INDUSTRIAL 3D PRINTING

3D printing has multiple purpose the most popular of which is prototyping. However, production is also becoming more and more commonplace, which brings together the need to dive into the area of industrial 3D printing. It is widely assumed that industrial 3D printers are old, take too much space, expensive and not very fast. All this is a misbelief. Industrial 3D printers today are Professional machines in terms of throughput, build volume, repeatability and precision. Now, let’s see some of the industrial 3D printing technologies there are so that you can decide which one fits the needs of your business.

First of all, it must be known that by 3D printing, we mean highly reliable and consistent 3D printers with high resolution, can print engineering-grade materials, fast, compatible with many materials and software, have large build volume, need rare maintenance and are equipped with safety features. Industrial 3D printing includes Fused Deposition Modelling (FDM) and Vat Photopolymerization or resin 3D printing along with other advanced technologies.

Fused Deposition Modelling (FDM)

Also known as Fused Filament Fabrication (FFF), it is a 3D printing extrusion process which melts thermoplastic filaments and prints it layer by layer on the print bed. They can print with engineering-grade thermoplastics, have low cost of technology acquisition, simple to understand, run and operate.

Vat Photopolymerization / Resin 3D Printers

It includes resin 3D printing processes such as Stereolithography (SLA), Digital Light Processing (DLP) and Masked Stereolithography (mSLA). These technologies make use of liquid thermosetting resin, meaning they cure or harden when they are exposed to laser or UV light source. This process must be repeated until the object is printed. Via this process, you can get high resolution and accuracy, achieve tight tolerances fast.

Selective Laset Sintering (SLS)

SLS 3D printers are widely used in a variety of industries and they are also used in many different applications. They are ideal for low volume manufacturing and they offer reliable part quality. In SLS, polymer materials are in powdered form. Then, the powder particles are sintered and fused by CO2 laser and form a bond. Then, the laser goes on tracing all individual points layer by layer until the whole object is printed.

For further information on these industrial 3D printing technologies and many more, get in touch with our team of experts today!

Choosing the Right Desktop 3D Printer

Most people are still under the impression that 3D printers are expensive, take too much space and are unfit for office use. That’s why they prefer to have their parts outsourced. However, outsourcing parts requires money, time and effort. Having parts outsourced means you will spend more money to having them delivered to your end as well, which increases lead times and reduces the possibility of carrying out a smooth manufacturing process with no problems. This is why it is better to own professional desktop 3D printers, which have become affordable with proper build volumes. They are safe to use in offices, which is where you work all day. Thus, you will not need to transport parts to receive them.

Professional desktop 3D printers should provide higher throughput than others. Most 3D printers are built with plastics and acrylic. So, you might want to look for a printer which has metal construction. It might be a good idea to see them in person and check the rigidity of the printer. Nexa 3D’s XiP is built out of aluminium with an aluminium body. Its z-axis is anchored from top to bottom, which is uncharacteristic of most resin 3D printers. This results in less vibration during printing and causes better part quality. Furthermore, good results from a 3D printer can only be received if the materials are good. Some professional desktop 3D printers limit you to their materials, while others are more flexible with validated materials and the possibility to use third party materials. Nexa3D’s XiP offers you both, so that you can have an easy experience. It is also possible to achieve higher part throughput and speed while maintaining product quality.

Professional desktop 3D printers can be a good option for users who want to be hands-on with their 3D printer to achieve maximum access and want a higher end experience with improved performance and reliability.

Contact us for more detail on desktop resin 3D printers or visit our website: Nexa3D XiP

Speed and Ease of Use: The XiP

As 3D printing industry is growing day by day, choosing a 3D printer becomes challenging even for professionals. There are many options to choose from with very different features, which makes it all the more difficult. Almost everyone agrees on some points when they consider buying a new 3D printer. Among these are speed and the quality of the printed part. However, the process of 3D printing is also of great importance. Engineers at Nexa3D work hard to create a 3D printing experience which will make users happy. This is also true for the XiP, which is Nexa3D’s most accessible 3D printer. Let’s pinpoint what a smooth 3D printing experience means for the user.

