Fortify, a Boston startup, developed Digital Composite Manufacturing (DCM) to unlock new material properties that cannot be achieved with 3D-printed photopolymers alone. Their goal was to enable quick and seamless fabrication of composites with optimized microstructures. Through their research, they invented magnetic 3D printing or Fluxprint.
The design team helped Fortify develop its first integrated hardware platform with the flexibility to offer three tiers of Fluxprint performance printing. The first model developed was the Flux One 3D Printer with a z-axis magnetic field. Other printers that share the same platform are the Flux Core baseline printer without magnetic alignment and the Flux 3D leveraging a 3-axis magnetic field with unprecedented levels of control.
The primary use case of the Flux One is for small tool-making applications for injection molding. Users can print fiber-reinforced photopolymer mold tools in a matter of days and at a fraction of the cost of traditional metal tools. For this reason, the Flux One lives in production environments alongside traditional tool-making equipment and injection molding machines. Unlike most 3D printers that are shiny and delicate, the design team was asked to incorporate similar attributes and features found on the factory floor. Key design features include heavyweight steel panels with generous angles and radius and machine status lighting illuminating the factory floor to alert for any issues. There are also windows with 180-degree views of the z-axis to easily keep an eye on production, robust mechanical touch points for those wearing gloves, and a spring-loaded hatch that folds up and away from the user.
Key Challenges to be Solved : • Build upon the prototype printer to develop a visual design language that sets the tone for the initial platform, and future Fortify hardware.
Differentiate the look and feel from competitive 3D printing machines with an industrial approach. • Establish a feasible and easy-to-use consumable interface. • Create a door/window that maintains user visibility of the z-axis and accommodates maintenance work in and around the reservoir. • Use materials and processes requiring minimal tooling for smaller production quantities. • The printer platform will be in both large-scale manufacturing facilities and smaller R&D labs. Maintaining a minimal footprint and low ceiling height clearance are essential. • User interface and machine status should be easy to access and control, even when wearing protective gloves.
Key Successes of the Flux One Design: • A design language that drew attention from the printing industry and instilled confidence in the Fortify brand from early customers.
The heavyweight, faceted look and unique door mechanism differentiates itself in the 3D printing category. • The easy-to-access, slide-out media reservoir is at a comfortable height and provides ample work surface when filling. • The angled door face allows users to clearly see the build area when closed. There is also ample room to reach into the build area. The door, when opened, does not reach outside the machine footprint nor exceed a low ceiling height requirement. • All parts are bent sheet and machined plate. The yellow e-stop surround is actually injection molded from a Fortify Flux One printed mold. • Levers and controls were designed keeping in mind readability, force, angle and reduced dexterity due to resin-covered gloves.
Category:ElectronicsYear:2023Designers:Scott Stropkay, Jason Cooper, Taehak Kwon, Mark Matthews, Mike Le, Jonathan Wenderoth, PA Consulting Team, PA Consulting, Boston, Massachusetts, USAManufacturer:Fortify, Charlestown, Massachusetts, USA
