Concr3de Armadillo White - Industrial binder jetting 3D printer

Concr3de, founded in 2016, are a brand specialized in developing cutting-edge binder jetting 3D printing technologies. With a background in architecture and a dream to transform abstract ideas into tangible objects, Concr3de has created a versatile ecosystem accessible to creators seeking novel material properties and unprecedented scalability, enabling the additive manufacturing of physical objects in any size on an industrial scale. The brand's mission encompasses guidance, customization, testing, and fostering collaborative development ventures.

What is binder jetting?

Exploring the benefits of binder jetting 3D printing reveals insights for businesses. Unlike traditional manufacturing with its wasteful subtractive or casting processes, binder jetting constructs objects layer by layer, minimizing waste and offering sustainability. This cost-effective technology, exemplified by the CONCR3DE Armadillo printers, demonstrates remarkable scalability, producing up to 100 liters per day even at a smaller scale, outperforming traditional FDM printers by almost 50 times.

Additive manufacturing via binder jetting with the Concr3de ecosystem consists of the following steps: (1) loading and processing the STL/OBJ files in the laminating software, (2) powder loading (feed bed low, print bed high), (3) powder spreading, (4) binder jetting, (5) the print is complete, encapsulated in powder, (6) depowdering, (7) part is ready for post-processing.

Image 1: The binder jetting process. Source: Concr3de.

Binder jetting's cost-effectiveness is emphasized by its use of low-cost materials, including potential utilization of waste like sawdust. Operating at room temperature reduces energy consumption, and the process involves minimal equipment investment. The method's material versatility, showcased by open-platform Armadillo printers, allows printing from various powders, serving diverse industries like automotive, medical, and aerospace. Beyond traditional manufacturing constraints, binder jetting excels in creating complex designs with intricate details, optimizing final parts for material efficiency and lightweight structures. Ongoing research and development initiatives position binder jetting as a technology with limitless potential and significant advantages across sectors.

Armadillo White

The Armadillo White industrial 3D printer from Concr3de's Armadillo family of printers was developed specially for R&D applications as a tool for facilitating and accelerating progress in various science fields. Concr3de achieves that by equipping the Armadillo White 3D printer with a fully open binder jetting platform with customizable hardware, an open material platform and accessible software. This enables material scientists and researchers to experiment with 3D printing materials without limits.

Image 2: The Armadillo White 3D printer. Source: Concr3de.

The cutting-edge Armadillo White 3D printer revolutionizes 3D printing by enabling the use of previously unimaginable powder and binder combinations, offering unparalleled possibilities for applications such as biocompatibility, tailored material properties, and upcycling, with the fastest and highly precise printing capabilities. The Concr3de platform allows comprehensive customization of the printing process, eliminating restrictions imposed by inaccessible technology, while the NOAH software provides control over the printer and material-specific add-ons. Armadillo White's manufacturing scale and features can be customized according to research needs, thus allowing to conduct consistent testing with small material volumes, cure with heat or UV light, or opt for the XL printer version to double the build envelope.

Image 3: The build space of the Armadillo White 3D printer. Source: Concr3de.

With a spacious print box measuring 370 x 260 x 250 mm (34 liters), Armadillo White provides ample room for intricate creations. If the print scale is smaller, the reduction insert will allow for the use of less than 1 liter of powder, thus making the workflow more sustainable and efficient. The printhead precision is adjustable, offering either 400 DPI or 720 DPI for precise and high-quality prints. The layer height ranges from 40 to 500 µm, ensuring flexibility in design. The printer's drop size variability spans from 5 to 200 pL (editable via the NOAH software along with the drop shape), catering to diverse printing needs. Its connectivity features Ethernet, with the cable included, and the power requirements are 2 x 230 V. The printer's overall dimensions are 1600 x 1100 x 1600 mm, with space requirements of 2400 x 2000 x 2200 mm. Despite its robust capabilities, the Armadillo White 3D printer maintains a manageable weight of 450 kg, making it a formidable choice for professionals seeking precision and reliability in their 3D printing endeavors.

Image 4: The Armadillo White 3D printer in operation. Source: Concr3de.

Armadillo White utilizes a piston system equipped with a counter-clockwise rotating roller, eliminating the need for a recoater or hopper. This design allows for the easy spreading of less flowable powders like ceramic, alumina, porcelain, or cement. Adjustable parameters, including Y-direction movement speed, X-direction movement speed, roller rotational speed, spreading speed, feed height, and layer height, further facilitate precise powder spreading. The actuators on the Z-axis exhibit a 2 µm repeatability, ensuring reliable and accurate spreading of very thin layers, down to 40 µm thickness.

The workflow

Material compatibility - Armadillo White is meticulously engineered for extensive material compatibility, allowing printing with a broad spectrum of powders and binders. Whether it's from Concr3de's certified material range or an undiscovered compound, if the material is or can be provided in powder form, Armadillo White can effectively print with it. Some examples are biopolymers, nylon, ashes, wood pulp, geopolymers or photocuring polymers. In terms of binders, Armadillo White accommodates aqueous, solvent, particle-filled, phenolic, inorganic, and UV curing binders, offering versatility in material options for diverse 3D printing applications.

Image 5: Part 3D printed with the Armadillo White 3D printer. Source: Concr3de.

