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Fabrication Process

Rael San Fratello, Emerging Objects, ExOne – Involute Wall

The involute wall is a prototype for thermal mass and acoustic dampening in a massive 3D printed sand structure. The involuted surfaces reduce resonance in the room, by absorption and redirection of sound waves. The massive 600lb 3D sand print presents the opportunity for surfaces to serve as thermal mass while keeping much of the wall in shade—ideal for hot climates with extreme temperature shifts.

 

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Fabrication Process

ExOne’s Cold-Hardening Phenol Binder in Production Now

The ExOne Company’s “cold hardening phenol” (CHP) binder agent is now in commercial operation on a machine in Freiberg, Germany, for prototype casting producer, ACTech GmbH. It is the first 3D printer in the world using the new binder, which was first reported last September as a further development of the phenolic binder formulations ExOne debuted in 2013.

According to the developer, ACTech is able now to produce prototypes of challenging designs more quickly and cost-effectively. “Compared to traditional rapid prototyping procedures, this new technology enables the production of high-strength molds and cores for sand castings, which until now were achievable only with laser sintering,” according to an ExOne announcement.

http://m.foundrymag.com/moldscores/exone-s-cold-hardening-phenol-binder-production-now

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Fabrication Process

3Dealise, ExOne und Bruil lassen Architektenherzen höher schlagen

Mehr und mehr kommen Unternehmen auf den Markt, die den 3D-Druck auf einen größeren Maßstab als nur den Schreibstisch bringen wollen. ExOne bietet da mit seinem S-Max ein Modell zum Druck extrem großer Bauteile. Genau richtig für kreative Architekten und Ingenieure, wie 3Dealise und Bruil demonstrieren.

http://www.3d-drucken.de/2015/02/3dealise-exone-und-bruil-lassen-architektenherzen-hoeher-schlagen/

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Fabrication Process

3Dealise, ExOne and Bruil introduce new technology for freeform 3D-printed architectural concrete

3Dealise, an industrial 3D printing and 3D engineering company and Bruil, a Netherlands-based construction company, have partnered to develop a way for fabricating large-scale concrete structures that brings to architects and engineers what they are calling ‘freedom of design’ or “freeform design”.

One example of how they are using their technology is in forms like the one below, which is a 1.6 m twisted H-profile that was presented at the GEVEL 2015 trade show last week.

http://www.3ders.org/articles/20150217-3dealise-exone-and-bruil-introduce-freeform-3d-printed-architectural-concrete.html

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Fabrication Process

Better Buy in 2014: Voxeljet AG (ADR) vs. ExOne Co

On the surface, ExOne (NASDAQ: XONE) and voxeljet (NYSE: VJET) are very similar 3-D printing companies. Both compete in the industrial segment, use a similar 3-D printing technology, and boast some of the largest print beds in the world.

Where these two companies differ boils down to the materials they can print with. Voxeljet only offers 3-D printing in two different types of plastic and one type of sand. ExOne, on the other hand, offers 3-D printing in two different types of sand, five types of metals with seven different finishes, and a soda lime glass that’s available in three different finishes.

This greater range of materials gives ExOne a competitive advantage over voxeljet, 3-D printing analyst Steve Heller argues. With more materials, ExOne can serve a greater base of customers and has a larger business opportunity than voxeljet. Check out the video below to get the full story.

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Fabrication Process

Rapid-prototyping-anlage aufweisend eine baubox

EP 2391499 B1

Die vorliegende Erfindung betrifft eine Anlage zum schichtweisen Aufbau eines Formkörpers durch Ausbilden übereinander liegender Schichten von Baumaterial auf einem Baufeld und durch selektives Verfestigen eines Teilbereichs der jeweiligen Baumaterial-Schicht vor dem Ausbilden der nächstfolgenden Schicht, wobei die Anlage mit einer Baubox versehen ist.

Eine derartige Anlage (z.B. eine sog. Rapid-Prototyping-Anlage) kann einen horizontal verfahrbaren Beschichter aufweisen, mit dem gleichmäßige Schichten aus dem zu verfestigenden Baumaterial, z.B. ein Partikelmaterial oder ein Gemisch enthaltend Partikelmaterial, in mehrfacher Wiederholung auf das Baufeld aufgebracht werden können, wozu der Beschichter horizontal über das Baufeld hin verfahrbar ist.

https://www.google.ch/patents/EP2391499B1

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Fabrication Process

History of sand printing

Digital part materialization for the sand printing business began in 1999 when a group of engineers at a start-up company called Generis in Augsburg, Germany developed the prototype 3D printer for making sand casting molds and cores. The first printing system was sold to BMW AG in 2001. Generis was focused on the development of machines and processes for sand and investment casting before it was divided in 2003 into ProMetal RCT for sand and Voxeljet for investment casting. As a division first of Extrude Hone Corporation and then ExOne, ProMetal RCT developed a worldwide market for sand printing with dozens of machine installations. A smaller printer was developed in 2004 for printing with different materials and binders. With the introduction of the S-Max in 2010, ExOne released the largest 3D sand printer in the world, redesigned for production flexibility and efficiency. The development and production facility in Augsburg, Germany now operates as ExOne GmbH. The ExOne® 3D sand printing business has grown from a handful of engineers to a worldwide team with operation and support facilities in Germany, the United States and Japan. ExOne is the global leader in sand printing systems.

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Fabrication Process

The Top 10 Biggest 3D Printers

Most people generally associate 3D printing with small size objects, the truth seems to be quite different. In fact, there seem to be two diametrically different concurrent trends in the industry. One is towards printing with the finest resolutions and the other is aimed at printing the largest sizes possible.

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Fabrication Process

ExOne Binders

ExOne® binders are central to the printing process. The type of binder used depends on the type of powder or system that is being used, or customer application requirements.

Furan Binder

Furan binder is a typical no-bake binder found in traditional sand casting applications, and therefore no foundry changes are required to utilize this binder material. Printed cores are  immediately available for casting with no heat required.

Phenolic Binder

Utilized for printing sand molds and cores, phenolic binder is the best suited for high temperature pouring of castings. Very thin walls or thin pipes can easily be printed, due to the high heat strength of the core. Parts are easily cured using microwave technology.

Silicate Binder

ExOne offers an innovative environmentally-friendly option, with a binder based on silicate for printing sand molds and cores. Using this binder for printing results in low gas emissions during the casting process. Parts are easily cured using microwave technology.

Aqueous-Based Binder

Many of our directly printed materials (primarily metals) utilize a proprietary aqueous-based binder, which acts as an adhesive, bonding layers of powdered metal together. Once the parts are printed, they are placed into a furnace and the binder is burned out of the parts while powder particles fuse together in a sintering operation.

http://www.exone.com/Resources/Binders

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Fabrication Process

Involute Wall

The involute wall is a prototype for thermal mass and acoustic dampening in a massive 3D printed sand structure. The involuted surfaces reduce resonance in the room, by absorption and redirection of sound waves. The massive 600lb 3D sand print presents the opportunity for surfaces to serve as thermal mass while keeping much of the wall in shade—ideal for hot climates with extreme temperature shifts.

http://www.emergingobjects.com/projects/involute-wall/