Quality Digest Bio Quality Insider Cost-Effectiveness in Composite Extrusion Modeling (CEM) with PA6GF30 Polyamid 3D printing material offers high tensile strengths Published: Thursday, July 21, 2022 - 12:01 Comment Rss Send Article (Must Login) Print Author Archive (AIM3D: Rostock, Germany) -- The composite extrusion modeling 3D process shows great potential to be cost-effective compared to alternative 3D printing processes. In cooperation with the University of Rostock, the startup company AIM3D has conducted a series of tests with PA6GF30 (BASF Ultramid B3WG6) material. Test specimens were printed on the AIM3D ExAM 255 and ExAM 510 machines, and the tensile strength of the specimens was compared with alternative processes such as injection molding and conventional 3D printing. Evaluations of the material tests were surprising: Printed PA6GF30 is clearly superior to other 3D printing processes and almost achieves the tensile strength of classic injection molding. 3D printed glass-fiber reinforced polyamide exhibits high tensile strength Today, PA6GF30 is an indispensable material in industrial series production applications, almost ideally combining high mechanical properties with temperature and media resistance. PA6GF30 is thus a fully established material for applications in automotive, special-purpose machine construction, or in equipment technology. PA6GF30 components are highly suitable for replacement applications for metal or aluminum parts wherever operating temperatures allow (PA6GF30: 130°C in continuous use; 150°C for short periods). Regarding mechanical properties—such as tensile strength—very high values were obtained by 3D printing on the AIM3D ExAM 255 and ExAM 510 systems (see graph below). Compared to powder-bed processes or 3D printing processes that use filament materials, the CEM process systems achieve tensile strengths close to classic thermoplastic injection-molded processes.     Material tests and analyses in detail First, tensile bars were printed on an ExAM 255 machine with PA6GF30 and on the larger ExAM 510 (which will be launched at Formnext 2022). The orientation of the 3D printed webs was also varied: 0° for a layup in line with the tensile direction (the orientation of the fibers was also in the tensile direction) and +/- 45° for a pattern with an alternating direction of +/- 45° to the tensile direction. Additionally, the Rostock-based company compared this with data sheet values for injection molding with the original material, as well as with filament use for comparable PA6GF30 filaments. A comparison was also made with a PA12 material used for 3D powder bed printing, as this material is often used as a reference in 3D printing. The graph shows that CEM technology is very close to injection molding but has a significant advantage over filaments. This phenomenon is due, among other things, to the fact that the original granules used from BASF's injection-molding technology actually contain glass fibers as long as 3 mm that can withstand the tensile forces for a longer period. In comparison, the fiber length in the filaments is significantly shorter for technological reasons. Generally, a distinction is made between fiber-reinforced (GF) and fiber-filled (if only short fibers are used). If other characteristics from the data sheet of BASF’s Ultramid B3WG6 material used in the test are also considered, it is clear that the combination of high strength when 3D printing and the high continuous operating temperature of 130°C to 150°C means that this is a universally applicable material. Paired with excellent printability on the CEM systems, versatile applications such as grippers or handling tools can be printed in the future. Today, these components are usually milled from aluminum, which is material-intensive. In contrast to this, 3D printing shows great potential in material costs, conserving resources, component weight, speedy component production and, ultimately, greater energy efficiency. A general approach when printing these components should not be forgotten: The application of bionic design approaches can increase performance of 3D printed components with regard to their mechanical properties. In summary, there are numerous positive aspects in terms of costs (unit costs) as well as the enhanced performance parameters of a 3D printed component. The results of the investigations at the University of Rostock will be part of a scientific publication. Cost advantages gained through functional integration in 3D printing Compared to conventionally manufactured components, the particular appeal of 3D printing lies in the so-called functional integration through 3D printing-compatible design approaches. Functional integration means that assemblies can be manufactured in one printing process—just one of the strategic advantages of 3D printing. AIM3D produced a motor mount-equipped extruder housing made of PA6GF30 as a demonstration of the process. The motor mount, two air ducts routed in the walls, a ventilation outlet, and a mounting for sensors were all integrated into the housing as a single component. In the case of a conventional production strategy with milled aluminum parts, three or four parts would have had to be milled from one block, resulting in a waste of raw materials. In addition, time would be required during the design phase to devise a workaround to avoid the use of special tools (such as slot drills) and to implement a suitable form-fitting connection of the components. The time spent writing CAM milling programs is also eliminated, especially for small batch production. Manual assembly work is significantly reduced, which also has a positive effect on the cost calculation of the parts. Convincing cost efficiencies in CEM PA6GF30 is usually difficult to use for 3D printing. It is difficult to obtain and, where it is available, it costs 20 to 30 times the price of other materials (500 g of Owens Corning XSTRAND PA6GF30 three-dimensional filament costs 86 euros). When processing with filaments, additives must also be used, which can have an unfavorable influence on both price and certification. Original granulates, as used in classic injection-molding applications, form the reference for costs at around 5 euros for 6 kg. The CEM process is unique in enabling the use of commercially available granules without filaments where the material procurement costs are the same as for injection molding but without the tooling costs. However, as a 3D printing process, it is more likely to be found in the small and medium-sized series production segment. In addition, there are advantages in 3D printing in terms of geometric freedom (such as undercuts), bionic designs, or selective densities (different strengths, material savings, selective elasticity, etc.). “Pricing that is comparable to injection molding for raw materials which do not contain filaments is a tremendous advantage for our CEM 3D printing systems technology,“ says Vincent Morrison, CEO of AIM3D. “Using PA6GF30, our ExAM 255 machine is able to produce both complex, delicate parts with fine print resolution as well as large structural components with greater layer thicknesses, resulting in maximum cost-effectiveness with state-of-the-art 3D printing.” PA6GF30 as a substitute for aluminum in 3D printing Of course, a state-of-the-art 3D printing process cannot match the cost-savings of injection molding for medium-sized or large series production runs. Its advantages lie more in the production of smaller batches and bionic design approaches. However, 3D printing has the upper hand in the case of small to medium-sized production runs and rapid prototyping, since here tooling costs form a disproportionate part of price calculations. Above all, CEM process substitution for milled aluminum production solutions has high potential, as Morrison explains: “Aluminum as a material is comparatively expensive because of its energy-intensive production." “Aluminum parts are often milled from a solid block. This puts great pressure on pricing. Added to this are the current shortages of raw materials. PA6GF30 material printed with our CEM technology as an alternative production solution creates completely new dimensions in terms of cost efficiencies. This applies all the more when bionic design approaches come into play to increase component performance.” Examples of 3D printed parts made from PA6GF30. On the right, an extruder housing was produced with functionally integrated 3D printing. Quality Digest does not charge readers for its content. We believe that industry news is important for you to do your job, and Quality Digest supports businesses of all types. However, someone has to pay for this content. And that’s where advertising comes in. Most people consider ads a nuisance, but they do serve a useful function besides allowing media companies to stay afloat. They keep you aware of new products and services relevant to your industry. All ads in Quality Digest apply directly to products and services that most of our readers need. You won’t see automobile or health supplement ads. Our PROMISE: Quality Digest only displays static ads that never overlay or cover up content. They never get in your way. They are there for you to read, or not. So please consider turning off your ad blocker for our site. Thanks, Quality Digest Discuss ( 0 ) Hide Comments Comment About The Author Quality Digest For 40 years Quality Digest has been the go-to source for all things quality. 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(AIM3D: Rostock, Germany) -- The composite extrusion modeling 3D process shows great potential to be cost-effective compared to alternative 3D printing processes. In cooperation with the University of Rostock, the startup company AIM3D has conducted a series of tests with PA6GF30 (BASF Ultramid B3WG6) material. Test specimens were printed on the AIM3D ExAM 255 and ExAM 510 machines, and the tensile strength of the specimens was compared with alternative processes such as injection molding and conventional 3D printing. Evaluations of the material tests were surprising: Printed PA6GF30 is clearly superior to other 3D printing processes and almost achieves the tensile strength of classic injection molding.

