The latest 3D printing efforts against Covid-19

As many of us adjust to new routines and take extra precautions to look after the heath and wellbeing of our families and colleagues, we are all too familiar with the escalating nature of the coronavirus crisis.

The additive manufacturing (AM) sector is an interesting place to be amidst this pandemic. As governments and medical professionals call out for manufacturers to step up supply of equipment and devices such as ventilators and protective gear to help treat patients, AM companies have answered the call in their droves, citing speed of production and distributed manufacturing networks as key enablers. It has been almost impossible to keep up with the number of initiatives setup to help deliver these parts so we're endeavouring to share as much as we can.

This will, of course, be a developing story so to keep you up to date with the latest news, consortiums, and calls to action, the TCT editorial team will be regularly updating this blog with news on the 3D printing industry's response to this growing crisis.

Share your stories with us here.

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July

WATCH: How Photocentric is mass 3D printing millions of face shields 

Week commencing 30th June ... 

Structo to 3D print a million NP testing swabs per week

Singapore-based 3D printing company Structo is set to begin deliveries for 1 million 3D printed nasopharyngeal (NP) testing swabs this week to help in the fight against the COVID-19.

Working in collaboration with authorities and healthcare professionals in Singapore, the dental 3D printer manufacturer is scaling up to deliver over 1 million pre-sterilised NP testing swabs each week to fulfil orders from healthcare institutions and other key parties.

Since the start of the pandemic, Structo has worked with other 3D printing partners, universities and medical institutions to help ramp up COVID-19 testing across the region. Whilst Singapore has deployed effective contact tracing mechanisms to curb the spread of the virus, continued large scale testing is seen as critical in allowing it to return to a state of normality. 

Structo's 3D printed NP testing swabs are FDA registered medical devices, manufactured in accordance with Structo's ISO 13485 QMS requirements from biocompatible material, and sterilised and packed individually to ISO 11135 standards.

Huub van Esbroeck, Founder of Structo commented: "In this climate, we recognize the importance of the availability of testing kits and the strain that the COVID-19 pandemic has placed on the economy and supply chains worldwide. We hope that our in-house manufacturing capabilities will be able to help alleviate some of those problems and help us avoid a shortage of critical testing equipment globally."

Week commencing June 1st

SLM Solutions and MAGNET partner to deliver face shields to medical workers

SLM Solutions has been harnessing its metal additive manufacturing technology to produce injection moulding tools to assist the Manufacturing & Advocacy Growth Network (MAGNET)’s production of face shield headbands.

It has allowed the group to move quicker to supply much needed PPE equipment to medical professionals across the State of Ohio during the COVID-19 crisis.

“We needed the parts as soon as possible. The speed and throughout of [SLM’s] quad laser machine has available was a critical aspect of the decision to work together,” commented Dave Pierson, Senior Design Engineer at MAGNET.

Sulzer orders 6,000 face masks from Essentium

Essentium has received an order of 6,000 of its protective face masks made with its High Speed Extrusion 3D printing equipment from engineering firm Sulzer.

The kits will be worn by employees in Sulzer locations in North and South America. Sulzer also commissioned Essentium to design a child version of the mask kit and donated a quantity to its chosen charity, Todays Harbor for Children, a La Porte-based residential community for youth.

The reusable mask frame, designed for non-medical use, is additively manufactured in Essentium’s TPU74D material, which allows for easy cleaning, and is used with a single-use filtration media. Essentium’s face masks conform to FDA EUA guidelines and the filtration media to ASTM Level 2 and BFE97.

“The global shortage of masks could have made it challenging for us to remain open,” commented Darayus Pardivala, President of Rotating Equipment Services Americas at Sulzer. “Essentium’s ability to produce a quality solution at scale and to our timeline solves the issue. That they also agreed to partner with us to produce a child version of the kit underlines the shared values of our companies.”

Blake Teipel, CEO and co-founder of Essentium added: “Where the supply chain for PPE is faltering, Essentium and 3D manufacturing can and has stepped in. To play our part in helping essential businesses stay open and keep our essential workers safe is hugely rewarding.”

