10 Reasons

Why Multi-Material 3D Printing is Better for your Product Design & Development

Stratasys Ltd.

Introduction
Based on their innovative use of inkjet printing technology, Objet 3D printers are the only additive layer manufacturing devices in the world able to combine different 3D printing materials within a single 3D printed model. Objet 3D printing technology is also the first in the world to offer a choice of over 120 different 3D printing materials, ranging in properties from rigid plastic to rubber-like, opaque to transparent, and standard to engineering-grade ABS toughness. When talking about multiple-material 3D printing, we actually refer to a number of different capabilities which we will aim to categorize and clarify in this white paper. We will also outline the uses and advantages of this unique 3D printing technology for companies using rapid prototyping during the design and development of manufactured end products.

Dual Material Jetting - The Technology

Objet Connex 3D printing technology works by jetting two distinct Objet materials. The technology can work with any mix of rigid and flexible materials, various transparent and opaque materials, and different color materials. Each material is funneled to a dedicated liquid system. The liquid system is connected to the Objet printing block, which contains eight printing heads. Every head includes 96 nozzles, each measuring 50-microns in diameter. Each material has two designated printing heads that work in sync.

Objet 3D printing block, consisting of 8 printing heads:

- Heads 1 & 2 jet material A - Heads 3 & 4 jet material B - Heads 5 - 8 jet the support material

A Word about Objet 3D Printing Materials

Objet range of over 120 3D printing materials is based upon proprietary acrylicbased photopolymer resins. These materials are jetted as a liquid from sealed cartridges inserted into the machine. Once a layer of material is deposited on to the build tray, it is immediately cured by a UV light. The UV light follows the print head and turns each liquid material layer into a solid. The material is immediately ready to be built upon with successive layers. These fully cured models can be handled immediately after printing - a unique advantage over other rapid prototyping technologies and materials which require lengthy post-processing treatments. Loading and unloading the print cartridges is similar to the process of installing and removing inkjet cartridges from a paper-feed printer.

10 Advantages of Dual Material Jetting

Independent Nozzle Control

Objet 3D printing technology is able to control every nozzle in every print head independently. This means that preset combinations of model materials can be jetted from designated nozzles to create new materials, different material parts within a model, as well as different material models that are being printed at once. Here are ten benefits of this unique dual-material jetting in more detail:
1. Fabricate Composite Digital Materials

Composite materials have been in use for many years. They are used today in many industries, including building construction, sports equipment and car and aircraft manufacturing. Objet Digital Materials are multi-phase composite materials created by the Objet Connex 3D printing system. The benefit of Digital Materials is the ability to produce new, composite materials with attributes that are not available in the individual constituents. Based on this multi-material jetting technology, the Connex family of 3D printers is able to simultaneously print two resin materials to create 90 different types of Digital Materials. Starting with 17 cartridge-ready materials, Objet Connex users have the ability to choose from a total of 123 different materials and composite material combinations.

Digital Materials have mechanical and physical properties that vary from the primary, cartridge-based materials. This additional set of materials improves upon the mechanical properties available from the existing materials - providing new values of tensile strength, flexural strength and Izod Impact. Rubber-like Digital Materials enable the precise selection of new Shore A values to suit the specific application purposes of the designer. Objet Digital Materials are generated on the fly, based on the two cartridge-based materials that are installed in the system. The selection of the Digital Material is made by the user through dedicated software that determines the appropriate jetting parameters. The materials are created automatically during printing, without the need for additional human input.
2. A Recipe for Future Scalability

90 Digital Materials can be derived from just a small number of primary materials. Every additional new material introduced therefore opens up tens of new Digital Material options. With Objet multi-material technology, the potential palate of Digital Material combinations will continue to expand and grow exponentially.
Objet Material Range Increase over Time With Over 100 Materials by 2012

3. Simulate Plastics with Engineering Properties

When the Objet multi-material process combines specific rigid materials with specific flexible materials, the resulting Digital Material can be tougher than the individual material components from which it is comprised.

Objet ABS-like Digital Material is an example of such, combining the toughness of one material with the temperature resistance of a second material to provide a hybrid that can simulate ABSgrade engineering plastics. Using this advanced material, designers, engineers and manufacturers can achieve advanced functional simulation of their intended end-product without the fear of easy breakage. Examples include a foldable stool able to support over 100kg in weight, functioning clips and closers that can be repeatedly flexed and stressed, functional wrenches and even functional bike parts that can be taken directly from the 3D printer to the bicycles in the field!

