Caracol is calling WASP against Covid-19
CARACOL is calling WASP to product Covid 19 3D printed masks
Everything happened during the lockdown; CARACOL, a reference company in Italy for the services of Additive Manufacturing asked for help to WASP : 10 Delta WASP 2040 PRO and 2 Delta WASP 2040 INDUSTRIAL 3D printers must be produced in the shortest time.
We had to act quickly and well, Milan was calling and we decided to work together to produce protective devices against Covid-19.
In a few days the 3D printers were in the CARACOL production center in Lomazzo (Milano).
The non-stop production of more than 2000 Covid 19 3D printed masks, per week, printed with hypoallergenic polymeric material and equipped with an interchangeable filter, begins.
CARACOL, through a crowdfunding campaign and the support of the community, has donated masks to the Italian Red Cross, to small Italian municipalities such as Lomazzo, Cusano Milanino, Rivoli, Lanciano, and Sorrento, and to therapeutic and treatment centers.
A victory from a cooperation point of view and in the 3D printing field which leads the attention to an essential role in the manufacture of medical equipment.
The health care emergency due to the Covid-19 has shown the strengths of 3D printing which can obviate the lack of some essential devices in record times.
Now the global market shows that 3D printing must be used for additive manufacturing like never before. This allows the relocation of some production in order to face the demand peaks. It also allows diversification of the supply chain in case of emergencies in many sectors, not only the medical one but also the Automotive and Motorsport, Aerospace and Defense, Industrial Machinery, Design and Architecture fields.
CARACOL like WASP believes in a collaborative future and in technological progress, in the evolution of digital manufacturing in order to meet the needs of humanity.
3D printing for model making: from the idea to the masterpiece
The scenario of 3D printing for model making
Before 3D printing or in any case before the boom of 3D printers, the models were made either by milling or even using an older technique like building a wooden skeleton (ribs which were nothing more than the master sections) on which the planking was applied, a thin wood covering that followed the shape of the skeleton longitudinally, in short a long and painstaking work.
3D printers have existed (on an industrial level) since the end of the 90’s, but they had prohibitive costs for the most, although some pioneers were already there and some (very expensive) models were made. Only in the last decade the 3D printers market development has favored the interweaving between the two worlds: 3D printing for modeling.
What problems does 3D printing solve?
There are many difficulties in making and maintaining the accuracy and the precision of some very complex models.
We can begin to mention the "human" commitment in terms of working hours, necessary to create the main structures and all the components of the models, a factor that is sometimes prohibitive. Furthermore, the shapes could not be accurate because they were too complex to be made by hand. Another limit was the weight. The models had a considerable weight whether they were made with milling or with the planking technique.
Another recurring problem was breakages due to heat: the models are exposed under the sun in plexiglass cases during the faire, which, for the most part, are in the hot months (September), therefore unfavorable conditions are created for those materials that do not have suitable characteristics for the environment.
The advantages of using a 3D printer for model making
3D printing solves some of the limitations of manual manufacturing and it opens the door to new possibilities that were not previously considered.
The time necessary for the realization is shorter but these advantages are not among the main ones. The post production takes time on FDM printed parts, even if they are printed at very narrow layers.
The main advantages are in the freedom of form: the domotic models have many wiring to be made and thanks to the WASP technology they can be designed in advance and they pass directly into the molded piece, with channels and slots made before, an unthinkable possibility for traditional manufacturing. Furthermore, thanks to the materials used in 3D printing and thanks to the potentiality to adjust the "infill" of the pieces, it is really possible to think freely.
Another important plus is being able to predict the division of the various pieces into the CAD. The good division choice allows a much more precise lacquering.
"We used to divide objects according to their color, i.e. on a black and white piece we do not want to see the slightly smudged masking, on the contrary a nice clean line which gives a vision of clean unity", says Riccardo Suriano, CEO of MATERIA.
To solve the problem of breakages, not only do we use technical materials that can withdraw high temperatures, but the pieces are completely removable too. The least possible quantity of glue is used, preferring the joints, a system that 3d printing allows you to do without manufacturing problems.
Using a 3D printer for model making allows you to create modular models so that you can only work on the piece that needs maintenance and / or repair both in case of hull break or in case of bollard break; before however, everything was firmly glued and a break in the hull compromised the entire model.
Why WASP?
"When we started we wanted an Italian and young-minded company to support us and we chose WASP. We studied the Delta WASP 3D printers and understanding the concept we found that they were all what we needed: speed, precision and a large volume in z rather than in x, y." says Riccardo Suriano.