Speed is the priority for designers and engineers from all sectors, with industries becoming more competitive every day. In order to keep up with this competition, brands have to produce parts in the shortest period of time. Same the other Nexa3D printers, the XiP is also engineered with LSPc technology, which makes them ultra-fast. It also features 4.8 litres build volume, making it the largest on the market. This means both larger and more parts to be produced. However, speed and productivity begin before printing starts. The amount of time spent while preparing the print also has to be short. Uploading and orienting the print file and loading the resin all have to take as little time as possible in order for the printing process to be actually “ultra-fast”. The XiP makes all these possible. NexaX software is a fast and intuitive one, which makes the preparation process quick and simple no matter how many parts you are printing. Loading and changing the resin are both easy and quick steps with the XiP. It is possible to print prototypes and production parts on the XiP as it is able to handle a wide variety of resins. The users can also design their own resins specific to their needs. All in all, the XiP makes every step of the printing process fast and easy. Furthermore, the XiP is also the perfect choice for dental and orthodontics purposes. Conventional solutions are very slow, which makes the paint wait for a very long time. Now, an orthodontist can use an intraoral scanner on the patient’s teeth, which is then converted into a CAD file to be sent to a dental lab. The part is then 3D printed. Even though it may also take a long time depending on how busy the lab is, the XiP dramatically reduces the time spent on these processes as it is able to print many dental parts in one build.

The XiP has a simple resin system, an intuitive software and other features including a replaceable LCD module and a two-part vat system to clean failed prints easily. The Everlast-2 membrane and aluminium frame fit together smoothly and easily. They can be used repeatedly, which is something other resin 3D printers cannot provide.

As a result, Nexa3D’s game-changing desktop resin 3D printer XiP makes it possible for the user to experience a fast, easy and smooth 3D printing process.

Check out Nexa3D XiP or request a quote Get a Quote

Nexa3D Launches New Desktop Resin 3D Printer: XiP

Nexa3D has recently launched its new desktop resin 3D printer: XiP. The XiP uses Nexa3D’s signature technology, Lubricant Sublayer Photocuring (LSPc) technology just like its other industrial 3D printers NXE400 and NXD 200.

Resin 3D technology is generally divided into 3 categories: Stereolithography (SLA), Digital Light Processing (DLP) and Masked Stereolithography (mSLA). Mainly, mSLA technology exposes resin material to UV light to cure it. It does not trace each layer, but uses a large area UV light source, which is masked with LCD screen. In this way, the patterned light is exposed to the resin simultaneously throughout the curing plane, which makes the whole process fasther than SLA. However, LSPc is the fastest among all.

Nexa3D improved printing times in a revolutionary way by introducing a self-lubricated membrane which does not stick to the printed part or the LCD screen underneath. This is what makes ultrafast printing possible. Furthermore, the XiP is easy to use. It can be easily operated by an expert user or a dentist who does not have any related experience in 3D printing. Another user-friendly feature the XiP provides is the Smart Resin System. Nexa3D cartridges provide ease of use, allowing quick load and unload of the materials. Also, thanks to its modular design, XiP gives you the possibility of repairing or replacing parts easily and quickly. You will not need to do this very often, though, as the XiP is tough and long-lasting. You can also easily leave the printer unattended overnight. Without the need of constant monitoring, the XiP provides fast and easy 3D printing experience. Also, Nexa3D cares about maintaining sustainable production. As mentioned earlier, the XiP is long-lasting. However, if your printer needs to retire, the aluminium body can be easily recycled.

Contact us for more information on the XiP or take a look at our website: Nexa3D

Ultimaker Cura 5.0

Ultimaker Cura 5.0

Ultimaker has announced the latest version of Cura: Cura 5.0! The new version offers a lot of advantages such as higher print quality with finer details and stronger part production in less time.

The slicing engine is the most important part of the software. As it is known, a slicing engine is what transforms a 3D model into G-code and prepares it to be printed. Ultimaker 5.0 offers a new slicing engine with an important feature: variable line width. Sliced files used to use a consistent line width that depends on the nozzle diameter and the setting. Basically, if less noticeable lines are desired, a smaller nozzle was used and vice versa. So, if part of the print was two and a half lines thick, two lines would occur which led to a gap between them. This resulted in errors and inconsistent lines, and thus there were many gaps in a printed part. Because of this, printing took a much longer time and caused vibrations and noise.

