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3D Printing in Automotive: Advancing the Industry

3D printing technologies, like 3D printed auto parts, have been used by the automotive industry for years, especially within research and development (R&D). But as 3D printing in automotive continues to advance, this technology offers more and more beneficial use cases within this sector.

Present-day automotive manufacturing operations have expanded beyond R&D and are also using 3D printing to create commercial end-use products. From faster production times to lighter, more durable parts, 3D printing capabilities provide a number of benefits to automotive manufacturers.

3D Printing in Automotive Manufacturing

There is a significant 3D printing presence in automotive manufacturing today, for everything from prototyping to custom interior parts to personalized commercial end-use products. Metal 3D printing in particular has really taken off in automotive. But where 3D printing technologies are really progressing with the automotive industry is in the electric vehicle (EV) sector.

“In the EV sector, weight is much more important and plays a role in the vehicle’s battery life,” explains Neil Glazebrook, Vice President of 3D Solutions at ABCorp. “Industrial 3D printing can easily lightweight vehicle parts, reducing the overall weight of a vehicle.”

This decrease in weight helps EVs perform better, making 3D printed parts the obvious choice for these types of vehicles. But it’s more than just 3D printed parts, an automotive manufacturer can design parts for additive manufacturing. This allows manufacturers to make adjustments in the design process to create a better part when compared to traditional design and manufacturing methods.

“Design for additive has really taken off in the last couple of years. Using additive design principles, manufacturers are lightening the vehicle, which makes it more efficient. And they’re also looking at different stresses in the part. With additive and new design technologies, manufacturers can design for those stresses and create a 3D printed part that performs better and lasts longer than a traditionally manufactured part,” describes Glazebrook.

Additive Manufacturing vs. Traditional Manufacturing in Automotive

Introducing additive technologies into automotive production has led to some changes in the industry’s manufacturing methods. Industrial 3D printing has a faster turnaround time than traditional manufacturing. In the early days of additive technology, this increased speed was the basis for rapid prototyping and resulted in wide-scale adoption of additive manufacturing in R&D.

When manufacturers saw the benefits of additive manufacturing, they started to use this technology to produce end-use parts. In recent years, 3D printed end-use parts have become even more prevalent in automotive manufacturing. Rather than relying on a traditional production line for everything, manufacturers are now introducing more additive manufacturing into their production processes.

“One of the best things about 3D printing is automotive manufacturers can create parts a lot quicker. The faster turnaround time has led to many more 3D printed automotive components in vehicles, which improves the overall performance and efficiency of the vehicles,” says Glazebrook.

When it comes to production, 3D printing can speed up time to market for products, and it can also bring the supply chain closer to manufacturers, particularly original equipment manufacturers (OEMs). The flexibility that 3D printing gives manufacturers allows them to better navigate problems that arise, not only in their own operations, but also on a larger scale. Having easy access to a 3D printer can really minimize unexpected situations, such as supply chain constraints.

“From an OEM and supply chain standpoint, 3D printing has really been a game changer for automotive manufacturing,” explains Glazebrook. “Parts that use to take weeks to make or receive, those can now be printed overnight.”

Implementing additive manufacturing within production processes enables manufacturers to create 3D printed auto parts that are more durable while using less material compared to traditionally manufactured parts. These parts tend to perform better and often take less time to create.

“Not every design can be created with traditional manufacturing,” Glazebrook says, “that’s one reason designing for additive is gaining more traction in the automotive industry. However, additive and subtractive manufacturing can work well together to create an end-use part. Overall, though, when it comes to additive vs. traditional, additive manufacturing significantly improves production speed and time to market, in addition to creating parts up to 50% lighter.”

Automotive Industry Investing in Industrial 3D Printing

As industrial 3D printing becomes more prevalent across multiple industries, automotive manufacturers are seeing the benefits of this technology and starting to invest more into it. These manufacturers are adding multiple 3D printers into their operations and investing more capital and engineering budgets into additive manufacturing. Investing in additive enables automotive manufacturers to create better parts, have more control over their supply chain, and get products to market faster.