“We exploit the advantages of delta mechanics, placing 99% of our pieces in z for a very satisfying finish. We use the Delta WASP 4070 INDUSTRIAL for the larger parts while the Delta WASP 2040 TURBO2 realization of all the smallest parts printed without any problems with an excellent surface given by the double WASP ZEN Extruder ”.
“An important concept for us is the 3D modeling realized through additive manufacturing as a final result. Normally, when designing for manufacturing, there are a lot of constraints to take into consideration: draft angles, cutter rays, etc., due to this we have radically changed our concept of design”.
"We try to make the most of the characteristics of 3D printing by making shapes for the joints but also the gears for completely unconventional movements, we try to exploit the elasticity created by the infill, we create reticular structures as supports for bridges and we are convinced that there is still a lot to be found in terms of design 4.0 ”, comments Riccardo Suriano passionately.
MATERIA is a young company whose aims are to create scale models of the highest quality, reflecting reality as much as possible and offering constant service to customers not only during project development but also after sales.
3D printed furniture, when Art meet Additive Manufacturing
by Carolyn Schwaar thanks to all3dpi
Images and project by piegatto.com
Delta WASP: 3D Printed Furniture With Beauty & Form
Delta WASP 3D Printing Case Study: How a Guatemalan architect creates stunningly intricate furniture designs achievable only with a large format 3D printer.
A sculpture machine – this is how an artist sees a 3D printer. To furniture designer, architect, and artist Alejandro Estrada, his 3D printer is a tool on par with a hammer and chisel. He didn’t choose this method because it was faster, cheaper, or easier. He creates with a 3D printer because it expands what’s possible in design and challenges his imagination.
“When you know how to draw a line it’s completely unimportant if it’s with a stick, with your hand, with a pencil, or with a computer,” he says. “And when you know how to draw a line and you find much more accurate ways of doing so, then you take this new way of doing to create a work of art.”
Estrada’s art includes contemporary furniture design through additive manufacturing, specifically with the technology of Italian printer manufacturer WASP.
CASE STUDY AT A GLANCE
Type of Print: Final Piece - 3D printed chaise longue
Options: Injection Molding vs FDM
Industry: Furniture
3D Print Volume: 1 per week on average
Print Material: Various PLA, wood composite pellets
Printer selected: Delta WASP 3MT INDUSTRIAL 4.0
Printer investment: $40,000 with accessories
Time to ROI: Expected: 1.5 years
Art Meets Technology in Unique and Beautiful Ways
Estrada’s 3D printed furniture isn’t just an expression of art, it’s an expression of additive manufacturing technology itself because he only produces pieces that can’t be made any other way. “If it looks like you can do it with your hands or it can be done with another machine, then I think it doesn’t make any sense to 3D print it,” he says.
Some designers might imagine a chair then look for a unique way to produce it. Instead, Estrada begins with the method – the 3D printer – and then, with an intimate understanding of its capabilities, imagines what type of chair only it could produce.
And with this approach the Truss line of outdoor furniture was born. Retailing in exclusive designer furniture galleries in New York, Miami, and Los Angeles, each piece of Estrada’s furniture created by his company, Piegatto, is a solid, intricate object of art that is as beautiful as it is comfortable. Printed from biodegradable and weatherproof PLA with openings that create transparency, the chair stretches in some parts and stays sturdy in others.
Not many 3D printers are capable of producing prints at this level of complexity and size, and finding the right printer took Estrada time and testing.
Choosing the Right Printer and Material
Dozens of printer manufacturers display their machines at the IDTechEx Show in California every year. Estrada spoke with several and narrowed the companies to one that appeared to have the quality and scale he needed to create unique outdoor furniture. He traveled to Germany, conducted printing tests, and was very close to buying a machine, he says. “But the big problem was that we could only buy the material through them and, for the material alone, one chair was around $700. For what we wanted to do, it didn’t make any sense.”
The material had to be less expensive. Spools of filament, which start at $20 per kilogram, were out of the question for making a full-size chair. Instead, Estrada looked at thermoplastic materials in pellet form, which can run as low as $2.50 per kilogram.
More commonly used in injection molding, pellets are not only less expensive but come in a wider range of materials than filament, including a long list of recycled and sustainable products. Plus, because a high volume of pellet material is fed via a hopper into the extruder, pellet-based 3D printers typically can print large objects quicker than filament-based printers.
