. kicked off the event, which included 12 sessions with 45 presentations. The 2015 conference is timed to allow attendance at SME RAPID 2015 (Long Beach, CA, May 18-21, 2015).

• An Introduction to Metal Additive Manufacturing / 3D Printing /introduction_to_metal-additive_manufacturing) Excellent overview of technologies, materials, finishing processes and the market, all in one place. This website launched in May 2014.

• ASTM standards for metals (ASTM F3049) ASTM International Committee F42 on Additive Manufacturing Technologies is working to create standards for metal powders, especially to help with highly regulated industries such as aerospace and medical. A proposed new standard, ASTM F3049, Guide for Characterizing Properties of Metal Powders Used for Additive Manufacturing Processes, will point users to existing standards that may be appropriate for AM applications. A companion standard covering the mechanical properties of metal parts, ASTM WK43112, Guide for Evaluating Mechanical Properties of Materials Made via Additive Manufacturing Processes, is also underway.

Applying metal AM to part repair is a topic gaining more attention through the activities of America Makes, the National Additive Manufacturing Innovation Institute program. As part of this effort, Optomec will lead the Re-Born in the USA project for repair of aerospace metal components for the U.S. Air Force. Optomecs powder-fed DMD technology (based on the LENS process licensed from Sandia National Laboratories) can add metal onto an existing substrate of almost any 3D shape.

We will demonstrate the benefits of additive manufacturing over traditional welding techniques and enable a repair, dont replace approach to critical part sustainment for high-value aerospace components, says Dr. Richard Grylls, Optomec LENS general manager and Re-Born in the USA project leader.

Inspired by customer requests for large-part volume repair and manufacturing, in 2009 RPM Innovations, a spin-off of RPM & Associates, developed its own industrial-grade Laser Metal Deposition (LMD) equipment that features a 5x5x7-ft. work envelope and multiple powder feeders. Company founder Robert Mudge says that writing their own motion-control software has been the key to running the equipment 24/7; the company currently operates three such systems, doing jobs that can go for 1,500 hours.

Another company with a growing presence in the DMD world is Sciaky, founded in 1939 as a welding system manufacturer. In 2009, it introduced its Electron Beam Additive Manufacturing (EBAM) process that deposits metal into a melt-pool via wire feedstock. Depending on part geometry and material selected, the Sciaky VX-110 system can deposit near-net layers at a rate of 7 to 20 lbs. per hour in a build envelope of more than 9 ft. each in XYZ. The company has been awarded several U.S. Department of Defense (DoD) and America Makes contracts, working with such partners as Lockheed Martin Aeronautics and the Applied Research Laboratory at Pennsylvania State University.

AM is indeed an umbrella term for dozens of fabrication technologies. Fabrisonic, based in Columbus, OH, is re-energizing a version of layered AM formerly called ultrasonic consolidation, now termed ultrasonic additive manufacturing (UAM). The company began in 2008 as a joint venture between EWI (an Ohio-based non-profit) and Solidica (now defunct, which had developed the low-temperature, sound-based process). UAM builds objects by ultrasonically bonding layers of metallic foil, then performing precision computer numerically controlled (CNC)-machining on the solid object after each layer. The process forms 100% dense parts and supports welding dissimilar metals without the formation of brittle intermetallics.

Fabrisonics CEO, Mark Norfolk, says the company has enjoyed 70% growth since 2012, and offers both part production and machine sales. Its largest system, built for repairing existing parts, can even ultrasonically bond material over a curved surface; the company has been awarded funding to add a rotary axis for welding on cylindrical parts. An interesting option exclusive to the UAM process is that of inserting continuous fibers or stainless steel meshes between layers, creating metal matrix composites that add high strength at low weight for aerospace applications.

A hybrid of another kind is the LUMEX Avance-25, a combination selective-laser-sintering (SLS) and machining system from Matsuura Industries now available in the U.S. The equipment houses an end-mill supplied by a tool magazine that can accommodate 20 milling tools. System operation alternates laser-sintering a succession of 10 layers of 0.05mm-thick powdered metal, then milling the part as needed, producing a finished part with high dimensional accuracy and surface smoothness. Matsuura has targeted customers looking to reduce production time of complicated mold dies.

