Can you share with us the most groundbreaking biomaterials your team Aitiip is currently researching for 3D printing applications?
We are currently developing sustainable materials taking into account two concepts when referring to a biomaterial: their origin and their end of life.
On the one hand, when focussing on the origin of the materials we work with bio-based materials, which means that they come from biomass. Some examples are PLA, bioTPU and bioPA. These materials, together with the advantages of Additive Manufacturing, allow us to obtain innovative and environmentally responsible products.
Depending on the requirements of the application for which they are intended we develop novel blends, in this case specific for 3D printing applications. For example, the integration of natural fibers, such as hemp, gives better mechanical properties and provides better dimensional stability during the printing process. The use of natural fibers helps the performance and printability of the filaments without compromising their biodegradability, as they may be good alternatives to carbon or glass fibres.
On the other hand, if we focus on the End-of-Life of the products, we always look for sustainability according to product disposal. Sometimes we look for biodegradability properties, while other times recyclability is preferred. Recycling materials for 3D printing allows us to have a closed cycle in which waste materials, such as printing supports or failed prints, can be shredded and rewound for reuse without compromising their mechanical properties.
The materials we develop are revolutionary because they are innovative in nature, we seek to produce new materials that stand out for their properties, which are often defined by the application for which they are intended. As we work in a wide range of applications and sectors, we can boast a wealth of experience in the development of groundbreaking materials.
How does Aitiip envision the role of 3D printing biomaterials in advancing sustainable manufacturing practices?
Nowadays, companies demand more sustainable materials and Additive Manufacturing technologies, and in particular Fused Filament Fabrication (FFF) provides the chance to use these new materials in an efficient and sustainable way.
Additive Manufacturing is a very flexible industry that is constantly changing and growing, this ability to adapt allows for the incorporation of new developments that benefit the industry, users and the environment.
One of the applications of Additive Manufacturing is prototyping. In such cases, it is often not necessary to use the final technical material with which the part is going to be manufactured (which may even be produced using another manufacturing process). The client just needs to have a physical proof of concept to keep working on the design. In these cases, sustainable materials are an ideal choice if you do not want to use fossil-based or non-degradable materials.
Anyhow, recycled and biobased materials may perfectly be used in final products too. The challenge here is to be able to develop a full biobased technical material that meets the client's requirements, by formulating novel printable polymeric blends containing for example biobased colourants, fibres and antioxidants, that are conceived from a sustainable point of view.
This is for example the case of the BARBARA (Barbara) and INNPRESSME (INN-PRESSME) projects´demonstrators. Both projects aimed to develop biobased printable filaments as a sustainable alternative to fossil derivatives in several industries, including transport and consumer goods sectors.
What challenges have you faced in integrating biomaterials into existing 3D printing technologies at Aitiip, and how have you overcome these challenges?
At Aitiip 3D, we have a wide variety of additive manufacturing technologies, so we are able to manufacture and test with many types of materials. The sustainable by-design materials we develop are often more complex to print than commercial materials. In every case, it is very important to carry out a detailed study of the processing parameters to test the materials in order to understand which are the optimum conditions for printing the parts. The more challenging ones are:
- Temperature is a very important factor to consider, as it can degrade bio-based materials, recycled materials and fibres. This is why we must find a balance in the temperature of the nozzle without compromising a good melting point of the material for its correct deposition.
Taking into account the above, it is important that the molten material solidifies in a controlled way before the top layers are printed, that is why sometimes a heated bed and a heated chamber are needed. Depending on the type of material being printed, layer fans can be used to accelerate the cooling of the deposited material. - When printing materials with gross additives such as fibres or certain colourants, their size must be considered in order to choose a nozzle diameter large enough for the fibres to pass through without clogging, but the quality of the part must match the design specifications. The agglomeration of fibres in the nozzle can generate jams and spoil the print.
To avoid this problem, the dispersion and orientation of the fibres should be defined in the material development process, which will also benefit the mechanical behaviour of the printed piece. The friction of the fibres with the nozzle causes wear and therefore more frequent maintenance is required. - Sometimes when we develop complex materials, the diameter of the filaments that feed the 3D printer is not as homogeneous as it should be, having a rough surface which can lead to clogging too. We are currently developing devices to help us achieve a constant and smooth diameter for better prints of our own material formulations.
As you can see, there are many complications we have to face when working with sustainable materials, but we love working on these types of innovative processes where the important thing is to propose solutions that help to overcome these challenges in the most efficient way possible.
Could you share insights into how Aitiip collaborates with clients to develop custom solutions using biomaterials in 3D printing?
The current demand from customers is to produce 3D printing filaments made from waste, whether from 3D printing or other manufacturing processes. This type of work requires a recycling process that goes from the collection and screening of waste to the printing and validation of the parts (mechanically and functionally), passing through the process of shredding, compounding and spooling.
Developing this type of project hand in hand with our clients allows us to customise the material as much as possible so that it meets the requirements they expect. We define the best methodology that permits achieving a production process for our novel biobased materials as efficiently as possible in order to optimise initial steps at the laboratory level in our pilot plants and speed the scaling-up to commercial products at the industrial level.
Beyond private customers, we participate in Research, Development and Innovative competitive international projects in which we develop materials that solve a technological challenge posed by industrial needs. These projects aim to develop advanced sustainable materials for 3D printing for application fields such as automotive, construction or house appliances.
This kind of project allows us to explore and design novel materials that are not yet commercially available in the market and explore their great potential. These materials are conceived not only based on thermoplastics and for FFF or pellet deposition, but also for thermoset-based technologies. In such projects, we participate with all kinds/categories of companies and research institutions (large companies, SMEs, start-ups…) collaborating as partners and contributing with our expertise to develop the project activities in a global and satisfactory way.
What future developments in biomaterials for 3D printing are you most excited about, and how is Aitiip preparing to integrate these advancements into your services?
We are not only focused on FFF (Fused Filament Fabrication) but we are also working on DIW (Direct Ink Writing) technology with biobased and biocompatible materials for applications in the medical sector.
During the last 10 years, we have been getting experience in how to modify, adapt and develop advanced additive manufacturing technologies by ourselves, by working for example in the design and integration of physical tools for activating the surface of the layers (Barbara), or even working not only at small-medium size/volume scales but also in large-sized part scales (KRAKEN).
In this case, we work coupling heading robots to own machinery developments with different configurations and sizes of heads depending on the material to be deposited. Our aim in the future is to grow this research line to better satisfy the continuous demands of our industrial clients. Some of our future challenges are the hybridization of additive manufacturing technologies and materials and exploring new applications of 3D printed products enhanced by surface customisation.
It is very exciting to work in such a new and constantly changing field, you never get bored, and every week you are doing something different. It is very satisfying to be able to propose sustainable alternatives that prevent us from continuing to deteriorate our planet.
