At RAPID+TCT tradefair

The renamed thermoplastic materials for the three 3D printing technologies will be featured at RAPID+TCT tradefair from 17-19 May 2022 in Detroit, Michigan (booth #2301), alongside the company’s Somos® resins for stereolithography and DLP/LCD. On booth #2301, ����AV will showcase a broad range of prototyping and end-use applications across many vertical markets. The company will also present at the RAPID Conference about how manufacturers who want to 3D print end-use parts need to select relevant test metrics to be sure the application will function properly in the end-use application, including throughout the complete product lifetime.

Phase out of the old thermoplastics brand names will be completed by May 30, 2022.

Arnilene®, Arnite®, Arnitel®, EcoPaXX® and Novamid® are registered trademarks of DSM.

Addigy^® FPC SOL1 HT provides a soluble support material for FDM printing of overhangs and cavities in high temperature materials such as polyether ether ketone (PEEK), with up to 100 percent infill of the support structures. The filament is easy to print without pre-drying. After printing, the translucent material can be removed easily and quickly by dissolving in a standard chemical solvent resulting in smooth surfaces. Both solvent and support material can be reused after a simple distillation process, making it a more sustainable solution.

Soft, elastomeric materials typically don’t 3D print easily. With Arnitel^®1 AM3001 (P) for SLS, ����AV material scientists successfully combined both. A Shore hardness of A88 and D35 with an excellent elongation at break, the thermoplastic copolyester exhibits a very high energy return. It processes easily and without common side effects such as odors. The material is compliant with Directive 2009/48/EC on Toy Safety and pending biocompatibility approval. The material shall be available for customer evaluation and development early in 2022.

����AV is announcing both an SLS and an HSS version of its thermoplastic polyurethane (TPU) powder Addigy^® PPU 86AW6. These materials exhibit excellent rebound, easy post-processing and high reuse rate of unsintered powder. Their easy handling during the printing process and properties make them suitable for a broad range of applications.

The four new materials complement ����AV’s recently launched Somos^® resins for SLA and DLP, and the company’s relaunch of the Low Smoke glass-filled PA6-66 flame retardant filament .

����AV now offers one of the largest choices in polymers for 3D printing since its acquistion of the additive manufacturing business from DSM earlier this year.

"If we want manufacturers to increasingly adopt additive manufacturing in industrial production, they need access to many more functional materials with properties matching their applications in terms of performance, regulations, safety and quality," said Hugo da Silva, Head of Additive Manufacturing at ����AV. "It takes solid material expertise to design materials that exhibit the required properties, not only when coming off the printer though also over time, in varying functional and environmental conditions."

����AV material scientists and application experts will be at the ����AV booth to discuss their innovations, the current state of engineering-grade materials for additive manufacturing, various test methods developed by industry groups to replicate application conditions in vertical markets, and what to consider when selecting materials for functional applications.

Visit ����AV at Formnext 2021, booth C11 in Hall 12.1.

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¹ Arnitel^® is a licensed trademark of DSM.

After jointly developing and qualifying a Thermoplastic Polyurethane (TPU) powder for HSS, the two companies are taking their collaboration to the next level by bringing customers a seamless material-process solution for volume manufacturing of their specific applications.

"Typically, material and processing technology work separately in the value chain, with customers having to figure out how to make them work," said Geoff Gardner, Innovation Director Additive Manufacturing at ����AV. "Together with voxeljet, we want to remove what we believe is still a barrier for adopting additive manufacturing on the production floor. Thanks to its size and speed, coupled with the constant layer time, HSS offers manufacturers an economic solution for series production."

Seamless material-process solution

voxeljet will contribute its knowledge with its large format VX1000HSS printer platform, and ����AV its expertise in designing functional materials, to develop a seamlessly working material-process solution that can be deployed for large scale manufacturing.

James Reeves, Global Director of Polymer Sintering (HSS) at voxeljet added: "This is a match of two companies strongly believing in really close collaboration across the additive ecosystem. The potential of HSS to process specialty powder materials is tremendous. By offering customers material choices, we accelerate their access to pioneering products."

Material possibilities that the companies are considering are TPUs, which are suited well for footwear and cushioning applications, as well as thermoplastic elastomers (TPE), polybutylene terephthalate (PBT) and polypropylene (PP). The collaboration with voxeljet involves scaling new materials on the large-format, industrial manufacturing machine – VX1000HSS, currently accessible via voxeljet’s Early Access Beta Program.

If you are interested in collaborating in this program, please reach out – both companies will showcase their polymer powder materials and printers at Formnext 2021, Nov. 16th-19th in Frankfurt, Germany, in hall 12.1; ����AV at booth C11 and voxeljet at booth C129.