Today, PA6GF30 is an indispensable material in industrial series production applications, almost ideally combining high mechanical properties with temperature and media resistance. PA6GF30 is thus a fully established material for applications in automotive, special-purpose machine construction, or in equipment technology. PA6GF30 components are highly suitable for replacement applications for metal or aluminum parts wherever operating temperatures allow (PA6GF30: 130°C in continuous use; 150°C for short periods).

Regarding mechanical properties—such as tensile strength—very high values were obtained by 3D printing on the AIM3D ExAM 255 and ExAM 510 systems (see graph below). Compared to powder-bed processes or 3D printing processes that use filament materials, the CEM process systems achieve tensile strengths close to classic thermoplastic injection-molded processes.

First, tensile bars were printed on an ExAM 255 machine with PA6GF30 and on the larger ExAM 510 (which will be launched at Formnext 2022). The orientation of the 3D printed webs was also varied: 0° for a layup in line with the tensile direction (the orientation of the fibers was also in the tensile direction) and +/- 45° for a pattern with an alternating direction of +/- 45° to the tensile direction.

Additionally, the Rostock-based company compared this with data sheet values for injection molding with the original material, as well as with filament use for comparable PA6GF30 filaments. A comparison was also made with a PA12 material used for 3D powder bed printing, as this material is often used as a reference in 3D printing.

The graph shows that CEM technology is very close to injection molding but has a significant advantage over filaments. This phenomenon is due, among other things, to the fact that the original granules used from BASF's injection-molding technology actually contain glass fibers as long as 3 mm that can withstand the tensile forces for a longer period.