Sustainability is an important aspect of Piegatto’s designs. Not only should the furniture be made of sustainable materials but the process should create little waste, which is a hallmark of additive manufacturing.
For Estrada, 3D printing is a way to add even more beauty to an object. “We realized that we needed to do wise objects without waste, as the beauty of an object not only resides in what you see as a final product, but what … you practice in achieving that beauty.”
An Innovative Artist Meets an Innovative Printer
Material, size, and quality needs led Estrada to Italian printer manufacturer WASP (World’s Advanced Savings Project).
Known for its mission to 3D print clay houses to solve the world’s housing issues, WASP has grown over the years to offer a wide range of industrial printers for construction, architecture and design, art and culture, energy, medical devices, and food.
Test prints on the Delta WASP 3MT INDUSTRIAL 4.0 printer convinced Estrada to make the investment. Although WASP offers a printing service, purchasing the printer at $40,000 with accessories, made more sense, he says, not only because his design company is located in Guatemala City, Guatemala, some 10,000 miles away from WASP, but because his creative process required multiple iterations and testing
“Imagine all the trials and errors that we make,” says Estrada, “it would be impossible to do it with an outsource service.”
Piegatto’s two WASP printers (he also owns the Delta WASP 40100 Clay) run almost every day when there aren’t electricity blackouts, which are common in Guatemala. It takes six days to print one Truss chair and customer demand is high.
“We’re working on some modular benches for a shopping center, as well as some small pieces and vases,” says Estrada. “And the other thing is testing and more testing.”
Stay tuned to Piegatto for more innovative creations from Alejandro Estrada, a visionary pushing the boundaries of additive manufacturing for design.
Together with Technogym we present 3D printing in wellness
We had the opportunity to talk to the designers who work of Design Department of Technogym, the wellness giant. They explains us how large format 3D printing accelerate the company’s ability to innovate.
With yearly revenues above € 650 million in 2018, Cesena, Italy, based Technogym is one of the largest global operators in the wellness segment. Since it was founded in 1983 by Nerio Alessandri, the company has focused on key values such as environmental sustainability and innovation, which are clearly reflected in its state of the art Technogym Village headquarter. Here you will find its T-Factory and T-Research and Development Department, where over 130 engineers and designers have produced over 140 international patents and more than 93 trademarks.
The Research and Development Department plays a central role in the innovation process at Technogym, along with the Design Centre, which is responsible for the state-of-the-art product design and ergonomics. In the past few years, many of these innovations have been prototyped using a Delta WASP 4070 INDUSTRIAL 4.0 3D printer.
Conceptualizing innovation
Technogym decided to work with one of the world’s leading manufacturers of Delta architecture 3D printers and brought a 3D printer into their design department. “Our primary objective was to visualize and accurately represent our ideas, intended as the shapes of the parts we design as well as test how we are going to use these parts on our machines”.
In Technogym, he is in charge of conceptualizing technical tools and design the products that will arrive on the market. Needless to say, 3D printing has become a central part of workflow, drastically reducing errors during the product development phase and reducing lead time, especially for large size parts.
“In both the conceptualization phase and in the project assistance phase we need to be certain that what we model in CAD on a computer gives us the same answers in real physics as well. We need a component or product to convince us in real life, and not just on a monitor. At this time, this is a specific demand of the design department. Of course, the production teams are also always looking for a way to reduce the number of iterations in the production phase.”
Why Technogym has chosen WASP technology
At the beginning the company was already using a small filament based system for prototyping in ABS, using a closed materials system. The choice to turn to WASP was dictated by the need to have a system that was easier and more intuitive to use, with lower maintenance costs and - in particular – that could produce very large parts without using support material that would need to be removed using environmentally toxic products.
The choice fell on the Delta WASP 4070 INDUSTRIAL 4.0, which is now located inside a modeling center with sufficient space and tools to manage the full 3D printing workflow. A single system enables to company to produce between 15 and 20 parts, measuring as much as 30 cm in height, each month. The team use it mainly for 3D printing style models or to verify shapes, ergonomics and design elements. For this, they use mainly PLA-based materials, which are ideal for concept models and do not release toxic fumes during extrusion and deposition.
