“This investment marks a bold commitment to our future and signals our readiness to take the lead in the light industrial market,” said Xavi M. Faneca, CEO of BCN3D. “Our new facility, located in a European technology hotspot, confirms our dedication to producing high-quality 3D printers and provides our team with an environment primed for advanced quality production and continuous innovation.” This investment, backed by established Spanish firms from traditional industrial sectors, reflects confidence in both BCN3D’s innovative technology and the dedicated team driving BCN3D forward.

Celebrating One Year of the Omega I60

This announcement also coincides with the one-year anniversary of the BCN3D Omega I60, which has quickly become the go-to choice for users looking to scale up from one-off models to consistent production parts, as well as for those seeking to add a nimble layer of light industrial 3D printing to their established manufacturing fleets. The Omega I60 minimizes long-term expenses and eliminates the hidden costs often associated with traditional industrial machines, particularly concerning maintenance contracts and the high costs of filaments and consumables.

During its first year, the BCN3D Omega I60 has been widely adopted by companies across key sectors worldwide, especially in the manufacturing and engineering industries. This adoption is focused on applications in tooling and functional prototyping, directly aligning with BCN3D’s go-to-market strategy for the Omega I60. This approach leverages the printer’s unique features—such as its heated chamber for processing technical materials, an advanced materials operation system for humidity control and spool recovery, and a large 60-liter print volume—to meet the specific demands of these applications and industries.

BCN3D highlights the success of clients like Wisconsin Precision Casting and Camper, whose use of the Omega I60 exemplifies the printer’s performance in action. Wisconsin Precision Casting is an investment casting foundry based in the United States that supplies low to medium volume castings to various sectors. They integrated FFF 3D printing technology into their operations in 2019 to complement the traditional lost wax casting process, particularly for low-quantity batches. Machining wax injection dies can take weeks and be cost-prohibitive for small orders. Since adopting 3D printing, they now operate a fleet of nine FFF 3D printers, including the Omega I60, to produce plastic patterns using 3D printing casting filament to create molds around them. The Omega I60 has proven extremely useful thanks to its capacity to print many parts in one go at speeds of up to 150 mm/s, significantly reducing production times.

Camper, a renowned global footwear brand, is likewise benefiting from the Omega I60’s versatility and speed. By complementing their prototyping capabilities with the Omega I60, Camper has accelerated the design and launch process for new collections. With the ability to print in-house prototypes at speeds of up to 150 mm/s with Omega Proto filament, Camper has improved both the quality and lead time of their prototypes, enabling their teams to iterate and refine designs rapidly and effectively.

Recalibrating Offerings to Meet Evolving Industry Needs

BCN3D’s recent recalibration of its product lineup reflects a strategic response to customer feedback and evolving industry trends. The Epsilon Series is now dedicated to clients who need the flexibility to produce technical, one-off models, while the Omega I60 is designed for users transitioning from one-off prototypes to consistent production runs. It also seamlessly integrates into the workflows of established 3D printing labs that are looking for agile solutions within their production fleets.

“Our ambitions have always been bold, but we recognize that a focused approach is essential to deliver outstanding results for our customers,” said Pol Domenech, General Manager of BCN3D. “By concentrating on light industrial additive manufacturing, we can allocate resources where they drive the greatest impact. Supported by our new facility and recent investment, this strategic direction positions BCN3D to meet the evolving needs of the 3D printing market and drive innovation forward.”

Formnext 2024

BCN3D will be exhibiting at Formnext 2024, Europe’s leading additive manufacturing tradeshow, at booth 12.1-B120. The company will showcase its full product lineup, including customer applications and the new Omega Impact ABS material for the Omega I60. Visitors will have the opportunity to request one-on-one demonstrations of the Omega I60 with BCN3D’s applications engineers.

About BCN3D

BCN3D is a leading developer and manufacturer of 3D printing solutions, with an installed base in over 60 countries. Its main clients include Nissan, BMW, NASA, Camper, Louis Vuitton, and the Massachusetts Institute of Technology (MIT).

BCN3D PR Contact: press@bcn3d.com

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Founded in 1909, Vollmer Group has established itself as a global leader in state-of-the-art grinding, erosion, and processing machines for the wood and metal industries. The company is renowned for its commitment to quality, precision, and innovation, serving a diverse range of customers, including sharpening services, saw mills, and tool manufacturers. With over 800 employees worldwide, with around 550 of these at the main headquarters in Biberach (Germany) alone, and a strong focus on research and development, Vollmer continuously strives to maintain its position at the forefront of technological advancements.

At one of its subsidiaries, Vollmer of America, the integration of 3D printing technology has proven to be a game-changer in their operations. Derrick Bailey and Carlos Becerra, Applications Engineers for Rotary Tooling, have spearheaded this transformation, driven by the need for rapid prototyping and the creation of custom tools. “We needed quick, cost-effective solutions to address specific challenges our service engineers faced, such as removing caps from mixing valves and preventing damage to expensive wheels in our smart cabinets,” explains Derrick. Traditional methods, while effective, were either too slow or incurred high costs, prompting Vollmer to explore the capabilities of 3D printing.

The introduction of BCN3D Epsilons has provided Vollmer with significant advantages. “The ability to produce prototypes and fixtures almost instantly has revolutionized our workflow,” says Carlos. The printers’ dual extrusion capability, fully enclosed design, and humidity control were key factors in their selection, ensuring that each print meets the high standards of precision and reliability that Vollmer is known for.

The ability to rapidly iterate and refine prototypes has accelerated Vollmer’s innovation process, allowing them to respond to customer needs with greater agility. “3D printing has fundamentally changed how we approach problem-solving,” Derrick adds. “We can now bring our ideas to life in a matter of days, not weeks. I would highly recommend BCN3D printers to any company looking to enhance their production capabilities and streamline their operations.”

