2019 Winners & Highly Commended
The TCT Awards 2019 were a huge success with this year seeing an abundance of highly innovative entries that present advancements in 3D technology that have raised the standards in the world of 3D printing, there has been a wide variety of ground-breaking applications displaying examples of how far these technologies and the industry has come.
Following some very strong competition we are pleased to present the 2019 TCT Award Winners and Highly Commended.
Innovations and developments in the aerospace industry are renowned for ultimately benefitting all other engineering industries - from developing new and ground-breaking materials, to advanced electronics and automation. It is therefore unsurprising that the aerospace industry has been a key adopter of 3D technologies, and we are excited to see what pioneering applications have been released this year.
VeriPart Digital Supply Chain
Tech Lead: Moog Inc
End User: Air New Zealand
Partners: Microsoft; ST Engineering
In a world first experiment, Moog’s blockchain enabled VeriPart process was utilised to create a point of use, time of need digital supply chain. The proof of concept had Air New Zealand order a digital aircraft part from Singapore-based ST Engineering. The digital file was immediately sent to an approved printer (Moog) in LA, 3D printed and installed on an Air New Zealand Boeing 777-300 aircraft 30 minutes after landing.
Rocket Engine Combustion Chamber
Tech Lead: Frazer-Nash Manufacturing
End User: Skyrora
Using AM as a reliable manufacturing process for the creation of complex cooling channels has allowed a more efficient rocket engine to be designed and produced at lower cost than conventional engines. Efficient engines not only reduce the cost of launching satellites into orbit, but they also reduce the amount of exhaust gases (including CO2) that are released into the atmosphere.
The automotive industry has benefited from additive manufacturing since its birth over 30 years ago. As one of the first industries to adopt 3D technologies, the industry has integrated them into its design and development phases as well as growing their use in the manufacturing phase. We are interested to discover the most recent advancements to this application.
Automated Design of Jigs & Fixtures
Tech Lead: Trinckle
End User: Ford Motor Company
Partners: Ultimaker B.V.
Ford and Trinckle have partnered to enhance the use of AM for the production of labelling jigs and fixtures. Through the development of an internal application using Trinckle’s paramate software, the design of AM jigs has been automated - reducing design time from 2-4 hours to 10 minutes and saving up to 50% of the total costs..
PSPM Ball-Joint Exhaust System
Tech Lead: Poly-Shape
End User: Pipo Moteurs
PipoMoteurs and Polyshape have partnered to develop a solution to mechanical failures in the exhaust system in extreme Rally and Rallycross competitions. Utilising DFAM, a brand new ball joint exhaust system has been designed with 2 sliding layers to allow for +/- 10 degrees of movement. Not only has their design solved the problem, it has also produced a more lightweight and compact part.
We use consumer products every day, often taking for granted their impact on our daily lives. Behind each of those products is a product designer – designing the look, feel, function and production route of these products. The use of 3D technologies in the life of a product designer has increased 10-fold over the past few years, and as the adoption increases, so do the innovations. So which application is the most innovative for 2019?
Precision Diamond Helmet Liner
Tech Lead: Carbon
End User: Riddell
Carbon and Riddell have partnered to produce the first ever digitally printed helmet liner for the SpeedFlex Precision Diamond football helmet. Athlete data from Riddell’s proprietary database of 5 million head impacts was used to create the next-gen head protection precisely contoured to the athlete’s head. Incorporating intricate, bespoke lattice structures with custom energy absorbing materials developed by Carbon.
Home Appliance Spare Parts
Tech Lead: Spare Parts 3D
End User: Whirlpool EMEA
Whirlpool have partnered with Spare Parts 3D to enhance their aftercare services with the use of AM. The DigiPART software was used to perform a catalogue analysis of over 11000 SKU’s to automatically identify suitability for AM in cases of obsolescence and part shortages. 7% were found to be economical, with the first part now in production.
The film, theatre, art, architecture and jewellery industries all have one thing in common – they take a creative vision and turn it into a physical realisation. As such it is one of the most fascinating areas of innovation in 3D technologies. We are excited to see where this industry can push the boundaries in using the technologies in the creative arena.