“With additive, manufacturers are becoming more efficient in their production operations while also creating better-quality parts,” says Glazebrook. “3D printing creates parts that are lighter, stronger, and more durable, and this technology is going to continue to grow in the automotive industry and beyond.”

If you’re a manufacturer interested in exploring 3D printed auto parts and more solutions, check out ABCorp’s 3D printing division. To explore even more industrial 3D printing, check out RAPID + TCT: North America’s largest additive manufacturing and industrial 3D printing event, taking place at the Los Angeles Convention Center from June 25-27, 2024.

Why Security is Critical in 3D Printing

In this new age of technological advancement, 3D printing has emerged as quite the game-changer across multiple industries, promising unparalleled innovation and customization. But in the midst of this revolutionary potential lies a critical concern within 3D printing security: cybersecurity.

Although the relationship between 3D printing and cybersecurity is not often showcased in the headlines, that doesn’t mean it isn’t of paramount importance. The 3D printing industry on its own has a set of unique challenges that demand the spotlight, one of which revolves around the protection of personally identifiable information (PII). Protecting sensitive and proprietary information, patient PII, and design files is vital wherever 3D printing is a part of the production process, like for instance the medical 3D printing prosthetics industry.

Robust cybersecurity protections are required due to the volume of sensitive data involved when designing custom-made 3D medical prostheses, ranging from medical scans to personalized prosthetic designs. Protecting patient trust and privacy depends on protecting the confidentiality and integrity of this information, which is also required under laws like HIPAA.

No matter how slight, any lapse in security could lead to not only the unauthorized access of proprietary information, patient PII, and exposure of brand and trade secrets, but major financial loss as well as tarnished brands and reputations.

What is PII and Why Do People Want it?

Personally identifiable information (PII) is any data that can, well, personally identify us. PII can take on many forms, ranging from our full names, physical and email addresses, and phone numbers, to our social security numbers, biometric data, and medical records—and everything in between.

PII is, clearly, highly sensitive. Exposure of any kind can lead to identity theft, financial fraud, and privacy breaches. When discussing cybersecurity, protecting PII is of the utmost importance, especially in industries like healthcare and finance where the collection and storage of such information are extensive. Robust security measures, encryption protocols, and strict access controls are just a few PII safeguarding methods that can prevent unauthorized access or disclosure.

When PII is mishandled or compromised, it can lead to severe financial consequences for both individuals and corporations alike. It helps to think of PII as being as valuable as the money in your bank account and wallet. Why? Simply because it really is. According to the 2023 IBM and Ponemon Institute report, the cost of an average data breach is $4.45 million. While regulatory fines and maintaining a company’s reputation make up the majority of these expenses, they can nevertheless mount up when personal information is at risk.

So, why do hackers want our PII? Well, it’s sensitive and expensive.

PII can be exploited for financial gain through identity theft and fraud, giving hackers the ability to impersonate individuals, make unauthorized transactions, or apply for loans and credit cards in their name. PII is as lucrative as gold in underground marketplaces, like the Dark Web, where it can be sold to other cybercriminals or as ransom for other illicit activities, like extortion or blackmail.

Regardless of the motive for why a hacker may seek out PII, acquiring it provides them with a wide range of opportunities for financial gain, identity manipulation, and other malicious activities, making it a nice shiny target for cyberattacks.

Issues of Cybersecurity in 3D Printing

Proprietary Information

One of the main reasons cybersecurity is so paramount in 3D printing revolves around the protection of proprietary information. Proprietary information is data that belongs to a company or individual and is not meant to be released to the public.

It’s no secret that the corporate world is competitive. (Hence the phrase, “dog eat dog world.”) So when companies heavily invest into research and development, they expect to always stay one step ahead of their competition in return. Take Apple and Samsung. The two create similar devices and are always compared to one another during new releases. However, Apple has the funds to invest significant resources into opportunities that will allow them to stay ahead of the technologically innovative curve, leaving Samsung (to be viewed by some as) “less advanced.”