Moreover, 3D printing has enabled Vollmer to solve multiple operational challenges efficiently. For instance, when off-the-shelf tools failed to meet their needs, the team quickly designed and printed custom tools at a fraction of the cost and time compared to traditional outsourcing. This flexibility has also extended to the development of protective solutions for sensitive components, such as custom holders for wheels in smart cabinets, preventing damage and ensuring easy access.

Beyond prototyping and custom tools, Vollmer has also explored the potential of advanced materials like Hotend X and PAHT CF15 in their 3D printing processes. Although still in the testing phase, these materials offer promising results in terms of strength and heat resistance, making them suitable for more demanding applications. “We’ve only just begun to tap into the capabilities of these materials, but we’re already seeing the potential for even more robust and durable parts,” Derrick adds.

Through the strategic implementation of 3D printing, Vollmer of America continues to uphold its tradition of excellence while embracing new technologies that drive efficiency and innovation across its global operations.

The post Precision Grinding and Erosion Leader Vollmer of America Innovates with Specialized, Cost-Effective 3D Printed Tooling appeared first on BCN3D Technologies.

The Active Heated Chamber facilitates the fabrication of engineering polymers by maintaining an ideal temperature for the part throughout the printing process. In this article, it is explained how the heated chamber works and what stability is achieved throughout the entire printing process within the chamber.

The Omega I60 features a heating duct that filters and heats the air in the printing module and can reach up to 70ºC (158 ºF). A heated chamber facilitates the manufacturing of engineering polymers by maintaining an ideal temperature for the printable part throughout the printing process. This temperature control ensures the uniform construction of the part, minimizing the formation of internal stresses. Heating the chamber promotes relaxation and eliminates internal tensions during manufacturing, effectively preventing issues like warping and cracking. All of this ensures the best dimensional accuracy and mechanical durability for the printed part. The BCN3D Omega I60 heated chamber can reach temperatures of up to 70ºC (158 ºF), making it ideal for printing materials such as ASA, PA, ABS and reinforced PA, among others.

Given the wide range of materials, the most effective way to ensure the proper printing of any polymer not included in the BCN3D portfolio or the Open Filament Network is by understanding how the heated chamber works. Therefore, we provide an analysis of the temperature across the print bed and throughout the entire volume that the part can occupy.

Temperature Test

Starting from an ambient temperature of 20ºC, once the Heated Chamber reaches the target temperature of 70ºC, the average temperature of the print plane (Figure 1) is within a margin of 70ºC +/-1ºC, as shown in chart below.

To measure the rest of the print volume, the position of the measurement plane was changed along the Z-axis. As seen in the following chart, the average temperature of the print plane remains constant over six height changes, with a maximum variation of +/-2ºC.

For lower Heated Chamber temperatures and high HotBed temperatures, there may be a temperature deviation on the print bed of +5ºC.

Finally, the airflow generated by the heating system of the Heated Chamber does not exceed 0.5 m/s over the print volume.

Remember that when printing, the recommended print profiles in BCN3D Stratos take into account the influence of the Heated Chamber and the HotBed on the part, so it is always optimal to use them or use them as a base to ensure proper printing with engineering materials.

Conclusions

• At 70ºC, the temperature in the print volume is homogeneous with a variation of +/-1ºC.
• Below the maximum temperature, the HotBed affects the temperature on the print bed by up to +5ºC when the Heated Chamber is set to 50ºC.
• The airflow from the heating duct of the printing module can be considered negligible.
• BCN3D Stratos includes optimized print profiles for the fabrication of parts requiring the Heated Chamber.

The post BCN3D Omega I60: How Does the Active Heated Chamber Work? appeared first on BCN3D Technologies.

The BCN3D Epsilon W50 printer was employed, using commonly used materials in this technology: PLA, PETG, and ABS. The assessment of mechanical strength was carried out through uniaxial tensile tests, considering the diverse parameters. This study has been conducted by testing a total of 495 specimens following the UNE-EN ISO 527-2 Type 1A standard, adhering to the plastic molding or extrusion testing model.

The expectation is that an increase in extrusion temperature, density, and the number of walls will result in printed parts exhibiting enhanced properties. As a consequence, higher print speed and reduced layer height may potentially lead to a decrease in mechanical strength, although the precise extent of their impact remains uncertain.

Main Hypotheses

• Infill Type: The Grid infill is hypothesized to offer superior strength compared to Gyroid and Triangular infills due to its interconnected grid structure.
• Infill Density: Higher infill density is anticipated to contribute to increased mechanical strength, as more material within the part should enhance its ability to withstand stress.
• Layer Height: A lower layer height is presumed to adversely affect mechanical strength due to weaknesses in adhesion between layers.
• Print Speed: Elevated print speed is predicted to result in decreased part quality due to extrusion instability and less effective bonding between layers, potentially weakening mechanical strength.
• Print Temperature: A higher temperature range is expected to improve bonding between layers, thereby enhancing the mechanical strength of the parts. Conversely, lower temperatures might result in cold extrusion with material loss.
• Number of Walls: A higher number of walls is suggested to significantly increase the mechanical strength of printed parts, providing greater structural stability.

[Download Whitepaper – Study of the impact of 3D printing parameters on the mechanical properties of FFF samples.]

Results

In the following section, the charts display various results and conclusions. For detailed analysis and data, please consult the whitepaper.

