Supernova to Launch Viscous Supplies and 3D Printer at Formnext – 3DPrint.com

Forward of Formnext 2024, Supernova has launched a brand new ecosystem for polymer additive manufacturing (AM), with the introduction of its proprietary Viscogels supplies and the Pulse Manufacturing Platform. The ecosystem is supposed to allow the manufacturing of components that mimic molded plastic properties at scale, a troublesome process with extra conventional stereolithography (SLA) and digital gentle processing (DLP) applied sciences on account of their inherent materials limitations.

Viscogels: Breaking Viscosity Limitations for Molded Plastic Properties

On the coronary heart of Supernova’s new ecosystem are Viscogels, proprietary photopolymers characterised by exceptionally excessive viscosities that usually exceed 1 million centipoise (cP). This viscosity stage—lots of of instances increased than typical 3D printing resins used with SLA and DLP, in addition to inkjet—permits a considerably increased oligomer content material, leading to supplies with enhanced properties for demanding functions. Supernova’s Viscous Lithography Manufacturing (VLM) expertise, particularly designed to harness quite than mitigate excessive viscosities, allows this breakthrough, making Viscogels the cornerstone of the corporate’s new Pulse Manufacturing Platform.

The distinctive composition of Viscogels brings key mechanical benefits to the desk, akin to improved influence resistance, flexibility, flame retardancy, and electrostatic discharge (ESD) safety. This characteristic set positions Viscogels as an interesting alternative for functions like automotive cable grommets and connectors, the place resilience to environmental put on is crucial. Moreover, the supplies permit for increased additive hundreds with out compromising viscosity, increasing their versatility throughout varied industrial functions.

Viscogels are supplied in 4 materials households, every tailor-made to fulfill particular efficiency calls for:

• RC 3500 (Inflexible Composites): Similar to molded POM and PA6-GF20, RC 3500 gives a tensile modulus of 3500 MPa and influence power of 80 J/m, superb for automotive connectors and inside trims. Moreover, flame retardant (FR) and electrostatic discharge (ESD) variants cater to safety-critical environments.
• DU MD1500 and DU MD750 (Ductiles): DU MD1500 combines power with flexibility, attaining a tensile power of 38 MPa and influence resistance of 200 J/m. DU MD750 affords higher flexibility with a decrease modulus (750 MPa), each performing comparably to supplies like ABS and molded PP, suited to client items and customer-facing merchandise.
• RU D70 (Rubbers): With an 8% compression set and a tear power of 44 kN/m, RU D70 rivals conventional elastomers like EPDM and NBR. Its variant RU H60, boasting 48% rebound resilience, is suited to high-durability functions needing fast restoration, broadening utility prospects in fields the place such efficiency is essential.
• SL 50 and SL 70 (Silicones): SL 50 affords a tear power of 20 kN/m and an elongation at break of 550%, matching molded LSR silicone in flexibility and sturdiness. These properties, coupled with an operational temperature vary of -40 to 180°C, make the SL line applicable for under-the-hood automotive seals and gaskets.

Pulse Manufacturing Platform: A Complete Finish-to-Finish Manufacturing Resolution

Designed to print with Viscogels, the Pulse Manufacturing Platform is a whole 3D printing workflow that features a printer, post-processing cell and software program, all meant to allow streamline the fabrication course of:

• Pulse One: Supernova’s VLM 3D printer designed to supply detailed, exact geometries with a 46 µm XY decision and a Z decision vary of fifty–200 µm. Its construct quantity of 350×200×300 mm and throughput of 5 kg/hour make it viable for large-scale manufacturing. Moreover, Pulse One’s dual-material functionality allows the creation of multi-material elements in a single construct, akin to inflexible connectors with built-in elastomeric seals. The printer’s devoted breakaway assist materials additionally simplifies post-processing, decreasing each time and labor.
• Pulse Postprocessing Cell: This automated post-processing unit is claimed to finish as much as 24 builds per day, performing washing, curing, and high quality management with out handbook intervention. The combination of RFID expertise permits full traceability, and superior washing and curing methods guarantee every half reaches optimum mechanical properties.
• Pulse Management Middle: This centralized software program manages the complete manufacturing workflow, from construct preparation and slicing to high quality management. Outfitted with clever algorithms, it detects defects in actual time, adjusts manufacturing parameters as wanted, and information each construct element, supporting stringent regulatory compliance—a requirement in sectors akin to rail and automotive.

BCN3D’s entry into high-viscosity 3D printing already upped the ante for the remainder of the vat photopolymerization house, however dedicating a whole firm to it was a giant indicator of simply how necessary the expertise could be. Since its spinout of BCN3D in the beginning of the yr, Supernova has been quietly placing its complete product bundle collectively, making information solely as soon as to announce an explosive supplies division. The time was properly spent, as the corporate has come out of the gates with a whole ecosystem.

The printer and supplies are sufficient to counsel that the Pulse may make true finish components utilizing Viscogels and VLM expertise. Nevertheless, to really allow excessive throughput manufacturing, Supernova’s automated post-processing system is supposed to take the handbook labor out of post-processing as a lot as attainable. Mixed, the ecosystem is telling clients that that is for true manufacturing of real-world items.

An industry-first characteristic of Supernova’s VLM expertise is its dual-material functionality, enabling producers to include two distinct supplies in a single construct, basically extraordinary with SLA and DLP exterior of analysis settings. This flexibility permits functions that historically require pricey overmolding, akin to creating inflexible connectors with built-in elastomeric seals, to be produced extra cost-effectively with Pulse. By integrating two supplies seamlessly, this technique reduces tooling prices and lead instances in comparison with conventional strategies, providing unprecedented design freedom in polymer additive manufacturing.

Viscogels additionally present vital environmental advantages over standard 3D printing resins, primarily because of the diminished emission of unstable natural compounds (VOCs). The upper oligomer content material in Viscogels not solely enhances mechanical properties but in addition results in fewer VOC emissions, providing a extra sustainable possibility for industrial manufacturing. With its materials properties proof against environmental components, Viscogels are doubtlessly much less poisonous than conventional DLP and SLA processes, which regularly depend on acrylate supplies that degrade and have an effect on the encompassing atmosphere.

Supernova plans to launch the Viscogels and Pulse Manufacturing Platform at Formnext 2024 in Frankfurt, additionally taking early entry inquiries from potential adopters curious about evaluating VLM expertise and its supplies previous to the projected cargo date of Fall 2025.