You know the basic benefits of AM with metals: cost-savings when creating a one-off part, combining a multi-part assembly into a single piece, constructing complex inner geometries and using smaller amounts of expensive materials. But for more detailed comparisons of what to use when, and how to justify equipment investments in the broader business scheme, check out these timely resources:

Metal Options Design FAQs ProtoLabs

Annual Worldwide Progress Report on AM

Global 3D Printing Materials Market Research Report MicroMarket Monitor

Advanced Materials Enabling 3D Printing

German manufacturer DMG Mori is marketing its own version of a hybrid AM system: The Lasertec 65 combines laser DMD technology with a five-axis milling machine. The system features a build volume of 23.6 x 15.7 in.; wall thicknesses of 0.1mm to 5mm are possible.

Two more deposition-type hybrid systems are now coming into production. Based on a four-year UK research project, Hybrid Manufacturing Technologies announced its AMBIT Multi-Task system, a docking system of robotically controlled tools. Supported functions include laser cladding, five-axis machining, touch-probe precision measurements, polishing, annealing and even cleaning, all in a single set-up.

Optomec has also introduced a hybrid component called the LENS Print Engine, which adds laser deposition capabilities to CNC machines. Working with new or existing tooling systems, the LENS Print Engine includes proprietary powder feeders, deposition heads, LENS process controls, fiber laser support, integrated tool-path generation software, and safety packages. The companys first announced customer is the Center for Remanufacturing and Resources Recovery (C3R) at the Rochester Institute of Technology (RIT).

Materials development by independent suppliers is expanding as more AM systems work with non-proprietary powders. Metalysis of Rotherham, UK, working with engineers at Sheffield Universitys Mercury Centre, has developed a new way to produce titanium powder that is cheaper compared to the usual multi-step, energy-intensive Kroll process. It extracts titanium from rutile sand (naturally occurring titanium ore present in beach sands) in a single electrolysis step. Dion Vaughan, CEO of Metalysis, says that the process could reduce the price of titanium by as much as 75%. The company is also developing tantalum powder.

Last year Materialise, whose software solutions, consulting services and production facilities support the full breadth of the AM world, opened a Metal Competence Research Centre. Abbey Delaney, Materialise North American marketing manager, says the Centre was established to offer surgeons a wider range of products and services. They are working with pure titanium and titanium grade 23 materials, especially to create porous structures.

Thinking of developing your own materials, or at least doing R&D on the latest equipment? Linear Mold & Engineering is currently expanding its facility space and AM machine capacity.

We see ourselves as a solution provider, offering not just part production but training sessions, consulting and, coming next year, leased pods for private customer R&D, says Director Paul Parzuchowski. He says Linear Mold & Engineering will not only provide dedicated or time-shared equipment, but also maintenance and training. The goal is to help its customers develop new materials, techniques and products using high-end AM systems.

No discussion of metal AM news would be complete without mentioning the start-ups tackling desktop metal systems. Vader Systems, matterFab and Newton3D have all emerged this year as contenders in the (previously non-existent) personal metal-AM system space, and warrant continued attention.

Among the big-name players, AM developments happen daily. GEs Avio Aero division recently developed a new, higher-power electron-beam gun for Arcam equipment that in turn will allow use of lightweight titanium aluminide for turbine-blade production. JPL is working on depositing layers of metal on a rotating rod, creating parts with gradient metal alloys. And the buzz from the 3DPrint Show London 2014 is to watch for Stratasys to directly enter the metals market, rather than rely on third-party equipment.

National Additive Manufacturing Innovation Institute

Pennsylvania State University, Applied Research Laboratory

Rochester Institute of Technology, Center for Remanufacturing and Resources Recovery

Sheffield University, Mercury Centre

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Contributing Editor Pamela Waterman,

simulation expert, is an electrical engineer and freelance technical writer based in Arizona. Contact her viaDE-.

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AUDI announces partnership with EOS 3D printing company

German Based Audi AG, a leader in automobile manufacturing, has announced a new partnership agreement with fellow German 3D printer manufacturers, EOS e-Manufacturing Solutions. EOS is a leading global technology company known for its high-end metal and polymer additive manufacturing (AM) solutions and is known for their industrial-sized Direct Metal Laser Sintering machines.

Following the German Governments push for more advancing new digital technologies in the industry, the two industry-leading companies came to an agreement.

One of the industries where additive manufacturing is continually making advancements is the automotive field. With 3D printed cars developed by Local Motors and Divergent 3D, many automotive companies are making sure that additive manufacturing has a place on their production floor.

