voxeljet AG and Evonik Industries— a multi-billion global leader in specialty chemicals, enter into a technology partnership to develop methods for series production of plastic components using 3D printing

voxeljet AG (NASDAQ: VJET) (the “Company”, or “voxeljet”), a leading OEM and provider of high-speed, large-format 3D printers and on-demand parts services to industrial and commercial customers, today announced a joint research and development partnership with Creavis- the strategic innovation unit of Evonik Industries, to develop methods for series production of plastic components using 3D printing.

Evonik and voxeljet have a long-standing cooperation, particularly in the development of polymer powders for voxeljet’s binder jetting processes. In order to expand the portfolio of materials for 3D printing of plastic parts, the two companies have decided to intensify their cooperation.

“In Evonik, we have found an excellent partner who provides us with customized material systems for our 3D printing technology. This research collaboration is intended to enhance our efforts in the 3D printing of polymers for series production,” says Dr. Ingo Ederer, CEO of voxeljet.

The joint research project combines Evonik’s many years of experience in polymer powders for additive manufacturing technologies with voxeljet’s 20 years of expertise in industrial 3D printing.

“voxeljet is one of the leading manufacturers of large-format, high-speed 3D printers. Together, we aim to develop new powder-binder systems which allow the 3D printing of polymer components with industrial utility”, says Prof. Dr. Stefan Buchholz, Managing Director of Evonik Creavis GmbH.

Evonik will provide insights into their research work on binder jetting developments for additive manufacturing at the formnext show, the international exhibition and conference on the next generation of manufacturing technologies in Frankfurt, Germany Hall 12.1, Booth C71, from November 19 to 22, 2019.

Evonik is one of the world leaders in specialty chemicals. The focus on more specialty businesses, customer-oriented innovative prowess and a trustful and performance-oriented corporate culture form the heart of Evonik’s corporate strategy. They are the lever for profitable growth and a sustained increase in the value of the company. Evonik benefits specifically from its customer proximity and leading market positions. Evonik is active in over 100 countries around the world. In fiscal 2018, the enterprise with more than 32,000 employees generated sales of €13.3 billion and an operating profit (adjusted EBITDA) of €2.15 billion from continuing operations. corporate.evonik.com

Leading companies from the core making, 3d printing and material-science industries join forces in a key alliance to pioneer additive manufacturing in foundry serial-production and are going to show the complete integrated solution at GIFA 2019.

Loramendi, voxeljet and ASK Chemicals have taken a major step to reinvent the manufacturing landscape by developing the world’s first fully automated 3D printed core production solution. The technology called Industrialization of Core Printing (ICP) allows automated production of highly complex sand cores for casting processes. By harnessing the flexibility of additive manufacturing, ICP eliminates design limitations of conventional tooling and is capable of matching conventional core making in serial-production.

Loramendi & Aurrenak hold an extensive background as a leading group for the design and supply of complete solutions and turnkey projects for core making, moulding and casting services. With this broad expertise, Loramendi designed a fully automated, 3D printed, inorganic core production line. The ICP technology and equipment has been developed to enable a high production flexibility and to boost the opportunities of industry 4.0 for core making factories and foundries. The know-how and experience of Loramendi as a main contractor have been a key success factor to deploy this disruptive innovation by integrating process development and the equipment industrialization.

“Loramendi has built equipment for the foundry industry for more than 45 years and nowadays enjoys world-wide prestige. We are recognized as a builder of heavy duty, reliable machinery and solutions specifically designed for the unique challenges of the foundry industry” stated Joseba Goitia, General Manager of Loramendi. “We are really excited about starting this new journey that will completely transform the landscape of the foundry industry and set new standards for core making.”

The new solution leverages voxeljet’s decades of research and expertise in precision mechanics, microfluidics and materials sciences and features a new type of 3D printer, which is more than ten times faster than previous models.

Dr. Ingo Ederer, Chief Executive Officer of voxeljet, commented: “We started nearly 20 years ago as a spin-off from Technical University Munich with a clear vision in mind: to match conventional manufacturing by constantly pushing technological boundaries. Today I can say that, together with our partners, we are set to become the world’s first to use fully automated 3D printing in automotive serial-production. The 3D printing industry is at an inflection point and this achievement marks a key milestone in our mission.”

ASK Chemicals, a leading supplier of innovative casting materials, developed the new inorganic binding materials and tailored them to the specific ICP requirements in order to meet the expected quality and productivity Goals.

“3D sand printing has been used in the foundry industry for many years to produce prototypes and small series. However, with the development of ever faster printers, the technology now offers new opportunities for foundries. We are therefore very pleased to take the important step towards industrialized core printing with our alliance partners Loramendi and voxeljet.”, states Frank Coenen, CEO of ASK Chemicals. The inorganic two-component system INOTEC 3D, consisting of an INOTEC 3D printing fluid and an INOTEC 3D promoter, is applicable for hot-curing additive manufacturing processes. Further advantages are the low finishing effort of the sand cores produced, which lead to castings of high dimensional accuracy and surface quality due to the high thermal stability. Above all, INOTEC 3D supports current trends in the engine casting segment of the light metal casting Industry.

