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Large 3D Printers in the Additive Manufacturing

Industry Advanced Manufacturing


TechVision Opportunity Engine (TOE)

Opportunities for 3D Printing Large-Format Items

D718-TV
July 08, 2016

Contents
Section

Slide Numbers

Large 3D Printers for Additive Manufacturing Applications

One of the Largest FDM Printers in the 3D Printer Market

3D Printer that can Print Life-sized Objects

3D Printer Capable of Printing Objects up to One Meter in Length

One of the Worlds Largest 3D Printer for Printing Sand Molds

Strategic Insights

Key Patents

10

Industry Interactions

13

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Large 3D Printers for Additive Manufacturing


Applications

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One of the Largest FDM Printers in the 3D Printer Market


Builder 3D Printers, Netherlands
Innovation
The Builder Extreme 2000 is an
industrial fused deposition modeling
(FDM) three-dimensional (3D) printer
capable of 3D printing objects and
components with a maximum build
height and volume of 700 x 700 x
1820 mm.
The printer uses a dual-feed
extruder for mixing colors and
printing objects with high accuracy.

Description
The dual-feed extruder can be
removed and replaced with different
nozzles with a higher diameter. The
machine has the capability to print two
materials or two colors through a
single nozzle.
The printer uses Builder 3D Printers
proprietary software called Builders
color mixing software to print mixed
colored objects and components.

Analyst Insights

Builder 3D Printers is a 3D
manufacturing company
developing and offering large
scale and multicolor printers
with a large build envelope.

Builder 3D Printers has


been
developing
3D
printers capable of 3D
printing
large
scale
components and objects.
The company has recently
launched Builder Extreme
2000, which is one of the
tallest FDM printers on the
market.

Who

Tech
Profile
Builder 3D Printers,
headquartered in the
Netherlands,
makes
industrial and desktop
3D printers.

Where

What

Wide Scale Adoption

Key Technology Attributes


The Builder Extreme 2000 has a printer speed of 10 to 120 mm
and is capable of printing materials such as wood, polylactic acid
(PLA), and polyvinyl alcohol (PVA).
The printer is fully enclosed and has other features such as WiFi,
inboard camera, and can be remotely controlled with a
tablet/smartphone

Technology Readiness Scale


Readiness Level

1 2 3 4 5 6 7 8 9

This novel 3D printer


was launched during
March 2015 and has
been available for the
market from early 2016.
Wider adoption of large
scale printers such as
the Builder Extreme
2000 can be anticipated
by the end of 2017.

TechVision finds that the Builder Extreme 2000 3D printer is an effective solution that can be adopted by industries that need to 3D print large prototypes
or objects, such as automotive, aerospace, and architecture for rapid prototyping and 3D printing relatively low-volume, large scale models of components
and objects.
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3D Printer that can Print Life-sized Objects


Leapfrog, The Netherlands

Innovation
The Leapfrog XceL 3D printer is an
industrial grade 3D printer capable of
3D printing objects and components
with maximum a build volume of
530 x 500 x 2300 mm, when using
one extruder and 510 x 500 x 2300
mm when using 2 extruders.
The
printer
has
a
closed
environment and a dual extrusion
system. It can be controlled using a
smartphone.

Leapfrog BV is a 3D printer
manufacturing
company
that has its own R&D
facility, which concentrates
on
designing
and
developing large scale 3D
printers capable of printing
objects with huge build
envelopes.

Leapfrog
is
headquartered in The
Netherlands.

The company has recently


introduced a larger largescale industrial grade 3D
printer, the Leapfrog XceL.
It can 3D print objects with
huge envelopes using
PLA plastic.

Who

Tech
Profile

Where

What

Wide Scale Adoption

Description
The
printer
uses
Leapfrogs
PerfectLevel
automatic
calibration
system, which automatically checks the
calibration of the print bed before the
printing process starts. This eliminates
the risk of printing errors, which might
lead to wastage of filament/material
when printing large objects.

Analyst Insights

Key Technology Attributes


The Leapfrog XceL 3D printer is integrated with an automatic
filament detection and loading system, which alerts the users
regarding the amount of filament left in the system.
The printer consists of two extruders and uses PLA filament of
1.75 mm for printing the objects.

LeapFrog XceL was


launched during May
2016 and is available in
the market for purchase.
Wide scale adoption of
large scale printers can
be anticipated circa
2017.

