A Modular, Expandable Thermoplastic Digital Factory 

3D Systems has announced the general availability of its first completely scalable production platform for thermoplastic manufacturing, the Figure 4 Modular 3D printer. The company also announces five new materials to become available in the next few months, extending the value of the Figure 4 platform. 

The Figure 4 Modular is a flexible production system capable of growing as needed. 3D Systems’ Figure 4 technology allows a high-volume production solution for thermoplastic parts requiring high surface quality and fidelity. 3D Systems says the time reductions in each step of the plastic manufacturing process make it much faster than using traditional injection molding in most applications. 

The focus of this Product Brief is the Figure 4 Modular, one of three configurations of the Figure 4. Also available are Figure 4 Standalone for low-volume use, and Figure 4 Production, for companies seeking the highest degree of automated throughput for long part production runs. 

Figure 4 uses non-contact membrane  technology and state-of-the-art plastic resins. Unlike other printers in this category, 3D Systems says Figure 4 can manufacture parts from hybrid materials (multi-mode polymerization) to meet specific requirements for toughness, durability, biocompatibility, high temperature deflection and elastomeric properties. 

With up to 100mm per hour print speeds and rapid post- processing, 3D Systems offers fast time-to-part production throughput. In an 11-day period, eight Figure 4 printers can turn out 10,000 units of a textured automotive vent. 

Manufacturers can scale the Figure 4 Modular by adding up to 24 total print engines. Powered by 3D Systems’ 3D Sprint software, each engine can run different materials and jobs simultaneously as part of a single, high-throughput line. Other options include separate modules for automated materials handling and centralized post-production. 

Four thermoplastics are already available for the Figure 4 Modular; four more will be released shortly. Figure 4TOUGH-BLK 20 is an ABS-like black material with UV stability and high accuracy for production applications. Figure 4 FLEX-BLK 10 is a flexible material for durable propylene-like black parts. Figure 4 MED-AMB 10 and Figure 4 MED-WHT 10 are an amber and white version of a biocompatible, sterilizable material. Both meet ISO 10993-5 and ISO 10993-10, making them suitable for use in general medical applications requiring translucency, sterilization and/or thermal resistance. Figure 4 HI-TEMP-AMB 250 is a high thermal-resistant material (HDT > 250C) for design verification testing, motor enclosures and low pressure molding/tooling with transparency for flow visualization.

3D Systems says internal testing and outside verification has proved that Figure 4 with the accompanying 3D Sprint software can deliver a six sigma repeatability score of Cpk > 2.0. Tests were conducted on eight Figure 4 Standalone machines, where each system can be calibrated through a series of preset test models to deliver the repeatability necessary.

Three early industrial users of the Figure 4 Modular system have made public comment regarding their experience. One of them is Decathlon, a global sporting goods manufacturer based in France. According to Decathlon’s Julian Guillen, “using an existing desktop SLA solution, it would take 29 hours to produce our tensile test for material validation. With the Figure 4 Modular using the Figure 4 TOUGH-GRY 10 material, we were able to print the same quantity in 90 minutes—more than 19X faster.” 

For more information on the 3D Systems Figure 4 Modular 3D printer click here. 

Check out this video on how Midwest Prototyping uses the Figure 4 Modular to deliver test parts the same day requested. 

See why DE’s Editors selected 3D Systems’ Figure 4 Modular 3D printing production system as their Pick of the Week. 

Sources: Press materials received from the company and additional information gleaned from the company’s website.