The Problem: Complex composite parts with hollow interiors are difficult to manufacture. Complex composite structures, with hollow interiors, present unique manufacturing challenges where internal tooling, generally referred to as a cores or mandrel, is required to define the hollow internal features. Any part configuration that traps the mandrel inside the composite part, requires sacrificial tooling* or a more complex, collapsible or inflatable tool. *Sacrificial tooling – tooling that is only used once and must be broken or washed out. Current sacrificial tooling technology uses materials such as eutectic salts, ceramics, cast urethanes and other similar materials. These options present many challenges, including: Difficulty handling due to fragile material properties Require tooling to produce Limit design freedom due to production or removal methods The Solution: 3D Printing (Additive Manufacturing) Stratasys FDM® technology is capable of producing geometries in dissolvable thermoplastic materials. Although these materials were originally developed to serve as support structures to enable printing highly complex geometries, OEMs and tier suppliers in the automotive and aerospace industries have been utilizing their unique dissolving properties for sacrificial mandrels. In an effort to improve their solution and value to the sacrificial tooling market, Stratasys released a new soluble material dubbed ST130™ along with an in-depth [...]

There is a new game-changing thermoplastic material for the Stratasys FDM family called Nylon 12CF. The CF is an abbreviation for carbon filled. In this material, chopped carbon fibers are added to a proven FDM Nylon 12 polymer blend resulting in one of the strongest thermoplastics in the FDM material portfolio. Commercial production of carbon fiber began in the early 1960's, resulting from requirements for lighter weight parts and alternatives to metal. Its low thermal expansion, heat resistance, and chemical stability made it a viable solution for aerospace parts as it offered ten-times the strength of steel at one-quarter of the weight. Over the years, the use of carbon fiber branched out into many other industries. It is extremely popular in performance racing, where it is used to create composites that are light and have exceptional fatigue characteristics. For 3D printing, Nylon 12 CF provides the highest flexural strength and highest stiffness-to-weight ratio of any FDM material currently produced and a tensile strength on par with other high-performance FDM materials. Appropriate uses include strong but lightweight tooling, functional prototypes and end-use parts in aerospace, automotive, recreational and industrial applications. In tooling applications, thermoplastics might have the strength but lack the rigidity that is [...]

3D printing is a powerful technology with the potential to significantly change the practice of medicine. In the field of structural heart disease, this rapidly evolving technology can make a powerful impact. Limitations of two-dimensional imaging and added benefits of 3D printing Current conventional cardiac imaging modalities such as echocardiography (EKG), cardiac computed tomography (CT) or magnetic resonance imaging (MRI) primarily utilize two-dimensional (2D) methods that require significant expertise and experience to interpret. In the field of pediatric or congenital cardiology, complex structural heart disease requires precise anatomical delineation before intervention. Consider a heart no larger than a walnut with multiple levels of abnormal connections. Using standard methods of visualization, whether by echo, CT or MRI, the interpreter essentially “reconstructs” a three-dimensional (3D) image from multiple slices or sweeps through this complex heart. By and large, this method works well for the structurally normal heart or for “simple” lesions (1); however, the challenges of interpretation and potential for errors are compounded for heart lesions of moderate or great complexity (1). Three-dimensional methods of visualization such as 3D echo, volume or surface rendering give the added perception of depth, but they are fundamentally limited by 2D displays on which they are viewed. Thus, complex, [...]

There is a new FDM material from Stratasys called Nylon 6. The Nylon family of polymers is one of the most widely used thermoplastics in manufacturing. Nylon 66 was created in 1935 by DuPont as a synthetic substitute for silk. This synthetic plastic could be stretched into a fiber that increased in strength as it was stretched. Notable uses were toothbrush bristles, women's stockings and parachutes for the U.S. military during WWII. Shortly afterward; engineering resins based on nylon 6, 66 and copolymers were developed. These thermoplastics provided a powerful combination of properties, including: Today Engineering-Grade Nylon resins are used in a broad range of applications that require high tensile strength and durability. Industries encompass; automotive, aerospace, industrial machinery, consumer, and recreational goods. Easy modification makes them practical for this diverse assortment of uses. Specially formulated for FDM printing, Nylon 6 delivers the best combination of strength and toughness among all Stratasys FDM materials. It combines the strength of ULTEM 9085 with the toughness of Nylon 12. With Nylon 6 engineers now have an ideal 3D Printing material to create low volume end-use parts requiring high tensile strength and durability or to produce prototypes that look and respond like the final product. Nylon [...]

Designers at Hong Kong-based toy manufacturer Toy State International found a way to utilize 3D printing in ways that were beneficial and supportive to their business needs. The recently begun to use the Stratasys F370 3D Printer to create drone prototypes. Prior to using an FDM 3D printer, Toy State would outsource their functional prototyping projects, leading to a much lengthier time-to-market for products developed by the company. But with the F370 incorporated into the design and verification process, the team is now empowered to be more responsive to projects in a collaborative environment. This is evident in their recent project to create a drone that is strong and stable enough to withstand wind in mid-air, while light enough to fly with all the electronic components embedded. Watch the full story below. For more information on our full line of Stratasys 3D printers, please click the button below. [button link="https://cimquest-inc.com/products/stratasys-3d-printing-solutions/" color="default" size="" stretch="" type="" shape="" target="_self" title="" gradient_colors="|" gradient_hover_colors="|" accent_color="" accent_hover_color="" bevel_color="" border_width="1px" icon="" icon_divider="yes" icon_position="left" modal="" animation_type="0" animation_direction="down" animation_speed="0.1" animation_offset="" alignment="left" class="" id=""]More Info[/button]