Continuous 3D printing technology represents a new dimension in the
manufacturing of moulds and models without tools. At the GIFA trade
fair, voxeljet will be unveiling the world’s first continuous 3D
printing machine at exhibition stand 13/B32-01. The process
steps of building and unpacking run in parallel, without having to
interrupt system operation.
With its ground-breaking concept study, voxeljet has become the pioneer
of a completely new machine generation. Dr. Ingo Ederer, CEO of voxeljet
AG, sums up the advantages of this unique concept: ”The innovative
system design allows unprecedented performance to be achieved. While
printing is carried out on one side of the system, unpacking can take
place synchronously on the other. This is all done without operation
being interrupted. It raises production, in particular patternless small
batch production of moulds and models for metal casting, to a higher
dimension of speed and cost-efficiency.”
This leap in technology has become possible thanks to the novel design
(patent pending) with a horizontal belt conveyor that controls the layer
building. The layers are built at the entrance of the belt conveyor, the
unpacking takes place at the exit.
The core of the process is the printing, which is done on a level tilted
to the horizontal. The printing process is similar to conventional 3D
printing. First the recoater generates a layer of powder. This layer is
at an angle to the horizontal that is smaller than the repose angle of
the powder. The high-performance print head then selectively bonds the
layer. The conveyor system moves the entire fill toward the unpacking
area by one layer thickness. The finished component can simply be
removed from the rear end of the system when it has gone through the
entire material on the conveyor belt.
The concept study allows for a build space of 500 x 500 millimetres
in height and width. The length of the moulds is virtually unlimited
with this type of system as there is no restriction to the length of the
belt conveyor. The usable build length is only limited by the
manageability of the moulds. The tilt of the print level enables the
print head to take far less time for positioning movements, which
improves the print speed.
The system technology also offers additional benefits. Apart from the
technological highlights, users will be pleased with the investment and
operating costs because they are lower than those of conventional
systems. With the continuous printing system, there is no need for a
build container or separate unpacking station, which has a positive
effect on the purchase costs. The printer also scores points with its
high re-use rate for the unprinted particle material, which is returned
straight to the build zone from the unpacking area. Consequently, the
machine requires smaller filling quantities and incurs lower set-up
costs.
The concept study uses the time-proven voxeljet printing technology,
which guarantees the exceptional quality of the moulds generated. It
involves a high-definition voxeljet print head with a resolution of 600
dpi. The machine works with layer thicknesses of 150 µm to 400 µm. ”At
the present time we are working flat out on refining the system for
series production. Customers should be taking delivery of the first
machines by the beginning of next year at the latest. The new machine
concept is set to become a real highlight in our wide-ranging portfolio
of standard and high-definition printers. With this system we now have a
unique product range and can offer customers from a variety of
industries the perfect solution for any application,“ says Dr. Ederer.
The concept study uses the time-proven voxeljet printing technology,
which guarantees the exceptional quality of the moulds generated. It
involves a high-definition voxeljet print head with a resolution of 600
dpi. The machine works with layer thicknesses of 150 µm to 400 µm. ”At
the present time we are working flat out on refining the system for
series production. Customers should be taking delivery of the first
machines by the beginning of next year at the latest. The new machine
concept is set to become a real highlight in our wide-ranging portfolio
of standard and high-definition printers. With this system we now have a
unique product range and can offer customers from a variety of
industries the perfect solution for any application,“ says Dr. Ederer.