News – Zortrax

How to Get Perfect 3D Prints with BASF Ultrafuse® PPSU on Zortrax Endureal

Jacek Krywko — Fri, 04 Aug 2023 07:40:17 +0000

BASF Ultrafuse® PPSU is a high-performance, flame-retardant 3D printing filament designed for railway applications and compliant with the European EN 45545-2 standard. Here is a simple guide to using this extraordinary polymer to its full potential on the Zortrax Endureal industrial 3D printer.

How to Store BASF Ultrafuse® PPSU Spools

Successful 3D printing with BASF Ultrafuse® PPSU begins with storing the material properly. Before first use, it is best to keep the filament in its original packaging at room temperature. Later on, after the printing process is done, the spool should be removed from the Zortrax Endureal 3D printer and kept in a place with limited exposure to sunlight and moisture.

BASF Ultrafuse® PPSU spools have to be stored in dry conditions without exposure to sunlight.

To make sure the BASF Ultrafuse® PPSU filament spool is in perfect condition for future prints, it is best to use vacuum packaging for storage.

How to Prepare BASF Ultrafuse® PPSU Spool for 3D Printing

Even if the spool was stored properly, it should always be dried before loading it into the Zortrax Endureal 3D printer. The reason why this step is so important is that moisture absorbed by the material evaporates when the material is heated in the extrusion process. Resulting steam creates tiny bubbles in the 3D printed part which can compromise its geometry and mechanical properties. Zortrax recommends two, alternative drying procedures:

Drying process can be performed in the printing chamber of the Zortrax Endureal 3D printer. Recommended settings are 48 hours of drying at 120 °C.
Drying process can be also performed in a vacuum dryer. While using the vacuum dryer, the drying temperature can be set to 125 °C and the duration to 8 hours.

Drying BASF Ultrafuse® PPSU filament before printing is necessary to achieve accurate geometry and optimal mechanical properties of 3D printed parts.

Using dedicated drying devices is generally faster and does not occupy the Endureal 3D printer which can be used for other projects. If the dedicated drying device is not available, however, the drying procedure performed in the Endureal itself is just as effective, albeit significantly longer. Either way, the spool of BASF Ultrafuse® PPSU 3D printing filament should be loaded into the Endureal 3D printer immediately after the drying process is done.

How to Prepare Zortrax Endureal 3D Printer for BASF Ultrafuse® PPSU

Once the BASF Ultrafuse® PPSU 3D printing filament spool is loaded into the Zortrax Endureal 3D printer, the build platform has to be covered with Magigoo HT glue to ensure proper adhesion of the material. Skipping this step may result in prints failed due to the material rolling up from the build platform which usually compromise the model geometry beyond recovery, and in extreme cases, can damage the Endureal’s extruder’s module.

The Endureal’s build platform has to be covered with Magigoo HT glue to ensure proper adhesion of the BASF Ultrafuse® PPSU filament.

It is also important to follow all standard maintenance guidelines for the Zortrax Endureal 3D printer such as cleaning the printing chamber and emptying the waste container before every printing session.

What Are the Best Printing Settings for BASF Ultrafuse® PPSU

When the BASF Ultrafuse® PPSU 3D printing filament is loaded to the Endureal 3D printer and the build platform is covered with the Magigoo HT glue, the next step is choosing the right printing settings. Z-SUITE slicer, which is a 3D printing software that comes free with every Zortrax 3D printer, has a large portfolio of predefined printing profiles for each supported 3D printing filament.

Z-SUITE software has a predefined 3D printing profile with throughly tested settings for BASF Ultrafuse® PPSU filament.

These profiles are thoroughly tested by Zortrax engineers and guarantee best possible printing results. BASF Ultrafuse® PPSU also has its predefined printing profile in Z-SUITE and it is highly recommended to use it when printing with this filament.

Why Zortrax Endureal is the Best 3D Printer for BASF Ultrafuse® PPSU

Zortrax Endureal is an industrial 3D printer with large workspace and excellent quality-to price ratio. It is a flexible additive manufacturing tool that can work with multiple high-end filaments like BASF Ultrafuse® PPSU. It can also process more affordable materials like BASF Ultrafuse® PC/ABS FR and Nanovia PC-ABS V0, which are a more budget-friendly choice for less demanding applications.

Zortrax Endureal 3D printer works with a wide range of flame-retardant 3D printing materials.

The printer has a closed printing chamber that guarantees optimal printing conditions throughout the entire 3D printing process, advanced safety systems compliant with EU and US health and safety regulations and is even capable of 3D printing metal parts when the strongest polymer filaments prove too weak for the job.

Contact Zortrax Sales Team at sales@zortrax.com to learn more about how Zortrax Endureal 3D printer and BASF Ultrafuse® PPSU filament can improve the workflows at your business.

The post How to Get Perfect 3D Prints with BASF Ultrafuse® PPSU on Zortrax Endureal appeared first on Zortrax.

Zortrax Forges a Partnership with AM-COE on a Ceramic 3D Printer

Agnieszka Kileńska-Ziółek — Thu, 27 Jul 2023 07:57:18 +0000

On July 18, 2023, a letter of intent was signed between Zortrax, and a British company specializing in the production of advanced resins, AM Centre of Excellence (AM-COE). The goal of this collaboration is to develop a 3D printer designed specifically for demanding, advanced ceramic resins. Zortrax, as the manufacturer of the solution, will supply AM-COE with the printers.

Developing a 3D Printer For Advanced Ceramic Resins

Zortrax has decided to work with AM-COE to develop and market a professional 3D printer for handling demanding ceramic resins, ActiveCera M. Zortrax has the necessary experience in developing high-quality 3D printers, automatic post-processing devices, a wide range of resins, as well as printing software to support resin 3D printing. AM-COE, in turn, owns professional research facilities and has the necessary capabilities to produce specialty resins.

The picture shows two ceramic resin 3D printers, coming from the first batch, tested by AM-COE at their facilities.

“The cooperation between Zortrax and AM-COE will allow us to develop an optimal solution for printing demanding ceramic resins. I am convinced that Zortrax engineers’ experience and skills in the development of resin 3D printers, peripheral devices, and printing software, combined with the relevant background of AM-COE, specializing in the production of ceramic resins, will lead to the release of a modern printer, tailored to the needs and requirements of both businesses and individual users producing ceramic parts.” – underlines Mariusz Babula, CEO at Zortrax.

Zortrax’s R&D team has been working with resin 3D printing daily for many years. Last year saw the premiere of a new comprehensive resin printing system, Zortrax Powerful Trio, which consists of the Zortrax Inkspire 2 resin 3D printer and two automatic resin post-processing devices – Zortrax Cleaning Station and Zortrax Curing Station. Numerous technical improvements introduced in the Powerful Trio, as well as collaborations with world leaders in the chemical industry, BASF Forward AM and Henkel/Loctite on the double validation of Zortrax machines and the expansion of the resin portfolio, have provided the experience that proves invaluable in the collaboration with AM-COE and the development of a new specialized printer designed to work with ceramic resins.

The ceramic resin 3D printer from the first batch was presented by AM-COE at Advanced Ceramic Show in Birmingham.

Zortrax and AM-COE’s Printer Suited for Mass Resin Manufacturing

“AM-COE is the biggest research and manufacturing centre on vat-photopolymerization of ceramic parts and components for aerospace, electronics, chemical, automotive, and other industries. In our strive for offering a mass manufacturing solution for 3D printed ceramics, we’ve partnered up with Zortrax to develop a versatile, fast, effective, and affordable ceramic 3D printer, like no other. ActiveCera M is an open-source solution with free software that assists researchers to develop material and ceramic printing processes, as well as manufacturers who are after a low-maintenance and easy-to-run ceramic printer for mass manufacturing.” – says Ehsan Sabet, CEO at AM-COE.