A leader in both AM and quality assurance processes, EOS recently completed the pilot testing for its successful EOS MeltPool solution. Through the application of its industrial 3D printing technology as well as assisting with the development of a 3D printing center in Ingolstadt, EOS consulting division, Additive Minds, will support Audi in fully implementing AM to its business.

Tool making and the casting technical center for planning will take the center stage in this new partnership. AUDI will apply the industrial 3D printing to equipment and prototype building. Though, it will continue its use with their motorsports division. AUDI plans to transform the tool manufacturing process, citing that when it comes to industrial 3D printing, the design determines the production.

The agreement will help AUDI to further themselves in faster more efficient and sustainable, flexible production processes of methods such as additive manufacturing. And with EOS providing, all the necessary elements for industrial 3D printing, including material, system, and process parameters, it is a possibility. Partnerships like these help contribute to the continued automation and digitization of manufacturing.

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3D printing company to move headquarters to Pflugerville

3D printing company to move headquarters to Pflugerville

After more than a year of negotiations, the Pflugerville Community Development Corp. and Michigan-based 3D printing company EOS of North America have entered a performance agreement to relocate the companys headquarters to the city.

Approved by Pflugerville City Council on Oct. 27, the contract stipulates EOS will relocate its North American headquarters to the 130 Commerce Center in Pflugerville and create 74 jobs over the next three years, PCDC Interim Executive Director Amy Madison said.

EOS creates 3D products from plastic, metal and other materials used in the medical and aerospace industries, Madison said.

The reason [3D printing] is so critical for our world is there are certain types of parts that cant really be manufactured any other way, she said. [EOS builds its products] from the ground up one layer at a time.

As an incentive, PCDC granted EOS a furnished lease beginning Dec. 1 in the building previously occupied by firearms company TrackingPoint. The furniture provided for EOS is valued at $151,000, Madison said.

Madison said the EOS of North America headquarters will be able to draw on the skilled workforce of the Pflugerville area as it expands operations.

The first concern of any company that has 3D printing as their core industry is a skilled labor pool that has a strong STEM focus, Madison said. And we have that in Pflugerville.

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3D-Printing Technology Leader EOS will establish North American HQ in Pflugerville.

3D-Printing Technology Leader EOS will establish North American HQ in Pflugerville.

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Manufacturing With 3D Printing

We shrank the overall design and manufacturing cycle time from 16 to 20 weeks with traditional manufacturing, to three to five weeks with Stratasys 3D printing.

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Innovations in Metal 3D Printing

The 3D printer market is rapidly transforming, and nowhere is this more evident than in the metal 3D printing segment. Competition among the largest market players is one of the major reasons new technologies are arising at such breakneck speeds.

There is so much innovation going on in 3D metal printing right now. Its almost difficult to keep up with, explains Andy Snow, Senior Vice President atEOS North America. Balancing systems, materials, and process is the biggest quality factor in todays additive manufacturing capabilities.

With new innovations in metal additive manufacturing (AM) technology, it is important to carefully evaluate the pros and cons of each. For example, direct metal laser sintering (DMLS), selective laser melting (SLM), and electron beam melting (EBM) are among the powder bed fusion forms of metal 3D printing. These techniques use either a laser or electron beam to melt and fuse powdered metals such as aluminum or stainless steel powder into a solid, finished product. Other materials used in powder fusion processes include Inconel, a variety of nickel-based alloys, and reactive alloys such as titanium.

There are other 3D metal printing technologies such as binder jetting technology. This AM process involves the layering of a powder bed of material and fusion of the material together with a binder, creating what is referred to as a green part, explains Snow. This part then can be transferred into a secondary process, like a nitrogen furnace, allowing an infiltration by a capillary effect to fill the voids and burn off the binder.

Although binder jetting technology requires a lot of post processing, it can do things that powder bed fusion cannot. For example, HÜganäs Digital Metal subsidiary can create microscopic details and some of the thinnest walls possible with its binder jetting technology and fine metal powder.

In addition, the spreading speeds for binder jetting are significantly faster than other forms of metal AM, thereby allowing for the creation of large parts with a more cost-effective price tag. Ultimately, the type of printer and technology used will depend upon the application.

The aerospace industry was a primary early adopter of metal AM, and it comes as no surprise that it still is one of the largest users of metal 3D printing to this day. GE Aviation, Avio Aero, MTU Aero Engines, and a number of gas turbine manufacturers have adopted 3D printing for end-part production.

