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This 3D printer can rival standard manufacturing on the factory floor – Computerworld

by • April 11, 2016 • No Comments

Start-up Carbon began shipping its industrial-grade 3D printing device with the expectation that big-name companies can soon be via it to replace traditional forms of making.
Last year, the Silicon Valley company emerged of quiet mode to announce its innovation: a machine that can turn it into objects 25 to 100 times faster than other 3D printing devices.
Carbon is not selling its M1 3D printing device outright, but instead is offering it through a subscription price of $40,000 per year, that comes with a service and maintenance plan.Carbon M1 3D printing deviceCarbonSimilar to existing stereolithography (SLA) rapid prototyping systemes, the Carbon M1 3D printing device uses an ultraviolet light projector under a light-sensitive resin pool to harden the liquid and and so pulls the object of the pool.The three-year-old company based in Redwood City, Calif. said its Continuous Liquid Interface Production (CLIP) printing system can turn it into objects in minutes compared to the hours a typical 3D printing device requires.Kirk Phelps, Carbon’s vice president of product management, said the M1 can print production-ready parts that can complete price parity with traditional making methods with runs of up to 45,000 units.
Because the cost of parts is amortized over an entire run, the additional parts created, the less every unit costs. So Carbon is estimating price parity for production runs of around 45,000.
Many parts can print at 200 to 350 millimeters per hour, Phelps said. “A thin-walled duct for the aerospace industry can print at 500 millimeters per hour,” he introduced.
“There are lots of applications in the car and aerospace industries with 45,000 part runs,” Phelps said. Compared to traditional making methods such as injection molding, 3D printing carries with it no upfront capital costs other than the machine itself. There is no engineering of steel or aluminum tools for every new part runoff and engineering costs are reduced for the reason modifying creations can be done with CAD software that is transferred directly to 3D slicer software for printing.Similar to existing stereolithography (SLA) rapid prototyping systemes, the Carbon M1 3D printing device uses an ultraviolet (UV) light projector under a light-sensitive resin pool. As the platform moves upward, the projector moves light along cross sections of the liquid polymer, solidifying it as it goes and forming objects.
The difference between CLIP and traditional SLA is that instead of a UV light or laser drawing the create on every layer of the liquid polymer pool, CLIP projects an entire cross section of the object across the pool, a thing akin to a slideshow that hardens the object continuously as the create platform rises. Unlike SLA methods, CLIP carefully balances the UV light with oxygen – the light cures the resin while the oxygen inhibits that reaction. This results in a far additional gentle system, capable of making “isotropic”, or layerless parts, according to Phelps.
“All other 3D printing techniques are only 2D printing over and over again — hence, the layers and the weaker mechanical properties,” Phelps said, referring to the layer-by-layer additive-making system. ” CLIP’s system is completely continuous, meaning there are no layers — expanding parts pretty than printing them layer by layer.”
Whilst traditional approaches to additive making (3D printing), such as futilized filament fabrication (FFF) or selective laser sintering (SLS), manufacture trade-offs between surface finish and mechanical properties, the M1 creates high-resolution parts with engineering-grade mechanical properties and surface finish, the company claims.Carbon M1 3D printing deviceCarbonA pipe printed with Carbon’s M1 3D printing device.”This product lays the groundwork for addressing leading gaps in additive making as we work with our customers to continually innovate and hustle the boundaries of product create and production,” Carbon CEO Joseph DeSimone said in a statement.
Phelps compared the M1’s production high end to that of injection molding or urethane casting, where molten metal or liquid resin is poured into a cast where it hardens.
Carbon offers seven resins of that the M1 can print objects; the resins range of rigid and semi-rigid materials to high-temperature resistant resins and rubbery plastics that meet the specifications for commercial running shoes.Carbon M1 3D printing deviceCarbonA 3D-printed turbine.For example, Carbon’s Cyanate Ester-based resin is a high-performance material with heat deflection up to 219 degrees Celsius (426 degrees Fahrenheit). The Cyanate Ester resin is createed for car under-the-hood applications, such as ducting, electronics and other industrial components.
Carbon has been working with beta customers in industries such as auto, aerospace, medical and athletic apparel, which include a number of Fortune 500 companies. BMW, for example, uses the M1 3D printing device to manufacture the name badges on a few of its models, that were formerly generated via injection molded thermoplastic.
Ford has in addition tested Carbon’s M1 for printing engine duct work, Phelps said.Carbon M1 3D printing deviceCarbonThe difference between Continuous Liquid Interface Production (CLIP) and traditional stereolithography 3D printing is that instead of a UV light or laser drawing the create on every layer of the liquid polymer pool, CLIP projects an entire cross section of the object across the pool.”With our innovation, for the reason we have this amazingly high functional, high temperature material, they’re quite excited to be printing ducting that performs only like the injection-molded duct,” Phelps said.
The M1 is being utilized to shorten product development cycles, address new lightweight, high-strength geometries, and create customized medical devices, Carbon said.
“The medical device community is via that material in sterilizable applications,” Phelps continued. “I’m not aware of any 3D printing device in the world — SLS included — that can do a thing like that.”


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