Functional material solutions – meeting the needs of multiple end markets – that will be introduced and displayed at Formnext 2021 include:

• New powder materials for selective laser sintering (SLS), high speed sintering (HSS), and new filaments for fused deposition modeling (FDM)
• E-Perform™ optimized for EnvisionTEC’s equipment, bringing the benefits of Somos^® PerFORM to a faster and more economical printer technology, released at RAPID + TCT in September
• Somos^® PerFORM HW, the DLP/LCD version of their industry-leading SLA resin Somos® PerFORM, including proven post-processing solutions developed with automated resin removal technology from PostProcess Technologies Inc.
• Somos^® WaterShed AF, the new launched stereolithography resin that simplifies 3D printing investment casting patterns
• Low Smoke filament PA6/66-GF20 FR LS, whose certifications for flame, smoke and toxicity (FST) and easy printing make it a popular flame retardant material in the railway industry; the filament is part of the
• Proven material-machine solutions for PBT printing with Farsoon
• Digital tools for scaling additive manufacturing, including the anisotropic design optimization software launched with ParaMatters at RAPID+TCT, and a virtual AM expert which helps customers navigate brand-agnostic AM solutions for their applications.

The booth will feature applications for the automotive and transportation, sports and lifestyle, industrial, electronics, and medical industries printed in a variety of ����AV’s materials for stereolithography, fused filament fabrication, fused granulate fabrication (pellet printing), DLP/LCD 3D printing and powder bed fusion.

Focusing on functional materials, industry experts will be at the booth discussing the current state of engineering-grade materials in the industry, various test methods developed by industry groups to replicate application conditions in vertical markets, and how ����AV continues to develop truly functional 3D printing solutions.

Hugo da Silva, Head of Additive Manufacturing at ����AV commented: "Everybody across the AM value chain recognizes that industrial AM will only occur if and when manufacturers have the functional materials that bring the required properties to their components. We are excited to attend a physical Formnext event and show what our two bright teams have been working on in the past two years."

Visit ����AV at booth C11 in Hall 12.1. Start early and learn more about our solutions on our .

Higher overall efficiency

Additively manufactured tooling offers foundries, service bureaus and other producers of investment casting tooling overall efficiency including cost savings and faster lead times without degrading part properties. Complex and intricate patterns are possible so engineers can optimize the cast for the part rather than for the mold-making process. And the ability to quickly print and test multiple design variations is more easily accomplished versus traditional manufacturing. That said, as a relatively new processing technology, it is often regarded as difficult and adding risk.

"SLA resins designed especially for investment casting offer foundries an investment casting solution that reduces risks and saves time – from printing to finishing," said Geoff Gardner, Innovation Director Additive Manufacturing at ����AV. With no detectable levels of antimony¹, Somos^® WaterShed AF enables investment casting for all types of high performance metals such as nickel-based super alloys and titanium. "It also reduces the chance of imperfections appearing on the cast part, requiring less rework to finish the part.”

Somos^® WaterShed AF is highly dimensionally stable thanks to its low moisture uptake, so parts maintain their dimensions and mechanical properties, even under varying environmental conditions. This is particularly important in applications with tight tolerances like e.g. aerospace and aviation, transportation, energy and utilities. The resin can create accurate, complex patterns with excellent surface finish. Its low viscosity makes parts easy to print and easy to clean – typical for all resins in the Somos® WaterShed family.

����AV will showcase the new Somos^® WaterShed AF resin at the Investment Casting Institute Conference, from 7-9 November in Grand Rapids, MI, USA, and at Formnext, from 16-19 November in Frankfurt, Germany (Hall 12.1, booth C11).

¹ Measured by ICP-AES test methodology

Both Farsoon and ����AV are committed to an open systems philosophy so customers are free to choose materials for their 3D-printing systems that suit their end-use applications. In this collaboration, ����AV is contributing its expertise in polymer-based 3D printing materials and Farsoon its expertise from powder-based laser sintering machines. ����AV has already successfully launched TPU and PBT polymer powders developed on Farsoon 252P-series machines. The development of additional powders and the upscaling to larger series applications is part of the strengthened collaboration.

Expanded opportunities in the 3D printing market

����AV, Farsoon and (SLG) in Ulm, Germany jointly developed TPU parts for footwear. Seifert Logistics fabricates TPU parts on a Farsoon SS403P at high productivity levels.

����AV, Farsoon and a partner from the automotive industry collaborated to develop end-use parts for interior car applications using legacy-DSM PBT powder Arnite® T AM1210 (P).

"We are very pleased to extend the opportunities to the additive manufacturing market by proactively supporting new applications with new polymer powders," says Dr. Dirk Simon, Managing Director of Farsoon Europe GmbH and member of Farsoon's Global Management Team. "Farsoon SLS machines are very compatible with ����AV's polymer powders, which offer a very interesting property profile to form an important foundation for our customers' market success."

