A Smarter Way to Make Plastic Parts
One of the major announcements from 3D Systems at the RAPID+TCT event in Detroit was the launch of the Figure 4 135 3D printer, specifically designed for high-mix, low-volume (HMLV) production. This system is intended for manufacturers that need to produce various small batches without relying on expensive molds or long lead times. The Figure 4 135 printer helps solve the problem of traditional injection molding, which can be expensive, slow, and inflexible. According to 3D Systems, this printer delivers high accuracy and repeatability to replace or supplement traditional tooling, significantly reducing costs while maintaining production demands. To illustrate this point, let’s consider an example from the automotive industry. Motor manufacturers need to produce complex components, such as engine parts, at a high level of precision. Traditional injection molding can fail to deliver, resulting in costly rework and wasted materials. The Figure 4 135 printer can help manufacturers overcome these challenges by producing parts with high accuracy and repeatability. This not only reduces costs but also enables manufacturers to respond quickly to changing production demands.
Pellet Printing Gets a Boost
Another major development announced by 3D Systems is an upgrade to its EXT Titan Pellet extrusion printers, specifically the EXT 1070 and EXT 1270 models. This upgrade promises to boost process efficiency by up to 60% for certain applications, such as jigs, fixtures, tooling, and patterns. The new module optimizes the material flow as the part is printed, making it more solid and consistent. This can lead to significant savings in machining time, as much as 50%, according to 3D Systems. The upgrade also features a rapid print-bed scanning system, which allows the printer to scan and generate a numeric map showing any unevenness in the bed in just under a minute. This takes away a lot of the guesswork and leads to fewer failed prints and smoother workflows.
Speeding Up Casting
The third key announcement from 3D Systems is an upgrade to QuickCast, a method used to support investment casting. Casting is a common way to make complex metal parts, especially in aerospace. The traditional method of creating wax patterns for casting often takes a long time and costs a lot. QuickCast helps solve this problem by letting manufacturers 3D print patterns instead. These printed patterns are then used to make ceramic molds, which are filled with molten metal to create the final parts. 3D Systems has been improving this method for decades. The new QuickCast Diamond build style is available for use with its PSLA 270 printer and promises to print master casting patterns faster, with better stability and fewer defects. The updated 3D Sprint software also enables users to create casting trees more easily. These structures group multiple parts together for casting, making it faster and more efficient to produce metal parts.
Innovation and Application-Specific Solutions
In a statement, 3D Systems CEO Jeffrey Graves highlighted the company’s commitment to delivering application-specific solutions that address the rapidly evolving needs of manufacturers. “Innovation is in our DNA,” he said. “Our historic R&D surge in 2024 yielded dozens of polymer and metal products, all driven by a rising demand to address an increasing number of applications using additive manufacturing.”
The goal now is to commercialize these advancements and make them accessible to manufacturers who are looking for smarter, more efficient ways to work. Each of these new releases points to the fact that AM is becoming more focused and valuable, helping the manufacturing ecosystem make better parts faster and cheaper.
“The future of manufacturing is not about the technology itself, but about how it is applied. We are committed to helping our customers solve real-world problems with innovative solutions.” — Jeffrey Graves, CEO of 3D Systems
- High-mix, low-volume (HMLV) production
- High accuracy and repeatability
- Cost reduction
- Increased speed
- Improved flexibility
- Reduced costs
- Increased speed
- Improved flexibility
- Increased accuracy and repeatability
| Application | Traditional Method | Additive Manufacturing |
|---|---|---|
| High-mix, low-volume (HMLV) production | Expensive molds and long lead times | High accuracy and repeatability |
| Casting | Long process times and high costs | Faster production and reduced costs |
As the manufacturing industry continues to evolve, it’s clear that additive manufacturing is becoming an increasingly valuable technology.
These innovations highlight the potential of additive manufacturing to solve real-world problems and drive business success.
In conclusion, 3D Systems’ recent announcements demonstrate the company’s commitment to delivering application-specific solutions that address the evolving needs of manufacturers. The Figure 4 135 printer, EXT Titan Pellet extrusion printer, and QuickCast Diamond build style are just a few examples of how additive manufacturing can be used to solve real-world problems and drive business success. As the manufacturing industry continues to evolve, it’s clear that additive manufacturing will play a major role in shaping its future.
