November 20, 2018
3D Print Formnext 2018 Materials Implants

Freeformer 300-3X for Hard/Soft Combinations Using Three Components

Arburg celebrated a world premiere at the Formnext 2018: the new large Freeformer 300-3X processes three components using the Arburg Plastic Freeforming (APF) process, enabling the industrial additive manufacturing of complex functional parts in resilient hard/soft combinations using support structures as a world first. In addition to the new "large machine", two proven Freeformer 200-3X machines were shown, as well as more examples of functional plastic parts than ever seen before. The APF process operates on the basis of qualified standard granulates, which are the same as those used for injection moulding.

"The Freeformer 300-3X marks another major step forward, enabling our customers to develop completely new applications," says Martin Neff, Head of Plastic Freeforming at Arburg. "This open system can produce complex and durable functional parts in hard/soft combinations from qualified standard plastics and a support material, offers more space and higher temperatures in the build chamber and can be automatically integrated into networked production lines."

Industrial-grade machine has 50 percent more space
With the Freeformer 300-3X, the designation 300 stands for the available surface area of the platform in square centimetres. This is just under 50 percent larger than on the Freeformer 200-3X. The build chamber now offers space for larger small-volume batches and parts with dimensions of up to 234 x 134 x 230 millimetres. "3X" stands for the moving axes of the part carrier in the x, y and z directions. The Freeformer 300-3X has three directly heated discharge units. As an option it can be equipped with only two nozzles. Like its injection moulding machines, the machine manufacturer Arburg also manufactures the Freeformers for industrial additive manufacturing centrally at its site at Lossburg in the Northern Black Forest region, offering quality "Made in Germany". The company uses only high quality, durable components: the plasticising unit is equipped with servo motors. The modern operating panel comprises a robust industrial PC with multi-touch screen. The stable machine base accommodates the control cabinets and cooling system. The closed cooling system is also available with an optional industrial-grade cooling water connection. This will allow the processing of high-temperature materials at build chamber temperatures up to 200 degrees Celsius.

Designed for automation and process integration
A two-part build chamber door is a new feature on the Freeformer 300-3X. This means, for example, that the material containers can be refilled during ongoing operation by opening the top half of the door. The heated build chamber now only needs to be opened for inserting the part platform and removing the finished parts. Automatic opening and closing of the build chamber door as well as optional robot interfaces also enable automation of the additive manufacturing process and integration of the Freeformer in complete production lines. Above and beyond the additive manufacture of one-off parts and small-volume batches, high-volume parts can also be enhanced and customer wishes incorporated directly in the added value chain in batches as small as a single unit by combining additive manufacturing, injection moulding and Industry 4.0 technologies.

Wider range of applications
The two Freeformers, 200-3X and 300-3X, cover a wide range of applications for industrial additive manufacturing and produce the required plastic parts in reproducible high part quality. The Freeformers can be connected to an MES, such as the Arburg ALS host computer system, so that they can be used in IT-networked production lines. If necessary, the relevant process and quality parameters can be traced back to the specific part.

The open system is in high demand in the medical technology sector, for example for orthotics, implants and models for surgery preparation. Arburg Plastic Freeforming with the Freeformer is also ideal for low-volume pre-series parts, assembly devices, automation components and other equipment, as well as for functional spare parts and individually manufactured consumer goods.

Open system offers great material freedom
Reproducible additive manufacturing requires the materials used to be qualified in a standardised process. This results in pre-defined process settings. Users can use the open Freeformer system either to process their own original materials or to optimise droplet size and process control for themselves. Alternatively, they can access Arburg's material database of reference materials. The numerous qualified standard granulates documented there include ABS (Terluran GP 35), PA10 (Grilamid TR XE 4010), PC (Makrolon 2805), TPE-U (Elastollan C78 A15) and PP (Braskem CP 393). Further examples are special plastics for specific applications such as medical PLLA (Purasorb PL18, Resomer LR 708) and a PC (Lexan 940) approved for aerospace use. The range of qualified materials is continuously being expanded.

Source: ARBURG GmbH + Co KG