Exploring Dyndrite’s Advancements in 3D Printing Materials at Formnext 2023


Dyndrite has collaborated with Constellium, Elementum 3D, and Sandvik to kickstart the industry-driven Materials Consortium for additive manufacturing (AM). This partnership initiative is envisioned to open up the field of metal 3D printing by widely sharing laser powder bed fusion (LPBF) powder parameters and corresponding test data. Its focus lies in promoting honesty and speeding up the acceptance of materials and AM methodologies, with the consortium firmly believing that such initiatives will drive the industry forward through mass knowledge dissemination and catalyzing innovation.

3D Printing Materials Consortium

There’s an increasing demand for parts produced through additive manufacturing, especially those fashioned from metal. This growing requirement aligns with the capabilities of the latest 3D printing equipment. Following this requirement, Dyndrite, in association with prominent LPBF material providers, have committed to offering public access to their most frequently used material parameters and data. Hence, establishing a setting conducive to quick experimentation and material qualification.

“Materials are one of the critical aspects of additive manufacturing,” asserted Harshil Goel, the CEO of Dyndrite. “However, in our industry, optimizing a material’s potential as it pertains to the printed geometry often remains arcane. For additive to transform into a mainstream manufacturing protocol, we need transparency and standardization. Offering public access to a trusted, democratized set of parameters unveils the pathway to adoption.”

The goal of the consortium is to improve the quality and cost-effectiveness of Additive Manufacturing (AM) components by simplifying the process for customers. This project includes steps like achieving accurate geometries, improved surface quality, optimizing the print cycle times, and reducing production costs. The consortium plans to achieve this by working together to create, test, and share parameters for materials which will promote a culture of open innovation and mutual success.

Features of Dyndrite LPBF Pro

Dyndrite is synonymous with its high-powered GPU-driven geometry engine referred to as the Dyndrite Accelerated Computation Engine (ACE). ACE has the capability to process complex 3D models and geometries swiftly. The company followed this with an App Development Kit (ADK) that allows 3D printer manufacturers to personalize the software to include their features through an easy-to-use interface. Dyndrite also developed its own set of tools, one of which is a Materials and Process Development app for LPBF, that allows for advanced development processes like volumetric segmentation.

In addition to establishing the Materials Consortium, Dyndrite has also released its brand new Dyndrite LPBF Pro software. Dyndrite LPBF Pro is a comprehensive software package that is designed to improve the efficiency and capabilities of LPBF metal 3D printing processes. It sets out to automate and streamline the build preparation process, expedite the materials and processes development, and enable repeated qualification processes for serial production.

The software is designed to provide precise control over LPBF machines. This control enables the development of new material parameter sets, printing intricate geometries, and enhancing build rates and part quality. The software also features substantial computational capabilities for handling large datasets, and it automates workflows from CAD to print, thus eliminating manual tasks.

Additionally, Dyndrite LPBF Pro provides flexibility in toolpath optimization, including for multi-optic systems. This flexibility enables engineers to customize their processes to match unique printing requirements. The software also comes with a comprehensive API for integration and automation, fostering an open exchange of information and negating the need for extra charges for unique modules or build processors. It supports printers from numerous companies, including Aconity3D, EOS, Renishaw, and SLM. It is available through a VIP Onboarding Program for direct support.

“For more than 6 years, AMS has collaborated with aerospace, space, and motorsport companies to push the boundaries of LPBF,” stated Rob Higham, CEO of Additive Manufacturing Services (AMS) Ltd. “Within two days of using Dyndrite, we managed to print a thin-walled heat exchanger that others had been trying to print for over 18 months, without success – such an accomplishment speaks for itself.”

Multi-material Resin 3D Printing

Dyndrite’s products go beyond the domain of metal LPBF. At Formnext, they announced a collaborative venture with BCN3D, in which they facilitated use of their software for BCN3D’s 3D printing of multi-material resin parts with BCN3D’s viscid lithography manufacturing (VLM) technology. The VLM high-viscosity procedure ramps down restrictions on 3D printable materials, hence enhancing robust and detailed part production.

Currently, VLM, with the help of Dyndrite software, is able to merge different resin types into a single printed part. To exemplify, BCN3D exhibited at Formnext an electrical connector which complies with the industry standards for flame resistance, impact resistance and flexible strength. Accompanying this was a silicone-based seal, designed to bear remarkable stretching and pulling.

Metal 3D Printing Market

Despite VLM technology’s potential, it seems like Dyndrite’s instant revenue generator could be the metal AM division. As per the “Metal AM Markets: 2023” report released by Additive Manufacturing Research (AMR), the anticipated revenue from metal AM by the end of 2023 is around $5.4 billion, in spite of economical slowdown. In the first half of the year, the growth in metal AM powders was approximately 33% year-over-year. AMR predicts that the global market for metal 3D printed parts will generate revenue up to $75 billion annually by 2031.

For this growth to happen, it will be necessary for metal 3D printing, particularly LPBF, to become easier to use and more predictable. Key to that development is the opening up of materials parameters, which the Materials Consortium seems intent on doing.

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