FDM and FFF – hidden difference in the market

Author : Varinex Date : 2026-02-12

FDM and FFF – hidden difference in the market

Many in the industry incorrectly use the term FDM 3D printer, when in fact they are referring to machines based on FFF technology. This can easily cause confusion for companies looking for a reliable, professional industrial 3D printing solution. In this post, we will clarify the terms and explain why this distinction is important.

FDM – Stratasys’ patented industry standard

FDM (Fused Deposition Modeling) is a proprietary 3D printing technology developed by Stratasys in the late 1980s. Today, FDM technology is used worldwide to produce functional prototypes, tools, templates, fixtures, and finished products.

Advantages of FDM printers:

FFF – open concept for simpler machines

FFF (Fused Filament Fabrication) is essentially the same process as FDM – molten plastic is extruded layer by layer – but the concept was introduced by the RepRap community as an open alternative in the early 2000s.

FFF is mainly used in hobby and simpler desktop machines, where the documentation, material safety testing, and certifications required by the industry are not required.

So it is very important to emphasize that an FFF 3D printer is not an FDM 3D printer, even though the technology is based on the same basic principle.
These machines do not have the same documentation and industry certification requirements as their counterparts boasting FDM technology.

Be careful when looking at 3D printers available on the market

Many market players market simpler FFF printers the FDM designation, which is misleading.
If the given model is not a Stratasys 3D printer, it is definitely not an FDM 3D printer.

This is worth checking:

A little attention here can make a significant difference in quality, reliability and long-term cost-effectiveness.

Why is this key for you?

The difference between an industrial Stratasys FDM printer and a simple FFF machine is key in terms of:

Reliability: stable, predictable production processes.

Controlled properties of materials: use of industrial-grade, certified materials.

Quality: results that meet industry standards and high expectations.

Stratasys FDM technology is like a long-term, reliable, well-equipped tool – designed, precise and predictable. FFF machines are more for hobby and simpler applications: fun and creative, but do not provide consistent industrial quality and documented, verified results.

Summary: both get you from A to B, but which technology you choose is critical for industrial needs, responsibility, and predictability.

For those who want to deal with additive manufacturing professionally, it is of utmost importance to make a decision according to their needs, and for this it is essential to know what really lies behind the name.

8 pages of knowledge and inspiration – download now!

We've gathered together why manufacturers around the world choose the Stratasys Fortus® 450mc FDM system.
Technological developments, real-world examples, and the latest material innovations all in one place.

New colors for the Stratasys F770 3D printer

New colors added to the Stratasys F770 3D printer material range

Author : Varinex Date : 2024-07-05

New colors added to the Stratasys F770 3D printer material range

Color is a fundamental means of communication, although we rarely think of it that way. From art to traffic lights, we use color in many areas of life to convey information and categorize the events and objects around us. This is one of the main reasons why the Stratasys F770 3D printer material range has been expanded with six new colors.

Color coding is also used for differentiation and communication. It can be product differentiation, safety classification, or indicating the difference between tools, to name a few. Color can quickly and clearly convey information in a process-driven manufacturing environment. It is therefore not surprising that customers are showing a high interest in colored 3D printing materials, as many use additive manufacturing for applications where color plays an important role.

In the aerospace industry, for example, tools that need to be removed before flight are colored red. By printing these tools in red ASA, the painting phase can be skipped, allowing for faster parts availability. Similarly, 3D printing manufacturing tools in different colors provides an effective visual tool for classification and organization, eliminating the need for painting or other post-production markings. White, gray, and black are most commonly used in various stages of prototyping and engineering to quickly and clearly present the final product design.

With seven color ASA substrates, the Stratasys F770’s large work area improves efficiency in fast-paced manufacturing environments and opens up new possibilities for producing large-scale parts – whether it’s a prototype for a car fender or a component for a large appliance concept.

It's time to think BIG!

Did you know that the Stratasys F770 is the best value FDM 3D printer with the largest heated work area on the market?

Get to know this large-format additive manufacturing equipment!

3D printing in NASCAR racing

Author : Varinex Date : 2024-04-02

3D Printing in NASCAR

Motorsport, when viewed in its entirety, is driven by a single goal: to be as fast and reliable as possible, by any means possible. With the ever-increasing complexity of shapes, infinitely lighter components, and the ever-increasing pace of development caused by expanding race calendars, existing manufacturing technologies have imposed a kind of barrier to the exterior and interior construction of cars, which have been revolutionized by 3D printers. But how does this work in a sport like NASCAR?

Why 3D printing?

3D printing serves many purposes in motorsport. From the initial stages of prototype and vehicle design to the production of final parts, it can even bring long-forgotten cars back to the racetrack after decades!

With the development of 3D printing, mechanical simulations and computer-aided design programs, increasingly complex parts can be created that cannot be realized with production technologies already known in Hungary. This allows for a drastic weight reduction in the total mass of cars. In a fierce motor sport like NASCAR, where every thousandth of a second counts, this is essential!

But what is 3D printing?

Let's start with a quick introduction. What is 3D printing?
The essence of 3D printing is that we set a selected 3D model according to our wishes in a software that breaks the shape into layers that we define. A 3D printer places these layers on top of each other, creating the part.

We have a lot of materials at our disposal, from concrete to metals and even chocolate! The most common printers are plastic printers. And the sky is the limit there. And NASCAR knows this too.

From the first printed parts to Next Gen

The first true pioneer in the sport was Joe Gibbs Racing. JGR partnered with the world's largest manufacturer, Stratasys, back in 2004. At that time, they used the technology to produce even simpler parts and tools, but they also made analog clock cluster mounts and electronic system boxes.

The partnership is still active today, with Stratasys being a key technical partner for JGR and Penske. Penske has been using Stratasys machines to manufacture their 3D printed car components since 2017. One of the best examples of this is their 3D printed rearview mirror bracket, which was made from carbon fiber reinforced material.

Recognizing the success of the relationshiptoday there is no that does not have at least one 3D printer in their workshop Even the Le avine FamilyRacingteam - hadathat. MakerBot printer allowed reinforced parts.

With the design and arrival of Next Gen cars, NASCAR realized that the components of the new generation of cars could also be 3D printed. Seeing the clear successes of JGR and Penske, NASCAR also voted for Stratasys. The first prototypes, and their various versions, were all made with or with the help of 3D printing, and in fact, the first final Next GEN cars contained and still contain nearly 30 different 3D printed components when they were released!

For example, the air intake in the center of the front windshield, the air intakes behind the driver, and the air intakes on the bottom of the cars were 3D printed. These components are still manufactured by NASCAR at its own headquarters today!

Manufacturers engineersChevrolet also used a lot of 3D-printed prototype parts to shape cars to their specifications.ownoptimized the the 2020 Camaro aerodynamic performance of and more than 500 3D -printed prototype partsto develop the body. The car also featured a 3D-printed transmission cooling duct, which by the end of 2020 in 27 races18,500 miles had logged.

What are these parts good for?

The idea for the opening in the front windshield was born in September 2021.

“During testing at Daytona, drivers reported that excessive heat was a problem inside the car. During testing, the NASCAR aero team came up with the idea of adding vents and channels to the lower intakes and windshield. This airflow reduced temperatures by approximately 35 to 40 degrees Fahrenheit (1.6 to 4.4 degrees Celsius),” said Brandon Thomas, NASCAR Next Gen car designer and executive director.

For NASCAR, the windshield air ducts, which help direct air into the cockpit, H350 printer using SAF powder bed technology . NASCAR’s Concord R&D facility Fortus 450mc 3D printers to design and manufacture the NACA underhood ducts needed to cool the engines.

But why not put the production of 3D printed parts in the hands of the teams?
Simple, to eliminate cheating and protect the drivers.

Where are we going?

It’s hard to say what the next big thing will be that will change NASCAR and the way cars are built. What’s certain is that teams and owners are increasingly investing in technology. Perhaps the best proof of this is Brad Keselowski himself, who spent more than $10 million to create Keselowski Advanced Manufacturing. Keselowski’s goal was to create a company that would combine cutting-edge technologies to produce the highest quality metal parts. Inside his factory, a CNC machining center and a 3D printer fit perfectly side by side, because the two technologies complement each other.

Metal-printed parts have been used in previous generations as well. For example, SHR used radically lighter brake pedals printed from titanium in GEN 6 cars. The brake pedal is 32% lighter but 50% stronger than the original pedal.

The evolution of parts and cars is therefore clear. Of course, 3D printing is not a panacea, let's not expect printantoentire race car. But we can be sure that more and more 3D printed parts will appear in the racing cars of our beloved sport.

The article Menjetek korbe! podcast, Ground Effect and VARINEX Zrt was written in cooperation

Did you know that the most reliable and popular solution for additive manufacturing is Stratasys FDM technology, and within it, carbon fiber reinforced materials?
Did you know that you can replace your metal parts with lightweight and extra-strong carbon fiber composite 3D printed parts?

Get to know Stratasys' reliable composite 3D printers from the VARINEX team!
We have been helping Hungary's leading industrial companies and their innovations with additive manufacturing for 25 years!

Faster and cheaper production of production line clamping devices

Author : Varinex Date : 2024-03-19

Faster and cheaper production of production line clamping devices

Sounds too good to be true? If so, then definitely read on because you can choose a more efficient way compared to the traditional seat making method!

Manufacturing production line fixtures by machining and clamping or welding metal parts is undoubtedly a viable solution. Due to the familiarity and predictability of the process, many manufacturers have no desire to change. If you share this view, it may ultimately result in wasted time and additional costs for you, as better, more efficient methods are available.

The truth is that manufacturing is not static, and those who choose to stick with the status quo risk becoming stagnant and falling behind their competitors. New technologies are replacing older, less efficient technologies, improving manufacturing methods and streamlining supply chains. 3D printing is one of these, but it is not a new technology. In fact, it is used every day by smaller shops and large companies – in other words, your competitors.

In short, 3D printing offers a more time- and cost-effective means of manufacturing clamping devices than traditional technologies.

Disadvantages of traditional manufacturing

Design and manufacturability constraints
There are physical limits to the complexity of parts that can be produced by machining, which limits the ability to create fixtures optimized for the task or the operator using the tool.
Heavy and non-ergonomic
Production line fixtures machined from metal are usually bulky and heavy, which limits the possibility of ergonomic design.
Low Utilization
Due to the challenges associated with traditionally manufactured clamping devices, their use is typically limited to essential applications. This ignores the potential benefits that could be achieved with more devices, improving efficiency and productivity.

3D printing helps

Minimal labor and skill requirements
an FDM 3D printer requires minimal effort, and the printer does not require supervision during the printing process.
Shorter production time
FDM technology can produce 3D printed fixtures and seats in hours, instead of the days, weeks, or longer times available with traditional machining.
Lower cost
Since fixture devices are usually produced in small series, their unit cost is determined by the infrastructure required to manufacture them. Small series production is cheaper with 3D printing.
Design freedom
3D printing is not affected by the physical and geometric limitations of traditional manufacturing, so the design of the clamping devices can be optimized for the task and the operator.
Increased efficiency
3D printed fixtures can be made in a single piece, eliminating assembly or reducing setup time.