Augsburg, Germany – November 08, 2018, voxeljet AG (NASDAQ: VJET) has announced the launch of its new VX1000-S IOB printing system for the series production of sand cores for aluminum casting. Until now, the company’s sand printing business has focused on the use of organic binder systems. The new VX1000-S inorganic IOB system significantly improves throughput and ensures high environmental compatibility throughout the value chain.

The new technology enables high-speed additive manufacturing for serial production of water jacket cores in light metal casting applications. Water jacket cores are used for the precise temperature management in not only internal combustion engines, but also electric motors, inverters and battery systems. Efficient temperature management improves overall vehicle performance.

• VX1000-S with a five times increased performance, compared to previous systems, resulting in a layer time of only 12 seconds
• Features new set of inorganic binding (IOB) material for high environmental compatibility already in production and during the casting process
• Orders for the VX1000-S system can be placed now for deliveries mid 2019
• On-demand production of IOB parts from our Services center is available from March 2019 onwards

voxeljet developed a solution for the serial additive production of crucial engine parts, such as water jacket cores. A water jacket is a liquid-filled casing surrounding a device, typically out of metal, having intake and outlet vents to allow water to be pumped through and circulated. The flow of water to an external heating or cooling device allows precise temperature control of the device.

The new VX1000-S IOB uses a special two-component inorganic binder system able to balance the technical requirements of the printing, core making and casting process: component one is the liquid binder based on a modified blend of alkali silicates, component two is a solid additive.

The advanced layering unit and high-speed printhead technology reduce the layer time to 12 seconds, generating a volume output of ca. 54 l/h. In addition to that, the inorganic materials only emit water vapor during the casting process. This significantly improves air quality and working environment in foundries.

The VX1000-S IOB offers a competitive advantage for automotive manufacturers. The technology has been engineered for highly complex geometries, which are particularly useful in the precise temperature management of not only internal combustion engines, but also electric motors, inverters and battery systems.

“voxeljet’s industrial printers enable high-quality print resolutions and constant layertimes and output volume. Our new S-line of 3D printers uses larger widths of our printheads, making our indirect metal processes even more productive compared to other direct metal additive manufacturing processes. I am convinced, this will become a state-of-the-art manufacturing process.” says Dr. Ingo Ederer, CEO of voxeljet.

voxeljet will present the VX1000-S IOB system at hall 3.1, booth D18 at this year’s formnext show, the international exhibition and conference on the next generation of manufacturing technologies in Frankfurt, Germany. For further information and a live demonstration of the VX1000-S IOB process visit us at our press conference at formnext on the 13th of November from 12:15 to 12:45 p.m.

February 2018 – voxeljet AG, a leading provider of high-speed, large-format 3D printers and on-demand parts services to industrial and commercial customers, today announced that Tooling and Equipment International in Livonia, MI (TEI) has signed a 3-year Volume Contract with voxeljet America Inc. in Canton, MI for 3D printed sand molds and cores.

In the contract, TEI has committed to purchase more than 500,000 liters of 3D printed sand from voxeljet over an expected three-year period. In connection with the contract, voxeljet will install additional printing capacity in TEI’s Livonia facility as well as using its existing machines in their Canton, MI facility.

TEI is the largest user of 3D printed sand in the USA and has a comprehensive low-pressure aluminum casting facility together with heat treatment and a state-of-the-art machine shop with over 50 CNC machines. TEI supplies machined prototype and low volume components in aluminum, iron and steel to automotive, aerospace and defense customers. With the help of voxeljet’s high productivity 3D printing systems, geared towards industrial production, TEI will offer all phases of manufacturing from one source: design, 3D sand printing, casting, heat treatment, machining, and inspection.

Oliver Johnson, President of TEI commented: “This is an outstanding opportunity for both companies to further capitalize on the benefits of large scale 3D sand printing for engineered aluminum castings. With voxeljet working alongside us to supply molds and cores, we will be able to compress lead times even further for our customers while also setting new records in terms of the size and weight of parts we can cast. ”

David Tait, Managing Director of voxeljet America Inc. commented: “The 3D printing industry is at an inflection point, and this marks another milestone in our mission to push 3D printing into industrial production. We are very proud to support TEI’s growth strategy with our unique 3D printing technology.”

