“There is so much noise in this market”, Vyomesh Joshi, better known as VJ, CEO of 3D Systems, commented during a Q&A at the company’s Littleton, Colorado-based medical facility earlier this month.
Compared to its founder-status and stronghold in the industry during the peak of 3D printing hype, you could be mistaken for believing the additive manufacturing (AM) giant has been keeping uncharacteristically quiet, but at a recent gathering for press, partners and investors, 3D Systems was out to shout loud and clear that it is still very much in the game.
On an ice cold Colorado morning, I arrived unsuitably-dressed in single layers, at the company’s Healthcare Technology Centre, an impressive facility from which its entire healthcare business operates. Throughout the day I heard engineers talking to surgeons and making changes to patient-specific devices remotely and in real-time, as part of its on-demand medical manufacture service. As fascinating as that was to an outsider like myself, it’s just another average day at the office around here and on this occasion, medical applications were not the primary reason for my visit. Instead the company had several announcements to make, some a long-time coming and others a little from the left-field, all set to materialise in the next 18 months.
The first was the commercial launch of its Figure 4 technology, shown in various iterations since CES 2016 where the average visitor would have probably skipped over the then-concept system printing at mega speeds against a backdrop of long-gone consumer tech. Now 3D Systems is launching the technology for real, as a modular system that allows users to choose from a standalone setup or scale up as they see fit to incorporate auxiliary elements such as post-processing.
Standalone Figure 4 system (left) and scaled up modular system (right).
Since Figure 4 was first announced, a technology which we have come to learn has been in founder Chuck Hull’s back pocket for some time, a number of similar technologies have come onto the market but 3D Systems isn’t shying away from the competition. Addressing what I’m sure most of us in the room were thinking, the team brings up the first and most obvious comparison with Carbon but is promoting a similar message of being able to scale from prototype to production using the same platform and material set, only with a bigger material portfolio (15 resins so far) and increased productivity (up to 40% faster according to 3D Systems’ statistics).
When I sit down with VJ, I ask why the long-patented technology has only come to fruition. He explains that materials were the real driving factor and says, “Let's just be real. My opinion is the starting point is materials, it's not the amazing technology.” This materials approach is vital and throughout the day we are increasingly being given the impression that hardware is only secondary to materials and software. It’s all about the wider ecosystem and how those processes and parts work together which VJ says the company is “uniquely positioned” to deliver.
The first iteration of Figure 4 on display was a dental-focussed machine, seen in its early stages during AMUG 2017, used in combination with NextDent materials, acquired by 3D Systems earlier this year. During a short demonstration, in the time it took for an engineer to introduce the technology and walkthrough the traditional way of making a dental model, the machine had completed a build. The dental model, equipped with an already tried and tested ecosystem of 3D scanning and materials, provides a guide to how the technology may be adopted in other verticals such as aerospace, healthcare and automotive, taking into consideration the appropriate materials and software for each. The technology will range from standalone configurations with prices starting at around $25,000 and allow users to scale up to highly-customised, in-line production systems over $1 million when demand requires it.
“If you go to the dental lab and say we have a new way of making dentures they will listen to you,” VJ explained. “They will tell you the first core barrier is materials. Here the machine is not that expensive, it's a good entry point, they can play with it. For most of the volume they do, this machine can do it. One machine can meet the dental lab's demand so that's why I think they'll want to try it out.”
VJ presenting the latest developments at 3D Systems' Littleton, CO office.
3D Systems has also grown its current line of SLS production systems with the new larger ProX SLS 6100 and three new nylon materials. Designed for tough, high-resolution end-use parts and functional prototypes, the system features automated material handling and 3D Sprint software to optimise builds. New SLS materials in the portfolio include DuraForm FR1200 fire retardant nylon, DuraForm EX BLK nylon 11 and DuraForm AF+ aluminium-filled nylon. The company also introduced new rigid and engineering-grade materials for its MultiJet Printing (MJP) technology that are more durable and produce lower cost functional prototypes than competing systems. The new engineering materials offer rigid and durable properties, high elongation and impact strength, and several of which are certified for use in medical device applications.
3D Systems’ metals family also received an update with the unveiling of a new DMP 8500 Factory Solution metal AM platform designed for high productivity with one of the largest metal build volumes (500 x 500 x 500 mm) on the market. Similar to Figure 4, the machine is a modular platform and features integrated powder management and a closed-loop system to ensure uniform, repeatable part quality at a lower total cost of operation. Kevin McAlea, Executive Vice President and General Manager, Metals & Healthcare, 3D Systems explained how more than any other technology 3D Systems has in its arsenal, it is metals that are most focussed on real manufacturing. Similar to several 'factory of the future' concepts we saw at formnext powered by tct last year, the vision sees the DMP 8500 installed in a 24/7 factory setting where a vacuum sealable Removable Print Module can travel from printer to Powder Management Modules for a continuous production workflow. It also makes use of 3DXpert, 3D Systems’ all-in-one software for metal AM which includes CAD import, geometry optimisation, lattice creation, calculation of scan paths and even post-machining tools. The commercial launch is set for the end of next year and it will be interesting to see if 3D Systems can be the first to live up to this automated AM factory vision.
The FabPro 1000 desktop industrial 3D printer.
Perhaps the most surprising announcement of the day was that 3D Systems is moving back into the desktop space. But forget ideals of a 3D printer in every home, this new machine, the FabPro 1000 is aimed solely at the industrial market and claims to be up to four times faster with a 40% lower part cost compared to similar machines. Targeting engineers with this sub-$5,000 DLP machine, VJ is quick to knock down any thoughts about the potential for the company to move back into the consumer area and once again, makes reference to the importance of materials in creating a true industrial desktop machine, primarily for functional prototyping.
“The way I think about that is there has to be a reason that customers will use that product and if you have productivity, if you have quality and if you have functional production parts you will use it,” VJ explained. “And once they use it it makes all the sense.”
Strengthening the wider ecosystem, 3D Systems also announced the introduction of 3D Systems Professional Services group to deliver applications engineering expertise and global technical support. Another big part of this is 3D Connect, a cloud-based software solution which will deliver proactive and predictive serviceability for production environments. We saw a demo during a tour which showed the ability to monitor a machine remotely, pinpoint any potential issues and perform a deep dive into where they are coming from to provide accurate solutions. Initially, 3D Connect will enable remote service and printer fleet support and will be integrated on new and select current systems beginning early next year. VJ explained that he believes 3D Systems is the first 3D printing company to really get into this services approach and commented, “we want to change this whole concept of up time and really make sure that our customers can continue to run these things day in day out 24/7 because that’s what they want to do.”
Overall it is evident that 3D Systems is taking an aggressive approach to its customer-centric strategy, looking at specific applications first and building a solution outwards from that, addressing the entire process chain. To quote VJ, this is a "printing not a printer company" after all. 3D Systems clearly knows the score with healthcare, and VJ says the company is taking a “thoughtful approach” to its next target verticals, concentrating on aerospace first with a similar dedicated facility. It understands that additive isn’t a simple thing for industries to adopt overnight, referring to it as a “business transformation technique” with no one-size-fits-all solution. With that in mind, VJ wants to be clear, “we are the innovation engine, we are going to listen to our customers and provide solutions.”
