Boosting resource efficiency for circular industry by additive manufacturing

Important results from the project

1. We developed an new FDM based 3D printing system, enablling homogenuous materials mixing in situ of 3D printing process and creation of a broad spectrum mechanical properties with only two materials. 2. With the 3D printing technique, we produced orthosis and prosthesis that passed the the ISO standard testing methods and with reduced the CO2 emission per orthosis according to LCA analysis. 3. The project led to new collaborations between companies of different sectors.

Expected long term effects

The new 3D printing technology offers significant advantages in production flexibility, efficiency, and product quality. Moreover, enabling material mixing in situ during 3D printing extends material availability, which has been a limiting factor for the industrial adoption of 3D printing. The concept of materials mixing in-situ can readily be extended to metallic 3D printing, which will accelerate industrial adaption of 3D printing and on-demand manufacturing in various industrial sectors.

Approach and implementation

Project started with design and manufacturing mixing device having two materials inputs and one reinforced mixing insert that directly connects with output nozzle.. The mixing device was integrated with the existing 3D printer. 48 thermal plastic elastomers (TPEs) were tested and evaluated prior to production of demonstrating orthosis and prothesis. The demonstrators were tested according to ISO standards, then with patients via clinic tests.