Additive manufacturing (3D printing) has evolved significantly since its inception in 1984, transitioning from a rapid prototyping tool to a fully-fledged manufacturing solution.
The technology behind the 3D printing process has progressed in many ways as well, which we’ll cover below too. But first, let’s explore the evolution of 3D printing materials and what’s possible in the world of additive manufacturing.
The Evolution of 3D Printing Materials
The early days of 3D printing were largely dominated by a few polymer materials, namely PLA and ABS. These were primarily used for concept models and low-stress applications. However, today’s advanced materials go far beyond these rudimentary options. Modern 3D printing materials enable high-performance, end-use parts in industries like automotive, aerospace, energy and healthcare.
Additive manufacturing materials now include high-temperature thermoplastics, reinforced composite materials, metals, ceramics, and even bio-compatible resins. Each of these materials brings unique characteristics to the table, enabling engineers to tackle designs previously unachievable using traditional manufacturing methods or 3D printing. Here’s a breakdown of the latest and greatest 3D printing materials available from Prototal.
High-Performance Polymers
Materials like Carbon PEEK and ULTEM are part of a new class of high-performance thermoplastics that offer exceptional mechanical properties combined with resistance to high temperatures, chemicals, and wear.
These materials increasingly see use in aerospace, automotive, and medical device applications where high strength-to-weight ratios and resistance to extreme conditions are essential.
Carbon PEEK – Has excellent mechanical properties and chemical resistance. This is one of the toughest 3D printing materials available so it’s ideal for the toughest applications.
ULTEM (PEI) – With a high melting point and excellent flame, smoke, and toxicity (FST) ratings, ULTEM is an excellent choice for motorsport or aerospace components.
PEEK – Flexible, resistant to high temperatures, chemicals and creep, PEEK is one of the most widely used thermoplastics in the world because of its versatility and precision.
The ability to print with the materials above enables the creation of lightweight components that can withstand harsh environments without sacrificing performance. In fact, using these additive manufacturing materials can result in improved fuel efficiency and thermal stability. Not to mention, complex geometries can be printed in a single part for better structural integrity when compared to traditional manufacturing methods and materials.
The Role of Material Science in Expanding AM Applications
The growing diversity of materials suitable for 3D printing is directly tied to advancements in material science. Researchers and engineers are not only developing new materials but also improving existing ones to work more effectively in additive manufacturing processes. Material properties like particle size distribution, viscosity, and flow characteristics are all critical to ensuring successful print outcomes.
Moreover, the ability to fine-tune material properties through post-processing methods such as vapour smoothing and other surface finishing techniques is further pushing the boundaries of what 3D-printed parts can achieve.
All of the recent advancements in additive manufacturing make it an even more versatile tool for creating high-performance parts.
The Evolution of Additive Manufacturing Technologies
It isn’t just the 3D printing materials that have evolved over the years, the printing process has also evolved and changed the manufacturing industry as a result. Advanced printing methods allow for even more ways to make these functional materials thrive out in the world. Prototal has some of the most advanced 3D printing machines in the world – let’s one of them, shall we?
The Roboze Argo 500 – High Performance FDM
This advanced 3D printer is designed for industrial-grade additive manufacturing, particularly for producing high-performance superpolymer parts. The Roboze specialises in high-precision 3D printing and uses many of the materials we’ve looked at above.
Our Roboze Argo 500 is primarily used to print parts for industries like aerospace, energy and motorsport. This filament based technology allows for precision parts right off the machine and the large print bed means we can print full-scale, complex parts in a single print.
Key features of Roboze machines include:
High-Performance Materials
Roboze machines are capable of printing with superpolymers and composite materials, including PEEK (Polyether Ether Ketone), Carbon PA6 and ULTEM. These materials are known for their exceptional mechanical properties, with a better strength to weight ratio than some metal materials. This makes them ideal for applications that require high strength, thermal stability or chemical resistance.
Beltless Technology
One of the defining features of Roboze machines is their patented beltless technology, which replaces traditional belt-driven systems with a mechatronic movement of the axes driven by hardened steel gears. This results in much higher precision than other 3D printers on the market. This precision makes Roboze printers suitable for producing highly detailed, accurate parts over and over again.
Industrial Applications
Prototal’s strong working partnership with Roboze allows us to print parts for various industries, including:
- Lightweight components for aerospace
- Chemical-resistant & non-corroding parts for the oil and gas industry
- Heat-resistant components for the automotive sector
The ability to print with high-performance polymers opens up new possibilities for many different industries looking to replace metal parts with lighter, equally durable polymer alternatives.
Metal Replacement
One of the biggest advantages of the Roboze machines is its focus on metal replacement. This enables companies in lots of different sectors to substitute metal parts with high-performance polymer parts. These parts offer significant weight reduction while maintaining structural integrity.
These parts can also be printed in a single part, as long as it fits on the large print bed. So, no matter how complex the geometries are, a part can be created in one piece. This isn’t possible with a traditional manufacturing process and material. This is especially useful in areas like ducting where weight reduction and complex shapes are needed to ensure the part performs at its best without reducing fuel efficiency. Another benefit of using these materials is the fact that they are non-corroding, reducing maintenance time in the field.
Industry Impacts and Future Possibilities
These materials and technologies are revolutionising various industries, like aerospace, automotive, energy and more. As a result, additive manufacturing is now a competitive alternative to traditional processes like injection molding, casting, and CNC machining.
In aerospace, for example, the ability to produce lightweight, complex parts is enabling fuel-efficient designs that were previously impossible. Automotive manufacturers are leveraging these technologies to produce lighter components, contributing to electric vehicle advancements and reducing overall emissions.
As the capabilities of additive manufacturing technologies continue to grow, more and more industries and sectors will adopt these faster ways of production. 3D printing is already taking the construction industry by storm with companies around the world offering 3D printing building services.
Want to discuss your next prototype or product with expert engineers? You’re in the right place. Prototal UK is the leading additive manufacturer in the UK. Get in touch today for a quote, free sample or to learn more about how 3D printing can revolutionise your industry.