Carbon tested swabs undergo Stanford University study

A Stanford University study suggests Carbon’s 3D printed Lattice Swab, designed and produced for the testing of COVID-19, has a lower false negative rate compared to traditional flocked swab, especially in patients with a low viral load.

It has been reported that in several cases at Stanford and Beth Israel Deaconess Medical Center the 3D printed Lattice Swab correctly identified known COVID-positive patients that the standard nasopharyngeal swab had missed.

Over 400 patients participated in the clinical assessment, which has yet to be peer-reviewed, though the researchers not a larger study would be required to draw definitive conclusions. More information on the study can be found here. 

Honda moves from 3D printing to injection moulding to deliver tens of thousands of face shields

Honda has donated 70,000 face shields to healthcare workers at 305 medical facilities in 45 of the United States of America using, initially 3D printing, and scaling with plastic injection moulding.

Another 60,000 face shields are to be donated in the coming days.

Honda began manufacturing face shields in March using a network of 3D printers at five manufacturing facilities, but as demand continued to increase, harnessed its in-house injection moulding capability to deliver tens of thousands of units. After studying various design in consultation with healthcare professionals, he team of Honda engineers began building a special die to enable the plastic injection moulding equipment to produce over 3,000 face shields per hour.

"It was a comprehensive effort with our Honda design and manufacturing teams working together to quickly solve this challenge," said Eric Walli, Regional Planning Leader of Honda North America. "We were looking at materials, doing scientific work to understand if what we put in a face shield would be safe for humans to wear and all of this was occurring as we sought to rapidly begin, and then ramp up production."

ELIX Polymers donating medical grade filament to manufacturers

Ford Motor Company is among the organisations additively manufacturing protective face shields with filament donated by ELIX Polymers.

The automotive company is manufacturing 300 units a day at its Valencia site, accessing ELIX Polymers’ ABS 3D-FC material through a collaboration between the National Federation of Innovative Business Groups and Cluster (FENAEIC) and the Advanced Materials Cluster of Catalonia (ClusterMAV). Research organisation AIMPLAS and two plastic processors, PESL and SIIM, are also using this material to produce protective equipment.

“Many companies with 3D printing capability are putting their equipment at the disposal of the community to produce medical parts. Demand for 3D printing filaments in Spain is being channelled through the 3Dcovid19.tech digital platform, an initiative linking hospitals’ needs and 3D printing production resources, as well as ClusterMAV and FENAEIC,” commented Luca Chiochia, Business Development Manager at ELIX Polymers. “Ford and Aimplas are both producing filaments in ELIX ABS 3D-FC and are also making masks and face protection companies in their own departments.”

Materials developed by ELIX Polymers for the healthcare sector are compliant with the ISO 10993 and USP class VI biocompatibility standards. They have been included in Drug Master Files (DMF) for use in medical and food contact applications in both Europe and the USA.

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Creatz3D 3D prints respiratory swab collection training aid

Creatz3D, a Singapore-based reseller of 3D printing equipment, has developed a training aid for respiratory swab collection in the fight against COVID-19.

The new '3D printed Medical Manikins' have been designed to address the growing need to ramp up training for swab testing to determine if a person has been infected. According to Creatz3D, training for swab testing in Singapore is typically carried out by healthcare professionals on a volunteer basis and existing medical manikins are deemed unsuitable for accurate simulation of the three essential procedures for COVID-19 testing including nasal mid-turbinate swabs, nasopharyngeal swabs and oropharyngeal swabs.

The manikin was designed using anatomical 3D models derived from sister company AuMed's CT and MRI library which were then put together in a 3D printable model using Materialise's Mimics Innovation Suite (MIS) Medical. The team were able to design and 3D print the device within four days using the Stratasys J750, allowing for multiple colours and materials to be used to differentiate parts of the anatomy and simulate soft tissue. 

By creating life-size manikins specifically for respiratory swab collection training, the model provides a tangible, life-like representation of the nasal, mouth, and throat internal structures to enable accurate demonstrations with standard medical-grade nasal swabs to ensure safer execution of swab collection and encourage interaction between trainer and trainee.