Larger, faster, better
“We chose the Delta WASP 4070 INDUSTRIAL 4.0 system for a number of reasons”. “One is certainly its large print volume, which enables us to print much larger parts than an average 3D printer. We also appreciated its printing speed and the much lower cost of supported materials, which allows us to buy more material spools and conduct more tests. Since it uses an open materials system, we can also decide to change the type of filament anytime, as our needs change over time. In addition, while it may seem like a trivial issue, the ability to select a filament’s color is actually very important for us. It allows us to save the time it would take to paint the part or, if we do need to paint it in a light color, we can just print in white so that the colors can stand out without requiring a base layer of white paint. The Delta WASP 4070 INDUSTRIAL 4.0 was also very easy to install and quite affordable for a system this large. Last but not least, it ensures a very high and repeatable quality standard of all the parts we print.”
Integration and innovation
Technogym’s development center makes intensive use of a number of machines to produce its functional prototypes. The company also often turns to external providers that can deliver mock-ups and prototypes on demand. 3D printing allowed the company to accelerate this process by ensuring that a part is error free even before the final prototype is completed and the actual final parts go into production.
“It is extremely important to have this kind of ability when you work on developing innovative concepts that have never been done, or even tried, before”. “This ability to rapidly innovate has made Technogym a global and technological leader in the wellness segment. Successfully integrating large format 3D printing into our workflow is going to continue to represent a key advantage for us going forward.”
Italdron revolutionizes drone production using Carbon Nylon and WASP 3D printing
The greatest value in terms of business and knowledge is formed at the crossroads of revolutionary technologies
Among the newest generations of products, drones are among those that best embody the concept of innovation. Not only for their technical characteristics, but also for the cutting-edge technologies used to develop and build them. As a manufacturing process, 3D printing is increasingly used within the drone production cycle, mainly for prototyping.
Italdron, an Italian company specializing in the design and production of innovative commercial drones, has been using 3D printing since 2014 and has further raised the bar by collaborating with WASP for the production of its latest, futuristic models. This latest application case clearly demonstrates how the right AM technology is now mature enough to ensure reliable final components and, at the same time, significantly reduce development times and costs.
Meet Italdron
Italdron was founded by three young entrepreneurs aiming to develop a service market using drones. Starting from aninnovative idea, the company has grown into the manufacturer with the highest number of Remote Piloted Aircraft (APR) authorized for flight by ENAC (the Italian National Civil Aviation Authority), as well as the first Italian manufacturer of professional drones to be licensed for "post-production flights".
Can it fly?
For its drone development and production needs, Italdron decided to turn to WASP’s 3D printing systems, integrating them within the production process . The relationship between WASP and Italdron has been going on for years, first with rapid prototyping and then gradually moving towards production of final components.
"We use WASP printers for different sectors: from production of mechanical tools, such as forklift hooks, to the creation of particular molds used to produce the drone body," explained Marco Solfrini, Italdron's design engineer. “We often work on customized vehicles. In most cases, in fact, the basic drone remains the same, but it needs to be customized to meet the customer's specific needs. WASP 3D printers are key for us given their precision and the significant printing height they can achieve”.
Italdron currently has 3 WASP printers, two Delta WASP 2040 and a latest-generation Delta WASP 2040 INDUSTRIAL 4.0 optimized for printing technical materials. The printers of the Industrial 4.0 Line can be networked and therefore managed directly from any mobile phone, tablet or laptop.
An innovative chamber system controlled up to 80 °C, with "Hot and Cold Technology" mechanical cooling, allows for optimal printing of advanced polymers and composites. A camera insidethe printer is used to monitor the print progress remotely. Thanks to these innovations, the printers can work 24 hours a day, producing both prototypes for testing and flying drone components, allowing the Italdron team to be able to evaluate their functionality and to detect any mechanical issue. In this way, the team can have tangible feedback on the project in extremely short times. The Delta WASP printers are able to print 24 hours a day because of their very robust mechanics, making them virtually indestructible.
Benefits of AM integration
"WASP 3D printing technology enabled us to speed up the production process and reduce costs," continues Solfrini. "In addition, they supported in every way. When you turn to WASP, you can count on an efficient customer support service. They help you at every stage, you can exchange ideas and develop new solutions. This relationship has greatly facilitated us in introducing this technology into our production cycle in a stable way ".Currently all the caps - which form the drone's hull - are 3D printed using Carbon Nylon filaments, to be installed on the final models. The choice of using Carbon Nylon as the main material for parts is tied toits excellent ratio between flexibility and resistance even at high temperatures: the latter, in particular, is fundamental to ensure that every Italdron drone can operate efficiently in the open air –where it is subjected to the most diverse climatic conditions.