Effect on Infill Type

Analyzing the obtained data and seeing that, depending on the material, each infill type affects differently, we can conclude that the pattern does not have a significant or relevant effect on the final properties of the pieces. While it is true that both ABS and PETG test specimens with the gyroid infill yield the highest loads, the difference and variability compared to PLA prevent us from asserting that this type of infill is the best in terms of improving mechanical properties. Therefore, the premise from which this test started, expecting a better performance of the grid infill followed by the triangular and lastly the gyroid, is incorrect.

Effect of Infill Density

Analyzing the results obtained, we can conclude that the premise established before the test was correct. In other words, the mechanical properties of the pieces increase in relation to the increase in density. This statement is much clearer in PLA and PETG, while in ABS, it is much less noticeable, to the point of not increasing tensile strength between the 60% infill specimens and those with 80%. This may be due to the type of polymeric structure that each of the materials forms, with PLA and PETG being materials with a crystalline structure, while this ABS formulation has a more amorphous structure. Additionally, we can also conclude that increasing the density of printed ABS parts by more than 60% does not ensure greater mechanical performance.

Effect of Layer Height

As expected, the increase in layer height provides better performance for printed pieces. This is because, as mentioned earlier, there are fewer ‘weaknesses’ throughout the piece. These weaknesses are the joints of each of the printed layers, as the adhesion between layers will never have the same mechanical strength as the material itself.

Effect of Printing Speed

After the analysis of the data, we conclude that just as higher printing speed increases the instability in material extrusion and, therefore, increases the possibility of imperfections in the printed piece, leading to poorer mechanical resistance, there is also a lower limit in this printing speed. That is, it is not true that lower printing speed results in higher mechanical resistance. Each material has an optimal working temperature range for printing. If the working temperature is below this range, the material will be extruded cold, while if the printing temperature is above this range, the material may degrade, crystallizing its polymeric structure and causing incorrect extrusion.

For a better understanding of the following conclusion, a brief explanation of the printing temperature (working temperature) of materials is necessary. As explained previously, the printing speed affects filament extrusion because this speed is the rate at which the filament passes through the heat block. This implies that the temperature of the heat block (printing temperature) must be higher than the melting point temperature of the material, as it has to compensate for the heat transmission deficit to the filament. In other words, and with this, we conclude that the printing temperature at which materials are typically extruded in FFF is much higher than the melting temperature of the material. Therefore, if the printing speed is very low, the material may degrade during extrusion and, therefore, lose properties of the material itself, including mechanical properties.

Printing Temperature 

Taking into account the data obtained and having previously analyzed the printing speed and how various parameters such as density or layer height affect, we deduce that the printing temperature does not significantly help improve mechanical properties or, rather, it is difficult to establish a constant to control the final result of the manufacturing. That is, like with printing speed, the printing temperature affects each material to a different extent and not always in an easily predictable way.

In the case of PLA, it is true that the trend is as expected, but with ABS and PETG, it is not. It is most likely that the polymeric structure of the different materials and the glass transition temperature of each material define this trend line.

Number of Walls

In this test, we have been able to observe how clearly each increase in the number of walls increases the tensile strength of the specimens in each of the materials, just like in tests 2.2 (infill density) and 2.3 (layer height). In the case of PETG, the evolution has been much clearer in each of the increments, but this may be due to the deviations from each of the other tests. It makes sense, and it is as expected, that each increase in the number of walls increases the tensile strength in the same way. That is, each increase in walls causes the maximum force to increase the same value consistently. This can be clearly observed in the test of PETG specimens, where every time a wall is added to the specimens, the maximum force increases by 30%. We are taking PETG as an example because we deduce, after seeing the deviation of the tests, that it has been the one that has suffered the least influence from external agents.

To read all the information in detail, don’t hesitate to download our specialized white paper featuring the impact of 3D printing parameters on the mechanical properties of FFF samples.

[Download Whitepaper – Study of the impact of 3D printing parameters on the mechanical properties of FFF samples.]

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• BCN3D has carved out its VLM business unit into Supernova, an independent company incorporated in the US that begins its own path in the AM industry.
• Supernova aims to unlock production applications by combining high-performance materials, a scalable production platform, and competitive cost per part, based on its patented VLM technology and proprietary high-viscosity materials.
• Supernova begins with significant market traction, with over 500 companies registering in the Technology Adoption Program, as well as key partnerships with prominent customers in the industry like Puma, Saint Gobain, Orbea, Hutchison, or Prodrive.
• Supernova’s focus in the next year will be on materials development targeting industrial applications, as well as the industrialization of the product ecosystem, with the first beta systems to be installed in 2024.

Media pack: Link

January 31st, 2024. – Today, leading 3D printing solutions manufacturer BCN3D, together with the newly formed company Supernova, have jointly announced that during Q4 2023, BCN3D executed a carve-out of its Viscous Lithography Manufacturing (VLM) business unit into Supernova. This new company has been incorporated in the US and will have headquarters in both Austin (Texas, US) and Barcelona (Spain). Supernova is not a subsidiary of BCN3D; instead, the two entities are completely independent, and since the carve-out, there are no further bonds between the two entities.

Supernova’s vision is to elevate products through advanced technologies, based on its breakthrough VLM technology. Supernova unlocks real production applications by providing solutions that combine quality, productivity, and a competitive cost per part.

BCN3D’s purpose is to enable innovators to create the future by making industrial additive manufacturing (AM) accessible. The company focuses on enabling engineers to enhance product design through functional prototyping and to improve factory operations with tooling, jigs, and fixtures.

To be successful, each of those visions will require a distinct business model, company structure, and, most importantly, a laser-focused team. The technologies, customers, applications, and materials all differ significantly. By carving out its VLM business unit into Supernova, BCN3D ensures that each has its own space to flourish in the long term.