GE Additive engineer develops simplified, low-cost 3D printable face mask

A GE Additive engineer has designed an open source protective face mask to help prevent the spread of COVID-19.

Mark Fuller, a Cincinnati-based engineer, typically used to designing parts for aircraft, rockets and race cars, saw the need for a low-cost flexible alternative to the PPE shortage amid the coronavirus pandemic following a shopping trip back in March to acquire protective gear for a woodworking project. Fuller found that standard equipment like face masks, gloves and goggles were nowhere to be found in local stores, while online, prices had risen significantly. Already a keen tinkerer, Fuller decided he could could up with an alternative.

The mask consists of a thin ring of 3D printed plastic which can be fitted with any fabric to act as a filter and rubber bands to attach to the wearer's face. Fuller posted the design in a Facebook group focused on open source COVID-19 solutions and used the feedback to create a second generation with a thinner nose area and more flexible material. 

Speaking about his design on the GE Reports blog, Fuller said: "I designed it in a way that you can take the same core geometry and go and injection mould them or go and laser cut them … What machines are not being utilised for production today can be used to help save lives."

Fuller produced a number of masks on his home 3D printer, each taking around 15 minutes to print at a cost of around 9 cents worth of plastic, and began delivering them to local hospitals under the GE Additive COVID-19 Task Force. While the mask isn't an alternative to standard N95, the design has been deemed suitable for community use against coronavirus by the National Institutes of Health.

GE has since offered the design to AM leaders at the U.S. Navy's Air Systems Command as a result of ongoing work around a 3D printed face shield designed to work with a hard hat to keep sailors healthy in the confined spaces of warships. Now the U.S. Navy is printing Fuller's masks by the tens of thousands while an additional 800 masks are also being produced daily by two non-commissioned officer at a Marine Corps air station in Japan, amongst many others around the globe. 

Liz McMichael, additive manufacturing integrated program team lead for the U.S. Navy, commented: "The GE face mask design gives us a way to immediately provide protective gear to our sailors and Marines anywhere there is 3D printer available - including aboard our ships and submarines, as well as with our expeditionary forces. It was fantastic to have a design that afforded us the opportunity to rapidly respond to this urgent fleet need."

21/05

Origin 3D printed Nasopharyngeal swabs now available for order

Origin is now shipping its FDA-registered (Class I, 510k) nasopharyngeal swabs, with bulk orders now able to be placed via the company’s website.

The testing swabs are additively manufactured with Origin’s Programmable Photopolymerization (P3) technology and have proven to display equal performance to standard testing swabs.

19/05

DSM launches open collaborative platform 

DSM has announced the launch of a digital, open and collaborative marketplace designed to provide solutions for healthcare professionals caring and treating COVID-19 patients.

UNITE4COVID will serve as a forum and collaborative hub for inventors, manufacturers and certification labs, bringing together users of additive and subtractive manufacturing technology, to relieve the urgent need for PPE and other safety equipment.

Healthcare workers, and employees from other institutions can access UNITE4COVID to see and request parts, while manufacturers can utilise the platform to share ideas and capacity.

We strongly believe that value chain collaboration is a must. The 3D printing industry was able to respond very fast when the COVID-19 pandemic disrupted the traditional supply chains as its digital, distributed way of manufacturing allows for creating solutions where the demand is highest. In the meanwhile, also out-of-the-box initiatives in the traditional manufacturing industry are starting to deliver solutions. By bringing together organisations with different manufacturing competencies and matching them with the needs of the organisations in vital sectors, we can offer effective solutions more quickly. It’s by collaborating that we’ll make the biggest impact in beating COVID-19 and saving lives.”

The UNITE4COVID platform has been highlighted on the World Economic Forum’s COVID Action Platform as a key effort from the manufacturing community in the fight against the COVID-19 pandemic.

14/05

Fortify 3D prints complex injection moulding tooling for face mask adapter production

Fortify has designed and 3D printed a complex injection mould tool to help produce an adapter component to convert a snorkel mask into a face mask.

