On September 2, 2023, there were several interesting news stories in the realm of 3D printing, including updates on alloy testing, advancements in modular buildings, and various other topics.

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Today’s 3D Printing News Briefs cover a range of topics, including defense 3D printing, modular buildings, and more. Let’s dive into the details!

Australian metal 3D printer manufacturer AML3D has been awarded a contract extension to continue testing Nickel-Aluminum-Bronze (NAB) 3D printing alloys for the US Navy’s submarine industrial base. The contract, signed with nonprofit BlueForge Alliance, is valued at approximately A$0.37 million (US$0.28 million). AML3D will use its ARCEMY metal AM technology to demonstrate that it meets US defense AM qualification requirements. The testing will take place at AML3D’s Adelaide facility in South Australia over the next 8-10 weeks. AML3D’s Interim CEO, Sean Ebert, expressed excitement about continuing the partnership with the US Navy and highlighted the company’s growing presence in the US defense sector.

Shapeways Holdings, a leader in digital manufacturing, has introduced MFG Materials, a new feature that expands its software service offerings. The feature offers manufacturers a range of raw materials at discounted rates. Through partnerships and negotiations with top-tier suppliers, Shapeways is able to provide significant cost savings on materials like plastics, aluminum, and iron/steel. This move aims to help manufacturers reduce their raw material costs, and the company estimates that it has the potential to offer 100% return on investment for its customers. Shapeways is also introducing a low-cost monthly membership option for manufacturers who only need access to the new service.

The Additive Manufacturer Green Trade Association (AMGTA) has released preliminary findings from a study conducted by the Yale School of the Environment (YSE) in partnership with Desktop Metal and Trane Technologies. The study compared the environmental impact of binder jetting to traditional metal casting. It found that binder jetting resulted in a 38% reduction in greenhouse gas emissions, mainly due to lower energy demand during the printing process. The research analyzed the entire manufacturing life cycle of a 3D printed steel scroll chiller, built by Trane for its HVAC system. The study also highlighted the significance of the manufacturing facility’s energy mix on emissions and emphasized that redesigning for lightweighting may not always lead to further emissions reductions.

In conclusion, today’s 3D printing news highlights advancements in defense applications, cost-saving initiatives for manufacturers, and the environmental benefits of binder jetting technology. These developments showcase the continued growth and innovation within the 3D printing industry.

A Fresh Perspective on Lowering Emissions in Metal Manufacturing

In the quest to reduce harmful emissions from traditional metal manufacturing, industry leaders are seeking innovative technology approaches. However, it is crucial for manufacturers to have access to sound data to make informed choices about their production processes. Greenwashing is not enough.

According to Jonah Myerberg, the Chief Technology Officer at Desktop Metal, a recent study conducted by Yale, Trane Technologies, and AMGTA has confirmed their long-held belief that binder jetting is a greener way to manufacture metal parts. The full results of this study, which has undergone a peer review process, are expected to be published in early 2024.

Another study, commissioned by Fraunhofer IAPT, has shed light on the importance of accurate density determination in additive manufacturing (AM). The density of a 3D printed component has a significant impact on its performance and structural integrity. By accurately measuring density, manufacturers can assess the reliability and quality of their parts, detect porosity or defects within the material, and ensure optimal execution of the AM process.

The study reviewed various density determination technologies, such as micrographs, computed tomography (CT), and the manual Archimedes method. It determined that Dimensionics Density offers an automated and cost-effective density determination solution that stands out among the rest.

Micrographs, although informative, destroy the 3D printed part and require extensive manual work. CT, on the other hand, is limited in its ability to detect pore size and necessitates expensive equipment and skilled operators. The Archimedes method, while easier to use, is less accurate due to factors such as environmental conditions and the precision of the experimental procedure. In contrast, Dimensionics Density’s solution is traceable to a recognized standard, exhibits higher repeatability, lower fluctuations, and shorter measurement time, making it the preferred choice.

Philipp Pruesse, Head of Sales at Dimensionics Density, explained their automated density determination process, which employs the Archimedes method combined with modern automation technology. The samples to be measured are placed in a specially designed component carrier, transported through the system by an axis robot, and then precisely positioned onto scales. This automated handling eliminates human influence, ensuring consistent measurement accuracy. The scales are insulated from vibration, and climate sensors monitor ambient conditions such as temperature, air pressure, and water temperature, all of which are factored into the evaluation algorithm during density determination.