3D printed fixtures can bring potential benefits – both financially and in terms of time. In today’s modern manufacturing industry, the speed, efficiency and adaptability of the manufacturing process greatly affect performance and profitability. with FDM technology is one of the tools that can provide these benefits.

Through the experiences of several Stratasys customers, we would like to demonstrate the benefits that 3D printed fixture solutions offer to manufacturers – whether they are large, well-known companies or small manufacturing plants.

Learn how additive manufacturing can bring new momentum to the fixture manufacturing process while increasing time and cost savings!

Download the 12-page, Hungarian-languagesolution guide titled Faster and Cheaper Manufacturing of Production Line Clamping Devices now!

Custom Assembly Solutions - Oreck Case Study

Custom 3D Printed Clamping Devices – Oreck Case Study

Author : Varinex Date : 2024-03-18

Custom assembly solutions

Oreck Manufacturing produces 40-50 identical assembly pallets for each series of vacuum cleaners. That was the case with the company’s Titanium series, the XL21 upright household vacuum. This high-end device provides users with features such as hypoallergenic filtration, an adjustable two-speed motor, and advanced sound-absorbing technology.

The production line pallets fix the top cover of the vacuum cleaner in precise position, making the device quick and easy to assemble. After the motor, fan housing and other supporting structural elements are placed in the fixed top cover, the bottom cover is fitted onto it.

“Some traditional clamping device projects cost over $100,000, so the savings can be significant.”

Bill Fish
Oreck

Simplified assembly

Each assembly fixture consists of four plastic posts that can be attached to a standard Bosch assembly pallet. In addition to being specifically tailored to hold the cover, the fixture components have a tolerance of 0.076 mm, so the cover is held firmly in place.

Oreck’s engineering team uses standard CAD tools to design the parts needed for each fixture. According to Oreck’s lead modeler, Bill Fish, “Designing the fixture parts is pretty straightforward. We already have a file for the standard support columns. We add the 3D top cover, embed it in the support column, and then remove the cover. The whole job takes about an hour and a half.”

Previously, Oreck used only traditional methods to make assembly fixtures. These included silicone or epoxy molds and urethane castings with inserts. A few years ago, Oreck acquired two Fortus 3D manufacturing systems . FDM technology gave them the ability to additively manufacture fixtures, which they use whenever possible.
“Using additive manufacturing reduces fixture manufacturing costs by up to 65 percent because we manufacture them in-house,” said Fish. “Some traditional fixture projects cost over $100,000, so the savings can be significant.”
At that rate, the machines can pay for themselves even with a small number of projects.

3D printing the pallet assembly fixture is just the beginning. Maintaining pallets in demanding production environments is just as important as sourcing original parts. “If for some reason a fixture snaps or breaks during use, we can quickly and easily replace it in-house. Anything that takes a pallet out of production costs us money. We run the Fortus systems 24 hours a day,” said Fish.

In addition to manufacturing fixtures, Oreck uses FDM technology to produce prototypes and models for marketing photos and advertisements.
“We also use the machines to manufacture special assembly tools, fixtures for coordinate measuring machines (CMMs), engineering inspections and CNC milling machines. We also produce complete mockups. The only limit to our machines is our imagination.”

Proceedings	Cost
Traditional pressing and casting	$100,000
FDM manufacturing	$35,000
Savings	$65,000 (65%)

Learn how additive manufacturing can bring new momentum to the fixture manufacturing process while increasing time and cost savings!

Download the 12-page
Solution Guide in Hungarian!

Stratasys F370CR composite 3D printer at Weber State University

Weber State University Expands Education with Stratasys F370CR Composite 3D Printer

Author : Varinex Date : 2024-02-21

Weber State University Expands 3D Printing Education with Stratasys F370CR Composite Printer

Weber State University's Advanced Research and Solutions Center serves as an innovation and collaboration hub for local industry, primarily in the aerospace, defense, and advanced materials industries. The institution offers students educational and hands-on opportunities, as well as access to a variety of research and development resources, including additive manufacturing.

The challenge

To give students and local industry the best chance of success, the university must provide access to current and emerging technologies, including additive manufacturing. However, Weber State University had older 3D printersthat were slow and expensive, and offered a limited selection of materials. This situation limited the university’s Advanced Research and Solutions Center from meeting the needs of students and industry.

The solution: composite 3D printing

To strengthen its 3D printing capabilities, the university has added a Stratasys F370^®CR composite 3D printer to its line of manufacturing equipment.

The F370CR is capable of using two composite materials and a variety of other engineering thermoplastics. Composite 3D printing materials include FDM^® Nylon-CF10 and ABS-CF10, which contain 10% shredded carbon fiber for increased strength and stiffness.

Composite 3D Printing at Weber State University

With the Stratasys F370CR composite 3D printer, Weber State University can take advantage of state-of-the-art technology with a wider range of materials, including advanced composite polymers. The F370CR’s ease of use and consistent print performance 3D printing solutions provide users with

The composite 3D printer will help the university provide innovative and cutting-edge tools to its current and future students and clients.

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9 important things about composite 3D printing

9 things you need to know about carbon fiber 3D printing

Author : Varinex Date : 2024-02-09

9 things you need to know about carbon fiber 3D printing

Carbon fiber composite materials are pushing the boundaries of performance in 3D printing due to their strength, stiffness, heat resistance, and durability. They offer a significant performance improvement over traditional thermoplastics for demanding 3D printing applications.

Carbon fiber reinforced materials are made by adding chopped or continuous fibers to a base polymer material to increase its toughness and strength. The fibers can be made from a variety of materials, such as carbon, glass, and Kevlar, and can be aligned in a specific direction to provide maximum strength in that orientation. The resulting composite materials are suitable for manufacturing stronger and more durable components.

What makes carbon fiber so attractive for 3D printing?
These materials have many beneficial properties. Below are 9 things you should know about using carbon fiber in 3D printing.
Keep these in mind when your 3D printing applications require a higher level of performance!

Strength:
Carbon fiber is one of the strongest materials available, and when combined with a base polymer, it can be used to make stronger parts than unreinforced materials.
Light weight:
Carbon fiber FDM materials offer a lighter alternative to metal, making them ideal for manufacturing parts that need to be strong but not heavy.
Durability:
Fiber-reinforced thermoplastics, depending on the specific base polymer, offer high durability and are resistant to high temperatures and harsh environments.
Stiffness: Carbon fibers are very stiff, making them ideal for making parts that need to be rigid and retain their shape without deformation.
Chemical resistance:
Fiber-reinforced materials also provide resistance to chemicals, depending on the properties of the base polymer.
Flexible design:
Carbon fiber-reinforced FDM materials are capable of creating strong parts with complex geometries and shapes that would be difficult or impossible to make using traditional manufacturing methods.
Cost-effectiveness:
Composite 3D printing can be more cost-effective than small-batch production using traditional manufacturing methods.
Less waste:
Carbon fiber 3D printing can reduce waste by only using the material needed to produce the part.
Efficiency Improvement:
Composite materials can improve efficiency by reducing the time and labor required to create a part compared to traditional technologies or molded alternatives.

Stratasys offers three carbon fiber reinforced composite FDM thermoplastics, learn about them by clicking on the images!

Carbon fiber combined with ABS base polymer

Nylon-based polymer mixed with chopped carbon fibers

Combination of Nylon 12 base polymer and 30% by weight of chopped carbon fiber

Did you know that the most reliable and popular solution for additive manufacturing is Stratasys FDM technology, and within it, carbon fiber reinforced materials?

Did you know that you can replace your metal parts with lightweight and extra-strong carbon fiber composite 3D printed parts?

New developments expand the manufacturing capabilities of the Stratasys F900 3D printer

Author : Varinex Date : 2024-01-24

New developments expand the manufacturing capabilities of the Stratasys F900 3D printer

Did you know that the Swiss Army Knife was invented over 120 years ago? However, regardless of its age, it is still a success today, a century after its creator, Karl Esener, combined many useful functions into a single tool. What is the secret to its long-term success? It follows several timeless principles that are characteristic of most long-lasting products:

Versatility – providing versatile capabilities for multiple uses.
Continuous innovation – updated with new values to meet changing needs.
Quality – made for long-lasting use, durable and long-lasting.

The same principles that make the Swiss Army Knife a steadfast, reliable tool are also the foundation of the Stratasys F900 3D printer , which customers refer to as a true FDM “workhorse.” While the latter is a bit more sophisticated than the former, the results they achieve are the same: reliable service and proven performance, while also allowing for continued innovation.

Users attest to the versatile capabilities of the F900

Make no mistake, the F900 is a significant investment for any business. At the same time, this machine represents the pinnacle of sophistication and capability in industrial FDM additive manufacturing. This is probably one of the main reasons why manufacturers are eager to adopt it – the F900 has the tools to get the job done, whether it’s the capacity to print large-scale parts, the materials needed to produce spacecraft parts, or anything in between – all with the proven accuracy and reliability that users expect.

Plyform, an Italian aerospace composites manufacturer, is using 3D printing to create tooling for composite parts because it is cheaper and more time-efficient than traditional metal tooling. The Stratasys F900’s large build volume is designed to accommodate the parts that aerospace companies want to print, and ULTEM™ 1010 resin, a high-performance thermoplastic in the F900, provides the material properties needed to produce 3D printed molds.

“Of all the additive manufacturing technologies we have tested, the Stratasys F900 offers the best accuracy and repeatability,” says Luca Ceriani, Plyform’s manufacturing technology manager.

Another aircraft manufacturer, British BAE Systems, is also benefiting from the F900’s capacity and versatile material offering. The company uses its F900s for a variety of applications, producing aerospace models, design verification prototypes, production line tools and end-use parts 24/7.

“We installed our latest Stratasys F900 3D printer towards the end of last year, primarily to increase our capacity through the wider use of FDM technology, but the ongoing material developments also give us a significant advantage in tooling applications,” says Greg Flanagan, head of additive manufacturing at BAE Systems.

These are just two examples of the more than 1,000 F900 installations where customers have improved their production processes with the help of capacity, wide range of raw materials, reliability and repeatability.

Of the additive manufacturing technologies we have tested, the Stratasys F900 offers the best accuracy and repeatability.

Luca Ceriani

Plyform Manufacturing Technology Manager

New features add further value to the F900

Just as the Swiss Army Knife has adapted to modern use, the F900 has received new features to keep up with the needs of manufacturers.

The two new printheads offer higher extrusion speeds to reduce part build time, especially for larger prints. The T40A and T40C tips print ULTEM™ 9085 resinand FDM^® Nylon 12CF material. The dual printheads allow for faster part build times, enabling faster production speeds. Print speeds vary by geometry, but some large Nylon 12CF parts can see an increase of up to 40%. Although the step-up surface formation may be slightly more pronounced depending on the shape of the part, this is not an issue if surface resolution is secondary to the priority of faster part production.