Technology Readiness Scale


Readiness Level

1 2 3 4 5 6 7 8 9

TechVision finds that the Leapfrog XceL is an advanced solution for 3D printing objects such as tables, chairs, and decorative items. The printer
has the ability to cater to the requirements of the architecture, fine arts, construction, and furniture industries.
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3D Printer Capable of Printing Objects up to One Meter in Length


WASP, Italy
Innovation
The DeltaWASP Pellet 3D printer is
an FDM technology-based 3D
printer that uses PLA pellets instead
of more conventional materials and
filaments.
One of the main costs in 3D printing
an object is that of the material used.
Since this novel printer uses PLA
pellets, the amount of material and
material cost are significantly
reduced.

WASP (Worlds Advanced


Saving Project), an Italian
start-up, was created in 2012.
The company focuses on
designing and developing
large scale professional 3D
printers
for
sustainable
development and in-house
production.
WASP is headquartered
at Massa Lombarda,
Italy.

The
company
has
designed and developed
the DeltaWASP Pellet 3D
printer. It is capable of
printing large life-sized
objects and components
measuring up to 1 meter
tall.

Who

Tech
Profile

Where

What

Description
The 3D printer is almost three meters in
height and consists of extruders, which
have nozzles varying from 4 and 10 mm
in diameter.
Since the diameter of the nozzles in the
extruders are large, 3D printing a huge
object, which will normally take few
days can be printed within few hours.

Analyst Insights

Wide Scale Adoption

Key Technology Attributes


As a part of a prototype exhibit, the company used the
DeltaWASP Pellet 3D printer for manufacturing furniture (that
is, chairs) with extreme designs and structures, which was not
possible using conventional manufacturing processes.

Technology Readiness Scale


Readiness Level

Sources at WASP have


indicated that
the
DeltaWASP Pellet 3D
printer is slated for
online release in the
near-term. Wide-scale
adoption of the printer
can be expected toward
the end of 2018.

1 2 3 4 5 6 7 8 9

TechVision anticipates that the DeltaWASP Pellet 3D printer will find adoption for printing large objects, due to lower cost of the material used
when compared to FDM machines that use standard filaments. This will allow industries to rapidly prototype and produce objects and components
more cost-effectively.
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Ultra-large Industrial 3D Printer for Sand Molds


voxeljet AG, Germany
Innovation
The VX 4000 has been acknowledged
as the largest industrial 3D printer for
sand molds, with cohesive build space
of 4,000 x 2,000 x 1,000 mm for sand
molds and a resolution of up to 300
DPI (dots per inch).
The printer is capable of 3D printing
individual large molds and small
components at the same time for an
economical production rate.

Description
The 3D printer uses a layered building
method for printing the molds. Rather
than lowering the build platform during
printing, the
printhead is raised
upwards after depositing each layer of
material. This technique allows the
printer to bear the weight of the objectbuilding platform.
The printer can print sand molds with
extreme geometries and undercuts
with high precision and accuracy.

Analyst Insights

voxeljet
manufactures
industrial inkjet/powder binding
3D printers for producing
molds or models for metal
casting without tooling. The
company
also
provides
services to create sand molds
and
plastic
molds,
and
provides 3D printing materials.

The
company
is
headquartered
in
Germany
with
operational facilities in
the US, UK, India, and
China.

Who
Voxeljets VX 4000 largeformat 3D printing system
has a build speed of 15.4
mm/h .

Tech
Profile

Where

What

Key Technology Attributes


The VX 4000 is capable of sand casting metals such as
steel, iron, brass, aluminum, magnesium, and alloys.
The printer is capable of printing both sand molds and cores
as one single component or piece.

Technology Readiness Scale


Readiness Level

Wide Scale Adoption


voxeljet launched the VC
4000 for operations in North
America in 2016. The printer
has operations in the US
foundry industry, as well as
in areas such as automotive
or special machine building.
Wide adoption of the printer
in North America can be
anticipated over the nearterm.

1 2 3 4 5 6 7 8 9

TechVision finds that the VX 4000 3D printer is an advanced solution for very large-format 3D printing sand and metal molds. This novel 3D printer
is expected to have opportunities to disrupt traditional processes used by the foundry industry or other sectors, including automotive.
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Strategic Perspectives

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Strategic Insights
Other Large 3D Printers in the Additive
Manufacturing Industry

Major Industries/sectors Impacted in


the Near Term
Lack of scalability options is one of the key challenges in the 3D printer
market. Hence, key 3D printer manufacturing companies and organizations
are constantly researching and innovating methods to manufacture enhanced
industrial grade large-scale 3D printers with improved scalability. Large scale
3D printers are expected to impact the industries mentioned below over the
near term:

Ultimaker Ltd.s KamerMaker 3D Printer (an enlarged Ultimaker


machine for 3D printing rooms)
WASPs BigDelta

Automotive

BetAbrams BetAbram P1

Aerospace

Sciakys EBAM (electron beam additive manufacturing)TM 300

Construction

MASSIVits GDP (Gel Dispensing 3D Printing)

Architecture and fine arts

Fabrisonics SonicLayer (ultrasonic additive manufacturing)

Consumer goods (for example, home appliances, sports, and


toys)

Concept Laser GmbHs X Line 2000R

Defense and military (for example, building temporary structurers


during missions)

Stratasys Fortus 900mcTM and Objet1000 PlusTM

Driving Forces
The need for efficient manufacturing and rapid prototyping of large
scale industrial components
3D printers capable of printing objects with a large build envelope in
around only a few hours when compared to around several days t to
print the same with conventional 3D printers.
Scalability options for manufacturers while using 3D printers to 3D
print different structural and geometry components and objects at
the same time

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Cincinnati Incorporateds BAAM (Big Area Additive Manufacturing)

ExOnes ExerialTM 3D printer

Entry barriers
High implementation cost
The 3D printers have huge footprints and will occupy a large
area on the shop floor
A large amount of material is required, which increases the
cost of printing the objects.
If the 3D print and build are wrong, a large amount of material
will be wasted.

Key Patents

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Key Patents

No.

Patent No.

Publication Date

Title

Assignee

WO2016101942

30.06.2016

Method and device for producing 3D shaped articles by


layering

voxeljet AG

The invention relates to a method and an apparatus for producing three-dimensional models by layering in a high-speed sintering process.

US20160107384

21.04.2016

Drive device for a filament in a 3D printer

Leapfrog B.V.

A drive device to be fitted in 3D for driving a filament in a longitudinal direction which is to be printed to form a workpiece in the 3D printer under
the control of a control element, including a frame, a drive wheel placed on a drive shaft mounted in the frame, a guide wheel placed on a guide
shaft mounted in the frame, a guide arrangement connected to the frame for passing the filament between the wheels, and an electric motor for
driving the drive shaft, in which the frame includes an auxiliary frame in which one of the shafts is mounted, and in that the position of the
auxiliary frame with respect to the frame is adjustable. The auxiliary frame may be coupled to the frame using an adjustment screw.

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Key Patents
No.

Patent No.

EP3002110

Publication Date

Title

Assignee

06.04.2016

System and method for additive manufacturing of an


object

Stratasys Ltd.

A method of additive manufacturing of a three-dimensional object (12) is disclosed. The method comprises sequentially forming a plurality of
layers in a configured pattern corresponding to the shape of the object. Each layer is formed by dispensing at least one modeling material (24) to
form an uncured layer, and curing the uncured layer by radiation. In various exemplary embodiments of the invention the method comprises, for
at least one layer, forming a stack (82) of sacrificial radiation-protective layers to cover an exposed portion of the layer, such that an upper layer
of the stack remains exposed during formation of any subsequent layer of the plurality of layers.

WO2016049640

31.03.2016

Print assembly for additive manufacturing system, and


methods of use thereof

Stratasys Inc.

A print assembly 18 for use in an additive manufacturing system 10 to print three-dimensional parts 12, which includes a coarse positioner 40, a
fine positioner 42, and a liquefier assembly 20, where a portion of the liquefier assembly 20 is operably mounted to the fine positioner 42 such
that the fine positioner 42 is configured to move the portion of the liquefier assembly 20 relative to the coarse positioner 40.

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Industry Interactions

Paul Hunck
Vlad Szilagyi

Senior Lecturer, University of Canterbury,


Smelterij 4, 2211 SH Noordwijkerhout, The Netherlands
Phone: +31-0-252-74-41-28
E-mail: paulH@builder3dprinters.com
URL: http://builder3dprinters.com/

Marketing Specialist, LeapFrog,


H. Kamerlingh Onnesweg 10,
2408 AW Alphen aan den Rijn, The Netherlands
Phone: +49-201-487-90-443
E-mail: Vlad@lpfrg.com
URL: http://www.lpfrg.com/en

Lelio Leoncini

Ralf Moller

WASP Medical Team, WASP,


Viale Zaganelli, 26, Massa Lombarda 48024 Ravenna,
Italy, P.I. IT02108930393
Phone: +39-0545-82966.
E-mail: lelio.leoncini@wasproject.it
URL: http://www.wasproject.it/w/en/

Managing Director India, voxeljet AG,


Paul-Lenz-Str. 1a, 86316 Friedberg, BY, Deutschland.
Phone: +91-97-02330088
E-mail: nidhi.shah@voxeljet.com
URL: http://engineering.illinois.edu/

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