Supernova to Launch Viscous Supplies and 3D Printer at Formnext – 3DPrint.com

Forward of Formnext 2024, Supernova has launched a brand new ecosystem for polymer additive manufacturing (AM), with the introduction of its proprietary Viscogels supplies and the Pulse Manufacturing Platform. The ecosystem is supposed to allow the manufacturing of components that mimic molded plastic properties at scale, a tough process with extra conventional stereolithography (SLA) and digital mild processing (DLP) applied sciences attributable to their inherent materials limitations.

Viscogels: Breaking Viscosity Boundaries for Molded Plastic Properties

On the coronary heart of Supernova’s new ecosystem are Viscogels, proprietary photopolymers characterised by exceptionally excessive viscosities that always exceed 1 million centipoise (cP). This viscosity degree—lots of of instances greater than typical 3D printing resins used with SLA and DLP, in addition to inkjet—permits a considerably greater oligomer content material, leading to supplies with enhanced properties for demanding functions. Supernova’s Viscous Lithography Manufacturing (VLM) expertise, particularly designed to harness moderately than mitigate excessive viscosities, permits this breakthrough, making Viscogels the cornerstone of the corporate’s new Pulse Manufacturing Platform.

The distinctive composition of Viscogels brings key mechanical benefits to the desk, comparable to improved affect resistance, flexibility, flame retardancy, and electrostatic discharge (ESD) safety. This function set positions Viscogels as an interesting alternative for functions like automotive cable grommets and connectors, the place resilience to environmental put on is crucial. Moreover, the supplies permit for greater additive masses with out compromising viscosity, increasing their versatility throughout varied industrial functions.

Viscogels are provided in 4 materials households, every tailor-made to satisfy particular efficiency calls for:

• RC 3500 (Inflexible Composites): Corresponding to molded POM and PA6-GF20, RC 3500 offers a tensile modulus of 3500 MPa and affect energy of 80 J/m, very best for automotive connectors and inside trims. Moreover, flame retardant (FR) and electrostatic discharge (ESD) variants cater to safety-critical environments.
• DU MD1500 and DU MD750 (Ductiles): DU MD1500 combines energy with flexibility, reaching a tensile energy of 38 MPa and affect resistance of 200 J/m. DU MD750 gives better flexibility with a decrease modulus (750 MPa), each performing comparably to supplies like ABS and molded PP, fitted to shopper items and customer-facing merchandise.
• RU D70 (Rubbers): With an 8% compression set and a tear energy of 44 kN/m, RU D70 rivals conventional elastomers like EPDM and NBR. Its variant RU H60, boasting 48% rebound resilience, is fitted to high-durability functions needing fast restoration, broadening software potentialities in fields the place such efficiency is vital.
• SL 50 and SL 70 (Silicones): SL 50 gives a tear energy of 20 kN/m and an elongation at break of 550%, matching molded LSR silicone in flexibility and sturdiness. These properties, coupled with an operational temperature vary of -40 to 180°C, make the SL line acceptable for under-the-hood automotive seals and gaskets.

Pulse Manufacturing Platform: A Complete Finish-to-Finish Manufacturing Answer

Designed to print with Viscogels, the Pulse Manufacturing Platform is an entire 3D printing workflow that features a printer, post-processing cell and software program, all meant to allow streamline the fabrication course of:

• Pulse One: Supernova’s VLM 3D printer designed to provide detailed, exact geometries with a 46 µm XY decision and a Z decision vary of fifty–200 µm. Its construct quantity of 350×200×300 mm and throughput of 5 kg/hour make it viable for large-scale manufacturing. Moreover, Pulse One’s dual-material functionality permits the creation of multi-material parts in a single construct, comparable to inflexible connectors with built-in elastomeric seals. The printer’s devoted breakaway assist materials additionally simplifies post-processing, lowering each time and labor.
• Pulse Postprocessing Cell: This automated post-processing unit is claimed to finish as much as 24 builds per day, performing washing, curing, and high quality management with out handbook intervention. The mixing of RFID expertise permits full traceability, and superior washing and curing methods guarantee every half reaches optimum mechanical properties.
• Pulse Management Middle: This centralized software program manages your complete manufacturing workflow, from construct preparation and slicing to high quality management. Outfitted with clever algorithms, it detects defects in actual time, adjusts manufacturing parameters as wanted, and information each construct element, supporting stringent regulatory compliance—a requirement in sectors comparable to rail and automotive.

BCN3D’s entry into high-viscosity 3D printing already upped the ante for the remainder of the vat photopolymerization house, however dedicating a complete firm to it was a giant indicator of simply how vital the expertise could be. Since its spinout of BCN3D in the beginning of the yr, Supernova has been quietly placing its total product bundle collectively, making information solely as soon as to announce an explosive supplies division. The time was effectively spent, as the corporate has come out of the gates with an entire ecosystem.

The printer and supplies are sufficient to counsel that the Pulse might make true finish components utilizing Viscogels and VLM expertise. Nevertheless, to actually allow excessive throughput manufacturing, Supernova’s automated post-processing system is supposed to take the handbook labor out of post-processing as a lot as doable. Mixed, the ecosystem is telling clients that that is for true manufacturing of real-world items.

An industry-first function of Supernova’s VLM expertise is its dual-material functionality, enabling producers to include two distinct supplies in a single construct, primarily unprecedented with SLA and DLP outdoors of analysis settings. This flexibility permits functions that historically require expensive overmolding, comparable to creating inflexible connectors with built-in elastomeric seals, to be produced extra cost-effectively with Pulse. By integrating two supplies seamlessly, this method reduces tooling prices and lead instances in comparison with conventional strategies, providing unprecedented design freedom in polymer additive manufacturing.

Viscogels additionally present vital environmental advantages over typical 3D printing resins, primarily because of the diminished emission of risky natural compounds (VOCs). The upper oligomer content material in Viscogels not solely enhances mechanical properties but additionally results in fewer VOC emissions, providing a extra sustainable possibility for industrial manufacturing. With its materials properties proof against environmental components, Viscogels are doubtlessly much less poisonous than conventional DLP and SLA processes, which regularly depend on acrylate supplies that degrade and have an effect on the encircling surroundings.

Supernova plans to launch the Viscogels and Pulse Manufacturing Platform at Formnext 2024 in Frankfurt, additionally taking early entry inquiries from potential adopters excited about evaluating VLM expertise and its supplies previous to the projected cargo date of Fall 2025.