Process improvement in additive manufacturing / 3D printing

3D printers are large investments for any business, so it's important to maximize returns wherever possible.

Use the opportunity to both protect the user and improve your part quality.

protect the user and improve your part quality

TAKE ACTION TODAY TO HELP IMPROVE YOUR ROI

The average price of industrial 3D printers is rising, with new technology, materials and faster processes demanding a higher price point. Additionally, with technology moving so fast – companies are spreading the capital expenditure of their machines over shorter and shorter time frames. It has never been more important to improve your return on investment by improving the quality of the parts printed and extending the life of your printer.

Thermal management

Users of 3D printing will understand all too well the difficulties with finding optimum printing parameters to avoid common problems such as deformation and lack of strength. It is becoming more common knowledge that for most 3D printing processes; to improve the quality of printed parts, one must be the master of temperature distribution across that part. Controlling heat will ultimately give the user control over the material’s phase and therefore the final quality of the print.

Most commonly a user typically has two controllable variables at their disposal to manage this; bed and nozzle temperature. A third parameter that is starting to be included in new printer specifications is chamber air temperature, i.e. active convection. The ability to control the speed and temperature of circulating air which directly impacts the rate of cooling of any print.

BOFA systems actively move air within 3D printers, therefore can be used for active convection. There are two main configurations in which a BOFA system can be used to help aid temperature control within a 3D printer:

Open loop

A configuration in which the BOFA system is pulling air from within the 3D printer, filtering, then pushing into the local environment. This configuration results in a net heat loss from within the 3D printer. This setup can be advantageous when attempting to keep air temperatures lower than otherwise would be found when printing without extraction.

Closed loop

A configuration in which the BOFA system is pulling air from within the 3D printer, filtering, then pushing back into the 3D printer. This configuration results in heat stability or increases within the 3D printer. This setup can be advantageous when attempting to keep air temperatures higher or more stable than otherwise would be found when printing without extraction.

Both configurations can help improve thermal gradients during 3D printing, depending on what is being printed and by which process. With tighter control of thermal gradients, one has better control over quality-related issues such as distortion and strength loss.

Contamination of machinery

Industrial 3D printer prices are increasing and with a higher price point, one can expect a higher-performing printer with better quality and increased productivity. To help reach optimum levels of productivity, one must decrease the downtime of the printer. Two of the biggest contributors to downtime of any printer are unexpected failure of componentry and maintenance. Though BOFA cannot help with all potential causes of downtime, a good extraction system can help reduce maintenance frequency and increase machine durability.

See below processes for how BOFA can help in each:

VAT Polymerisation (VP) & Material Jetting (MJ)

During the VP and MJ printing processes, photopolymers are cured, creating solid 3D structures. Owing to the use of photo-polymers and the curing process itself, gases and vapours are released. These emissions can condense on machinery and optics which could reduce the quality of the photon source, but also reduce the durability of ones machine and force a more demanding maintenance routine. BOFA systems can help remove these unwanted emissions and give significant improvements in quality and productivity.

Fused Filament Fabrication (FFF):

FFF Process typically extrudes filament through a nozzle and onto a heated bed where layer by layer a component is printed. During these prints the process can create debris and particulate emissions. Over time and dependent on material, this by-product can settle around the inside of the 3D printer and onto expensive mechanical componentry. If not cleared, this contamination can cause a disruption in mechanical travel which in turn reduces part accuracy and quality but also can lead to increased levels of wear on the affected components. BOFA Systems can help remove these unwanted by-products and give significant improvements in quality and durability.

Directed Energy Deposition (DED) / Binder Jetting (BJ)

BJ and DED processes both use powdered material to build and rebuild componentry. During these processes there is movement inside the build chamber which can cause powder to settle in unwanted places and ultimately not be used during the build. This powder wastage not only costs the user money, but also can detrimentally impact quality of prints and durability of the components. BOFA Systems can help remove and recover wasted powder which can save money, improve part quality and extend machine life.

Laser Powder Bed Fusion (LPBF)

The LPBF process also uses powdered material to build componentry. During the LPBF process there is movement inside the build chamber which can cause powder to settle in unwanted places and ultimately not be used during the build. Additionally, during the use of lasers on the powder bed a by-product is created known as ‘condensate’ or ‘soot’. Both the powder wastage and condensate can cause particulate to settle and gather on the inside of the build chamber. This not only costs the user money, but also can detrimentally impact quality of prints and durability of the components. BOFA Systems can help remove and recover wasted powder which can save money, improve part quality, and extend machine life.

How can BOFA help you?

Using effective fume extraction and filtration systems can help avoid the risk of costly health and safety litigation for the employer; maintains the reliability of the machine, and protects operators from potentially harmful fumes.

Our team of industry and application experts have developed systems specifically for the additive manufacturing / 3D printing sector.

Regardless of the size of process you are working with, BOFA has the system you need.

contact bofa today