Cura 5.0 offers a new slicing engine that unlocks variable line widths. The extremely fine details used to be omitted by the slicer as it was not possible to print them successfully. Ultimaker Cura 5.0 solves this problem with its new slicing engine. In the new version, the width of lines is adjusted, so there are no uneven lines. As a result, parts are much stronger and have finer details. Furthermore, thanks to increased toolpath efficiency, print time also improved. The new slicing engine allows us to improve print profiles, thus printing them faster. Printing time can now be reduced up to 20%. Also, there are fewer gaps between the lines as they are increased and are thinner, giving way to stronger parts.

To find out more, watch the recent Ultimaker showcase where Ultimaker Cura 5.0 was announced: ultimaker

Jigs and Fixtures

Jigs and Fixtures

When assembling a product, we can’t often use off-the-shelf tools during product development. It is through custom jigs and fixtures that help us get repeatable work. Custom jigs and fixtures can be adjustable, or specifically designed for a certain part, which makes production easier, faster and more accurate. However, producing these jigs and fixtures via traditional manufacturing methods might be expensive and time-consuming. Traditional methods are 100 times more expensive than 3D printing these jigs and fixtures, and much faster. 3D printing helps reach the final design faster, making it easier for engineers to print replicas, thus minimising lead times.

Ford’s engineers in Cologne produced a tool that they can hook at the back of the car, enabling them to position badges and emblems quickly. This tool was 3D printed with tough PLA in two parts on the Ultimaker s5 and glued together later on.

Volkswagen Autoeuropa’s engineers in Portugal developed a wheelgun jig, which helps them to place their wheelgun into the wheel. The part was 3D printed in multiple parts so that it can be quickly replaced in case of damage.

Traditionally, it takes a very long time to attach the pedal to a bicycle as one has to tighten it manually using a wrench. eBike Manufacturing 3D printed a tool using polycarbonate, which fits perfectly around the pedal and holds the nut in place. The pedal can be attached in less than a minute with the help of a drill.

At Ultimaker, several tools, jigs, and fixtures are 3D printed on Ultimaker 3D printers. The main axis of an Ultimaker 3D printer is connected to its motors via sliding blocks. Ultimaker uses a custom-designed pressure fixture that helps assemble the sliding blocks. This tool is 3D printed from XSTRAND™ GF30 PA6 (nylon with 30% glass fiber) which provides strength. It is combined with Ultimaker TPU 95A, which is a soft and flexible material, protecting the sliding block from any type of damage.

Factories may subject jigs and fixtures to high stress or temperature. So, it is important to choose the correct material. Ultimaker provides an open filament system, which offers a variety of industrial-grade materials from any brand, including industrial plastics, carbon, steel, or glass-fibre reinforced filaments. Therefore, you are provided with strong, tough, high-temperature resistant, flexible, rigid materials to choose from. Also, it is possible to have custom-designed filaments specifically designed for your requirements.

With Ultimaker’s dual extrusion 3D printers, it is possible to combine many materials. Many companies prefer Ultimaker Tough PLA for strength, combined with the protectiveness of TPU 95A. Another advantage is that you can use two colours. If you choose to use another colour for the outer surface of a part, the colour of the inner surface will show whether a part is ready for replacement.

3D Printing Waterproof Parts

3D Printing Waterproof Parts

Arun Chapman

The number of applications for 3D printers is endless even though they can sometimes be hindered by reality. When printing parts which require holding water, they may often leak. There are still ways to prevent that from happening.

Waterproofing watertight parts

It is possible to waterproof these parts despite the fact that it is not always that easy. In order to achieve the best possible result, one needs to be very careful about the material and the settings. Still, the parts may require some post-processing in order for them to be waterproof. When something is waterproof, it is expected that it is capable of pushing water out. The term water-resistant is also used when something keeps water out up to a limit. The parts that keep water in are watertight. Here, the word “waterproof” is used as an umbrella term for all of these terms.

There are certain stages that need to be followed in order to make something watertight and water-resistant even though not all parts require the same criteria. All in all, it would be wise to not rely on a printed part to protect sensitive material.

How waterproof parts are printed

There are three essential points in order to achieve waterproof parts which are: the material used, your slicer settings, and post-processing. Waterproof parts can be printed in a range of different 3D printing technologies. Many expensive industrial 3D printers have the ability to create highly reliable waterproof parts using metal. The majority of people cannot access these printers. In this case, it would be best to concentrate on the ones which are common, such as FFF printing.