Supernova will be led by Roger Antunez as CEO, who previously served as the General Manager of BCN3D since 2019. Joining him as a co-founder is Marta Mico, formerly the VLM Head of Business Development at BCN3D. Additionally, Eric Pallares, the former CTO of BCN3D, will join Supernova as a Distinguished Technologist. Meanwhile, the rest of the team will remain at BCN3D, with Pol Domenech, the Sales Director, stepping up as the new General Manager.

Under the leadership of its CEO Xavi M. Faneca, BCN3D will continue to focus on its core business of extrusion-based technologies. The company aims to expand its leadership in the IDEX segment that the company created in 2016, and grow its industrial offering with products like the BCN3D Omega I60, an all-in-one industrial FFF 3D printer built for the factory floor featuring IDEX technology, an actively heated printing chamber, a massive print volume, and an architecture ready for high speed.

At the core of Supernova there is Viscous Lithography Manufacturing (VLM), a lithography-based AM process that laminates thin layers of high-viscosity resins onto a transparent transfer film prior to photopolymerize the resin into the 3D printed object. The resins can be up to 100 times more viscous than those used in traditional DLP, SLA, or MSLA processes, unlocking an unparalleled range of properties. These properties are closer to thermoplastics than standard thermosets, achieved in an efficient and scalable manner.

With the formulation freedom enabled by high viscosity, Supernova’s materials portfolio benefits from a broader set of available ingredients, achieving superior properties. From a chemical-base standpoint, the process can handle not only acrylates but also silicones, epoxies, or filled materials, among others. To support its long-term materials strategy, Supernova has formed partnerships with major chemical companies in AM. These relationships include a Joint Development Agreement (JDA) with Arkema and other partnerships with Altana, Elkem, Henkel, and Rahn.

VLM technology has garnered significant interest in the market, evidenced by the registration of over 500 companies in the Technology Adoption Program. These companies span various industries, including Automotive, Aerospace, Manufacturing, Consumer Goods, Footwear, Audiology, and Healthcare, among others. Strategic partnerships with customers such as Puma, Saint Gobain, Orbea, Hutchison, and Prodrive have since been driving the materials and technology development in alignment with customer needs. Apart from industrial markets, Supernova will also concentrate on the Defense and Space sectors, aiming to develop industry-specific materials that other existing AM technologies cannot process.

During the next year, Supernova plans to leverage the Technology Adoption Program to develop applications in key vertical markets. This initiative aims to influence both materials development and the industrialization of hardware systems, ultimately forming a production-ready ecosystem. Beta deployments in customer sites are expected during 2024. In line with these goals, the company will be expanding its R&D teams in both materials and product (or hardware and software), as well as its business departments.

About BCN3D
BCN3D is one of the leading developers and manufacturers of 3D printing solutions in the world with an installed base in more than 60 countries. Its main clients include Nissan, BMW, NASA, Camper, Louis Vuitton, and the Massachusetts Institute of Technology (MIT).

About Supernova
Supernova is an innovative AM company offering solutions to produce end-use-parts at scale and cost based on its proprietary Viscous Lithography Manufacturing (VLM) technology. With headquarters in Austin TX and Barcelona, Supernova supports industrial customers like Puma, Saint Gobain, Hutchinson, and Prodrive.

Follow supernova on: Linkedin, Instagram, Twitter and YouTube.

Media contacts
BCN3D: press@bcn3d.com // www.bcn3d.com
Supernova: marta@supernova3d.com // www.supernova3d.com

The post Introducing Supernova: A New Company Born from the Carve-Out of BCN3D’s Viscous Lithography Manufacturing (VLM) Business Unit, Set to Revolutionize AM in Real Production Applications appeared first on BCN3D Technologies.

The upgrade consists of a new float glass that has a magnetic sheet attached to it on which the Flexible Printing Surface, a flexible magnetic PEI sheet, is positioned. The user must remove the current glass, which is made of borosilicate, and replace it with this new one. Once the upgrade kit is installed (in place of the standard glass), the Flexible Printing Surface can be switched out as many times as required. This is a consumable part and will wear down overtime at a rate depending on material, cleaning routine and printing temperature.

The option of choosing a float glass was analyzed in depth and several existing options on the market were studied, with float glass proving to be the best option as shown in the study below.

When developing this product, we had to have in mind 3 key aspects:

• Ensure maximum compatibility with the majority of Epsilon and Sigma D25 users. Those users that have autocalibration will be able to use this flexible printing surface upgrade.
  We are working on a new firmware version that will also make this product compatible with those users with an Epsilon or a Sigma D25 without autocalibration. At this moment, if you are one of these customers and you can’t wait to use it, you will need to remove the flexible surface each time you run a bed calibration.
  If you don’t know whether your printer has autocalibration, you can contact us at sales@bcn3d.com.
• Maintaining flatness is a crucial consideration, as it not only reduces the workload for mesh mapping but it’s also essential for printing modes like duplication and mirror print, where mesh mapping is disabled.
• Ensure the least deviation possible in different bed temperatures, which means less unpredictable movement when heating to different temperatures.

To achieve this, we focused on maintaining compatibility with existing hardware without any modifications. Our process involved experimenting with various base materials to place the flexible printing surface. We specifically assessed the average Z offset across different solutions, representing the average deviation from the center of the build plate.

In this analysis we can see that the float glass option with the magnetic sheet is the one that provides the best Z offset.

• Max ΔZ from 30ºC to 95ºC: Maximum deviation of the center of the surface along the Z axis.
• Stationary ΔZ at 95ºC: Deviation of the center of the surface along the Z axis at 95ºC compared to 30ºC. Less deviation means less unpredictable movement when heating to different temperatures.

After analyzing all the solutions, we determined that float glass is the best option. It ensures a consistently flat print surface and exhibits minimal deviation when exposed to various temperatures.

