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Innovative techniques and quality control in additive manufacturing and 3D printing
Additive manufacturing provides a fast, cost-effective way to build prototypes, customized products, small batches, and even products with complex designs. 3D printing is the most familiar of all the additive manufacturing methods, and it gives product designers the ability to print parts and assemblies with materials of different mechanical and physical properties using a single manufacturing process. There are several technologies and techniques to help material scientists ensure their products meet specifications.
Twin-screw compounding helps create new polymer printing materials in filament form. Rheometry combined with Raman spectroscopy allows for analysis of both printing material and final product properties. X-ray fluorescence and X-ray diffraction offer an excellent way to examine the quality of powders for metal 3D printing. See expert recommendations on how to enhance printing and product quality in the webinars, videos, articles, and application note resources listed in the sections below.
Additive manufacturing technologies and solutions
Advancements in additive manufacturing
Scientists and manufacturers continue to develop new capabilities in all areas of additive manufacturing. Some of the technologies involved include:
- Twin-screw compounding to create new filaments in polymer 3D printing
- X-ray analysis to determine quality of powders for metal 3D printing
- Rheology with Raman spectroscopy to optimize process parameters in polymer 3D printing
Extrusion and compounding solutions
Small-scale twin-screw extrusion technology is used for the formulation of new polymers at research and pilot scales. Transfer of new formulations from development to manufacturing is streamlined with scalable extruder systems.
The production of precise 3D filaments requires pulsation-free output which is achieved by attaching a melt pump to a twin-screw extruder. The extruder with melt pump combination offers the advantage of producing a stable, extruded product directly from a new compound formulation.
These Thermo Scientific extrusion and compounding solutions help material scientists create new printing materials for polymer 3D printing.
Process 11 Parallel Twin-Screw Extruder
Our lab-scale extruders allow you to conduct numerous trials efficiently and cost effectively, all while conserving precious laboratory space. They are vital for the comprehensive analysis, development, and optimization of polymer materials, helping to ensure that they meet the desired specifications and performance requirements.
Key features:
- Minimized sample material usage: The Thermo Scientific Process 11 Parallel Twin-Screw Extruder requires only 20 grams of material per experiment, optimizing resource use.
- Small footprint bench top design: Its compact design is ideal for fume hood applications and minimizes lab space usage.
- Easy-to-operate touch screen: The extruder features an integrated feeder control and easily removable product contact parts, enhancing user convenience.
HAAKE PolyLab OS Modular Torque Rheometer
The Thermo Scientific HAAKE PolyLab OS Modular Torque Rheometer is an advanced measuring mixer and extruder system that is focused on the specific needs in research and development. The HAAKE PolyLab OS provides you with process-relevant material data including melting behavior, influence of additives, temperature stability, shear stability, and melt viscosity.
Key features:
- Modularity: The system architecture is based on an open industry standard for flexible connection of different sensors and systems.
- Ease of operation: Fast and simple connection of measuring attachments without changing application and operating software.
- Remote controller: Operate the system from a distance and observe the entire test from a different location.
X-ray fluorescence solutions (XRF, EDXRF, WDXRF)
Homogeneity and contamination in metal powders can determine the mechanical quality of the final 3D printed product. X-ray fluorescence (XRF) offers an elemental analysis of powders to help determine quality and chemical purity while X-ray diffraction (XRD) provides structural information. Final product quality can therefore be improved by managing the quality of metal printing materials via XRF and XRD.
Thermo Scientific XRF solutions can help material scientists manage the quality (both structural and elemental) of metal powders to help meet product specifications.
ARL QUANT'X EDXRF Spectrometer
Identify and quantify the elemental composition and concentrations of inorganic additives such as pigments, fillers, flame retardants and stabilizers in the polymer. The Thermo Scientific ARL QUANT'X EDXRF Spectrometer is ideally suited to analyze and quantify various elements down to sub-ppm levels to comply with the different norms.
Key features:
- Exceptional sensitivity for trace analysis: The ARL QUANT'X Spectrometer offers exceptional sensitivity, making it ideal for trace element analysis.
- High measurement throughput: It provides high measurement throughput, which is crucial for process control applications.
- Advanced analytical algorithms: The spectrometer is equipped with advanced analytical algorithms that are suitable for analyzing atypical materials.
ARL X’TRA Companion Benchtop X-ray Diffractometer
Determine the crystalline, microcrystalline or amorphous forms of your polymers. The Thermo Scientific ARL X’TRA Companion Benchtop X-ray Diffractometer provides needed structural information such as the polymorphism, the degree of crystallinity, and the crystallite size of the polymers to ensure their structure-property relationship.
