The Virtual Foundry Awarded Patent for its FDM/FFF Metal 3D Printing System
The Virtual Foundry recently won a patent for its proprietary process for extruding metal, glass or ceramic powder with a thermoplastic binder into continuous filament suitable for use in fused filament 3D printers. Once an object is printed using this hybrid material, it is sintered to remove the plastic binder. This process produces an object of consistently high purity – up to 98% of the base material.
The Virtual Foundry’s plastic-infused metal, ceramic and glass filaments have the potential to revolutionize metal additive manufacturing, because they enable objects to be 3D printed on inexpensive FDM equipment. This breakthrough has been made possible by continuing advancements in powdered metallurgy and sintering practices.
“Together, our hybrid filaments, FDM printers and sintering ovens represent a new, more affordable, open-source platform for metal additive manufacturing,” explains Bradley Woods, founder of The Virtual Foundry. “We believe they will have an impact on every category of manufacturing, from aerospace and medical to general foundry and tooling applications,” he adds.
The Virtual Foundry’s patented approach enables manufacturers to significantly cut product development times. It’s now possible to create functional metal prototype parts in a few days, compared to several weeks to machine a part using subtractive manufacturing.
This breakthrough also significantly lowers the barrier to entry for manufacturers who want to begin experimenting with metal additive manufacturing.
“At the turn of the 20th century, Henry Ford’s assembly line approach revolutionized manufacturing and reduced the cost of new automobiles by an order of magnitude. We believe our platform will have a similar impact on the field of metal additive manufacturing,” Woods predicts.
You can read the patent here: http://www.freepatentsonline.com/y2018/0193912.html
stratasys, reprap, custom, foundry 3d printing, the virtual foundry, additive manufacturing
fdm patent, 3d printing patent, patent metal, 3d printer patents, foundry 3d printing, fff ceramic, patented 3d
Overview of The Virtual Foundry's Patent
The Virtual Foundry's recent patent represents a significant advancement in the field of metal 3D printing technology. This proprietary process allows for the creation of extrudable filaments that combine metal, glass, or ceramic powders with a thermoplastic binder, making it suitable for use in standard FDM/FFF printers.
This innovation not only streamlines the production process but also makes metal additive manufacturing more accessible to a broader range of industries. By reducing the cost and complexity associated with traditional methods, The Virtual Foundry is positioned to transform manufacturing practices across various sectors, including aerospace and medical applications.
Impact on the 3D Printing Industry
The introduction of extrudable metal filaments could redefine the landscape of 3D printing, particularly for small to medium-sized manufacturers. By enabling the use of affordable FDM printers for metal printing, The Virtual Foundry is lowering barriers to entry and fostering innovation in manufacturing.
This shift could lead to faster prototyping and production times, allowing companies to bring products to market more efficiently. The implications of this technology extend beyond cost savings, as it encourages experimentation and adoption of metal 3D printing in various applications, from custom tooling to intricate aerospace components.
Applications of Extrudable Metal Filaments
Extrudable metal filaments open up a wide range of applications in various industries. For instance, in aerospace, manufacturers can create lightweight yet strong components that meet stringent safety and performance standards. Similarly, the medical field can benefit from custom implants and devices tailored to individual patient needs.
Additionally, the versatility of these filaments allows for experimentation with different materials and designs, paving the way for innovative solutions in foundry work and tooling. As more industries adopt this technology, the potential for new applications will continue to grow, driving further advancements in metal additive manufacturing.
Future Prospects of Metal 3D Printing
The future of metal 3D printing looks promising, especially with innovations like those introduced by The Virtual Foundry. As the technology matures, we can expect to see improvements in material properties, printing speeds, and overall efficiency, which will further enhance its appeal to manufacturers.