Full Size 3D Printed Stool in Objet ABS-like Digital Material able to support 100kg

4. Segregate Different Materials within One Consistent Model

We previously mentioned the concept of creating a new material by combining two materials in the Objet jetting process. With this you can, of course, produce a uniform part made of one consistent color or rigidness. We can now move on to the next unique ability of Objet multi-material jetting technology segregating these different materials and Digital Materials within a single 3D-printed object. Thanks to the different nozzles within the print-head, Objet Connex 3D printers can selectively create up to 14 different Digital Materials based on the two cartridges in the machine and then selectively deposit each of these 14 in a different part of the model with sharp, defined material boundaries.

3D Printed Shape in Objet Clear Transparent Material with Black Hand Suspended Inside

This mixed part 3D printing capability eliminates the need to design and print separate parts using different materials and then assemble them together in a post-printing process, such as gluing. Using this capability, it is possible to simulate highly complex shapes, color shade mixes and unique geometries that combine different material elements.
5. Segregate Different Material Models on the Same Print Tray

In order to maximize system yield, the Objet Connex has the ability to simultaneously build different material parts on a single tray. This can improve productivity for companies requiring high volume prototyping. Using this feature increases the systems efficiency, enabling multiple build varieties to
Razors printed simultaneously in a single run. Each razor is composed of different materials with different mechanical properties (rigid and flexible).

be printed at the same time. This allows designers to then quickly select the most suitable model.
6. Create Grayscales and Tones

One of the advantages of using more than one model material is the ability to create grayscales and tones. For example, when using Objet Rigid Black and Rigid White primary materials it is possible to combine them in various ratios to create different grayscales. Creating grayscales and tones makes it possible to print marks and signs on a model, mark desired areas of interest and even add captions. The application uses for this capability are endless, ranging from artistic designs to functional simulation of assembled goods that, in the consumer world, are typically made of different material parts and then assembled. 7. Simulate Opaque Shades with Clear
Transparency
3D-printed corset prototype in gray shades. Courtesy of Neri Oxman.

Popular in the medical industry, Objet Connex line of multi-material 3D printers is used to create accurate models of body parts in transparent material with the internal structures in black, white, blue or grey shade combinations so that they are visible beneath the skin. The same process allows us to freeze objects or writing within a glass-like casing for the accurate simulation of consumer goods and electronics. Within the mechanical engineering world it is possible to use the opaque within a transparent model concept to highlight the internal structure of objects or to simulate areas of load useful in the design of weight-bearing parts for automotive, defense and architectural projects.

Shower head 3D printed in Objet Clear Transparent material with internal Objet Black Rubber-like Digital Material (Shore 40). Courtesy of Ideal Standard CG Germany.

8. More Efficient Short Series Injection Molding

Injection molds are usually constructed from specialty steel tools and are expected to withstand hundreds of thousands, or even millions of molding cycles. As such, molds are very expensive and the costs associated with mold construction increase significantly with part complexity. Tool construction is a long process that may take months. After the tool is ready, it is tested and usually additional correction is required. In some case, before going into tool steel molds, a preproduction aluminum tool is constructed for validation purposes. Although this may take less time as compared to the production of steel tools, it may still take several weeks. 3D printing the tool in Objet ABS-like Digital Material and using this for the injection molding of the intended plastic has several advantages including: Real prototype in hand early on in the Objet ABS-like Digital Material design process being used as a fast, economical More economical small series production short series injection mold Fast mold validation - reduced time to final mold Reduced time-to-market for final part and reduced overall costs

9. Combine Rigid Material with Rubber-like Over-Molding

Objet Connex 3D printers simultaneously print parts with different mechanical properties. This capability enables the user to test 3D printed prototypes that are very close to the production part in terms of mechanical properties and material combinations, e.g., over-molding and double injection. Prototyping in this way aids in the selection of the materials that will be used in the final product. This process saves days of simulating and preparing complex and expensive molds for double injection. It also eliminates the need for silicon molds and preparation of different end-product materials for testing; most of the testing can be performed early on with prototypes printed overnight on the Objet Connex system.