Whether it’s proprietary designs, trade secrets, or intellectual property, this kind of proprietary information is as “top secret” as it gets in the corporate world. Any breach in security could lead to the unauthorized selling of replicated products, IP theft, and intentional defects, resulting in critical financial loss and reputational damage.

PII in Medical Prosthetics & Patient Confidentiality

As we know, 3D printed medical prosthetics are precisely tailored to meet the unique needs of individual patients, which means engineers are relying heavily on the use of patient PII. From detailed scans of patient anatomy to customized digital designs, the sensitive data involved just emphasizes the importance of having robust cybersecurity measures in place.

The consequences of patient PII getting into the wrong hands go far beyond just financial loss, including the expulsion of patient trust, violations of privacy, and potential harm to individuals. Patient confidentiality is not merely a legal obligation but a cornerstone of ethical medical practice, regardless of the advances in technology. Any breach in security not only compromises the integrity of healthcare providers but also undermines the very foundation of patient-doctor relationships.

To prevent unauthorized access to or exposure of sensitive medical data, strong encryption measures, access controls, and frequent audits are important. Adherence to compliance regulations, like HIPAA, is vital since it guarantees the responsible and respectful handling of patient data while alleviating the potential of falling victim to cybersecurity breaches.

Protecting Brand and Trade Secrets

In addition to the issues mentioned above, the security of 3D printing processes is crucial for safeguarding brand reputation and trade secrets. Like we said, companies invest a lot of money in order to stay ahead of their competition, and they want to keep it that way. Without adequate cybersecurity measures, these efforts are left helpless to theft and exploitation, which can jeopardize the company’s market position and competitive leg up.

In fact, a major issue with 3D printing cybersecurity is intellectual property theft, a process where hackers try to reverse engineer items by scanning and replicating them. Files used for 3D printing are digital, so a hacker might duplicate and distribute them, making it impossible to secure the files once they are no longer in the public domain.

Big manufacturers frequently invest millions or even billions of dollars in research and development for a single product; therefore, intellectual property and trade secret theft can seriously harm the business and reputation.

Conclusion

To summarize, cybersecurity in 3D printing is not merely a technical concern but a fundamental aspect of risk management and ethical practice. As 3D printing continues to expand across various industries, prioritizing 3D printing security and cybersecurity measures will remain essential in mitigating risks, protecting sensitive information, and upholding trust and integrity. Whether it’s safeguarding proprietary information, preserving patient confidentiality, or defending the brand and trade secrets, proactive physical and cybersecurity strategies such as those employed by ABCorp 3D are indispensable in ensuring the security of PII in 3D printing.

3D Printing and Robotics: The Future is Now

In recent years, we have witnessed a paradigm shift in the way we think about, create, and produce robotic parts — all thanks to the radical advancements in 3D printing technology. This shift has not only pushed the boundaries of what was once deemed possible, but has started a revolution across industries, promising a world of opportunities to better our lives in ways that were once thought to be unattainable.

The Current State of 3D Printing in Robotics

Before we embark on a journey into the future, let’s take a beat to reflect on the current state of 3D printing within the robotics realm.

There’s no denying that 3D printing has made significant strides in the robotics field (and beyond) these past few years, cultivating a newfound sense of creativity that has led to the creation of intricate, innovative, and fully customized components. It’s also worth mentioning that one of the more notable benefits of 3D printing in robotics has been the ability to improve the production of these complex geometries that would otherwise be challenging, if not impossible, to achieve through more traditional manufacturing methods.

Material World

Looking ahead, the future of 3D printing in robotics is, without a doubt, going to be defined by a significant leap in material innovation and customization. As 3D printing technologies continue to rapidly advance, we can expect a much broader range of materials to become available for robotic fabrication, one of which being soft robotics.