AM-COE has high-end research laboratories for resin production, and focuses mainly on designing light-cured materials, where 3D printing is mainly used for prototyping and mass production of casting patterns and ceramic cores.

The models, 3D printed with a specialized ceramic resin by AM-COE.

Within the partnership agreement with AM-COE, Zortrax will be responsible for manufacturing the printers with embedded firmware, and the implementation of dedicated Z-SUITE software, designed strictly for the preparation of ceramic resin models on the printer developed under the project. Moreover, Zortrax will be responsible for the printer’s warranty and ongoing updates to the firmware and software. AM-COE will provide consulting services for ceramic resin printing, distribute the new printer, and will be responsible for testing the software before each update, particularly to ensure that ceramic resins are printed correctly.

Learn more about Zortrax resin 3D printing solutions.

The post Zortrax Forges a Partnership with AM-COE on a Ceramic 3D Printer appeared first on Zortrax.

Zortrax Endureal Can Now 3D Print Railway Flame-Retardant Parts with BASF Ultrafuse® PPSU Filament

Wojciech Szymański — Thu, 20 Jul 2023 13:14:49 +0000

As the next phase of the long-term cooperation between Zortrax and BASF Forward AM, we’re extending the portfolio of filaments compatible with the Zortrax Endureal industrial 3D printer. Today, we’re sharing a 3D printing profile for a new flame-retardant filament — BASF Ultrafuse® PPSU. It is yet another material with such properties, right after Z-PEI 9085, BASF Ultrafuse® PC/ABS FR, and Nanovia PC-ABS V0, supported to work on the Endureal. Here are the most important features of BASF Ultrafuse® PPSU.

A High-Performance Railroad and Aerospace 3D Printing Filament

Ultrafuse® PPSU filament has been developed by BASF Forward AM, one of the biggest chemical companies in the world, specifically for 3D printing in the FDM technology. It belongs to the group of polysulfones, which are high-performance engineering thermoplastics known for very good performance in extreme thermal conditions. One of the most important characteristics of Ultrafuse® PPSU is its inherent fire resistance.

The filament has passed the certification process in which it was tested in terms of its ability to ignite and spread flame. As a result, Ultrafuse® PPSU complies with the EN 45545-2 railway classification and has been approved for use during the manufacture of rail vehicles operating both on the surface and underground, such as high-speed trains, streetcars, or subways. Therefore, nearly every element of a train’s equipment, as well as its exterior or components protecting electrotechnical devices can be 3D printed with Ultrafuse® PPSU on the Endureal and placed in passenger railcars as end-use items. With the material’s fire protection standard, such components minimize the risk of spreading fire in case of an accident, protecting the people travelling or working on board the vehicle.

Now, Zortrax Endureal industrial 3D printer can produce elements which comply to the fire protection standards in rail traffic. These may include elements of seats like grab handles, overhead components, window frames, covers or air ducts.

A flame-retardant grab handle 3D printed on Zortrax Endureal with BASF Ultrafuse® PPSU 3D printing filament.

The 3D printed handle was cleared for use in passenger railcars.

UL 94 Flammability Standard in BASF Ultrafuse® PPSU

The filament’s flame-retardant properties have also been confirmed by the UL 94 flammability standard. During the fire tests, where an open flame is applied to vertically oriented samples with different thicknesses, BASF Ultrafuse® PPSU has gained the V-0 rating. It means that the burning stopped within 10 seconds on samples with both 1.5 mm and 3.0 mm thickness.

Compliance with this standard is highly required for the materials used in space exploration, where it is paramount to prevent any emergency scenarios. Therefore, Zortrax Endureal 3D printer and Ultrafuse® PPSU can provide aerospace-grade flame retardancy when manufacturing interior elements in an aircraft, such as cockpit panels, ductwork, or enclosures of electrical devices.

An end-use railroad air duct component 3D printed with BASF Ultrafuse® PPSU on Zortrax Endureal 3D printer.

The 3D printed air duct can minimize the risk of spreading fire in a vehicle in an emergency.

PPSU Flame-Retardant Filament: Dimensional Stability and Chemical Resistance

Because Ultrafuse® PPSU filament was meant to be used with extrusion-based 3D printers from the very beginning, BASF Forward AM’s engineers made sure that the filament would have superior dimensional accuracy to minimize the need to reprint or redesign parts in case of printing issues. This filament, combined with the Endureal’s capability to provide high-temperature 3D printing environment, lets you produce high-quality parts with consistent precision.

A strong mounting bracket retaining its geometry in a wide range of temperatures 3D printed with Ultrafuse® PPSU on Zortrax Endureal 3D printer.

Additionally, industrial components made with Ultrafuse® PPSU retain their properties and geometry when exposed to high temperatures and steam — up to 220 °C for a short contact time, and up to 180 °C for longer periods. For this reason, 3D printed parts can withstand repeated cycles in an autoclave.

Other properties of BASF Ultrafuse® PPSU include resistance to oils in temperatures reaching 170 °C, as well as resistance to fluorine, coolants, lubricants, and fuels. Thanks to that, 3D printed end-use gauges, valves, tubing, or pump housings can be applied in the hydraulic and mechanical industries.

A flow pipe resistant to heat and oils, 3D printed with Ultrafuse® PPSU on Zortrax Endureal 3D printer.

Outstanding dimensional accuracy allows users to assemble 3D models from several parts.

3D Printing and Storage Requirements

There are a few rules that must be followed when using and storing the Ultrafuse® PPSU filament. First, before each printing process on the Zortrax Endureal 3D printer, it is crucial to carry out the procedure of drying the filament. The recommended conditions include at least 120 °C for a minimum of 48 hours. It is also mandatory to follow all maintenance instructions before starting the printing process, as well as apply Magigoo HT adhesive onto the PEI platform when it is cold and cleaned from any residues. Finally, it is always best to keep the spool in a dehumidifier when it is not in use. You can find all guidelines for 3D printing with this filament in the article Tips for Printing with BASF Ultrafuse PPSU.

Go ahead and contact Zortrax Team at: sales@zortrax.com to learn more about Zortrax Endureal and the compatible high-performance filaments, including the newly introduced BASF Ultrafuse® PPSU.

The post Zortrax Endureal Can Now 3D Print Railway Flame-Retardant Parts with BASF Ultrafuse® PPSU Filament appeared first on Zortrax.

Your Ultimate Guide to Successful Metal 3D Printing with Zortrax Solutions

Agnieszka Kileńska-Ziółek — Wed, 21 Jun 2023 08:11:31 +0000

Metal 3D printing is an efficient manufacturing technology which involves using metal-polymer filaments to produce industrial-grade components. After proper post-processing, ‘green’ parts that come out of your printer become fully functional metal parts, which can be further processed just like regular steel.

Compared to traditional CNC machining or Metal Injection Molding, 3D printing with metal-polymer filaments ensures more design freedom. Moreover, the entry threshold into obtaining steel parts is much lower with additive manufacturing – the prices of CNC machining and injection molding remain in the range of tens of thousands euros. Zortrax offers a full set, containing everything one needs to start manufacturing metal parts, for less than 7 thousand euros. Look at the ALL3DP’s article for reference.

Recognizing these benefits, we have introduced metal printing capability for both industrial Zortrax Endureal and desktop M300 Dual 3D printers. The machines are compatible with two types of metallic powder filaments produced by the world’s leading manufacturer – BASF Forward AM: BASF Ultrafuse® 17-4 PH and BASF Ultrafuse® 316L. Along with high quality metal-polymer filaments, we offer all the other essentials to metal 3D printing within two comprehensive sets: Zortrax Full Metal Package 17-4 PH and Zortrax Full Metal Package 316L. Once you have a perfect metal 3D printing set, you probably seek advice on how to prepare your models for metal 3D printing most efficiently. You may also wonder what makes Zortrax solutions stand out from those offered by other 3D printers’ manufacturers. Read on to learn the technicalities which will make the whole process of working with metal easier than ever.