Binder delivery - the choice of printhead in Armadillo White plays a crucial role in determining the rheology needed for the binder, considering factors like viscosity, density, and surface tension. Users have the flexibility to opt for either a low-viscosity or high-viscosity printhead. CONCR3DE provides the freedom to customize waveforms controlling the printhead, allowing users to adjust parameters such as firing frequency and droplet size. These adjustments influence the saturation level of the powder, impacting the final printed result. Different liquids require varied flow rates and cleaning cycles, all of which are adjustable within the printer settings. Temperature influences the binder's viscosity, and both the inkjet module and printhead feature heaters for precise viscosity control during the process. The transparent design of the inkjet module allows researchers to visually monitor the binder flow. Additionally, the module is designed to accommodate various binder storage options, such as using a jerrycan or inserting binder with a 50 ml syringe, offering flexibility for different types of binders, especially costly or volatile ones.

Image 6: Part 3D printed with the Armadillo White 3D printer. Source: Concr3de.

NOAH software - Armadillo White comes equipped with an integrated control station featuring our customized and fully open NOAH software, pre-installed on optimized hardware. NOAH provides comprehensive control over every aspect of the 3D printing process, allowing users to manage all Armadillo add-ons with precision. The software goes a step further by enabling the modification of waveforms within the printheads, providing unparalleled control over droplet size and shape, and consequently influencing the final printing outcomes.

Image 7: The NOAH software. Source: Concr3de.

Post-processing - following the completion of the print, CONCR3DE provides diverse options for efficient depowdering and post-processing. The Concr3de standalone Depowdering Station facilitates the clean and dust-free removal and recycling of any unused powders. It offers the flexibility of integrating a Vacuum Arm directly into the printer. For materials like ceramics and metals requiring post-print curing to enhance green strength, the Depowdering Box allows a seamless transfer of the entire print box into a drying oven, eliminating the need for initial depowdering. This approach ensures the safety of delicate parts, minimizing the risk of breakage after the green strength has sufficiently increased. 

Add-ons for more research freedom

Reduction insert - this add-on designed to minimize the minimum print size, enabling printing with less than 1 liter of powder. This feature reduces waste, preparation time, and costs. As your printing requirements evolve, simply remove the Reduction Insert to transition seamlessly to full-scale printing, all within the versatility of a single printer.

Video 1: Reduction bed for Armadillo White. Source: Concr3de.

XL size (optional) - alternatively, for projects demanding an expanded construction volume beyond the standard, the XL size add-on extends the Armadillo printing dimensions to 440 x 440 x 250 mm, approximately 48 liters (space requirements of 3100 x 2200 x 2500 mm, weight 550 kg). This enhancement broadens the possibilities for conducting large-scale research, prototyping, and production using a single printer, eliminating the need for additional investments or concerns related to R&D transfer.

Video 2: Labjet ink supply for R&D. Source: Concr3de.

LabjetT LFR binder supply - when experimenting with new formulations, it's ideal to begin with small batches ensuring optimal stability and repeatability. The Labjet LFR Binder Supply facilitates this process by enabling the precise application of tiny binder volumes using a syringe. This add-on is particularly beneficial for handling volatile or expensive binders efficiently.

Integrated features for special needs

In order to accomodate all kinds of 3D printing materials with specific requirements and thus allow for creation without limits, the Armadillo White 3D printer has been equipped with integrated features such as a UV curing module and an infrared heater.

Image 8: The UV curing add-on allows to print with polymer or composite materials. Source: Concr3de.

UV curing - the UV Curing add-on is essential when working with polymer or composite materials in 3D printing. This addition enables the curing of materials using a 395 nm (+/- 5) light engine, featuring a typical radiation level of 5.5 W/cm² and an optical output power of 31 W, along with a UV power of 4.2 W/cm.

Image 9: The infrared heater is ideal for working with high-temperature materials. Source: Concr3de.

Infrared heater - certain powders necessitate high-temperature curing or exhibit faster binding at elevated temperatures. The Infrared Heater, featuring a potent infrared curing lamp, allows precise control of the print bed temperature, reaching up to 80°C. Positioned behind the roller as an add-on, it comprises an adjustable intensity infrared lamp for heating the print bed post-binder jetting. Elevating powder temperature offers advantages like reducing binder viscosity for deeper penetration, enhancing the green strength of printed parts through polymer curing, and expediting curing times, particularly in cementitious binders.

R&D redefined

The Armadillo White is ideal for academic and research settings, presenting an array of benefits that cater to the diverse and evolving demands of scientific exploration. Its exceptional appeal lies in the expansive material compatibility, providing researchers with the freedom to experiment with an extensive range of 3D printing materials. The fully adjustable software and customizable hardware of the printer serve as crucial tools, allowing researchers to fine-tune every aspect to meet the specific requirements of their unique projects. This adaptability ensures that the Armadillo White is not just a 3D printer but a tailored solution that caters to the nuanced needs of academic research, fostering innovation and experimentation.

Image 10: Part 3D printed with the Armadillo White 3D printer. Source: Concr3de.

A notable feature of the Armadillo White is its modular system, adding an extra layer of flexibility for researchers. This modular design enables the customization of the printer based on the distinct requirements of each research endeavor. Some modules are designed to streamline research processes, simplifying intricate tasks, while others extend the printer's capabilities, introducing additional functionalities. In essence, the Armadillo White emerges as a versatile and innovative tool, providing researchers with the necessary resources to navigate the intricate landscape of 3D printing with unprecedented ease, customization, and efficiency. Its commitment to adaptability positions it as an invaluable asset, empowering academic and research institutions to embark on diverse projects with confidence and precision.