High productivity

Farsoon machines are all truly open systems which means operators can optimize process parameters for highest productivity at required part qualities for the material of choice. The High-Temperature- and Super-Temperature-configuration of Farsoon machines allow process chamber temperatures of up to 220 °C or 280 °C, respectively. The machines are equipped with high-speed scanners and powerful lasers. Farsoon is committed to help making fabrication of 3D-parts cheaper, for instance with its Fiber-laser Flight™ Technology. The high productivity of parts production makes series applications increasingly accessible.

“By collaborating closely with printer manufacturers, we can test materials in the development process and provide customers verified material and printer solutions”, said Geoff Gardner, Innovation Director Additive Manufacturing at ����AV. “Farsoon SL printers and especially their Flight™ Technology can run at standard and high temperatures so we can print PBT, PP and TPU all on the same printer. And with their higher accuracy and productivity, and lower cost per part, they are well suited for industrial production.”

Both companies will showcase their polymer powder materials and printers at Formnext 2021, which takes place Nov. 16-19 in Frankfurt, Germany, ����AV at booth C11 and Farsoon at booth G 19, both in Hall 12.1.

Since 2016, the two companies have been partners, distributing filaments for 3D printing in Europe and North America. Through the expansion of material offerings and multiple inventory storage locations, 3D at Nexeo Plastics will distribute globally and ship directly to customers, shortening lead times. Industry players will also benefit from broader application development and technical support through Nexeo Plastics’ 3D team.

“As part of our business growth strategy, we continue to expand our 3D printing product portfolio and support services.” said Paul Tayler, president and chief executive officer of Nexeo Plastics. “Our expanded partnership with ����AV, an industry leader, enhances our material offerings with sustainable, quality materials that our customers want and need.”

����AV’s rapidly growing portfolio of high-performance and functional materials offers some of the best mechanical and thermal properties in the industry with a key focus on sustainability. As the 3D printing industry continues to grow, ����AV understands that manufacturers need a simple process to acquire materials without sacrificing technical expertise. 3D at Nexeo Plastics provides this solution.

Jill Cohen, Commercial Director Additive Manufacturing at ����AV, adds: “Our material experts develop material-processing combinations so customers can 3D print parts with the right properties for their applications. To deliver these materials when and where our customers need them, we work with fulfillment and tech service specialists like 3D at Nexeo Plastics. Their team is very complementary to our own team; we speak the same language.”

The combination of ����AV material expertise and EnvisionTEC printer technology resulted in a complete industrial manufacturing solution for 3D printing injection mold tooling. Until now, no solution was available that met the stringent industry-required properties in terms of dimensional stability and minimal warpage. The patented material formulation from e-PerFORM™, optimized for EnvisionTEC’s equipment, brings the benefits of Somos® PerFORM to a faster and more economical printer technology.

To bring customers a workable and proven material and printer solution, EnvisionTEC and ����AV optimized print parameters and verified ����AV’s new DLP resin e-PerFORM™ on EnvisionTEC’s Perfactory P4K series printer. EnvisionTEC further tested e-PerFORM™ resin with key molding institutes to validate the material’s performance. Completed mold trials demonstrate that e-PerFORM™ resin, with high stiffness and high temperature performance, behaves similarly to stereolithography resin Somos® PerFORM for injection molding tooling.

Tests confirm suitability for rapid mold making

Tests done by , the French Federation of Plastics and Composites, confirm the suitability for rapid tooling. Guy Chrétien, Process project manager at Polyvia confirmed: “We tested the new e-PerFORM™ resin printed on the EnvisionTEC P4K printer and demonstrated that we could achieve very good results in part fidelity and in the number of shots molded in both polypropylene and glass-reinforced nylon. With the cost effectiveness and print speed of the P4k platform and with the properties of the e-PerFORM™ resin, this creates additional opportunities for rapid tooling.” Learn more about their testing on .

The combined solution of ����AV DLP resin e-PerFORM™ on EnvisionTEC’s Perfactory P4K series DLP 3D printing will be presented during RAPID+TCT in Chicago from 13-15 September.

Al Siblani, EnvisionTEC CEO commented: “The combination of our P4K printer and ����AV e-PerFORM™ optimized for our printers enables fast, cost-effective production of injection molding tooling. Our collaboration has resulted in a new and much-needed solution.”

Hugo da Silva, Head of Additive Manufacturing at ����AV commented: “By working closely with our partner EnvisionTEC, we developed a material that meets critical needs voiced in the market: improved dimensional stability and minimal warpage for optimal functionality. The validation and proven solution with their P4K printers will help accelerate the adoption of additive manufacturing of injection mold tooling.”

To learn more about this solution, visit ����AV (booth E7212) and EnvisionTEC (booth E7501) at RAPID+TCT, September 13-15, 2021.

