1. Biodegradable Materials for Layer by Layer Processes César Carrión Rapid Manufacturing Manager Brussels, 2nd June 2009

2. 2 1.Índex 1.AIJU Overview 1.1. What is AIJU? 1.2. AIJU Location 1.3. Capabilities 1.4. Previous Experience 2. Project Intentions Overview 2.1. Project Title 2.2. Abstract 2.3. Objective 2.4. Justification 2.5. Previous Research

3. 3 1.AIJU SUBTITULO 1.1. What is AIJU? 1.2. AIJU Location 1.3. Capabilities 1.4. Previus Experience Overview

4. 4 1.1. What is AIJU? AIJU RESEARCH CENTRE AIJU – Asociaci ó n para la investigaci ó n de la Industria Juguetera, Conexa y afines – is a non-profit organization aiming to boost research development and technological innovation within toy and related industry. Thus making it possible the achievement of a constant competitiveness increase and product quality improvement

5. 5 1.1. What is AIJU? More than 550 associated companies: Toy manufacturers Mould-makers Plastics processors Other-industries: - Energy (PV, FC) - Fashion - Furniture - Medical engineering - Construction

6. 6 1.2. AIJU Location AIJU is located in the Toy Valley within the region of Alicante in the south-east of Spain : Toy Valley

7. 7 1.3. AIJU Capabilities Product Development & RM Rapid manufacturing Rapid tooling Functional prototypes Pre-series Personalised products Digitalisation - Verification 3D Design Vacuum Casting Injection Materials engineering SLS (Selective Laser Sintering) Objet Polyjet (3DP)

8. 8 1.3.Capabilities Materials & Processes Analyses of Plastic Materials and finished products New plastic functionalities Dimensional verification New formulations & New materials: Compounding & Extrusion Material identification & Characterization New technologies for product development CAD / CAE Injection Mould Simulation Thermography & Mould Quality Control Development of Chemical Analysis Methods

9. 9 1.3.Capabilities AIJU Objective Areas Toy & Children Childcare articles Leisure Disabled People Elder People Games

10. 10 1.4.Previous Experience European RM, RP, RT Project Participation TOYSCIM: “Toy Sector New Tecnologies Aplication (CAD/CAM and Rapid Prototyping)” - 1997 (Esprit Project - 5FP) TOYSLS: “Selective Laser Sintering Validation in Toy Sector: Mould and prototypes processes” – 1998 (INNOVATION – 5FP) T-SHOE: “Intersectorial Technology Transfer on Rapid Prototyping in the Toy and the Shoe industries - 2003 (INNOVATION – 5FP) VIM: “Virtual Injection Moulding for improving production efficiency, quality and time-to-market speed”. – 2003 (VI FP) FLEXRAP: “Development of an innovative, modular rapid prototyping system for rigid and flexible models. – 2003 (VI FP) CUSTOM-FIT: “A knowledge-based manufacturing system, established by integrating Rapid Manufacturing, IST and Material Science to improve the Quality of Life of European Citizens through Custom fit Products.” – 2004 (VI FP)

11. 11 2.Project SUBTITULO 2.1. Project Title 2.2. Abstract 2.3. Objective 2.4. Justification 2.5. Previous Investigation Overview

12. 12 2.1.Project Title Biodegradable Materials for Layer by Layer Processes

13. 13 2.2.Project Abstract In this project we wish try to find new materials to make RM more sustainable. To do it, we can test biodegradable, watersoluble, and other materials compounding. We need to use, modify or develop new technology capable to use this new materials. We need to develop new materials with good mechanical and physical properties (functional parts). We can found new properties (electric conductivity, degradability, recyclability…)

14. 14 2.3.Project Objectives If we want Rapid Manufacturing as Future Trend we need some Environmental changes: – Environmental implication in Processes (Energy optimization) – Environmental implication in Materials (Some RM composites can be made from natural materials), recyclability… –Some RP and RM processes can use composite materials with potential harmful effects.

15. 15 2.5. Justification Environmental impact of RM: Reduced waste during production, No over production, No excess of packaging vs other processes, but… What happens with RM Product when use life end? i.e: In SLS process: What we can do with PA powder when lost properties: roughness, hardness, orange skins, yellow color..) aprox. each 20 uses, we need renew all material In Polyjet process: Where we place empty Support and Model Jumbo Cartridges?

16. 16 2.4.Justification We think that Medical Applications isn’t only way for Rapid Manufacturing, we need to adapt to other sector needs

17. 17 2.3. Previous Research Project Objective: We can try to find functional biodegradable materials (hardness, roughness, mechanical properties…) AIJU is doing some proofs with almond shell in injection moulding (with PP, PS, PE…) and SLS (with PA) processes. AIJU is doing some proofs with PA (20%) with Carbon (80%) with good conductivity values (10 S/cm) Our Partner, Las Palmas de Gran Canaria University (Canary Islands) is doing some proofs with Banana fibber in Vacuum Casting Processes. AIJU hopes begin, this year, to develop a Miniexperimental 2D (or 3D) Laser Marker to test more material formulations without need to develop big batches of it.

18. That’s all!! Thanks for your atention!! César Carrión prototipos@aiju.info