Studio System 3d Printer

[Astryd Boschee]

TheStudio System debinder uses a solvent debind process to remove preliminary binder from the part in preparation for thermal debind and sintering. In this video, you will learn how the studio system debinder works, as we use it to debind a batch of parts.

The Studio System has the only office-friendly sintering furnace in the world. Scaled to fit through an office door, this compact, high-volume furnace serves two purposes in the Studio System process: first, to conduct a thermal debind, second, to sinter parts to full density. This video will explain how the Studio System furnace works and a few key features that set this one-of-a-kind sintering furnace apart.

Designed to be the easiest to use sintering furnace made, the Studio System 2 furnace first heats parts to remove all binders from parts, then ramps up the temperature to near-melting to deliver industrial-strength sintering in an office-friendly package. Built-in temperature profiles tuned to every build and material ensure uniform heating and cooling without the residual stresses introduced in laser-based systems.

Making complex, high-performance metal parts has never been easier. Featuring a breakthrough two-step process, next-generation Separable Supports, and a software-controlled workflow, the Studio System 2 makes it simpler than ever to produce custom metal parts.

The Studio System 2 unlocks two-step processing with a fully re-engineered materials library. New material formulations allow printed parts to be placed directly into the furnace, without the need for the typical solvent debind phase. The result is an easy-to-manage two-step process with a nearly hands-free experience.

With easy-to-use hardware, the Studio System 2 allows you to spend less time managing equipment and more time designing and fabricating parts. Change printheads with the press of a button, and change materials quickly with a refillable cartridge system that allows users to easily load material during print jobs and store excess material safely. A fully-accessible printer and sintering volume and a configurable furnace retort allow for maximum flexibility.

Easily produce difficult-to-machine parts featuring complex geometry like undercuts and internal channels. Live Studio, the software at the heart of the Studio System, automates complicated metallurgical processes to produce high-quality parts with densities and feature accuracy similar to casting.

The Studio System 2 leverages data and feedback from thousands of prints and hundreds of customers. Designed to deliver outstanding part success and excellent surface finish, the system allows users to achieve first-time part success across a wide range of geometries. This is made possible by a fully re-engineered material platform, updated interface technology and new print profiles.

A heated build chamber and Desktop Metal-engineered print profiles produce excellent surface finish right out of the furnace, while a high strength gyroid infill now lightweights parts. With materials that meet or exceed MPIF standards and the use of high metal volume fraction media, high-pressure extrusion and vacuum sintering at temperatures of up to 1400C, the system produces parts with densities of up to 98 percent - similar to cast parts.

The Studio System 2 allows you to tailor parts to your exact needs. Print parts with walls up to 4mm thick or fully-dense parts (with no infill) up to 5.25mm thick. Adjust shell thickness to create stronger parts or enable faster processing. Optimize prints for build speed using the standard (400m) print head, or print fine features with the high resolution (250m) print head.

The Studio System 2 features a two-step process that eliminates the need for solvents and uses materials that can be easily stored and handled, making it ideal for use in an office environment - no special facilities and no respiratory PPE needed. The only requirements are an internet connection, ventilation and power, making it easy to quickly start printing metal parts.

The Studio System 2 helps you regain control of your prototyping pipeline by allowing design and engineering teams to focus on making the best possible products. The simplified, easy-to-manage process allows users to quickly iterate on designs, print parts and monitor build progress from their desk, and significantly reduces operator burden - parts go directly from the printer into the furnace, where a large retort with stackable shelving (10x the capacity of a similarly-sized tube furnace) allows for batch sintering.

The Studio System 2 is a two-part solution that streamlines metal 3D printing. Simply load your CAD file into Live Studio, our proprietary software, print your part, and place it in the furnace for sintering.

Metal 3D printing reduces lead times and costs - allowing for rapid iteration and refinement of the die design. Furthermore, lower tooling costs and lead times makes low volume custom extrusion dies economically feasible.

This burner tip was originally cast in the 1950s, and the tooling has since been lost for it. When a customer needed a replacement, the quote for new tooling was in the tens of thousands of dollars.

Golf clubs, especially putters, are typically cast or machined. With the Studio System, manufacturers can achieve excellent material properties without tooling or expensive CNC machining.

The Studio System allows for customization of parts like putters, so each player can have a design that is best suited to them. And when those designs go into mass production, they can be manufactured via binder jetting.

Due to its complex geometry, these parts would typically be cast followed by extensive secondary machining. With the Studio System, the nozzle can be 3D printed without the lead times and setup costs of casting, enabling one-off and small batch orders.

Their complex vanes make impellers expensive and difficult to manufacture. When a custom impeller is needed metal 3D printing accelerates design optimization and product development by dramatically reducing lead time and cost.

3D printing the mold inserts shortens production run lead time and allows rapid iteration and refinement of zipper designs. Using a high resolution printhead allows for smaller parts with finer features, requiring less post processing.

After exploring a number of alternative manufacturing methods to produce the parts needed to keep crucial machinery up and running, Master Drilling chose 3D printing. The switch to 3D printing cut their lead time for replacement parts from about three months for off-shore castings, to just three weeks printing on-site, thereby reducing downtime for the earth drilling equipment.

The complex geometry of end effectors requires extensive CNC machining, resulting in long lead times that occupy valuable CNC capacity. Using metal 3D printing allows for on-demand manufacturing of custom end effectors while lowering part cost and lead time.

This fixture pushes a thread checker into a part on a manufacturing line. As a wear item, it needs to stand up to repeated use, and must be easily produced to keep the manufacturing line up.

This support is designed to carry a heavy load and withstand punishment. Engineers working on a bot used on a Discovery Channel program BattleBots had less than a month to produce a custom structural element on robotic arm. Using the Studio system, they were able to print a bracket capable of resisting bending and lateral motion while providing the stiffness, strength, weldability and fire resistance required.

These chuck jaws closely match the geometry of the part being machined - making them complex to machine. Printing them using the Studio System eliminates CNC lead time and frees up the machine shop for more critical work.

Fixture like this require custom geometry for each application, as well as superior wear resistance. The faster these parts are manufactured, the quicker a company can get get manufacturing lines running.

This heat exchanger enables a much higher heat transfer rate than a traditionally manufactured part. Featuring thin external fins and a complex, internal helical cooling channel, this exchanger would not be manufacturable as one component via CNC machining.

This 3D printed atomizer features complex internal channels and oblong shaped holes, which could not be manufactured with traditional methods. With the Studio System, the engineers were able to radically redesign their conventional atomizers for significantly better performance.

In some cases, replacement parts are no longer available, either off the shelf or from the OEM. Fabricating custom gears via hobbing and broaching is often prohibitively expensive, but metal 3D printing allows for the fabrication of legacy parts at much lower cost.

This part converges three flow paths into one via internal channels. These channels would be impossible to machine, and instead would need to be drilled as straight holes and plugged.

Printing on the Studio System allows these channels to be designed for their function rather than their manufacturing method. This part can be produced in just a few days with very little hands on work.

Typically CNC machined from aluminum alloy, pistons can be time consuming and difficult to rapidly prototype and test - often taking months or even years to move from design to production.

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