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Purmundus Challenge finalists announced; winners to be revealed at Formnext 2019

cirp GmbH, organiser of the Purmundus Challenge, which is
sponsored by Germany’s VDMA, has revealed the thirty-eight finalists in this
year’s competition. The challenge winners will be announced and presented
with their awards at Formnext 2019, Frankfurt, Germany, November 18-22.

Commenting on 2019 challenge, the organisers stated,
“this year’s finalists show the enormous potential of Additive
Manufacturing. 3D and 4D printing are more than ever and increasingly around
the world a core manufacturing process paving the way for smart innovations in
various different markets. The 2019 Purmundus Challenge shines a spotlight on
forward-looking product ideas from eighteen countries on five continents under
the motto ‘Beyond 3D Printing’.”

The finalists in this year’s challenge are said to include
forward-looking concepts in the fields of medicine, 4D printing, bionics,
mobility, safety and packaging. In addition to a fashion collection and
jewellery, finalists include a design product from the cosmetics sector.
Products in the fields of lifestyle, furnishings, art and household are also
included, as well as musical instruments and a biathlon rifle. Two AM
technologies and a new material were also entered.

The panel judges the entries in terms of use, economy and
aesthetics, as well as design and innovation. The awards given to the winners
are said to be worth a total of €30,000. In addition to the first three places,
a ‘special mention’ and an ‘innovation prize’ will also be given. One finalist
will also be awarded the prize for the ‘people’s choice’, voted for by visitors
to Formnext 2019.

www.purmundus-challenge.com 

Metal Additive Manufacturing finalists in the Purmundus
Challenge 2019 

Ginger/wasabi and nutmeg grater by Taktilesdesign GmbH

Ginger/wasabi and nutmeg grater by Taktilesdesign GmbH

Sylvia Goldbach of Taktilesdesign GmbH designed a
ginger/wasabi and nutmeg grater to increase the ease of grating and durability
of graters. The product design was optimised for metal AM and produced in
stainless steel with almost no support structures, making it possible to apply
the textured finish of the design to the full surface. 

The production time was two days, followed by an
electrolytic plasma polishing process for surface finishing. Small 115 mm
graters are now commercially available, while a larger variant is available as
a prototype. 

www.taktilesdesign.de

EAP Abutment by EAP Productions und Patentverwertungs GmbH

EAP Abutment by EAP Productions und Patentverwertungs GmbH

Prof Dr Mario Kern, EAP Productions und
Patentverwertungs GmbH, designed an EAP Abutment for dental applications.
The hybrid abutment for tooth implants is designed to work with any implant
system, and is said to have approved adhesive properties and be easier to use
than conventional abutments. 

The product is produced in titanium by Laser Powder Bed
Fusion (L-PBF) on a GE Additive Concept Laser MLab 200 system and finished by
CNC milling. Shipments of the new abutment began in September 2019.

www.ea-platform.at

Smash-proof guitar by Sandvik Additive Manufacturing and
Drewman Guitars

Smash-proof guitar by Sandvik Additive Manufacturing and Drewman Guitars

Sandvik Additive Manufacturing, in collaboration with
Drewman Guitars, manufactured a ‘smash-proof’ guitar for Swedish metal
guitarist Yngwie Malmsteen using milling and metal Additive Manufacturing technologies.
The guitar is said to be the world’s first all-metal, unbreakable guitar, and
was the result of a company-wide project at Sandvik to demonstrate how
sustainable technologies can be used to make objects which are both highly
precise and extremely durable.

www.home.sandvik 

Stealth Key by UrbanAlps AG

Stealth Key by UrbanAlps AG

Dr Alejandro Ojeda at UrbanAlps AG developed the Stealth Key
using industrial metal Additive Manufacturing technologies. This range of keys
was designed to overcome the security threat posed by the availability of
commercial AM technologies which might be used to scan and duplicate door keys.

The Stealth Key replaces the conventional key design, made
out of sheet metal with a visible ‘code’ shape, with a new design in which the
code is hidden within a superalloy cylinder, ensuring the key cannot be
photographed or scanned. 

www.urbanalps.com 

Mountain Bike Frame by NMU Eco-Car

Mountain Bike Frame by NMU Eco-Car

Byron Blakey-Milner of NMU Eco-Car, based out of Nelson
Mandela University, South Africa, designed and produced an additively
manufactured Ti-6Al-4V mountain bike frame, produced by L-PBF on the Aeroswift
large-scale Additive Manufacturing machine. Due to the very high cost of top of
the range mountain bike components, the company believes this design could
compete economically with high-end carbon fibre designs.

Using topology optimisation, the designer was able to
increase the frame’s competitiveness with regard to weight and stiffness,
without being limited to the single/split draw mould constraints of carbon bike
frames. 

www.mandela.ac.za 

Wing3D spoiler system by EDAG Engineering GmbH

Wing3D spoiler system by EDAG Engineering GmbH

Fabian Baum, Sebastian Flügel and Martin Rüde of EDAG Engineering
designed the Wing3D spoiler system, said to combine lightweight construction,
active aerodynamics, functional integration and a visually appealing design.
The spoiler system features a bionic aluminium mount produced by L-PBF.

The mount holds the AM spoiler and adjusts its position
using integrated hydraulics. Due to its design, the spoiler could not have been
manufactured by conventional methods. It is operated by a piston with oil
pressure up to 90 bar, which can set the spoiler at any angle between 6–42°,
allowing it to be adjusted to the driving situation in terms of draft and
resistance, in addition to an aerodynamic braking function.

www.edag-engineering.de 

#Swirl by Tamara Trusova

#Swirl by Tamara Trusova

Jewellery designer Tamara Trusova produced a set of
jewellery titled #Swirl using bronze Additive Manufacturing. The set includes a
bracelet, ring and earrings, and is said to be inspired by bionic structures,
mathematical forms and algorithms created by computational design. 

Monolithic Rocket Chamber by CellCore GmbH

Monolithic Rocket Chamber by CellCore GmbH

Dr Paul Schüler and Andreas Krüger of CellCore GmbH, in
collaboration with SLM Solutions Group AG, developed a monolithic and
multi-functional rocket engine concept to demonstrate the potential and
benefits of metal L-PBF Additive Manufacturing. The rocket engine demonstrator,
produced in IN718 on an SLM 280 machine, combines a fuel inlet, injection head,
thrust chamber and innovative structural cooling concept in one integrated
design. 

The core element of the demonstration piece is the
functionally optimized lattice structure integrated into the chamber wall,
which in addition to providing the necessary stability, but also offers
opportunities for cooling by efficiently conducting heat away from the thrust
chamber’s internal wall by actively circulating liquid hydrogen.

This structural cooling is said to offer a significant
improvement over conventional approaches such as concentric milled cooling channels.
It also reportedly offers an ideal ratio between stability and the amount of
material used, and has low flow resistance combined with a large reaction
surface.

www.cellcore3d.com 

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