Soft robots, made up of flexible and compliant materials, are quickly finding their way towards more diverse fields, from medical devices to search and rescue missions. 3D printing allows for the fabrication of intricate, soft robotic components that are able to seamlessly blend in with their rigid structure counterparts, allowing robots to navigate more diverse and complicated environments with a special degree of delicacy.

This future shift will allow designers to not only tailor the mechanical properties of their components to fit these more specific applications, but to also “kick the door wide open” to unprecedented levels of performance and efficiency, allowing for innovations like multi-material printing, bio-inspired structures, and AI-driven design optimization.

As one might expect, customization — a trademark of 3D printing — will continue to play an essential role in shaping the new world of robotics. Robots are often positioned in more diverse environments and faced with unique challenges, so customization becomes a lifeline when addressing more highly specific needs. With 3D printing, robotic components can be designed and produced with laser-level precision, taking into account the various intricacies of the projects they are assigned.

This high level of customization has the potential to elevate robotic systems from the basic, more standardized tools to innovative, highly specialized solutions, and is set to unlock new frontiers in the engineering and design worlds.

Medical Field

One of the most captivating promises of 3D printing robotics lies within the realm of medical technology. Imagine a future where 3D printed robotics pave the way towards the creation of customized medical implants, meticulously tailored to suit patients’ unique anatomies and needs. It’s this level of personalization that could mark a significant jump forward in the field of healthcare. After all, 3D printed customized pharmaceuticals are already a part of our reality.

Now traditionally speaking, prosthetics and robotic hands have long faced challenges when attempting to mimic the complexities of the human anatomy, especially when it comes to prosthetic hands, which are often forced to rely on simplified designs.

Now enter 3D printing, a technology that has shattered these limitations, introducing a paradigm shift in the process.

Robot Prosthetics

Engineers now have the capability to harness the precision of 3D printing to recreate hands with individual bones, ligaments, and tendons, bringing a whole new level of detail and functionality that once seemed virtually impossible. With 3D printing, engineers can replicate bone structures and ligaments with ease, creating robotic hands that move with the same fluidity and grace of their biological counterparts.

These 3D printed hands not only look remarkably lifelike but also provide their users with a natural range of motion and sensory feedback, and enhanced sensory feedback — an aspect that is lacking in most prosthetics — as well as the prospect of a future where those with limb differences experience a level of functionality and immersion they previously did not have.

Wearable Robotics

Wearable robotics, otherwise known as an exoskeleton, are a wearable mechanism or suit that is used as a tool during physical rehabilitation. Wearable robotics help patients in relearning skills as they are able to reduce energy consumption and streamline repetitive tasks. Additionally, in many military applications, exoskeletons have proven to be an instrumental tool in helping soldiers carry heavier loads over long distances.

Wearable robotics are made possible by the lightweight and customizable nature of 3D printing, carrying uses that transcend far beyond healthcare, assisting individuals with mobility challenges or enhancing performance in various physical activities. These wearable advances might not only improve the quality of life for their users, but also open up to a world of new possibilities in fields such as sports and rehabilitation.

Conclusion

In conclusion, the future of 3D printing within the robotics world is set to be quite the game-changer (for lack of a better term) sculpting a future that was once confined to the realm of science fiction. The intricate and delicate craftsmanship of 3D printed hands with bones and ligaments, coupled with the soft robotics revolution, showcases the transformative potential of this kind of technology. And as we continue to navigate the uncharted territories of 3D printed robotics, the only certainty we do have is that the future holds a world of innovation.

The Future of 3D Printing

The impacts of 3D printing are nothing short of extraordinary, with innovations spanning across industries and pushing the boundaries of what was once deemed impossible. However, the future of 3D printing has become even brighter. From the intricacies of medical advancements and the preservation of vintage vehicles with rare part replacements to expanding the horizons of construction, 3D printing is set to revolutionize the way we create, build, and design.

Customized Pharmaceuticals

With 3D printed prosthetics continuing to gain traction in the medical field, the possibilities that 3D printing bring to the industry continue to grow more and more remarkably. In fact, 3D printing has already made several large strides in the medical field.

