Additive manufacturing

A disruptive technology changing how we view modern manufacturing
The Sydney Manufacturing Hub additive manufacturing suite supports the manufacture of metals, ceramics and polymers.

Metals

The GE MLab 200R is a type of laser metal additive manufacturing machine. It is designed for use in various research, manufacturing and production environments and offers high accuracy and fast printing speeds. It supports a range of metal powder materials and is compatible with a range of software platforms for file preparation and control.

Specifications  
Build volume 100 x 100 x 100mm3
Laser system 200W Fiber Laser
Layer thickness 15-30μm
Currently printing with Bronze CuSn10
Supported materials Stainless Steel 316L
Maraging Steel M300
Aluminum AlSi10Mg
Nickel 718
Titanium Ti6Al4V ELI Grade 23
Titanium CPTi Grade 2
Bronze CuSn
Remanium star CL (CoCrW)
Rematitan CL (Ti6Al4V ELI)

The GE Concept Laser M2 is a high-performance industrial-grade 3D printer. It is designed for the production of complex metal parts and components using the process of laser powderbed fusion. The machine features a pair of high-precision lasers, a variety of recoater types, an optionally heated build plate and advanced software that allows for customizable layer thickness and optimized material usage. The M2 is widely used in industries such as aerospace, automotive and medical devices for production of functional prototypes and production parts.

Specifications  
Build volume 245 x 245 x 320 mm3
Laser system 2 x 400 W Fiber Laser
Layer thickness 20 - 80μm
Currently printing with Aluminium AlSi7Mg
Supported materials  Stainless Steel 316L
Stainless Steel 17-4PH
Maraging Steel M300
Aluminum AlSi10Mg
Aluminum A205
Nickel 718
Nickel 625
Titanium Ti6Al4V ELI Grade 23
Titanium Ti6242
Titanium cp-Ti
 

 

The GE A2X - Electron Beam Melting machine is a manufacturing process used to produce high-quality metal parts. This process uses an electron beam to melt and fuse metal powders in a heated chamber high vacuum environment. The electron beam heats the metal powder to a high temperature, causing it to melt and fuse together. This process can be used to produce parts with very good chemistry, accuracy and consistency. It is often used in aerospace and medical industries to produce complex and critical components.

Specifications  
Build volume 200 x 200 x 380mm3
EB system 3kw
Continuous build chamber temp 600 - 1100°C
Layer thickness 20 - 100μm
Currently printing with

Titanium Ti6Al4V ELI

Supported materials

Titanium Ti6Al4V
Titanium-Aluminide

Ti48Al2Cr2No
Titanium Grade 2

Cobalt-Chrome ASTM F75
Nickel Alloy 718

The GE Spectra H - Electron Beam Melting is a manufacturing process used to produce high-quality metal parts. This process uses an electron beam to melt and fuse metal powders in a heated chamber high vacuum environment. The electron beam heats the metal powder to a high temperature, causing it to melt and fuse together. This technology is used for applications in aerospace, defence, and medical industries as it provides high quality and consistency in the end product. This process can be used to produce parts with very good chemistry, accuracy and consistency. It is often used in aerospace and medical industries to produce complex and critical components.

Specifications  
Build volume 250 x 430mm (D,H)
EB system 6kw
Continuous build chamber temp 600 - 1100°C
Layer thickness 20 - 100μm
Currently printing with Nickel Alloy 718
Supported materials Titanium Ti6Al4V
Titanium-Aluminide Ti48Al2Cr2No
Titanium Grade 2
Cobalt-Chrome ASTM F75

Ceramics

The Lithoz Cerafab 7500 is a high-precision digital ceramic 3D printing system.  Using the Light Curing Method, it is capable of producing ceramic parts with exceptional accuracy, surface quality, and strength. The Cerafab 7500 is used in a wide range of applications including biomedical implants, opto-electronics and high-tech industries.

