Shortlist-TCT Award Finalists 2018
After long consideration, we are pleased to announce the TCT Award finalists 2018.
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.
Carbon Fibre Wing Repair Kit
Project: Carbon Fibre Wing Repair Kit
End User: Airbus
Tech Lead: FDM
Partners: HP, Catia, Faro
A unique application kit has been developed, produced with HP MJF technology in PA12 material, to enable high temperature repairs to carbon fibre aircraft wings. The bespoke designed tools increase accuracy, predictability and build rates compared to previous methods.
Liquid Rocket Engine Injector
Project: Liquid Rocket Engine Injector
End User: DLR (German Aerospace Centre)
Tech Lead: 3D Systems
Partners: PLD Space
The development of a dedicated Small Satellite Launch Vehicle is dependent on the successful design of a unique reusable liquid rocket engine. 3D systems and DLR have utilised direct metal printing to develop the most complex sub-component – the coaxial injector head – leading to a three-fold reduction in cost and lead time.
Overhead Spacer Panels
End User: Airbus
Tech Lead: Materialise
Materialise and Airbus have partnered to develop the first 3D printed customer visible parts approved for use in airbus commercial aircraft cabins. The ideal solution for low volume cabin retrofits, the overhead spacer panels have achieved a 15% reduction in part weight.
End User: European Space Agency
Tech Lead: BEEVERYCREATIVE
Partners: Sonaca Space, OHB-System, Active Space Technologies
Project MELT (Manufacturing of Experimental Layer Technology) has designed, developed and tested a fully functional ALM breadboard model, able to work under the ISS’s (International Space Station) microgravity conditions and 3D print with engineering polymers with high end mechanical and thermal properties such as PEEK.
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.
Bespoke functional dashboard prototypes
End User: Volkswagon
Tech Lead: Ricoh
VW and Ricoh have partnered to produce dashboard component prototypes using sintered PP. The ability to use the final end use material has allowed for accurate functional testing without the need for injection moulded parts leading to significant time and cost reductions.
BMW i8 roadster SLM bracket
End User: BMW
Tech Lead: SLM Solutions
Partners: Materialise, Altair Engineering
The first series production part manufactured using SLM at BMW, the convertible roof bracket has been designed to be entirely self-supporting and has been topology optimised - leading to a 40% weight reduction with 10x the stiffness.
Custom carbon fibre motorcycle seat
End User: Auto Fabrica
Tech Lead: Markforged
Custom-motorcycle company, Auto Fabrica, partnered with Markforged to create a contemporary carbon fibre motorcycle seat. Creating a race style seat which is 20% stronger and 40% stiffer than typical ABS plastic.
End User: Edag Engineering
Tech Lead: Simufact Engineering
Partners: Voestalpine Additive Manufacturing Centre, Hirtenberger
An active engine hood lifting system has been developed to meet the needs of small-series and sport cars. Using bionic design and topology optimisation, a 50% weight reduction and 68% component part reduction has been achieved whilst increasing pedestrian safety in case of collision.
LSEV - 3D Printed Urban Car
LSEV: 3D printed urban car
End User: XEV
Tech Lead: Polymaker
Extrusion-based technology has allowed XEV to create a lightweight efficient vehicle that contributes towards reducing emissions. With all external and internal panels printed on XEV’s custom 3D printer with specifically developed materials from Polymaker, XEV has become the first car manufacturer to adopt additive manufacturing (AM) on this scale.
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 2018?
Carbon Fibre Bike Frame
End User: Studio West
Tech Lead: AREVO
AREVO utilised their unique combination of robotics, software, and composite 3D print manufacturing to create a sleek and modern bike frame in collaboration with Studio West. Five times the strength of titanium and one-third of the weight, this bike is completely durable and 100% recyclable.
IKEA Omedelbar Hands
End User: IKEA
Tech Lead: Wazp
By using recycled PA-12 on HP MJF technologies, IKEA has created an extremely popular wall decoration with the help of Wazp. On sale in three continents, the Omedelbar hands decoration sold out in the first week of launch.
End User: Kallista
Tech Lead: 3D Systems
Partners: 3rd Dimension
Kallista has developed a modern luxury faucet collection in partnership with 3D Systems. These innovative luxury faucets are a single geometric piece without the need for the assembly of the water channel which was possible with Direct Metal Printing.
MINI YOURS Customised
End User: BMW
Tech Lead: HP, Carbon, EOS
BMW Group has developed a completely new way of vehicle individualisation, offering their customers the chance to personally customise selected upgrade products within their new MINI, manufactured using EOS SLS, HP MJF and Carbon DLS technologies.
