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7/29/2019 Stratasys 10 Reasons
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10 ReasonsWhy Multi-Material 3D Printing is Better for
your Product Design & Development
Stratasys Ltd.
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IntroductionBased on their innovative use of inkjet printing technology, Objet 3D printers are
the only additive layer manufacturing devices in the world able to combinedifferent 3D printing materials within a single 3D printed model.
Objet 3D printing technology is also the first in the world to offer a choice of over
120 different 3D printing materials, ranging in properties from rigid plastic to
rubber-like, opaque to transparent, and standard to engineering-grade ABS
toughness.
When talking about multiple-material 3D printing, we actually refer to a number
of different capabilities which we will aim to categorize and clarify in this white
paper. We will also outline the uses and advantages of this unique 3D printing
technology for companies using rapid prototyping during the design and
development of manufactured end products.
Dual Material Jetting - The TechnologyObjet Connex 3D printing technology works by jetting two distinct Objet materials.
The technology can work with any mix of rigid and flexible materials, various
transparent and opaque materials, and different color materials.
Each material is funneled to a dedicated liquid system. The liquid system isconnected to the Objet printing block, which contains eight printing heads. Every
head includes 96 nozzles, each measuring 50-microns in diameter. Each material
has two designated printing heads that work in sync.
Objet 3D printing block,
consisting of 8 printing
heads:
- Heads 1 & 2 jet material A
- Heads 3 & 4 jet material B
- Heads 5 - 8 jet the support
material
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A Word about Objet 3D Printing MaterialsObjet range of over 120 3D printing materials is based upon proprietary acrylic-
based photopolymer resins. These materials are jetted as a liquid from sealed
cartridges inserted into the machine. Once a layer of material is deposited on to
the build tray, it is immediately cured by a UV light. The UV light follows the print
head and turns each liquid material layer into a solid. The material is immediately
ready to be built upon with successive layers.
These fully cured models can be handled immediately after printing - a unique
advantage over other rapid prototyping technologies and materials which requirelengthy post-processing treatments.
Loading and unloading the print cartridges is similar to the process of installing
and removing inkjet cartridges from a paper-feed printer.
10 Advantages of Dual Material Jetting
Independent Nozzle Control
Objet 3D printing technology is able to control every nozzle in every print headindependently. This means that preset combinations of model materials can be
jetted from designated nozzles to create new materials, different material parts
within a model, as well as different material models that are being printed at
once. Here are ten benefits of this unique dual-material jetting in more detail:
1. Fabricate Composite Digital Materials
Composite materials have been in use for many years. They are used today in
many industries, including building construction, sports equipment and car and
aircraft manufacturing.
Objet Digital Materials are multi-phase composite materials created by the
Objet Connex 3D printing system. The benefit of Digital Materials is the ability to
produce new, composite materials with attributes that are not available in the
individual constituents.
Based on this multi-material jetting technology, the Connex family of 3D printers is
able to simultaneously print two resin materials to create 90 different types of
Digital Materials. Starting with 17 cartridge-ready materials, Objet Connex users
have the ability to choose from a total of 123 different materials and composite
material combinations.
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Digital Materials have mechanical and physical properties that vary from the
primary, cartridge-based materials. This additional set of materials improves uponthe mechanical properties available from the existing materials - providing new
values of tensile strength, flexural strength and Izod Impact. Rubber-like Digital
Materials enable the precise selection ofnew Shore A values to suit the specific
application purposes of the designer.
Objet Digital Materials are generated on the fly, based on the two cartridge-based
materials that are installed in the system. The selection of the Digital Material is
made by the user through dedicated software that determines the appropriate
jetting parameters. The materials are created automatically during printing,
without the need for additional human input.
2. A Recipe for Future Scalability
90 Digital Materials can be derived from just a small number of primary materials.
Every additional new material introduced therefore opens up tens of new Digital
Material options. With Objet multi-material technology, the potential palate of
Digital Material combinations will continue to expand and grow exponentially.
3. Simulate Plastics with Engineering Properties
When the Objet multi-material process combines specific rigid materials with
specific flexible materials, the resulting Digital Material can be tougher than the
individual material components from which it is comprised.
Objet Material Range Increase over Time
With Over 100 Materials by 2012
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Objet ABS-like Digital Material is an example of
such, combining the toughness of one material
with the temperature resistance of a second
material to provide a hybrid that can simulate ABS-grade engineering plastics. Using this advanced
material, designers, engineers and manufacturers
can achieve advanced functional simulation of their
intended end-product without the fear of easy
breakage.