In terms of materials, F900 users can now benefit from Validated Materials. Stratasys Validated Materials are thermoplastics that have been developed by a third party and meet Stratasys quality standards, and have been validated through fundamental reliability tests on Stratasys FDM printers. This new material category broadens the F900’s material portfolio, enabling faster introduction of new materials that open up new applications. For example, Kimya PC-FR: this fire-resistant polycarbonate meets the smoke and fire protection standards of the railway industry, making it the perfect material for low-volume applications such as replacing obsolete parts.

Proven performance that continuously evolves to adapt to production

The Stratasys F900 the FDM technologywithembodies itself countlessthat has over thein the hands of proven customers . But years changing the needshorizon. themore of its users. The new T40 tips and Validated Materials, including colored ULTEM™ 9085 resins, are just two recent additions, but there are more useful developments on

For businesses that require reliable industrial additive manufacturing capabilities, the Stratasys F900 should be on the list of systems to consider.

To learn more about the capabilities and value of the F900, visit the F900 3D printer website!

You can also access a wealth of additional information, including downloading the Stratasys White Paper on Validating FDM Repeatability and Performance!

Radford Motors: custom car manufacturing with 3D printing

News, events

Radford Motors: custom car manufacturing with 3D printing

Radford Motors produces small-scale, customized cars. Additive manufacturing is part of the company's recipe for success. They chose large-format 3D printers from Stratasys.

News, events

New developments expand the manufacturing capabilities of the Stratasys F900 3D printer

The Stratasys F900 3D printer is constantly expanding with new features and capabilities, offering added value to meet the changing needs of users

New Stratasys Materials for End-User Manufacturing and Industrial Prototyping

News, events

New Stratasys Materials

Stratasys Announces Four New Materials for the P3™ DLP Platform and Two New Materials and New Colors for the Stratasys F900 3D Printer

New Stratasys Materials

Author : Varinex Date : 2023-12-01

Stratasys Strengthens Commitment to End-User Manufacturing and Industrial Prototyping by Expanding Its Materials Offering

Stratasys Announces Four New Materials for the P3™ DLP Platform and Two New Materials and New Colors for the Stratasys F900 3D Printer

Stratasys, the leader in polymer 3D printing solutions, today announced four new materials, including Somos® WeatherX™ 100, for its P3 technology 3D printers, as well as new validated materials for the F900™ additive manufacturing system, including Kimya PC-FR and FDM HIPS. The introduction of these new materials opens the door to a wider range of manufacturing applications and accelerates the expansion of the material selection available in the market.

Four new materials for P3™ DLP technology

Stratasys Origin One 3D printers for end-user manufacturing and production-grade prototyping with four new high-performance materials for its P3™ DLP platform.

Somos® WeatherX™ 100*
For environmentally resistant applications such as vehicle interiors, motorcycle parts and outdoor consumer products. Provides manufacturers with more reliable test data on the weatherability, durability and dimensional accuracy of materials, as it is tested to rigorous SAE industry standards.
Somos® PerFORM™ HW*
for injection molds or high rigidity fixtures. Ceramic-filled material that provides high wear and high temperature resistance.
P3™ Deflect™ 190 ESD*
A specialty resin developed in collaboration with Henkel for the production of jigs and fixtures used in electronics and general manufacturing, as well as tooling and housings. Benefits include a 190°C HDT (Heat Transfer Temperature), electrostatic dissipative (ESD) properties and high rigidity.
P3™ Stretch™ 80*
An elastomer prototyping resin developed jointly by BASF and Forward AM for soft or flexible parts such as seals, seals, grips and masking devices. This material is an affordable addition to existing elastomers for users new to elastomer printing or looking for a replacement for traditional polyurethane or TPU.

Stratasys is also introducing automatic support generation for Origin One GrabCAD Print software, simplifying workflows by allowing users to choose from predefined support profiles based on material properties – rigid, tough or elastomeric – or customize them to optimize workflows.

Two new materials and new colors for the F900 3D printer

Stratasys is offering two new materials for the F900 fabrication system, as well as eight new colors in ULTEM™, PC and PC-ABS. The expanded material family provides a broader range of applications, while the new colors offer users greater flexibility and reduce post-processing costs.

Kimya PC-FR
Flame-retardant polycarbonate material that meets the requirements of EN45545 for railway applications and is specifically designed for end-use components, including small series production and replacement parts.
FDM HIPS
Affordable, high impact polystyrene-based material for low-demand applications.

The new OpenAM™ software is now available for the F900, which includes an open material license, enabling 3D printing with third-party materials.

“Expanding our portfolio of validated materials gives customers more choices to cover a wider range of applications and enable scalable manufacturing,” said Dr. Yoav Zeif, CEO of Stratasys. “As additive manufacturing continues to grow, there is no limit to what is possible with 3D printing, and we are excited to support our customers in this.”

* These materials will become commercially available in late 2023 - early 2024.

Get to know Origin 3D printers and the F900 additive manufacturing system!

5 reasons why composite 3D printing is revolutionizing manufacturing

5 reasons why carbon fiber composite 3D printing is revolutionizing manufacturing processes

Author : Varinex Date : 2023-11-29

5 reasons why carbon fiber composite 3D printing is revolutionizing manufacturing processes

'sIt time tomake explore the carbon fiber composite 3D printing world of, as a number of advantages that it offerscan . efficient your processes manufacturing more. Stratasys composite 3D printing is 2-4x faster than other carbon fiber solutions, depending on the geometryHere are five compelling reasons why this is cutting-edge technology revolutionizing manufacturing .

1. Replacing or improving metal parts with carbon fiber 3D printing

One common reality concern in manufacturingis whether thermoplastic the the counterparts molds of truly matchcan metal their strength. The surprising is thatwith the FDM Nylon12CF introduction of, a Nylon 12 and shredded carbon blend of, the resulting lighter stiffness thermoplastic fiber has highest to -weight ratio FDM of any material . compressiveThis makes an excellent it , offering metal parts replacement fora 3-7x steel or , with over alternative to aluminum ?a 900 bar strength of. The biggest advantage50-70% cost savings !

2. Harnessing the benefits of carbon fiber 3D printing

Carbon fiber reinforced composite materials and of stiffness strength while ABS a higher level offersignificantly traditional compared to overall weight reducing stiffermetal options . ABS of- CF10, a %10 chopped fiber and carbon plastic blend of, a 3D printing material combination introduces in that % is and % strongerthan traditional . This and with that robust tools resultsand meet demands the factory tooling applications thecost scheduling overcome traditional manufacturing tools associated issues 15 . 50ABS

3. Stratasys F190CR and F370CR 3D printers and composite materials outperform the competition

When reliability and accuracy it comes to, the and F370CR 3D printers and composites unmatched. With an % uptimeand impressive , 99 99 %dimensional repeatability F190CR you can trust these machines areto consistent, high- quality parts produce your for manufacturing needs.

4. Speed up production and improve worker safety

you with carbon fiber, composite 3D printing By using significantly reduce the tools to manufacture required lead time. Traditional metal tools often time-consuming machining processes and external suppliers rely on, resulting extended production schedules in. In addition 3D printed tools have the advantageof being significantly lighterthan metal counterparts, making them to handle, easier reducing the worker strain , and of injury risk.

5. Apply innovation and future-proof it

technology of manufacturing , continuous advancement printing integrating composite and carbon fiber is a 3D a competitiveadvantage strategic step to Byinvesting, Stratasys - solutions from in cutting equip the tools and materials your you businesswith needed to .the efficiently effectively and With solve everyday gain challenges manufacturing .edge

Composite materials for 3D printing can effectively overcome the schedule and budget challenges that are common in manufacturing.

Find out how you can make your manufacturing operations more efficient with composite 3D printing!

Download our 4-page Hungarian-language brochure on carbon fiber 3D printing now!

TDK Hungary Components Kft. uses Stratasys Fortus450 3D printer

At the forefront of industrial 3D printing – TDK Hungary Components Kft.

Author : Varinex Date : 2023-11-15

At the forefront of industrial 3D printing – TDK Hungary Components Kft.

TDK in Szombathely is one of the most significant European electronics development and manufacturing centers of the international TDK group, which supplies products to numerous automotive customers in Europe and worldwide. Miklós Koltay, process engineer at TDK Hungary Components Kft., has a long-standing relationship with VARINEX and works with the Stratasys Fortus 450 industrial 3D printer for most of his work.

"In future expansion, it is definitely advisable to think in the direction of industrial machines, as they are 4-8 times faster than small machines, so they are capable of a completely different volume. Even if they are more expensive, they are faster and the additional investment will quickly pay off."

What comes to mind when I say VARINEX?

We already had a printer from VARINEX at my previous workplace, and another department at TDK has had an Objet30 Prime printer for about 7-8 years. When we needed to produce in industrial volume and with materials that were the same as those used in industry, we decided to buy the Stratasys Fortus 450 from VARINEX, this large-scale machine that I also work with.

What was life like at TDK before the machine, and what challenge did the Stratasys Fortus 450 machine provide?

The most important aspect that made us buy this machine was the range of industrial raw materials. In fact, this is the only machine on the market that currently meets our raw material requirements.

In the pre-machine days, we were just making devices for manufacturing, basically auxiliary tools. Then we also helped developers with prototypes, but we wanted to do it all at the speed and quality that the Stratasys Fortus 450 allows.

We also appreciate the services, for example, if there is any problem with the machine, VARINEX comes to service it within days, and if the situation requires it, they will even print the parts for us. It's just not what we had with our previous machines, where if there was any problem, I had downtime and couldn't print.

Is the machine running almost constantly?

It's quite busy, yes, as it operates at least 16 hours a day all week.

What is the practical experience, how much human help is needed for operation?

I'm actually the one who runs the lab and manages the machine, and I even design it, so I'm not bored. Now it's possible that I'll need some help in order to be able to use our machines in the future. Basically, in our department within TDK in Szombathely, I deal with device design. That's how I got involved with 3D printing in the first place, that we wanted to print the devices and parts I designed as rapid prototypes, or even use them in production, if the plastic allows it.

In your opinion, is the demand for 3D printing expected to continue to grow at TDK?

In the future expansion, it is definitely advisable to think in the direction of industrial machines, as they are 4-8 times faster than small machines, so they are capable of a completely different volume. Even if they are more expensive, they are faster and the additional investment will quickly pay off.

As far as I know, there is a lot of interest in this technology within the international TDK, not just in Hungary. This is actually a kind of “test”, we are now developing the system, as everyone knows that 3D printing is the future, or at least a large part of the industrial revolution that is still underway.

"I love this machine because it's fast and the materials are not even comparable in terms of heat resistance and mechanical resistance to those used in a regular desktop machine."

Approximately how many parts or devices are produced with Fortus per day?