Moreover, ongoing research and development in this field may lead to the discovery of new materials and techniques that expand the capabilities of metal 3D printing. This evolution could not only enhance existing manufacturing processes but also inspire entirely new business models and applications in various sectors.
printer, 3d printing, metal, alloy, laser, 3d systems, heat, stereolithography, metal 3d printer, rapid prototyping, selective laser sintering, wire, software, powder, productivity, stainless steel, machine, steel, prototype, design, fused filament fabrication, manufacturing, 3d printing processes, geometry, scalability, data, aluminium, plastic, corrosion, volume, sintering, extrusion, innovation, research, tool steel, dmls, materials science, titanium, alsi10mg, tool, bed, surface finish, markforged, melting, fiber laser, selective laser melting, automotive industry, wear, superalloy, nozzle, binder, robot, efficiency, electron, industrial metal, copper, cost, simulation, operational efficiency, supply chain, energy, liquid, shape, metal3d, density, 3d printing metal, technology, lead, inconel, engine, aerospace, ultimate tensile strength, stress, ratio, titanium alloys, chromium, casting, bead, hardness, metal casting, binder jetting, cnc, resolution, yield, milling, cobalt, annealing, metal fabrication, sheet metal, liquid metal, vacuum, porosity, ductility, topology optimization, complexity, die casting, surface roughness, fatigue, accessibility, mold, dimension, alloy steel, ceramic, laser cutting, knowledge, melting point, behavior, 3 d metal, metal 3d printing
Frequently Asked Questions
Is post-processing required for metal 3D prints?
Post-processing is often required for metal 3D prints to enhance surface finish, achieve precise dimensions, and improve mechanical properties. This can include processes like sanding, polishing, or heat treatment, depending on the desired outcome.
What are the common applications of metal 3D printing?
The common applications of metal 3D printing include aerospace components, automotive parts, medical implants, and tooling. These industries benefit from the ability to create complex geometries and lightweight structures, enhancing performance and reducing material waste.
What is the process of metal 3D printing?
The process of metal 3D printing involves using advanced filaments, like those from The Virtual Foundry, to create parts layer by layer. This technique allows for intricate designs and efficient production of metal components tailored for various applications.
What are the benefits of using a metal 3D printer?
The benefits of using a metal 3D printer include the ability to create complex geometries, reduced material waste, faster prototyping, and the production of durable parts suitable for various industries, enhancing both efficiency and innovation in manufacturing processes.
Can metal 3D printing produce complex geometries?
Metal 3D printing can produce complex geometries. This technology allows for intricate designs and structures that are often impossible to achieve with traditional manufacturing methods, making it ideal for various applications in multiple industries.
What types of metals can be 3D printed?
The types of metals that can be 3D printed include stainless steel, aluminum, titanium, and various metal alloys. These materials offer diverse properties suitable for numerous applications across different industries.
Can metal 3D printing be used for aerospace applications?
Metal 3D printing can be effectively used for aerospace applications. Its ability to produce lightweight, complex geometries and custom parts makes it ideal for enhancing performance and reducing costs in the aerospace industry.
What is the cost of metal 3D printing?
The cost of metal 3D printing varies based on factors such as material type, print size, and complexity. Generally, it can range from a few hundred to several thousand dollars per part, depending on these variables.
What are the limitations of metal 3D printing?
The limitations of metal 3D printing include high material costs, slower production speeds compared to traditional methods, and the requirement for specialized equipment and expertise to achieve optimal results. Additionally, certain geometries may be challenging to print effectively.
What metals can be used in 3D printing?
The metals that can be used in 3D printing include stainless steel, aluminum, titanium, and bronze. These materials are ideal for creating durable and complex parts across various industries.
How does metal 3D printing differ from traditional manufacturing?
Metal 3D printing differs from traditional manufacturing in that it builds parts layer by layer, allowing for complex geometries and reduced material waste, whereas traditional methods often involve subtractive processes that can limit design flexibility and increase waste.
How does a metal 3D printer differ from a plastic one?
Metal 3D printers differ from plastic ones primarily in the materials they use and the printing processes involved. While plastic printers utilize thermoplastics that melt and solidify, metal printers work with metal powders or filaments, requiring higher temperatures and specialized techniques for effective metal part production.
Can metal 3D printing be used for aerospace industry?
Metal 3D printing can be effectively utilized in the aerospace industry. It allows for the production of lightweight, complex components that enhance performance and reduce costs, making it an ideal solution for aircraft manufacturing and parts replacement.