TEI is a global leader in the design, engineering and manufacturing of prototype, pre-production and mass production equipment for the casting industry. TEI products are the highest quality and are backed by a reputation for innovation, design excellence, and precise first-run performance. TEI is a full service, vertically integrated supplier offering a complete range of services in Engineering, Tooling, Casting, Machining and Inspection complete on one site. This approach delivers TEI and its customers’ fundamental advantages in terms of timing, confidentiality, and quality.

voxeljet has officially launched its new High Speed Sintering (HSS) technology. HSS is an inkjet process technology, that allows the tool-less production of functional prototypes as well as final consumer parts. Examples of use include product packaging or interior fittings for automobiles.  At this year’s formnext trade fair 2017 in Frankfurt, visitors were able to view the technology for the first time live at the voxeljet AG booth.

The HSS process combines the advantages of two existing additive processes: selective laser sintering and binder jetting. While laser sintering, already allows many powder materials to be sintered into functional prototypes today, binder jetting impresses with its high printing rates in terms of size and speed of the construction site. High Speed Sintering thus allows the economical processing of larger plots and a wider selection of materials.

In the HSS process, a thin layer of plastic granulate, such as PA12 or TPU, is applied on to a heated building platform. An inkjet print head then moves over the entire surface of the platform and moistens the areas of the construction site with infrared light-absorbing ink, on which the prototype is to be produced. The building platform is then irradiated with infrared light. The wetted areas absorb the heat, which sinters the powder layer underneath. However, the unprinted powder remains loose. After sintering, the building platform is lowered by one layer thickness. This process is repeated until the assembly of a component is completed. The sintered parts are then cooled down in a controlled manner in the installation space before they can be removed and unpacked. In contrast to laser-based processes, the entire building platform can be printed in just one go, which enables a constant layertime time, irrespective of the size and complexity of the parts. Inert gas atmosphere is also not necessary for the HSS printing process. The large-area print head has a resolution of 360 dpi achieved through 3000 individually controllable nozzles, which allows the smallest details to be manufactured with high precision of the edges. In combination with a minimum layer thickness, the resolution of the print head enables the production of the finest structures with wall thicknesses of up to 0.15 mm. Since the HSS printing process requires no other fluids than ink, material costs can also be reduced to a minimum. The high quality of the components is also underlined by high accuracy and impressive definition of the edges.

The VX200 HSS from voxeljet offers unprecedented open sourcing possibilities. With the new ProPrint control software, users can program and insert customer-specific macros in just a few steps to adapt the printer to the desired material parameters and process operations. In addition, the software can also be used for individual process data mining, enabling the recording and evaluation of a wide variety of process data as required. Moreover, the user can process different powder materials, as the powder material does not necessarily have to be purchased from voxeljet. With regard to layer thickness, it is currently possible to vary between 80 – 100 µm, depending on the choice of material.

One of the first users of HSS technology is the chemical company Evonik Resource Efficiency GmbH. Dr. Sylvia Monsheimer, Head of Market Segment New 3D Technologies at Evonik, has been working with HSS technology for some time: “We want to process a wide variety of materials with our VX200: from PA12 and PA613 to PEBA. However, we are generally not limited in the materials portfolio. The HSS technology from voxeljet allows the interaction between material and machine to be optimized and thus the offering of the best possible material,” says Dr. Monsheimer.  “The providing of an open machine with such a high degree of flexibility in terms of material possibillities and a rapidly adaptable process such as Binder Jetting is, definitely a unique selling point.

With regard to materials different powders can be printed, given, that sufficient flow ability is ensured. This depends on the average grain size (30 – 70 µm average grain size), fine powder content and powder composition. Powders with low thermal conductivity can currently be processed up to a melting temperature of 190 °C, provided that they have a sufficient sintering window. Due to the fact that the heat input in HSS is gentle, a much larger selection of workable materials opens up than with previous processes.

The temperature management is carried out via the external Heat Control Unit (HCU), which monitors the temperature inside the pressure chamber at all times and automatically corrects it if necessary. The HCU is operated conveniently via touch display. All five individual heat sources within the printer can be individually controlled and adapted to the individual material properties.

“The VX200 is our entry-level model and therefore particularly well suited for this new technology. It offers the opportunity to exploit the full range of limitations and applications on a resilient and industrial machine. In addition to PA12, elastomers such as TPU can be printed. The open sourcing program allows everyone to use their machines for their own individual benefit. The variety of possible applications is more than impressive,” says Dr. Ingo Ederer, CEO of voxeljet. “We see enormous potential for this technology. That’s why we’re already working on scaling the technology to our larger printers to ensure an even higher plateau of productivity.”

Evonik also sees great potential for the future in this technology: “I am convinced that this technology is only at the beginning. The wide range of materials is trend-setting for this technology,” says Dr. Monsheimer.

The VX200 is ideal for material developers, research institutes and OEM’s to explore and exploit the diversity of materials in the field of thermoplastics and elastomers. In addition, it is easy to produce consumer parts that for direct use.