Axtra3D Unveils TrueSil-X50 Silicone and Advanced Mold Solutions, Redefining Additive Manufacturing at Formnext 2024

Axtra3D stands as a beacon of innovation in the rapidly evolving additive manufacturing (AM) landscape. Renowned internationally for its groundbreaking Hi-Speed SLA systems, the company has consistently pushed the boundaries of what’s possible in 3D printing. Their proprietary Hybrid PhotoSynthesis (HPS) polymerization process, coupled with the flagship Lumia X1 solution, embodies Axtra3D’s unwavering commitment to delivering uncompromising performance across print throughput, accuracy, resolution, and surface quality. Building upon the significant global success of the Lumia X1 SLA system, Axtra3D continues its trajectory of innovation, poised to showcase an array of cutting-edge developments at Formnext 2024, the premier global event for additive manufacturing.

Among the most anticipated announcements is the introduction of TrueSil-X50, a revolutionary material designed to dramatically expand the application possibilities of the Lumia X1 system. TrueSil-X50 is a 100% pure silicone, meticulously formulated without any additives, setting a new benchmark in silicone 3D printing. This advanced material is engineered to deliver exceptional performance and unparalleled durability, enabling parts to withstand even the most demanding environmental conditions. Its inherently low viscosity is a key characteristic, facilitating effortless processing through 3D printing. This property empowers users to create extraordinarily complex geometries with intricate fine details, reaching down to the micrometer range. Furthermore, TrueSil-X50 ensures that high resolution and precision are maintained without any compromise on surface quality. Parts produced with this innovative silicone exhibit reliable waterproof characteristics, excellent electrical insulation, and true isotropy, allowing for the creation of designs with very thin walls and sophisticated internal structures that were previously unattainable with conventional methods. This opens up entirely new avenues for product design and functionality.

The versatile properties of TrueSil-X50 unlock a vast spectrum of applications across diverse industries, with particular emphasis on the industrial and healthcare sectors. In industrial contexts, specific applications include high-performance gaskets and seals, essential components for sanitary solutions, durable parts for household appliances, and specialized equipment for food processing where material purity is paramount. The medical sector stands to benefit immensely from TrueSil-X50’s unique combination of flexibility and biocompatibility. This makes it an ideal material for producing custom implants, comfortable hearing aids, protective mouthguards, highly detailed anatomical models for surgical planning and education, and a wide range of innovative applications within dentistry. Its ability to create patient-specific devices with superior comfort and fit truly underscores its transformative potential in medical 3D printing.

Rajeev Kulkarni, CSO of Axtra3D, eloquently summarizes the profound advantages offered by this revolutionary material: “The combination of silicone’s unmatched durability and Axtra3D’s Hybrid PhotoSynthesis technology makes TrueSil-X50 invaluable in both healthcare and industrial sectors. It’s not just the inherent properties of the material itself; it’s the optimized synergy between silicone’s impressive mechanical strength, high tear resistance, and our HPS technology’s precision and detail that truly elevates performance to an entirely new level. This powerful combination enables the creation of safe, exceptionally long-lasting medical devices and high-performance industrial components that were previously deemed unattainable through conventional or other additive manufacturing methods. TrueSil-X50 unequivocally sets a new standard in durability, resolution, and application flexibility, promising to reshape how we approach silicone product development.”

With the strategic introduction of TrueSil-X50, Axtra3D is directly addressing a significant market demand for superior quality, high-performance silicone solutions in additive manufacturing. This groundbreaking material will take center stage at Formnext 2024, which runs until November 22nd, providing visitors with an exclusive opportunity to witness its capabilities firsthand and explore a diverse range of application examples. However, TrueSil-X50 is merely one facet of Axtra3D’s extensive showcase at Formnext 2024. The company is also set to unveil a comprehensive suite of innovative solutions for advanced molds, further solidifying its position as a leader in industrial 3D printing. These pioneering mold solutions will be presented at Axtra3D’s dedicated stand in Hall 11.1, Stand C39, inviting attendees to discover the full breadth of their latest developments.

Axtra3D to Present Comprehensive Mold Portfolio at Formnext 2024

Building upon its established success in ceramic injection molding solutions, Axtra3D is significantly expanding its offerings for concept and small-series molds. At Formnext in Frankfurt, the company will introduce three new mold solutions, bringing its total portfolio to four distinct options, each tailored for specific production processes. These advanced mold solutions are meticulously produced using Axtra3D’s patented Hi-Speed SLA technology and the versatile Lumia X1 system, ensuring exceptional precision and efficiency. Each individual mold solution is specifically engineered to cater to different production requirements, encompassing investment casting molds, low-pressure molds, high-temperature micro-injection molding, and specialized silicone molds. This diverse portfolio promises to address a wide array of industrial needs, offering faster, more flexible, and cost-effective alternatives to traditional tooling methods. But what exactly can industries expect from this expanded range?