Fuel nozzles are just one application. There are hundreds of other applications that qualify for metal additive manufacturing technology. And I would expect that huge growth will come as these new applications get rolled out as flight certified hardware, explains Snow.

Perhaps the second largest industry adopting metal AM is the medical sector. Patient-specific instruments and implants are currently trending in surgical and other medical applications.

After a CT scan or MRI, doctors can extract data, create a 3D file, and then make a knee or hip implant, says Snow. This process can match your specific body geometry so this is a big change in the medical mindset.

A single sub plate, additively manufactured via an EOS M 290 system, bears nine individual parts. The sub plate is bolted onto a macro reference element (with a matching hole/dowel pattern) and is now ready for final machining and finishing using such traditional methods as milling, grinding, EDM, etc. Image credit: Georg Fischer Machine Systems.

These industries will further benefit from metal 3D printing with the increase of laser development. However, finished part quality often comes as a trade-off with speed. For example, if the user decides to grow a geometry at 10 microns, the surface quality is typically a lot better than if it were printed at 40 microns.

The subtractive technology of traditional manufacturing that exists in the world today, such as wire EDMs, grindings, high speed machining these are all often necessary secondary processes to additive metal manufacturing, says Snow.

According to Snow, additive and subtractive technologies are codependent on each other. Secondary finishing is often required to get to a point where the finished product out of the DMLS or powder bed fusion is going to be at the specifications of the end user, he adds.

That being said, there are applications where the surface quality created from the AM process alone is sufficient for certain applications. For example, when manufacturing implants for the human body, surgeons often prefer a rougher finish, meaning there is greater surface area, and therefore the opportunity for increased osseointegration, or bone growth.

As the use of metal 3D printing becomes more widespread across various industries, in-process quality assurance is also becoming more important.

One aspect that has been evolving and will continue to evolve is called in-situ monitoring of product quality, says Snow. EOS provides such monitoring in four elements.

The first is systems monitoring, which basically monitors control of all systems, settings, process parameters, etc. It ensures that the system and process conditions are optimized so that the user can get the highest quality parts.

Then, there is powder bed monitoring, which comes in a variety of forms. Integrated camera systems in the process chamber are able to monitor the powder bed as it builds layer by layer. Innovations in the technology allow users to perform image recognition of parts internally. Therefore, the improved error identification along with some closed loop controls allow for potentially short feeding on recoating.

Such monitoring allows for the automatic assurance of recoating quality before exposure. In addition, image recognition and part error identification is possible, detecting failures to specific layer and part number during the build process, says Snow.

The third area of in-process quality assurance, melt pool monitoring, has been developed primarily to meet the needs of the aerospace community. Extensive hardware helps to separate the light created by the fusion process from the reflected light, and that data is obtained and further processed in special software. The software automatically corrects errors in the data, as well as provides process visualization and evaluation in real time.

Optical tomography is the fourth area of monitoring. This technique uses cameras to continuously monitor the fusion process. When paired with several sensors that monitor the general system status, optical tomography is able to precisely control the exposure process and melting characteristics of the material at all times.

The camera platform takes pictures of the powder bed on an average of about 12 snapshots per second, explains Snow. This allows you to detect a variety of potential failure types such as cracks, voids, and inclusions within the part being processed. The process was co-developed between MTU Aero Engines and EOS.

With the help of in-process monitoring, metal 3D printer manufacturers are constantly striving to improve system productivity while maintaining part quality.

Technology issues are always about speed and productivity; therefore, trying to get the fastest laser will always be something the industry is chasing to bring to market systems, says Snow.

Unsurprisingly, one of the main benefits of using metal 3D printing is part consolidation. For example, the fuel nozzle incorporated in GEs Leap jet engine was originally manufactured with about 20 components. Now, the fuel nozzle is 3D printed as one component. 3D printing took away a variety of additional manufacturing steps that would be required to assemble the 20 components.

You couldnt do it on a traditional CNC. I think the two technologies are codependent on one another its all geometry dependent, says Snow. You also need to create a process chain almost like a factory of the future. Many people are working on creating a seamless process chain where you can go into the secondary processes. I think thats the way to the future fully integrated production cells.

This article originally appeared in theApril 2016 print issueof Product Design & Development.

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