In 2014, a 22-year-old woman in the Netherlands suffering from a chronic bone disorder had part of her skull removed and replaced with a 3D-printed one. In 2015, the antiepileptic drug Spritam became the first 3D-printed medication to be approved by the FDA. In 2020, a woman born with a misshapen ear was able to have a 3D-printed implant made from her very own cells.

In fact, the impressive strides 3D printing has made in the medical field go as far back as 1999, when the Wake Forest Institute for Regenerative Medicine was able to 3D print a bladder, cover it in the patient’s cells, and then implant it. As of 2018, the bladder was still fully functioning.

The remarkable possibilities don’t stop there.

One of the most promising aspects of 3D bioprinting is its potential to revolutionize personalized medicine. Medical professionals predict that there will soon come the day where they are able to create same-day custom medical devices while patients patiently sit in the waiting room, provide customized medications tailored to each patient’s needs, and create far more advanced 3D printed medical implants.

Imagine receiving a perfectly matched organ for transplantation, customized at the cellular level. While experts agree that our technology is not quite there yet, some say that we’re not too far off, potentially seeing the transplanting of complex human organs, such as hearts or lungs, and even cells, within the next 20 to 30 years.

In addition, 3D bioprinting is set to transform drug development by providing more accurate and realistic tissue models for testing. Traditional 2D cell cultures may not be able to capture all of the complexities of human tissues, but bioprinting allows for the creation of far more intricate structures, enhancing the reliability of drug screening and development processes.

This type of innovation could significantly reduce the risk of organ rejection, improve the overall success rates of such procedures, open unforeseen avenues for regenerative medicine, and provide accessible, cost-effective, life-saving, and life-changing medical equipment and medication to those who need it.

Rare Parts Replacement

Among the myriad exciting opportunities that come with 3D printing, rare parts replacement emerges as quite the industry game-changer, where the fusion of 3D printing and rare parts replacement not only preserves automotive heritage but also catalyzes a new era of accessibility and innovation within the world of vintage vehicle restoration.

In a typical situation, getting your hands on rare or discontinued parts for vintage or niche cars has been an intimidating challenge, often requiring extensive searches, costly custom manufacturing, or simply getting lucky by having the right network.

Metal-based 3D printing, coupled with flexible filaments, has the power to completely revolutionize how to approach the scarcity of these rare parts. 3D printing technology uses the exact reproduction of intricate and hard-to-find components with pinpoint accuracy, meaning that automotive enthusiasts and restoration specialists alike will be able to recreate vintage or niche components, ensuring the preservation of classic vehicles and offering a more efficient and sustainable solution to the sourcing of these parts.

Not only will 3D printing improve the automotive world with regard to recreating vintage or niche vehicles, but if parts (rare or not) are able to be produced swiftly, the same can be said for larger car parts. It’s not too far-fetched to say that we could be mass-producing fully customized 3D printed cars before we know it.

Building Dreams

Beyond the niche automotive community and medical field, 3D printing has already made strides in the construction industry. In 2021, Habitat for Humanity provided their first 3D-printed home to a family in Virginia. The 1,200-square-foot home took only 12 hours to build, saving upwards of a month of construction time for a traditionally built home.

The potential impact 3D printing can have on the housing crisis is quite profound. Traditional construction methods often struggle to keep up with the ever-increasing demand for affordable homes, leading to prices skyrocketing exponentially and a lack of housing availability. In fact, approximately 582,000 people are currently experiencing homelessness in the United States.

3D printing introduces a game-changing alternative, capable of rapidly constructing cost-effective and structurally sound houses, and for the construction of these houses in unconventional locations or challenging terrains, ultimately opening up new possibilities for urban planning and, in turn, reducing the number of communities in areas deemed unsuitable for traditional construction.

The impact on the housing crisis could be revolutionary, offering a glimpse of a world where everyone has a place to call home, built with precision, speed, and a touch of technological artistry.

