After years of research and optimization, a  joint vision goes live: voxeljet and Loramendi present  their flagship project for BMW Group Plant Landshut at this year’s GIFA foundry trade fair.  As part  of our cooperation project ICP (Industrialization of Core Printing), we have developed a fully automated and integrated production  line for the inorganic large-scale production of sand cores using 3D printing.

By using 3D printing in the production of water jacket cores, the design of the cylinder head for the BMW B48 engine can be significantly improved. The inorganic process protects the environment and improves working conditions, as only steam is produced during casting. At the same time, the efficiency and consumption of the engine can be optimized due to the complex design of the component. No other technology made it possible to mass-produce such a complex element in a cost-efficient manner.  Instead of complex individual parts, BMW can now produce the core entirely in one piece using 3D printing.  The ICP production line completely automates and optimizes the once manual and tedious process. Five voxeljet VX1300-X 3D printers now produce thousands of cores fully automatically every week using the binder jetting process. These are then unpacked, hardened, cleaned and prepared for casting in unpacking stations, microwaves and cleaning cells specifically developed by Loramendi.

“The fully automated 3D production line is the standard we want to implement: for four years, we have worked hard on this project with BMW. To see the VJET X printers in full operation now is extremely exciting and a milestone not only for us but also for the entire 3D printing and automotive industry,” highlights Dr. Ingo Ederer, voxeljet founder and CEO.

The VX1300-X 3D printer is a 3D printer designed for mass additive manufacturing. A high-performance process unit enables bidirectional recoating and simultaneous printing of the build area. As a result, the VX1300-X achieves extremely short layer times and high output volumes in multi-shift and continuous operation, which makes it ideal for series production. With a fully automated post-processing cell, the complex sand cores are prepared for metal casting and integrated into the existing casting process. The tool-free construction of the sand cores enables variant changes at unparalleled speed, without any time-consuming tool changes and production downtimes.

We will be presenting further innovations at GIFA, such as a completely new type of boat propeller. For Sharrow Marine LLC in Detroit, we manufacture PMMA 3D printed models for the award-winning  Sharrow MX-1 boat propeller. This new propeller is more efficient, faster and, above all, significantly quieter than other propellers. 3D-printed PMMA models from voxeljet in combination with investment casting enable a design that pushes conventional manufacturing technologies to their limits and is only possible thanks to additive manufacturing.

As part of the research project “ULAS-E-VAN” (“UltraLeicht AufbauStruktur eines Elektrischen VANs” – UltraLightweight Body Structure of an Electric VAN), nine partners are developing lightweight solutions for the body structure and a modular battery carrier system of battery-electric powered light commercial vehicles ( commercial vehicles, class N1 – Ford Transit – BEV). Ford is coordinating the research project with a total volume of 5.8 million euros, funded by the German Federal Ministry of Economics and Climate Protection (BMWK). The project partners are Altair Engineering GmbH, BENTLER Automobiltechnik GmbH, C-TEC GmbH, Ford-Werke GmbH, Franken Guss GmbH + Co. KG, MORPHOTEC, RWTH Aachen University, Chair and Institute for Structural Mechanics and Lightweight Construction (SLA), RWTH Aachen University, Institute for Automotive Engineering (ika), and voxeljet AG.

If a light commercial vehicle is equipped with an electric drive, the empty weight increases due to the high battery weight and the possible payload decreases. To counteract this, it is imperative to decisively reduce the weight, especially in battery-powered delivery vehicles, through lightweight construction measures. Lightweight construction makes it possible to increase the range, but also to reduce the battery size, secondary weight and thus battery costs while keeping the range unchanged. However, in the targeted sector of e-commercial vehicles, the need for cost-effective lightweight construction is even more critical due to the high-cost sensitivity of the potential customer base and the relatively low unit numbers.

This is where the project comes in. The consortium aims to develop ultra-lightweight solutions for the body and superstructure of such battery-electric light commercial vehicles using modern CAE methods such as “simulation-driven design” and innovative manufacturing methods. In addition to a special 3D printing process – 3D sand mold printing – to produce molds for the iron casting process, large-format structural plastic parts are also used.