Replica Dragon Conservation Project
Tech Lead: 3D Systems
End User: Historic Royal Palaces
Partners: Paul Jewby Master Carver
3D systems used digital scan-to-CAD workflow alongside SLS printing and intricate post processing techniques to produce 72 replicas of ornately carved dragons for Historic Royal Palaces. Missing from a UNESCO World Heritage Site for over 200 years, the replica pieces were a lighter weight, longer lasting alternative to direct replacement of the wooden pieces, and were achieved in a much quicker timescale.
Tech Lead: FIT AG
End User: Pfarrei St Laurentius Altmuhldorf
Partners: Kunstlerduo Empfangshalle Munchen; Studio Tessin
The Retable is an outstanding piece of sacred art which is the highlight of the sanctuary of St. Laurentius in Altmühldorf, in Bavaria, Germany. At a height of 8 meters, the complex 3d lattice piece is entirely 3D-printed in SLS and artistically finished with bronze thermal spraying. The project shows a fascinating convergence of historic and contemporary sacred art.
The Hardware awards celebrate the very best of the enabling technologies themselves, and are split into two distinct areas, the second of which is non-polymer systems. This could include metals, ceramics, composites, biomaterials or any other material that is not solely a polymer. We are looking for innovations which push the boundaries of current established systems.
Tech Lead: Anisoprint S.a.r.l
Anisoprint S.a.r.l have developed Continuous Composite Fibre Co-extrusion (CFC) technology which can produce parts which they say are several times stronger, lighter and cheaper than single material metal or polymer parts. The process can use different combinations of polymers and fibres, as well as extrude each filament at different rates to produce local variation in mechanical properties in the printed part.
Tech Lead: Velo 3D
A laser powder bed fusion system, Sapphire uniquely enables the realisation of support-free geometries such as designs with overhangs lower than 10 degrees and large inner diameters up to 40 mm. Coupled with the first ever non-contact recoater and closed-loop meltpool control, Sapphire promises to enable a higher degree of quality assurance for serial manufacturing.
The Hardware awards celebrate the very best of the enabling technologies themselves, and are split into two distinct areas, the first of which is polymer systems. We are looking for 3D printing or additive manufacturing technologies which push the boundaries of polymer processing, bringing innovative improvements or entirely new technologies to the table.
Tech Lead: Nanofabrica
Micro AM provides an end-to-end solution bespoke to manufacturers requiring micron and sub-micron levels of resolution and surface finish. Nanofabrica's technology allows the repeatable mass manufacture of micro parts and components via additive manufacturing for manufacturers that previously had to rely on disproportionately expensive and non-agile manufacturing technologies such as micro moulding.
Low Force Stereolithography
Tech Lead: Formlabs
Formlabs have introduced Low Force Stereolithography (LFS), the technology behind the Form 3 and Form 3L. The LFS process uses a flexible resin tank to drastically reduce peel forces, providing far superior surface finish and detail. The Light Processing Unit (LPU) directs the laser perfectly perpendicular to the print plane ensuring a uniform laser spot to deliver accurate and repeatable parts.
Healthcare is one of the most rewarding industries to be involved with, and the use of 3D technologies in this arena couldn’t be more fitting. The ability to create bespoke, one-off parts from scanned data is perhaps more suited to this industry than any other. With the ever-evolving development of new materials, software and hardware, it is no wonder that this industry grasps the benefits of these technologies – and we can’t wait to see what innovative applications have been launched this year.
Neuroinfuse Drug Delivery System
Tech Lead: Renishaw plc
End User: North Bristol NHS Trust
Partners: The Harley Street Clinic; Herantis Pharma plc
A 3d printed titanium port has been developed to allow accessibility to the brain as part of a neuroinfuse drug delivery system which allows pharmaceuticals to bypass the blood-brain barrier for ongoing treatment of neuro disorders. The port features a roughened surface below the skin to encourage bone integration, and a polished surface above the skin to discourage bacterial settlement.
Biomimetic Regenerative Scaffold
Tech Lead: Osteopore International Pte Ltd
End User: Queensland University of Technology
Partners: Julius-Maximilians University Wurzburg; Princess Alexandra Hospital, Australia
A 3D printing technique from Osteopore has been used to create a scaffold with the interconnected porous structure of the human cancellous bone using a bioabsorbable polymer to empower natural tissue regeneration. Patients eventually recover without a permanent implant and the overall healthcare costs are reduced, due to reduced likelihood of late complications or infections.
