Energy Tree provides consultation and design services for additive manufacturing projects specializing in technologies such as fused filament fabrication (FFF), stereolithography apparatus (SLA), metals, and binder jetting technologies. We integrate advanced technologies including 3D modeling, virtual and augmented reality, and digital simulations to provide in-depth analysis and realization of our projects.
Fused Filament Fabrication (FFF) is a form of additive manufacturing that uses an extrusion method to create 3D-printed parts by layering thermoplastic materials. Spools of thermoplastic material, called filament, feed into a heated extruder to be melted and deposited onto the print bed in layers predefined by a 3D model, cooling quickly to solidify the part as it builds. The majority of 3D printers available use FFF technology.
There are a variety of thermoplastic filaments available, each featuring their own unique characteristics. Two of the most common thermoplastics used in FFF 3D printers are PLA (polylactic acid) and ABS (acrylonitrile butadiene styrene). Some FFF printers can print a wide range of different materials, while some are limited to one or just a few. The ability to adjust the temperature of the 3D printer's nozzle and print bed enable the processing of varying materials.
In addition to printing a variety of materials, some FFF printers also have mechanisms that allow for more complex prints. When a machine features two extruders, this allows for the processing of two separate filaments in one print. This enables for the production of multi-color prints and complex prints that require supports. The use of dissolvable support filament facilitates the refining of completed parts for a professional appearance.
Another form of 3D printing, stereolithography apparatus (SLA), is a form of vat polymerization which uses UV lasers to cure photopolymer resin layer by layer to create 3D prints. In SLA devices, the UV lasers trace each layer of the object being printed to cure the resin, enabling the creation of smooth, high-definition prints with intricate detail. SLA technology is often used in applications such as medical fabrication and jewelry making because of the fine detail achievable.
Digital light processing (DLP) is another form of vat polymerization that uses photocurable resin to create 3D objects. However, it differs from SLA technology in that it uses light projection to cure the entire layer at once, as opposed to tracing each layer with a laser. This makes DLP a faster technology, although the resolution is generally not as refined as SLA because the light projection creates prints through voxels (square, 3D pixels) instead of the circular results achieved through laser curing.
Many photocurable resins are available for creating prints with unique characteristics, from durable, flexible, and elastic resins to speciality materials such as ceramics and castable wax. Vat polymerization only allows for processing of one resin at a time, so supports are printed in the same material, which can be difficult to remove and may require a substantial amount of post-processing to refine the part.
Additive manufacturing technologies such as direct metal laser sintering (DMLS), direct energy deposition (DED), and metal binder jetting enable the manufacturing of metal objects with distinct characteristics. Depending upon the technology, metals such as aluminum, stainless steel, copper, and titanium can be used to create solid, engineering-grade parts. Metal 3D printing is used in many industries and applications for its versatility, strength and diverse mechanical properties.
Carbon fiber is another material that can be used to create strong parts. Its high stiffness, tensile strength, chemical resistance, temperature tolerance, and low thermal expansion and weight make it an ideal material for many technical applications. Chopped carbon fiber filaments are made by combining thermoplastics such as PLA with short carbon fibers to increase the strength of the host material, while continuous carbon fiber filaments can be used to reinforce parts, making them very strong and lightweight.
In addition to metals and carbon fiber, other strong materials are being used in 3D printing applications for their unique properties. Thermoplastics such as nylon and polycarbonate yield stronger parts than PLA and ABS, while other materials, such as graphene, kevlar, and fiberglass, can be integrated into thermoplastics to increase their tensile, flexural, and shear strength.
3D printing is a versatile technology that enables the local manufacturing of parts and products. The diverse range of machines available make the production of everything from delicate replicas of historical art to strong parts used in the automotive industry a possibility. For many applications, local manufacturing can save time and resources, reducing the lead time for parts and prototypes and reducing the costs associated with designing and testing new parts for advanced applications.
3D scanning technologies, such as photogrammetry and contact, light, and laser-based scanning, turn physical objects into 3D models. These models can then be 3D printed for modification, testing, and replication. Photogrammetry uses photography to capture images of the object from many angles, while contact scanning physically interacts with the scanned object. Light and laser-based scanning can produce high resolution models, but are sensitive to ambient light and reflective materials that can interfere with scanning accuracy.
One of the most significant benefits of 3D printing is the ability to produce real, working objects on-site, when they are needed. This can make testing, changing, and refining parts and products more efficient and cost effective than traditional manufacturing methods. In addition, local manufacturing can reduce material waste and risks associated with traditional production, while enabling an increase in product accessibility, creativity, and quality.
Energy Tree provides consultation, design, research, and planning services related to renewable energy, indoor and urban agriculture, advanced manufacturing, and other sustainable technologies. Every project is approached with a combination of knowledge, experience, and innovation. We use advanced technologies to integrate the use of renewable energy, energy efficiency, and sustainable practices into every one of our projects.
At Energy Tree, we create working 3D models of every project and analyze various scenarios in a virtual environment to develop our designs. These scaled models and simulations enable us to provide comprehensive consultation and design services, allowing us to accurately display projects before construction and efficiently make adjustments when necessary. Thinking ahead, we always look for effective ways to incorporate sustainability into our projects. We stay on top of the latest developments, constantly researching new ideas in order to provide our clients with the best opportunities available.
Office: (877) 944-7749
Email: contact@energytree.us
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