Producing molds for low volumes or parts with detailed features is time consuming and costly, though with DLP and LCD 3D printing these barriers are lessened. DLP and LCD 3D printing offer fast printing speeds and a more economical cost of entry, making it more accessible to companies looking to adopt additive manufacturing.

One of the first resins meeting industry-required properties

Until now, no solution was available that met the stringent industry-required properties in terms of dimensional stability and minimal warpage for 3D printing injection mold tooling. Somos® PerFORM HW, based on the stereolithography resin Somos® PerFORM HW fills that gap. Its innovative and patented formulation makes it now possible to print large-scale and functional applications on DLP/LCD printers.

Completed mold trials demonstrate that Somos® PerFORM HW, with high stiffness and high temperature performance, behaves similarly to Somos® PerFORM for injection molding tooling.

Hugo da Silva, Head of Additive Manufacturing at ����AV commented: “By turning to our ecosystem of partners and working closely with EnvisionTEC, we developed a material that not only meets critical needs voiced in the market such as improved dimensional stability and minimal warpage for optimal functionality though we also ensure a processable material and a printer+material solution.” He added: “Customers need the right material for end-use parts though they also want materials that can be processed fast in volume production.”

Visit ����AV (booth E7212) and EnvisionTEC (booth E7501) at RAPID+TCT in Chicago, September 13-15, 2021.

Using the new optimization tool, designers and engineers can quickly obtain the most optimal part design based on material deposition and fiber orientation and generate the most efficient printer toolpath. The result is materials, weight, and cost savings – while maintaining part performance – that surpass what can be achieved today by engineers relying on experience or intuition.

Benefits of anisotropic materials

Additively manufactured parts produced from fiber-reinforced materials are a valid alternative to metal parts due to a better strength-to-weight ratio – reducing part costs and supply chain complexities. That said, none of the existing topology optimization tools were able to consider these anisotropic materials. Until now. Following successful initial evaluation by leading aerospace users, including , on multiple filament extrusion printers, ����AV and ParaMatters are introducing the beta version so more users can exploit the full benefits of anisotropic materials.

����AV and ParaMatters will be showcasing the new software at RAPID + TCT 2021, from September 13 to 15 at McCormick Place, Chicago, on ����AV booth E7212.

Composite Technology Center / CTC GmbH (An Airbus ����AV), with deep expertise in composites design and manufacturing, was one of the first companies to fully evaluate and validate the value of ParaMatters anisotropic generative design and manufacturing engine.

Marc Fette, CEO of Composite Technology Center / CTC GmbH (an AIRBUS ����AV): “The anisotropic behavior of 3D printed parts with fiber reinforcement allows us to gain weight potentials compared to conventional approaches. With our pre-existing methods of working, the design and sizing of 3D printed parts require multiple tools. ParaMatters anisotropic optimization capabilities allow us to combine multiple stages into a single step, enabling us to cut development times by orders of magnitude and create stronger and more light weighted components”.

Avi Reichental, ParaMatters co-founder and Chairman added: “We are proud to partner with ����AV and be the first to market with such a powerful design and manufacturing optimizer for the benefit of aerospace, defense and automotive customer around the world.”

Hugo Da Silva, Head of Additive Manufacturing at ����AV, added: “The collaboration between software, materials and equipment players takes manufacturing, material science and generative design to the next level. We can now realize large savings in materials, printing time and cost while maintaining performance and quality. Definitely a promising route toward scalable and more sustainable 3D printing.

Users who want to join the expanding beta program as well as providers of filament-based extrusion 3D printers that want to qualify and certify their systems can contact ParaMatters .

To learn more, check out this and watch this .

To learn more about upgrading your current filament extrusion 3D printer into a full capability composite system, ����AV and ParaMatters are organizing a series of webinars. More information on this .

The product sets the standard for performance by retaining its toughness and UV resistance in environments with higher temperatures of up to 122 degrees Celsius, enabling the printing of components for outdoor applications. Further, the new filament is very easy to print, providing the opportunity for broader applications in 3D printing. Nexeo Plastics and ����AV underline this with a 250 percent enlarged Benchy successfully printed on the Ultimaker S3 printer.

The polycarbonate blend is available in black and white and in filament diameters of 1.75 and 2.85 mm. In line with customer requests, a wider range of colors will be added to the PC/ABS portfolio later this year.

Multi-year cooperation

"For the last couple of years Nexeo Plastics and ����AV have worked extensively on customer applications and material requirements for OEMs. This collective know-how has built the foundation on which the product is being launched on the Ultimaker Cura platform in order to offer our customers the most convenient and reliable PC-printing solution," said Patrick Rosso, Global Head of Additive Manufacturing at ����AV.

