Additive manufacturing Aim 3D pushes boundaries with multi-material pellet extrusion technology

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3D pellet extrusion printers complement classic processes with an additive manufacturing strategy without tools. Aim 3D is now introducing universally applicable extruder developments for third-party providers to open up new areas of application for 3D screw extruders.

Aim 3D, a German company specializing in 3D pellet extrusion printing, has developed new extruders designed for both additive manufacturing and finishing applications. These universal pellet extruders support various industrial processes, including large-capacity 3D printing, robotic systems, and classic finishing techniques such as coating and joining. By integrating these extruders into third-party systems, Aim 3D seeks to enhance the efficiency and versatility of additive manufacturing.

Since 2017, Aim 3D has focused on 3D pellet printers that utilize granules instead of filaments, offering cost-effective and environmentally sustainable production methods. The use of granules significantly reduces material costs while allowing for the incorporation of recycled materials. The company’s CEM (Composite Extrusion Modeling) extruders, which are compatible with metal injection molding (MIM), ceramic injection molding (CIM), and high-performance plastics, have now been adapted for integration into external systems.

Daniel Selck, CSO of Aim 3D, highlighted the advantages of their technology, stating, “Our proven CEM extruders are characterized by material versatility, robustness, and reproducibility. The ability to use polymer granules provides a clear cost advantage over filament-based 3D printing, while also improving mechanical properties.”

Aim 3D’s new extruders include the CEM E2 and CEM E3 models, designed for use in the company’s Exam 255 and Exam 510 printer series. These extruders support multi-material printing with metal, ceramics, and plastics. Additionally, they offer a high build rate, currently at 150 cm³/h, with the potential to increase to 300–600 cm³/h in the future. This advancement is expected to facilitate an annual processing volume of up to 4,000 kg of material.

A key aspect of the technology is its ability to ensure high reproducibility, a crucial factor for manufacturers producing small and medium-sized series. Aim 3D has demonstrated the stability of its process through tensile tests conducted in accordance with DIN EN ISO 527-2 Type 1A standards. These tests confirm that the technology achieves consistent component quality with minimal deviations.

One of Aim 3D’s key areas of expertise lies in high-performance polymers such as Ultem 9085, a polyetherimide (PEI) material widely used in the aerospace, automotive, and defense industries. The use of granulated PEI in CEM extruders provides improved mechanical properties and a lower cost compared to filament-based printing. Furthermore, the material exhibits excellent flame retardancy, making it suitable for high-temperature applications up to 217ºC.

Beyond traditional 3D printing, Aim 3D’s universal pellet extruders offer opportunities for integration into diverse industrial applications. They can be utilized in large-capacity printers, combined with existing FDM printing processes, or incorporated into robotic manufacturing systems. Additionally, they provide solutions for non-printing applications such as coating, joining, and material application.

By expanding the scope of CEM technology, Aim 3D is paving the way for increased adoption of additive manufacturing strategies in various industries. The development of universal pellet extruders aligns with the growing demand for cost-effective, versatile, and sustainable 3D printing solutions in modern manufacturing.

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