dp polar AMpolar i2: Revolutionizing Industrial Additive Manufacturing with High-Speed Rotative AM

At Formnext, the premier global exhibition for additive manufacturing, industry observers and enthusiasts alike were captivated by a groundbreaking innovation: the AMpolar i2 from German manufacturer, dp polar. Our team at 3Dnatives had the distinct opportunity to experience this machine firsthand, and it immediately stood out as a pivotal step forward for industrial-scale production. The AMpolar i2 is engineered from the ground up to address the demand for high-volume, high-speed manufacturing in the additive sector, employing dp polar’s unique and proprietary technology known as the High-Speed Rotative AM Process (HSR). As its name ingeniously suggests, this innovative process leverages a continuously rotating print platform, allowing for the simultaneous creation of multiple parts across its expansive build area, fundamentally redefining efficiency in 3D printing.

The HSR technology is nothing short of intriguing, representing a significant leap beyond conventional additive manufacturing paradigms. It facilitates truly single-pass printing over an exceptionally large build area, spanning an impressive two square meters. This translates into an immense build volume of 700 liters, offering unparalleled capacity for large-batch production or the fabrication of oversized components. Conceptually, the HSR technology shares foundational similarities with Material Jetting, a well-established additive manufacturing method celebrated for its ability to produce highly detailed, multi-material, and multi-color parts. The core principle involves a printhead holder equipped with a multitude of precision nozzles, each capable of simultaneously “spraying” or jetting various materials onto the rotating platform. This synchronized operation not only ensures remarkable speed but also opens up a world of possibilities for creating complex geometries with diverse material properties within a single print job. The continuous rotation combined with the single-pass jetting strategy dramatically minimizes non-productive travel time for the printheads, maximizing throughput and operational efficiency, which are critical factors for industrial adoption.

Unprecedented Capabilities: Multi-Process Ability and Dual Production Modes

Beyond its impressive speed and build volume, the AMpolar i2 introduces a feature that significantly expands the utility and versatility of additive manufacturing: the Multi-Process Ability. This unique capability allows the printing process to be paused and resumed at any point, enabling the manipulation of a part during its creation. Imagine the possibilities: one could 3D print a part on the AMpolar i2, halt the process midway, precisely embed an electronic component, a sensor, or even another material, and then seamlessly resume 3D printing, encapsulating the added element within the printed structure. This level of in-situ integration is a game-changer for industries requiring functional parts with embedded electronics or complex assemblies, eliminating the need for post-print assembly and reducing overall manufacturing complexity. It allows for the creation of truly integrated smart components, streamlining production workflows and opening doors for innovative product designs.

Furthermore, the AMpolar i2 is designed with remarkable operational flexibility, offering two distinct production modes to cater to diverse manufacturing needs: the Manufacturing Mode and the Prototyping Mode. In Manufacturing Mode, the system fully leverages its expansive build volume and high-speed capabilities for efficient series production. This mode is optimized for producing large quantities of identical or customized parts with exceptional repeatability and low cost per part, making it ideal for industries requiring continuous output of end-use components. The focus here is on throughput, consistency, and economic scalability, transforming how companies approach high-volume additive manufacturing.

Conversely, the Prototyping Mode is finely tuned for high-speed rapid prototyping. In this mode, the machine prioritizes even shorter cycle times, enabling engineers and designers to quickly iterate on designs, test concepts, and validate functionalities with unprecedented speed. The ability to rapidly move from concept to physical prototype significantly compresses product development cycles, facilitating faster innovation and reducing time-to-market. Whether the goal is mass production of intricate components or accelerating the design validation process, the AMpolar i2’s dual-mode functionality ensures it can adapt to the specific demands of various industrial applications, offering an adaptable solution for both rapid development and sustained production.

Advanced Materials for Diverse Applications: The ALTANA Partnership

A critical component of the AMpolar i2’s versatility lies in its material handling system. The machine is ingeniously equipped with three individual print stations, a design choice that not only accelerates the production of multi-material parts but also ensures precise material deposition. This multi-station approach, coupled with the rotating platform, allows for complex layering and combination of different materials within a single manufacturing cycle, significantly enhancing the functional properties of the printed objects. To deliver a truly robust and adaptable solution, dp polar has forged a strategic partnership with ALTANA AG, a renowned specialty chemicals company. This collaboration is instrumental in developing and providing a tailored suite of advanced materials specifically optimized for the AMpolar i2 platform, ensuring peak performance and reliability.