The development of Addigy^® FPB 2684 was a collaborative effort. It resulted in a material that provides an extremely smooth surface finish while delivering impact resistance and superior strength. Leveraging its deep technical support services experience, Nexeo Plastics utilized testing scenarios based on real-world printing demands in the market to promote the development of ����AV’s Addigy^® FPB 2684. Ultimaker co-developed the printing parameters for its Ultimaker S3 and S5 series printers, which are ready for download on the Ultimaker Cura Marketplace.

"As part of our business growth strategy, we continue to invest in expanding our 3D printing product portfolio and support services," said Paul Tayler, president and chief executive officer of Nexeo Plastics. "Our collaboration with ����AV highlights our commitment to offering great products and working with industry leaders to support a wide range of users and manufacturing requirements."

The filament is particularly suitable for brands wanting to make their supply chain more sustainable, especially in combination with 3D printing technology for production on an industrial scale. Compared to virgin material, the filament using recycled material has a lower carbon footprint. The product is also more durable and meets industry-specific requirements such as the Blue Angel and EPEAT seal.

The fact that the waste comes from one single source is an advantage. This means that no prior sorting and identification of the plastics is necessary. The plastic waste is quite pure and can be recycled in a cost-effective manner. In addition, it is available in sufficient quantities. In China, large-volume water bottles are widespread in private households and public places. These are collected and refilled again and again before finally discarded and sent for recycling. This is another example of how ����AV is helping to build a circular economy in collaboration with partners along the value chains.

The high temperature post-consumer product has outstanding thermal stability and strength. Because of its properties, a constant temperature chamber is required to print successfully.

Machine manufacturer INTAMSYS conducted print tests with Polymaker™ PC-r on its FUNMAT PRO 410 printer. The printer can achieve a dual jet temperature of up to 500°C and a platform temperature of up to 160°C. The chamber temperature can be up to 90°C, which prevents warping of printed parts and allows larger and more complex models to be printed more successfully.

Tests have demonstrated that the Polymaker™ PC-r material is extremely easy to process. The test scores show good values for tensile strength, Young's modulus, flexural strength and flexural modulus, which were slightly higher than standard polycarbonate.

Extensive range of products at the TCT Asia trade show

Polymaker will be presenting a wide range of materials for 3D printing, ranging from high-performance plastics to unique aesthetic solutions, at booth number F44 at TCT Asia, the 3D printing trade show in Shanghai, China, from May 26-28, 2021.

At the trade show, ����AV and its additive manufacturing business, including the newly acquired business from DSM, will be exhibitingon two booths as both had registered separately prior to the transaction. Visitors to the trade show are invited to visit ����AV at booth number E46 and the former DSM AM at a at booth number C48 to learn more about the company's broadend product portfolio.

The glass-fiber filled pellet material brings structural performance to a part at a substantially lower carbon footprint than virgin material. Manufacturers can now make their supply chain more circular without the need to compromise on performance.

Increasing sustainability, reducing cost

The recycled PET has been optimized for 3D pellet printing. This technology, also known as fused granulate fabrication (FGF), allows for fast and economically viable additive manufacturing of large-size parts. Direct printing of applications lowers cost by reducing product development time. Plus 3D printing allows design flexibility, which can help reduce material cost. 3D printing is an intrinsically more sustainable production method as it only uses the material that is needed. By also making the material more sustainable, ����AV helps manufacturers shift toward a Circular Economy.

Arnite^® AM2001 (G) rPET‘s mechanical properties and broad processing window makes it ideally suited for structural applications across a variety of industries, including pedestrian bridges, tiles for cyclist or pedestrian tunnels, architectural applications like cladding or partition walls, in- and outdoor furniture, small boats, packaging crates or tooling.

Hugo Da Silva, Head of Additive Manufacturing (former-DSM) commented: “The introduction of this high-performing material for 3D pellet printing is an important step in creating circular supply chains. With PET packaging accounting for more than 50 percent of total plastic waste, extending its lifetime by re-using it as feedstock offers a broadly available alternative to virgin raw materials – without the need to compromise on performance or total cost of ownership.”

Patrick Rosso, Head of Additive Manufacturing (����AV) added: “We’re excited about the introduction of this circular material designed by our new colleagues. It perfectly fits the ����AV vision of a Circular Economy. This material is the best proof point we could want to underpin the two teams’ joint ambition to bring the market a stronger materials partner that can help accelerate industrial additive manufacturing.”

"Rethink Materials is an invitation to everyone to come into conversation with us and think jointly about new solutions for existing and upcoming challenges," says Christopher Schirwitz, one of the two ����AV stand managers at Fakuma-virtual. "As a supplier of high-tech polymer materials, we would like to learn about new perspectives in order to create innovations in close cooperation with our customers and partners that start with the material and ultimately go far beyond it. For us, Rethink Materials is inseparably associated with sustainability and our focus on the circular economy."