This is difficult to say because we are talking about pieces of very different sizes in each case. Thanks to the machine parameters, it is possible to create a very beautiful surface on the finished pieces, because FDM technology works with layer-by-layer construction and is capable of producing very complex geometries. However, when building with thinner layers, production is slower, so the volume that can be produced in a given time also decreases, so the number of parts it produces per day also depends on the complexity of the pieces and the desired surface quality, and this obviously varies. With complex geometries, the return on a single piece is much higher, since these parts cannot be produced with traditional technologies, or would only be very expensive. But if you need strong parts with simpler geometry, it also knows that, and it is incredibly fast there.

What makes this machine so lovable to you?

I like this machine because it is very fast and the materials are not even comparable in terms of heat resistance and mechanical resistance to those that a regular desktop machine can handle. Stratasys machines come in three levels: our machine also knows all-materials, i.e. normal materials, followed by engineering and high-level materials. At the top level, serious aerospace and space materials appear, and we use them, which is why we bought the machine. What makes it unique for us is that these materials are also available with it.

The Stratasys Fortus 450mc 3D printer delivers accurate, reliable performance to transform supply chains, accelerate manufacturing, and reduce manufacturing costs.

Learn more about the capabilities of the Stratasys Fortus 450mc used by TDK Hungary Components Kft.!

Toyota chooses Stratasys F3300 3D printer

Toyota's developments will be supported by the first Stratasys F3300 3D printer sold

Author : Varinex Date : 2023-11-09

Toyota's developments will be supported by the first Stratasys F3300 3D printer sold

Stratasys, the market leader in polymer 3D printing solutions, announced that it has signed an agreement with Toyota, a global industry leader in automotive manufacturing and innovation, to be the first to purchase the new, cutting-edge Stratasys F3300 3D printer.

to support new manufacturing, including parts and fasteners, as well as prototyping applications, will use the F3300 3D printerto bring new products to market faster.

The F3300 is Stratasys’ latest FDM (Fusion Deposition Modeling) 3D printer designed to expand manufacturing capacity. This next-generation manufacturing machine is capable of producing complex, high-precision that are critical to vehicle design and application – from prototypes to end-user parts. The 3D printer offers versatility, fast material changeover and loading, automatic calibration, and high production capacity. With these capabilities, the F3300 reduces the cost per part by up to 25 percent, prints up to twice as fast as any other production FDM 3D printer, and has 25 percent greater accuracy. The capabilities and production capacity offered by the F3300 align with Toyota’s reputation for delivering high-quality, innovative vehicles to customers worldwide.

“The ability to integrate the F3300 3D printer into our additive manufacturing processes is a major step forward in achieving our corporate goals,” said Eduardo Guzman, Toyota’s head of advanced technologies. “The capabilities of the new 3D printer will help us accelerate the introduction of new additive manufacturing capabilities into our manufacturing operations.”

“We share a common interest in delivering innovation and excellence to our customers, and this collaboration with Toyota demonstrates our shared commitment to better, smarter, and more sustainable manufacturing,” said Rich Garrity, president of Stratasys’ Manufacturing Enablement Business . “Designed with manufacturing in mind, the F3300 redefines additive manufacturing in factories with its speed, lower cost, and ease of use.”

New Stratasys FDM 3D printer debuts at Fomnext

Press release: Stratasys F3300 is here – a more accurate, faster FDM additive manufacturing system

Author : Varinex Date : 2023-11-02

To meet the increasing demands of industrial applications of additive manufacturing, Stratasys' latest 3D printer delivers even greater accuracy, uptime and at least double the production capacity

In industry, performance is everything. Accuracy, repeatability, and reliability are key to generating profits. Manufacturing and development companies know this best, and the F3300 3D printer is designed for them, expanding the scope of additive manufacturing and being the best FDM 3D printer in the industrial category.

Stratasys, a leader in polymer 3D printing and additive manufacturing solutions, will introduce its new F3300 Fused Deposition Modeling (FDM) 3D printer at the Formnext exhibition and conference in Frankfurt, November 7-10, 2023. This innovative 3D printer offers unparalleled value to manufacturing businesses through reduced labor requirements, maximized uptime, and higher part quality and production capacity.

Designed for manufacturing applications by the inventors of FDM, the F3300 will be the most advanced industrial 3D printer on the market. Its design and advanced features will transform the use of additive manufacturing in the most demanding industries, such as aerospace, automotive, military and contract manufacturing. The F3300 will be available from 2024.

Additive manufacturing has become increasingly competitive with other manufacturing technologies through the following developments:

Faster printing: with increased gantry speed, higher extrusion capacity and automatic calibration, with minimized downtime.
Higher part quality and increased production capacity: Up to 25% increased production capacity, along with improved accuracy and repeatability, along with automatic printer calibration.
Maximized uptime: with remote machine monitoring, extruder redundancy, and a user interface that prioritizes ease of use.
Lower costs: 25-45% lower manufacturing cost per part compared to other Stratasys FDM solutions.

“This next-generation additive manufacturing system enables users to scale production and reduce the need for trade-offs between additive and traditional manufacturing solutions,” said Rich Garrity, president of Stratasys’ Manufacturing Enablement Business. “ Increasing challenges, traditional capacity constraints and application complexity are placing incredible demands on manufacturing. The F3300 enables our customers to accelerate product development so they can innovate faster. The latest FDM industrial 3D printer helps overcome manufacturing challenges, allowing companies to get to market faster and maximize their return on investment.”

The F3300 is the latest addition to Stratasys' FDM 3D printer family, which includes the F900, F770, F450mc and F123 series. The F3300 complements Stratasys' F900 model, which is known for its reliability, high capacity and use of high-performance materials.

Stratasys will be hosting a special live event to unveil the F3300 on November 7, 2023 at 5:30 PM (CET). Please click the button below to secure your spot at the event or watch the premiere live stream!

ABOUT STRATASYS

Stratasys is a leader in the global shift to additive manufacturing, providing innovative 3D printing solutions to industries including aerospace, automotive, consumer products and healthcare. With intelligent and connected 3D printers, high-quality polymer materials, a comprehensive software ecosystem and on-demand components, Stratasys solutions provide competitive advantages at every stage of the product lifecycle. The world's leading organizations turn to Stratasys to transform product design, accelerate manufacturing and supply chain agility, and improve patient care.

An overview of the key differences between Stratasys FDM and FFF 3D printing

Author : Varinex Date : 2023-10-31

Learn more about integrating FDM 3D printed tools!

Download the 13-page composite 3D printing solution guide in Hungarian!

Understanding the Key Differences Between Stratasys FDM and FFF 3D Printing

Glossary and Origin:
FDM is, or FusedDepositiona patented technology developed by Stratasys that has received 1,820 patent applications over the past 30 years, of which 1,380 are active, and Stratasys has trademarked the term. Fused Filament Fabrication (FFF) is also a technology based on melting plastic filaments, but does not use the innovations that Stratasys has patented.

3D Printing Equipment:
Despite the differences in names, the basic concept behind FDM and FFF is the same. Both methods use a nozzle to spray molten thermoplastic onto a surface to build up objects layer by layer. The primary difference lies in the equipment used for printing and their technological sophistication. Stratasys FDM technology 3D printers specifically designed and manufactured by Stratasys , which are built around providing the environmental parameters necessary for processing plastic, while FFF technology is open source, allowing different manufacturers to produce compatible 3D printers, primarily for processing materials that do not require special environmental parameters.

Material selection:
Another significant difference between Stratasys FDM and FFF lies in the technological quality of the material processing. Stratasys FDM printers support a wider range of high-performance and engineering-grade thermoplastics, including Antero (PEKK) and ULTEM™ (PEI). These materials have excellent mechanical properties, heat resistance and chemical resistance, thus meeting strict aerospace, automotive and healthcare regulations. In contrast, FFF printers typically offer a narrower selection of engineering and high-temperature materials, most suitable for printing PLA, PETG, but even this does not guarantee successful production and repeatability, i.e. the ability to repeatedly produce a given part with the same quality.

Print Quality and Accuracy:
Stratasys FDM 3D printers are known for their high accuracy and print quality thanks to their controlled manufacturing process and advanced technology. These 3D printers have at least two print heads, which allows the use of support material to print complex geometries. The result is ready-to-use products that require minimal post-processing, quickly, on time, and with repeatability that meets industry demands. FFF printers show a wide variation in print quality and accuracy.

Costs and Affordability:
Stratasys targets industries where production line uptime is a top priority, as well as industries that may require high-end solutions. Stratasys and VARINEX are recognized for their commitment to quality and product support. In contrast, FFF 3D printers are popular with hobbyists, educators, and small businesses due to their lower price, for whom we recommend https://makerbotshop.hu , where they can choose from high-quality UltiMaker FFF 3D printers.

Summary:
Stratasys FDM technology usually brings tens of thousands of euros in monthly returns to companies interested in manufacturing, because it is suitable for applications that FFF technology does not, or only to a very limited extent. At the same time, FFF offers a more accessible and affordable entry point into the world of 3D printing, which appeals to a wider range of users. Regardless, it is not possible to judge based on the experience gained with FFF technology what application possibilities a Stratasys FDM 3D printer has for a given company, because the basic principle of the two technologies is the same, but the possibilities for their use are completely different. Undoubtedly, both FDM and FFF played a significant role in the development of the world of additive manufacturing.

Learn more about integrating FDM 3D printed tools!

Download the 13-page composite 3D printing solution guide in Hungarian!

Three inspiring stories: advancing manufacturing with carbon fiber 3D printing

Improving Manufacturing with Carbon Fiber 3D Printing: Three Inspiring Stories

Author : Varinex Date : 2023-10-26

carbon fiber composite 3D printers, such as the Stratasys F370^®CR, companies can leverage the benefits of carbon fiber-filled thermoplastics, revolutionizing manufacturing processes through additive manufacturing. In this blog post, we explore three notable stories in which companies have recognized the potential of carbon fiber 3D printing, demonstrating its efficiency, power, and versatility.

Graco: Increasing Efficiency with Ergonomic Tool Handles

Graco, a leading manufacturer of fluid and coating systems, was faced with a challenge regarding the pressure control tool for its paint sprayers. The teeth of the existing ABS plastic tool were wearing out with repeated use, requiring frequent replacement. The company sought a cost-effective, durable, and easy-to-manufacture solution that did not require frequent replacement.

The Solution: Composite 3D Printing with Carbon Fiber
a Stratasys F370^®CR composite 3D printer, Graco engineers FDM^® Nylon-CF10 thermoplastic, a material blended with 10% shredded carbon fiber, which provides greater strength and toughness compared to ABS. The 3D printed hand tool features an ergonomic handle that is faster and easier to produce and outperforms the traditional machining alternative.

JW Speaker: Rationalizing the production of automotive lighting fixtures

JW Speaker Corporation, a manufacturer of high-performance automotive lighting, was challenged with leak testing its newly developed luminaires. The traditional approach involved manufacturing custom mounts from aluminum, a time- and resource-intensive process.