Solfrini also emphasized how current AM technologies can provide a real added value for industrial production, and are destined to find more and more space in this area: “3D printing represents one of the key production tools of the future on an industrial level – he says. It is destined to play a more dominant role in production processes by integrating perfectly with technologies such as CNC and other machine tools. In our case it is a fundamental step: our drones, in fact, are assembled by combining pieces made of carbon, aluminum and 3D printed Carbon Nylon. This allows us to significantly reduce the weight of the vehicle, without sacrificing efficiency and robustness".
The collaboration between Italdron and WASP is not only a perfect example of "Made in Italy" innovation, but a strong demonstration of how the AM solutions offered by the Massa Lombarda company are now true technological enablers, which can help to address critical issues and improve traditional production process.
WASP realizes Carbon Fiber 3d printed parts on demand for Italian Speed Championship
WASP, the first and leading Italian manufacturer of advanced Delta 3D printers, has been pushing the additive manufacturing industry in new directions since it was founded by Massimo Moretti in 2012.
The latest evolutions are now heading towards leveraging the consolidated and highly reliable cinematics of its delta systems to address industrial-level end-use part production. With the introduction of the new INDUSTRIAL line 4.0, WASP supports the use of production grade material – such as the Nylon Carbon – for a growing range of products.
One such application highlights the versatility and accessibility of the Delta WASP 2040 INDUSTRIAL 4.0 for a racing team – competing in the Italian Speed Championship (CIV) – to bring, for the first time, a 3D printer inside the box, producing real racing parts.
“There is no doubt in my mind that having this technology inside the paddock represents a paradigm shift in the world of racing,” explained Flavio Gioia, the R&D Manager at WASP.
“You could theoretically replace the many parts that teams have to carry around with just a few spools of technical materials and a 3D printer.”
This approach is similar to that outlined by NASA for the future of long-distance space travel. However, its benefits are just as clear in a fast moving segment such as motorcycle racing: drastically reducing the time and cost for transporting spare parts can be a game changer. “All you need to do is take the filament with you and shape it up as you need it.”
Carbon fiber 3d printer
To respond to challenging requests as well as process reliability and parts repeatability: the new Delta WASP 2040 INDUSTRIAL 4.0 proved to be the ideal solution. This model is the natural evolution of WASP’s original Delta WASP 2040. It leverages the same general kinematics with the same cylindrical printing volume (20 cm diameter by 40 cm height) and its industry-recognized reliability.
The new line INDUSTRIAL 4.0 improves on the UI and UX, with a new capacitive touchscreen, a remote control system, and a live camera. Most of all, it introduces a new Hot and Cold technology with a new heated chamber, controlled up to 80°, and active cooling of the mechanics .
Hot and Cold technology of WASP printers allows the control of room temperature up to 80°C and cools down the mechanics making the print of technical materials easier.
This technology facilitates the use of technical materials such as nylon-carbon composites. Further improvements such as the aluminum heated plate and WASP’s auto-calibration system ensure even higher reliability during the print, as does the sensor on the chamber’s door, which ensures the heat is kept inside.
Carbon fiber 3d print
WASP and Toccio Racing have chosen the Nylon Carbon for its strength and lightweight properties, which makes it an ideal material even for extreme conditions, such as high speed racing at 300 Km/h.
“The growing use of composite materials is very relevant and shows how 3D printing is shifting from a tool for visual prototyping to functional prototyping and even direct production when needed.” Flavio Gioia explained.
“This is a key underlying trend for all 3D printing. Nylon CFR composites in particular are in very high demand due to the material’s excellent properties, especially for end-use parts such as those produced by a bike or automotive team."
“One of the most significant new developments is that we are making things easier to do than they used to be.” Gioia explains. “From our point of view as 3D print solutions providers, we continue to work toward this goal, without forgetting that a big impact comes from material research and the use of higher performance polymers and composites."
Gioia goes on to highlight how recent government incentives allowed some companies more freedom in exploring new technologies. “We always strive to find solutions to the many and very different requirements that our clients present to us. All this keeping in mind that several of them are now mature adopters of 3D printing, and they know what they want."
The ability to print directly on-location, on demand and, literally, on the go, parts that can be used during the race, such as, for example, the brake’s air conveyor, gives our clients more freedom with these ad-hoc components, the bike’s configuration can be customized based upon track-specific requirements. The team can also use 3D printers to replace parts that are damaged in a fall, which results in significant economic benefits as well.
“In the DNA of WASP there is the continuous research and improvement of the machines. I think that this attitude derives directly from a genuine curiosity and from the passionate investigation of discovery. Printing in the paddock at 300 per hour is just one of many daily challenges”, Gioia says with a smile.