{"id":194069,"date":"2022-12-22T00:00:00","date_gmt":"2022-12-22T00:00:00","guid":{"rendered":"https:\/\/facfox.com\/news\/3dpbms-guided-tour-of-hps-booth-at-formnext-2022-decision-makers\/"},"modified":"2022-12-22T00:00:00","modified_gmt":"2022-12-22T00:00:00","slug":"3dpbms-guided-tour-of-hps-booth-at-formnext-2022-decision-makers","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/3dpbms-guided-tour-of-hps-booth-at-formnext-2022-decision-makers\/","title":{"rendered":"3dpbm\u2019s guided tour of HP\u2019s booth at Formnext 2022 Decision Makers"},"content":{"rendered":"

At Formnext 2022, 3dpbm was given a tour of HP\u2019s booth. HP took an effective approach when choosing how to exhibit this year \u2013 with loads of different application<\/a> examples for their plastic and metal printing technology.<\/p>\n

White plastic<\/h2>\n

HP has been commercially printing plastic since 2016. However, this has previously been limited to derivatives of black. At Formnext, the company unveiled one of its latest milestones in plastic 3D printing<\/a> \u2013 the ability to print in white.<\/p>\n

<\/p>\n

With this milestone, HP is now enabling new post-processing capabilities, such as the ability to color the part<\/a>s to match any brand image, as well as have a better surface quality look and feel compared to the previous solution. Users in the medical<\/a> industry also tend to perceive white as cleaner, more sterile and more aesthetically suited when compared to colored part<\/a>s.<\/p>\n

HP\u2019s plastic material is biologically-certified and can therefore be used for surgical application<\/a>s (but not implants) and modeling as well as surgical equipment in small batch production \u2013 such as personalized insoles and surgical guides, for example.<\/p>\n

In terms of industrial application<\/a>s, HP\u2019s plastic printing technology is used for the creation of end-of-arm tooling, motorboats, filters for water filtration systems, interior car part<\/a>s, and the packaging industry, to name a few. In the consumer<\/a> segment, HP is enabling the creation of bike saddles, helmets, goggles, and other protective gear and comfort-enabling objects.<\/p>\n

The MetalJet S100 up close<\/h2>\n

When it comes to metal 3D printing<\/a>, HP appears to have been making significant progress with major part<\/a>nerships and application<\/a> case studies.<\/p>\n

\u201cPlastic is almost like a lubricant, when you get it in your system \u2013 bearings and stuff work better. When it comes to metal \u2013 it\u2019s electrical, it\u2019s abrasive, it\u2019s magnetic. And so we\u2019ve had to make this much more robust,\u201d according to Tim Weber, the Global Head of 3D Materials at HP, who leads the R&D teams in both Barcelona and on the West Coast of the United States.<\/p>\n

The system that HP uses for metal printing, and the one that was exhibited at Formnext, the MetalJet S100, is designed to be modular \u2013 meaning that one can start<\/a> with one printer and upgrade with different additions \u2013 and uses orthogonal printing to spread and sinter the powder, 100% of which is recycled, and ultrasonic blades that vibrate to ensure the powder fits uniformly. The powder system alone is designed to support six printers in production.<\/p>\n

<\/p>\n

\u201cMaybe you start<\/a> with a printer for doing your development. That printer is also the printer you\u2019ll scale with. You start<\/a> adding more \u2013 you start<\/a> adding the powder management and start<\/a> adding the automation to get labor out of it from that standpoint. If you want to build a factory, you start<\/a> replicating exact units that are already qualified rather than bringing in different units,\u201d said Devin Mourey, Director of Engineering, and the lead engineer for all of HP\u2019s metal application<\/a>s, engineering, and process development. \u201cIn some ways, it\u2019s kind of a miniature version of what intel does. Right? They have an exact copy. So they build this $10 billion fab and then they build another one that\u2019s identical. It looks completely identical because when you\u2019re trying to do process repeatability and process control if everything\u2019s exactly the same, it makes it much easier to qualify.\u201d<\/p>\n

The MetalJet S100 printer is the fourth generation of its kind and has recently been upgraded to include a \u2018hardcore transmission\u2019 and a closed loop controller in the lift mechanism that enables printing at the single micron level. According to Devin Mourey, all these small upgrades here and there have resulted in an increase of as much as 50% in productivity compared to the earlier generations.<\/p>\n

<\/p>\n

An advantage that HP has over many competitors is that of vertical integration. For example, the company makes about 400 million print heads per year. This enables HP to leverage the low cost per print head, and incorporate many more print heads into their machines, without it being as much of a financial burden compared to if competitors were to do the same. The result of this advantage is that \u201cfor every pixel where you\u2019re putting a drop of binder, we actually put four drops of binder. So, if for some reason you\u2019re missing one, this allows you to make sure you do not have a line across your part<\/a>, which is pretty bad for the manufacturers,\u201d said Devin Mourey.<\/p>\n

\u201cThere\u2019s a lot of intention to try to make it very easy for operators. So, for example, this build unit knows, digitally, what it is. So it knows the build when it loads over there, it knows what I\u2019m trying to print with it. It loads the right amount of powder there when you move it to the printer. It knows how long it needs to cure. All of that intelligence is contained, digitally, inside the build boxes,\u201d said Tim Weber. Of course, physically, the bold blue touch points only add to the ease of the user experience \u2013 lowering the barrier to train new people.<\/p>\n

\u201cOur digital workflow also enables the traceability of metal powder all the way to your part<\/a>s, which is really important for medical<\/a>, aviation, and even auto. In addition to making the workflow easier, some industries actually require this,\u201d said Devin Mourey.<\/p>\n