End User: Vitamix
Tech Lead: Carbon
Vitamix collaborated with The Technology House (TTH) and Carbon to create a specialized fluidic cleaning nozzle to be used within commercial settings. Its unrestrained design means its ten times more durable and 33% more economical.
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.
Ancient Roman Helmet
Tech Lead: Custom Prototypes
Incorporating both metal and plastic with precision finishing, Custom Prototypes has combined DMLS and SLA parts to create a 100% 3D printed ancient Roman helmet. The piece showcases what is achievable with truly enhanced finishing techniques for AM.
End User: Natural History Museum
Tech Lead: Laser Prototypes Europe
Partners: 3D Systems, FARO, Sketchfab
The Natural History Museum has replicated a full scale dinosaur head using Faro Edge laser scanning and 3D systems SLA technology. The skulls are used as a learning resource for ‘Dippy on Tour’ and work at inspiring the next generation of scientists across the UK.
Embrace - Jewellery with embedded gemstones
End User: Boltenstern
Tech Lead: Cookson Gold
Partners: Heimerle + Meule, University of Technology Vienna, Hafen City University Hamburg
Boltenstern’s Embrace collection of fine jewellery offers customers personalised pieces using direct precious metal 3D printing. Boltenstern developed a technique to directly 3D print pieces with gemstones already set within complex woven structures to create a truly stunning collection.
Life Size Star Wars Executioner Trooper
End User: Disney / Lucas Film
Tech Lead: 3D Systems
Partners: Gentle Giant studios
Lucas Film Art Department partnered with 3D Systems to use ‘real geometry’ from the Star Wars film to create a life size Star Wars Executioner Trooper used as physical theatrical marketing for the promotion of Disney’s “The Last Jedi”.
Pleated costume for Beijing Opera
End User: Royal College of Art
Tech Lead: Sinterit
Partners: Beijing Opera
PhD students, Mingjing Lin and Tsai-Chun Huang, have created the world’s first 3D printed pleated costume for the Beijing Opera. Combining the traditional Chinese way of pleating textiles with SLS techniques, this pleated costume has been used in more than 10 events and performances.
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.
Desktop Metal Production System
Tech Lead: Desktop Metal
Delivering speed and accuracy, Desktop Metal has produced, what it says is one of the first metal 3D printing systems for mass production, building parts at up to 100 times the speed of today’s fastest additive systems enabling a rapid go-to-market production capability.
Dynamic Multi Laser Assignment
Tech Lead: Additive industries
Additive Industries has developed a unique hardware and software solution to issues relating to multi-laser powder bed fusion. By minimising laser interaction whilst maintaining maximum use of all lasers, Additive Industries promise true productivity.
Tech Lead: GEFERTEC
The GTarc 3DMP Technology launched at the beginning of Autumn 2017, utilises arc-welding techniques to produce near net shape additive parts which are then milled with an integrated milling system to produce high-quality metal parts.
Tech Lead: SPEE3D
With promised speeds of 100 to 1000 times faster than existing metal 3D print systems, and using casting grade materials, LightSPEE3D focuses on easing the manufacturing process by using supersonic 3D deposition (SP3D), a patented technology that enables faster, cost-effective production.
Olsson Ruby FDM Nozzle
Tech Lead: 3DVerkstan Nordic
Partners: Uppsala University
With the help of 3DVerkstan, research engineer, Anders Olsson, launched the Olsson Ruby FDM Nozzle. The industrial grade ruby tip allows users to print highly abrasive materials (such as carbon filled filaments and boron carbide composites) with consumer grade FDM printers and has seen steady popularity since its launch in January 2017.
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: Apium Additive Technologies
Apium M220 rapidly produces patient specific PEEK medical implants and devices. It allows on-demand production of personalised implants which are more lightweight and biocompatible than metallic based implants, and therefore have been said to lead to better treatments in the medical industry.
Tech Lead: E3D Online
This kinematic-coupling based tool-changer is lightweight and allows integration without increasing the printer cost. Used both in consumer machines and professional systems, it allows the use of multiple tools in a single print, including different nozzles, cameras and pick and place tools.
EOS P 500
Tech Lead: EOS
Suitable for the mass production of high quality polymer parts on an industrial scale, this new system platform fulfils industrial requirements with higher productivity and a promised 50% higher material efficiency.