The company designed and printed the mould on its Flux One system within three days, a reduction in time of more than 75% compared to the 14-day lead time when using aluminium tooling. Cost also came down from around $2,000 to $300.

Fortify used Loctite’s Digital Tooling resin to produce 25 of the parts – the amount needed for design validation of this project – and was able to integrate multiple inserts into the design of the tool to bypass potential bottlenecks and form the inner geometry of the adapter. The company then manufacturer 25 adapters on an in-house Nissei injection moulding press and is now set to use the machine, which is typically utilised for R&D, to contribute to quick-turn COVID-19 response projects.

13/05

Caracol-AM uses robotic 3D printing solution to print 1,000 PPE parts per day

Italian additive manufacturing service provider Caracol-AM is using its industrial 3D printing and robotics capabilities to produce face shield components and masks to support the urgent demand for protective equipment amid the coronavirus pandemic.

The company is deploying automated AM solutions comprising of a KUKA robotic arm with proprietary material extruder to manufacture head mounts for face shields, while its in-house FDM 3D printers are being used to produce reusable protective masks. The company is said to be producing 1,000 components each day which are being donated to local hospitals and institutions such as the Italian Red Cross.

In a post from KUKA, Francesco De Stefano CEO of Caracol-AM said the robots are in operation around the clock to keep up with the demand.

"Thanks to our experience in this field, we were able to react quickly and convert our production," says De Stefano. "Our robotic systems and industrial printers are running at full speed to produce protective equipment. The headgear printed by the KUKA robots is complemented by a plexiglas, which Caracol-AM purchases from a partner company, to protect against droplet infection."

America Makes announces top designs of Fit to Face—Mask Design Challenge

America Makes has revealed the top teams from its rapid response Fit to Face - Mask Design Challenge.

Organised in collaboration with the Department of Veterans Affairs (VA), the challenge was setup to provide a solution for the ongoing shortage of suitable PPE for frontline workers amid the COVID-19 pandemic. The design needed to deliver continuous fit-to-face contact for a wide range of users based on five headform datasets shared by the National Institute for Occupational Safety and Health (NIOSH). The designs were also judged on manufacturability, assembly and instruction. Top submissions were fast-tracked through the VA, FDA, and NIH testing and evaluation process.

"Through our ongoing collaborations with VA, FDA, and NIH, America Makes has facilitated entry paths for the AM community to engage and address PPE supply chain gaps during this crisis," said America Makes Executive Director John Wilczynski. "With the Fit to Face Challenge, participants leveraged leading Design for Additive Manufacturing (DfAM) principles under a compressed timeframe to advance designs that demonstrated considerable improvement of mask fit characteristics. It truly showed the remarkable innovative nature of the additive community."

The top designs were from Alliance PCB Solutions, LLC for their "Vader Small mask" and Carnegie Mellon University for their "Moldable Mask Small and Moldable Mask Large". Honorable mentions went to the National Institute of Standards and Technology (NIST) for the "Every Mask" and Re:3D Inc. for the "Flex Fit Small and Flex Fit Large".

The designs will be showcased on both the NIH 3D Print Exchange and America Makes websites, where an online repository has been setup to connect healthcare providers with the design and 3D printing capabilities of U.S. manufacturers.

12/05

Dunlee ramps up production on 3D printed anti-scatter grids for CT systems

In response to COVID-19 pandemic, imaging solutions specialist Dunlee is boosting production of 3D printed anti-scatter grids used in CT systems. 

CT is used to assess respiratory conditions and monitor severe COVID-19 cases, making CT exams an important component of COVID-19 diagnosis and assessment. Dunlee, a brand of the Philips Company Group, is increasing its output of these pure tungsten grids, manufactured in Best, the Netherlands, which absorb unwanted scatter radiation to significantly improve the quality of CT images. For example, Dunlee says with Cone Beam CT, its 2D anti-scatter grids provide an improvement in signal-to-noise ratio up to a factor of 1.7 compared to previous solutions.