Examples include a foldable stool able to support
over 100kg in weight, functioning clips and closers
that can be repeatedly flexed and stressed,
functional wrenches and even functional bike partsthat can be taken directly from the 3D printer to
the bicycles in the field!
Full Size 3D Printed Stool in
Objet ABS-like Digital Material
able to support 100kg
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4. Segregate Different Materials within One Consistent ModelWe previously mentioned the concept of creating a new material by combining
two materials in the Objet jetting process. With this you can, of course, produce a
uniform part made of one consistent
color or rigidness.
We can now move on to the next unique
ability of Objet multi-material jetting
technology segregating these different
materials and Digital Materials within a
single 3D-printed object.
Thanks to the different nozzles within the
print-head, Objet Connex 3D printers can
selectively create up to 14 different
Digital Materials based on the two
cartridges in the machine and then
selectively deposit each of these 14 in a
different part of the model with sharp,
defined material boundaries.
This mixed part 3D printing capability eliminates the need to design and print
separate parts using different materials and then assemble them together in a
post-printing process, such as gluing.
Using this capability, it is possible to simulate highly complex shapes, color shade
mixes and unique geometries that combine
different material elements.
5. Segregate Different Material Models
on the Same Print Tray
In order to maximize system yield, the Objet
Connex has the ability to simultaneously
build different material parts on a single tray.
This can improve productivity for companies
requiring high volume prototyping.
Using this feature increases the systems
efficiency, enabling multiple build varieties to
3D Printed Shape in Objet Clear
Transparent Material with Black
Hand Suspended Inside
Razors printed simultaneously in a single run. Each
razor is composed of different materials with
different mechanical properties (rigid and flexible).
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be printed at the same time. This allows designers to then quickly select the most
suitable model.
6. Create Grayscales and Tones
One of the advantages of using more than one model material is the ability to
create grayscales and tones. For example, when using Objet Rigid Black and Rigid
White primary materials it is possible to
combine them in various ratios to create
different grayscales.
Creating grayscales and tones makes it
possible to print marks and signs on a model,
mark desired areas of interest and even addcaptions.
The application uses for this capability are
endless, ranging from artistic designs to
functional simulation of assembled goods that,
in the consumer world, are typically made of
different material parts and then assembled.
7. Simulate Opaque Shades with ClearTransparency
Popular in the medical industry, Objet
Connex line of multi-material 3D printers is
used to create accurate models of body
parts in transparent material with the
internal structures in black, white, blue or
grey shade combinations so that they are
visible beneath the skin. The same process
allows us to freeze objects or writing within a
glass-like casing for the accurate simulation
of consumer goods and electronics.
Within the mechanical engineering world it is
possible to use the opaque within a
transparent model concept to highlight the
internal structure of objects or to simulate
areas of load useful in the design of
weight-bearing parts for automotive,
defense and architectural projects.
3D-printed corset prototype in gray
shades. Courtesy of Neri Oxman.
Shower head 3D printed in Objet Clear
Transparent material with internal Objet
Black Rubber-like Digital Material (Shore
40). Courtesy of Ideal Standard CG
Germany.
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8. More Efficient Short Series Injection Molding
Injection molds are usually constructed from specialty steel tools and are expected
to withstand hundreds of thousands, or even millions of molding cycles. As such,
molds are very expensive and the costs associated with mold construction
increase significantly with part complexity.
Tool construction is a long process that may take
months. After the tool is ready, it is tested and
usually additional correction is required. In some
case, before going into tool steel molds, a pre-
production aluminum tool is constructed for
validation purposes. Although this may take less timeas compared to the production of steel tools, it may
still take several weeks.
3D printing the tool in Objet ABS-like Digital Material
and using this for the injection molding of the
intended plastic has several advantages including:
Real prototype in hand early on in thedesign process
More economical small series production Fast mold validation - reduced time to
final mold
Reduced time-to-market for final part and reduced overall costs9. Combine Rigid Material with Rubber-like Over-Molding
Objet Connex 3D printers simultaneously print parts with different mechanical
properties. This capability enables the user to test 3D printed prototypes that are
very close to the production part in terms of mechanical properties and material
combinations, e.g., over-molding and double injection.
Prototyping in this way aids in the selection of the materials that will be used in
the final product. This process saves days of simulating and preparing complex and
expensive molds for double injection. It also eliminates the need for silicon molds
and preparation of different end-product materials for testing; most of the testing
can be performed early on with prototypes printed overnight on the Objet Connex
system.