How strong are 3D printed metal parts?
The strength of 3D printed metal parts can be comparable to traditionally manufactured metals, depending on the material and printing process used. High-quality filaments like those from The Virtual Foundry can produce durable and functional components suitable for various applications.
How does metal 3D printing improve product design?
Metal 3D printing enhances product design by enabling complex geometries, reducing material waste, and allowing for rapid prototyping, which accelerates the design process and fosters innovation in creating tailored solutions for specific applications.
How does metal 3D printing compare to traditional machining?
Metal 3D printing offers greater design flexibility and reduced material waste compared to traditional machining, enabling the production of complex geometries and customized parts more efficiently.
What are the benefits of metal 3D printing?
The benefits of metal 3D printing include reduced material waste, complex geometries that traditional methods can't achieve, faster prototyping, and the ability to create lightweight yet strong components, making it ideal for various industries.
What are the applications of metal 3D printing?
The applications of metal 3D printing are diverse and include aerospace components, automotive parts, medical implants, and intricate tooling. This technology enables the production of lightweight, customized, and complex designs that traditional manufacturing methods may not achieve.
Can a metal 3D printer be used for jewelry making?
Metal 3D printers can indeed be used for jewelry making. They allow for intricate designs and precise detailing, enabling jewelers to create unique and customized pieces with metal materials.
Can a metal 3D printer produce functional parts?
Metal 3D printers can indeed produce functional parts. Utilizing advanced materials like those offered by The Virtual Foundry, these printers create durable and precise components suitable for various applications across multiple industries.
Can metal 3D printing be used for medical implants?
Metal 3D printing can be effectively used for medical implants. It allows for the creation of custom, biocompatible components tailored to individual patient needs, enhancing the fit and functionality of implants in various medical applications.
What materials enhance metal 3D printing durability?
The materials that enhance metal 3D printing durability include high-strength alloys, such as stainless steel and titanium, as well as specialized filaments like those offered by The Virtual Foundry, which provide improved mechanical properties and resistance to wear.
How does temperature affect metal 3D prints?
Temperature significantly influences metal 3D prints by affecting material flow, adhesion, and overall print quality. Proper temperature settings are crucial for achieving optimal layer bonding and minimizing defects in the final product.
What are best practices for metal 3D printing?
The best practices for metal 3D printing include ensuring proper material preparation, optimizing print settings for temperature and speed, maintaining a clean build environment, and using appropriate post-processing techniques to enhance the final part quality.
Can metals be recycled in 3D printing?
Metals can indeed be recycled in 3D printing. Many metal 3D printing processes allow for the reuse of metal powders, reducing waste and promoting sustainability in manufacturing.
What industries benefit most from metal 3D printing?
The industries that benefit most from metal 3D printing include aerospace, automotive, medical, and manufacturing. These sectors leverage the technology for creating lightweight, complex parts, reducing material waste, and enabling rapid prototyping.
What advancements are being made in metal 3D printing?
Advancements in metal 3D printing include the development of more efficient printing techniques, improved material formulations, and enhanced post-processing methods, all aimed at increasing accessibility, reducing costs, and expanding application possibilities across various industries.
How to select metal for 3D printing projects?
Selecting metal for 3D printing projects involves considering factors such as the desired mechanical properties, the specific application, and compatibility with your 3D printer. Evaluate options like strength, weight, and thermal conductivity to make an informed choice.
What post-processing methods improve metal print quality?
Post-processing methods that improve metal print quality include heat treatment, which enhances strength and ductility, and surface finishing techniques like polishing or sandblasting, which refine surface texture and remove imperfections for a smoother final product.
Are there safety concerns with metal 3D printing?
Safety concerns with metal 3D printing include potential exposure to harmful metal powders and fumes, which can pose health risks if proper ventilation and protective equipment are not used. Additionally, the high temperatures involved can lead to fire hazards if not managed correctly.
metal 3d printing, metal 3d printer, virtual foundry, metal printing, 3d print metal, 3d metal printing
