Concr3de Elephant 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 Elephant Gray printer, demonstrates remarkable scalability, producing up to 2000 liters per day.

Additive manufacturing via binder jetting with the Concr3de Elephant Gray 3D printer consists of the following steps: (1) sourcing the material, (2) 3D printing with Elephant Grat, (3) transporting the job box, (4) depowdering, (5) removing the part from the job box, (6) dipping, (7) storage and drying, and, finally, (8) sealing. Elephant Gray is an integrated production solution that enables the creation of large-scale objects in stone-like materials.

Image 1: The manufacturing workflow with Elephant Gray. Source: Concr3de.

In binder jetting, post-processing often involves crucial steps that give the parts special properties. In the case of the Elephant Gray printer, the steps involve dipping, where the green printed objects are immersed in water overnight to enhance their structural integrity. This is followed by drying to remove excess liquid and ensure dimensional stability. The drying time, suggested by the Concr3de software, will depend on the material, part size and factory climate. The last but optional post-processing step is sealing is performed to further fortify the part's strength and prevent moisture absorption, especially crucial for parts destined for outdoor use. These post-processing techniques, integral to the binder jetting workflow, enable the customization and optimization of material properties, contributing to the overall quality and performance of the 3D-printed objects.

Image 2: The post-processing workflow with Elephant Gray. Source: Concr3de.

Binder jetting's cost-effectiveness is emphasized by its use of low-cost materials, including potential utilization of waste. Operating at room temperature reduces energy consumption, and the method's material versatility 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.

Elephant Gray

The Elephant Gray industrial 3D printer was developed specially for additive manufacturing with stone material in the form of recycled stone-based powders. With the Elephant Gray 3D printer, strong and durable stone parts with dimensions of up to 2 x 1 x 1 m and excellent detail can be 3D printed for use in restoration work, art and architecture, consumer goods and molding applications. With a spacious print box measuring 1000 x 2000 x 1000 mm (2000 liters), Elephant Gray provides ample room for intricate creations at a speed of 54 mm/hour. At peak efficiency, the Elephant 3D printing procedure generates a maximum of 2 cubic meters of components each day. With an assumption of 240 production days annually, the potential output volume reaches 480 cubic meters for each printer.

Image 3: Elephant Gray can produce objects with dimensions of up to 2x1x1 m. Source: Concr3de.

The printhead precision is 400 DPI, the layer height is 300 µm, and the XYZ accuracy is 50, 50, 30 µm. This means that, unlike most large-scale solutions, Elephant Gray ensures astonishing surface quality and detail despite its large build volume. The Elephant Gray 3D printer can be used as an industrial production tool alongside the Armadillo Gray printer, a printer designed for testing, prototyping and small-scale production in industrial settings. The printer's connectivity features Ethernet, with the cable included, and the power requirements are 2 x 400 V. The printer's overall dimensions are 2800 x 6500 x 4500 mm and the structure of Elephant Gray consist of a printing bar mounted on a gantry, a recoater and an array of printheads. The jobbox is fuly removable and multiple jobboxes can be ordered. 

The workflow

Material compatibility - as mentioned previously, Elephant Gray was designed for additive manufacturing with stone and minerals, including recycled or waste materials such as marble, limestone and granite (Concr3de's PS, and PR range mineral powders). As far as binders, Concr3de has developed the PS and BS range of binders specially for the Elephant Gray 3D printer. With Elephant Gray complex and highly customized forms in large batches 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 4: Architectural elements 3D printed in limestone (left) and marble (right) on the Elephant Gray printer. Source: Concr3de.

Concr3de's stone material catalog encompasses a diverse selection of high-quality options, prominently featuring Concr3de Marble (PS1001 Marble), Concr3de Granite (PS1003 Granite), and Concr3de Limestone (PS1003 Limestone). These materials use the same binder (BS1001 Mineral Binder) and are renowned for their exceptional properties, they provide a superior surface finish, ensuring precision in intricate designs. Notably, Concr3de's material offer boast cost-effectiveness and scalability in production, making them an ideal choice for various applications. The utilization of these materials guarantees accuracy in translating complex designs into tangible forms, while their impressive mechanical properties contribute to their reliability. Furthermore, Concr3de prioritizes sustainability through a waste-free production process, aligning with environmentally conscious practices within the professional sector.

Image 5: A gargoyle 3D printed on the Elephant Gray printer. Source: Concr3de.

Zero waste and automation - due to the nature of binder jetting, printing with Elephant Gray does not require support structures. This combined with the 100 % rate of powder reusability implies a zero waste manufacturing process. Furthermore, to make the workflow as convenient and efficient as possible, Elephant Gray offers features such as automated powder feeding to swappable job boxes and industrial post-processing stations for automated cleaning, powder recycling and sealing. The only cleaning arrangements that will have to be made concern the printer ink (for printhead self-cleaning, discarded as low caloric waste), the water in the dipping station (can be disposed of in the sewer), and the dipping station filters (sediment is treated as construction waste, less than 1 ton yearly). This complete ecosystem makes for a manufacturing solution that will result in a significantly increased level of independence and flexibility in the manufacturing and post-processing, as well as faster lead times and overall agilization.

Image 6: The NOAH software. Source: Concr3de.

The software - the Elephant Gray printer features the NOAH Mammooth custom laminating software installed on an included central computer, streamlining print preparation. This software supports loading .stl and .obj files to create batches for printing, accessible remotely via USB, ethernet, or the company server. Multiple files can be positioned within each batch, with the option to optimize nesting using external software. The slicer enables quick batch preparation, providing printing time estimates. Operators load batches via USB, and the printer performs automatic self-leveling and powder-filling, and then alerts the operator upon completion. The Scalance system allows status monitoring, and regular software updates enhance functionality and integration with the manufacturing execution system, offering data for planning optimization and reducing downtime.

The complete workflow with the Elephant Gray 3D printer, as well as the printer's technical specifications, a material overview, factory and staff requirements, service and maintenance, software and safety are discussed at length in the Manual in the Downloads section.

Upcycling stone and mineral resources

The Elephant 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 large-scale production and batch production, Elephant Gray leverages Concr3de's high-precision binder jetting platform, accommodating various stone- and mineral-based materials. The printer's enormous print box allows for the 3D printing of parts with dimensions of up to 2 x 1 x 1 m.

Image 7: The Elephant Gray printer is an excellent tool for the art, archaeology and construction sectors. Source: Concr3de.

Similar to Concr3de's Armadillo 3D printers, the Elephant Gray printer aligns with the brand's fundamental philosophy and mission centered around upcycling waste materials. The Elephant 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 Elephant Gray 3D printer, along with its compatible materials and binders, stone-based materials that would otherwise go to waste can now find reuse in a zero-waste and sustainable manufacturing process. Elephant Gray is an excellent additive manufacturing solution for various sectors, including architecture, design, art, archaeology, construction, consumer goods or molding.