AIM3D and Naddcon revolutionize 3D printing process chain with new collaboration

Sebastian Kallenberg, project engineer at Naddcon, while operating the CEM system

Naddcon, a research and development centre specialising in additive manufacturing, has collaborated with AIM3D to integrate a classic industrial design tool, the Siemens NX package, into the process chain. This package includes extensive CAD, CAM, and CAE solutions already used for conventional component manufacturing in the machining industry.

Naddcon integrated an ExAM 255 from AIM3D into the Siemens NX environment to make the 3D CEM system accessible as a digital 3D machining system. As the example of the NX tool shows, users now have an alternative approach to operating 3D printers and generating G-code.

Sebastian Kallenberg, a project engineer at Naddcon, provided insights into the continuous digital process chain of a 3D printing process with an ExAM 255 from AIM3D. "Our digital NX approach aims to better leverage the CEM machine technology from a design and production preparation standpoint. There is significant potential for free-form surfaces, that is, genuine 3D contours, as well as bionic design strategies," he said.

The bridge between the machine firmware of AIM3D and the CAD/CAM environment of Siemens NX integrates the 3D printer as a CAM processing machine. Using CAD, CAM, and CAE approaches, NX offers users a comprehensive tool for designing and iteratively optimising additive components.

Component made of PA6 30GF. Original design (top) and NX-optimised design (bottom).

Integrating the ExAM 255 from AIM3D into the NX environment allows for the generation of toolpaths along curved surfaces, creating true 3D paths that generate planes independently. Using this technology in process development makes it possible to eliminate the staircase effect typical of AM processes. As a result, obtaining a true 3D contour of a solid body is possible.

Sebastian Kallenberg developed a process for integrating a standard component made of PA6 GF30 into the ExAM 255 3D printer using NX. The first step in this process was to create a kinematic model of the 3D printer by incorporating the CAD model of the ExAM 255 into NX and determining the machine zero point. The kinematic model allowed for machine simulation of the toolpaths before production.

The next step involved generating toolpaths for the extruder based on the component geometry and machining operations. The third step involved simulating the machine to determine the application of material and potential collisions. A post-processor was programmed to translate the NX toolpaths into G-code, a programming language used to program numerically controlled machine tools. Post-processor programming allowed for machine-specific adjustments, leading to improved process control.

"The 'demonstrator,' which is a standardised component made of PA6 GF30, was used to test the programming on the ExAM 255," explained Sebastian Kallenberg. "After generating the toolpath, we tested the machine to find the optimal process parameters and potential errors in the post-processor. Using NX, we were able to optimise the demonstrator in various ways. The user can adjust densities, incorporate lattice structures to reduce weight, manage shrinkage, add stiffeners, relocate 'drill holes' to optimise the entire component, and print it using the 3D printer in a qualified manner."

Digital process chain with the NX software for a 3D printing process (design, pre-processing, processing and post-processing) 

Integrating the ExAM 255 from AIM3D into the NX environment represents a significant step forward in additive manufacturing. The continuous digital process chain of a 3D printing process allows for greater flexibility and optimisation in component design and production preparation. Using free-form surfaces and bionic design strategies can further enhance the capabilities of 3D printers and lead to the creation of more complex and efficient components.