This specialized material suite is branded as Cubik Ink, offering a diverse range of chemistries designed to meet stringent industrial requirements. Each Cubik Ink material is available in both transparent and a wide array of vibrant colors, providing designers and manufacturers with extensive aesthetic and functional choices. The portfolio includes the high-performance Cubik Ink Tough materials, engineered for applications demanding exceptional mechanical strength, durability, and resilience. These materials are perfect for creating robust engineering components, prototypes requiring high impact resistance, or functional parts designed for demanding environments. On the other end of the spectrum, the Cubik Ink Flexible materials cater to applications requiring soft-touch surfaces, elastic properties, or flexible parts. Ideal for gaskets, seals, grips, ergonomic components, or medical devices, these materials exhibit excellent elongation and recovery characteristics. This broad spectrum of materials, meticulously developed in conjunction with ALTANA, empowers AMpolar i2 users to produce a wide array of functional parts, from rigid structural components to compliant, flexible elements, all on a single, highly efficient platform. The partnership with ALTANA underscores dp polar’s commitment to not just hardware innovation, but also to ensuring that users have access to a sophisticated and reliable material ecosystem that fully unleashes the potential of their HSR technology.

Streamlined Post-Processing: Water-Soluble Supports for Efficiency

One of the most significant bottlenecks in traditional additive manufacturing workflows is the post-processing stage, particularly the removal of support structures. This often labor-intensive, time-consuming, and potentially damaging step can add considerable cost and complexity to the overall production process. Recognizing this critical challenge, dp polar has engineered the AMpolar i2 with an ingenious solution: integrated water-soluble support materials. This feature allows for the quick and automatic removal of all support structures, dramatically simplifying the finishing process. Unlike conventional methods that might require abrasive mechanical treatments or harsh chemical solvents, the water-soluble supports simply dissolve away, leaving behind a clean, undamaged part.

The manufacturer proudly states that this innovation reduces post-processing steps by a remarkable 50%. This percentage translates directly into tangible benefits for industrial users: significantly lower operational costs due to reduced labor and material expenditure, a quicker turnaround time for finished parts, and a substantial decrease in the risk of damaging delicate components during support removal. The ability to automate support removal with such ease not only enhances efficiency but also ensures greater consistency and quality in the final product. This thoughtful integration of water-soluble supports exemplifies dp polar’s holistic approach to industrial additive manufacturing, where every stage of the production workflow is optimized for speed, cost-effectiveness, and superior output quality. This feature alone makes the AMpolar i2 a highly attractive proposition for businesses looking to scale their additive manufacturing operations while minimizing post-production headaches. More comprehensive information on this innovative system and its capabilities can be found on dp polar’s official website HERE.

The Future of Industrial Additive Manufacturing is Here

The dp polar AMpolar i2 stands as a testament to the rapid advancements within the additive manufacturing industry. Its High-Speed Rotative AM Process (HSR) technology, combined with a colossal build volume, multi-material capabilities, in-process part manipulation, and streamlined post-processing, positions it as a true leader in industrial 3D printing. This machine is not just an incremental improvement; it represents a paradigm shift, enabling manufacturers to transition from prototyping to full-scale, cost-effective series production with unprecedented efficiency and flexibility. For businesses aiming to integrate high-speed, high-volume additive manufacturing into their operations, the AMpolar i2 offers a compelling, robust, and future-proof solution that can accelerate product development, enhance product functionality, and significantly reduce manufacturing costs.

The AMpolar i2 was undoubtedly one of the many exciting 3D printers that captured our attention at Formnext 2019, showcasing the cutting edge of what’s possible in industrial fabrication. The exhibition floor was buzzing with innovations, and this machine certainly highlighted the direction in which industrial additive manufacturing is heading: faster, more versatile, and more integrated than ever before. We invite you to explore more of our selection from the show in the video below, offering a glimpse into the future of manufacturing technologies.

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