Materials used

A good deal of FFF filaments consists of thermoplastics. Plastic is a reliable element when it comes to producing waterproof objects such as water bottles. Another advantage of plastic at this point is that water does not damage it. Before starting to print waterproof parts, it is essential to know that there are still different kinds of thermoplastics which have a variety of characteristics.

Swelling

Several materials used in 3D printing are hygroscopic; they absorb water. PETG, Nylon and PLA are not as good as others while ABS and PP are better than most. However, most of these materials absorb water up to a point. When a part is exposed to water for long, some swelling occurs. Despite the fact that this swelling might be small, there is still deformity on the part and it may even start to break which means that it is no longer waterproof or watertight. This swelling stops after some time. One may think of drying this swollen part, but this may cause more damage to occur.

Slicer settings

The working principle of FFF printers is that they stack the materials layer by layer. However, there is always the possibility of a small gap occurring between every layer. In order to prevent this from happening, there are some settings that should be followed.

Wall line count

Wall line count is self-explanatory in that it is the number of layers there are in the outer wall of the print. Basically, the principle is that the more layers there are the more waterproof it is as there is less possibility for the water to pass through the walls. If, by chance, there is a tiny gap, the other walls will protect it.

Normally, 3 is a good number for wall line. It is important to know that when there are more wall lines, it does not protect the part. A single wall may be sufficient at times, namely when you use vase mode.

Vase mode

Vase mode is also referred to as spiralise outer contour, which is a setting that is capable of printing objects with single wall line. There is one continuous print part, meaning there are no retractions and no Z seam, which is the most important advantage of vase mode. Z seam is the most common areas where a gap occurs. When Z seam is removed, a single-wall part becomes waterproof. Still, the parts that require certain geometry are not suitable for this setting. Vase mode is best suitable for vases, cups, bowls etc.

Temperature

When two layers are not bonded appropriately, gaps occur. In order to increase layer adhesion, the printing temperature must also be increased. Depending on the material, the highest possible temperature should be set to print at. If the temperature is too hot for the material, it may boil which leads to more gaps.

Flow rate

The most common reason that there are gaps in a part is under-extrusion. Prioritising high dimensional accuracy, structural strength or visual fidelity may cause to under-extrusion even in well-tuned print profiles. Increasing flow rate slightly might be enough for development. Starting with %105 and increasing until you see a reaction might be sufficient.

Post-processing parts to make them waterproof

Apply a waterproof coating

Waterproofing spray, a clear coat, water-resistant paint can cover up the gaps in a printed part, which is the easiest method.

Vapor smoothing

A chemical is used to melt the surface, which smooths the part and removes the layer lines. This method makes the part look more appealing and makes the part more waterproof by filling gaps.

Temperature treatment

There are two ways and two purposes of temperature treatment. It is used to apply heat to the outside of a print which causes the surface to melt in a way to fuse the layers together. This is very similar to vapour smoothing. The other way is to heat soak the part in a period of time, which is called annealing. This causes the layers to bong together more strongly.

What are the applications for waterproof parts?

Scientific research

Scientific research on fluid dynamics and microfluidics are a great area for 3D printed parts.

Gardening

Plant pots, composting containers, and hydroponics are some of the areas suitable for 3D printing. It is important to use materials that are suitable for the climate.

Water features

3D printed water features can be perfect for a pond or a fish tank.

Carbon 3D Printer Nottingham

Carbon 3D Printer Nottingham

We are proud to announce that our official Carbon 3D printer M2 is installed in our office in Nottingham. In the name of PLG Global we proudly started producing with Carbon’s unique Digital-Light-Synthesis. One of the fastest 3D printer in Nottingham through DLS’s multi-layer approach. Join the PLG Global manufacturing network, start serial manufacturing processes locally and become part of The Link to the Future.

To all manufacturing companies in Nottingham

If any of our local neighbours is struggling with their production due to the Coronavirus and its economic consequences. Please do not hesitate to contact us! Fortunately, we produce in a wide range of materials with both Zortrax and Carbon 3D printers locally. See our services on the website-menu for further information or contact us directly.