The Solution: 3D Printing with Carbon Fiber Materials
FDM ,^® NylonCF10 JW Speaker tool designers achieved remarkable results. The material mixed with carbon fiber offers increased stiffness and strength, making it suitable for more demanding applications. The Stratasys F370CR composite 3D printer allowed the team to reduce tool production time by 80%, providing greater flexibility in tool design.

Mercury Marine: Faster and more robust custom masking devices

Mercury Marine, a leading manufacturer of power systems for consumer and commercial boats, faced challenges in manufacturing custom masking tools for applying decals to engine hoods. Traditional methods were costly and time-consuming, leading to frequent replacements due to damage and wear.

The Solution: Carbon Fiber 3D Printing Technology
Mercury Marine designers Stratasys F370^®CR composite 3D printer used FDM^®Nylon-CF10 and FDM^® TPU-92A (flexible thermoplastic polyurethane) resulted in a fixture that conforms to the curvature of the engine cover and avoids scratching the surface.

Summary

The combination of 3D printing technology and carbon fiber materials has catapulted the manufacturing industry into a new era of efficiency, strength, and versatility. With carbon fiber 3D printers like the Stratasys F370^®CR Composite 3D Printer, companies like Graco, JW Speaker, and Mercury Marine have redefined their toolmaking processes, optimizing productivity, reducing costs, and enabling flexible design iterations. As the potential of carbon fiber 3D printing continues to expand, the technology holds great promise for driving innovation across a wide range of industries. Using this innovative technology is no longer about whether we can print carbon fiber, but rather as an opportunity to revolutionize manufacturing processes and stay at the forefront of development. The production of complex, undercut geometries was made possible in the examples above by the soluble support material used by Stratasys.

The aforementioned companies have already recognized the potential of carbon fiber 3D printing, its efficiency, strength, and versatility.

Download the extended version of the 3 inspiring case studies in Hungarian now!

Comparison of Stratasys FDM and FFF technology

An overview of the key differences between Stratasys FDM and FFF 3D printing

Author : Varinex Date : 2023-10-17

Understanding the Key Differences Between Stratasys FDM and FFF 3D Printing

Learn more about integrating FDM 3D printed tools!

Download the 13-page composite 3D printing solution guide in Hungarian!

Aurora Flight Science Case Study

Author : Varinex Date : 2023-07-06

Shaping the future of aviation

Aurora Flight Sciences, a US-based company that has been developing unmanned aerial vehicles (UAVs) for both civilian and military markets for nearly three decades, recently teamed up with engineers at Stratasys to embark on an ambitious project: building a jet-powered, remotely piloted aircraft.

The wings and fuselage were manufactured using Stratasys Fortus 3D printers using ASA thermoplastic to provide the necessary strength and stiffness. The aircraft’s production time was cut in half by using additive manufacturing, and eliminating the need for tooling significantly reduced lead times.

"The misconception that 3D printing is a prototyping technology persists. But this is not a tabletop model that will break if you touch it. This is a jet plane capable of speeds of 240 km/h!"

James Berlin, Additive Manufacturing Research Engineer at Stratasys

One of the fundamental advantages of 3D printing is the ability to design beyond surface geometry. While other airframe designs now enjoy much greater freedom, designing engineered structures for the aerospace industry is a more complex task. Stratasys’ additive manufacturing technology allowed for the optimization of the design, creating a rigid, lightweight structure while enabling the cost-effective development of a customized, mission-specific aircraft.

What challenges did Aurora Flight Sciences face and how did they use additive manufacturing to build an aircraft capable of speeds of 240 km/h?

Download the 4-page, free, Hungarian-language case study now!

PRESS RELEASE: Stratasys Expands F123 Series with Two New 3D Printers Optimized for Composites Manufacturing

Author : Varinex Date : 2022-05-13

Stratasys Expands F123 Series with Two New 3D Printers Optimized for Composites Manufacturing

New printers and nylon-carbon fiber material bring new applications of additive manufacturing to the production line

Stratasys, a leader in polymer-based 3D printing solutions, today announced the addition of the F190^™CR and F370®^CRmodels to its F123 Series^™3D printer family, along with the introduction of new carbon fiber-reinforced FDM®^Nylon -CF10 material. The new printers also feature materials with superior stiffness and durability, and are engineered for reinforced composite manufacturing. The new composite 3D printers are designed for manufacturers and industrial operators to complement traditional manufacturing technologies with the 3D printing of heavy-duty composite materials. The printers enable faster and more cost-effective production of end-user parts, making them ideal for the production of tooling, assembly seats and other workpiece holding tools.

“I have been in engineering for over 35 years and I am passionate about innovation – not just in the development of new products, but also in the processes and tools used to develop those products. Stratasys has been enabling me to do that for over 20 years through 3D printing,” said Dave Thompson, vice president, global engineering, customer service and subcontract equipment, Graco Inc., a global leader in fluid handling equipment and a beta customer for the F370CR.

*New 3D printers and nylon-carbon fiber material bring new applications of additive manufacturing to the production line*

“Over the years, we have expanded our Stratasys printer fleet and their applications beyond prototyping to include tooling, assembly seats, and the gripping tools used by our robots. The new Stratasys F370CR printer allows us to take our advanced manufacturing applications to the next level, increase tool life, and even achieve better surface quality.”

The new 3D printers include integrated GrabCAD Print^™ software, which provides a simple, intuitive workflow between CAD files and 3D printing, and advanced features to ensure print success. Stratasys also provides connectivity to enterprise applications through the MTConnect standard and its GrabCAD software development kit. Optimized for composite manufacturing, the F123 series of 3D printers feature reusable print trays, a built-in camera for remote monitoring, and a 7-inch touchscreen control panel. The F370CR printer also features automatic material change, meaning there is no need to interrupt the print to change materials – the system simply inserts a new cartridge and the print continues.

*New composite 3D printers are designed for manufacturers and industrial operators to complement traditional manufacturing technologies with 3D printing of heavy-duty composite materials*

“Stratasys provides 3D printers and materials that help advance advanced manufacturing across the production line, such as these new CR 3D printers that enable us to print with stronger, stiffer materials and greater accuracy,” said Dick Anderson, vice president of manufacturing at Stratasys. “These new printers have proven with verified and published data that they can achieve up to 99% dimensional repeatability regardless of part size and geometric complexity. Combined with 99% uptime and dedicated service and support, manufacturers can confidently accelerate their transition to additive manufacturing.”

Compared to other printers, Stratasys’ F123 series of printers optimized for composite manufacturing offer a wider range of substrates with greater print capacity, soluble support materials and lower printing costs due to a larger build area. Additionally, compared to other printers, the F370CR’s larger, fully heated build chamber, which can be combined with stabilizer walls, allows users to print taller parts with superior mechanical and aesthetic quality.

Stratasys has also introduced a new composite material called FDM Nylon-CF10 for the F123 Series printers. This material is more than 60% stronger and nearly three times stiffer than its base nylon material. The chopped carbon fiber material is just one of several thermoplastic materials available for the F123 Series printers. When combined with Stratasys’ soluble support materials, manufacturers can print any geometry without limitations. The F190CR and F370CR printers also support a number of other modified thermoplastic materials.

The new composite-compatible F123 Series printers and FDM Nylon-CF10 material are available to order now, with shipping expected in June. Stratasys live event shared information about the new manufacturing solutions during Stratasys F123 Series product page optimized for composite manufacturing .

Stratasys is leading the global shift to additive manufacturing technologies with innovative 3D printing solutions for industries such as aerospace, automotive, consumer products and healthcare. Stratasys solutions provide competitive advantage across the product value chain with intelligent and connected 3D printers, polymer materials, software ecosystem and made-to-order parts. The world's leading organizations are transforming product design, increasing the flexibility of their manufacturing and supply chains, and improving the quality of patient care with Stratasys. To learn more about the above products, contact VARINEX Zrt., your distributor of Stratasys products in Hungary (3dp@varinex.hu,)

Stratasys F770 for 3D printing large parts

Author : Varinex Date : 2021-04-29

Stratasys' new F770 3D printer makes it easier to 3D print large parts

*The Stratasys F770™ 3D printer has the longest fully heated build chamber on the market – measuring 1171 millimeters diagonally*

for manufacturers^® 3D printer
The Stratasys F770™ 3D printer features the longest fully heated build chamber on the market. Measuring 1171 millimeters diagonally, it offers a spacious build volume of more than 370 liters, opening up new possibilities for industrial manufacturing, prototyping,and production-line part applications. The F770 3D printer is available to order now and is expected to ship in late June.

The F770 uses standard thermoplastics and a soluble support material. This allows for the design and 3D printing of complex internal structures with minimal rework. In addition, the integrated GrabCAD Print™ software allows for 3D printing directly from CAD files, even for large, complex parts. The device can also be connected to enterprise management systems via the MTConnect standard and the GrabCAD Software Development Kit. The mobile device monitoring system and built-in camera enable 24/7 remote operation. It provides up to 140 hours of unattended printing, 7 days a week, without changing materials.

3D printing of large parts in-house

*Luxury appliance manufacturer Sub-Zero Group uses the F770 3D printer to produce parts that were previously too large to make in-house*

Sub-Zero Group Inc., a luxury appliance manufacturer in the US, was one of the beta testers of the F770. Doug Steindl, head of the company’s development lab, said the 3D printer helps it keep larger parts in-house, saving 30 to 40 percent. “Our 3D printing lab is faced with building a new product every six weeks. The faster we can get things done, the better! And the fastest way to do that is to keep as much of the work in-house as possible. The F770 fits that need.”

The F770 helps manufacturers eliminate the high cost and long lead times of traditional machining, the complexity of some high-end 3D printers, and the poor quality and hidden costs of many other low-end large-format 3D printers on the market. The F770 offers the intuitive interface and ease of use of the Stratasys F123 series, in jumbo size. The system has an accuracy of better than 0.25 mm on the XY axis and a build space of 1000 x 610 x 610 mm. Its key applications include large-scale jigs and fixtures, bulky functional prototypes such as vehicle panels, and large print trays full of small-scale production line parts.

Time to think big

“It’s time to think big,” said Dick Anderson, vice president of Stratasys Manufacturing. “As 3D printing becomes more common in manufacturing plants, this machine will make it possible for them to 3D print large-scale or high-volume parts. However, our experience with the world’s leading companies has taught us that quality parts are non-negotiable, and that labor productivity and capital costs are essential for competitive advantage. We built the F770 to flawlessly meet all manufacturing requirements.

The Stratasys F770 3D printer is available in ivory ASA and black ABS-M30™ base materials, and SR-30™ soluble support material.

If you are interested, you can find more information about the Stratasys F770 3D printer

Stratasys FDM additive manufacturing in Naples public transport

Author : Varinex Date : 2021-02-26

Stratasys FDM additive manufacturing in Naples public transport

The downtime of trolleybuses in Naples has been reduced from 12 months to just two weeks using replacement parts manufactured with a Stratasys F900 industrial 3D printer. Encouraged by the success of the project, there are plans to expand FDM additive manufacturing to the entire Italian public transport network.