On our latest Stratos version, the 2.0, users will need to select the option for the flexible printing surface when slicing a print job. In this article from our knowledge base, we explain all the details on how to install and configure it. The new flexible printing surface is available as an upgrade kit, which includes float glass with the magnetic sheet and the flexible surface, or as a consumable, which only includes the flexible surface.

Considerations:

• When performing an XY calibration, users should remove the flexible surface and place the original borosilicate glass to achieve precise and reliable calibration.
• The flexible surface is not compatible with metal filaments due to their significant thermal contraction. Therefore, the original borosilicate glass is essential for optimal performance.

Users interested in the new flexible printing surface can acquire it through their nearest BCN3D distributor by 1st February.

The post Introducing the Epsilon Flexible Printing Surface for Effortless Print Job Removal appeared first on BCN3D Technologies.

Introducing the BCN3D Omega I60: An industrial FFF 3D printer built for the factory floor

In June 2023, we proudly introduced the BCN3D Omega I60, an industrial FFF 3D printer meticulously crafted for optimal performance on the factory floor. Engineered to excel in producing large-scale, robust tooling, jigs, and fixtures, the BCN3D Omega I60 boasts cutting-edge features, including BCN3D’s renowned Independent Dual Extrusion (IDEX) technology. With an expansive print volume of 60L, a heated chamber reaching 70ºC, and a precision-controlled material operations system, this printer sets a new standard for industrial 3D printing. The direct-drive high-speed extruder further enhances its capabilities.

Over the past few weeks, BCN3D, in collaboration with their sales partners, has showcased their latest product, the BCN3D Omega I60, at various trade shows. These include Formnext in Frankfurt with iGo3D partner, Advanced Manufacturing in Barcelona and also in Madrid with their Spanish partner, Sicnova; 3D Print Paris with BCN3D’s sales partner in France, Imprimante3D; and Envitech in Brno with their partner, 3D Wiser.

Unveiling the New Generation of the Epsilon Series

The Epsilon Series proved itself to be the flagship of BCN3D since it arrived on the market in 2020. In January 2023, we introduced the New Generation of the Epsilon Series, which has been fine-tuned with new aesthetics, upgraded electronics, XYZ autocalibration, local network access and much more!

Reducing production times and manufacturing costs at RMC Motorsport

In April, RMC Motorsport, a rally sector leader, harnessed 3D printing to revolutionize internal processes for their N5 category rally cars. Founded by Roberto Méndez, the company sought to increase design capacity and streamline manufacturing. Choosing the BCN3D Epsilon W27 with IDEX technology, they transitioned from prototyping to producing end-use parts. This shift, including air intakes and bulkheads, led to a 40% cost reduction and a remarkable 5-hour turnaround for complex components. Notably, the technology allowed them to create intricate parts, like the air intake for the car’s filter, previously challenging with traditional methods. 3D printing has not only met but exceeded RMC Motorsport’s goals, offering freedom and innovation in their N5 car production.

Revolutionizing ABLE Human Motion’s exoskeletons design workflow, by improving rapid functional validation and prototyping with 3D printing

Last November, ABLE Human Motion, a pioneering medical device start-up in Barcelona, reshaped their exoskeleton design workflow through the transformative integration of 3D printing technology. Central to their mission is the active involvement of end users in the design process, enabling rapid iterations by incorporating valuable patient feedback. Prior to 3D printing adoption, testing proposals consumed a minimum of two weeks when using traditional manufacturing. Now, within a day, at a more affordable cost, 3D printing facilitates agile adjustments, speeding up the resolution of design flaws. This change has not only significantly decreased development costs and time but has also empowered ABLE to affordably prototype solutions, validate design improvements, and iterate production tooling in-house, without depending on external suppliers. Beyond cost efficiency, 3D printing enables the creation of more complex geometries, quick testing of new designs, and versatile problem solving, ultimately embodying a commitment to innovation, efficiency, and improved mobility for all.

To sum up, the above list highlights some of our most significant accomplishments during 2023. The unveiling of the new Epsilon Series, a flagship since 2020, showcased a redefined version boasting enhanced features like XYZ autocalibration and local network access. June saw the introduction of the BCN3D Omega I60, an industrial FFF 3D printer setting a new standard with its Independent Dual Extrusion (IDEX) technology, 60L print volume, and heated chamber. In April, RMC Motorsport harnessed the BCN3D Epsilon W27 to revolutionize rally car manufacturing, achieving a 40% cost reduction. November witnessed ABLE Human Motion’s revolutionary integration of 3D printing, streamlining exoskeleton design with rapid iterations and cost-effective solutions. These accomplishments highlight BCN3D’s commitment to innovation, efficiency, and showing the possibilities of additive manufacturing. As we embark on the new year, the journey continues towards unlocking our full potential.

The post BCN3D Recap 2023: The most important highlights from the year appeared first on BCN3D Technologies.

BCN3D Omega I60 is an industrial FFF 3D printer built for the factory floor designed specifically to produce large-scale, strong tooling, jigs, and fixtures. It has a wide range of  features designed to take your 3D printing experience to new heights. In this blogpost, we invite you to explore the capabilities of BCN3D Omega I60 and delve deep into the potential of Omega Proto, Omega Tooling CF, and Omega Resistant Nylon to discover how these materials specially developed for this industrial machine can boost your projects.  Among all its functionalities, the Omega I60, features an active heated print chamber, a custom motion system designed for precision and speed, and a revolutionary Material Operations System (MOS). The MOS eliminates concerns about filament humidity through active heating and humidity control, allowing for seamless filament switching and minimizing machine downtime. 

The Omega I60 is a reality, available for under 20.000 eur and already shipping. Get in touch directly with us or contact your local BCN3D partner to receive your quotation.