"As a result of the COVID-19 pandemic, we are in operation around the clock, so we are working closely with our long-term partner EOS to obtain new printers while also fine-tuning our existing printers to increase output," says Jan Laheij, Global Head of Commerce - Imaging Components. "We are fortunate that we can count on quick response from the EOS maintenance and service team to keep our machines running 24/7."

The company also is hiring more operators and engineers and has re-prioritised projects so it can provide anti-scatter grids as quickly as possible to CT system manufacturers. 

11/05

3DPRINTUK develops SLS face shield design; Arts University Bournemouth prints 5,000

London-based 3D printing bureau 3DPRINTUK has developed a face shield design optimised for manufacturing with selective laser sintering.

The company, which houses a fleet of SLS systems from EOS, has created a design which can be stacked in batches of 260 components into a single 27-hour build on an EOS FORMIGA P110 printer. 

Nick Allen, MD at 3DPRINTUK said: "That is 6 minutes per shield, which is a game changer. The design that we created clips together in 10 seconds, uses silicone straps for adjustment, can take an acetate sheet with 3 holes, is lightweight at only 42 g, and is sterilisable with IPA, autoclave, or ethylene oxide (Et0). All in all, we believe that this is the most efficient visor design to produce via 3D printing available today."

Printed in Nylon 12, the design features a closed peak for extra protection and can be flat packed into an A4 envelope for easy postage and storage.

To ramp up production, 3DPRINTUK has partnered with the Arts University Bournemouth (AUB) to manufacture the shields and has so far produced an initial 5,000 units, which are to be distributed free to keyworkers. The collaboration builds on wider efforts from the university which has been offering its facilities for the production of visors, facemasks, scrubs and gowns since its temporary closure in March.

AUB Vice Chancellor Professor Paul Gough said: "As a specialist university, we firmly believe in the ways in which research and creativity can greatly improve productivity. In times like these, we're challenged to rapidly innovate, and at such a crucial time, it's hugely heartening to see those from across the creative industries maximising PPE production through design and collaboration."

While much of 3DPRINTUK's current 3D printing capacity is being leveraged for a number of the UK's ventilator projects, the company says it is inviting anyone with SLS capabilities to join in with its PPE provision efforts. 

Allen added: "We're sad that we will not be able to manufacture many of them in house, but to see the project come to fruition and with such gracious and dedicated work from so many people is truly humbling."

America Makes to discuss COVID-19 response in first Virtual "Game Day" Event 

America Makes will host its first Virtual "Game Day" Series event today, which will focus on the organisation's response to COVID-19 in an interactive online panel session.

The panel will be moderated by Terry Wohlers of Wohlers Associates and include representatives from America Makes, US Food & Drug Administration (FDA), National Institutes of Health (NIH), and Veterans Affairs Health Administration (VA).

Speakers include: 

• John Wilczynski, Executive Director, America Makes
• Matthew Di Prima, Ph.D., Materials Scientist, FDA
• Meghan McCarthy, Ph.D., Program Lead, 3D Printing Biovisualization NIH/NIAID/OD/OSMO/OCICB
• Beth Ripley, MD., Ph.D., Chair, VHA 3D Printing Advisory Committee Veterans Affairs Health Administration, Innovation Ecosystem

The session will kick off with a virtual networking session hosted by Link3D followed by a welcome address, panel session and Q&A. Register here.

The event is the first in a new series of virtual panels and networking activities which aim to cover the most important topics facing the AM community today.

"During this time, it is important to find new ways to engage our members and the AM community with opportunities to connect and deliver high value information," said America Makes Executive Director John Wilczynski. "We are excited to partner with an industry expert like Terry Wohlers to roll out this new virtual event series as a way to convene the community and start the discussion on how we move forward."

To help combat COVID-19, America Makes has already set up an online repository to connect healthcare providers with the design and 3D printing capabilities of U.S. manufacturers, and launched two rapid response additive manufacturing challenges to address the shortage of equipment for frontline workers.

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Finalists of CoVent-19 Challenge announced

A hackathon designed to deliver a rapidly deployable, minimum viable ventilator in response to the COVID-19 crisis has garnered more than 200 submissions from teams around the world, according to Stratasys.