Essentium High Speed Extrusion (HSE)
Tech Lead: Essentium
The HSE from Essentium aims to address the limitations of FDM based technologies to serve as a complete solution to the industrial application of AM. With only seven moving parts this machine is built to transform manufacturing floors and solves issues of strength, speed and cost.
Tech Lead: 3D Systems
3D Systems has made immediate, full scale automated 3D production a reality with Figure 4 production. The digital moulding workflow process provides increased productivity, durability and repeatability for low and mid-range volume manufacturing.
High Speed Sintering
Tech Lead: Voxeljet AG
Partners: University of Sheffield, Evonik
This versatile platform for material development from Voxeljet has allowed new materials to be printed that were previously too sensitive for existing AM processes. With High Speed Sintering, new additively producible powders are quicker to reach the market.
Tech Lead: Mimaki USA
Mimaki has taken their many years of experience of producing highly accurate colour in the 2D printing world to the 3D printing world with the Mimaki 3DUJ-553. This photo-realistic full colour printer can produce over ten million unique colours that can aid in the prototyping process.
Tech Lead: Tiertime Corporation
The development of Tiertime’s continuous printing workhorse has allowed an increase in productivity for factory floors. The swappable print bed makes continuous printing possible driving costs down and allowing 24/7 operation.
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.
125kg weight bearing prosthetic
End User: Prosfit Technologies
Tech Lead: HP
A world first for 3D printed prosthetic sockets, ProsFit has developed a definitive socket fit for patient weight rating up to 125kg. Produced using HP’s MJF in HR PA12 material, the socket also has improved performance - with decreased weight and increased flexibility and strength.
Acetabular Cup Cutter
End User: Endocon
Tech Lead: GE Additive
Partners: Weber K+P
Thanks to DMLM technology, GE Additive and Endocon were able to create a precise instrument to save patients bone stock while reducing surgery time from 30 minutes to an impressive 3-5 minutes.
DURAN® DFAM lab equipment
End User: DWK Life Sciences
Tech Lead: Lasertek
Partners: Autodesk, EOS
For use in pharmaceutical laboratories, a unique four post connector cap has been designed for AM and produced using EOS DMLS. The device, which could not be produced using conventional processes, reduced weight by 60 % and time to market by a third.
Pre-op planning model aids world first surgery
End User: Belfast City Hospital
Tech Lead: Axial 3D
Belfast Transplant team and axial3D has enabled a world-first kidney transplant with the use of 3D printed planning models of the organ. The clinical team were able to transplant a kidney with a potentially malignant cyst into a patient by first removing the cyst on the backbench before transferring to the patient.
Single socket upper limb prosthetics
End User: Glaze Prosthetics
Tech Lead: EOS
Partners: Cabiomede, New Era Materials
Use of EOS’s laser sintering technologies has allowed Glaze Prosthetics to offer completely customisable prosthetics to upper limb amputees worldwide. Prosthetics that not only provide comfort but utilise a unique single socket system to enable interchange between prosthetics in less than 5 seconds.
Topology optimised spinal implant
End User: NuVasive
Tech Lead: 3D Systems
NuVasive Inc has partnered with 3D Systems to develop the first spinal implants to utilise topology optimisation with micro porosity lightweight tools and biomimetic features that match optimal stiffness and porosity for bone integration.
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 2018?
3DP Investment casting patterns
End User: Sylatech
Tech Lead: Ultimaker
Partners: Superprop, SolidWorks
The investment casting firm, Sylatech, has worked in conjunction with Ultimaker 3D printers to speed up their prototyping process. Using FDM patterns as opposed to traditional tooling has reduced prototyping costs by 1/25th and time by 1/4, whilst reducing required tool modifications to below 5%.
80% time saving in tool fabrication
End User: Jabil
Tech Lead: Ultimaker
The global manufacturing services company, Jabil, utilised Ultimaker 3D printers to significantly reduce the fabrication time (by 80%) and costs (by 30%) involved in producing tools and fixtures for their manufacturing processes.
Andbarb fastening system
Tech Lead: Andbarb
3DP Andbarb is a unique connecting and fastening system for joining together 3D printed components. Inspired by biomimicry and designed with a unique algorithm leveraging ‘continuum mechanics', Andbarb is a globally patented, efficient, safe, secure and sustainable solution for affixing multiple components together.
DFAM Condiment Nozzle
End User: Grote Company
Tech Lead: Frazer Nash Manufacturing
Partners: Renishaw, Graitec UK
Design for Additive Manufacturing (DFAM) has been employed to develop a set of unique interchangeable condiment dispensing nozzles for the mass production of sandwiches. The use of SLM has enabled higher productivity whilst reducing part cost by 25 % and halving part manufacturing time.
