stratasys 10 reasons

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10 ReasonsWhy Multi-Material 3D Printing is Better for

your Product Design & Development

Stratasys Ltd.


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IntroductionBased on their innovative use of inkjet printing technology, Objet 3D printers are

the only additive layer manufacturing devices in the world able to combinedifferent 3D printing materials within a single 3D printed model.

Objet 3D printing technology is also the first in the world to offer a choice of over

120 different 3D printing materials, ranging in properties from rigid plastic to

rubber-like, opaque to transparent, and standard to engineering-grade ABS

toughness.

When talking about multiple-material 3D printing, we actually refer to a number

of different capabilities which we will aim to categorize and clarify in this white

paper. We will also outline the uses and advantages of this unique 3D printing

technology for companies using rapid prototyping during the design and

development of manufactured end products.

Dual Material Jetting - The TechnologyObjet Connex 3D printing technology works by jetting two distinct Objet materials.

The technology can work with any mix of rigid and flexible materials, various

transparent and opaque materials, and different color materials.

Each material is funneled to a dedicated liquid system. The liquid system isconnected to the Objet printing block, which contains eight printing heads. Every

head includes 96 nozzles, each measuring 50-microns in diameter. Each material

has two designated printing heads that work in sync.

Objet 3D printing block,

consisting of 8 printing

heads:

- Heads 1 & 2 jet material A

- Heads 3 & 4 jet material B

- Heads 5 - 8 jet the support

material


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A Word about Objet 3D Printing MaterialsObjet range of over 120 3D printing materials is based upon proprietary acrylic-

based photopolymer resins. These materials are jetted as a liquid from sealed

cartridges inserted into the machine. Once a layer of material is deposited on to

the build tray, it is immediately cured by a UV light. The UV light follows the print

head and turns each liquid material layer into a solid. The material is immediately

ready to be built upon with successive layers.

These fully cured models can be handled immediately after printing - a unique

advantage over other rapid prototyping technologies and materials which requirelengthy post-processing treatments.

Loading and unloading the print cartridges is similar to the process of installing

and removing inkjet cartridges from a paper-feed printer.

10 Advantages of Dual Material Jetting

Independent Nozzle Control

Objet 3D printing technology is able to control every nozzle in every print headindependently. This means that preset combinations of model materials can be

jetted from designated nozzles to create new materials, different material parts

within a model, as well as different material models that are being printed at

once. Here are ten benefits of this unique dual-material jetting in more detail:

1. Fabricate Composite Digital Materials

Composite materials have been in use for many years. They are used today in

many industries, including building construction, sports equipment and car and

aircraft manufacturing.

Objet Digital Materials are multi-phase composite materials created by the

Objet Connex 3D printing system. The benefit of Digital Materials is the ability to

produce new, composite materials with attributes that are not available in the

individual constituents.

Based on this multi-material jetting technology, the Connex family of 3D printers is

able to simultaneously print two resin materials to create 90 different types of

Digital Materials. Starting with 17 cartridge-ready materials, Objet Connex users

have the ability to choose from a total of 123 different materials and composite

material combinations.


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Digital Materials have mechanical and physical properties that vary from the

primary, cartridge-based materials. This additional set of materials improves uponthe mechanical properties available from the existing materials - providing new

values of tensile strength, flexural strength and Izod Impact. Rubber-like Digital

Materials enable the precise selection ofnew Shore A values to suit the specific

application purposes of the designer.

Objet Digital Materials are generated on the fly, based on the two cartridge-based

materials that are installed in the system. The selection of the Digital Material is

made by the user through dedicated software that determines the appropriate

jetting parameters. The materials are created automatically during printing,

without the need for additional human input.

2. A Recipe for Future Scalability

90 Digital Materials can be derived from just a small number of primary materials.

Every additional new material introduced therefore opens up tens of new Digital

Material options. With Objet multi-material technology, the potential palate of

Digital Material combinations will continue to expand and grow exponentially.

3. Simulate Plastics with Engineering Properties

When the Objet multi-material process combines specific rigid materials with

specific flexible materials, the resulting Digital Material can be tougher than the

individual material components from which it is comprised.

Objet Material Range Increase over Time

With Over 100 Materials by 2012


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Objet ABS-like Digital Material is an example of

such, combining the toughness of one material

with the temperature resistance of a second

material to provide a hybrid that can simulate ABS-grade engineering plastics. Using this advanced

material, designers, engineers and manufacturers

can achieve advanced functional simulation of their

intended end-product without the fear of easy

breakage.