Conclusion

In conclusion, the future of 3D printing holds immense promise, ushering in a new era of innovation and transformative possibilities across diverse industries. As we stand at the intersection of technology and progress, 3D printing is not just a tool but a catalyst for change, transforming the way we approach medicine, the preservation of automotive history, and construction. The journey into this bright future is marked by endless possibilities, where customization, efficiency, and creativity converge to shape a world where the unimaginable becomes reality.

All About 3D Printing Finishes

When it comes to successful 3D printed parts and prototypes, it all comes down to 3D printing finishes.

When it comes to 3D printing, the technology itself is undeniably impressive. It allows us to transform digital designs into tangible objects with the highest levels of precision.

At ABCorp 3D, we provide the latest generation of HP Multi Jet Fusion (MJF) 3D printing technology to create simple prototypes and complex multi-color 3D objects while continuing to serve a multitude of industries. Whether it’s aerospace, automotive, or prosthetics, no other company has more experience than ABCorp 3D.

In addition to utilizing cutting-edge MJF technology, ABCorp 3D has the core understanding that a product is not complete without proper finishing. A quality finish on a newly printed 3D product can provide it with the following:

Enhanced durability, malleability, and load characteristics;
Functional improvements, such as those to reduce friction, improve grip, be resistant against water, heat, corrosion, etc.;
Customization to fit a specific aesthetic, cosmetic quality, or brand; and
Antimicrobial properties to seal the parts against bacteria, and more.

Whether it’s for aesthetic, durability, or hygienic purposes, the right finish can elevate a product from a prototype to a polished, functional, and aesthetically pleasing piece. At ABCorp 3D, we offer a range of finishes that allow our current and prospective clients the opportunity to get more out of their 3D printed product.

Our Selection of Finishes

All of our 3D printing finishes come in standard PA12, TPU, and PA12CB materials.

Standard MJF Finish

ABCorp 3D offers a Standard MJF Finish in a classic HP grey. While the color may be “standard,” it makes an ideal choice for any internal and non-cosmetic parts where aesthetics and color schemes are not a priority.

What’s not-so-standard about this finishing agent is that the powder used in MJF products is significantly more recyclable than other materials. With up to 80% of the powder often being reused, it means that any non-fused powder can be recycled. Not only does this ultimately lower production costs, but when coupled with its accelerated build speed, the Standard MJF finish is cost-effective and great for fast turnarounds, significantly reducing production lead times and, at least in the medical field, allowing for a quicker response to patient needs.

Dyed Black

The color black, whether it be in the form of an empowering pantsuit, a brand new sports car, or cutting-edge 3D printed devices, often lends an air of sophistication, elegance, and sleekness to whatever the medium may be. Our dyed black finish gives our products a more polished and reformed look and provides the products with a much smoother surface than undyed finishes. Regardless of whether or not the point is to impress, black dye is crisp, it’s sharp, it’s classic!

AMT Smoothed

AMT vapor smoothing is a finishing process that applies a chemical vapor finish to a 3D printed product’s surface. The vapor smoothes over any bumps or ridges from the printing process and greatly reduces the surface’s porosity while also lowering its chances of cracking, providing a smoother, more consistent surface as opposed to unfinished products.

Additionally, the AMT vapor smoothing finish is antimicrobial, meaning it kills microorganisms and stops their growth — a great feature when designing medical equipment and prostheses. The vapor completely seals its parts to prevent water absorption, bacteria buildup, and makes it easier to clean. Combined with other additional surface treatments, AMT vapor smoothing finish can be dyed with sharp and vibrant colors, providing the opportunity for a fun aesthetic and distinct look.

AMT Smoothed with Black Dye

AMT vapor smoothing finish with black dye has all of the same properties as the standard AMT finish: improved surface quality, water and airtight surface, and is antimicrobial. The only difference? This finish is combined with black dye, offering creators a sleeker, sharper, and more polished look to their products.