Industrial products work behind the scenes to keep our industries working. Whether it be factory automation equipment, farming tools or material handling machines, there is little that is not touched by an industrial designer. 3D technologies are being increasingly adopted by this sector to drive unique developments, but which are the most innovative for 2019?
Industrial Robot Dough Cutting Knife
Tech Lead: K3D B.V
End User: Kaak Group
Partners: Additive Industries ; Civon Project
An industrial robot dough cutting knife has been redesigned for powder bed fusion leading to a myriad of benefits including part reduction of 20 to 1 and weight reduction of 90%. Unique AM improvements include porous structures for better cleaning as well as an inbuilt bearing, leaf spring and thread. This led to more cuts per hour reducing the need from 8 to 6 robots and saving €120k.
Generatively designed AM workholding
Tech Lead: Matsuura Machinery Ltd
Partners: Autodesk; HP
Metal based work-holdings for CNC 5 axis metal cutting applications can take many weeks to design & manufacture. Using Autodesk Fusion 360 generative design software and HP 4200 Multi-Jet Fusion the work-holding has been redesigned for plastic 3d printing and manufactured in under 24 hours, delivering faster in-process production and slashing time to market.
If you can’t measure it, you can’t make it — a fact that is as true for additive manufacturing and 3D printing as it is for milling, moulding and other conventional manufacturing techniques. The Inspex Application Award seeks to commend the most significant case study in the field of metrology and inspection.
Non Destructive Imaging in Forensics
Tech Lead: University of Warwick
End User: West Midlands Police
Partners: Crown Prosecution Service; University Hospital Coventry and Warwickshire
Numerous criminal cases have benefited from a range of scanning and multi material 3D printing technologies that have, up until now, not been readily available within the Criminal Justice System. This technology has been used to provide evidence in over 120 Homicide cases for over 14 Police Forces throughout the UK and overseas.
Tech Lead: University of Warwick
End User: Oxford University Museum of Natural History
The use of 3D scanning has rewritten natural history for a number of rare objects within Oxford University Museum of Natural History’s collection. Looking specifically at two case studies the project has proven that 3D scanning can unearth previously unknown findings about the way extinct creatures lived and died on this planet.
Inspection and metrology technologies ensure that parts and products are fit for purpose. Innovation often happens in this space at incremental levels but breakthroughs in ease-of-use, portability and accuracy are constant. This award seeks to commend the quest for absolute accuracy, which comes in many technological guises including 3D scanning, CMMs, and measuring arms.
FARO® OPTOR™ LAB
Tech Lead: Faro
Optor Lab is a 3D dental scanner that combines all kinds of dental professional needs to support a digital workflow. This all-in-one 3D scanning device with its flexible modules is both an ideal entry-level solution and the most advanced 3D scanning desktop scanner. The flexibility in features and the open structure is built for convenient desktop scanning applications in any dental laboratory.
Ophir BeamWatch AM
Tech Lead: MKS Instruments
Ophir BeamWatch AM is said to be the industry’s first non-contact laser beam monitoring system for additive manufacturing. With an integrated laser measurement system designed to measure critical laser beam parameters for laser-based additive manufacturing systems, real-time performance also allows for measurement of dynamic focal shift during laser startup.
3d printing and additive manufacturing processes would not succeed but for the development of appropriate materials for the job. Though often underappreciated, the amount of science and innovation which goes into the development of materials for these processes can be overwhelming. We would like to celebrate advancements in these materials in 2 different awards – the first being polymers.
Formlabs Draft Resin
Tech Lead: Formlabs
Draft Resin is the fastest-printing Formlabs resin, making it ideal for rapid prototyping. Parts printed with Draft Resin print three to four times faster than parts printed with other Formlabs general purpose resins. The print speed of Draft Resin makes it ideal for same-day design iterations and printing bulky, full-build-volume parts.