In comparison, the fiber length in the filaments is significantly shorter for technological reasons. Generally, a distinction is made between fiber-reinforced (GF) and fiber-filled (if only short fibers are used). If other characteristics from the data sheet of BASF’s Ultramid B3WG6 material used in the test are also considered, it is clear that the combination of high strength when 3D printing and the high continuous operating temperature of 130°C to 150°C means that this is a universally applicable material. Paired with excellent printability on the CEM systems, versatile applications such as grippers or handling tools can be printed in the future.

Today, these components are usually milled from aluminum, which is material-intensive. In contrast to this, 3D printing shows great potential in material costs, conserving resources, component weight, speedy component production and, ultimately, greater energy efficiency. A general approach when printing these components should not be forgotten: The application of bionic design approaches can increase performance of 3D printed components with regard to their mechanical properties.

In summary, there are numerous positive aspects in terms of costs (unit costs) as well as the enhanced performance parameters of a 3D printed component. The results of the investigations at the University of Rostock will be part of a scientific publication.

Compared to conventionally manufactured components, the particular appeal of 3D printing lies in the so-called functional integration through 3D printing-compatible design approaches. Functional integration means that assemblies can be manufactured in one printing process—just one of the strategic advantages of 3D printing.

AIM3D produced a motor mount-equipped extruder housing made of PA6GF30 as a demonstration of the process. The motor mount, two air ducts routed in the walls, a ventilation outlet, and a mounting for sensors were all integrated into the housing as a single component. In the case of a conventional production strategy with milled aluminum parts, three or four parts would have had to be milled from one block, resulting in a waste of raw materials.

In addition, time would be required during the design phase to devise a workaround to avoid the use of special tools (such as slot drills) and to implement a suitable form-fitting connection of the components. The time spent writing CAM milling programs is also eliminated, especially for small batch production. Manual assembly work is significantly reduced, which also has a positive effect on the cost calculation of the parts.

PA6GF30 is usually difficult to use for 3D printing. It is difficult to obtain and, where it is available, it costs 20 to 30 times the price of other materials (500 g of Owens Corning XSTRAND PA6GF30 three-dimensional filament costs 86 euros).

When processing with filaments, additives must also be used, which can have an unfavorable influence on both price and certification. Original granulates, as used in classic injection-molding applications, form the reference for costs at around 5 euros for 6 kg. The CEM process is unique in enabling the use of commercially available granules without filaments where the material procurement costs are the same as for injection molding but without the tooling costs. However, as a 3D printing process, it is more likely to be found in the small and medium-sized series production segment. In addition, there are advantages in 3D printing in terms of geometric freedom (such as undercuts), bionic designs, or selective densities (different strengths, material savings, selective elasticity, etc.).

“Pricing that is comparable to injection molding for raw materials which do not contain filaments is a tremendous advantage for our CEM 3D printing systems technology,“ says Vincent Morrison, CEO of AIM3D. “Using PA6GF30, our ExAM 255 machine is able to produce both complex, delicate parts with fine print resolution as well as large structural components with greater layer thicknesses, resulting in maximum cost-effectiveness with state-of-the-art 3D printing.”

Of course, a state-of-the-art 3D printing process cannot match the cost-savings of injection molding for medium-sized or large series production runs. Its advantages lie more in the production of smaller batches and bionic design approaches.

However, 3D printing has the upper hand in the case of small to medium-sized production runs and rapid prototyping, since here tooling costs form a disproportionate part of price calculations.

Above all, CEM process substitution for milled aluminum production solutions has high potential, as Morrison explains: “Aluminum as a material is comparatively expensive because of its energy-intensive production."

“Aluminum parts are often milled from a solid block. This puts great pressure on pricing. Added to this are the current shortages of raw materials. PA6GF30 material printed with our CEM technology as an alternative production solution creates completely new dimensions in terms of cost efficiencies. This applies all the more when bionic design approaches come into play to increase component performance.”

Examples of 3D printed parts made from PA6GF30. On the right, an extruder housing was produced with functionally integrated 3D printing.

Quality Digest does not charge readers for its content. We believe that industry news is important for you to do your job, and Quality Digest supports businesses of all types.

However, someone has to pay for this content. And that’s where advertising comes in. Most people consider ads a nuisance, but they do serve a useful function besides allowing media companies to stay afloat. They keep you aware of new products and services relevant to your industry. All ads in Quality Digest apply directly to products and services that most of our readers need. You won’t see automobile or health supplement ads. Our PROMISE: Quality Digest only displays static ads that never overlay or cover up content. They never get in your way. They are there for you to read, or not.

So please consider turning off your ad blocker for our site.

For 40 years Quality Digest has been the go-to source for all things quality. Our newsletter, Quality Digest, shares expert commentary and relevant industry resources to assist our readers in their quest for continuous improvement. Our website includes every column and article from the newsletter since May 2009 as well as back issues of Quality Digest magazine to August 1995. We are committed to promoting a view wherein quality is not a niche, but an integral part of every phase of manufacturing and services.

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