Examples include a foldable stool able to support

over 100kg in weight, functioning clips and closers

that can be repeatedly flexed and stressed,

functional wrenches and even functional bike partsthat can be taken directly from the 3D printer to

the bicycles in the field!

Full Size 3D Printed Stool in

Objet ABS-like Digital Material

able to support 100kg


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4. Segregate Different Materials within One Consistent ModelWe previously mentioned the concept of creating a new material by combining

two materials in the Objet jetting process. With this you can, of course, produce a

uniform part made of one consistent

color or rigidness.

We can now move on to the next unique

ability of Objet multi-material jetting

technology segregating these different

materials and Digital Materials within a

single 3D-printed object.

Thanks to the different nozzles within the

print-head, Objet Connex 3D printers can

selectively create up to 14 different

Digital Materials based on the two

cartridges in the machine and then

selectively deposit each of these 14 in a

different part of the model with sharp,

defined material boundaries.

This mixed part 3D printing capability eliminates the need to design and print

separate parts using different materials and then assemble them together in a

post-printing process, such as gluing.

Using this capability, it is possible to simulate highly complex shapes, color shade

mixes and unique geometries that combine

different material elements.

5. Segregate Different Material Models

on the Same Print Tray

In order to maximize system yield, the Objet

Connex has the ability to simultaneously

build different material parts on a single tray.

This can improve productivity for companies

requiring high volume prototyping.

Using this feature increases the systems

efficiency, enabling multiple build varieties to

3D Printed Shape in Objet Clear

Transparent Material with Black

Hand Suspended Inside

Razors printed simultaneously in a single run. Each

razor is composed of different materials with

different mechanical properties (rigid and flexible).


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be printed at the same time. This allows designers to then quickly select the most

suitable model.

6. Create Grayscales and Tones

One of the advantages of using more than one model material is the ability to

create grayscales and tones. For example, when using Objet Rigid Black and Rigid

White primary materials it is possible to

combine them in various ratios to create

different grayscales.

Creating grayscales and tones makes it

possible to print marks and signs on a model,

mark desired areas of interest and even addcaptions.

The application uses for this capability are

endless, ranging from artistic designs to

functional simulation of assembled goods that,

in the consumer world, are typically made of

different material parts and then assembled.

7. Simulate Opaque Shades with ClearTransparency

Popular in the medical industry, Objet

Connex line of multi-material 3D printers is

used to create accurate models of body

parts in transparent material with the

internal structures in black, white, blue or

grey shade combinations so that they are

visible beneath the skin. The same process

allows us to freeze objects or writing within a

glass-like casing for the accurate simulation

of consumer goods and electronics.

Within the mechanical engineering world it is

possible to use the opaque within a

transparent model concept to highlight the

internal structure of objects or to simulate

areas of load useful in the design of

weight-bearing parts for automotive,

defense and architectural projects.

3D-printed corset prototype in gray

shades. Courtesy of Neri Oxman.

Shower head 3D printed in Objet Clear

Transparent material with internal Objet

Black Rubber-like Digital Material (Shore

40). Courtesy of Ideal Standard CG

Germany.


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8. More Efficient Short Series Injection Molding

Injection molds are usually constructed from specialty steel tools and are expected

to withstand hundreds of thousands, or even millions of molding cycles. As such,

molds are very expensive and the costs associated with mold construction

increase significantly with part complexity.

Tool construction is a long process that may take

months. After the tool is ready, it is tested and

usually additional correction is required. In some

case, before going into tool steel molds, a pre-

production aluminum tool is constructed for

validation purposes. Although this may take less timeas compared to the production of steel tools, it may

still take several weeks.

3D printing the tool in Objet ABS-like Digital Material

and using this for the injection molding of the

intended plastic has several advantages including:

Real prototype in hand early on in thedesign process

More economical small series production Fast mold validation - reduced time to

final mold

Reduced time-to-market for final part and reduced overall costs9. Combine Rigid Material with Rubber-like Over-Molding

Objet Connex 3D printers simultaneously print parts with different mechanical

properties. This capability enables the user to test 3D printed prototypes that are

very close to the production part in terms of mechanical properties and material

combinations, e.g., over-molding and double injection.

Prototyping in this way aids in the selection of the materials that will be used in

the final product. This process saves days of simulating and preparing complex and

expensive molds for double injection. It also eliminates the need for silicon molds

and preparation of different end-product materials for testing; most of the testing

can be performed early on with prototypes printed overnight on the Objet Connex

system.

