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ExAM 510 multi-material printer. Photo Credit, all images: AIM3D GmbH

(Rostock, Germany), a manufacturer of multi-material 3D printers, has developed a 3D printer for the composite extrusion modeling (CEM) process, which combines metal injection molding with additive manufacturing (AM). The ExAM 510 boasts a larger build area, higher precision and faster build rates, AIM3D says, and is a multi-material printer for AM that can print up to three different materials in parallel, including pellet-based processing of high-performance plastics such as PEEK and PPS. ExAM 510 is planned to be ready for series production in time for Formnext 2022, according to the manufacturer.

The latest addition to Rostock’s product lineup, the ExAM 510 is a performance-enhanced version of the previous ExAM 255. It can process up to three materials; this allows for two building materials and a support material. The extended build platform at 510 x 510 x 400 mm reportedly enables a multitude of applications. Build area can be heated up to 200ºC in order to reduce stresses in the component and to process high-performance materials. It also features a considerably increased build rate, depending on the material, of up to 250 cm³/h (when using a 0.4-mm nozzle).

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Moreover, the ExAM 510 concept enables increased precision of printed components, with the objective of taking advantage of AIM3D’s patented extruder technology. This extruder class offers an output up to 10 times higher than standard filament extruders, the company notes. Further, the use of linear motors and a stable mineral cast bed makes highly precise operation possible even at high speeds.

Coolant distributor nozzle from Schaeffler (Herzogenaurach, Germany), 3D printed with the CEM process and made of PPS GF 40 Type Fortron 1140L4 injection molding pellets from Celanese (Dallas, Texas, U.S.).

The use of a wide range of materials is one particular appeal, especially for composites fabricators. AIM3D equips the machine with a heated process chamber specially designed for high-temperature plastics. This enables the processing of high-temperature plastics such as PEEK, PEI, PSU, PPS, with and without fiber filling, directly in pellet form. 

Inexpensive recycling is also a capability. According to the manufacturer, a material can be tested in 1-2 working days and established for production in 5-10 working days. AIM3D uses PEEK as an example: if the price for PEEK filament is around €700/kg used on conventional AM machines, the ExAM 510 can use PEEK pellets, as deployed in convential injection molding. The market price of around €50/kg for PEEK pellets amounts to only 7% of comparable material costs or a cost reduction by a factor of 14. This opens up new dimensions in terms of cost efficiencies, AIM3D concludes.

Areas of application for high-performance polymer materials can be found in automotive, medical technology or aerospace, end markets in which AIM3D’s pilot customers are based in. Reinforced plastics such as PA6 GF30, PPS GF 40, PEEK and PEI can specifically be used for applications like coolant technology, automotive and ESD housings. Aluminium and zirconium oxide, silicon carbide and silicon nitride ceramic materials are applicable for chemical process technology, high-voltage isolators and thermally stressed components. Metals like stainless steel, copper, tool steels, tungsten and tungsten carbide can be used with the ExAM 510 as well.