Key features:
- Designed for durability and consistency: Engineered to deliver consistent and reliable performance, ensuring that your analytical needs are met with precision every time.
- One-click analysis—from data collection to results in minutes: From data collection to results, you can get clear and reliable insights quickly and efficiently, making your daily operations smoother and more productive.
- Intuitive interface and educational support: The ARL X’TRA Companion X-ray Diffractometer features an intuitive interface and excellent support, making it an ideal choice for materials research.
Raman imaging solutions
The end product of additive manufacturing – either a part or a complete product – has to be of high enough quality to perform its intended function. One way to ensure final product quality is by determining optimal parameters for the 3D printing process.
Desired parameters can be identified by correlating rheometric measurements of a raw material that’s being printed simultaneously with the crystallization of the solid that is extruded as a result. The rheometric measurement provides information on flow and shear at different temperatures and in different areas of the printer nozzle. That data can be examined along with the characteristics of the printed product – how the material crystallizes, how well the layers coalesce, etc. – to determine the optimal 3D printing process for the desired end product.
These Raman and rheometer systems can help material scientists obtain comprehensive insights into a material’s behavior.
RheoRaman Module for HAAKE MARS Rheometers
Molecular structures can be tracked as a function of stress, strain and temperature with simultaneous rheological measurements and Raman spectroscopy. The Thermo Scientific HAAKE MARS Rheometer combines rheological measurements – to analyze how a substance behaves under stress or strain – with simultaneous Raman spectroscopy – to help explain why it behaves that way by providing information on the sample's micro-structure.
Key features:
- Real-time insight: Obtain real-time insight into molecular changes that drive a shift in rheological behavior.
- Phase transitions and stability: Gain deeper insight into phase transitions, crystallization, and product stability.
- Simultaneous data collection: Collect simultaneous rheological and Raman data on the same sample under identical conditions, saving time and increasing information content.
DXR3xi Raman Imaging Microscope
Rapidly explore the entire sample area and find exactly what you are looking for using our intelligent approach to chemical imaging and data collection. The Thermo Scientific DXR3xi Raman Imaging Microscope, with advanced imaging capabilities coupled with minimal sample prep and intuitive software, gives users the power of Raman at speeds researchers need. With enhanced software features and higher spatial resolution, the user can gain visual information instantly.
Key features:
- High spatial resolution for detailed chemical imaging: The DXR3xi Raman Imaging Microscope offers high spatial resolution, enabling detailed chemical imaging.
- Advanced software for data analysis and visualization: The microscope is equipped with advanced software for data analysis and visualization, enhancing its performance and usability.
- Ease of use with intuitive controls and interface: The DXR3xi Raman Imaging Microscope is designed for ease of use with intuitive controls and interface, accommodating users of all skill levels.
Rheology solutions
Rheology is the study of the flow and deformation behavior of materials, particularly their viscoelastic properties. This understanding is crucial for ensuring that materials exhibit the appropriate viscoelastic properties during the printing process, which affects the quality, consistency, and performance of the final products. Rheology helps in optimizing material formulations, improving process parameters, and ensuring that the materials behave predictably under different processing conditions, leading to better control and efficiency in additive manufacturing.
These rheology solutions can help material scientists obtain comprehensive insights into structural behavior.
HAAKE MiniLab 3 Micro Compounder
Getting new compounds faster and documenting structural changes online has never been easier. The Thermo Scientific HAAKE MiniLab 3 Micro Compounder provides extrusion specifications and online rheology measurements for pilot and scale-up projects across a range of compounded materials. It is a useful instrument to screen the effects of different additives. Only a small amount of sample (7 g) is required. A quick look at the pressure dependence data gives a first indication of the functionality of the additives.
Key features:
- Co- and counter-rotating twin screws: The compounder is equipped with twin screws that can rotate both co- and counter-wise, providing flexibility in processing different materials.
- Integrated viscosity measurement: The system includes integrated viscosity measurement capabilities, allowing for real-time monitoring of structural changes during processing.
- Automatic bypass operation: The compounder features an automatic bypass operation for circulation and extrusion, ensuring efficient and continuous processing.
HAAKE MiniJet Pro Piston Injection Molding System
Eliminate worries of limited material quantities and produce various sample geometries using the Thermo Scientific HAAKE MiniJet Pro Piston Injection Molding System. You can now reduce costs by efficiently preparing specimens from as little as 2 to 5mL of material.
Key features:
- Small sample volume: Test specimens can be produced from various materials, including powders, pellets or melts.
- Interchangeable molds: Specimen geometries offered from standard to unique, customized molds.
- Ease of use: A control and design concept that provides simplistic handling with consistent, reproducible results.
Resources
Additional resources
For Research Use Only. Not for use in diagnostic procedures.