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<\/p>\n

In terms of post-processing \u2013 \u201cwhat you want to do is get the powder out, recycle it, run it all the way back there to get the part<\/a>s ready to actually put into a sinter. There\u2019s an Ultrasonic Bite Radar in there \u2013 it pulls the powder down, and, in a lot of cases, 95% of the powder comes off the part<\/a>s,\u201d said Devin Mourey.<\/p>\n

\u201cRemoving the bulk powder around the part<\/a>s allows an operator to dramatically improve the effectiveness. It also lets the powder get back into production very quickly, instead of having it tied up at a very manual processing step where somebody\u2019s trying to reclaim all the material,\u201d added Tim Weber while referring to the usual modus operandi of powder removal as, ironically, an \u2018archaeological dig\u2019.<\/p>\n

Targeting new metal AM application<\/a>s<\/h2>\n

HP\u2019s metal printing technology is applied to four different segments \u2013 automotive<\/a>, industrial, consumer<\/a>, and medical<\/a>.<\/p>\n

Until now, the team has been focused on making their stainless steel (316L and 17-4 \u2013 the most prevalent materials in metal injection molding) printing technology as robust as possible, to \u2018get people to trust this technology\u2019. \u201cThat\u2019s what the industry is comfortable with. Those two materials cover a huge number of application<\/a>s in those four segments, and that\u2019s why we chose those,\u201d said Tim Weber. Although HP\u2019s systems work with many different materials too.<\/p>\n

<\/p>\n

Major OEMs such as John Deere and Schneider Electric, have chosen to use HP\u2019s metal printing technology to transform the way they make products \u2013 from prototyping to serial production.<\/p>\n

For example, Schneider Electric turned to HP to 3D print their electric filters to fit into breaker boxes that are used within the marine, defense, and industrial environment<\/a>s. Previously, \u201cthese filters were being made with sheet metal and nickel metal mesh and assembled in this extremely expensive process,\u201d said Tim Weber. \u201cThis [HP\u2019s printing technology] allowed them to reduce the size of the entire fuse box by 20%, which allowed them to pack more into the given space. And so the entire system became substantially cheaper and lighter weight by doing this.\u201d<\/p>\n

\u201cWe have a lot of people come to us and say I want to make 10,000 part<\/a>s, 20,000 part<\/a>s, 100,000 part<\/a>s, and it allows us to point them to a company that can actually produce. Those companies [such as GKN, one of HP\u2019s digital manufacturing part<\/a>ners, that is currently producing part<\/a>s at scale] will ultimately buy machines from HP and produce part<\/a>s from them,\u201d said Tim Weber.<\/p>\n

<\/p>\n

Another example of a major company using HP\u2019s metal printing to produce final part<\/a>s is the fuel bypass manifold for cold winter tractor conversion kits produced by John Deere, who, according to Tim Weber, \u201chas been producing using additive for a very long time, for prototyping. This is their first ever production metal part<\/a>, and the reason is that previously, it was unaffordable for them to actually do production with powder bed fusion and other techniques,\u201d \u2013 until, through HP\u2019s metal additive technology, it was proven to be a viable option.<\/p>\n

Previously, in the automotive<\/a> industry, HP\u2019s technology has been applied to the creation of cosmetic and structural part<\/a>s for companies like Volkswagen, for example.<\/p>\n

How HP\u2019s printing technology is applied really depends on the customer. \u201cThere are some companies that are more vertically integrated \u2013 so they\u2019ll buy machines, and go through their own design, within their own business. Others will come to us and they\u2019ll say, \u2018we want to work with you on design for MetalJet\u2019, and then they\u2019ll work with one of our digital manufacturing part<\/a>ners, such as Parmatech, a company with a long history of producing with some of the world leading medical<\/a> part<\/a>ners in metal injection molding, to have it produced,\u201d said Tim Weber.<\/p>\n

As an example of how HP caters to the consumer<\/a> industry \u2013 the company part<\/a>nered with Cobra Golf to create a putter in collaboration with the professional golfer, Bryson DeChambeau. Over the course of a couple of months, Bryson DeChambeau \u201cwent through many, many iterations, and tried all these different designs, but ultimately found one he liked. So it was this incredible power of being able to iterate with additive, find a design he liked, and produce the exact number of part<\/a>s he wanted \u2013 which sold out almost instantly,\u201d said Tim Weber. \u201cCobra had never made a putter before. So for all they knew, they weren\u2019t going to sell very many. This gives them the flexibility now to scale it up or scale down based on whether or not they\u2019re going to have successful SKUs. You\u2019re going to see that same thing in jewelry and watches. Rather than making ten or 15 SKUs, figuring out which five SKUs sell, and then figuring out what to do with the inventory of the other ten SKUs \u2013 you\u2019re going to figure out which SKUs work. You\u2019re then going to make exactly those things. It is transforming the way people make consumer<\/a> products.\u201d<\/p>\n

<\/p>\n

The case study application<\/a>s we were privy to at HP\u2019s booth at Formnext were a select few, and only the tip of the proverbial 3D printed iceberg. However, what we do know for certain is that the company is making a noteworthy contribution to the adoption of AM technology, across major market segments.<\/p>\n

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You might also like:<\/h5>\n

re:3D launches Gigabot 4, Terabot 4, GigabotX 2, and TerabotX 2: <\/a>re:3D was born out of Engineers Without Borders, at the NASA Johnson Space Center, in 2013. It is a social enterprise pioneering innovations to remove the cost and scale barriers to 3D printing in order to create jobs and enable problem-solvers around the world to independently address local needs. re:3D has customers in more than 50 countries, and claims to offer the world\u2019s largest industrial FFF 3D printer under $9K.<\/p><\/blockquote>\n

* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author: Edward Wakefield<\/p>\n","protected":false},"excerpt":{"rendered":"

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