Objet ABS-like Digital Material

being used as a fast, economical

short series injection mold


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This capability improves the communication between different groups and

decision makers in the company, such as R&D, internal/external customers,

engineering, marketing, sales and management.

The ability to combine rigid and flexible

rubber-like materials is a real necessity

for applications that have a rigid body

with areas of flexible material for grips

and protection of the mechanism, and

thus require a double-injection

production process.

This pressing need exists in most of the

current products in consumer goods andelectronics, automotive, shoe and

medical industries.

A cellular phone with a rigid body,

rubber-like keys and over-molded parts is

one example of such an application.

Other examples are a car wheel printed

complete with its rubber-like tire or a shoe

sole with over-molded, rubber-like treads.

10.Combine High Temperature Material with Rubber-like Material

Combing Objet High Temperature material with Rubber-like materials enables the

formulation of high-temperature parts with over-molding. Automotive air-

ventilation systems, for example, can now be printed in Objet High Temperature

material with Rubber-like over-molded edges to produce an air-tight fit for moving

opening/closing paddles.

When combined to produce Digital Materials, the High Temperature/Rubber-likecombination produces composites with both durability and temperature

resistance suitable for a range of applications such as medical devices, surgery

planning, automotive parts or models used in high humidity environments.

A GPS device with over-molding, 3D-printed

in a single run on the Objet Connex.

Eliminates the need for providing separate

silicon molds and then gluing them

together.


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SummaryObjet material range reaches 123 materials. 90 of these are Digital Materials,

derived by the composite mixing of primary Objet materials. More than ever

before, this expanded material range allows designers, engineers and

manufacturers to simulate very precise material properties that closely resemble

their intended end-product. This development places Objet users at the forefront

of additive manufacturing and rapid prototyping.

Designers can now select from materials ranging from rigid to rubber-like

substances in terms of texture; standard to ABS-grade engineering plastic in terms

of toughness; and transparent to opaque in terms of clarity and shades.

The Objet Connex multi-material 3D

printer allows users to combine up to 14of these materials at the same time

within a single consistent model.

Using the Objet Connex enables the 3D

printing of prototypes that are very close

to the production part in terms of

mechanical properties and material

combinations, e.g., over-molding.

Objet Connex technology also enables

designers to simultaneously print different

material versions of the same part;

completely different material parts

together on the same tray; or short-run

injection molds. All of this results in very

significant time savings and reduces the

overall product development cost.

As Stratasys continues to exponentially

grow the Objet line of material range, these

new prototyping possibilities will serve to

further improve the product development process for virtually every industry

segment in every stage of prototyping, from initial form concept; to fit testing; to

final functional verification.

Objet Connex350 with multi-material 3D

printed model ready for removal from thebuild tray.

Variety of multi-material 3D printed models

printed at the same time on the same Objet

Connex build tray.


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About the Objet Connex Multi-Material

3D Printing SystemThe Objet Connex range of multi-material 3D Printers includes the Objet1000 with a build volume

of 1000 x 800 x 500 mm (39.331.419.6 inches) Objet Connex500 with a build volume of 500 x

400 x 200 mm (19.7 x 15.7 x 7.9 inches),

the Objet Connex350 with a build

volume of 350 x 350 x 200 mm (13.8 x

13.8 x 7.9 inches) and the Objet260

Connex with a build volume of 260 x

260 x 200mm (10.02 x 10.02 x 7.9 inches)The Objet Connex range of 3D printers

offers three printing modes:

Digital Material (DM) printing mode

operates at 12 mm per hour in 30 micron-

layers, providing the ability to print parts

made of multiple model materials

including Digital Materials.

High Quality (HQ) printing mode builds parts at 12 mm per hour in 16-micron (0.0006 inch) layers.

High Speed (HS) printing mode runs at 20

mm per hour in 30 micron (0.001 inch)-

layers.

Printing 600 x 600 dpi in both the X and Y axes, the Objet Connex enables thin walls down to

0.6mm, fine details in all dimensions, and a smooth surface finish, assuring high quality for every

part.

Highly precise 3D printing, with a maximum tolerance of 0.3mm over large models ensures

repeatability and accuracy.

The Objet Connex line 3D printers support four sealed 3.6kg (7.9 lb.) cartridges of material,

allowing unattended operation for extended periods. The systems enable the loading of 2 different

model material types when using the DM printing mode.

Trademarked company and product names are the property of their respective owners.

www.stratasys.com | www.objet.com |[email protected]

Objet Connex500 Multi-Material 3D Printing System
mailto:[email protected]:[email protected]:[email protected]:[email protected]

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