A metal 3D printed model after post-processing.

Why Metal 3D Printing Must Take Place on a Dual-Extrusion 3D Printer

When printing with metallic powder filaments, it is necessary to print a shrinking plate, which holds the entire model in place and ensures its correct position during post-processing. Using a shrinking plate prevents deformation of the model in the debinding and sintering processes. The main advantage of the support material we recommend, BASF Ultrafuse Support Layer, is that it is removed at the optimal time during post-processing, allowing the shrinking plate to be easily separated from the rest of the model after a post-processing stage.

The use of Support Layer ensures a much easier removal of support structures, particularly in the Zortrax ecosystem, where it is used to divide support structures consisting mostly of model material, that is metal. Z-SUITE software makes it possible to combine a metal support structure with layers of support material, thus dividing it into small pieces that can be easily removed together with the shrinking plate.

Watch the video to see how easy removing supports is with Zortrax solutions!

How to Use Zortrax 3D Printers to Obtain Quality Metal 3D Printed Models

Step 1: Preparing Metal Models in Z-SUITE

As in the case of all the other 3D printing filaments, manufacturing metal parts starts with preparing 3D models for printing in a Z-SUITE slicer. Regardless of the modeling software used, the 3D project, in order to be read by the slicing software, has to be saved in one of the following extensions: .stl, .obj, .dxf, .3mf, .ply. Then, you should align the part on the build volume in such a way that minimizes the need for support structures. We recommend using the automatic support option, as our engineers have worked on it and tested it extensively to guarantee that they are generated in a most efficient way.

The models 3D printed with metal-polymer filaments shrink by approximately 20% after the necessary post-processing, as the contents of the polymer filler are removed during the process. To guarantee the best results and compensate for the metallic powder material’s shrinkage, Z-SUITE has an Autoscaling option for metal models. If you have scaled the prints in the modeling stage, you can skip this step by selecting Disabled.

Step 2: 3D Printing with Metal-Polymer Filaments on Zortrax 3D Printers

Having prepared the model in Z-SUITE, you can proceed to 3D printing. The machine that you use hugely influences the print quality and your overall working experience. In order to decrease the risk of warping, it is essential that your 3D printer has an enclosed printing chamber with a low chamber airflow.

The extensive manual for working with Zortrax Full Metal Packages is available at our Support Center.

Depending on the type of Zortrax 3D printer you own, the steps of 3D printing with metal-polymer filaments may slightly vary. There are some ultimate guidelines that you need to follow, though, regardless of whether you work with a desktop or an industrial machine. Remember to calibrate the platform properly or use an auto-calibration option and always apply the Magigoo Pro Metal adhesive to make sure your metal 3D prints will stick to the platform well. Make sure that there are no metal particles in the printer’s chamber, paying special attention to the area around the heatbed cable socket, as metal remains may cause short circuit. In the case of working on a desktop 3D printer with metal capability, Zortrax M300 Dual, before any other activity, install all the components included in each Zortrax Full Metal Package.

Zortrax 3D printers compatible with metallic powder filaments: M300 Dual and Endureal.

Step 3: Getting Your ‘Green Parts’ Post-Processed

Once the model has been 3D printed with a chosen metal-polymer filament, it is called a ‘green’ part, which needs to be post-processed to obtain the target properties declared for a given metal material by its manufacturer. To take advantage of professional post-processing, you just use the voucher to our trusted Partner’s, Elnik Systems, facility, where the models undergo two crucial steps: debinding and sintering. In the first stage, your parts are placed in a special furnace where the right temperature is applied to remove the polymer filler from the models. In result, the green part becomes the so-called brown part.

Then, the brown part turns into fully metal alloys with thermal processing. Here, the metallic powder left after removing the polymer filler turns into a solid structure of a metal alloy.

The photo shows a special furnace used for sintering 'green' parts.

The machine for post-processing 'brown' parts in a debinding process.

After the process, the models are cooled down, thoroughly packed, and sent to your doorstep. The items can now be welded, polished and further processed just like regular steel.

We have outlined the step-by-step instructions for working with BASF Ultrafuse® 17-4 PH and BASF Ultrafuse® 316L using both Zortrax M300 Dual and Zortrax Endureal in our previous articles, so check them out for more detailed instructions.

Z-SUITE 3.2.0 BETA: Slicing Software Packed with Metal 3D Printing-Facilitating Features

The latest update of Zortrax proprietary software, Z-SUITE in a BETA version 3.2.0, available to download at Zortrax Support Center, brings several major improvements in printing with metallic powder filaments. First, all support structures are here divided into smaller blocks and narrowed towards the bottom, which makes their removal, even from small crevices, much easier. It also significantly reduces the supports’ mark on the metal 3D printed models. Getting rid of supports now boils down merely to breaking off the unnecessary structures in your metal 3D printed models with no additional tools required.

Z-SUITE 3.2.0 introduces new gyroid Infill pattern, which allows you to 3D print metal models with infill of density range from 60 to 90%. This is particularly useful for cases where the part’s weight must be as low as possible (especially in such industries as space, aerospace, or automotive). Last, but not least, we’ve improved the way the shrinkage plate is printed. Therefore now, this element, which is essential for metal 3D printing, helps to counteract model deformation even better.

The model 3D printed with a metallic powder filament before and after post-processing.

Another metal model before and after post-processing.

A 3D printed model with easily removed support structures beside.

A super tiny 3D printed metal model.

All these improvements translate into a convenient support removal and better-looking metal 3D printed components. What is worth underlining is that, although many companies offer metal printing capability, none has yet found a solution for how to efficiently remove supports from metal 3D prints. Except for Zortrax, that is.

Discover metal-compatible 3D printers: Zortrax Endureal and Zortrax M300 Dual.

Learn more about metal 3D printing and Zortrax Full Metal Packages, including all the essentials to metal 3D printing.

The post Your Ultimate Guide to Successful Metal 3D Printing with Zortrax Solutions appeared first on Zortrax.

4D Printing Breakthrough Achieved in ESA-Funded Project

Jacek Krywko — Wed, 31 May 2023 09:47:23 +0000

For over a year Zortrax has been a prime contractor of the European Space Agency in a project aimed at developing new 4D printing technologies for space industry. Now, the project is done, our research and development teams achieved major breakthroughs in the field and we are finally ready to tell you everything about it. Strap in and enjoy the ride.

What is 4D Printing

3D printing is an additive manufacturing technology that enables building physical, three-dimensional objects layer by layer based on the digital model. The forth additional dimension added in the 4D printing technology is time. 4D printed objects can change their properties like geometry in response to various stimuli, be it temperature, moisture, electric current, and many more. Imagine an origami-like structure that stays folded in room temperature but unfolds when heated up.

Zortrax M300 Dual 3D printer used for making 4D printed mechanisms in the ESA project.

4D printing generated a lot of interest in the space industry because, in theory, the technology could enable engineers and mission designers to reduce weight of deployable structures like antennas, booms, or various sensors. The weight of such structures made in a traditional way is always a sum of the structure itself and the mechanism that is supposed to deploy it. Astronika, one of Zortrax’s key partners in space industry, can make such booms and antennas incredibly light. But if it was possible to get rid of the deployment mechanisms altogether, they could be made even lighter and smaller.

Challenges of 4D printing

Now, 4D printing made headlines when the team of researchers working at MIT made deployable 4D printed structures that could move when heated to a certain temperature back in 2013.

While their results looked impressive, there were a few apparent problems that needed solving before this technology could find any real-world applications.

Shape changing was triggered by the environment’s temperature which heated up the entire structure at once.
The process was hardly controllable – it got triggered when the environment temperature reached certain level and you can’t always control the environment.
Shape changing started in relatively low temperature of 40 degrees Celsius
Because the shape changing was triggered by the environment, there was no way to deploy such structures sequentially which limited their applications.

