AON3D, a North American manufacturer of industrial 3D printers and software, has unveiled the company’s latest system: Hylo, a new “smart” high-temperature 3D printer, and Basis, an additive manufacturing software powered by process simulation and machine learning controlled thermals is equipped with optimization and parts qualification tools. Together, the two solutions simplify and accelerate the process of printing freely available materials, carbon fiber composites and high-performance polymers: materials with greater specific strength than many metals, continuous use temperatures up to 260°C, extreme chemical resistance, etc.
Hylo prints PEEK, ULTEM and more
With a generous 25.6 x 17.7 x 17.7 inch build area, a 250°C chamber and over 8x throughput, Hylo offers print speeds of up to 500 mm/s and IDEX-ready duplication/support modes. Beyond its impressive specifications, it is the industry’s first “smart” 3D printer – with advanced process control and monitoring as well as thermal optimization software. Equipped with over 25 integrated sensors, Hylo produces reliable, precise and exceptionally stable parts from commercially available materials by continuously monitoring, controlling and compensating for process fluctuations.
The challenge of printing high-performance polymers
Many high-temperature 3D printers and associated software struggle to print high-performance polymers such as PEEK and ULTEM. This is primarily attributed to outdated, open hardware/software architectures. Slicers lack material-specific thermal awareness, 3D printers lack proper process control/monitoring, and there are no feedback loops between the two.
Current material extrusion printers rely on workaround solutions such as: B. reducing variability by specifying materials and process settings or using “uniform” process parameters, e.g. B. Print speed and thermals. Combined with the unique properties of a printed part, these limitations result in visible/hidden defects, printing errors, variable part performance, and the perception that high-performance polymers are difficult to print.
A digital twin of a 3D printed part shows an area of a print that began to warp. Including warpage, AON3D’s foundation allows manufacturers to detect and prevent defects such as cracks, over/under extrusion, thermal fluctuations, internal defects, dross/debris inclusions and more.
AON3D’s Hylo and Basis solve these limitations by using process simulation and automation to integrate material awareness into the cutting process.
Basic – optimize part properties
The basis is the foundation of AON3D’s new product ecosystem. Intelligent hardware is combined with intelligent slicing and in-process monitoring – transforming process variability into part safety with just a few clicks. Although full details have not yet been released, AON3D Basis adds material-specific thermal awareness to the cutting process, dynamically adjusting process parameters to optimize properties such as layer weld strength, dimensional accuracy, surface finish and more.
In addition, AON3D Basis users can quickly check the quality of printed parts by viewing Hylo’s process monitoring data in three dimensions. While many high-temperature 3D printer manufacturers offer rudimentary heat maps, AON3D’s quality control tool also captures deformation/cracks, over/under extrusion, filament diameter variations, hidden defects, slag/debris inclusions, and more.