Materials

Now, let’s dive into the materials meticulously crafted to complement the Omega I60:

1. Omega Proto: First in line is Omega Proto, which is the top choice for functional prototyping, producing precise parts with a premium surface finish. Omega Proto stands out for its exceptional versatility, providing remarkable durability, toughness, and chemical resistance. It surpasses PLA in strength, is more user friendly than ABS, and delivers a surface finish superior to PETG. On top of that, Omega Proto offers great layer adhesion, creating stronger bonds between layers than what is achievable with typical prototyping materials.
2. Omega Resistant Nylon: Omega Resistant Nylon is a custom copolymer of PA6 and PPA formulated especially for Omega I60 and designed for the most demanding manufacturing applications. This innovative material boasts exceptional resistance to chemicals, wear, and solvents, making it ideal for challenging environments. With superior heat deflection properties and printability surpassing traditional ABS and nylons, Omega Resistant Nylon sets a new standard for durability and performance in industrial settings. In fact, in terms of mechanical properties, it’s closer to Ultem™ 9085 than it is to standard FFF Nylon-based materials.
3. Omega Tooling CF: Omega Tooling CF is a carbon fiber-reinforced PA6 copolymer filament designed exclusively for use with the Omega I60 printer. This specialized filament boasts remarkable strength, durability, thermal stability, and stiffness, characteristics you’d expect from carbon fiber materials. It excels in high-temperature environments, boasting a high heat deflection temperature (HDT) of 177ºC.

Applications

Now, let’s explore the specific applications where Omega I60 stands out:

1. Jigs and Fixtures: When it comes to manufacturing, precision is a key factor. Omega I60 becomes the perfect ally for creating manufacturing fixtures with ease and speed. Whether low temperature applications like positioning fixtures or high temperature stress applications like welding fixtures, Omega Proto and Omega Tooling CF adjust to every need.

In other words, BCN3D’s Omega I60, combined with its revolutionary materials, marks a significant advancement in industrial 3D printing. It’s not just an industrial printer; it’s a solution that takes your projects to higher levels of precision and efficiency. 

2. Surface Treatment Masking: When we look at Omega I60’s applications, we turn our attention to surface treatment masking. A crucial step in processes like painting, powder coating, and chemical treatment. The Omega I60 shines in this area, providing a perfect solution for customizing masking components. 

Traditional methods of production can be costly, and alternatives like tape can be time-consuming.  For chemical treatments, Omega Resistant Nylon emerges as the ideal choice, boasting incredible resistance to chemicals and solvents. When it comes to high impact surface treatments such as shot blasting and powder coating, Omega Tooling CF takes the stage with its unmatched strength and impact resistance. 

The Omega I60, combined with these advanced materials, streamlines surface treatment masking, offering efficiency and precision like never before.

3. End of Arm Tooling: Transitioning to another critical application, let’s delve into End of Arm Tooling (EOAT) and how the Omega I60 is a game-changer in its design and production. 3D printing opens the door to rapid prototyping and customization of EOAT components, facilitating a swift and cost-effective iteration process. The flexibility provided by 3D printing allows for the creation of intricate geometries and lightweight structures, optimizing overall tooling performance while reducing payload. Traditional machined tooling often faces challenges in achieving such complexity and lightweight attributes. Here, Omega I60 and its advanced materials offer a cost-effective and efficient solution, aligning perfectly with the demands of modern automation.

In conclusion, these are many applications perfectly aligned with the capabilities of the Omega I60. However, considering the varied properties of the three materials launched alongside, and the promise of future materials including ABS, ASA, and ESD filaments, the potential applications are huge.

If you’re eager to learn more about the BCN3D Omega I60 or any of the materials highlighted in this journey, don’t hesitate to reach out to us. Our team of 3D printing experts is ready to guide you through the possibilities and help you harness the full power of BCN3D’s innovative solutions.

Thank you for joining us on this deep dive of the Omega I60, its materials and applications. Stay tuned for more exciting developments from BCN3D. Until next time!

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Transforming ABLE’s Product Development

ABLE Human Motion is a medical device start-up based in Barcelona with the mission of enabling mobility for everyone. They design, develop, and commercialize exoskeleton technology to empower people with disabilities, by providing better mobility and increased independence. They have developed the world’s first lightweight and accessible robotic exoskeleton to allow individuals with mobility impairments walk again in clinical rehabilitation, which comes together with ABLE Care, a cloud-based mobile app for personalized and data-driven therapy.

At ABLE, they believe the best way to design compelling and really useful technology is by involving the final users from the beginning. This implies fast design iterations incorporating our patient’s feedback, and this is where 3D printing excels.  

Before using 3D printing, testing a new proposal for ABLE took a minimum of 2 weeks and cost around 5 times more when relying on traditional manufacturing methods and external suppliers. The process was slow, inflexible, and fixing design flaws was time-consuming. Now, thanks to 3D printing, they can test a new proposal in less than one day at an affordable price. The 3D printer provides flexibility, allowing rapid adjustments to fix design flaws.

Thanks to additive manufacturing technology, ABLE has experienced significant advantages in their product development process. Firstly, they have been able to affordably prototype solutions, validating new design improvements efficiently. Additionally, the printers have enabled the iterative development of production tooling and testing setups, eliminating the need for external manufacturing suppliers.

3D Printing vs Traditional Methods

Comparing 3D printed parts with traditional methods reveals important benefits. The technology has allowed them to manufacture more complex geometries compared to CNC machines. Moreover, they can print parts directly “in situ,” avoiding the long supply process associated with external companies.  