The 3D printing leader hosted the CoVent-19 Challenge on its GrabCAD platform and has now announced the final seven teams which have been selected to participate in building prototypes using the companies 3D printers as needed.

"The CoVent-19 Challenge has been an amazing demonstration of what's possible when a global community of innovators comes together for the common good," said Stratasys Chief Innovation Officer Scott Crump, one of the challenge judges. "In one month, we have gone from a problem statement to remarkably creative solutions from students and professionals, engineers and designers, from everywhere. It brightens my spirit during what is otherwise a pretty dark time for our world."  

The finalists are SmithVent, CoreVent, InVent Pneumatic Ventilator, RespiraWorks, OP Vent, Lung Evolve and Baxter Ventilator. The prototypes will be evaluated by a panel of judges led by a dozen anaesthesiology resident physicians from Massachusetts General Hospital. The aim is to announce a winner next month and then work on bringing the product the market with FDA approval.

"Healthcare systems around the world continue to face a period of great uncertainty caused by the COVID-19 pandemic," said Dr. Richard Boyer, founder and director of the CoVent-19 Challenge. "Will they be able to provide invasive mechanical ventilation to all who need it? As anesthesiologists, we are experts at using ventilators to care for critical ill patients and believe there is an opportunity for innovative new designs particularly for areas where standard mechanical ventilators may be hard to obtain."

First order of SPEE3D's antimicrobial ACTIVAT3D copper placed

SPEE3D has announced the Northern Territory Department of Trade, Business and Innovation has become the first organisation to use the company’s antimicrobial ACTIVAT3D copper throughout their building to help combat the spread of COVID-19.

Tests conducted last month found ACTIVAT3D copper kills 96% of SARS-CoV-2 in two hours and 99.2% of the virus is killed in five hours.

The Northern Territory Department of Trade, Business and Innovation thus placed an order with SPEE3D to replace existing door handles throughout its building.

Department of Trade, Business and Innovation CEO, Shaun Drabsch commented: “The Department of Trade, Business and Innovation is thrilled to be the first to have this innovative technology installed in our workplace, ensuring an even safer place for our staff and community to do business here. We thank our landlord for agreeing to the installation of copper handles. It is great to see a local Territory company taking advantage of this very challenging time and drive a new innovative product that can further protect Territorians from COVID-19.”

RIZE face shields protecting hundreds of healthcare workers

RIZE has revealed it has delivered hundreds of face shields produced with the help of its 3D printing technology to healthcare professionals.

The company harnessed its RIZIUM One 3D printing material, which boasts a high level of biocompatibility, resilience and can be sanitised by washing with soap and water or other common sanitising agents, to produce hundreds of face shield components. RIZE’s face shields have been designed to be lightweight and durable and have achieved US Pharmacopeia Class VI certification – the highest industry level for biocompatibility. The face shields are also being personalised to each healthcare professional to help patients identify them around the hospital.

“RIZE shields are easy to wear, light on the head, have a great fit, and thin enough for us to look through without compromising our safety,” said Dr. Rafat Padaria, MD, FACC, cardiologist at Cardiovascular Medicine, PC, in Davenport IA and Moline IL.“Treatment is not just about therapeutics. It’s also about how you make patients feel. Patients feel more comfortable when they can identify you. With the RIZE face shield our practice logo and my name on the top of the shield, are the first things patients see. They instantly identify me and helps to create a more personal connection and reassure them. It helps to make the patient more assured.”

RIZE’s face shields are also being made available to supermarkets, coffee shops and other essential work areas, with the 3D printing company hoping to scale to meet increased demand.

06/05

SHIELD initiative supplies vital PPE through collaboration and 3D printing

An emergency working group has been setup in the UK to respond to the growing demand for PPE amid the coronavirus pandemic. 

SHIELD, which stands for Sustainable Hub for Innovation, Execution, Launch and Distribution, is bringing together experts from across healthcare, 3D printing, engineering and construction to fast track items such as visors, gowns, ventilator consumables and other medical devices to frontline staff using additive manufacturing, injection moulding and textiles. 

