Massivit 3D launches large 3D printer for composite molds based on “Cast In Motion” technology

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Israeli manufacturer of 3D printers Massivit 3D has launched a new machine specifically designed to reduce the time it takes to make large format composite molds.

Powered by the company’s Cast-In-Motion (CIM) technology, the Massivit 10000 enables users to create complicated molds in a fast, four-step gel dispensing and casting process that simplifies the injection molding workflow. In this way, the system enables higher throughputs and shorter tool iteration cycles for users, especially those in the automotive, aerospace, energy, and shipping industries.

“We are very excited to showcase our advanced cast-in-motion composite manufacturing technology,” said Erez Zimerman, CEO of Massivit 3D, at the CAMX 2021 Industrial fair. “This market is hungry for innovations that will change the paradigm for molding so that manufacturers can finally cut lead times from several weeks to a few days.”

Large format gel dispenser print

Massivit was founded in 2013 and specializes in the manufacture of large format machines for customers in the fields of engineering, science, architecture and visual communication. Each of the company’s systems are based on its proprietary Gel Dispensing Printing (GDP) technology, an approach that is basically a mixture of FFF and Material Jetting, in which gels are extruded at high speed and cured into layers.

Available in regular and ‘Pro’ versions, Massivit’s flagship 3D printer, the 1800 series, is a 145 x 111 x 180 cm machine capable of producing oversized models and molds up to 30 times faster than conventional technologies. Over the years, this scalability has enabled the systems to cover diverse applications, including the manufacture of thermoforming tools and giant advertising displays.

Building on the success of its 1800 3D printer, the company decided to launch a new machine in April 2021: the Massivit 5000. Designed to meet the needs of suppliers producing large photopolymer parts for automotive, marine and Manufacture railway customers, the unit has a unique dual material system, which makes it possible to 3D print two parts at the same time with different materials and resolutions.

To support its growing printer portfolio, the company has also launched two new materials, including the flame retardant Dimengel 20-FR and the translucent design verification and architecture-oriented UL94-V0 It raised $ 50 million and now has its offering the Massivit 10000 further expanded.

Massivit released its updated Massivit 5000 3D printer earlier this year. Photo via Massivit.

The ‘massif’ in massivit. bring in

The whopping 1.2 x 15 x 1.65 meter 10000 3D printer showcased at CAMX 2021 was designed to solve the problems Massivit sees in making large composite parts: cost, lead time and complexity. The machine can counteract this largely thanks to its integrated CIM technology, which compresses a normal 19-step injection molding workflow into a four-step process, in which an initial “plug” is superfluous.

Instead of a traditional master design, the CIM process instead begins with users creating a desired tooling pattern from UV curable gel, which can then be 3D printed from various thermosetting engineering materials. Once printed, these parts are immersed in water where their patterned sacrificial material can break off, leaving a shape that is instantly ready to use after curing and polishing.

According to Massivit, this approach results in parts with “improved accuracy, consistency, and reliability” while being less wasteful than the tools traditionally used to make large composite structures. The company also says the Massivit 10000 is 80% faster and requires 90% less labor than regular part design machines, making it a “disruptive mold making solution” that “changes the tooling paradigm.”

“By automating the mold-making process, we can offer manufacturers a way to dramatically cut costs and reduce the associated waste of materials,” added Zimerman. “The increasing demand for this digital injection molding solution is proof of the urgent need for this technological milestone, and we are pleased to be able to offer it to the CAMX community in advance of the launch of Massivit 10000.”

A Bell helicopter in flight.  Photo over bell.
In the past, 3D printing was used extensively in mold construction at the helicopter manufacturer Bell. Photo over bell.

3D printing impressively large shapes

Outside of the industrial manufacturing circle, shapes may seem like an inconspicuous part of the production process, but their accuracy and durability can be critical to the success or failure of your end products. To improve the speed, scalability, and sustainability with which these shapes can be made, several commercial and academically funded projects have been commissioned for 3D printing instead.

In such an initiative that Thermowood Corporation Partnership with air carriers bell to 3D print a 20 foot helicopter blade shape. The temperature and pressure resistant device is considered to be the largest autoclavable tool of its kind and was specially developed for use in the shaping and development of robust shredded parts.

Elsewhere, on a more experimental level, researchers from ETH Zurich have tried to address similar architectural applications to Massivit’s by creating a prototype metal facade using 3D printed sand molds. The 3.5 meter high “Deep Facade” design, made up of 26 individual parts, was ultimately built from large-format molded aluminum parts.

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The image shown shows a 3D printed shell seat shape for cars with the new 3D printer Massivit 10000. Image via Massivit 3D.


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