Specifications  
Lateral resolution 40 μm (X-Y)
Layer thickness 10 – 100 μm (Z)
Number of pixels 1920 x 1080
Build volume (X,Y,Z) 76 mm × 43 mm × 170 mm
Data format stl (binary)
Light source LED
Build speed up to 100 slices per hour
Supported materials Aluminium oxide
Yttria-stabilised zirconia
Tricalcium phosphate
Hydroxyapatite
Silica-based material
Silicon nitride
 

The Delta WASP 40100 Clay is an FDM professional system for ceramic 3D printing. Accurate and reliable, it is successfully used in prototyping and small-scale manufacturing.  It can print directly on the floor or on an intermediate removable steel surface (60 cm from the ground).

Specifications  

Layer thickness

Minimum 500 µm

Build System

Fused Deposition Modelling [FDM]

Build volume (X,Y,Z)

Maximum Print Volume: Ø 400 x h 1000 mm (h 450 mm with interim plate)

Data format

File type *.stl, *.obj, *.gcode

Build speed

150 mm/min

Supported materials


Porcelain
Earthware
Refractory
Clay

Polymers

The Noztek Pro Extruder is a is a filament extruder that converts pellets or chips of plastic into a melted, extruded filament that can be used in an FDM 3D printer. The Noztek Pro Extruder features an advanced design that includes temperature control, a powerful feed motor, and a flexible, easy-to-use interface.

The 200 Series 3D Platform Work Bench is a large format dual nozzle Fused Deposition Modeling (FDM) machine. The 200 series workbench is designed for large format 3D printing, meaning that it is capable of handling prints that are significantly larger in size than standard FDM 3D printing equipment. It features a durable construction, designed to withstand the demands of 3D printing, and it is built to meet the needs of professional and industrial users.

Specifications  

Layer thickness

0.05 - 0.35 mm

Build System

Fused Deposition Modelling [FDM]

Build volume (X,Y,Z)

1,000 × 1,000 × 500 mm

Data format

*.stl

Supported materials

Wide range of basic thermoplastics, including PLA, PETG, ASA, ABS, PC (Polycarbonate), CPE, PVA/BVOH, PVB, HIPS, PP (Polypropylene), Flex, nGen, Nylon, Carbon filled, Woodfill and other filled materials.

The Prusa i3 MK3S is an FDM machine that allows the user to create three-dimensional objects from digital models by depositing successive layers of material. The MK3S is an updated version of the Prusa i3, and it features improved hardware, software, and print quality compared to its predecessor. The MK3S is also equipped with features such as automatic bed leveling, filament run-out sensor, and improved cooling system, making the printing process easier and more efficient.

Specifications  

Layer thickness

0.05 - 0.35 mm

Build System

Fused Deposition Modelling [FDM]

Build volume (X,Y,Z)

250 ×210 × 210 mm

Data format

File type *.stl, *.obj, *.gcode

Supported materials

Wide range of thermoplastics, including PLA, PETG, ASA, ABS, PC (Polycarbonate), CPE, PVA/BVOH, PVB, HIPS, PP (Polypropylene), Flex, nGen, Nylon, Carbon filled, Woodfill and other filled materials.

The AON M2+ is a high chamber temperature FDM printer, for manufacturing strong, high-performance polymer parts in materials such as PEEK, PEKK or ULTEMTM. The machine can achieve parts with high crystallinity, reduced part porosity by using advanced process controls such as water-cooled hot ends and an actively heated build volume. It is equipped with independent dual extruders.

Specifications  

Resolution

X/Y: 25 µm

Z: 1 µm

Layer thickness

0.05 – 0.5 mm

Build System

Fused Deposition Modelling [FDM]

Build volume (X,Y,Z)

450 x 450 x 565 mm

Data format

*.stl

Supported materials

ABS, ASA, Nylon (PA 6, 6/66, 12), PAEK, PC, PEEK, PEI (ULTEM™ 9085, 1010), PEKK, PETG, POM, PP, PPSU, PSU, PVDF, TPE, TPU

Carbon fiber, glass fiber, Kevlar®, and ESD safe variants of the above. Various soluble and breakaway support materials.

