FuseLab FL300M's new rotary extruder can enhance metal FFF 3D printing-3D printing industry

2021-11-13 02:19:21 By : Mr. AMOS FAN

Belgian 3D printing startup FuseLab has launched its first FFF metal 3D printer FL300M, which has a patented rotary extruder designed to enhance metal powder-based filament printing.

Due to its novel rotary extruder design, FL300M claims to minimize the risk of filament failure and insufficient extrusion in metal 3D printed parts by increasing the contact points between the filament and the nozzle drive system.

The FL300M is produced at FuseLab's Belgian plant and will debut at the Formnext trade fair in Frankfurt this month and will be available in early 2022.

In addition to providing a relatively lower system cost than other additive manufacturing processes, FFF also provides easy handling, wide availability of raw materials, and the ability to produce parts with completely enclosed hollow features or internal support structures, which are powder or resin-based systems Unachievable. 

Although it has existed for decades, the FFF 3D printing process continues to improve to minimize part irregularities, increase particle emission rates, and optimize interlayer heat transfer and adhesion. In fact, the veteran 3D printer manufacturer 3D Systems only released its first industrial-grade FFF 3D printing system this year, laying the foundation for its High Speed ​​Fusion (HSF) platform. 

FFF 3D printing is also constantly advancing through the development of new materials, such as soft and flexible TPU filaments, medical and engineering grade filaments, biodegradable filaments and high-performance filaments.

FuseLab's novel extruder design

FuseLab was founded by Jonathan Palmaers in 2018. It was inspired by the potential of 3D printing and sought to address areas of improvement in this technology. The company began to develop its patented rotary extruder and, after realizing its expected advantages in metal printing, began to develop the FL300M. 

FuseLab’s facilities are equipped with in-house engineering, prototyping and manufacturing capabilities, and run on a closed-loop system, enabling rapid development cycles and enhanced product quality control. 

The company's first FFF 3D printer, FL300M, stands out in the crowded FFF market with its patented new rotary extruder and high performance and precision motion system. 

Traditional FFF extruders tend to use one or two drive gears to feed the filament into the melt zone of the printer, and only one or two contact points are provided between the drive system and the filament. At higher speeds or squeezing forces, this can cause filaments to "slip" and subsequent under-squeezing.

In order to solve this problem, FuseLab designed an extruder design based on three drive rollers. Each drive roller provides 12 contact points. There are a total of 36 joints between the extruder drive mechanism and the filament. 

According to FuseLab, the increase in the number of joints is particularly advantageous when printing with metal powder-based filaments, because these filaments tend to be more fragile due to the high metal powder content and low binder content. Therefore, distributing multiple contact points in the entire extruder can minimize the risk of filament failure, and the anti-skid characteristics of the extruder can reduce insufficient extrusion, so that the metal parts have high rigidity. 

With its patented extruder technology, the ultimate goal of this startup is to improve the quality and reliability of FFF metal printing.

Although the patented extruder design is a model of FL300M, the machine also provides a series of other noteworthy features. The printer is equipped with a build volume of 300 x 300 x 280 mm, can print a variety of materials, and is optimized for metal powder filaments. 

The printer runs on an open filament system of filaments with a diameter of 2.85 mm, while a rigid motion system separate from the build housing is designed to enhance the printing process. The machine also has a closed build room with HEPA filter function.

FL300M will debut on Formnext 2021 and will be available in early 2022. 

Subscribe to the 3D printing industry newsletter for the latest news on additive manufacturing. You can also keep in touch by following us on Twitter and like us on Facebook.

Looking for a career in additive manufacturing? Visit 3D printing jobs to learn about a range of roles in the industry.

Subscribe to our YouTube channel to get the latest 3D printed video clips, reviews and webinar replays.

The featured image shows the FuseLab FL300M 3D printer. Photo from FuseLab.

Hayley is a 3DPI technical reporter with a background in B2B publications across manufacturing, tools, and bicycles. She writes news and features, and has a keen interest in emerging technologies that affect the world in which we live.

© Copyright 2017 | All Rights Reserved | 3D Printing Industry