Researchers on the SEAM Analysis Middle have launched new purposes for Screw Extrusion Additive Manufacturing (SEAM), specializing in its use in development.
On the coronary heart of this improvement is the Epic3D portal printer, a system able to producing large-format plastic elements for purposes resembling facade parts, fences, and gates. Utilizing a steady deposition course of and stiffening buildings, this expertise delivers sturdy, weather-resistant elements tailor-made for out of doors development purposes.
Working with Wirth & Co. GmbH, Fraunhofer Institute for Machine Instruments and Forming Know-how (IWU) is utilizing this method to provide large-scale facade parts that meet hearth security, UV, and climate resistance requirements. In keeping with the group, SEAM expertise addresses longstanding challenges in additive manufacturing, together with the constraints of small construct platforms and reliance on sluggish, costly filament-based processes. By adopting granulate because the printing materials, SEAM permits quicker, cheaper manufacturing of custom-made elements.
Fraunhofer IWU plans to current its newest developments in SEAM expertise on the Formnext 2024 commerce present. Led by Dr. Martin Kausch Head of the Division of Sustainable Fiber-Plastic Composites, the analysis group will showcase their work at Corridor 11.0, Stand E38, and Corridor 11.0, Stand C29, in collaboration with Metrom.
Attendees can have the chance to discover how granulate-based 3D printing is being utilized to development, together with facade manufacturing, and its potential to reshape the trade.
Dr. Kausch stated, “We make subtle design reasonably priced. The non-public contact in facade design is, in fact, additionally achievable in conventional manufacturing. However solely with processes like SEAM is it cost-effective.”
Customization and flexibility in SEAM expertise
Customization is a major benefit of SEAM, notably for creating facade parts with intricate textures or distinctive shapes, resembling firm logos. This course of makes use of a modified extrusion screw to soften and deposit granulate layer by layer onto the construct platform.
In contrast to conventional strategies resembling fiber lamination and forming processes, SEAM eliminates the necessity for molds, decreasing prices and manufacturing time. The flexibility to make use of pre-colored supplies additionally removes the necessity for extra coating steps, streamlining the general course of.
Three techniques developed by collaboration with Metrom and 1A Applied sciences develop SEAM’s utility potential. These embrace Epic3D, METROM P1410, and SEAMHex. Amongst them, Epic3D stands out for its functionality to deal with large-format manufacturing, supported by a construct platform measuring 2 meters by 1.7 meters. Complementing this, METROM P1410 brings extra versatility by integrating processing steps resembling milling, increasing its utility potential.
Lastly, SEAMHex employs a singular six-axis parallel kinematics system that gives excessive dynamics and motion flexibility, making certain distinctive positioning and path accuracy. This design ensures distinctive positioning and path accuracy whereas decreasing shifting mass, leading to dependable and environment friendly manufacturing of medium-sized elements. Collectively, these techniques cater to a broad vary of producing wants with precision and flexibility.
Florian Stöckel, managing director of Wirth & Co. GmbH, underlined the significance of the collaboration with Fraunhofer IWU in enhancing the SEAM course of for development purposes. He defined that the Epic3D portal printer performs a vital position in enabling new design prospects for facade development.
Stöckel famous that the partnership focuses on optimizing varied points, together with design, supplies, and the 3D printing course of itself. He additionally highlighted that the corporate’s funding within the Epic3D system represents a step towards making additive manufacturing extra appropriate for producing constructing elements.
Broadening the frontiers of development analysis
Past SEAM, different analysis highlights the evolving panorama of additive manufacturing in development. One notable instance contains Massachusetts Institute of Know-how (MIT) and Evenline researchers who studied the feasibility of utilizing glass 3D printing to create interlocking masonry items. Revealed in Springer Nature, this analysis highlights how glass AM can improve design flexibility and scale back tooling prices in comparison with conventional strategies.
Utilizing the G3DP3 printer, the group developed modular masonry items examined throughout three fabrication strategies: Totally Hole, Print-Forged, and Totally Printed. Findings revealed various strengths and floor accuracies, with Totally Hole items displaying the best structural efficiency. As per the group, this research emphasizes glass AM’s potential for recyclable, sustainable development, although additional refinement is required for large-scale purposes.
Elsewhere, College of Virginia (UVA) researchers developed a sustainable cementitious composite for 3D printing by incorporating graphene nanoplatelets (GNPs) into limestone-calcined clay (LC2). Led by Professor Osman Ozbulut, this analysis enhances structural integrity and environmental efficiency, growing compressive power by 23% with simply 0.05% GNPs whereas enhancing printability.
A Life Cycle Evaluation revealed a 31% discount in greenhouse fuel emissions in comparison with conventional cement-based mixtures. Carried out with the Virginia Transportation Analysis Council, the research positions graphene-enhanced LC2 as a promising materials for sustainable development, notably in transportation infrastructure.
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Featured picture exhibits the SEAM Analysis Middle: Epic3D (backside left), METROM P1410 (heart), and SEAMHex. Photograph through Fraunhofer IWU.