Premiere for digital showroom

At Fakuma-virtual, the new virtual showroom of ����AV will experience its global premiere: From October 13, visitors can discover the showroom rooms and experience how innovative and functional materials are changing the way people live, work and communicate. Future design can be experienced in developments created with thermoplastic composites or advanced 3D printing technology.

It is not only presentations and customer experiences that are increasingly being conducted in virtual rooms. "Design processes are also becoming increasingly digital," says certified designer (Dipl. Des.) Hans-Eberhard Stein from Central Marketing at ����AV. "For example, this also includes the creation and use of digital prototypes." ����AV intends to intensify its focus on the target group of designers and their specific needs.

New Virtual Sample Library and CMF Library App

The virtual sample library is also making its debut: Here, everything is centered around the optical and haptic design of products. Designers and other visitors can search for specific materials or be inspired by the wide range of products. The combination of color, material and finish (often abbreviated as CMF) opens up a wide range of design possibilities. For this purpose, ����AV is offering the CMF Library App in its virtual showroom and is presenting the sample library in the form of a video – a new way of making materials tangible.

Companies are also invited to Topic Days on the first three days of the fair. In this context, videos on the following topics will be shown: 

• October 13: Designs for the Future (Topics: 3D printing and the Maezio® thermoplastic composite)
• October 14: Streets of Tomorrow (Topics: Car interior concept of the future, multi-functional display concept and efficient assembly of lithium-ion cells in the car battery)
• October 15: Future Home (Topics: 5G telecommunications, design of charging stations for electromobility and connectivity)

Visit the ����AV digital showroom and talk to the experts. You can reach them there from October 13 to 15 from 10 a.m. to 4 p.m. CET. Further information is available at: . As of October 13, you will also find a link to the ����AV digital showroom there.

The logo consists of the two letters N and L of the country code, each one meter high. The main frame of the figures is made of polycarbonate, which contains recycled materials from waste sources such as used water bottles. It has been 3D printed using innovative large format technology. This finished part is strong and durable and is suitable for both indoor and outdoor applications. ����AV is already working with Chinese partners in the value chain to transform used polycarbonate water bottles into high-performance recycled plastics for the electronics, household appliances and automotive industries.

The facade of the logo is made from recycled Maezio^® composite sheets, which are made from processing waste. This material is not only light, strong and durable, but also corrosion resistant to meet the demanding requirements of outdoor installations. Its thermoplastic matrix makes it possible to completely recycle the material from both industrial waste and end-of-life products.

With open innovation to recycling management

"Circular economy must become the new guiding principle and that’s why we are working with the Consulate General of the Kingdom of the Netherlands in Guangzhou and partners in the value chain to design and produce this creative logo," said Holly Lei, President of ����AV China. "Through open innovation, we are striving to integrate the industrial chain and involve the end users to achieve a fully circular economy."

Michiel Bierkens, the Consul General of the Kingdom of the Netherlands in Guangzhou, said: "We are happy to be working with ����AV to enhance our new logo, as such cooperation will underscore our joint efforts to create a circular and sustainable world. We expect to promote this concept locally and globally by using it in our events so that more people can see this initiative and contribute their own efforts."

����AV is on the way to fully aligning its entire production and product range, and in the long term all areas, to a new circular concept. The initiative to anchor circularity in a holistic approach focuses on four priorities: an increased use of alternative raw materials, innovative recycling processes, renewable energies and joint solutions.

"The partnership with NANOxARCH and the Dutch Consulate for the new logo is just another concrete example of how our open-innovation collaborations in China can drive solid progress towards the future, especially in a circular economy," said Dr. Michael Schmidt, ����AV's Head of Innovation for Asia Pacific. "For us, this is just the beginning, as we and our partners are working on numerous concrete measures and projects along the value chain for improved recycling and reusing plastics."

The ����AV products used in the logo include an aqueous polyurethane dispersion for adhesives that bond the main frame and facade securely, easily and efficiently, and raw materials for aqueous polyurethane coatings that offer good adhesion to the recycled polycarbonates, flexible surface design, anti-stain and durability. Both waterborne systems are also characterized by very low VOC emissions.

Signify chose for polycarbonate from ����AV, as it fulfills customer requirements like high impact and heat resistance, design freedom, transparency and flame-retardance, which allows luminaires to be quickly designed and tailored to customers´ exact needs. Not least it is 100 percent recyclable, supporting the concept of a circular economy.

“We are the first lighting manufacturer to produce 3D-printed luminaires on an industrial scale. This reinforces our position at the forefront of lighting and sustainable innovation,” said Coen Liedenbaum, Venture Manager 3D Printing at Signify. “Customers are able to bring their ideas to life in a matter of days rather than months, and printing uses less energy.” The announced that it was providing printed luminaires to multiple major retailers.

