Extrusion 3D printers provide significantly faster build speeds and can print up to three different materials simultaneously for metals, ceramics, and high-temperature plastics (such as PEEK and PPS), with or without fibers. #peep

ExAM 510 multi-material printer. Picture source, all pictures: AIM3D GmbH

Multi-material 3D printer manufacturer AIM3D (Rostock, Germany) has developed a 3D printer for the composite extrusion molding (CEM) process, which combines metal injection molding with additive manufacturing (AM). AIM3D said that ExAM 510 has a larger build area, higher accuracy and faster build speed, and is a multi-material printer for AM, which can print up to three different materials at the same time, including particle-based high Performance plastic processing, such as PEEK and PPS. According to the manufacturer, ExAM 510 plans to prepare for mass production by Formnext 2022.

As the latest member of the Rostock product family, ExAM 510 is a performance-enhanced version of the previous ExAM 255. It can handle up to three materials; this allows the use of two building materials and one support material. According to reports, the extended build platform of 510 x 510 x 400 mm supports a variety of applications. The build area can be heated to 200ºC to reduce stress in components and process high-performance materials. It also has a significantly increased build speed, depending on the material, up to 250 cm³/h (when using a 0.4 mm nozzle).

In addition, the ExAM 510 concept can improve the accuracy of printed components, with the purpose of using AIM3D's patented extruder technology. The company pointed out that the output of this type of extruder is 10 times higher than that of a standard filament extruder. In addition, the use of a linear motor and a stable mineral casting bed enables high-precision operation even at high speeds.

The coolant distribution nozzle of Schaeffler (Herzogenaurach, Germany) is 3D printed using the CEM process and is made of PPS GF 40 Type Fortron 1140L4 injection pellets from Celanese (Dallas, Texas, USA).

The wide range of materials is a particular attraction, especially for composite manufacturers. AIM3D equips the machine with a heat treatment chamber specially designed for high temperature plastics. This allows high temperature plastics (such as PEEK, PEI, PSU, PPS) to be processed directly in pellet form, whether or not filled with fibers. 

Cheap recycling is also an ability. According to the manufacturer, a material can be tested within 1-2 working days and production confirmed within 5-10 working days. AIM3D takes PEEK as an example: if the price of PEEK filament used on a traditional AM machine is about 700 Euro/kg, then ExAM 510 can use PEEK pellets, just like deployed in conventional injection molding. The market price of PEEK pellets is about 50 Euro/kg, which is only 7% of the cost of comparable materials or a cost reduction of 14 times. This opens up a new dimension in cost efficiency, AIM3D concludes.

 ExAM 510 material range

 PETG, PP, PA6, POM, PPS, PEEK, PEI, TPE

PA6 GF30, PA6 GF40, PA6 MF60, PBT GF30, PA12 GF30, PA6 GB, PA6 CF15, PPS GF40, PEEK CF, PEEK Si

 316-L, 17-4PH, 8620, 42CrMo4, 304, 420 W, WcCo, Ti64, Cu99

Al2O3, ZrO2, SiC, Si3N4

Application areas of high-performance polymer materials can be found in the end markets of automotive, medical technology or aerospace, and AIM3D pilot customers. Reinforced plastics such as PA6 GF30, PPS GF 40, PEEK and PEI can be specifically used in applications such as cooling technology, automotive and ESD enclosures. Aluminum and zirconia, silicon carbide and silicon nitride ceramic materials are suitable for chemical process technology, high voltage isolators and thermal stress components. Metals such as stainless steel, copper, tool steel, tungsten and tungsten carbide can also be used in ExAM 510.

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