Zortrax, working with ESA, managed to solve all these problems. Here’s how.

Selecting the Right Materials

Manufacturing of 4D printed mechanisms requires three basic components. These are:

Right materials providing the shape memory effect.
The right software which enable fabricating 4D printed parts.
The right 3D printer which can physically make the 4D printed parts.

The development process at Zortrax started with choosing the right filaments for the job. For the RnD team selected a pool of shape memory polymers that would drive the movement in the system and a pool of electrically conductive filaments that would act as an electrically activated heater activating the shape memory effect.

4D printing technology demonstrators delivered to ESA by Zortrax.

Right from the get-go, it became apparent that commercially available shape memory filaments had glass transition temperature of up to 55 ℃ which was not enough for space applications. A 4D printed mechanism with such filaments would activate on its own in temperatures exceeding 55 ℃ which happens quite often on Low Earth Orbit when the spacecraft is exposed to sunlight.

For this reason, Zortrax made a custom shape memory filament which had glass transition temperature of 75 ℃ which was 50% higher than anything available on the market. The material got delivered, thoroughly tested, and found suitable for proof-of-concept 4D printed systems.

Choosing the right conductive material was easier since multiple off-the-shelf filaments met the requirements. After an extensive test campaign where thermal and electrical properties of these filaments were tested, the FIBERFORCE NYLFORCE Conductive was selected as the material to heat the shape memory polymer in the 4D printed mechanisms.

Bending movement 4D printing technology demonstrator in the testing setup.

In the last step, the Zortrax RnD team checked if the two selected polymers could be printed in the bi-material 3D printing mode that enables manufacturing of parts made with two different materials. This bi-material 3D printing mode was made possible by combining experimental version of Z-SUITE software, initially developed specifically for ESA, and the dual extrusion M300 Dual 3D printer which could operate with two printing heads at once.

The Making of 4D Printing Demonstrators

Under ESA contract, Zortrax had to develop three 4D printing demonstrators, each showcasing different type of electrically activated movement. These types of movement were:

Bending.
Torsion.
Deployment.

Work on the bending movement demonstrator began with designing simple, rectangular shapes with electrically conductive heating core and outer layers made with the shape memory material.

From those simple shapes the RnD team moved to more advanced designs, eventually ending up with a bar capable of bending roughly 30 degrees within one minute from turning on the power.

Torsion movement was a little more tricky since it is easier to make 4D printed mechanisms bend rather than rotate when activated. The first shot was a spiral design that would compress and cause the rotary movement in the center.

Spiral design which was the very first iteration of the torsion movement demonstrator made by Zortrax.

This however proved difficult to power up due to long conductive lines. On the other hand, shorter and thinner versions of this design were fragile and couldn’t generate enough torque.

For this reason the team took a radical step and made an entirely new, spring-like design that had short conductive lines and could generate enough torque to turn the 3D printed chassis even without lubrication or bearings. The mechanism could turn 30 degrees when powered.

Final torsion movement demonstrator. A 3D printed mechanism on the left and a working principle on the right.

The last and most complicated design was deployment movement demonstrator. Zortrax team started with rather elaborate three-leaf membrane with the leaves closing in like a flower upon providing electric current.

Deployment movement demonstrators on the left and spring-like torsion movement demonstrators on the right.

This proved too complicated and and the movement was pretty slow. In the next iteration the number of leaves was reduced to two and then further down to just one. Using two of these one-leaf membranes it was possible to build a single-use reversible system where the shape memory effect of one membrane programmed the movement in another membrane.

This way it was possible to move the system from closed to open to closed again using electric current only.

The Future of 4D Printing in Space

4D printed is a technology which have the potential to revolutionize how mechanisms work in space. Because the movement is an inherent feature of the materials used, there is no need for a separate actuation systems that add weight and therefore increase cost of the mechanism.

With this future in mind, the simple demonstrators made in this ESA project can be used as basic building blocks in larger mechanisms. This means they are easily scalable, can be activated at will, and are incredibly simple which translates into reliability.

Spring-like torsion movement demonstrator installed in a 3D printed case.

Such systems can be used in multiple applications. Single-use array sensors which are scattered over a large area to take measurements in difficult environments where using more expensive materials would make little sense are one example. Other include deployable antennas that could be deployed and folded at will with no actuation mechanisms at all. Using multiple 4D printed building blocks such as the one used as bending demonstrator here, it is possible to make pointing mechanisms which can be controlled with amazing precision.

Of course, there is lots of work still to be done before 4D printed systems go beyond experimental phase and fly on an actual space mission. But what was done here at Zortrax is a solid starting point. The electrically activated 4D printed mechanisms can activated with a push of a button, they can work in any temperature not exceeding 75 ℃, heat can be delivered precisely to chosen points in the mechanism and first steps towards achieving reversibility have been made. The remaining work is fine-tuning and evolution.

4D printing is just one of many exciting ways to use the Zortrax M300 Dual 3D printer. Another one is 3D printing with 316L or 17-4 PH stainless steel. You can learn more about it here.

The post 4D Printing Breakthrough Achieved in ESA-Funded Project appeared first on Zortrax.

Metal 3D Printing Comes to Your Desktop with Zortrax M300 Dual

Jacek Krywko — Fri, 26 May 2023 11:39:26 +0000

Zortrax M300 Dual is one of the most versatile 3D printers in Zortrax range. The combination of large workspace, dual extrusion technology, and a very wide selection of supported materials has made this machine an amazing value for money. Now, we’re taking this all to a whole new level with a capability to make parts out of either 316L or 17-4 PH stainless steel and new, updated Z-SUITE software. Here’s how we made an already great M300 Dual even better.

Zortrax M300 Dual is equipped with a double hotend which enables using two separate filaments.

Metal Printing Capability Available on Zortrax M300 Dual

Working with BASF, one of the world’s leading chemical companies, we have added BASF Ultrafuse® 316L and BASF Ultrafuse® 17-4 PH metallic powder 3D printing filaments to the range of materials factory calibrated on the Zortrax M300 Dual. This means that the metal printing capability has finally trickled down from the industrial Zortrax Endureal 3D printer to the most advanced machine in the more budget-friendly M-Series. Manufacturing of the 3D metal parts on the Zortrax M300 Dual is a simple and straightforward process.

It all starts with Zortrax Full Metal Package, a kit containing necessary components and accessories to make either 316L or 17-4 PH steel parts on the M300 Dual. Working with Zortrax Full Metal Packages boils down to following those simple steps:

First, the hotend module in the Zortrax M300 Dual 3D printer has to be switched to the one provided in the kit.

Second, a PTFE tube with adapter has to be installed following this manual to prevent breaking of the metallic filament.

Third, a spool of either BASF Ultrafuse® 316L or BASF Ultrafuse® 17-4 PH metallic powder 3D printing filament has to be installed as the model material and the BASF Ultrafuse® Support Layer has to be installed as the support material in the M300 Dual 3D printer.

Fourth, the parts that are to be 3D printed need to be checked for compliance with our design guidelines explained in this Metal 3D Printing Manual.

Fifth, the glass build platform in the M300 Dual has to be covered with Magigoo Pro Metal glue to facilitate proper build platform adhesion.

Sixth, the 3D printing process has to be started using the default settings available in Z-SUITE software for BASF metallic powder filaments.

Seventh, the 3D printed models have to be packed and sent to post-processing which is free with the included post-processing voucher.

Eighth, post-processed, fully functional metal parts arrive are delivered to your door.

