1A Technologies

Industrial high-speed 3D printing with plastic granulate

Screw Extrusion Additive Manufacturing = SEAM

Why SEAM?

Handling and Speed

• High discharge performance up to 18 kg/h suitable for the efficient production of large-format, load-bearing structural components
• Easy handling (compared to powder)
• Continuous material supply (no spool exchange)
• True 5-axis 3D printing can be realized through special material forced feed into the screw for continuous conveyance process even for forced positions
• Almost all plastics can be processed without changing the screw and with highly wear-resistant components

*see diagram Build rate comparison

Material Costs and Availability

• More cost-effective than filament
• Wide range of series materials available (PA6GF/CF, PP GF, TPE, TPU) Standard up to 400°C
• Recyclate can be processed
• Regulated melt discharge -> significantly better layer adhesion and shorter dwell times in the screw for the processing of temperature-sensitive materials (e.g., natural fiber compounds) compared to the melt pump.

*see diagramm Cost Comparison

General

• Patented bypass nozzle concept for volume flow control
-> no additional expensive and heavy melt pump required
• Volume flow control between 0…100% (e.g., 0% for position jumps / 80% in corner areas to avoid contour overfill)
• Automated pressure regulation in the extruder to +- 1bar high consistent strand quality (independent of material batches) even with parameter drifts
• Damage-minimizing processing of fiber-reinforced plastics through gentle material discharge.
Build rate comparison 3D printing
cost comparison 3D Printing
Screw Extrusion Additive Manufacturing

Screw Extrusion Additive Manufacturing – Implementation

Penta SEAM - High-Speed 3D Printer + Milling

The extrusion unit is integrated in the 5-axis machines from Metrom. There, the machine is used for hybrid machining, i.e. additive and subtractive processing in one machine.

SEAM Hex - High-Speed 3D Printer + Milling

The extrusion unit is available in combination with a hexapod table as a pure 3D printer. The incredible performance of the parallel kinematic table allows industrial parts to be produced in a very short time without support structures.

Gantry SEAM

The high output rate of the extruder enables integration in a gantry machine for the production of large components.

HY5CAM - CAD-CAM software system

CAD-CAM software system programming environment for additive + subtractive processes based on RhinoCAD and moduleworks machining plugin.

Robo SEAM - Individual in production technology and process combination

The extrusion unit is integrated in the 5-axis machines from Metrom. There, the machine is used for hybrid machining, i.e. additive and subtractive processing in one machine.

SEAM variants and upgrade options

SEAM light

SEAM light

  • Minimal interface to kinematics
  • Includes extruder with 4 heating zones, 1 pressure sensor, and gear motor (On-OFF, speed)
  • HMI for controlling all functions.
SEAM 1K

SEAM 1K

  • Minimal interface to kinematics OR adaptive process control with LookAhead
  • Includes extruder with 5 heating zones, 2 pressure sensors + gear motor (constant speed)
  • Combined pressure and discharge control via patented 1K bypass system.
SEAM 2K

SEAM 2K

  • Adaptive process control with LookAhead Feedforward control
  • Includes extruder with 5 heating zones, 2 pressure sensors + gear motor (constant speed)
  • Pressure and discharge control via patented 2K bypass system for rapid process control.

What Can We Do For You?

Vacuum Clamping Device

Application scenario: Vacuum clamping device

• Manufacturing of the individual component with a surcharge of 4mm
• Final machining with final dimension tolerance
• Plastic instead of aluminum for lighter, more cost-effective components
• Simple and tool-less machining through material substitution.

Application scenario: Production of laminating devices (with internal honeycomb structure)

• Recreational vehicle bodies

• Special vehicle bodies

• Boat and yacht construction

• Floor plates

• Facade claddings

• and more…

Direct printing of TPU/TPE onto fixtures or textile

Application scenario: Direct printing of TPU/TPE onto fixtures or textile

  • printing on textile structures applications and advantages
  • piping for covering and fixing of textiles, possibility of easy disassembly and replacement of the textile
  • Local reinforcement, directional reinforcement
  • Functionalization -> Anti-slip
  • edge reinforcement, prevention of textile unraveling
  • Cutting aid
  • Flexible application of 3D structures
  • Flexible production processes due to fast change of variants by changing the printing program
Application scenario Furniture pieces

Application scenario: Furniture pieces

• Control panel with integration for 19″ rack PC
• Bar stools
• Conference tables and chairs

Application scenario: Orthopedic components

Current project Fraunhofer IWU AM-Ortho
• Process chain from scanning to direct printing can be represented
• Saving the plaster blank as an intermediate step
• Saving manual orthosis production by two people with warm film and hot air hairdryer

Application scenario: Structural components machine frame

• Production time 1 week instead of 3.5 weeks steel frame
• Weight saving of 50% compared to the original
• Expansion of the machine’s working area by 80%
• Manufacturing costs 50%