DFAM Rollertrain Bearing Cages
End User: John Handley Bearings
Tech Lead: Bowman Additive Production
Partners: EOS, Europac3D, DyeMansion, 3DPRINT-UK
Bowman Additive Production has utilised DFAM to make significant improvements of rollertrain bearing cages for use in industrial machinery. Produced using HP MJF in PA11, the new design has increased the life of the bearings by 300%, with a 30-40% load capacity and 50% reduction in assembly time.
Mass Customisation of copper inductors
End User: PROTIQ
Tech Lead: Trinckle 3D
PROTIQ has partnered with Trinckle 3D to successfully develop an online configurator that can be used to customise the design of high conductivity copper inductors. The inductors are then manufactured using SLM technology allowing customers of the manufacturing industry to co-create tools for metal heating.
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.
Biocompatible Temporis Photoshade
Tech Lead: DWS Srl
Developed for the printing of dental restorations, this biocompatible material produced by DWS uses colour gradients to produce the natural colours of the patient’s teeth.
DuraForm ProX FR1200
Tech Lead: 3D Systems
3D Systems has developed a new flame retardant PA12 nylon which is compliant with US FAR regulations for interior cabin parts and AITM guidelines. 10% lighter than the average aviation plastic, it has been subjected to durability and impact resistance testing to achieve certification for UL 94 V2.
Tech Lead: Carbon
This high strength engineering material from Carbon has a combination of strength, toughness and thermal cycling durability making it ideal for automotive and industrial applications.
Formlabs Ceramic Resin
Tech Lead: Formlabs
Partners: Nervous System
Two years in the making, Formlabs has developed a silica-filled photopolymer resin that can create ceramic pieces. Once printed and after burnout of the resin, the material forms a true ceramic part. Affordable and accessible, this material pushes the limits of what is possible for ceramic 3D printing.
SABIC EXL AMHI240F filament
Tech Lead: Sabic
SABIC has developed a polycarbonate-siloxane material formulated to provide designers with a filament that can be processed as standard PC, but with up to 4x impact strength and ductile failure mode.
Tech Lead: CRP Technology
Windform RL is a durable thermoplastic elastomer material with rubber-like distinguishing features. Its mechanical properties make it particularly suited for AM applications requiring complex geometries, and where flexible characteristics is a key requisite.
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.
Additive LFRP Composites
Tech Lead: Impossible Objects
A variety of LFRP composites have been developed to enhance the offerings for Impossible Objects CBAM technology. New composites include carbon, glass, aramid and polyester long fibres combined with polymers such as PEKK, PEEK, ULTEM and TPU matrices.
Aluminium alloys for AM
Tech Lead: Arconic
3 new aluminium alloys have been developed and optimised for EOS DMLS technology. Previously Aluminium alloys have been notoriously difficult to process using AM technologies, however Arconic has developed AM specific alloys to overcome these issues and match wrought mechanical properties.
Tech Lead: Stratasys Direct Manufacturing
Stratasys Direct Manufacturing has developed a high strength copper chromium zirconium alloy for metal powder bed fusion with high-strength and excellent thermal and electronic conductivity – ideal for applications in aerospace.
NanoSteel BLDRmetal L-40
Tech Lead: NanoSteel
This innovative material can be printed at room temperature on laser powder bed fusion processes to manufacture components with a combination of high hardness, toughness and ductility. Ideal for producing tools and dies in a matter of days, not weeks – reducing cost and time.
Vibenite® 290 hard steel
Tech Lead: VBN Components AB
VBN Components has developed the world’s hardest commercially available steel for metal powder bed processing with a unique combination of hardness and toughness to meet the industrial demand of new alloys with increased performance.
An important and often under-appreciated area of 3D technologies, metrology is the backbone of ensuring that parts and products are fit for purpose, and includes a wide variety of processes including 3D scanning, CMMs, measuring arms, and reverse engineering. We are thrilled to showcase innovations and advancements in the metrology arena.
Aircraft Damage Assessment
End User: easyJet
Tech Lead: 3D Systems
easyJet, OR3D and 3D Systems have worked together to develop a new way to identify and characterise aircraft surface defects. Using Geomagic Control X software and a handheld 3D scanner, reliable damage reports can be produced in a few hours, increasing accuracy and achieving time savings of 80%.