At a technical level, a 3D print made on the M300 Dual with a BASF metallic powder filament is not yet a steel part. It is called a “green” part comprising roughly 80% of metallic powder and 20% of polymer filler. To turn into fully functional steel, it must undergo a two stage post-processing developed by BASF. Remember that the voucher for a professional post-processing procedure is included in each Zortrax Full Metal Package so that you can obtain fully-functional steel parts. In the first stage of the process, the polymer filler is separated from the metallic powder through thermal and chemical treatment. Once the polymer filler is gone, the remaining metallic powder is sintered into solid steel. Of course, this means that the model shrinks 20% – a phenomenon that is automatically accounted for in Z-SUITE software which rescales the models appropriately. Here’s how it works:

Overall, the process works the same way as in the industrial Endureal 3D printer which received the metal printing capability a couple months earlier. The steel parts made this way have all the properties of standard steel. They can be polished and welded at will. More details on how to handle metal 3D printing on the M300 Dual can be found on Zortrax Support Center.

What Makes Zortrax M300 Dual a Great Desktop Metal 3D Printer

Adding the BASF metallic powder filaments to the range of materials supported on the M300 Dual has made this 3D printer a truly do-it-all solution that is extremely price-competitive. The printer relies on the tried and true design that won countless awards for the Zortrax M-Series machines. This means the printer is very easy to operate and maintain, ensuring consistent high-quality prints each time. Outstanding reliability is particularly important when it comes to printing metals because all flaws and imperfections introduced during the printing itself get magnified and aggravated at the post-processing stage. The large glass build platform used in the M300 Dual for printing metals makes it possible to print multiple metal parts in one printing session.

But the M300 Dual offers way more than just printing with metals. It supports quality filaments starting from standard ABS and PLA-based materials through advanced composites for 3D printing reinforced with either glass or carbon fiber like BASF Ultrafuse® PPGF 30 or BASF Ultrafuse® PAHT CF15 to engineering classics like Z-NYLON or NYLON-based materials. The catalogue of printing profiles available in Z-SUITE software for the M300 Dual includes filaments made by market-leading brands like BASF Forward AM, KIMYA, Nanovia, or 3DxTech. This means the Zortrax M300 Dual 3D printer can deal with a vast majority of applications in nearly all industries.

A 3D printed steel screw made on Zortrax M300 Dual with BASF Ultrafuse® 316L metal filament.

A triangle bracket made on Zortrax M300 Dual with BASF Ultrafuse® 17-4 PH metal filament.

Zortrax Full Metal Package with metallic powder filaments.

Steel Parts 3D Printing and More in Z-SUITE 3.2.0 BETA

The greatest highlight of the latest Zortrax software beta version is definitely a set of improvements in printing with metallic powder filaments. Z-SUITE BETA became even more aligned with the needs of the 3D printers user base and the nature of the two-stage post-processing that turns “green” parts into steel. The most important features in this area include a new gyroid infill which enables printing metal models with 60% to 90% infill. This is a handy feature in industries like aerospace or automotive where weight of the part has to be kept as low as possible.

Another change improves the way support structures are 3D printed while printing with BASF Ultrafuse® Support Layer, a support material dedicated for metal printing. In Z-SUITE 3.2.0 BETA supports are separated along the Z axis and divided down into small blocks along the XY plane to make their removal easier after post-processing. For the same reason, support structures are also narrowed down towards the bottom which additionally reduces the supports’ footprint on the model. All this especially applies to getting rid of supports placed in small crevices or other areas in the parts that are difficult to access. Support structures’ deformation caused by shrinkage of the part is further reduced due to switching the direction of printing from one layer to another. Z-SUITE 3.2.0 BETA changes the way the shrinkage plates are printed to maximize dimensional accuracy of parts that rest on such plates. The trick relies on intertwining the paths of material deposited by the printing head.

The most important features for metal 3D printing in the Z-SUITE 3.2.0 BETA are highlighted below:

Improved shrinking plate

Support structures divided along the Z axis

Automatic scaling of metal models

Last but not least, Z-SUITE 3.2.0 BETA brings lots of new materials and performance improvements for all Zortrax 3D printers. For more details, feel free to read the full changelog of the Z-SUITE 3.2.0 BETA, and learn what makes it groundbreaking software appreciated by thousands of users and world-leading manufacturers of 3D printing materials.

“Z-SUITE software is intuitive, flexible, and easy to use. It comes with a lot of ready-to-use profiles and clear guidelines. I recommend using it and consider it to be the best 3D printing software available on the market.” – Sam de Jong / International Sales Manager & Distributor Manager, BASF FORWARD AM

To wrap it up, the M300 Dual working with the Z-SUITE 3.2.0 BETA is a powerful tool for prototyping and on-demand manufacturing. Go ahead, order your own Zortrax M300 Dual, and take your 3D printing operations to a whole new level today.

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Print up to 3 Times Faster with Speed Mode – a New Feature for Zortrax FDM 3D Printers

Wojciech Szymański — Wed, 10 May 2023 09:32:30 +0000

As a response to our community’s expectations, Zortrax engineers have developed a new feature thanks to which Zortrax FDM 3D printers can work with an increased printing speed within the new Speed Mode. What we wanted to deliver was a completely free feature which our customers could use right away with no need to buy additional spare parts or dedicated kits. All they have to do to take advantage of the new printing mode is update the firmware in their 3D printer with the latest version, which is ready for download at the Zortrax Support Center from today. Read on to learn how to use the new option and what benefits it can bring to your work.

What the Zortrax Speed Mode is Best for

The Zortrax Speed Mode, which is dedicated to Zortrax M200 Plus, Zortrax M300 Plus, and Zortrax M300 Dual 3D printers, is available in the Print Speed Adjustments tab that will appear in each printer’s menu after you carry out a standard firmware update. With a few parameters that you can change before or during the printing, you can easily control the 3D printing speed and complete your projects up to 3 times faster.

Zortrax Speed Mode is available in a free firmware update for your 3D printer. You can control the 3D printing speed in the printer’s menu.

Since it is now possible to optimize manufacturing processes and produce more units in shorter time, the new feature will best suit companies that offer 3D printing services or run 3D printing farms, and manufacture many 3D parts on a daily basis. Essentially, the Speed Mode is a way of increasing production capacity of Zortrax 3D printers and brings measurable benefits to many branches of industry, where time of execution is crucial for both the business and the client.

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We can take a look at large automotive factories where 3D printed tools are extensively used on assembly lines. Such tools, usually with simple geometries, have to be delivered to the assembly workers as quickly as possible so as not to suspend further production. And that’s where using the Speed Mode can make a great impact. You can read how Toyota factory in Poland uses such 3D printed tools in one of our articles: How Toyota Factory Works with Zortrax 3D Printers. Another examples may include departments responsible for rapid prototyping as well as companies with significant production output which incorporate 3D printed elements in their products. Finally, the Speed Mode will work great with models intended for further post-processing through sandblasting or painting.

Take a look at a short tutorial which shows how to use the Speed Mode in your 3D printer. In the second part of the clip, you can see a comparison of 3D printing with the standard speed and with the Speed Mode.

How to Use Print Speed Adjustments Options

Using the Speed Mode doesn’t require any hardware modifications. When installing the new firmware update, follow the instructions displayed on the screen. Once it has been installed, go to Settings -> Working options -> Print Speed Adjustments.

There are three parameters which enable you to increase the 3D printing speed. Let’s shine some light on the available options:

Print speed (%) – it is a value which determines the speed of the extruder moving along the X and Y axes while printing. The default value is 100%, and you can go as high as 300%. It is, however, important to remember that the speed values for printing infill, supports, and contours are not identical. Therefore, when you set the printing speed to 300%, each section of the model will be printed 3 times faster than their default values.

Acceleration (x) – it is a value which determines how fast the extruder will accelerate after changing the direction of printing from 0 to the speed set earlier. It can gain speed slowly or more rapidly. The default value is x1.0; we recommend using x1.5.