Additive construction presents opportunities to optimize production processes and fabricate unique concrete components and geometries that would be challenging with traditional formwork. In Beckum, North Rhine-Westphalia, a recent project showcased the use of 3D printing technology and sustainable building materials.

Collaboration between planning office MENSE KORTE, 3D printed prefabricated parts specialist Röser GmbH, and construction chemical product manufacturer MC-Bauchemie resulted in the successful completion of a modular building. The structure features an elliptical façade and a unique design made possible through 3D printing.

To reduce CO₂ emissions, the team conducted extensive material tests and utilized MENSE KORTE’s special 3D dry mortar, MC-PowerPrint GeCO₂. This mortar incorporates blast furnace slag and fly ash as a binding agent instead of cement. Alternative binders made from industrial by-products can significantly reduce CO₂ emissions, with potential savings of around 70% compared to cement.

The individual prefab parts for the building were printed at Röser’s site, showcasing the efficiency and feasibility of 3D printing in construction projects. This innovative approach not only enables the creation of complex designs but also contributes to sustainability efforts by utilizing eco-friendly materials.

In conclusion, these recent studies and projects demonstrate the importance of using innovative technologies to reduce harmful emissions in metal manufacturing and construction processes. By utilizing greener methods such as binder jetting and incorporating sustainable materials in 3D printing, manufacturers can make significant strides in environmental responsibility. With access to accurate density determination technologies like Dimensionics Density, they can ensure the reliability and quality of their products. This valuable data empowers manufacturers to make informed choices and drive positive change in their respective industries.

Title: Revolutionizing Construction with 3D Printing: A Sustainable Journey

Introduction:

In an era where sustainability is at the forefront of our concerns, it’s no surprise that industries are constantly seeking innovative ways to reduce their carbon footprint. Today, we delve into a remarkable story that highlights the power of 3D printing in construction and the challenges it poses when it comes to achieving sustainability goals. So, fasten your seatbelts as we embark on a journey that transports us over 500 kilometers, exploring how this state-of-the-art technology is redefining the construction landscape.

The Genesis:

In order to push the boundaries of possibilities and stress test crucial components, a decision was made to transport these elements across a significant distance using a closed inboard loader. While this choice negates the immediate reduction of CO₂ emissions, it was deemed necessary to ensure the durability and efficiency of these parts. We understand how it may seem counterintuitive, but in order to achieve long-term sustainability, sacrifices need to be made in the short term.

Arrival at the Construction Site:

After the arduous journey, successfully transporting the key pieces to the construction site was cause for celebration. The efficiency at this stage was awe-inspiring. Within hours, the parts were seamlessly placed on a precast concrete slab and connected with anchors. This streamlined process demonstrates the incredible potential of 3D printing technology to revolutionize construction timelines and reduce labor-intensive procedures.

The Sustainability Conundrum:

While this cutting-edge technology offers immense potential, we must acknowledge the sustainability conundrum it presents. 3D printing in construction has the power to dramatically reduce waste, as it allows for precise material usage and eliminates the need for extensive resources. However, the transportation aspect poses a challenge. Minimizing CO₂ emissions is a crucial objective for any sustainable venture, and in this case, transporting the parts over a long distance seems counterproductive to that goal.

The Road Ahead:

As we navigate the future of 3D printing in construction, it is imperative that industry leaders address this sustainability challenge head-on. Investing in local manufacturing facilities equipped with 3D printers could significantly reduce transportation distances, thus mitigating the negative environmental impact. Furthermore, exploring alternative transportation methods powered by renewable energy sources could also offer a promising solution.

Conclusion:

In the quest for innovation and progress, sustainability should always remain a top priority. The fascinating tale of transporting 3D printed components over 500 kilometers reminds us that sometimes short-term sacrifices are necessary to achieve long-term sustainability goals. As this technology continues to evolve, it is essential for all stakeholders to work collaboratively towards finding greener solutions. By tackling the transportation challenge and adopting sustainable practices in all aspects of the 3D printing process, we can ensure a brighter, more eco-conscious future for the construction industry.

And remember, stay up-to-date on all the latest news from the 3D printing industry and receive information and offers from third-party vendors to witness the transformative power of this technology firsthand!

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