3D pellet extrusion printers complement conventional processes with an additive manufacturing strategy without moulds. AIM3D is now presenting universally applicable extruder developments for third-party suppliers in order to open up new areas of application for 3D screw extruders. These universal pellet extruders can, on the one hand, be used for 3D printing applications (large-scale printers, process combinations or robotic systems) and, on the other hand, for refinement applications such as coating or joining. The universal pellet extruders therefore offer a comprehensive approach to expanding established processes with a 3D production strategy.
Development of universal pellet extruders from AIM3D for new areas of application
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| Photo: AIM3D |
Based on AIM3D's patents and experience in the field of compact screw extruders for highly demanding materials such as MIM (Metal Injection Moulding), CIM (Ceramic Injection Moulding), but also high-temperature materials such as ULTEM 9085 and PEEK, third-party suppliers are now also able to use CEM extruders. The options range from the purchase of standard extruders from AIM3D, such as the CEM E2 or the CEM E3, to the development of application-adapted extruders in the project business. The objectives of using CEM extruders are cost reduction, lightweight construction, bionic designs or the optimisation of certain material groups. The CEM extruders CEM E2 and CEM E3 are the "in-house" extruders for the 3D printer series ExAM 255 and ExAM 510 from AIM3D. These 3D screw extruders are characterised by their material versatility in the material classes of metals, ceramics and plastics (multi-material 3D printers), but also by their robustness and high output rate in everyday production.
Performance and build rates of CEM extruders
The build rate of a CEM extruder from AIM3D is currently 150 cm³/h. According to the manufacturer, the aim is to eventually achieve build rates of 300 to 600 cm³/h. With this, processing volumes of 1,000 to 4,000 kg per year could be reached. These figures refer to components with a maximum layer thickness of 300 µm and the use of a 0.5 mm nozzle on the 3D printer and are therefore comparable to 3D components made using fused deposition modelling (FDM). Reproducibility, i.e. the repeatability of the process, is crucial for the construction of a 3D component. For users, this is a key point to ensure consistent component quality, especially in the series production of small and medium-sized batches.
Range of applications and material diversity of CEM extruders
AIM3D's expertise primarily includes high-performance polymers such as ULTEM™ 9085 from Sabic (PEI (polyetherimide)) on a pellet basis. The cost benefits of using standard pellets compared to 3D printers that process polymers with filaments are enormous. When using ULTEM™ 9085 with the CEM technology, the homogeneities that can be achieved are comparable to those obtained from injection moulding technology. The low standard deviations achieved during tensile tests according to DIN EN ISO 527-2 Type 1A prove a high process stability and reproducibility. These features are achieved thanks to the patented pellet extruder technology, which ensures gentle processing of the material and minimises the degradation of the polymers in the extruder. The material PEI is also flame-retardant in accordance with UL 94-VO. PEI is therefore suitable for high application temperatures, that is, permanently 180 ºC (217 ºC up to glass transition). With the PEI material Sabic ULTEM™ 9085, 3D pellet printing now reaches component properties that significantly surpass FDM printing. As a result, 100% higher elongation at break is achieved compared to FDM printers. PEI therefore opens up numerous areas of application in automotive, aerospace, machine industry, rail vehicles and defence technology with high economic efficiency. The range of materials is also supplemented by the processability of ceramic or metallic materials.
Versatility of universal pellet extruders
By specialising in certain material classes or applications, advantages can be achieved when using CEM extruders in terms of discharge rate, extruder weight or production costs. Expanding the range of use of CEM extruders to special applications or integrating them into the system technology of third-party suppliers opens up new areas of application for this proven and robust production strategy as a universal pellet extruder. This, for example, refers to 3D printing applications such as in large-scale 3D printers (for example additional printing of a smaller material component), process combinations (for example retrofitting an FDM printer) or robotic systems. Additionally, the CEM extruders also open up applications outside of 3D printing, including tasks such as coating, joining or application.