Engineering company 3DnA aims to revolutionize the maintenance and repair of public transport in Italy using Stratasys FDM additive manufacturing. Recent work the company has done for Azienda Napoletana Mobilità (ANM), the public transport company in Naples, has shown that on-demand 3D printing of spare parts can reduce vehicle downtime by up to 95% compared to traditional spare part manufacturing.

***The Naples trolleybus provides a cost-effective, sustainable mode of transportation throughout the city.***

ANM manages the entire public transport network in Naples, including the city’s famous trolleybuses. The company recently discovered that many of the bus pantographs – the vital components that connect the bus to the overhead line – were broken or no longer usable. Without a working pantograph, these buses would be inoperable and the service would have to be suspended.
Due to the age of the trolleybus fleet, the replacement part in question was no longer available on the market – which would not only have meant the bus being out of service, but would have put the entire fleet at risk in the event of repeated component breakages. Addressing the problem brought 3DnA’s additive manufacturing expertise to the fore – ANM’s large-scale, industrial Stratasys F900® 3D printer was the solution.

“Manufacturing the pantographs using traditional processes would have taken up to 12 months. This would have resulted in a long downtime for the vehicle, which is simply unthinkable,” explains Alessandro Manzo, CEO of 3DnA.

“With our Stratasys F900, we were able to manufacture and deliver around 20 of the most critical components of the pantograph in two weeks, allowing ANM to eliminate the further risk of downtime for its fleet and ensure reliable public transport for three million Neapolitans. Overall, this production flexibility is extremely important for ANM, as it can now order parts based on actual demand, without the need to stock large, costly inventories.”

3D printed parts are used throughout the entire fleet

As the original pantograph was obsolete, 3DnA redesigned the part using 3D scanning. Importantly, by taking advantage of the geometric freedom offered by additive manufacturing, the team was able to redesign the part so that in the event of damage, only a small part of the pantograph would need to be replaced – not the entire unit as before.
The core of the new pantograph is a metal structure, and the F900 3D printer is used to produce the outer casing that connects the pantograph to the overhead lines.

3D printed pantograph top cover made of ULTEMTM 9085 material, F900 equipment — ***durable Stratasys ULTEM^™ 3D printed pantograph top cover made of***

***New 3D printed pantograph connects trolleybus to overhead line***

“The innovative new design was so well received that ANM decided to replace the pantographs on its entire trolleybus fleet with the new 3D printed version,” Manzo continues. “Without such high-precision part manufacturing capabilities, this would not have been possible. The beauty of the matter is that the F900 not only ensures a high level of part accuracy, but also has an industry-leading repeatability.”

The outer shell is printed using Stratasys ULTEM^™ 9085 resin , which provides the structural support needed for everyday use while also meeting the required electrical insulation standards. Manzo adds, “The part is non-conductive, so using this resin is essential. In addition, ULTEM^™ 9085 resin provides three key requirements for end-user transportation applications: excellent heat resistance with a heat deflection temperature of 153°C, a flame-retardant thermoplastic, and a very high strength-to-weight ratio.”

Expansion nationwide

Encouraged by the success in Naples, 3DnA’s management sees it as a catalyst for the transformation of the wider Italian transport sector.
“We believe that additive manufacturing will become the primary method of spare parts production in the public transport sector,” concludes Manzo. “Small-volume, on-demand production is cost-effective and the industry is ripe for transformation, as the ANM example shows. As a result of the project, we are already in advanced discussions with several transport management companies in Italy to support their spare parts needs with this technology.”

Here you can find more information about the F900 3D printerand the durable ULTEM™ 9085 resin material.

Continental uses Stratasys Fortus 450 3D printer

Continental strengthens with Stratasys Fortus 450 3D printers

Author : Varinex Date : 2020-11-12

Continental strengthens production capabilities with Stratasys FDM additive manufacturing

Continental AG, a leading automotive technology company, has been successfully using additive manufacturing for more than 20 years. Its Additive Design and Manufacturing Competence Center in Karben, Germany, integrates the technology into its entire design and production process.

To address its in-house manufacturing needs and meet customer expectations, Continental has invested in a Stratasys Fortus 450mc™ 3D printer to strengthen its manufacturing capabilities. The technology enables the production of durable, high-performance parts made from ULTEM™ 9085 resin, while the ABS-ESD7™ material also enables Continental to 3D print ESD-compatible assemblies.

"The Fortus 450mc stands out in our portfolio because it gives us access to highly specialized materials like ULTEM™ 9085 resin and ABS-ESD7™, which allow us to meet demanding manufacturing applications in the production facility."

Stefan Kammann

Continental Engineering Services

The challenge

• To prevent production disruptions, replacement tools and equipment need to be procured quickly and customized solutions are needed.
• Increased work with electronic components means that ESD-compatible tools and manufacturing support equipment are essential.

The solution

• In-house Stratasys FDM^® additive manufacturing increases production speed by producing customized, high-performance tools and components on demand.
• The Fortus 450mc 3D printer enables rapid production of ESD-compliant production support tools in ABS-ESD7 material, avoiding damage to parts or downtime when coming into contact with sensitive electronics.
• The Fortus 450mc enables parts to be produced in a matter of hours. This means Continental can schedule print jobs to run overnight, so they can receive finished parts the next morning.

Learn how Continental integrated the Stratasys Fortus450 3D printer into its manufacturing processes!

Download our 4-page case study in Hungarian now!

Learn about Stratasys FDM carbon fiber technology!

Author : Varinex Date : 2020-11-05

Learn about Stratasys FDM carbon fiber technology!

Strong as metal, light as plastic

Strong as metal, light as plastic, and highly resistant to heat, chemicals, and corrosion – all of this is provided by carbon fiber FDM 3D printing. Due to its excellent thermal and mechanical properties, carbon fiber is often used in the automotive and aerospace industries.

FDM (Fused Deposition Modeling) technology is an efficient additive manufacturing method patented by Stratasys. FDM allows concept models, functional prototypes, and end-user parts to be created from standard, engineering, and high-performance thermoplastics. It is the only professional 3D printing technology that uses industrial thermoplastics, giving the finished parts unique mechanical, thermal, and chemical resistance.

The fundamental trend in the design of industrial manufacturing tools is to use aluminum or an alternative metal alloy. This is because their mechanical properties meet the necessary requirements. In many cases, thermoplastics have the necessary strength to function, but are not strong enough to perform the task. This is where composite materials come into play. Adding some kind of reinforcement to a base polymer drastically changes its mechanical properties, making it suitable for replacing metal parts in many manufacturing tooling. Stratasys, one of the world's largest 3D printer manufacturers, has developed FDM Nylon 12CF ™ for this task.

We want to know how a part will look, feel, and function before manufacturing. That's what prototypes are all about.

When the final part needs to be strong and functional, a carbon fiber prototype is the way to go. In many cases, these carbon fiber prototypes are built to prove the concept works in real-world conditions – think of robotic arms, engine components, or door hinges.

Compared to traditional prototypes, mainly made of metal, carbon fiber 3D printing has the advantage of faster iteration and lower cost. Fine-tuning prototypes with 3D printing is significantly cheaper and takes less time than with traditional methods, thanks to the ability to create countless versions that can be printed immediately. This speeds up product development and allows us to get the product to market earlier than our competitors.

Carbon fiber FDM 3D printing offers countless applications beyond prototyping. Among other things, it is perfectly suited for the direct production of robot arm ends, such as gripping and positioning, deburring robots, and grippers. In the case of robot arm ends, wear resistance is usually emphasized, but reducing the weight of the arm end is often overlooked, even though it has countless advantages, such as resulting in a lower-cost robot.

Carbon fiber material enables 3D printing of manufacturing support tools and clamping seats in applications that were previously unimaginable due to the flexibility of the material. Since the elongation coefficient of FDM Nylon 12CF is three times that of the closest FDM material, its use can be expected to significantly reduce the deformation of parts.

Due to the carbon fiber reinforcement, FDM Nylon 12CF is much stiffer and more wear-resistant than other FDM materials, so parts made from it can also be used to shape metal sheets. It is also an excellent choice for making drilling templates, as the carbon fiber reinforcement provides greater rigidity, so the drilled hole will be more precise.

Its excellent mechanical properties make carbon fiber suitable for printing fixtures, even replacing metal fixtures in industrial environments. This is particularly beneficial for particularly complex fixture tools, where the complex geometry would require multiple components or complicated machine settings.

In conclusion, using FDM Nylon 12CF as an alternative to metal parts can help reduce costs and increase overall efficiency for companies. Carbon fiber increases the strength and stability of 3D printed parts while reducing their overall weight. This makes it an ideal composite material for a wide range of applications, from functional prototypes to end-user parts.

When manufacturing plants work with the right manufacturing support tools, it speeds up production, which means increased productivity. But that's just the beginning! Well-designed tools are more ergonomic and increase both worker safety and efficiency, while also saving costs.
3D printed manufacturing support tools
can reduce manufacturing costs by up to 50-90%!

Download our free, 7-page, Hungarian-language brochure entitled Production Support Tools in Production Plants!

Boeing receives certification for Antero 800NA material

Author : Varinex Date : 2020-11-04

Boeing receives certification for Antero 800NA material

***The PEKK (polyether ketone ketone)* *-based material has enhanced chemical and fatigue resistance. This offers Boeing a new opportunity in the production of polymer aircraft parts.***

Boeing, one of the world’s largest aircraft manufacturers, has qualified and accepted Stratasys’ Antero 800NA thermoplastic for 3D printing, Stratasys announced. The qualification means that this high-temperature material can now be used for the direct production of 3D printed parts for Boeing aircraft, meaning these parts will not function as prototypes but will be directly incorporated into the aircraft.

*Boeing qualifies Stratasys Antero 800NA material, enabling use of high-temperature material in the company's aircraft components*

The PEKK-based Antero 800NA polymer was developed specifically for the industrial Stratasys FDM^® 3D printer. Boeing issued the BMS8-444 specification and, after a comprehensive evaluation of the material, added the 800NA material to the Qualified Product List (QPL). This is the first Stratasys material that Boeing has used to meet qualified chemical resistance and fatigue requirements.

“Boeing recognized the enormous advantage of Antero in applications where 3D printing was previously not possible,” said Scott Sevcik, vice president, Stratasys Aerospace. “Additive manufacturing offers tremendous benefits in streamlining aerospace supply chains for both new parts and maintenance, repair and operational parts. Robust materials are needed to meet the requirements to meet challenging aerospace specifications.”

The 800NA, part of the Antero family, is an ESD-protected material, just like the Antero 840CN03.
Stratasys has made these materials available to users with the F900 and Fortus 450mc 3D printers.

Unique, fast production – 3D printing

Author : Varinex Date : 2020-05-14

Custom, fast production - 3D printing

The demand for unique, fast production has exploded, and 3D printing is becoming increasingly popular among entrepreneurs. NEW technology magazine spoke with György Falk, one of the owners of VARINEX and Dénes Gábor Award-winning engineer, about the current state of the market.

