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Covestro Develops New 3D Printing Materials for Industrial Mass Production

Published on 2016-06-27. Author : SpecialChem

3D printing is a fascinating method for designing three-dimensional parts of complex geometry on computer, and then using the CAD data to manufacture the parts on a special 3D printer. Prototypes and samples can be fabricated layer by layer at a reasonable cost.

3D Printing material

After recognizing the advantages of these additive manufacturing processes, industry now also views them as a major opportunity for efficient mass production of complex or individualized parts.

3D printing has to clear some hurdles before it can go into more widespread use. One key issue is the lack of suitable materials. While over 3,000 materials are available for conventional component manufacturing, only about 30 are available for 3D printing.

Covestro Offers Product Line for 3D Printing

New Materials for all Common 3D Methods

Covestro is currently developing a comprehensive range of filaments, powders and liquid resins for all common 3D printing methods.

The company markets products with a variety of properties like toughness and heat resistance as well as transparency and flexibility that support a number of new applications. Covestro's efforts will make a key contribution to advancing the use of 3D printing in industrial mass production.

Partners Wanted

“We want to work with leading partners in the process chain to further advance these developments,” added Julien Guiu, who leads the company's global 3D printing activities. “These include formulators, 3D printer manufacturers, software companies, service providers and of course OEMs.” The company believes that the material data should be integrated into the software used on 3D printers so that component structures can be further optimized.
Covestro Opens New Laboratory for 3D Printing
Fig. 1: Covestro Opens New Laboratory for 3D Printing

Covestro to Contribute in Advancing Use of 3D Printing

  • Recently opens a new laboratory for 3D printing at its headquarters in Leverkusen. 
  • Lab to receive additional equipment.
  • Covestro and its partners to develop material solutions and test them under practical conditions. 
  • Covestro competence team for additive manufacturing possesses extensive know-how in the processing of materials using common 3D printing technologies. 

Versatile Offer for Fused Filament Fabrication Process (FFF)

Covestro offers a broad choice of filaments for the FFF process: flexible thermoplastic polyurethanes (TPU) and high strength polycarbonate (PC).

Covestro TPU

  • It is very well suited for additive manufacturing because of its excellent abrasion resistance and elasticity. 
  • Typical applications of Covestro TPU are sports, footwear or automotive.

Covestro PC

  • Polymaker transforms Covestro PC grades into filaments which show excellent temperature stability and toughness. 
  • 3D printed products made from Covestro PC can be used in lighting, design and other applications that depend on good strength even with exposure to high temperatures. 

First Fully Flexible Materials for Selective Laser Sintering (SLS)

Covestro also offers TPU powders for selective laser sintering (SLS), in which a laser beam is used to sinter the material. Spatial structures are thus created layer by layer. TPU displays significant advantages over materials commonly used in SLS, which tend to be less tough and elastic.

TPU powders are already used in the industrial production of individualized high-performance soles for shoes, for example. Those products are formulated and commercialized at key footwear OEMs by Covestro’s partner Lehmann&Voss&Co.

Next Generation Liquid Resins for Industrial Additive Manufacturing

  • Covestro has been developing systems for stereolithography (SLA), digital light process (DLP) and inkjet printing.
  • Covestro’s PU-based resins offer the unique opportunity to customize performance (toughness, flexibility, chemical & weathering resistance) due to the broad range of isocyanates and polyols from Covestro. 
  • This chemistry will enable customization of object properties at the voxel level, for example to create gradient materials.

About Covestro

With 2015 sales of EUR 12.1 billion, Covestro 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, electrical and electronics, construction and the sports and leisure industries. Covestro, formerly Bayer MaterialScience, has 30 production sites around the globe and as of the end of the first quarter 2016 employed approximately 15,700 people (full-time equivalents).

Source: Covestro

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