Our integral approach
To realize our ambitions, we follow an integral, multidisciplinary approach toward developing our technology. Recognizing the market need for integral solutions, including pre- and post-processing, we decided to develop our own software, for slicing and simulation, and process engineering, in addition to the hardware manufacturing. The increased upfront cost of developing solutions in-house is outweighed by the benefits of managing quality control and speeding up the internal feedback loop, while avoiding dependencies on third-party hardware or software development partners.
Why Bond3D?
Bond3D might not be the first in industrial 3D printing. But we are absolutely the first to print real functional parts from PEEK for critical applications. Our production process retains all the great properties of the PEEK base material. That solves a lot of engineering challenges. So let’s put an end to ‘yes, but’ and start thinking ‘yes, and’.
Process
Commercial printer
Following this holistic approach, we elaborated our design into a commercial printer. It features three printheads for multi-material or multi-resolution printing, a heated print bed and build chamber for optimal process conditioning, a 400 x 400 x 400 cubic millimeter build volume, and full material and product traceability. We incorporated extensive 24/7 process monitoring of every critical quality parameter to facilitate data analysis for process control and continuous improvement.
Slicer software
As mentioned, we developed our own slicer software to have full control over our print strategies; for example, to decide how and where to apply our innovative pressure control during the print process. In this way, we really built a game-changing product. Our slicer turned out to be a great asset, as it enables us to modify the slicer to keep up with printer development and to meet specific customer requirements that are not feasible with a generic slicer. With our slicer we can program the printer for solid parts as well as porous products, for example infill structures. These can be designed for medical applications, such as bone ingrowth enhancement for implants, or filtration purposes. Numerous other applications have come within reach as well.
Application team
Our dedicated application team of engineers can help customers to rethink their product and translate functional requirements into an optimal printable design meeting customer demand. We have this team, which takes the product from design to production to qualification, in place because we are a service provider. We print parts, we do not sell printers.
Post-processability
So, what can customers expect for their specific applications? Surface quality, for one. As we master voidless printing, we can produce near-net-shape products. With post-processing, for example by milling or turning, we then achieve a smooth surface finish, for sealing or visual purposes. With conventional FDM-generated products, this post-processing would reveal internal voids at the surface, destroying any sealing or visual quality.
Warpage reduction
The issue of shrinkage, and the associated warpage, in injection molding, as referred to above, is also a challenge in printing. We developed software to simulate the shrinkage process and compensate for it during printing, and fully integrated this in our slicer. Using this feature, we managed to reduce deformation and hence warpage with a factor of over five. This allows us to print more accurate parts, even in larger dimensions.
We are there
Given the benefits of additive manufacturing in general and of our pressure-control print strategy in particular, the ‘holy grail’ of polymer printing comes within reach: making functional parts. For example, when (compound) metal products are not subjected to extreme temperatures or mechanical loads, they can be replaced by high-performance polymer parts. This will reduce weight and vibrations (when organic shapes have been created), and improve thermal insulation and chemical resistance. In addition, assembly effort will decrease, yielding more reliable parts.