3D printing has become very popular recently, with more and more companies joining the industry. How are you different from the others?

In recent years, domestic companies in the sector have developed a lot, and clever initiatives have been launched. With due humility, we differ from the others in that we have had much more time to gather knowledge and experience in the past two decades. We are happy to help our customers, regardless of whether they are just getting acquainted with the world of 3D printing or are looking for a solution for a wide range of manufacturing technology optimization.

Our greatest experience is in effectively integrating 3D printing processes into traditional manufacturing technologies. In VARINEX solutions, the most profitable approach to manufacturing is a systemic approach, of which 3D printing is just one element. With our help, you can join this process at any level of knowledge, and we see that the further ahead someone is, the greater the profit they can realize with our solutions.

It gives me a good feeling that we have several active customers with whom we have been working for 20 years. I have been teaching additive technologies for decades together with excellent colleagues from BME, and so far more than 1,000 students have visited us, in our 3D printing factory with unique industrial capacity in our country.

The impact of the coronavirus on the 3D printing industry is a current and unavoidable question. What conclusions have you drawn from the events so far, and in what direction has the 3D printing market moved?

We see that the demand for quickly produced, customized products has increased dramatically, which is why 3D printing is one of the most suitable solutions to the emerging issues. At the same time, the changed circumstances have put everyone in a new situation. Most industrial players are facing serious challenges, so they need to make the best possible decisions in optimizing their development and production. VARINEX will be their reliable partner in this.

One more question about the coronavirus. How does VARINEX help those in need during this difficult time?

My friend and business partner Gyuri Voloncs and I have always tried to support good causes within our means for the past 30 years. It was also clear to both of us that we had to help in the fight against the coronavirus. So far, we have supported nearly 20 hospitals and healthcare institutions in Budapest and the countryside with 3D printed protective equipment.

One of the most important things about a 3D printer is what materials it can work with. What kind of machines and materials do you work with?

VARINEX deals with Stratasys industrial equipment. We undertake the printing of thousands of models per year as a service and enjoy the innovations of professional, industrial machines. These equipment have a decade-long technological advantage, are manufactured with patented technology and use truly technical materials from simple ABS to special high-standard ULTEM^™9085 and ULTEM ™ 1010 resins. For 3D printing of production line jigs, the extremely strong and wear-resistant new polyamide Diran material is recommended, and the Stratasys FDM carbon fiber technology we distribute is excellent for replacing some metal parts.

Learn more about FDM Carbon Fiber technology here: varinex.hu/stratasys/cf

Source: Botond Némethi/NEW technology magazine

Hospital application of Stratasys 3D printers against coronavirus

Author : Varinex Date : 2020-04-16

Paris University Hospital receives 60 Stratasys 3D printers to help fight coronavirus

Paris hospital system deploys 60 Stratasys 3D printers to fight COVID-19. The F123 series 3D printers were delivered and installed at the hospital within 24 hours.

The University Hospital of Paris (L'Assistance Publique – Hôpitaux de Paris), the largest hospital system in Europe, has deployed 60 Stratasys 3D printers to support the fight against the coronavirus. Delivered within 24 hours of ordering, the equipment will allow the French hospital system to manufacture medical devices and components on site to meet emerging needs.

Stratasys F123 3D printers at the University Hospital of Paris (Photo: 3Dprintingmedia.network)

The 60 F123 series 3D printers, which are housed in a 150-square-meter facility at the hospital, were supplied by Stratasys’ French reseller CADvision. The FDM-based machines are being used to print everything from face shields and masks to electric syringe pumps and intubation devices to ventilator valves to help alleviate the challenges posed by the coronavirus pandemic.

The hospital is being assisted by Bone3D, a 3D printing service provider with extensive experience in the medical sector, to manage the large-scale 3D printing project, providing engineers to manage the installation, operation and servicing of the Stratasys fleet. The hospital has also launched a dedicated 3D printing platform (3dcovid.org) to help meet the rapid needs of 3D printed equipment for healthcare workers in and around Paris, in the part of France most affected by the pandemic.

Stratasys F123 3D Printers Deployed at Paris University Hospital as Part of Fight Against Coronavirus — Stratasys F123 3D printers under installation at the University Hospital of Paris (Photo: Facebook.com/Stratasys)

3D printers are used to provide equipment needed against COVID-19

The 3D printing resources acquired with the support of the University of Paris and the Kering Group will allow a wide range of healthcare institutions to address emerging supply shortages and provide the equipment needed to protect their staff and treat hospital patients.

“The overwhelming and severe nature of COVID-19 continues to impact the supply chain of the world’s most essential equipment,” said Andreas Langfeld, President, Stratasys EMEA. “Thanks to 3D printing technology, the University Hospital of Paris has its own rapid-response supply chain in-house, allowing it to move production directly to where it is needed, immediately providing essential equipment to frontline healthcare workers who are saving lives every day.”

The building of the University Hospital of Paris (Photo: 3Dprintingmedia.network)

Stratasys is also supporting the fight against COVID-19 in another way: it is working with partners to produce and distribute thousands of face shields for healthcare workers. The company said it received more than 350,000 requests for face shields last week and is seeking manufacturing partners to meet the urgent need.

Source: www.3dprintingmedia.network

Learn more the Stratasys F123 series 3D printers!

Simplifying automotive processes with additive manufacturing

Author : Varinex Date : 2019-12-27

Simplifying automotive manufacturing processes with additive manufacturing

Quality and manufacturing performance are key issues in automotive production today. With the emergence of many new technologies, such as autonomous vehicles and smart cars, there is great pressure on manufacturers and suppliers to rely on new manufacturing technologies and expertise to ensure efficient design, cost management and work.
Our article discusses the advantages of 3D printing automotive fixtures and seats over traditional manufacturing methods, as well as its ideal application on production lines.

Advantages of additive manufacturing of clamping devices and seats

Manufacturers traditionally work with CNC-machined or injection-molded fixtures and seats, which are time-consuming and labor-intensive to manufacture, and their return on investment is not guaranteed. Additive manufacturing allows new parts to be produced in a shorter time from engineering-grade materials without CNC machining, thus achieving significant cost savings during the production of the devices.

3D printing of fixtures and seats offers the following main advantages:

Fast time to market: 3D printing allows you to produce fixtures and seats faster and on-demand. Lead times are 70-90% faster than traditional manufacturing.
Design freedom: 3D printing builds parts from the ground up, layer by layer, which removes the traditional limitations of manufacturing-oriented design and opens up a host of new possibilities for tool configuration. When engineers design for additive manufacturing, holes, contours, and complex organic structures are no longer obstacles.
Consolidation of components: thanks to the design freedom inherent in additive manufacturing, assistive devices that previously consisted of components that required their own assembly time can be re-manufactured to be made from a single component, thus reducing maintenance costs.
Ergonomics: Designing components along new guidelines also allows you to increase worker comfort and the ergonomics of the aids you produce. When designing, you can prioritize functionality over manufacturability. This does not add additional costs or increase production time, but it does increase the safety and comfort of employees using the aids.
Weight reduction: Another benefit that increases the comfort and safety of employees working on the production line is the reduction in the weight of auxiliary equipment. 3D printing allows the use of strong, high-quality materials, while maintaining the functionality of the parts compared to metal versions.
Digital inventory: 3D printers work directly from CAD data, so new designs can be created quickly and existing ones can be modified easily. For example, if the final part size changes and a new fixture is needed, all you have to do is update the CAD model that represents the fixture, order the additively manufactured part, and the new fixture can be on the production line within a few days.

Additive Manufacturing on the Automotive Production Line
Although the terms “clamps” and “stakes” are often used interchangeably, there are clear differences between them and their applications are diverse. Clamps are custom-made devices that control and monitor the position and movement of a part during an operation. They ensure repeatability and accuracy in the manufacturing of products. In contrast, seats are devices that hold a part in a fixed position during a machining operation or other industrial process. Seats ensure consistent quality, reduce production costs, and enable different parts to be manufactured to their respective specifications.

From assembly to quality assurance to logistics, “clamps and seats” make the automotive component manufacturing process seamless. Here are some examples of 3D printing applications for clamps and seats in the automotive industry:

Manufacturing and assembly: 3D printed tools are most often used in this step of the manufacturing process to guide and maintain the position of tools and rails while milling and drilling parts.
Safety: It is often left to the workers to check the safety of parts and equipment, so it is important that the clamping devices and seats are lightweight and ergonomic for ease of use.
Quality Assurance and Inspection: 3D printing can be used to create precise, customized tools that meet the stringent requirements of quality assurance departments for fixture and inspection tools. The thermoplastic, durable plastics developed for additive manufacturing can provide a non-marring surface for final inspection.
Packaging and logistics: the most common application area we encounter is the production of customized clamping devices to facilitate transportation within the factory. Additive manufacturing thermoplastics are durable and heat-resistant and can withstand the stresses encountered during transportation, such as vibrations, pressure and moisture.

The automotive industry is experiencing exciting and disruptive times. Manufacturers that are able to innovate beyond vehicle design and are ready to transform all aspects of the design and manufacturing process will gain a competitive advantage. Fixtures and seats created through additive manufacturing play a key role in this process, making work more efficient, helping to eliminate errors, and shortening turnaround times for inspections.

3D printing has been indispensable for years in the automotive prototype development process and in the production of unique or customized parts.

Learn about the 5 key areas where innovative 3D printing is transforming the automotive industry from design to manufacturing! Download our Hungarian-language publication!

3D printing and a profit-oriented approach from our experts!

VARINEX Zrt.'s 3D printing business has more than 25 years of experience in the field of 3D printing services, i.e. contract printing. Our engineering colleagues, who use FDM and PolyJet technologies on a daily basis, are able to fulfill customer orders at the highest level. The experience gained from the contract printing of tens of thousands of various parts per year ensures the right choice between FDM and PolyJet technology in the given application area.

Before starting a project, contact our expert engineering colleagues 3dp@varinex.hu !

Hand in hand: additive manufacturing and the digital process

Author : Varinex Date : 2019-12-12

Hand in hand: additive manufacturing and the digital process

Manufacturers are constantly looking for new ways to optimize their design tasks and become simpler, more flexible and more agile to keep up with customer customization demands. This includes investing in manufacturing tools and machinery that are designed to meet the needs of the companies and contribute to achieving broader strategic goals.

Forward-thinking manufacturers are preparing for this trend in advance and opening up to emerging technologies – one of the most important customization opportunities is combining additive manufacturing and the digital process.

Additive manufacturing, also known as 3D printing, is the process of building physical objects layer by layer. Creating new parts and products has traditionally been a time-consuming and expensive process, requiring the reconfiguration of manufacturing systems (production and assembly lines). The cost associated with setup and changeover time is a financial disadvantage, especially for unique products. This cannot happen in today’s fast-paced world of customized products – additive manufacturing offers a solution to this problem.

the most common additive manufacturing technologies Among FDM and PolyJet manufacturing technology are suitable for the rapid and cost-effective production of parts and prototypes. PolyJet technology is known for its detail, while FDM technology focuses on the production of durable, end-use parts. If mechanical strength and durability are key for the part, FDM is the best choice.