Hotend temperature offset (°C) – it is a value which determines the hotend temperature during the printing process. Faster extruder movements with default hotend temperature may result in material deficiency in the prints’ structure. So in order to “keep up” with the proper extrusion for printing with very high speeds, you can increase the extrusion temperature by 5 °C (more is not recommended).

Controlling the 3D printing speed is possible with two parameters: Print Speed and Acceleration.

It is worth noting that with the new tool users also gain more design flexibility, as it is possible to change the printing speed during the printing process, without having to hit the pause button. Let’s take for example designs which contain both simple and more complex structures. With such models, you can use the standard speed to maintain high precision of details and increase the printing speed during the process for less complicated parts.

The model 3D printed with a metallic powder filament before and after post-processing.

Another metal model before and after post-processing.

A 3D printed model with easily removed support structures beside.

A super tiny 3D printed metal model.

There are a few things to remember before trying out the Speed Mode. First, follow the maintenance guidelines and perform all crucial activities beforehand. Next, carry out platform calibration and make sure that there is no residue of adhesives on the perforated plate. Finally, despite increasing the printing speed, the raft is always printed with the standard speed to make sure it properly adheres to the perforated plate and facilitate further fast 3D printing.

Thanks to the Speed Mode option, our workhorse 3D printers – M200 Plus, M300 Plus, and M300 Dual – enter a new dimension of manufacturing possibilities, becoming even more effective and faster than ever!

More information about all Zortrax devices can be found at zortrax.com/3d-printers.

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The post Print up to 3 Times Faster with Speed Mode – a New Feature for Zortrax FDM 3D Printers appeared first on Zortrax.

Ceramic-Filled Resin Now Available for Zortrax Inkspire 2

Wojciech Szymański — Thu, 27 Apr 2023 08:00:11 +0000

As the next stage of Zortrax and BASF Forward AM’s partnership, we are extending the range of resins validated to work with our refined resin 3D printing and post-processing system — Zortrax Powerful Trio, encompassing Zortrax Inkspire 2, Zortrax Cleaning Station and Zortrax Curing Station. Our newest resin 3D printer gains a 3D printing profile for BASF Ultracur3D® RG 3280 — a unique photopolymer resin with ceramic particles. Read on to learn more about this high-performance material for industrial applications.

Ceramics in Industrial Applications

Ceramic materials are heavily used in many branches of industry mainly due to their resistance to all kinds of wear, such as corrosion, shape change, melting, stretching and distortion. In comparison with other materials, such as stainless steel, ceramics components offer very good strength-to-weight ratio, which makes them easier to handle. As a result, ceramic parts are employed in many manufacturing processes, where they provide highly desirable mechanical, electrical, thermal, and chemical properties. Essentially, ceramics show great potential in aerospace, automotive, robotics, electronics, metallurgy, energy production and chemical industry.

Now, devices included in our new resin 3D printing and post-processing system gain the ability to fabricate 3D parts that closely resemble ceramics. It becomes possible with the use of BASF Ultracur3D® RG 3280 3D printing resin which we have thoroughly validated. Starting from today, its calibrated profile can be found in Z-SUITE 3D printing software with 0.05 mm layer thickness.

Zortrax Inkspire 2 resin 3D printer now works with BASF Ultracur3D® RG 3280 ceramic-filled photopolymer resin.

Intuitive Z-SUITE Features for 3D Printing Photopolymers

Preparing models in Z-SUITE when working with photopolymers like Ultracur3D® RG 3280 has been made more convenient and easier. The slicing software not only gains a ready, calibrated profile, but also a notification with suggestions for proper post-processing steps to be performed once the 3D printing has been finished. Thanks to that, the users know the exact cleaning and curing times of their 3D prints. For parts made with Ultracur3D® RG 3280, post-processing in Zortrax Cleaning Station takes about 10 to 20 seconds, whereas in Zortrax Curing Station it can take about 30 minutes for each side of the model.

Watch the video below to see how easy it is to fabricate ceramic-like parts using Zortrax Inkspire 2 resin 3D printer together with two post-processing devices: Zortrax Cleaning Station and Zortrax Curing Station. The video show the process of 3D printing, cleaning and curing an exhaust mixer used in modern drones.

Ultracur3D® RG 3280 3D Printing Photopolymer Resin: Main Features

Ultracur3D® RG 3280 is a specialized, ceramic-filled resin belonging to the rigid line of BASF Forward AM’s 3D printing photopolymers. When used with Zortrax Inkspire 2, it offers our users the possibility of 3D printing unique parts which, after proper post-processing in Zortrax Cleaning Station and Zortrax Curing Station, gain properties similar to ceramics. And it can take place without the use of specialized furnaces. It is, however, important to remember that you have to remove the support structures right after the 3D printing process, as after the post-processing stages it won’t be possible. The target 3D prints are white and have a characteristic, ceramic look to them.

3D parts made with BASF Ultracur3D® RG 3280 ceramic-filled resin have properties similar to ceramics and have a characteristic look to them.

Despite the high particle content, the Ultracur3D® RG 3280 resin has low viscosity and its sedimentation in the vat is limited, which leads to maximized ease of use and print quality. The material is versatile and opens up a wide application possibilities thanks to a very interesting set of properties. You can read more about them below.

Rigidity and Electrical Voltage Insulation

Parts 3D printed with RG 3280 exhibit high stiffness (up to 10 GPa) and electrical non-conductivity. The resin can therefore be used to 3D print objects required for specific manufacturing processes, for example, ceramic handling arms that move semiconductor wafers from one station to another. Other applications may include positioning and guide pins used in pressure welding. Such parts can function as a non-conductive, thermal insulation which doesn’t interfere with the welding process.

3D printed handling arm that can be used to move semiconductors around workstations.

3D printed insulators which can be used as a bridge between electronic components.

Ultracur3D® RG 3280 models can be 3D printed in series, covering the majority of build platform in Inkspire 2, and then post-processes all at once.

Heat Deflection Temperature and Chemical Resistance

With HDT values reaching 132 °C at 1.82 MPa and 280 °C at 0.45 MPa, models 3D printed with the Ultracur3D® RG 3280 resin can withstand high temperature operating conditions. So, they can be used for thermal shields, engine systems, turbine components, high-performance parts, or injection molds intended for high temperature molding. Additionally, such parts have outstanding chemical resistance to many industrial fluids, such as acetone, engine, hydraulic and transmission oils, brake and cooling fluids, and multi-purpose fats.

A 3D printed exhaust mixer for a modern drone. After UV curing, the components gains resistance to high temperatures.

An exhaust mixer during UV curing in Zortrax Curing Station.

We highly encourage you to try out BASF Ultracur3D® RG 3280 resin with your Inkspire 2 and post-processing equipment. The whole procedure using these three devices lets you fabricate highly precise and wear resistant 3D parts with unmatched properties.

For more detailed information about our high-end resin 3D printer and post-processing devices – Zortrax Inkspire 2, Zortrax Cleaning Station and Zortrax Curing Station – go to: Zortrax Inkspire 2 product page.

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The Summary of 2022 at Zortrax

Agnieszka Kileńska-Ziółek — Thu, 29 Dec 2022 18:35:21 +0000

2022 has been fruitful at Zortrax, bringing further development of our brand and our portfolio. We’ve launched several new, groundbreaking products, including a vastly media-covered Zortrax Powerful Trio – a refined resin ecosystem, which comprises Zortrax Inkspire 2 UV LCD 3D printer, as well as two automatic post-processing devices, Zortrax Cleaning Station, and Zortrax Curing Station. All the machines have been validated and approved by Henkel/Loctite and BASF Forward AM, who have officially become our business partners this year. Thanks to these partnerships, there are now many special engineering resins manufactured by these world’s leading companies available in our portfolio.

