Concr3de Armadillo Gray - 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 Gray

The Armadillo Gray industrial 3D printer from Concr3de's Armadillo family of printers was developed specially for additive manufacturing with stone material in the form of recycled stone-based powders. With the Armadillo Gray 3D printer, strong and durable stone parts can be 3D printed for use in restoration work, art and architecture. With a spacious print box measuring 370 x 260 x 250 mm (48 liters), Armadillo Gray provides ample room for intricate creations at a speed of 35 mm/hour. The printhead precision is 400 DPI and the layer height is 230 µm. When coupled with the large scale production Elephant Gray 3D printer, Armadillo Gray can be used as a testing and prototyping printer.

Video 1: The GeoSlate project by Concr3de and Studio Mixtura for 3DPC. Source: Concr3de.

A great example of how the Armadillo Gray 3D printer can be used is the GeoSlate project, a collaboration between Concr3de and Studio Mixtura where slate quarry sludge was reused to create a sustainable 3D printing material. This material, in turn, was used to recreate roof tiles for Slot Schaesberg in The Netherlands.

Video 2: The project Gothic Reimagined by Dustin White 3D printed in stone with the Armadillo Gray printer. Source: Concr3de.

Another interesting project is the Gothic Reimagined project by Dustin White, also in collaboration with Concr3de. In this project the aim was to demonstrate the potential of the stone 3D printing technology. The undertaking marks a pioneering translation from an AI-generated image to an actual 3D printed stone representation, representing one of the first projects like thisin the architecture field.

Image 2: Architectonic element 3D printed on the Armadillo Gray 3D printer. 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 1200 x 1600 mm, with space requirements of 2400 x 2000 x 2200 mm. Despite its robust capabilities, the Armadillo Gray 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. 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 96 liters (space requirements of 3100 x 2200 x 2500 mm, weight 550 kg).

The workflow

Material compatibility - as mentioned previously, Armadillo Gray was designed for additive manufacturing with stone and minerals, including recycled or waste materials such as marble, limestone and granite (Concr3de's PS, PF, and PR range mineral powders). As far as binders, Concr3de has developed the BS and PF range of binders specially for the Armadillo Gray 3D printer. With Armadillo Gray complex and highly customized forms in small series or as one-offs can be created in an fast, affordable and sustainable way. This feat is often a labor-intensive and costly task when traditional manufacturing methods are used.

Image 3: A marble structure 3D printed with the Armadillo Gray 3D printer. Source: Concr3de.

Another manufacturing possibility is using the Armadillo Gray 3D printer in foundry and refractory applications. 
The Concr3de series of foundry materials provides a range of material characteristics suitable for 3D printing of non-combustible molds, cores, and consumables. Alongside the reliable Phenol system binders, Concr3de presents environmentally friendly alternatives, such as their Inorganic binder option. 

Image 4: A refractory (left) and foundry (right) applications of the Armadillo Gray 3D printer. Source: Concr3de.

Notable offerings within the Concr3de foundry materials include Foundry Quartz P, suitable for both ferrous and non-ferrous casting with excellent dimensional stability; Foundry Quartz I, a sustainable, compostable option with reclaimable sand and SK33 refractoriness; Foundry Cerabeads P, featuring stable grain size for wear, crush, and thermal shock resistance; and Foundry Cerabeads, known for excellent fluidity, sustainability, compostability, and reclaimability with SK37 refractoriness. For refractory needs, Concr3de provides Refractory Cement material with high heat resistance, suitable for large-scale firebox and glazed applications, making it ideal for kilns and ovens.

Image 5: The NOAH software. Source: Concr3de.

NOAH Production software - Armadillo Gray 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 6: The Concr3de Depowdering Station. 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 Gray 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.

Upcycling stone and mineral resources

The Armadillo Gray 3D printer from Concr3de stands out as a comprehensive solution for achieving high-quality 3D printed parts from reclaimed stone and mineral materials. Specifically tailored for prototyping, material testing and small-scale production alongside the Elephant Gray 3D printer, Armadillo Gray leverages Concr3de's high-precision binder jetting platform, accommodating various stone- and mineral-based, as well as refractory and foundry materials. The printer's sizable print box dimensions further allow the simultaneous production of multiple parts in a single run.

Image 7: A structure 3D printed with the Armadillo Gray 3D printer. Source: Concr3de.

Similar to all Concr3de 3D printers, the Armadillo Gray printer aligns with the brand's fundamental philosophy and mission centered around upcycling waste materials. The Armadillo Gray enables the creation of new value by producing sustainable, functional printed end-use products from mineral materials that were previously considered worthless or costly to dispose of. With the Armadillo Gray 3D printer, along with its compatible materials and binders, stone-based materials that would otherwise go to waste can now find reuse in various sectors, including architecture, design, art, archaeology, construction, as well as foundry and refractory applications and more.