In terms of problem solving, 3D printing has had a great impact on their business. It facilitates quick and efficient testing and validation of new geometries, saving substantial costs on design iterations and reducing the time spent managing prototype manufacturing with external suppliers.  Furthermore, they have been able to leverage 3D printing to design and produce tools that assist in the assembly of exoskeletons and to test components for quality compliance, highlighting its versatility in addressing diverse business challenges. 

Overall, by the end of the year, the savings in development costs and time are substantial compared to traditional prototyping methods. 

3D printing Integration

In conclusion, the integration of 3D printing technology into ABLE Human Motion’s exoskeleton design workflow has not only revolutionized their approach but has also given a sense of optimism and innovation into their mission of enabling mobility for everyone. The adoption of 3D printing stands to the company’s commitment to creating compelling and useful exoskeleton technology by actively involving end users in the project’s inception. 

The ability to swiftly incorporate patient feedback, facilitated by 3D printing, has not only streamlined design iterations but has also created a dynamic environment where the patient’s experience takes center stage. The impact of 3D printing is reflected in the transformation of ABLE’s product development process, which is helping them make things better by quickly and affordably testing and creating prototypes.

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Barcelona (Spain), June 14th, 2023. – Today, leading 3D printing solutions manufacturer BCN3D has introduced the brand new BCN3D Omega I60 at a special event held at its Barcelona headquarters. BCN3D Omega I60 is an all-in-one industrial FFF 3D Printer designed to produce big, strong prototypes and end-use parts, particularly tooling, jigs, and fixtures. The BCN3D Omega I60 features a modernized version of BCN3D’s signature IDEX technology, which doubles productivity by using both toolheads simultaneously. It boasts a massive print volume of 60L and a heated chamber that can reach temperatures up to 70ºC, allowing for the production of large-scale, robust pieces in engineering-grade materials. The printer is equipped with a temperature and humidity-controlled material operations system that prepares filaments for printing. Additionally, it utilizes a 1.75mm direct-drive high-speed extruder capable of speeds up to 300 mm/s, enabling faster production of parts than ever before.

This momentous occasion coincides with BCN3D’s 11-year anniversary, a testament to their unwavering commitment to innovation. Over the course of this remarkable journey, BCN3D has successfully distributed more than 10,000 units worldwide across more than 100 points of sales. Notable success stories include the partnership with automotive powerhouse Nissan and French multinational Saint Gobain, leveraging the power of 3D printing to produce tailored tools, jigs, and fixtures for immense time and cost savings, and Prodrive, which develops 3D printing end-use parts for cross-country cars. During this decade BCN3D’s pioneering spirit also led to the introduction of the revolutionary IDEX technology in 2015 and the groundbreaking VLM™ technology, unveiled just last year.

A glimpse into BCN3D Omega I60’s specifications

BCN3D Omega I60 has been designed from the ground up and features:

• Modernized BCN3D’s signature Independent Dual Extrusion (IDEX) technology: IDEX stands out as the sole extrusion system with the unique capability of printing using two independent heads. Users can double productivity with duplication and mirror modes or produce parts with support without cross-contamination. BCN3D Omega I60 is equipped with a refined IDEX technology, where the X motors remain stationary during the printing process. This design feature minimizes inertia, resulting in accelerated print speeds.

• HAQ-XY Kinematics: This motion architecture is considered one of the best systems for dual 3D printers and CNC machines, as it provides a lightweight, robust and precise approach. BCN3D Omega I60 utilizes an improved version of this kinematic system by placing the pulleys in a more optimal position. As a result, the system experiences a significant reduction in torsional moments along the X axis during the printing process. These torsional moments are highly undesirable as they can have detrimental effects on the system’s performance and potentially lead to undesired deformations in the X axis, thereby directly impacting the quality of the printed parts.

• Extrusion system: BCN3D Omega I60 equips a powerful extrusion system with industry-leading components, including 1.75 mm direct drive Bondtech LGX Pro extruders. This system provides more control and precision. It also includes custom E3D Revo hotends, which offer best-in-class extrusion reliability, as well as an easy-swap nozzle change.

• High speed ready: BCN3D Omega I60 is equipped with built-in accelerometers and 32-bit electronics, together with a custom version of Marlin 2.1. This combination enhances the capabilities of the BCN3D Omega I60, enabling it to efficiently manufacture parts at an impressive speed of 300 mm/s and achieve accelerations of 10 m/s². With this state-of-the-art platform, BCN3D Omega I60 is the only high-speed and IDEX 3D printer on the market, providing users with exceptional productivity.

• Active Heated Chamber: A heated chamber facilitates the manufacturing of engineering polymers by maintaining an ideal temperature for the printable part throughout the printing process. This temperature control ensures the uniform construction of the part, minimizing the formation of internal stresses. By heating the chamber close to the material’s glass transition temperature, it promotes relaxation and eliminates internal tensions during manufacturing, effectively preventing issues like warping and cracking. After completion, the part undergoes a gradual cooling process. All of this ensures the best dimensional accuracy and mechanical durability for the printed part. The BCN3D Omega I60 heated chamber can reach temperatures of up to 70ºC, making it ideal for printing materials such as ASA, PA, ABS and reinforced PA, among others.

• Massive print volume: The printing volume available in the BCN3DOmega I60 is 450 x 300 x 450 mm (17.7 x 11.8 x 17.7 in), offering up to 60 liters. This, combined with the heated chamber, gives BCN3D Omega I60 the ability to produce large technical parts.

• Material Operations System (MOS): This integrated material module offers a complete all-in-one experience. The MOS allows you to control not only the humidity, but also the temperature. It provides two key advantages: the ability to recover compromised material and the ability to preheat your filament before starting a print. This is especially important for engineering materials with higher heat deflection temperatures. Furthermore, the material operating system enables automatic filament loading and unloading. So, if your print job runs out of filament halfway through, the machine will automatically change the filament for you. BCN3D’s Omega I60 MOS can reach up to 70ºC (158 ºF) and provides an RH below 10%.

