Concr3de Armadillo Blue - 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 Blue

The Armadillo Blue industrial 3D printer from Concr3de's Armadillo family of printers was developed specially for industry and high-tech production applications in the ceramics and metals sector. With the Armadillo Blue 3D printer the users can manufacture parts with validated materials such as alumina and silicon carbide. With a spacious print box measuring 370 x 260 x 250 mm (24 liters), Armadillo Blue provides ample room for intricate creations at a speed of 7.2 mm/hour. The printhead precision is 400 DPI and t he layer height ranges from 100 to 150 µm, ensuring flexibility in design.

Image 2: Parts 3D printed on the Armadillo Blue 3D printer with alumina powder. Source: Concr3de.

The printer's 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 Blue 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 3: Parts 3D printed on the Armadillo Blue 3D printer with silicon carbide powder. Source: Concr3de.

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 continuous serial production of parts. With the higher production capacity Armadillo Blue takes less than 72 hours (sintering included) to produce a finished part.

The workflow

Material compatibility - as mentioned previously, Armadillo Blue was designed for additive manufacturing with ceramic and metal materials such as alumina and silicon carbide powders (Concr3de's PC and PM range). As far as binders, Concr3de has developed the BC and BM range of binders specially for the Armadillo Blue 3D printer. 

Image 4: Part 3D printed with the Armadillo Blue 3D printer with silicon carbide. Source: Concr3de.

The two ceramic materials are the Concr3de alumina 92 % (PC1002 Alu92 powder) compatible with the BC1002 Alox binder. This alumina powder is best described as an off-shelf production solution charracterized by swift and high-capacity production, exceptional mechanical characteristics, and suitability for printing sizable components. The Concr3de silicon carbide powder (PC1001 SiC powder) was designed to be used together with the BC1001 SiC binder. The PC1001 SiC powder can manufacture large and highly complex parts in a waste-free, sustainable and safe workflow, with no wear of tooling to machine intricate designs. More about the benefits of 3D printing with silicon carbide can be read in this blog post on the Concr3de blog.

Image 5: Part 3D printed with the Armadillo Blue 3D printer with silicon carbide. Source: Concr3de.

Armadillo Blue can also be used with pre-engineered metal materials to 3D parts that will stand out with their accuracy and intricate design while preserving the material's properties and haptics, and ensuring ultimate accuracy. Some of the metal materials that can be used with the Armadillo Blue 3D printer are Concr3de stainless 316L (PM1001 SS316L powder + BM1001 Metal binder), Concr3de stainless 17-4 PH (PM1002 SS17-PH4 powder + BM1001 Metal binder), and the Concr3de copper (PM1003 Copper powder + BM1001 Metal binder). All these materials are cost-effective solution well-suited for extensive volume production and batch printing. Intricate forms can be achieved with outstanding precision and detail (50 microns).

Image 6: The NOAH software. Source: Concr3de.

NOAH Production software - Armadillo Blue comes equipped with an integrated control station featuring the customized and fully open NOAH Production software, pre-installed on optimized hardware. NOAH Production provides comprehensive control over every aspect of the 3D printing process, allowing users to manage all Armadillo add-ons with precision. Furthermore, the software comes with predefined printing profiles for the validated materials to make the user experience even more enjoyable and the production process even more efficient and reliable.

Image 7: The Concr3de Depowdering Box. 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 (identical in dimensions to the Armadillo Blue print box) allows a seamless transfer of the entire print box into a drying oven (even with the help of mechanical lifting tools, such as forklifts or hoists), eliminating the need for initial depowdering. This approach ensures the safety of delicate parts that require sintering (e.g., ceramics), minimizing the risk of breakage after the green strength has sufficiently increased. 

Extra features

In order to accomodate all kinds of 3D printing materials with specific requirements and thus allow for creation without limits, the Armadillo Blue 3D printer has been equipped with features such as an 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. 

Image 8: The infrared heater is ideal for working with high-temperature materials. Source: Concr3de.

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.

Agilizing ceramic and metal production

The Armadillo Blue 3D printer from Concr3de stands out as a comprehensive solution for achieving high-quality 3D printed parts. Specifically tailored for industrial and high-tech applications, this printer offers integral solutions with validated material and sintering guidelines, ensuring efficient production of intricate components on an unprecedented scale. With its just-in-time and cost-effective serial parts production capabilities, the Armadillo Blue leverages Concr3de's high-precision binder jetting platform, accommodating various technical materials. The printer's sizable print box dimensions further allow the simultaneous production of multiple parts in a single run.

Image 9: Part 3D printed with the Armadillo Blue 3D printer. Source: Concr3de.

Designed with industry and high-tech production in mind, the Armadillo Blue by CONCR3DE is more than just a 3D printer; it's a tool for pushing the boundaries of additive manufacturing. Armadillo Blue also serves as a gateway for researchers to explore and develop various material options. The accessible technology not only supports the creation of certified materials but also contributes to the rapid expansion of material choices, offering applications in both high-tech and sustainable domains.