This capability improves the communication between different groups and decision makers in the company, such as R&D, internal/external customers, engineering, marketing, sales and management. The ability to combine rigid and flexible rubber-like materials is a real necessity for applications that have a rigid body with areas of flexible material for grips and protection of the mechanism, and thus require a double-injection production process. This pressing need exists in most of the current products in consumer goods and electronics, automotive, shoe and medical industries. A cellular phone with a rigid body, rubber-like keys and over-molded parts is one example of such an application. Other examples are a car wheel printed complete with its rubber-like tire or a shoe sole with over-molded, rubber-like treads.

A GPS device with over-molding, 3D-printed in a single run on the Objet Connex. Eliminates the need for providing separate silicon molds and then gluing them together.

10. Combine High Temperature Material with Rubber-like Material

Combing Objet High Temperature material with Rubber-like materials enables the formulation of high-temperature parts with over-molding. Automotive airventilation systems, for example, can now be printed in Objet High Temperature material with Rubber-like over-molded edges to produce an air-tight fit for moving opening/closing paddles. When combined to produce Digital Materials, the High Temperature/Rubber-like combination produces composites with both durability and temperature resistance suitable for a range of applications such as medical devices, surgery planning, automotive parts or models used in high humidity environments.

Summary
Objet material range reaches 123 materials. 90 of these are Digital Materials, derived by the composite mixing of primary Objet materials. More than ever before, this expanded material range allows designers, engineers and manufacturers to simulate very precise material properties that closely resemble their intended end-product. This development places Objet users at the forefront of additive manufacturing and rapid prototyping. Designers can now select from materials ranging from rigid to rubber-like substances in terms of texture; standard to ABS-grade engineering plastic in terms of toughness; and transparent to opaque in terms of clarity and shades. The Objet Connex multi-material 3D printer allows users to combine up to 14 of these materials at the same time within a single consistent model. Using the Objet Connex enables the 3D printing of prototypes that are very close to the production part in terms of mechanical properties and material combinations, e.g., over-molding.

Objet Connex350 with multi-material 3D printed model ready for removal from the build tray.

Objet Connex technology also enables designers to simultaneously print different material versions of the same part; completely different material parts together on the same tray; or short-run injection molds. All of this results in very significant time savings and reduces the overall product development cost. As Stratasys continues to exponentially grow the Objet line of material range, these new prototyping possibilities will serve to further improve the product development process for virtually every industry segment in every stage of prototyping, from initial form concept; to fit testing; to final functional verification.
Variety of multi-material 3D printed models printed at the same time on the same Objet Connex build tray.

10

About the Objet Connex Multi-Material 3D Printing System

The Objet Connex range of multi-material 3D Printers includes the Objet1000 with a build volume of 1000 x 800 x 500 mm (39.331.419.6 inches) Objet Connex500 with a build volume of 500 x 400 x 200 mm (19.7 x 15.7 x 7.9 inches), the Objet Connex350 with a build volume of 350 x 350 x 200 mm (13.8 x 13.8 x 7.9 inches) and the Objet260 Connex with a build volume of 260 x 260 x 200mm (10.02 x 10.02 x 7.9 inches) The Objet Connex range of 3D printers offers three printing modes: Digital Material (DM) printing mode operates at 12 mm per hour in 30 micronlayers, providing the ability to print parts made of multiple model materials including Digital Materials. High Quality (HQ) printing mode builds parts at 12 mm per hour in 16-micron (0.0006 inch) layers. High Speed (HS) printing mode runs at 20 mm per hour in 30 micron (0.001 inch)layers.
Objet Connex500 Multi-Material 3D Printing System

Printing 600 x 600 dpi in both the X and Y axes, the Objet Connex enables thin walls down to 0.6mm, fine details in all dimensions, and a smooth surface finish, assuring high quality for every part. Highly precise 3D printing, with a maximum tolerance of 0.3mm over large models ensures repeatability and accuracy. The Objet Connex line 3D printers support four sealed 3.6kg (7.9 lb.) cartridges of material, allowing unattended operation for extended periods. The systems enable the loading of 2 different model material types when using the DM printing mode.

Trademarked company and product names are the property of their respective owners.

www.stratasys.com | www.objet.com | objet-info@stratasys.com

11