Researchers on the SEAM Analysis Middle have launched new purposes for Screw Extrusion Additive Manufacturing (SEAM), specializing in its use in building.
On the coronary heart of this improvement is the Epic3D portal printer, a system able to producing large-format plastic parts for purposes resembling facade parts, fences, and gates. Utilizing a steady deposition course of and stiffening constructions, this expertise delivers sturdy, weather-resistant parts tailor-made for out of doors building purposes.
Working with Wirth & Co. GmbH, Fraunhofer Institute for Machine Instruments and Forming Expertise (IWU) is utilizing this method to supply large-scale facade parts that meet hearth security, UV, and climate resistance requirements. In accordance with the workforce, SEAM expertise addresses longstanding challenges in additive manufacturing, together with the constraints of small construct platforms and reliance on gradual, costly filament-based processes. By adopting granulate because the printing materials, SEAM permits quicker, cheaper manufacturing of personalized parts.
Fraunhofer IWU plans to current its newest developments in SEAM expertise on the Formnext 2024 commerce present. Led by Dr. Martin Kausch Head of the Division of Sustainable Fiber-Plastic Composites, the analysis workforce will showcase their work at Corridor 11.0, Stand E38, and Corridor 11.0, Stand C29, in collaboration with Metrom.
Attendees may have the chance to discover how granulate-based 3D printing is being utilized to building, together with facade manufacturing, and its potential to reshape the business.
Dr. Kausch stated, “We make subtle design reasonably priced. The private contact in facade design is, in fact, additionally achievable in conventional manufacturing. However solely with processes like SEAM is it cost-effective.”
Customization and flexibility in SEAM expertise
Customization is a major benefit of SEAM, notably for creating facade parts with intricate textures or distinctive shapes, resembling firm logos. This course of makes use of a modified extrusion screw to soften and deposit granulate layer by layer onto the construct platform.
Not like conventional strategies resembling fiber lamination and forming processes, SEAM eliminates the necessity for molds, lowering prices and manufacturing time. The power to make use of pre-colored supplies additionally removes the necessity for extra coating steps, streamlining the general course of.
Three techniques developed by way of collaboration with Metrom and 1A Applied sciences increase SEAM’s utility potential. These embody Epic3D, METROM P1410, and SEAMHex. Amongst them, Epic3D stands out for its functionality to deal with large-format manufacturing, supported by a construct platform measuring 2 meters by 1.7 meters. Complementing this, METROM P1410 brings further versatility by integrating processing steps resembling milling, increasing its utility potential.
Lastly, SEAMHex employs a novel six-axis parallel kinematics system that gives excessive dynamics and motion flexibility, making certain distinctive positioning and path accuracy. This design ensures distinctive positioning and path accuracy whereas lowering shifting mass, leading to dependable and environment friendly manufacturing of medium-sized parts. Collectively, these techniques cater to a broad vary of producing wants with precision and adaptableness.
Florian Stöckel, managing director of Wirth & Co. GmbH, underlined the significance of the collaboration with Fraunhofer IWU in enhancing the SEAM course of for building purposes. He defined that the Epic3D portal printer performs a vital function in enabling new design potentialities for facade building.
Stöckel famous that the partnership focuses on optimizing varied points, together with design, supplies, and the 3D printing course of itself. He additionally highlighted that the corporate’s funding within the Epic3D system represents a step towards making additive manufacturing extra appropriate for producing constructing parts.
Broadening the frontiers of building analysis
Past SEAM, different analysis highlights the evolving panorama of additive manufacturing in building. One notable instance consists of Massachusetts Institute of Expertise (MIT) and Evenline researchers who studied the feasibility of utilizing glass 3D printing to create interlocking masonry items. Printed in Springer Nature, this analysis highlights how glass AM can improve design flexibility and cut back tooling prices in comparison with conventional strategies.
Utilizing the G3DP3 printer, the workforce developed modular masonry items examined throughout three fabrication strategies: Absolutely Hole, Print-Solid, and Absolutely Printed. Findings revealed various strengths and floor accuracies, with Absolutely Hole items exhibiting the very best structural efficiency. As per the workforce, this examine emphasizes glass AM’s potential for recyclable, sustainable building, although additional refinement is required for large-scale purposes.
Elsewhere, College of Virginia (UVA) researchers developed a sustainable cementitious composite for 3D printing by incorporating graphene nanoplatelets (GNPs) into limestone-calcined clay (LC2). Led by Professor Osman Ozbulut, this analysis enhances structural integrity and environmental efficiency, growing compressive energy by 23% with simply 0.05% GNPs whereas enhancing printability.
A Life Cycle Evaluation revealed a 31% discount in greenhouse fuel emissions in comparison with conventional cement-based mixtures. Performed with the Virginia Transportation Analysis Council, the examine positions graphene-enhanced LC2 as a promising materials for sustainable building, notably in transportation infrastructure.
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Featured picture exhibits the SEAM Analysis Middle: Epic3D (backside left), METROM P1410 (heart), and SEAMHex. Photograph by way of Fraunhofer IWU.