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3D printing, or additive manufacturing, has unlocked access to materials and geometries once deemed impossible. While the technology dates back as far as the mid-80s, it’s still relatively new. Here are three exciting new projects that stand to make a big impact on the industry or the world as a whole.
Printing Big Parts with Recycled Material
Researchers at Oak Ridge National Lab recently collaborated with engineers from Cincinnati, Inc. to print large parts using recycled materials. Cincinnati is the company behind the Big Area Additive Manufacturing (BAAM) machine that can print parts 8-feet by 20 feet and lays about 80 pounds per hour, typically commodity pellet thermoplastics.
A recent ORNL and Cincinnati demonstration showed the ability to print multiple materials through a single extruder and recycled composites in large-scale applications. The team installed a dual-feed system on the BAAM that allowed them to print with multiple materials using one extruder. They produced a 400-pound, 10-foot long mold out of recycled carbon fiber reinforced thermoplastic and syntactic foam in seven hours. The mold replicated a single facet of a precast concrete tool.
The technology has potential, primarily lowering tooling costs and printing large structures with lightweight cores and specific properties.
Bioprinting New Noses
Researchers at the University of Alberta have developed a new way to 3D bioprint custom-shaped cartilage.
The team uses a custom hydrogel mixed with cells harvested from a patient and then printed in a specific shape. Within a few weeks, the material is grown in a lab to become functional cartilage.
The work stands to significantly impact people disfigured from skin cancer by making it easier for surgeons to restore lost facial features.
Next, the team will transplant lab-grown cartilage in animal models to make sure it retains its properties. If everything goes well, it could be in clinical trials within the next two to three years.
Printing with Tungsten
With a melting point of 3,422° C, tungsten is an incredible material used to make everything from space rocket nozzles to heating elements in high-temp furnaces. Unfortunately, it’s a brittle metal that is hard to work with; processing is time-consuming and expensive.
Researchers of Karlsruhe Institute of Technology (KIT) are using electron beam melting technology to make tungsten soft and easier to process.
Electron beam melting technology uses electrons accelerated under vacuum to selectively melt metal powder and build a part layer by layer. The electron beam pre-heats the metal powder and the carrier plate before melting, which reduces deformation and stress on the material.
The work could lead to new components designed for high-temperature applications in the aerospace, energy, and medical industries.
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