The collaboration with BASF Forward AM has also resulted in expanding our offer with metal 3D printing filaments for Zortrax Endureal industrial 3D printer. Two comprehensive sets, containing all the essentials to metal 3D printing, have been introduced as Zortrax Full Metal Packages, offering two different kinds of metal-polymer filaments to fit a wide range of engineering applications. Metal-polymer filaments are not the only novelty introduced for Zortrax Endureal, though, as VICTREX PAEK AM 200 has also joined the range of high-performance polymers dedicated to it.

New product launches aside, 2022 has been full of groundbreaking projects, industry fairs we’ve been a part of, and applications worth your while! Here’s a recap of all the key events of 2022!

Expanding Our Product Portfolio

1. Zortrax Powerful Trio

In 2022, we introduced a next-gen resin 3D printing and post-processing system: Zortrax Inkspire 2 UV LCD 3D printer, together with automated post-processing devices, Zortrax Cleaning Station and Zortrax Curing Station. The Inkspire 2 combines utmost precision with high speed and is compatible with a wide range of high-grade engineering resins by top global manufacturers, like Henkel/Loctite and BASF Forward AM. Through a detailed double-validation process, it is guaranteed that the prints, manufactured and post-processed with new Zortrax machines, meet all the properties declared for a given resin by its manufacturer. The range of technological advances, introduced in the Inkspire 2, translates into a huge step forward in Zortrax UV LCD solutions. Compared to the previous generation Inkspire 3D printer, the refined resin 3D printing system has:

7x more powerful UV light engine

40% more uniform UV light distribution

4x more build volume

Zortrax Powerful Trio, a comprehensive resin 3D printing and post-processing ecosystem, consists of Zortrax Inkspire 2 UV LCD 3D printer, Zortrax Cleaning Station, and Zortrax Curing Station.

#ZortraxPowerfulTrio has generated mass media coverage and evoked enthusiastic comments within the 3D printing community. Look at the exemplary publications covering the machines in the leading industry media:

2. Zortrax Full Metal Packages

The passing year marked a milestone for Zortrax solutions dedicated to industrial applications, as, from now on, metal 3D printing is available on Zortrax Endureal. Zortrax Full Metal Package 316L and Zortrax Full Metal Package 17-4 PH are comprehensive sets, containing everything that’s needed for quality, convenient metal 3D printing. Each kit comprises, amongst other elements, BASF Forward AM’s filaments: either BASF Ultrafuse® 17-4 PH or BASF Ultrafuse® 316L. Using these metal-polymer filaments is an efficient manufacturing method to produce industrial-grade, stainless steel components. Compared to traditional production technologies, such as CNC machining or Metal Injection Molding, metal 3D printing ensures more flexibility of design, and most importantly, is much more affordable. While 3D printing with metallic powder filaments, however, it is vital to use a quality, reliable 3D printer, capable of processing them properly. It is also crucial to take care of proper post-processing – hence Zortrax Full Metal Packages includes a voucher which covers post-processing services at Elnik Systems GmbH in Germany.

Zortrax Full Metal Packages contain all the essentials for metal 3D printing, including quality metal-polymer filaments by BASF Forward AM.

3. VICTREX PAEK AM 200

Another novelty, introduced for Zortrax Endureal, is VICTREX AM 200 low-melt PAEK filament, a high-performance polymer that belongs to the same thermoplastics’ family as Z-PEEK. The most important features of VICTREX PAEK AM 200 FIL include low viscosity, assuring easier flow through the nozzle, slow crystallization rate facilitating strong interlayer bonding that improves tensile strength along the Z-axis, high dimensional stability, and minimized warpage.

“I’ve enjoyed seeing what the Zortrax Endureal 3D printer can do with an easier printing PEEK-based polymer like VICTREX AM 200, especially when combined with soluble supports. Overhang surfaces that are often a problem area in filament fusion have looked great, the Z-direction properties seem competitive, and some of the small precision samples Zortrax has made on the machine impressed me,” says Robert McKay, Victrex Head of Additive Manufacturing Business Development.

VICTREX PAEK AM 200 is an easier-to-print high-performance equivalent of PEEK, available for Zortrax Endureal industrial 3D printer.

4. Z-SUITE 3.0 BETA

In a ’22 major update, the slicer has gained new, previously unavailable functionalities which help Zortrax 3D printers users prepare models for 3D printing more effectively. One of the main novelties is the Outer walls option, ensuring control over mechanical durability and dimensional accuracy of the target parts. One can now give prints extra strength and even better precision by increasing the number of printed contours. Z-SUITE 3.0 BETA also brings major changes and improvements to the key parameters, including Infill and Seam, and the prints’ overall quality.

5. New 3D Printing Profiles for M300 Dual

Another dual-extrusion 3D printer, Zortrax M300 Dual, in turn, has gained new printing profiles for external materials in Z-SUITE. The range of filaments has been extended with ones from such manufacturers as Kimya, Nanovia and 3DXTECH. Apart from Z-ULTRAT and Z-ASA Pro, Zortrax M300 Dual can now print on the BETA version with some more advanced, carbon-fiber-reinforced filaments, like BASF Ultrafuse PET CF15, 3DXTECH CarbonX PETG+CF, Kimya PETG Carbon or Nanovia PETG CF.

New Business Partnerships

1.BASF Forward AM

In 2022, we continued our long-term partnership with BASF, the largest chemical company in the world. Our goal here is to further expand the range of high-quality materials compatible with Zortrax machines.

BASF Forward AM is one of the largest suppliers of photopolymer resins for the Zortrax Inkspire 2, our latest high-end UV LCD 3D printer. Currently, the Inkspire 2 supports 12 different BASF Ultracur3D resins which have been calibrated and thoroughly tested by both Zortrax and BASF engineers.

Besides photopolymer resins, BASF Forward AM has a range of exceptional, high-end FDM filaments which are already available for Zortrax FDM 3D printers: Zortrax Endureal and Zortrax M300 Dual. BASF metal-polymer filaments included in Zortrax Full Metal Packages are a perfect fit with Zortrax Endureal. Automotive-grade filaments like BASF Ultrafuse PP GF30 and BASF Ultrafuse PAHT CF15 are already calibrated and available for the Zortrax M300 Dual 3D printer.

The picture shows Zortrax and BASF representatives during Formnext 2022.

2. Henkel/Loctite

Zortrax 3D printing resins portfolio has been extended by cooperating with another top global brand: Henkel/Loctite.

“We engaged with Zortrax a few years ago when they decided to open their system to industrial-focused materials and re-design their system towards the engineering and industrial users. It is worth mentioning that Zortrax focuses on, in addition to print performance, an integrated solution including post processing. They were taking a new approach, and we wanted to be a part of that process as a high-performance material provider,” says Maarten Adolf, Senior Business Development Manager – 3D printing Europe at Henkel AG & Co. KGaA.

The selection of 3D printing photopolymers in our portfolio includes Tough resins, which endure significant loads before they break. Hence, they are perfect for 3D printing mechanically strong, wear and tear resistant, load-bearing components.

3. VICTREX

Victrex is a world leader in PEEK and PAEK-based polymer solutions. We’ve teamed up with the company in 2022 and launched VICTREX AM 200, a high-performance PAEK polymer that has been designed for extrusion-based 3D printing from the ground up.

Groundbreaking projects

1. Z-PEEK certified by ESA

In 2022, our high-performance filament, Z-PEEK has met the stringent outgassing requirements and has been certified to the European Space Agency standard. Therefore, this high-temperature filament, compatible with the Zortrax Endureal industrial 3D printer, joined the few polymers that are suitable for use in space.

Z-PEEK has passed the stringent tests at ESA and is therefore officially qualified for use in space.

„Compliance with outgassing requirements is absolutely crucial when it comes to providing materials for space industry. Having those properties confirmed by tests done at ESA’s ESTEC facilities and getting an official report from those tests enable us to provide more value to our most demanding customers” says Michał Siemaszko, Head of Research and Development Department at Zortrax.