New age of digitalization As this economic breakdown is rapidly changing our working environment. We are recognizing that how our daily work fully switched to the computer. Our developing engineers in England and Turkey are working from home and directly speaking to our local team member Cem Severcan. Our marketing student in Germany is supporting the PLG Global family with his work on the website and social media. Let us know on our Social Media channels, how your daily life has changed! And do not hesitate to contact us for our local digital production expertise.

Using the Carbon 3D printer is our daily business. In our local manufacturing plant in Nottingham, Cem produces face shields in serial production with Carbon’s Digital Light Synthesis for hospitals in the UK. We are using our power for good & support each other on the Link To The Future.

carbon 3d printer dls

Covid-19 Statement

12 face shields printed in less than 3 hours

Covid-19 Statement

Our thoughts are with everyone affected by Covid-19. It is our duty to help those in needs and support our local environment. As the team of PLG Global, we want to reassure all our partners that any of our provided services are going to be fulfilled completely. Our Covid-19 statement: We are fully confident in offering the option of outsourcing your production to our facility in Nottingham or another one in the United Kingdom or Europe. If you are struggling with project deadlines due to Chinese factory closures, we have the capacity within our Additive Manufacturing, Rapid Prototyping and CNC-departments. All office staff members are working at home and there should be no effects felt by our customers. You can still contact us via our Social Media channels, or directly via the website. All deliveries will be fulfilled as national carriers are working. Our sourcing and product teams are on hand to assist you if your regular suppliers experience problems.

Because of our brand-new Carbon 3D printer implementation, we have the capacity of producing more than 100 face shields in 48 hours for our dedicated workers from the National Health Service (NHS) and from all over the world. This is the perfect situation of saying “Thank you!”. Enjoy some behind the scenes from our office in Nottingham:

The best way of thanking some body is showing support. We are supporting German and British hospitals with face shields – manufactured around the corner in Nottingham with various Carbon materials.

We are printing 12 face shields in less than 3 hours, or one face shield uniquely in 16 minutes. Carbon’s Digital Light Synthesis is one of the fastest 3D printing technologies suited for serial production.

Please visit our website for our in-house competencies and our global manufacturing network e.g. Poligon Mühendislik. Nevertheless, we are sending good thoughts to all the people in need. At PLG Global, we remain ready and able to support your business in these extremely challenging times.

carbon 3d printer covid-19 dls statement

Carbon 3D Printer Installation M2

Today, Carbon’s 3D printer M2 is being installed into our office in Nottingham! Due to the situation we are limiting the number of participants down to two: Our team member Cem Severcan and Carbon’s technical expert Paul Holland. Four other colleagues who stay with their families abroad are joining the 3D printer installation via Video-Chat. As you can see, the corona virus is changing our all’s working environment. Though, the PLG Global family stays optimistic and excited about the future. See our brand-new 3D printer! Carbon’s M2 with specifications explained by Carbon’s leading technician Paul Holland.

Carbon's 3D printer M2

Before installing our M2 3D printer, Paul Holland, the Carbon representative leading the instalment of our printer explains how our engineers have to insert pressure differentials and internal cavities into the 3D printed objects. Preparation is the most efficient way to solve future problems before they happen. Education is the key to the Link to the Future, join PLG Global and benefit from our local digital manufacturing services.

Impressions from our local digital manufacturing introduction

Here are some impressions from our local digital manufacturing introduction with Carbon, Poligon Mühendislik and PLG Global. In these days (the printer is installed during the corona crisis 2020) the PLG Global team is supporting the local team from abroad. See our office in Nottingham and visit us for a talk! Don’t bother about manufacturing problems, delivery bottlenecks due to politics and other reasons. Join PLG Global to the Link to the Future and benefit from our Carbon 3D printer M2.

Safety First! Paul Holland’s explanation about Material Hazards is a critical point when it comes to daily operation of Carbon’s 3D printer M2. On the right side you can see our marketing student Maximilian Lehmann and our 3D printing engineer Enes Arslan supporting our local team via Zoom.

The PLG Global family abroad is supporting and learning with our partners. Here is Maximilian Lehmann in his homeoffice with his family in Germany.

PLG Global’s leading team member Cem Severcan and Carbon’s technical expert Paul Holland are leading our Carbon 3D printer M2 installation in Nottingham.