Successful upscaling

“����AV offers a comprehensive range of polymeric materials for all common 3D printing methods, including polycarbonate raw materials for this promising application,” explained Patrick Rosso, Global Head of Additive Manufacturing. “By partnering with companies like Signify, we are pushing existing scale boundaries and supporting various industries along the value chain on their way to digital mass production.”

����AV is currently researching materials to enable an extended range of industrial applications. To this end, the company is upgrading laboratories for 3D printing at its Leverkusen, Pittsburgh and Shanghai sites, where it develops and tests material solutions for serial additive manufacturing in collaboration with different customers. At the forthcoming trade fair from 19-22 November 2019, ����AV will be showcasing a number of current developments for 3D printing at its Booth E11 in Hall 12.1.

Signify´s investment further illustrates the company´s commitment to better serving its customers while reducing their, and its own, carbon footprint. The company´s 3D-printed luminaires are designed for a circular economy as nearly every component may be reused or recycled.

Strategic program to promote circular economy

����AV regards the circular economy as a key topic and has launched a long-term strategy programme for this purpose. “Our company wants to shape the transition from a disposable economy to a circular economy with as many partners as possible,” said Rainer Rettig, Head of the Circular Economy program at ����AV. “To this end, we already provide our customers with tailor-made products today. This project is a wonderful example for this.”

“Our finished luminaires have a 47 percent lower carbon footprint than traditionally built metal luminaires,” added Coen Liedenbaum. “They also weigh less, which allows us to reduce the carbon footprint in shipping by 35 percent. And by keeping production locally we reduce the footprint even further.” Signify plans to integrate energy-efficient LED lights into its luminaires at all existing and new production sites.

Using 3D printing, shoes could be made from only two parts – upper and sole. ����AV has developed a material that enables automated production at lower cost and complete recyclability of the finished shoe. At the trade fair from 19 to 22 November 2019 in Frankfurt am Main, Germany, the company will be presenting these and other developments of its additive manufacturing programme at Booth E11 in Hall 12.1.

A powder and a filament, both based on thermoplastic polyurethane (TPU), proved to be the material of choice for meeting all the above requirements. The plastic offers high rebound and abrasion resistance and is therefore ideally suited for the production of both shoe parts. In addition, the shoe can later be recycled in a single step, including the polyurethane adhesive used for production – an important milestone towards recycling. Old shoes are thus turned into filaments for new shoes.

����AV also operates its own 3D printing laboratories in Leverkusen, Shanghai and Pittsburgh to support its customers in the key regions. There, the company works hand-in-hand with them to develop material solutions and test them in practice.

“Thermoplastic polyurethane is the material of choice for this application thanks to its favorable range of properties,” says Patrick Rosso, Head of Additive Manufacturing at ����AV. “In particular, our TPU products cover a wide range of hardness. The hardness can also be adjusted by changing the printing structure. This allows manufacturers to print shoe insoles that are completely custom-made – with hard or soft contact areas.”

High functionality and durability

Together with a partner, ����AV is currently testing different sole designs to determine which are the easiest to print along with the most durable. Initial tests have been promising, both in terms of functionality and longevity. Orthopedic insoles are often produced by hand and take a lot of time.

Besides that, conventional insoles are e.g. made by forming or machining rigid foam blocks and are also less breathable. Using additive manufacturing offers a more sustainable approach to producers. It could help significantly more people to get access to orthopedic insoles.

Successful last production using 3D printing

Already back in May 2018, ����AV presented the design of an efficient complete solution for the manufacture of orthopedic shoe lasts at the OT World orthopedics trade fair in Leipzig. Thanks to 3D printing technology, the time required for production has been reduced from several weeks to just a few days. At the same time, patient visits to the shoe manufacturer can be reduced to a minimum. After the trade fair, customers expressed the idea of also printing the insoles instead of manufacturing them by hand as before. The idea and the favorable material properties of TPU were the reason for the current project.

The three new materials consist of:

• Polymaker™ PC-ABS – a blend of already commonly used 3D printing materials, polycarbonate and ABS. The advantages of this blend are high impact and heat resistantancy and easy processing. The polycarbonate boosts the heat resistance and toughness of the material while the ABS contributes to the good processing properties. This PC-ABS is also specialized for surface finishings, i.e. by electroplating and metallization, providing a good approach for post processing.
  
  Polymaker™PC-ABS uses ����AV’s Bayblend^® family as its base material which is a commonly used plastic in the automotive and information technology industry today. Polymaker™ PC-PBT – this polymer blend combines the good chemical resistance of PBT with the strength and toughness of polycarbonate. Polymaker™ PC-PBT performs very well under extreme circumstances whether in contact with hydrocarbon based chemicals or operating at subzero temperatures. The product maintains good toughness and its natural ductile fracture behavior at low temperatures.
   