Tech Lead: Artec 3D
The first Al-based handheld 3D scanner makes 3D scanning easier than ever. The Artec Leo captures and processes data onboard at a rate of up to 80fps - scanning, processing and displaying 3D models in real-time.
Tech Lead: Ametek Creaform
Ametek Creaform has introduced a new educational solution suite enabling an innovative way to provide students with a hands-on experience in data acquisition. The ACADEMIA package includes professional 3D scanners, free reverse engineering and inspection software as well as an array of customisable teaching presentations, video tutorials and pre-built lab exercises.
FARO Design ScanArm 2.0
Tech Lead: FARO Europe
The FARO Design ScanArm 2.0 is a marked improvement on its preceding version, with a promise of 25% improved scanning accuracy. It allows designers and product engineers a customised solution with high accuracy, resolution and ergonomics.
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: Dyemansion
Partners: EOS, Daimler, FKM Sintertechnik, ic! Berlin
The Dyemansion print-to-product workflow encompasses automated cleaning, surface-finishing and colouring to provide an industrial end-to-end solution for high-volume finishing of printed polymer parts.
DLyte: Metal DryLyte Electropolishing
Tech Lead: Steros GPA Innovate S.L.
The Dlyte electropolishing system provides polishing solutions for various metals without changing the geometry of the object. With the innovative use of solid bodies as opposed to liquid as an electrolyte, the system has been used as an AM post-processing solution for products such as dental prosthetics and implants.
Hybrid DECI Duo System
Tech Lead: PostProcess Technologies
This automated post-processing system has been developed for surface finishing and support removal in one compact footprint. The Hybrid DECI Duo System provides high productivity due to its multi-functionality for part post-processing of a range of polymer and metal technologies.
PostPro3D - Automated part finishing
Tech Lead: Additive Manufacturing Technologies
The PostPro3D uses boundary layer automated smoothing technology (BLAST) to treat the surface of various polymer printed parts, providing an accurate and reproducible surface finish. Processed components also achieve improved mechanical properties and water tightness.
Russell AMPro Sieve Station™
Tech Lead: Russell Finex
Russell Finex has developed a system that overcomes the challenges associated with the qualification and recovery of AM powders. By creating an automated and versatile powder recycling system, they can eliminate powder wastage and improve operator safety.
Sinterit Sieve for Sinterit Lisa
Tech Lead: Sinterit
The Sinterit Sieve is a cost-effective solution to reusability of powder used in the Sinterit Lisa SLS process. The sieve enables the reuse of up to 70% of the PA12 used in Sinterit Lisa printers.
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: Autonomous Manufacturing
The automation software solution that was launched at the beginning of this year is a unique way for companies to coordinate their entire AM ecosystem and makes SM production a scalable and repeatable process.
Tech Lead: Axial 3D
Following on from its success at the TCT Awards 2017 (TCT Software Award, highly commended entry), Axial3D’s software solution ‘Axial3Dinsight’ has been incorporated into the resource-efficient, safety and audit ability software – ‘axial3Dassure’. It enables the smooth and efficient operation of a medical 3D printing lab.
Tech Lead: Ultimaker
Under a single interface, Ultimaker’s Cura Connect facilitates the management of multiple printers at once, enabling several users to schedule, prioritise and monitor numerous print jobs. Ultimaker promise flexibility and scalability making the Cura connect an accessible solution for prototyping, tooling and small-scale production.
Digital Supply (Block)Chain
Tech Lead: Identify3D
This blockchain technology replaces centralised databases to provide intellectual property protection, manufacturing repeatability and traceability to counter constantly evolving cybersecurity threats.
Tech Lead: Ansys UK
ANSYS has developed a software that provides instantaneous 3D simulation. Enabling an interactive experience for the user in which you can manipulate geometry, material types or physic inputs.
LINK3D Digital Factory
Tech Lead: LINK3D
Link3D has developed a workflow software system that helps organisations achieve on-demand manufacturing. This is achieved using the software for scheduling, build planning, automatic pricing and order management.
Materialise e-Stage for Metal
Tech Lead: Materialise
The Materialise e-stage has moved on from purely plastic as 10 years later Materialise has developed e-stage for metal. It automates the support generation process for metal parts promising better control of the printing process due to optimised and flexible parameter sets.
Support Optimization Module for LBM
Tech Lead: Additive Works
Launched in May 2018 this new support module was developed to generate optimised support structures for Laser Beam Melting processes. Additive Works promises that the software ensures no critical force to the structure is exceeded to achieve first-time-right production.