Innovative Mold Solutions for Diverse Industrial Needs

**Investment Casting Molds:** Crafted from Ultracur3D® RG 3280 ceramic, these investment casting molds are perfectly suited for both concept injection molding and small-series production. These solutions are distinguished by their extreme rigidity and exceptional ability to withstand high temperatures, making them ideal for applications requiring robust and stable tooling. The ceramic-loaded polymer ensures dimensional stability and integrity even under intense thermal stress, critical for producing high-quality metal parts through casting.

**High-Temperature Micro-Injection Molding:** For specialized applications demanding molds capable of enduring extreme temperatures, Axtra3D offers high-temperature micro-injection molds. These are primarily intended for use in highly demanding sectors such as the automotive and aerospace industries, where components must perform flawlessly under harsh operating conditions. The Figure 4 HI TEMP 300-AMB material used for these molds guarantees a high degree of durability and precision, crucial for manufacturing intricate parts with tight tolerances and superior thermal resistance. This innovation significantly reduces lead times and costs associated with producing complex, high-performance components.

**Low-Pressure Molds for High-Viscosity Materials:** Addressing the challenges of working with high-viscosity materials, Axtra3D introduces low-pressure molds made from Ultracur3D RG 1100 resin. These molds are celebrated for their remarkable rigidity, excellent chemical resistance, and robust mechanical properties. Such attributes enable them to meet and exceed the stringent requirements of high-performance sectors, allowing for efficient molding of challenging polymers that are difficult to process with traditional methods. This solution offers an invaluable advantage for industries producing specialized rubber and plastic components.

**Silicone Molds for Healthcare and Beyond:** In the highly sensitive healthcare sector, Axtra3D’s solution for silicone molded parts is particularly impactful. These molds are meticulously created with the Lumia X1 system using Ultracur3D ST 45 Black material. Molds fabricated from this material are characterized by their exceptional durability, high tensile strength, and remarkable thermal stability, ensuring they remain intact and perform reliably over numerous casting cycles. This specific solution was engineered with the unique demands of silicone casting in mind, where achieving tight dimensional tolerances and an impeccably smooth surface finish are paramount. These molds enable the production of medical-grade silicone components with unprecedented accuracy and consistency, enhancing patient safety and product efficacy.

The Power of HPS Technology in Mold Making

Axtra3D’s proprietary HPS (Hybrid PhotoSynthesis) technology is the cornerstone of these new mold solutions, as Rajeev Kulkarni emphasizes: “Axtra3D’s mold solutions provide a faster, more flexible, and significantly more cost-effective alternative to traditional metal tooling, drastically reducing lead times and enabling truly affordable small-batch production. This breakthrough is achieved primarily through HPS, which ingeniously combines laser precision with DLP (Digital Light Processing) for rapid, high-resolution mold production. Complementing this is our TruLayer technology, designed to boost print layer separation speed, optimize surface finish, and ensure overall quality. This integrated approach effectively overcomes all the inherent limitations of conventional metal molds, offering unmatched design freedom and production agility. Furthermore, each mold solution is meticulously tailored to specific production needs, ensuring optimal performance and efficiency for every application.”

There is no doubt that this expanded and diversified mold portfolio significantly strengthens Axtra3D’s position in the global additive manufacturing market. It emphatically highlights the company’s profound expertise in concept casting and developing specialized molds for small series production. This innovative offering presents users with an expansive range of possibilities, as a wide variety of industries — from medical and automotive to consumer goods and specialized manufacturing — can derive substantial benefits from these advanced tooling solutions. This strategic expansion is perfectly aligned with Axtra3D’s core intention to constantly introduce new, transformative methods of additive manufacturing and proactively overcome prevailing hurdles that have traditionally limited industrial production.

At Axtra3D, our goal has always been to push the boundaries of what additive manufacturing can achieve, without compromising quality, speed, or material flexibility. We continue to work collaboratively with customers to develop solutions tailored precisely to industry-specific requirements. This customer-centric approach has ensured a strong alignment between Axtra3D’s advanced technology offerings and the critical needs of industries where precision and performance matter most. – Rajeev Kulkarni

You are cordially invited to explore all these groundbreaking solutions firsthand at Formnext 2024 and engage directly with the Axtra3D team. If you have the opportunity to attend, be sure to stop by booth C39 in Hall 11.1 to witness the future of additive manufacturing. For those unable to attend, more information about Axtra3D, including detailed insights into the Lumia X1 system, can be found by visiting their official website. Additionally, you can gain a deeper understanding of their revolutionary mold solutions by downloading their recent Mold Solutions White Paper.

Will you be visiting Axtra3D’s booth at Formnext? What aspects of these new innovations are you most excited to learn about? Share your thoughts and questions in a comment below or join the conversation on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here to receive the latest 3D printing news directly to your inbox. You can also find all our compelling videos and interviews on our YouTube channel for more in-depth content.

*All Photo Credits: Axtra3D