Formnext 2021 Day 2 Highlights: The Crucial Role of Materials in Advancing 3D Printing

The second day of Formnext 2021 proved to be an extraordinary success, marking a significant milestone with record-breaking participation from industry leaders, innovators, and enthusiasts alike. As the largest international trade show dedicated to additive manufacturing, Formnext serves as a vital hub for showcasing cutting-edge technologies and fostering collaborative discussions that shape the future of industrial production. Our team was on the ground, engaging with a diverse array of market players, including prominent material manufacturers, to delve into a fundamental truth: materials are undeniably at the very heart of innovation in additive manufacturing. The energy and excitement were palpable, reflecting a rapidly evolving industry that continues to push the boundaries of what’s possible.

Understanding the transformative power of 3D printing hinges on recognizing the pivotal role of advanced materials. While printer technology and software are crucial, it is the development of novel and specialized materials that truly unlocks new applications, enhances part performance, and drives the industry forward. From aerospace to medical, automotive to consumer goods, the ability to print with diverse materials offering specific mechanical, thermal, and chemical properties is what enables the creation of highly functional and customized components. Formnext 2021’s second day specifically highlighted this focus, bringing together experts to discuss how material science is the bedrock upon which the next generation of additive manufacturing capabilities will be built.

During our extensive engagements, we had the distinct pleasure of connecting with several visionary leaders who provided invaluable insights into the burgeoning potential of various materials within the 3D printing ecosystem. Among these esteemed experts were Gert-Jan Nijhuis, General Manager of 3D Printing Solutions at Lubrizol, Karsten Schlichter, Business Development Manager at Elkem Silicons, and Michael Fokine, Co-Founder of Nobula. Each of these individuals shared their perspectives on how materials like silicone, glass, and Thermoplastic Polyurethane (TPU) are poised to revolutionize numerous sectors, opening up unprecedented design possibilities and application areas for the additive manufacturing market.

The discussions illuminated how material innovation is not just about creating new substances, but also about refining existing ones to be more compatible with additive processes, improving their performance characteristics, and addressing industry-specific challenges. This convergence of material science and manufacturing technology is creating a fertile ground for breakthroughs that were once thought impossible. From flexible and durable elastomers to highly transparent and precise optical components, the spectrum of materials compatible with 3D printing continues to expand, paving the way for truly disruptive innovations across engineering, design, and product development.

Exploring Key Material Innovations: TPU, Silicone, and Glass in 3D Printing

Lubrizol and the Versatility of TPU in Additive Manufacturing

Gert-Jan Nijhuis from Lubrizol provided a compelling overview of the advancements in Thermoplastic Polyurethane (TPU) for additive manufacturing. Lubrizol, a global specialty chemicals company, is at the forefront of developing high-performance polymers that cater to the exacting demands of industrial 3D printing. TPU is a remarkable class of plastic known for its exceptional elasticity, abrasion resistance, chemical resilience, and durability. These properties make it an ideal material for applications requiring flexibility and robustness, such as specialized footwear components, custom gaskets and seals, medical devices, and intricate automotive parts.

Nijhuis elaborated on how Lubrizol is innovating to optimize TPU formulations for various 3D printing technologies, including Fused Filament Fabrication (FFF), Selective Laser Sintering (SLS), and Binder Jetting. The ability to fine-tune material properties allows manufacturers to achieve specific mechanical characteristics, from very soft and pliable textures to more rigid, impact-resistant structures. This adaptability means that designers and engineers are no longer constrained by the limitations of traditional manufacturing methods, enabling the creation of complex geometries with superior performance. The discussion also touched upon the challenges and solutions in processing TPU, such as ensuring consistent print quality and managing post-processing requirements, highlighting Lubrizol’s commitment to advancing the material science behind flexible 3D printed parts.

Elkem Silicons and the Promise of Silicone in 3D Printing

Karsten Schlichter, Business Development Manager at Elkem Silicons, shared fascinating insights into the evolving landscape of silicone 3D printing. Elkem Silicons is a leading global producer of silicon-based materials, and their work in additive manufacturing is opening up new frontiers, particularly in demanding applications. Silicone, with its unique blend of properties—including excellent thermal stability, biocompatibility, electrical insulation, and extreme flexibility—has long been a material of choice for critical applications. However, its viscous nature has historically presented significant challenges for additive manufacturing processes.

Schlichter detailed the breakthroughs Elkem is achieving in developing printable liquid silicone rubber (LSR) materials and the specialized printing technologies that accommodate them. The ability to 3D print silicone is revolutionary for industries such as healthcare, where custom prosthetics, orthotics, and medical implants can be manufactured with unprecedented precision and personalization. It also holds immense potential for soft robotics, custom seals and gaskets for industrial machinery, and intricate components for the electronics sector that require high temperature resistance and flexibility. The discussion underscored the importance of developing integrated material and hardware solutions to overcome the technical hurdles, emphasizing Elkem’s dedication to making high-performance silicone a readily accessible material for advanced additive manufacturing workflows.

Nobula and the Pioneering Field of Glass 3D Printing

Michael Fokine, Co-Founder of Nobula, presented a captivating glimpse into the cutting-edge world of glass 3D printing. Glass is an ancient material with incredible versatility, valued for its transparency, chemical inertness, high temperature resistance, and optical properties. However, its processing for intricate geometries has traditionally been limited to subtractive methods or highly specialized casting, making it one of the most challenging materials to adapt for additive manufacturing.

Nobula is pioneering novel approaches to overcome these challenges, enabling the 3D printing of functional glass components with exceptional precision and clarity. Fokine explained the complex processes involved, which often entail sintering glass powders or using specialized photopolymerization techniques with glass-ceramic composites, followed by high-temperature treatments. The implications of this technology are vast and transformative. Imagine custom optical lenses for advanced sensors, intricate microfluidic devices for biological research, transparent architectural elements with unique designs, or even bespoke laboratory glassware. The ability to directly print complex glass structures opens up new avenues for innovation in fields ranging from telecommunications and optics to medical diagnostics and high-performance industrial applications. Nobula’s work represents a significant leap forward, demonstrating that even the most challenging materials can be brought into the additive manufacturing realm through dedicated research and innovative engineering.

The 3D Daily Show: Capturing the Pulse of Formnext 2021

For those who couldn’t attend Formnext 2021 in person or wish to revisit these groundbreaking discussions, we highly recommend checking out the second episode of the 3D Daily Show. This exclusive series was designed to bring the most impactful news, interviews, and insights directly from the exhibition floor to a global audience. The episode features in-depth conversations with Gert-Jan Nijhuis, Karsten Schlichter, and Michael Fokine, allowing you to hear directly from these experts about the exciting developments in TPU, silicone, and glass 3D printing. It’s an invaluable resource for anyone looking to stay abreast of the latest trends and technological advancements driving the additive manufacturing industry forward. The show effectively captures the spirit of innovation and collaboration that defined Formnext 2021, providing a comprehensive overview of the material-centric discussions that took place on day two.

Engage with Us: Your Thoughts on Material Innovation

What were your key takeaways from the second day at Formnext 2021? Are you particularly interested in exploring the unique capabilities of silicone, glass, or TPU for your own projects or industry? We are eager to hear your thoughts and perspectives on these fascinating material developments. Your engagement fuels our community and helps us understand which topics resonate most with our audience. Join the conversation by leaving a comment below, or connect with us directly on our various social media platforms. We actively monitor and respond to discussions on our LinkedIn, Facebook, and Twitter pages, where you can share your insights, ask questions, and connect with other professionals in the additive manufacturing space.

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