Objet ABS-like Digital Material
being used as a fast, economical
short series injection mold
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This capability improves the communication between different groups and
decision makers in the company, such as R&D, internal/external customers,
engineering, marketing, sales and management.
The ability to combine rigid and flexible
rubber-like materials is a real necessity
for applications that have a rigid body
with areas of flexible material for grips
and protection of the mechanism, and
thus require a double-injection
production process.
This pressing need exists in most of the
current products in consumer goods andelectronics, automotive, shoe and
medical industries.
A cellular phone with a rigid body,
rubber-like keys and over-molded parts is
one example of such an application.
Other examples are a car wheel printed
complete with its rubber-like tire or a shoe
sole with over-molded, rubber-like treads.
10.Combine High Temperature Material with Rubber-like Material
Combing Objet High Temperature material with Rubber-like materials enables the
formulation of high-temperature parts with over-molding. Automotive air-
ventilation systems, for example, can now be printed in Objet High Temperature
material with Rubber-like over-molded edges to produce an air-tight fit for moving
opening/closing paddles.
When combined to produce Digital Materials, the High Temperature/Rubber-likecombination produces composites with both durability and temperature
resistance suitable for a range of applications such as medical devices, surgery
planning, automotive parts or models used in high humidity environments.
A GPS device with over-molding, 3D-printed
in a single run on the Objet Connex.
Eliminates the need for providing separate
silicon molds and then gluing them
together.
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SummaryObjet material range reaches 123 materials. 90 of these are Digital Materials,
derived by the composite mixing of primary Objet materials. More than ever
before, this expanded material range allows designers, engineers and
manufacturers to simulate very precise material properties that closely resemble
their intended end-product. This development places Objet users at the forefront
of additive manufacturing and rapid prototyping.
Designers can now select from materials ranging from rigid to rubber-like
substances in terms of texture; standard to ABS-grade engineering plastic in terms
of toughness; and transparent to opaque in terms of clarity and shades.
The Objet Connex multi-material 3D
printer allows users to combine up to 14of these materials at the same time
within a single consistent model.
Using the Objet Connex enables the 3D
printing of prototypes that are very close
to the production part in terms of
mechanical properties and material
combinations, e.g., over-molding.
Objet Connex technology also enables
designers to simultaneously print different
material versions of the same part;
completely different material parts
together on the same tray; or short-run
injection molds. All of this results in very
significant time savings and reduces the
overall product development cost.
As Stratasys continues to exponentially
grow the Objet line of material range, these
new prototyping possibilities will serve to
further improve the product development process for virtually every industry
segment in every stage of prototyping, from initial form concept; to fit testing; to
final functional verification.
Objet Connex350 with multi-material 3D
printed model ready for removal from thebuild tray.
Variety of multi-material 3D printed models
printed at the same time on the same Objet
Connex build tray.
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About the Objet Connex Multi-Material
3D Printing SystemThe Objet Connex range of multi-material 3D Printers includes the Objet1000 with a build volume
of 1000 x 800 x 500 mm (39.331.419.6 inches) Objet Connex500 with a build volume of 500 x
400 x 200 mm (19.7 x 15.7 x 7.9 inches),
the Objet Connex350 with a build
volume of 350 x 350 x 200 mm (13.8 x
13.8 x 7.9 inches) and the Objet260
Connex with a build volume of 260 x
260 x 200mm (10.02 x 10.02 x 7.9 inches)The Objet Connex range of 3D printers
offers three printing modes:
Digital Material (DM) printing mode
operates at 12 mm per hour in 30 micron-
layers, providing the ability to print parts
made of multiple model materials
including Digital Materials.
High Quality (HQ) printing mode builds parts at 12 mm per hour in 16-micron (0.0006 inch) layers.
High Speed (HS) printing mode runs at 20
mm per hour in 30 micron (0.001 inch)-
layers.
Printing 600 x 600 dpi in both the X and Y axes, the Objet Connex enables thin walls down to
0.6mm, fine details in all dimensions, and a smooth surface finish, assuring high quality for every
part.
Highly precise 3D printing, with a maximum tolerance of 0.3mm over large models ensures
repeatability and accuracy.
The Objet Connex line 3D printers support four sealed 3.6kg (7.9 lb.) cartridges of material,
allowing unattended operation for extended periods. The systems enable the loading of 2 different
model material types when using the DM printing mode.
Trademarked company and product names are the property of their respective owners.
www.stratasys.com | www.objet.com |[email protected]
Objet Connex500 Multi-Material 3D Printing System
mailto:[email protected]:[email protected]:[email protected]:[email protected]