School of Mechanical, Electrical and Manufacturing Engineering

Research

3D Printer Facilities Page

3D Printing Facilities

Within the Wolfson School of Mechanical, Electrical and Manufacturing Engineering, we use various 3D printing facilities to undertake our research. The facilities used within the High Value Manufacturing research theme include:

Fused Filament Fabrication (FFF)

FFF is the most common and accessible form of 3D printing producing parts from many common plastics. This process uses plastic filament (such as ABS or PLA) extruded through a hot nozzle onto a heated bed building the part layer by layer. A great introduction to 3D printing, these are used heavily by our students and researchers. The material costs are low and apart from removal of support material post processing is minimal. Examples include:

Stratasys

Machine: Dimension Elite
Materials: ABS Plastic
Build Volume: 203mm x 203mm x 305mm
Layer Thickness: 0.178mm or 0.254mm

Stratasys

Ultimaker

Machine: Ultimaker 2+
Materials: PLA, PETG, Nylon
Build Volume: 223mm X 223mm x 305 mm
Layer Thickness: 200 - 800 microns

Ultimaker

Raise3D

Machine: Raise3d Pro 2
Materials: ABS. PLA, PETG, Nylon
Build Volume: 305mm x 305mm x300mm
Minimum Layer Thickness: 0.01mm
Nozzle Diameter: 0.4 mm (Default), 0.2/0.6/0.8/1.0 mm (Available)
Max Nozzle temperature: 300 ºC
XYZ Step Size: 0.78125, 0.78125, 0.078125 micron

Raise3D

Markforged

Machine: Markforged Mark Two
Materials: Nylon (Base Material), Carbon Fibre, Glass Fibre, Kevlar (Reinforcement Materials)
Build Volume: 320mm x 132mm x 154mm
Layer Thickness: 100 - 200 microns

Markforged

Selective Laser Sintering (SLS)

SLS allows for precision manufacturing through selectively sintering polyamide nylon powder with a CO2 Laser. The EOS P100 SLS (Selective Laser Sintering) machine is where a 70W CO2 laser is used to scan across a bed of fine powder (typically PA12 nylon) sintering/fusing the powder together layer by layer. The un-sintered powder acts as a support meaning when finished the part can be dusted down without further support removal.

EOS

Machine: EOS P100 Formiga
Materials: Polyamide Nylon Powder (EOS PA2200)
Effective building volume: 200 mm x 250 mm x 330 mm
Building speed (material-dependent): up to 24 mm height/h
Layer thickness (material-dependent): typically 0.1 mm
Laser type: CO2, 30W
Precision optics: F-theta lens

EOS

Selective Laser Melting (SLM)

The Trumpf Truprint 1000 uses a 200W Fibre Laser to scan across a bed of fine metal powder to selectively melt each build pattern layer by layer producing intricate components which would be difficult or impossible to manufacture using conventional methods.

Trumpf

Machine: Trumpf Truprint 1000
Materials: Aluminium, nickel-based, cobalt-chromium, copper, titanium
Build Volume: Diameter 58 mm x 100 mm Height (normal Builld Volume diameter 100mm x 100mm height)
Laser beam diameter: 55 μm
Layer thickness: 10 - 50 μm
Building rate: 2 - 18 cm³/h
Gas: Nitrogen, Argon

Trumpf

VAT Polymerisation

VAT polymerisation allows for precision manufacturing using UV curing photopolymer resin. The Wolson School has a 3D Systems Viper SLA 3D printer, Formlabs 2 and a Photocentric Precision. This process utilises either a UV laser or digital light projection (DLP) to precisely cure UV curable resin producing highly accurate detailed components.

3D Systems

Machine: 3D Systems Viper Si2
Materials: Accura 60 Resin
Build Volume: 250mm x 250mm x 250mm
Vertical Resolution: 0.0025mm
Beam diameter: 0.075mm (Hi Res), 0.25mm (Standard)

3D Systems

Formlabs

Machine: 3Formlabs Form 2
Materials: Formlabs Clear Resin, Formlabs Flexible Resin
Laser Spot Size: 140 microns
Laser Power: 250mW Laser
Build Volume: 145mm X 145mm x 175mm
Layer Height: 25-300 microns

Formlabs

Photocentric

Machine: Photocentric LC Precision 1.5
Materials: Photocentric Daylight Precision Resins
Build Volume: 121mm x 68mm x 160mm
Layer Thickness: 25, 50, 100 microns
XY Resolution: 47 micron

Photocentric

Athena Swan Bronze award

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The Wolfson School of Mechanical, Electrical and Manufacturing Engineering
Loughborough University
Loughborough
Leicestershire
LE11 3TU