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Fabrication Process

Metamaterial Mechanisms

Fabrication research from Hasso Plattner Institute is process to give single 3D printed objects elastic mechanical properties:

Recently, researchers started to engineer not only the outer shape of objects, but also their internal microstructure. Such objects, typically based on 3D cell grids, are also known as metamaterials. Metamaterials have been used, for example, to create materials with soft and hard regions.

So far, metamaterials were understood as materials—we want to think of them as machines. We demonstrate metamaterial objects that perform a mechanical function. Such metamaterial mechanisms consist of a single block of material the cells of which play together in a well-defined way in order to achieve macroscopic movement. Our metamaterial door latch, for example, transforms the rotary movement of its handle into a linear motion of the latch. Our metamaterial Jansen walker consists of a single block of cells—that can walk. The key element behind our metamaterial mechanisms is a specialized type of cell, the only ability of which is to shear.

 

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Fabrication Process

What is 3D printing?

The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object.

http://3dprinting.com/what-is-3d-printing/

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Fabrication Process

$350 Colorpod Converts FDM to Full-Color Powderbed 3D Printer

Though there have been numerous attempts to bring full-color 3D printing to the desktop, the technology is still far from widespread and affordable.  The closest solution currently on the market is the $5,995 full-color ARKe paper 3D printer from Mcor. Other than that, color-mixing extruders are slowly making their way into the market, via brands like ZMorph and XYZprinting, but are still far from achieving the full spectrum of colors desired by consumers and prosumers. Lunavast, from Japan, has put together an interesting package for full color dying of FDM prints that has some potential. I also met a talented PhD team in Taiwan that is working on their own full-color FDM process, which seems very promising. Most recently, I was introduced to a new DIY development called Colorpod, published by one of 3DPI’s community writers.

http://3dprintingindustry.com/2016/03/28/350-colorpod-converts-fdm-to-full-color-powderbed-3d-printer/

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Fabrication Process

The Future of Construction Carbon Concrete: Hard shell – lightweight core

With over 100 million cubic meters used each year, steel-reinforced concrete is the most important construction material in Germany – for now. There’s a modern alternative on the horizon: Instead of steel, reinforcement is provided by carbon fibers, which are four times lighter than steel, offer six times the load capacity and don’t rust.

C3 (Carbon Concrete Composite) is the name of the carbon fiber-reinforced concrete project which is now slowly moving out of its infancy. It is the biggest construction research project in Germany and has received government funding of around 45 million euros. The project team includes specialists from our TechCenter Carbon Composites. Christoph Klotzbach, head of the TechCenter, says: “Initial applications show we’re on the right track.”

 

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Fabrication Process

Carbon-fiber epoxy honeycombs mimic the material performance of balsa wood

As turbine makers produce ever-larger blades—the longest now measure 75 meters, almost matching the wingspan of an Airbus A380 jetliner—they must be engineered to operate virtually maintenance-free for decades. In order to meet more demanding specifications for precision, weight, and quality consistency, manufacturers are searching for new sandwich construction material options.
Now, using a cocktail of fiber-reinforced epoxy-based thermosetting resins and 3D extrusion printing techniques, materials scientists at the Harvard School of Engineering and Applied Sciences (SEAS) and the Wyss Institute for Biologically Inspired Engineering have developed cellular composite materials of unprecedented light weight and stiffness. Because of their mechanical properties and the fine-scale control of fabrication (see video), the researchers say these new materials mimic and improve on balsa, and even the best commercial 3D-printed polymers and polymer composites available.

https://www.seas.harvard.edu/news/2014/06/carbon-fiber-epoxy-honeycombs-mimic-material-performance-of-balsa-wood

https://www.sciencedaily.com/releases/2014/06/140625151548.htm

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Fabrication Process

How To Make Any 3D Printed Part Much Stronger

The traditional way to make stronger 3D printed parts, at least on plastic extrusion machines, is two-fold:

Pick a strong material, such as ABS over PLA
Print with higher internal density, even 100% solid
Either of those work, but the printing solid objects quickly raises the cost. It also delays your print significantly. Instead of a two hour 3D print operation, you might be looking at six hours or more.

But now there’s another approach. The folks at Lantern Robotics have been injecting hot melt adhesive (basically a glue gun) into sparsely filled 3D prints.

 

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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

Topology optimisation of material microstructure

This project is aimed at establishing effective and efficient computational algorithms for optimising the microstructures of materials and composites with single or multiple functional properties.

New and advanced materials are of critical importance to the aerospace, automotive, medical and other industries.

Using the simple BESO technique, we have successfully developed optimisation algorithms for the topological design of cellular and composite materials considering a wide range of design objectives, including maximising bulk modulus, maximising shear modulus, maximising thermal conductivity, maximising magnetic permeability, maximising electrical permittivity, and maximising or minimising a combination of these properties. We have also used the same technique to design microstructures for functionally graded materials, and for orthotropic materials with prescribed ratios between effective stiffnesses in three directions.

https://www.rmit.edu.au/research/research-institutes-centres-and-groups/research-centres/centre-for-innovative-structures-and-materials/projects/topology-optimisation-of-material-microstructure/

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Fabrication Process

Emerging Objects has big, bold plans for 3D-printed rooms

“Durability” and “strength” are about the last words I would ever associate with 3D printing. But I’m not talking about the small, plastic trinkets you would print out with your MakerBot. This is Emerging Objects, a small fabrication studio in Oakland, CA that’s researching how to 3D-print using materials like wood, ceramic, newspaper, concrete, and salt.

Everyone is focusing on machines, and we’re interested in what machines can make,” Emerging Objects co-founder Ronald Rael explained to TechHive. “We saw a limitation in what a machine can make because of the medium, and so we wondered if we could reformulate that media to suit our own architectural agendas to print big.

http://www.pcworld.com/article/2046172/emerging-objects-has-big-bold-plans-for-3d-printed-rooms.html

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Fabrication Process

This 3D Printer Builds Full-Color Paper Models!

Traditional desktop 3D printers use melted plastic as their build material, but Mcor’s printers layer sheets of paper on top of each other to create their models. We check out the new Mcor Arke, a printer that cuts from a large spool of paper, glues those sheets together, and then prints color on them to turn digital files into large paper models!