Read the report issued by ESA qualifying Z-PEEK for space applications here.

2. 4D printing in a joint project with ESA

First successful demonstrators with electrically activated movement have been 3D printed on Zortrax M300 Dual 3D printer under a European Space Agency contract. 4D printing technology means that 3D models can change their geometry under the influence of external stimuli (e.g., structures that fold when the ambient temperature falls below a certain value, or mechanisms in which movement is activated electrically). In this joint project, the 4D printing capability was achieved using multi-material printing feature currently under development for Z-SUITE software.

Zortrax engineers, together with ESA specialists, have developed 4D printing technology, in which the models change their shape under external stimuli.

3D Printing Events

1. Formnext 2022

This year, we once again exhibited at the renowned, international 3D printing fair, Formnext 2022 in Frankfurt. We officially presented our new products, including Powerful Trio there. We also showed Zortrax Inkspire 2 Clinical, a brand-new 3D printer and complementing software to bring new quality to 3D printing for the medical sector. The printer is set to go on sale in 2023. Formnext 2022 was an excellent opportunity to experience the capabilities of the machines and top-grade materials live and learn more about their features from both Zortrax and our partners’ representatives.

Zortrax Powerful Trio has garnered true interest during the international 3D printing fair, Formnext 2022.

2. IEEE Conference in the USA

Zortrax specialists participated in IEEE Aerospace Conference 2022 in Big Sky, Montana, one of the most important conferences in the world dedicated to the latest aerospace research. Michał Siemaszko, Head of Research and Development and Jacek Krywko, Leader of Advanced 3D Printing Solutions, depicted there the results of Zortrax engineers’ work on composite 3D printing in double extrusion in cooperation with European Space Agency. At the conference, Michał Siemaszko also presented a research paper entitled “3D Printing CubeSat Parts with Power and Data Transfer Functionalities with Two Blends of PEEK”, which describes the results of exhaustive tests performed at ESA’s facilities that Z-PEEK has passed, qualifying it for space applications.

The outgassing property test report is available here.

3. Warsaw Industry Week

In November, our Official Distributor in Poland, 3Druktronik, took part in Warsaw Industry Week, international industry fairs. During the event, the company exhibited all Zortrax machines, working in four different technologies (UV LCD, LPD, LPD Plus, and SVS).

In addition to the aforementioned, the Zortrax brand was a part of many other events in 2022, where our distributors and resellers presented our offer, novelties and solutions. Check the full list of events in 2022 at our blog.

Interesting Use Cases

1. Maciej Szczepański – prostheses for dogs / medicine

https://zortrax.com/blog/the-superhero-of-3d-printing-how-veterinary-medicine-can-benefit-from-the-am-technology/

2. Custom bike lamps by Krzysztof Urban / engineering

https://zortrax.com/blog/how-inkspire-2-and-basf-forward-am-resin-fill-the-void-for-custom-sports-gear/

3. Pistol grip for an Olympic athlete by Athletics3D / sports

https://zortrax.com/blog/3dprinted-custom-biathlon-rifle-handstop/

4. Quandum Aerospace / aerospace

https://zortrax.com/blog/quandum-aerospace-tested-with-zortrax-resin-3d-printing-ecosystem/

5. ABLAB mock-up/ design, industry, manufacturing

https://zortrax.com/blog/how-3d-printing-helps-to-plan-the-layout-of-production-lines-in-factories/

As 2022 has shown to us all, 3D printing continues to innovate, improving various businesses as well as the lives of individuals. We’re glad that we are the part of this ever-growing industry.

We’re looking forward to even more exciting projects in 2023!

For even more interesting user stories, go to our Zortrax blog.

The post The Summary of 2022 at Zortrax appeared first on Zortrax.

BASF Forward AM and Zortrax Forge a Long-Term 3D Printing Partnership

Agnieszka Kileńska-Ziółek — Fri, 18 Nov 2022 12:00:23 +0000

Zortrax has entered in a long-term partnership with BASF, the largest chemical company in the world, to further expand the range of high-quality materials compatible with its machines.

“We are excited to collaborate with Zortrax as both companies share a common vision for additive manufacturing. Zortrax is well recognized for their FDM 3D printers. It also constantly innovates its photopolymer 3D printer platforms. The newly released Inkspire 2 is an industrial-grade UV LCD 3D printer with a very large build volume and automated systems which many other industrial platforms in this price category do not provide,” says dr Piotr A. Bazuła, Global Key Account and Business Development at BASF.

Zortrax Powerful Trio: Zortrax Inkspire 2, Zortrax Cleaning Station, Zortrax Curing Station and BASF 3D printing resins.

Engineering Photopolymer Resins

BASF Forward AM is a BASF subsidiary unit focused on developing and producing cutting-edge additive manufacturing materials. It is as well one of the largest suppliers of photopolymer resins for the Zortrax Inkspire 2, the latest high-end UV LCD 3D printer from Zortrax. Currently, the Inkspire 2 supports 12 different BASF Ultracur3D resins which have been calibrated and thoroughly tested by both Zortrax and BASF engineers. Double validation process ensures that the parts, 3D printed on the Inkspire 2 and post-processed with Zortrax Cleaning Station and Zortrax Curing Station match or even exceed mechanical and thermal characteristics specified by BASF Forward AM. This has been achieved through close cooperation at a technical level that’d started long before the Inkspire 2 was released.

The picture presents Zortrax CEO, Mariusz Babula (left) and MD BASF Forward AM, Global CEO, CFO BASF, Martin Back (right).

“Zortrax and BASF Forward AM joined forces already in the early stages of the machine development, allowing a well-thought-through validation process and excellent fit of resins to the Inkspire 2 characteristics. The unique composition of the printer’s high intensity UV light engine, easy, automated, and user-friendly Cleaning and Curing Stations are a perfect match with the Ultracur3D® resins, resulting in faster curing and post-processing times.” – Bazuła claims.

The picture shows Zortrax and BASF representatives, with Piotr Bazuła, quoted in the text (in the middle, dressed in a black suit).

The range of Ultracur3D® resins calibrated on the Zortrax Inkspire 2 is set to significantly grow in the future. New materials will be added in each of the three Ultracur3D® lines which are: elastomeric, high rigidity, and tough resins.

Zortrax portfolio offers a range of 12 BASF Forward AM photopolymers for various engineering applications.

“Ultracur3D® from BASF Forward AM is an exceptional range of materials offering broad array of capabilities to engineers worldwide. Each resin in the family is throughly tested to give consistent, quality results each time. BASF Forward AM’s know-how in the field of photopolymers has led to development of materials with properties previously found only in high-performance FDM filaments,” says Artur Chendoszko, Resin Technology Leader at Zortrax.

Innovative FDM Filaments

Besides photopolymer resins, BASF Forward AM has a range of exceptional, high-end FDM filaments which are already available for Zortrax LPD 3D printers. Automotive-grade filaments like BASF Ultrafuse PP GF30 and BASF Ultrafuse PAHT CF15 are already calibrated and available for the Zortrax M300 Dual 3D printer. Moreover, BASF Forward AM and Zortrax engineers are on the verge of bringing the metal 3D printing capability to the Zortrax Endureal, the largest industrial 3D printer in Zortrax range.

The models 3D printed with BASF Ultrafuse PP GF30 on Zortrax M300 Dual: a fan shroud (left), and a custom part for an Olympic biathlon silver medalist made by Athletics3D (right).

“Using BASF Forward AM unique printing and post-production process, we want to expand the Endureal to become a viable alternative to more costly and infinitely more complex SLS metal 3D printing systems. We will disclose further details closer to official release but it is already apparent that working with world-leading partners like BASF Forward AM helps us innovate and expand the capabilities of Zortrax resin and FDM 3D printing systems far beyond what’s been considered possible merely two or three years ago, “ says Michał Siemaszko, Head of Research and Development at Zortrax.

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