Stratasys is a 3D printing company that has been around for almost thirty years. They produce 3D printers and printing material as well as offering 3D printing services. Stratasys printers are offered as either fused deposition modeling (FDM) or Polyjet (which work on the same principle as inkjet printers). They also offer the Makerbot line of desk top printers that are only available as FDM.

Stratasys recently held an automotive supplier event in Dearborn, Michigan. The purpose of the event was to introduce some new materials and new systems. There were several speakers from Stratasys and a guest panel of three people from the automotive industry.

Mark Dabe was the first speaker and led the event. He gave a presentation on the 3D Demonstrator systems. The Continuous Build 3D Demonstrator is a system of FDM printers in three-cell units. The units are grouped together for a 3D printing center. Units can be added as needed. Each cell can be programed to print different parts at the same time or they can all print the same parts for increased volume. Units can run continuously with little interaction from the operator. Cells are interconnected so that in a multi cell build project if one cell stops working the project will be completed by the other cells. The Infinite Build 3D Demonstrator is a horizontal FDM printer. Other 3D printers build parts vertically. By building the parts horizontally they can be of any length so that an entire airplane wing could conceivably be built as one part. Tooling and fixtures can be produced of lightweight material and of any size needed. The Robotic Composite 3D Demonstrator is an eight-axis robotic printer. The FDM print head is placed on a robotic arm and the printer has a robotic build platform. With this configuration the build material can be precisely placed. This eliminates the need for support material and reduces post processing time.

The event leader Dabe then introduced Allen Kreemer and Tom Formus. Their presentation was focused on using FDM for jigs and fixtures. The speakers explained that with 3D printing a permanent base structure can be built for a fixture. Then, pads and holders can be 3D printed and placed on the fixture. These can easily be replaced in situations of wear or breakage. The pads can also be easily replaced when the design changes without the need to replace the entire fixture. The speakers spoke of how composite tooling can be 3D-printed for sand casting, thermoforming and sheet metal forming, including hydroforming. The speakers explained that final design parts can be produced for training purposes. Employees would be trained in the assembly of new parts during model change or when there is a mid-production design change.

Dabe returned to the podium to introduce Bob Wolter who spoke about new systems and materials. Under new FDM systems is the F123 series in their design series of printers. This includes the F170, F270 and F370. The F123 series has received several updates. The printers are now easier for the operator to learn and to use with a new user interface and auto calibration in the F270 and F370 printers. They are practically plug and play with a minimal set up time. There is also a built in camera for remote monitoring. Material changing has been improved with the F370 able to use the new PC-ABS material. Stratasys has also made the printers faster to cut down on printing time and has also made them more accurate. The print envelope for the F170 is 10x10x10 inches (254x254x254mm), for the F270 it is 12x10x12 inches (305x254x305mm), and for the F370 it is 14x10x14 (356x254x356mm). The F170 can hold two material spools at one time while the F270 and F370 can hold four spools. Material swaps are now faster and easier.

During the presentations there was a Fortus 900mc running at the back of the room. The printer was so quiet that it was not a distraction unlike 3D printers once were. The Fortus 900mc is part of a group of printers that also includes the Fortus 380mc and the Fortus 450mc. These printers are part of what Stratasys calls their production series of printers. These printers can be installed just about anywhere since there are no special requirements for installation and they are quiet enough to run in an office environment. They use high performance thermoplastics and can produce complex parts quickly. The new hardware and circuitry allows for fine tuning of the parts produced. The Fortus 900mc also has an internal camera for remote monitoring. Both the 450mc and 900mc offer high capacity material options that allow as long as two weeks of continuous operation.

Wolter continued with the introduction of a new material for FDM printers which is Nylon 12CF (the CF stands for carbon fiber). Carbon fiber filled Nylon parts can be used as a replacement for metal parts in many applications. The carbon fiber filled Nylon combines the necessary strength with a lighter weight. To go along with the new material there is a new extrusion tip, the T40A. This new tip is larger for faster layup of large parts.

Wolter introduced the Stratasys J750 which is a Polyjet printer. This 3D printer can achieve a fourteen micron layer thickness, which is 0.014 millimeters or 0.034 inches. Whichever way you look at it, that is pretty thin, so that post processing can be greatly reduced or even eliminated. The number of nozzles has been doubled for increased speed of printing. The J750 printer can hold up to six different materials at one time. This printer can also produce 3D prints with photo realistic colors.

Wolter also introduced Agilus 30 which is a rubber like material for the Polyjet printers. It can be used for any soft flexible application. The material comes in gray, black, white and translucent. Color can be added to the material for added realism of the final product. Agilus 30 can be combined with other material to simulate a greater ranger of rubber like hardness.

George Russell was the last presenter that Dabe introduced. Russell discussed the ways in which 3D printing was affecting the automotive industry. He described how more complex parts could be produced less expensively with 3D printing than with conventional methods. Printers can be brought closer to the engineers and designers so that prototype parts can be made and assessed during the design phase. Printers will also see more use for production parts in the future.

The final session was a Q&A period. The panelists were Dr. Ellen Lee-a researcher at Ford, Andrew Storm-CEO of Eckhart and Associates and Allen Kreemer of Stratasys. There were a variety of questions including what Ford is doing in research with 3D printers and where can employers find talent in the 3D printing field. Dr. Lee explained the ways in which Ford was using the 3D Demonstrator series in their research. Storm talked about how his company trained their most experienced people in 3D printing because those people would have the most insight into how best to employ 3D printing in their work environment. Kreemer spoke about how many community colleges were now adding 3D printing and scanning courses in conjunction with internships to fill the need for people with 3D printing and scanning knowledge.

A big thank you to the folks at Stratasys for putting on the event. Thank you to the speakers and the panelists for their time and expertise. And thank you to the Stratasys and Fisher-Unitech people who were there to answer questions and provide support for the event.