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EOS P 500: 3D Printing of Polymers on an Industrial Scale

November 16, 2017

Manufacturers benefit from maximum productivity, automation readiness and processing materials up to 300°C

EOS, the world's leading technology supplier in the field of industrial 3D printing of metals and polymers, introduces its EOS P 500 system for additive manufacturing (AM) at formnext 2017. The system addresses companies who want to mass produce polymer parts on an industrial scale in combination with premium part quality.

The new system offers high efficiency for lowest cost-per-part, comes automation ready and can process polymer materials, which require operating temperatures of up to 300°C. For the development of a first high performance polymer, EOS recently signed a joint development agreement with Arkema. With the EOS P 500 businesses receive smart and robust technology to foster a reliable, flexible and cost-effective production.

Doubled build rate and maximized machine uptime for increased productivity

The EOS P 500 builds twice as quickly as the current fastest laser sintering machine (EOS P 396) thanks to a dual-laser system fusing the powder, and a new recoater. The latter applies a new layer of powder to the building platform with high speed (600mm/s) and maximum adjustability. Also, the material flow has been optimized. In contrast to previous systems, the EOS P 500 preheats polymer material in advance, before it is applied on the build platform, reducing layer times. The system can also reuse all recycled powder for the next build job at higher fill rates, further increasing the efficiency of the system.

The steps before and after the actual build process are streamlined substantially: Pre-heating of the exchangeable frame and cool-down of the used exchangeable frame (containing the manufactured part) take place outside of the EOS P 500. Additionally, switching between the exchangeable frames is extremely short – within 15 minutes after a build job is completed, a new manufacturing process can be started. In combination with rarely needed cleaning (typically 1x per week) and maintenance (typically 1x per year), the total cycle times of the EOS P 500 are improved significantly by up to 75 percent compared to the EOS P 396 – giving businesses a system with maximized machine uptime.

The high productivity comes with the known EOS premium part quality. The EOSAME feature homogenizes the energy input of the laser, thus ensuring high quality and reproducible part properties and dimensional accuracy across the complete build volume – key for serial production.

Ready for digital production thanks to monitoring and integration

The EOS P 500 comes alongside several solutions for monitoring and integration. The system offers industrial quality assurance through sensory, as well as camera based (optical and thermal), data evaluation, for example stating residual oxygen levels or the temperature of the build chamber. In conjunction with EOSCONNECTsoftware, machine and production data can be gathered and made available in real-time. EOS also offers an intuitive app to visualize the data on a dashboard. This is the next step towards comprehensive and user-friendly machine park surveillance.

Software integration also plays an important role for preparing the AM build job. The EOS P 500 is the first EOS system for additive manufacturing with polymers that is supported by the intuitive, open and productive CAM tool EOSPRINT 2 – a software that already successfully supports a large number of EOS metal systems. The software enables engineers to assign and to optimize build parameters for their CAD data.

This industrial grade connectivity before, during and after the AM build process is key to embed the EOS P 500 into an automated manufacturing environment and the first step towards automatized polymer production chains.

Processing of new materials

Users can process materials up to 300°C with the EOS P 500 – making it possible to manufacture polymer material classes such as PA6, PBT, PET, PPS, PEKK and others. A three stage filter-unit – consisting of a cooling trap, fines filter and reactive coal filter – counters material outgassing and particle contamination, contributing to a high quality of the AM build process. Being able to manufacture high performance polymer materials opens up new application areas where businesses can benefit from industrial 3D printing – for example in the mobility and automotive sector or when manufacturing electronic components.

The first high performance polymer available for the EOS P 500 will be PEKK, a material known for its high thermal stability, inherent flame retardancy and high chemical resistance, that makes it a lightweight alternative to metal. The goal is to release a high performance material at a competitive cost-per-part, enabling industrial applications not feasible until now. EOS recently signed a joint development agreement with Arkema, a leading global manufacturer in specialty chemicals and advanced materials, to develop an EOS material based on the KEPSTAN® PEKK product line of Arkema. As the EOS system is an open platform, other companies can develop materials for the EOS P 500 too. Today, EOS also cooperates with Evonik and BASF for developing future polymer materials.

Materialise acquires first EOS P 500

The first company acquiring the new polymer system EOS P 500 is Materialise. The company incorporates more than 27 years of 3D printing experience into a range of software solutions and 3D printing services, which together form the backbone of the 3D printing industry.

“We look forward to the boost in productivity delivered by the EOS P 500 solution and the new possibilities for series manufacturing created by the integrated platform automation. The shorter cycle times will help us to meet increasingly tight deadlines as the demand for industrial polymer printing grows. We look forward to exploring the use of new materials and new applications with the support of the mid-temp capability,” says Bart Van Der Schueren, Chief Technology Officer at Materialise.

Dr. Tobias Abeln, Chief Technical Officer at EOS states, “We are delighted that Materialise, a pioneer with much expertise in leveraging the possibilities of industrial 3D printing, trusts in our new EOS P 500. The system unites nearly 25 years of EOS expertise in the field of laser sintering. We reviewed and optimized all technical features to make the most out of the current technology for serial production. We are proud that the improvements we achieved are the right ones so that Materialise is already acquiring an EOS P 500 before the system is officially launched.“

About EOS

EOS is the world's leading technology supplier in the field of industrial 3D printing of metals and polymers. Formed in 1989, the independent company is a pioneer and innovator for comprehensive solutions in additive manufacturing. Its product portfolio of EOS systems, materials, and process parameters gives customers crucial competitive advantages in terms of product quality and the long-term economic sustainability of their manufacturing processes. Furthermore customers benefit from deep technical expertise in global service, applications engineering and consultancy. www.eos.info

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