Conclusion

The importance of having a quality finish on a 3D printed product cannot be overstated. Whether it’s a first-draft prototype, a thoroughly developed functional part, or a life-changing prosthetic, a well-chosen finish enhances the appearance, durability, and functionality of the printed product.

It really does come down to that final step of elevating your 3D printed object from a mere concept to a tangible masterpiece, ready to fulfill its intention to be reliable yet stylish.

All About BASF Ultrasint TPU01

I recently had the opportunity to hear how Additive Manufacturing or 3D Printing made a dramatic difference in someone’s life. Through a combination of digital scanning, CAD work, and 3D Printing, this client was able to get the “perfect fit” with his lower limb prosthetic — something he’s wanted for 20 years

It reminded me of the sensitive side of manufacturing and how 3D Printing or Additive Manufacturing can be an asset to traditional manufacturing. As I mentioned in an earlier post, Additive Manufacturing continues to grow and touch on markets segments that are new and labor intensive that can benefit from the digital component of 3D Printing. As printing processes and materials develop, we will see more life changing benefits outside the traditional manufacturing space.

When we look at HP’s Multi Jet Fusion (MJF) process, we see a variety of materials for different applications. And the material that gave this client that “perfect fit” was BASF Ultrasint TPU01.

What is BASF Ultrasint TPU01?

Thermoplastic Polyurethane (TPU) is a very elastic and flexible material. It is durable, strong, and smooth to the touch, and it has high wear resistance, withstanding environments of oils, grease, and solvents. Additionally, TPU has superior resistance to high and low temperatures, making this material a great substitute for hard rubber parts.

Current markets that can benefit from the BASF TPU material are as follows:

Sports
Automotive
Footwear

Electronic cases
Industrial tools/fixtures
Orthotic & Prosthetic (O&P) and other medical applications

Each of these markets require unique material requirements and finishes. The Ultrasint TPU01 along with post processing applications can give the customer a part that is quicker to market with similar characteristics to a traditionally manufactured part.

Post Processing of TPU01

Several post-processing applications are available for the BASF TPU Ultrasint material. ABCorp 3D currently provides dyeing and vapor smoothing. When MJF printed, TPU01 will be grey in color; dyeing the part gives the printed part a black uniform color that has penetrated the part surface.

When Vapor Smoothing is added as a surface treatment, a part that has been printed with the MJF process will change from grey to black and parts that have been dyed will have a part finish with an average surface roughness (Ra) of around 1.18. This effectively seals the part, adding to the surface properties of moisture and airtightness along with improving bacteria protection.

Another popular post process is ceramic coatings: Cerakote and Durakote. Both have solutions for 3D Printed parts.

Latticing with Ultrasint TPU01

The lattice structure is found in nature and mimicked within the structural foam industry. Incorporating lattice design into the HP MJF printing process gives parts an additional level of performance properties. Parts can be printed with different lattice structures incorporated into specific areas of the part, and the result is added flexibility in those areas with what could be called a “customized durometer” applying to different areas of the part.

Latticing of MJF Printed TPU parts has opened up areas in the sports, O&P, and automotive industries.

A recent article in AM Magazine discussed how latticing along with TPU material can be used to better fit a sports helmet to the wearer’s head. The article goes on to note, “Meanwhile, padding made via 3D printing in this way can also be customized to the wearer by designing from a scan of the head. We experienced this with digital-material helmet padding that was made from our personal scan data.”

In the O&P field we are seeing parts that have custom lattice structures that specifically tailor to different parts of the prosthetic, giving a better fit and happier client. Just ask the guy that finally found the best prosthetic fit after 20 years!

“He was very excited about it. Happy to see we finally got him fit going totally plasterless — he has been working to that goal for the last 20 years”.

Who we are, what we do, and how to connect for more information.

ABCorp has been a secure contract manufacture since 1795, creating the first anti-counterfeit currency for the United States. As markets change, we now create and manufacture a good portion of the world’s plastic Credit Cards, Passports and Gift cards. When COVID hit, our punch presses transitioned to face masks and we ventured into Additive Manufacturing to help address the tightening supply chain concerns.