The design of the body structure is to be based on a frame-stringer construction, thus transferring the proven aircraft construction method to light commercial vehicle construction with higher annual production figures. The frames are to be designed as a single piece wherever possible and in a bionic-optimized manner. The outer skin will be formed by prefabricated plastic panels that are connected to the load-bearing structure. A load-bearing, ultra-lightweight, scalable and modular battery support system is to be integrated in the underbody, which will provide functional support for the body structure in terms of stiffness, fatigue strength and crash. The technologies used are expected to achieve weight savings in the order of up to 150 kg on a total vehicle level, thus enabling an increased range or payload.

Alongside the standard polymer PA12, TPU is one of the polymers increasingly in demand for 3D polymer printing. With its cushioning properties, the thermoplastic material has proven itself for decades in the production of shoe soles, it offers impact protection and is being used more and more across industries: in the plastics processing industry, in the automotive and consumer goods industry, in aerospace and in the engineering sector.

In the production of polymer components, voxeljet takes advantage of the special material properties of TPU in conjunction with the HSS technology: TPU can be very soft and elastic or very hard and persistent. These properties can be specifically influenced in all three dimensions using HSS technology. In High Speed Sintering, a fine layer of polymer powder is applied onto a heated build platform and the areas where the part is to be built are then inked with a heat-absorbing ink. Infrared light is used to fuse the printed areas of the polymer powder, leaving unprinted material loose. Layer by layer, the polymer is applied, printed, and irradiated until the build-up of the full jobbox and the parts within it, is complete. How soft or solid the part is depending on the volume of infrared-absorbing ink introduced. The more heavily a build area is inked, the stronger the part. By using industrial inkjet print heads, it is possible to print correspondingly different gray levels within a layer and thus realize different product properties per layer. In addition to this grayscale printing, the strength of a component can also be influenced by its geometry. Lattice structures with different wall thicknesses are used to print geometries that can be adapted to individual load profiles in order to save additional material.

“The HSS technology in combination with the TPU material allows us to provide an inherently hard, highly stressable part with soft properties. This opens up completely new and highly individual application possibilities of 3D printing for plastic parts,” says Tobias Grün, Global Product Manager at voxeljet. TPU components produced with the HSS printing process have particularly long-lasting permanent elasticity and excellent rebound properties compared to other TPU 3D printing processes. The successfully passed Cytotoxicity test also confirms that there is no damage to cells and tissue when the material comes into contact with the skin. In addition, no discoloration of the components occurs. “With the HSS process, we can produce individualized polymer parts on-demand at high quality and speed at comparatively low cost. High Speed Sintering is an economical, efficient and resource-saving solution due to the use of large-format print heads. The technology offers enormous potential for future-oriented products,” says Tobias Grün.

The TPU qualified for the HSS technology was co-developed by voxeljet and materials manufacturer Covestro. “The close cooperation between material and machine manufacturers enabled us to bundle our joint know-how and thus coordinate and optimize the part quality as well as the 3D printing process.” says Grün. With the collaboration, the two companies aim to develop integrated material and process solutions for the economical additive high-volume production of polymer components.

To the extent this document contains forward-looking statements, such statements are not statements of fact and are made using words such as “expect”, “believe”, “estimate”, “intend”, “strive”, “assume” and similar expressions. These statements are an expression of the intentions, views or current expectations and assumptions of voxeljet AG and are based on current plans, estimates and forecasts made by voxeljet AG on the basis of its best knowledge, but do not constitute any statement with respect to their future accuracy. You should not place undue reliance on these statements. voxeljet AG cannot provide assurances that the matters described in this press release will be successfully completed or that voxeljet AG will realize the anticipated benefits of any transaction. Forward-looking statements are subject to risks and uncertainties, which are usually difficult to predict and ordinarily not in the domain of influence of voxeljet AG. These risks and other factors are discussed in more detail in the company’s public filings with the SEC. It should be noted that actual events or developments could materially differ from the events and developments described or included in the forward-looking statements. Statements made herein are as of the date hereof and should not be relied upon as of any subsequent date. The company disclaims any obligation to update any forward-looking statements except as may be required by law.