How do you know which technology is right for your parts? >>> Learn all about PolyJet and FDM technology!

The digital process is key to the scheduling of additive manufacturing

Additive manufacturing enables the rapid production of new prototypes, parts and products without large-scale conversions of production equipment. Cost savings can be significant even for unique products – for example, consider a machine failure when a replacement part can be produced using an on-site 3D printer. To fully exploit their potential, it is worth combining additive manufacturing and the digital process. In the example above, IoT (Internet of Things) and analytics allow us to prepare for equipment maintenance in advance and take proactive measures. By feeding a virtual model of the required spare part from the digital inventory into the 3D printer, we can produce the replacement part in a short time and avoid costly downtime.

IoT can also provide key performance data that can be used to create a closed-loop feedback loop for product designers. Real-world product usage data can be accessed by designers planning to create the next product version through the digital process.

Generative design and the digital process

Artificial intelligence (AI) is transforming industries, companies, and the roles they play. Product design and engineering roles are being equipped with AI-powered generative design tools to create smaller, more efficient future product variants.

What are the techniques for designing for additive manufacturing?

When choosing the design technique(s) to use, it is important to consider how the part will be used and what role it will play. In fact, topology optimization and generative design are often related. The of generative design is to create a design that can meet performance requirements better, faster, and with reduced weight, using computational methods and existing resources. Topology optimization is a proven generative design method that focuses on optimizing material distribution using reliable numerical methods. In many cases, the optimized shapes obtained through topology optimization cannot be manufactured using traditional processes.

>>> Learn about generative design technology, the future of creation, from our Hungarian-language summary publication!

Every manufacturing process has its own design techniques: parts that are to be machined are designed differently than those that are to be 3D printed. Additive manufacturing uses unique design rules and tools to create optimized designs that are ready for 3D printing. These design solutions are developed with the goal of optimizing the cost, reliability, and other aspects of the product’s life cycle as much as possible.

Additive manufacturing brings these innovative, generative designs to life by printing materials layer by layer. These optimized product designs can significantly reduce waste, material usage, and product weight, which has a significant impact on product manufacturing costs and practical performance.

By combining additive manufacturing and generative design, the overall cost of prototyping can also be significantly reduced. Using an on-site 3D printer, product designers can quickly produce a prototype optimized with generative design. Rapid prototyping also impacts subsequent steps in the process. It allows manufacturers to bring their products to market faster than ever before and meet the demands of ever-shortening lead times.

Manufacturers will need an additive manufacturing strategy to keep up with mass customization trends and competitive challenges. Combined with the digital design process, additive manufacturing provides an opportunity for the spread of innovative technologies and can facilitate collaboration between different roles. Additive manufacturing will revolutionize the physical production line, while the digital process will be able to extend its broad impact to all operations.

FDM and PolyJet technology from 3D printing pioneers

Being a member of the family that invented FDM technology means that we are supported by Stratasys’ strong commitment to research and development. VARINEX Zrt. has 25 years of experience in the field of 3D printing services, i.e. contract printing. Our engineering colleagues, who use FDM and PolyJet technologies on a daily basis, are able to fulfill customer orders at the highest level. The experience gained from contract printing tens of thousands of different parts per year ensures the right choice between FDM and PolyJet technology for the given application area.

Before starting a project, contact our expert engineering colleagues 3dp@varinex.hu !

FDM printing technology

Author : Varinex Date : 2019-11-04

Design Guide: FDM Technology

Our guide explains the basic considerations to consider when designing and preparing parts made with Fused Deposition Modeling (FDM) technology. When designing parts to be printed with FDM technology, the specifics of the printing process must also be taken into account.

FDM part design

The FDM process builds thermoplastic plastic layer by layer. Since the range of products and parts that can be created with the FDM process is much wider in terms of both raw materials and special unique properties than other prototype and small-series manufacturing processes, it is increasingly being used to produce products that go directly to the user, a process called Direct Digital Manufacturing.

Size and orientation

With Stratasys FDM manufacturing systems, we can create discrete FDM parts as large as 914x610x914 mm in one piece. Designers should consider that the tensile strength of extruded plastics is highest along the xy plane.

Because the Stratasys FDM system produces models in a closed, heated work space, warping is generally not an issue. The support required for undercuts is provided by either a soluble or breakable, easily separable support material, depending on the model material.

Design considerations for FDM printing

Based on the design of traditional plastic parts, we present the design considerations for quality FDM parts in the downloadable document.

Download our design guide to learn about design considerations for the FDM technology process!

VARINEX Zrt.'s 3D printing business has been providing 3D printing for more than 20 years and offers a profit-oriented approach. Before starting a project, contact our expert engineer colleague 3dp@varinex.hu .

Download the brochure Design Considerations for FDM Manufacturing

High-strength composites and thermoplastic materials

Author : Varinex Date : 2019-10-15

High-strength composites and thermoplastic materials

Stratasys composite materials make it easier than ever to create high-strength, reliable end-user parts. Use Stratasys materials for your 3D printing technology to quickly develop and implement designs that deliver the best possible performance under the most demanding conditions, every time!

Carbon fiber

Carbon fiber composite 3D printing material, carbon fiber Nylon12 can provide the durability and stiffness needed for rigid tooling, prototypes and production parts. Due to its durability and stiffness, this material can be an excellent replacement for aluminum for lighter parts and tooling. With carbon fiber Nylon12, you can create extremely strong and rigid parts.

Chemical and high temperature resistant material

With its chemical and high temperature resistance and outgassing properties, Antero 800NA combines the design freedom of FDM with the high strength and dimensional stability of PEKK, making it suitable for aerospace applications. The PEKK-based Antero 800NA material provides excellent chemical resistance.

High tensile strength – high-performance thermoplastic material

The strongest thermoplastic FDM base material, ULTEM™ 1010 resin combines high tensile strength with excellent thermal properties, making it a good choice for high-temperature applications, such as replacing heavy composite tools with autoclave-compatible, lightweight alternatives or creating medical devices that can withstand heat sterilization. ULTEM™ 1010 resin allows for much faster production of lighter, layered composite devices.

High strength-to-weight ratio and FST certification

With its high strength-to-weight ratio and FST (flame, smoke, toxicity) rating, ULTEM™ 9085 resin is an excellent choice for weight-saving applications in the aerospace and automotive industries. ULTEM™ 9085 CG resin is fully traceable to aerospace industry requirements. High-strength ULTEM™ 9085 resin plastic parts, such as the aircraft tube shown in the image, enable aerospace companies to reduce weight.

VARINEX Zrt.'s services are not only backed by industry leader Stratasys - in addition to more than 20 years of 3D printing experience, we also have a tireless team of engineers who can assist you at any stage of your project. Contact us before starting a project!

FDM and PolyJet: professional 3D printing technologies

Author : Varinex Date : 2019-10-14

FDM and PolyJet: professional 3D printing technologies

Choices and decisions. In life, we are constantly faced with choices between possible solutions. This is no different in the world of 3D printing. Both Fused Deposition Modeling (FDM) and PolyJet technologies have unique characteristics and special advantages.

How do you know which technology is right for your parts? To better understand the options, it is important to understand the processes involved.

FDM . uses a thermoplastic polymer base material that is melted by the machine and the melt is continuously and precisely deposited, a process called extrusion. After extrusion, the material solidifies immediately

The PolyJetprocess is similar to traditional inkjet printing, except that it doesn’t lay down the “drops” in a single layer, but rather in layers on top of each other. The droplets are made of a special polymer material that hardens when exposed to UV light. These are called photopolymers. Once a layer is created, the machine creates additional layers and repeats the process until the part is complete.

FDM and PolyJet manufacturing technologies are different, so the properties of the finished products will also be different. Here are some things to consider when choosing the right technology:

Application area – what will the component be used for?

PolyJet technology allows you to create lifelike, colorful parts, making it a great choice for concept models.

While PolyJet is known for its detail, FDM focuses on producing durable, end-use parts. If mechanical strength and durability are key to the part, FDM is the best choice.

Raw material

If the detail of the part is particularly important, then PolyJet technology is worth choosing. It can be used to create even the most complex colored textures. Do you need elements with different material properties within one element? Thanks to PolyJet technology, it is also possible to print parts with various flexibility, from rubber-like parts to hard plastics.

Fused Deposition Modeling (FDM) technology allows for a wide range of materials to be used. The finished product is robust and resistant to extreme conditions and chemicals.

Surface quality – how important is the surface quality of the finished pieces?

It is usually determined by the method of use. In the case of concept models and some prototypes, surface treatment and aesthetics can be of fundamental importance. VARINEX Zrt. employees will always recommend the optimal solution to customers based on 25 years of experience!

Although FDM does not provide the same level of detail as PolyJet, it can still create parts with complex geometries and intricate assemblies. Parts created using the FDM process have visible layers, but these do not affect the strength or functionality of the part.

Component size

Part size is also a consideration when choosing a technology. PolyJet and FDM offer similar maximum build volumes: PolyJet parts can have a maximum size of 998 x 797 x 497 mm, while FDM parts can have a maximum size of 914 x 609 x 914 mm.

FDM technology can be used to create parts of any size. If the part size exceeds the above, the part can be cut up and the individual pieces can be manufactured separately. These can be later joined together, the finished product will be as strong and functional as if it were a single part.

Both technologies have their advantages. Ultimately, the intended use of the part will determine the 3D printing process that you can use. If you need high-resolution, extremely fine parts, PolyJet is a great choice. If durability and the ability of the product to function in extreme conditions are important, FDM is the way to go!

5 reasons to choose Stratasys PolyJet technology for prototyping – Download our Hungarian-language brochure to learn why you should choose PolyJet 3D printing technology for prototyping

Design Considerations for FDM Printing – Download our design guide to learn about design considerations for the FDM technology process!

FDM and PolyJet technology from 3D printing pioneers

Before starting a project, contact our expert engineering colleagues 3dp@varinex.hu !

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FDM part design

Size and orientation

Design considerations for FDM printing

Download our design guide to learn about design considerations for the FDM technology process!

Download the brochure Design Considerations for FDM Manufacturing

High-strength composites and thermoplastic materials

Carbon fiber

Chemical and high temperature resistant material

4. Speed up production and improve worker safety

Learn more about integrating FDM 3D printed tools!

Download the 13-page composite 3D printing solution guide in Hungarian!

Learn more about integrating FDM 3D printed tools!

Download the 13-page composite 3D printing solution guide in Hungarian!

Learn more about integrating FDM 3D printed tools!

Download the 13-page composite 3D printing solution guide in Hungarian!

***The PEKK (polyether ketone ketone)* *-based material has enhanced chemical and fatigue resistance. This offers Boeing a new opportunity in the production of polymer aircraft parts.***