The FUNMAT HT is a single nozzle high chamber temperature FDM printer with a build volume of 260 x 260 x 260 mm. Achieves 50-micron high-resolution industrial quality 3D printing.

The advanced thermal system design of this 3D printer includes:

90°C constant temperature chamber

160 °C heated build plate

450 °C high-temperature extruder with an all-metal hot end

The Phrozen Sonic Mini 8K is an ultra-high resolution small form factor LCD resin 3D printer.  It uses a photopolymer resin cured by UV light passing through an 8K resolution LCD mask.  The 8K LCD with 165 x 72 x 180 mm build volume creates an impressively high level of detail, with a lateral resolution of 22 microns.  This machine is useful in cases where very high level of detail is required, or for the creation of intricate parts.

The Phrozen Sonic Mega 8k is an ultra-high resolution large form factor LCD resin 3D printer. It uses a photopolymer resin cured by UV light passing through an 8K resolution LCD mask.  The 8K LCD with 330 x 185 x 400 mm build volume creates an impressively high level of detail, with a lateral resolution of 43 microns. This machine is useful in cases where very high level of detail is required for large parts.

The Formlabs Form 3B is an advanced desktop 3D printer optimized for biocompatible materials.  The Light Processing Unit (LPU) inside the printer uses a system of lenses and mirrors to deliver accurate, repeatable prints with smooth surface finish, high detail, and incredible clarity. It has a XY resolution of 25 microns to print high details parts.  The Form 3B is optimized for biocompatible materials but can also print with Formlabs full range of Form 3 resins including standard, jewellery, engineering, dental and medical resins.

Boston Micro Fabrication’s (BMF) microArch S240, is a 3D printer designed for short-run industrial production. The microArch S240 is based on BMF's patented Projection Micro Stereolithography (PµSL) technology, which enables the rapid photopolymerization of an entire layer of liquid polymer using a flash of UV light at micro-scale resolution. This makes PµSL ideal for end-part and prototyping use cases across a wide range of industries, including medical device manufacturing, microfluidics, MEMS, biotech, pharma, electronics, education, and research and development. The microArch S240 has a larger build volume and faster print speeds, enabling the production of bigger parts or a higher throughput of smaller parts, while achieving the same resolution and tolerance as other BMF printers. It also features the capacity to handle higher molecular weight materials with viscosities of up to 20,000 Cp, resulting in the production of stronger functional parts.

Specifications

 

Surface Finish

0.4-0.8µm Ra (top)

1.5-2.5µm Ra (side)

Layer thickness

10μm~40μm

Build volume (X,Y,Z)

100 x 100 x 75mm

Data format

STL

Light source

UV-LED (405μm)

Supported materials


Photosensitive Resins

Ceramic

3D Printing design

A powerful computer that offers bespoke software solutions and run complex digital simulations.

A powerful digital model analysis software which is used to set up the 3D printing workflow for both the laser and electron beam metal powder printers. The software can also be used to repair digital models before they are used in other additive manufacturing technologies in our facility.

A robust simulation software that can be used to emulate the flow of liquid or gas under complex scenarios using computational fluid dynamics. This software can also be used to understand how the melt and layering processes work in various additive manufacturing technologies for research purposes. 

An engineering design simulation software that can validate and optimise a structure for additive manufacturing.

A highly capable computer aided design (CAD) software used to make complex digital designs for 3D printing.


Contact

Sydney Manufacturing Hub

Address
  • Sydney Manufacturing Hub Rm S260, Level 2 Mechanical Engineering Building J07 University of Sydney NSW 2006
Delivery address
Sydney Manufacturing Hub Building J07 Loading Dock Entry via Gate 2 Blackwattle Creek Lane University of Sydney NSW 2006