• XYZ Autocalibration: This technology, that uses piezoelectric sensors, eliminates human dependence and guarantees correct first layer adhesion. It calibrates by measuring multiple points to adjust printing surface height (Z) and (XY) offset between nozzles. For BCN3D Omega I60 with Independent Dual Extrusion System (IDEX), precise XY alignment is crucial. A dedicated calibration zone outside the printing surface is used for toolhead alignment. The toolheads make contact with the machined calibration zone in order to calculate positioning and automatically calibrates offsets to avoid crossovers or shifting layers in duplication mode.

Last but not least, BCN3D Omega I60 is equipped with a vast array of other important features such as a built-in camera, a flexible build plate, an Uninterruptible power supply (UPS), a Filament Runout Sensor (FRS), a barcode sensors for spool and components recognition, a andon light, a 7” capacitive touchscreen, an HEPA and Carbon filter, a Safety Pause function, an emergency stop button and WiFi or Ethernet connectivity functions.

Applications and materials

The portfolio of materials offered for BCN3D Omega I60 has been carefully selected to cater to specific verticals such as tooling, jigs and fixtures, short run production, masking, large prototyping, production line replacements, and end-use parts. The materials include:

• Omega Proto: A custom formulation developed for BCN3D Omega I60 and ideal for prototyping, jigs and fixtures, low load bearing alignment guides, and drill guides. It offers a smooth matte black surface finish and isotropic properties, making it suitable for both basic and functional prototyping.

• Omega Impact ASA: This material excels in UV resistance, making it ideal for outdoor end-use parts. It is highly durable, making it suitable for tooling subjected to repetitive loading.
• Omega Resistant Nylon: Ideal for the factory floor environment, this material is chemical, wear and solvent resistant. It serves as a drop-in replacement for materials like Acetal commonly found across production lines.
• Omega Tooling CF: Specifically formulated for maximum strength, this material is well-suited for producing metal replacement parts, metal forming dies, bend tooling and end-use parts that require exceptional strength.
• Omega Support: A breakaway support material that works with all the aforementioned materials. This allows for easy removal of supports without the need for dissolving, enabling the immediate use of printed parts.

Customers have three pathways to choose from when selecting a filament for their BCN3D Omega I60. The first option is BCN3D Filaments, which encompasses all previously mentioned materials as well as upcoming materials currently in development and scheduled for future release. The second option is the Open Filament Network, where BCN3D collaborates with material manufacturers to create specialized printing profiles. These materials cater to niche applications with materials that offer unique properties like ESD, flame retardant, or food-safe. Lastly, since the BCN3D Omega I60 is an open material platform with no limitations, customers can use custom materials and create their own printing profiles at no additional cost.

The Omega Launchpad Program

To let customers experience BCN3D Omega I60, BCN3D has devised the Omega Launchpad Program, aimed at businesses of all shapes and sizes. By participating in this program, individuals can anticipate being among the first to explore the capabilities of the new BCN3D Omega I60, witnessing its true potential through the creation of tangible, 3D printed parts. Moreover, participants will have the opportunity to collaborate closely with a dedicated Additive Manufacturing applications engineer who will provide personalized assistance in analyzing and developing custom solutions specifically designed for the integration of the BCN3D Omega I60 within their respective organizations. 

The BCN3D Epsilon Series gets an update

Earlier this year, BCN3D unveiled the latest generation of their Epsilon Series, characterized by a sturdier structure, enhanced electronics, and XYZ autocalibration. Additionally, during 2023 BCN3D announced firmware 2.0, equipped with first-layer live adjustment, new calibration routines, and improved duplication and mirror printing capabilities, among others. On the software front, BCN3D elevated the performance of their Stratos software by improving 16 print profiles, resulting in a remarkable 35% increase in printing speed and 25% reduction in material consumption. Additionally, BCN3D extended their support for the Open Filament Network (OFN) by introducing 25 new print profiles. This collaboration with leading material manufacturers ensures that customers gain access to top-tier filament profiles, delivering exceptional print results.

During the recent live streaming event, BCN3D made two major announcements for their Epsilon Series 3D printers. Firstly, a flexible build platform that allows users to remove prints with even greater ease. This innovation will be compatible with all Epsilon and Sigma D25 3D printers. Secondly, BCN3D announced their upcoming release of Stratos 2.0, which is built on the powerful Cura v.5 engine. This upgrade will bring a wealth of new features, an improved user interface, and an overall smoother experience. Starting from September of this year, users will have access to both the flexible build platform and Stratos 2.0, enhancing their 3D printing capabilities.

Pricing and shipping

BCN3D Omega I60 starts at 19.995 € // 21.995 USD (excl. VAT) and the first units will be shipped on September 15th, 2023. From today can be reserved by contacting BCN3D at sales@bcn3d.com or contacting any of the official distribution partners of BCN3D. Customers interested in discovering more about BCN3D Omega I60 can enlist in the Omega Launchpad Program and gain access to individualized online product demos, tailored quotes, or the opportunity to receive customized sample parts.

About BCN3D

BCN3D is one of the leading developers and manufacturers of 3D printing solutions worldwide with clients including Nissan, Saint-Gobain, NASA, Haribo, and Louis Vuitton. It made a name for itself as a pioneer in FFF with its signature IDEX technology and recently released Viscous Lithography Manufacturing™ (VLM™), a brand new additive manufacturing technology that leverages high viscosity resins to unlock manufacturing autonomy.

BCN3D PR Contact: press@bcn3d.com

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