Filamentive ONE PET
Tech Lead: Fliamentive Ltd
Partners: Tridea; MCPP Netherlands
ONE PET is a 100% recycled plastic filament made from post-consumer PET plastic bottle waste. ONE PET has been extensively tested for 3D printing applications – it is stiff and tough with excellent interlayer adhesion. Where regular PETg has a better impact resistance, ONE PET boasts superior technical properties such as tensile strength.
3d printing and additive manufacturing processes would not succeed but for the development of appropriate materials for the job. Though often underappreciated, the amount of science and innovation which goes into the development of materials for these processes can be overwhelming. We would like to celebrate advancements in these materials in 2 different awards – the second being non-polymers – be it metals, ceramics, composites, biomaterials or any other material that is not solely a polymer.
XJet S100 Soluble Support
Tech Lead: XJet
XJet S100 is the only 100% soluble support material in the additive manufacturing of stainless-steel that has fully automated support removal. It brings huge advantages to the user in geometric freedom, preservation of fine details & smooth surfaces, as well as huge savings in post processing labour time and cost.
Vibenite® 480, cemented carbide
Tech Lead: VBN Components AB
Partners: Uppsala University
VBN’s uniqueVibenite 480 cemented carbide has an extremely high carbide content of 65%, long-term heat resistance of 750° C, and high hot hardness. Developed specifically for powder bed fusion, it is suitable for applications where traditional cemented carbides are too brittle and the heat resistance of PM-HSS is too low.
The post processing award aims to celebrate the technologies which add the final touches to the 3d printing/additive manufacturing process chain. The often essential processes which impart material properties and surface finishes to a 3D printed or additively manufactured part. We are excited to commend new innovations in post processing technology.
Tech Lead: Siemens AG
Partners: Solukon Maschinenbau GmbH
Partnering Solukon’s SFM de-powdering technology with Siemens’ software has enabled a unique solution for powder removal of DMLM parts. The parts are rotated in a sequence calculated from the CAD geometry to precisely drain the residual powder from intricate cavities such as conformal cooling channels. This not only saves manual labour time, but also reduces waste powder and scrap parts due to powder residue issues.
Tech Lead: Hirtenberger Engineered Surfaces
The H6000 offers fully automated post-processing of up to 100 3D printed metal parts using a combination of electrochemical pulse methods, hydrodynamic flow and particle assisted chemical removal with no mechanical processing. The process automatically removes powder cake and support structure whilst achieving a surface roughness of Ra < 1µm including inside cavities and undercuts, whilst retaining edge sharpness.
As the industry grows there are numerous newcomers bringing fresh innovations to the table. From hardware start-ups, material developers and software companies to companies with new and exciting applications for the technology. Which of these industry entrants has gone above and beyond to deserve this year’s TCT Rising Star 2019?
California-based VELO3D’s Intelligent Fusion technology was developed to deliver support-free metal additive manufacturing and reduce the need to re-design production parts for additive. Launched last year, the company’s Sapphire System and Flow print preparation software has already been adopted by a number of large-scale service providers and aerospace customers such as Boom Supersonic to produce parts for its XB-1 demonstrator aircraft.
The disruptive Silicone Additive Manufacturing Technology (SAMT) developed by Spectroplast AG enables the direct fabrication of functional silicone products straight out of the printer without the use of moulds, cutting costs, time and waste.
3D technologies are only as good as the software which links them. The development of specialist software to process, validate and control the systems can mean the difference between a fantastic system and a dud. This award celebrates innovations in any software which impacts product development using 3D technologies from the design phase through to manufacture and end of life.
Tech Lead: nTopology
nTop Platform is a unified engineering environment for design, simulation and advanced manufacturing processes. It is said to be the only design solution that allows engineers to simultaneously consider function, geometry, and manufacturing within a single computational methodology. Engineers can create lightweight and optimized parts with functional requirements built right in.
Dyndrite Additive Toolkit
Tech Lead: Dyndrite Corporation
Dyndrite Additive Toolkit, built on the Dyndrite Accelerated Geometry Kernel (AGK), enables the printing of native CAD geometry, without the need to first convert to an STL. Doing so increases flexibility, printing speeds and quality. Complex geometries which lead to huge STL file sizes take up only a few kb with Dyndrite, leading to faster processing speeds and lower storage requirements.