Polymer Addictive Manufacturing of Medical Device
In the Medical field, stereolithography (SLA), the masking process and selective laser melting (SLM) have established themselves. Often, with increasingly complex geometries and undercuts, the tools simply cannot gain access to mill properly. The use of AM has made it possible to build objects with complex geometries and cavities that otherwise would have been difficult to attain with subtractive manufacturing. For example, in template guided surgery, drill templates have been printed using SLA processes for years.
The process converts liquid plastic into solid 3D geometric objects, through sequential printing, layer by layer, of liquid plastics (photopolymer resin) that are hardened with an ultraviolet light source or laser. In the dental setting, SLA is used in fabricating dental models as well as patterns for fixed and removable dental prostheses The dental model is ideally produced parallel to the corresponding crown or bridge. Through the time-efficient production method the manufacturing time can be reduced on average by one working day
A 3D model used for surgical planning
3D printed neuroanatomical models can be particularly helpful to neurosurgeons by providing a representation of some of the most complicated structures in the human body. The intricate, sometimes obscured relationships between cranial nerves, vessels, cerebral structures, and skull architecture can be difficult to interpret based solely on radiographic 2D images. A realistic 3D model reflecting the relationship between a lesion and normal brain structures can be helpful in determining the safest surgical corridor
The customizable implant made of the plastic material PEKK is designed to restore voids in the skull caused by trauma or disease. Manufactured in a matter of hours with Additive Manufacturing (AM) technology, the implant saw its use just a few days later when the device was successfully implanted in a patient missing a significant portion of cranial bone. It has a density and stiffness similar to bone, it is lighter than traditional implant materials such as titanium and stainless steel.
Polymer Addictive Manufacturing of Aeronautics
Companies in the aerospace industry manufactures parts using traditional injection molds. This tradition method is time-consuming and expensive and can not produce parts with complex geometries. Polymer AM technologies allow the production of parts with complex geometries and optimize the weight of each part. As a result, AM technologies enable the design of parts with difficult aerodynamic properties if not impossible to manufacture with traditional methods for engine parts, turbine, aircraft wing or cabin interior
Air ducts for laminar flow
Air duct requires complex geometry, easily depicted in a 3D model but not trivial to replicate with standard manufacturing techniques. Polymer Selective Laser Sintering process is well suited for complex fittings and designs. In addition, the number of parts required for complete assembly can be reduced.
Prospective study of engine pylon
The engine pylon makes the connection between the wing and the turbine. The pylon of the A320 is predominantly made of 650 parts of titanium with a weight of about 650kg. therefore, airline wants a prospective study of engine pylon to design a prototype made of polyamide. Thanks to plastic laser sintering technology, it becomes possible to make parts with complex shapes and lightweight that were impossible with traditional methods As a result. The number of parts can be reduced by 50%, and the final weight can be reduced by about 100 kg.
Cabin ventilation distributor
Helicopters cabin ventilation distributor was originally made by using composite of 7 separate parts. The objective was to minimize the final delivery time by reducing manufacturing time through 3D printing, using plastic laser sintering technology, also ensuring lower manufacturing costs. As a result, Design suitable for additive manufacturing as 1 part, saving 30% to 40% of time in the development of the prototype device.
Polymer Addictive Manufacturing of General Industry
Additive manufacturing technologies provide you to design automotive parts with complex structures that are difficult or impossible to produce with conventional methods. For example, the weight reduction offers benefits such as optimizing high energy efficiency and reducing CO2 emissions of the vehicle. 3D printing eliminates the need for tooling and assembly, greatly reducing the cost and development time of prototyping and manufacturing of functional, durable and rigid parts.
Wind tunnel model
The car model in the wind tunnel features a complex network of pressure sensors. These were positioned by drilling pressure tapings into metal and carbon fiber components before SLA technologies became available. The ability to create solid forms with complex channels through SLA has revolutionized our ability to increase the number of channels and to deploy sensors. It’s a dream come true for aerodynamicists!
Intake manifold model
One of Ford’s most famous samples prepared by additive manufacturing is the intake manifold which is the most complicated part of an engine. They say that an engineer can spend up to four months and cost up to $500,000 on the prototype design and production in the traditional methods. Using additive manufacturing for their prototype engineers can make an intake manifold within four days at a cost as low as $3,000. The most important advantage of additive manufacturing is that you do not have to go offsite. Engineers are able to get the parts much faster.
Oil and gas relevant 3D printed PEEK parts
The material PEEK brings along properties which make it suitable for use in extremely demanding operating environments. These properties make it attractive to use PEEK for components supporting down-hole equipment such as sealing systems, fasteners, gas separation systems, gears, impellers, plugs, tubes and housings. Recently, industrial SLS technology has enabled us to manufacture additional PEEK parts. An obvious advantage is that it can easily and significantly shorten the time it takes to achieve maintenance-based goals.