The SEAM Research Centre has unveiled a groundbreaking approach to facade construction, leveraging Screw Extrusion Additive Manufacturing (SEAM) technology to produce large-scale plastic components.
At the centre of this innovation is Epic3D, a newly developed portal printer capable of creating durable, custom-designed elements for construction, such as facades, fences, and gates.
The SEAM process, developed by Fraunhofer IWU in collaboration with Wirth & Co. GmbH, offers a cost-effective alternative to traditional methods by using granules instead of filaments.
This approach eliminates the need for moulds and enables faster production while meeting fire safety, UV, and weather resistance standards.
The SEAM process also meets stringent fire safety, UV, and weather resistance standards, making it a practical choice for outdoor construction.
“With 3D printing in the SEAM process, completely new design possibilities are opening up in facade construction,” said Florian Stöckel, managing director of Wirth & Co GmbH.
In particular, SEAM utilises granule-based material, which is drawn and melted through a modified extrusion screw before being layered onto the build platform.
This tool-free manufacturing eliminates the need for molds, cutting production costs and time. Colored materials further streamline the process by removing the need for additional coating steps.
Dr Martin Kausch, head of the Department of Sustainable Fiber-Plastic Composites at Fraunhofer IWU, highlighted the affordability of SEAM for customized designs.
“The personal touch in facade design is achievable in traditional manufacturing, but only with processes like SEAM is it cost-effective.”
The SEAM Research Center houses three advanced systems:
- Epic3D: Featuring a spacious 2-meter-long and 1.7-meter-wide build platform, this portal printer is ideal for producing large-format components.
- METROM P1410: Combining additive manufacturing with milling capabilities, this system allows for additional processing steps, enhancing component versatility.
- SEAMHex: Equipped with a 6-axis hexapod, this system offers unparalleled movement flexibility, enabling precise production of medium-sized components.
Fraunhofer IWU will present its latest SEAM advancements at the Formnext trade fair in Frankfurt, 19 to 22 November 2024.
Visitors can explore the technology at Hall 11.0, Stands E38 and C29, where Dr. Kausch’s team will demonstrate how SEAM is revolutionizing facade construction.