• Polymaker™ PC-PBT is created from ����AV’s Makroblend^® family which is widely used in various industries. Compared to PC resins and PC-ABS compounds, PC-PBT has better resistance to chemicals, which enables printed applications where resistance to intermittent contact with fuels, oils, lubricants, cleaners is necessary.
   
• PolyMax™ PC-FR, a creation from ����AV’s Makrolon^® family, where the FR stands for flame retardant – the main feature of this polycarbonate based compound. This base material achieves V0 performance in the UL94 flame retardancy test and benefits applications where respective material approval is required. This allows PolyMax™ PC-FR to be applied for battery housings, motor mounts in aerospace and other industries. Within the automotive and electrical and electronics industry, many professionals are well accustomed with such FR materials.
  
  Polymaker have introduced their nano reinforcement technology that is featured in all PolyMax™ materials. This boosts the fracture toughness of the FR material and produces a flame-retardant filament that can still perform in demanding applications. PolyMax™ PC-FR uses ����AV’s Makrolon^® showing a good balance between mechanical performance and safety, which has already been applied in electronic motorbikes, aerospace spare parts, and automotive production.

Silicon Valley based company has developed Digital Light Synthesis™ (DLS™) technology, which can accelerate the production of parts up to a hundredfold compared to previous processes. After years of R&D, Carbon developed a novel polyurethane liquid resin suitable for production parts.

����AV is a key partner in the scale-up and high-volume production of this material. The company invested a significant sum to enable the production in commercial quantity. As a result, joint forces proving mass production viability of the 3D-printing process and the respective material, and this is a current success of the partnership.

Wanted: suitable materials for mass production

"Our biggest challenge in the upscaling of additive manufacturing until series production lies in the supply of suitable materials in the required quality and quantity," explains Patrick Rosso, global head of additive manufacturing at ����AV. "By partnering with companies like Carbon, we are pushing existing scale boundaries and supporting various industries along the value chain on their way to digital mass production.”

����AV is currently researching materials to enable an extended range of industrial applications. To this end, the company is upgrading laboratories for 3D printing at its Leverkusen, Pittsburgh and Shanghai sites, where it develops and tests material solutions for serial additive manufacturing in collaboration with different customers.

Efficient manufacturing process

DLS™ technology developed by Carbon, is now being used for the first time on a large scale. Similar to stereolithography, the workpiece is created in a vat of liquid plastic resin that is cured by means of UV radiation.

At Carbon’s DLS™ technology, oxygen is supplied from below to counteract the curing and thus creating a liquid dead zone. For this purpose, the bottom of the vessel is made of a light- and air-permeable membrane, similar to a contact lens. Due to this dead zone, the printed part can be pulled continuously upward without the formation of individual layers.

Production using DLS™ technology is up to 100 times faster than with stereolithography – another important prerequisite for industrial mass production. In that context, a proprietary process combines software, hardware and materials. It imparts the desired technical and mechanical properties to the finished parts.

About ����AV:

With 2018 sales of EUR 14.6 billion, ����AV is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. ����AV has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

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Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by ����AV. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in ����AV’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

The most technically challenging step in this process is bonding the outsole to the shoe upper. ����AV developed an efficient solution for this within a very short time. It is based on polyurethane raw materials for adhesives, which are applied to the outsole or upper by means of digital printing.

Digital printing of adhesives

For the application, ATOM Lab used a variation of the melt layer method (Fused Filament Fabrication, FFF, or Fused Deposition Modeling, FDM). This method uses strands of melt-processable adhesives – so-called filaments – which are melted. The molten adhesive is applied according to a digital print layout. The sole and upper are then joined under pressure. This creates a solid, permanent adhesive bond.

This application using adhesive filaments is quick and efficient. Furthermore, it is very precise and reproducible, and it is also well suited for absorbent substrates. Due to the use of solid filaments, for example, the subsequent drying process may be dispensed. The adhesive features a high initial strength. Since application takes place from the melt, the adhesive is already activated. If the open time is sufficiently long, the fabricator can dispense with prior heat activation. Thus, two process steps can be saved in total.

Broad experience in additive manufacturing

����AV benefited from its experience in additive manufacturing with the technology and material solution developed on short notice. The company is involved in conventional printing methods and is currently developing a wide range of materials. Among these are filaments and raw materials for the FFF method, which so far has been used primarily in rapid prototyping.

Polyurethane adhesives have proven to be successful in shoe manufacturing. They are easy to process and result in flexible yet strong and durable adhesive joints with high impact resistance. ����AV offers a comprehensive range of raw materials for one- and two-component adhesives that are often developed in close collaboration with formulators.

About ����AV:

With 2016 sales of EUR 11.9 billion, ����AV is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. ����AV has 30 production sites worldwide and employs approximately 15,600 people (calculated as full-time equivalents) at the end of 2016.

For more information please see www.covestro.com.

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Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by ����AV. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in ����AV’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.