In a sort time ABCorp 3D Inc. has grown to house multiple HP MJF 580 and 5210 series printers in our secure Boston facility. Our current material offerings are Nylon PA-11, PA-12, Polypropylene and flexible TPU. The HP 580 creates colors parts in Nylon PA-12CB material.

If you’re in a position to review your parts for a digital inventory or would like us to print a few parts, please reach out to us. A CAD file with an .stl or 3MF file along with design specifications is enough to start the conversation.

And of course, samples are available upon request.

Vic Little
Business Development
ABCorp-3D

3D Printing = Cost-Effective Manufacturing

3D prototypes are essential for product production and testing, and cost-effective manufacturing is critical for business success. 3D printing is used across many different industries for all sorts of projects including sports, aerospace engineering, architecture, industrial machinery, prosthetics, consumer goods, and many more. These 3D prints can serve many different purposes within their respective industries, and these industries typically need a high volume of manufactured parts in short periods of time made of quality and cost-effective materials. These demands can be met more efficiently through 3D printing rather than traditional manufacturing.

Traditional manufacturing is simply not a cost-effective manufacturing method for many reasons. Just the material costs for tooling changes alone can add up to more than $100,000. Traditional manufacturing has elements to it like mold casting, tooling amortization, tooling changes, and minimum order quantities that are typically used to hide tooling fees. The National Institute of Standards and Technology reported that over $537 billion was tied up in inventory in 2011 and this statistic has only increased since then. Additionally, traditional manufacturing timelines can range anywhere from 3-6 months based on the specific item being produced, type of mold being used, and the number of units needed to fill the order.

3D printing eliminates many of the downsides of traditional manufacturing. One of 3D printing’s biggest benefits is that it allows manufacturers to produce one or multiple prints without charging for each individual part. This cuts out the cost of the tooling step and does away with those minimum order quantities that so often end up stretching the budget.

3D printing also cuts down on operational costs. Most of the “heavy lifting” in the 3D printing process is done autonomously by the machine itself. Traditional manufacturing requires a lot of hands-on attention from people, which inevitably costs money. 3D printing cuts down on the amount of time needed to produce parts, and companies only pay for the percentage of time the machine is operating versus the amount of personpower and time combined.

Another big chunk of savings comes from material costs. Far less material is used to produce parts 3D printed parts than traditional manufacturing. A heavily used printer (40-168 hours per week) uses about 20 kilograms of fresh material a week, not including recycling the unused powder back into the next build, meaing that the 20 kilograms of powder can be reused for up to 10 times after the initial use. Cutting down on costs and consumption.

Another benefit that cannot be overstated is that 3D printing is more eco-conscious than traditional manufacturing techniques. 3D printing cuts down on carbon emissions as well as reduces waste by only printing what is necessary. 3D printing achieves a smaller carbon footprint by cutting down on supply chain and delivery carbon-producing transportation steps. As an example, parts produced by traditional manufacturing create about 14 tons of CO2 emissions whereas the same parts 3D printed clock in at only 0.8 tons of emissions. Shipping products and finished goods via plane accounts for about 10 tons of traditional manufacturing CO2 emissions. 3D printing also operates on lower power systems than the machinery of traditional manufacturing.

At ABCorp we keep all of these costs in mind when we provide services to our customers. There are a few things we continue to do to make sure we can keep satisfying any request that comes our way. Having technology like SolutionIX that automates inspection and the Girbau DY130 to apply consistent color helps streamline the manufacturing process and cut down on mistakes during production. Adding materials like durable Nylon 11 (PA11) that is made from renewable castor beans to our full roster of great materials allows us to offer more to our customers than we could before. Expanding our catalog of materials and expanding our additive manufacturing practices makes it easier for us to assist customers with their manufacturing needs as well as keep the costs of production to a minimum.