The collaboration has set up a network of 3D printing hubs starting with Makerversity in London, which aims to use its resources to 3D print components for 1,700 visors per day with funding from non-profit organisation HEROES. So far over 30,000 visor headbands are said to have been produced with 13,000 procured and an additional 10,000 on order. SHIELD is also said to be close to achieving BSI approval for its face shield design.

Nate Petre is leading the effort at Makerversity and said: "Practical people around the world, enabled by digital tools, platforms to collaborate and low-cost desktop prototyping and manufacturing have volunteered to help fight the spread of COVID-19. I felt like Makerversity, a space filled with tools and the members' enormous creativity could help the government create useful solutions to the growing crisis."

Other SHIELD members include The National 3D Printing Society, The National Equipment Appeal Database (NEAD), Med Supply Drive UK, Helpful Engineering, ContractorsAppeal.com, Do Some Good, The Industry Prints, and Women in 3D Printing.

Women In 3D Printing's Kadine James told TCT: "We've really seen the adoption of additive manufacturing in ways that have been incredibly powerful and instrumental in terms of speeding up process and allowing us to develop and respond in a way that has been incredibly useful and powerful in getting the equipment out to frontline staff."

Speaking about the importance of collaboration in building new supply streams in response to the crisis, James added: "During this global health crisis we all need to be working together to support our industry and we need to bring together a collective intelligence in order to have an impact."

HP reveals UK-wide application of its Jet Fusion technology

More than 50,000 face shields, mask adjustors and hands-free door openers have been manufactured with the help of HP’s Jet Fusion 3D printing technology for use by UK healthcare institutions.

HP’s users throughout the UK, including regional service providers, universities and large scale manufacturers are said to have quickly deployed their additive manufacturing capacity and are ramping up to ensure healthcare providers have access to more equipment.

Among the companies harnessing HP’s 3D printing technology are Dartford-based service bureau Printing Portal, who is delivering face shield to local NHS facilities; Design Reality, a design firm in North Wales, who is supplying arm-operated door handles to local hospitals; FDM Solutions, a Burnley-based bureau making face mask adjustors for local hospitals; Matsuura Machinery, who is working with Nottingham University to create CE-certified and NHS England-approved face shields; Cardiff University, who is printing parts for face visors; and Pro2Pro, a Telford-based service provider producing hundreds of face shields for NHS hospitals.

HP’s UK & Ireland MD, George Brasher, commented: “HP and our digital manufacturing partners are working non-stop to provide as much support as possible to those leading the UK’s response to this unprecedented virus. We are collaborating across industries to identify required parts, hone designs, and create them though the power of 3D printing technology. Our sincere thanks go to our employees, partners and customers for their tireless efforts in supporting the medical professionals on the front line in their hour of need.”

To ensure support is available across the world, HP is collecting and publishing approved product/part design files on its website, for other printing companies and manufacturers to download and use in their own efforts.

05/05

Solid Solutions & Solid Print3D call on customers to 3D print face shields

Solid Solutions and Solid Print3D have brought together over 300 of their customers to 3D print face shields to support front line workers in the UK and Ireland. 

To date, in excess of 10,500 face shields have been printed and distributed to hospitals, nursing homes and healthcare workers after the companies put a call out to their customers to join them in helping to produce much needed PPE. 

The SolidWorks reseller and 3D printing specialist were initially manufacturing around 175 face shields per week from their Leamington Spa office but now, with the help of their user community, are able to ramp up production into the thousands.

Neil Sewell, Managing Director at Solid Print3D commented, "The response has been incredible. We have had over 300 companies get in touch to volunteer their time and filament (for free), meaning we are likely to receive over 1,000 face shields per day that we can distribute to the NHS as soon as possible."

The Solid Solutions office in Dublin, Ireland is also said to be running 15 printers for 24 hours a day to produce over 1,000 face shields per week.

Canadian companies deploy 3D printing with support from national supercluster

Burloak Technologies and Mosaic are both harnessing 3D printing technology to develop face shields with the support of Canada’s advanced manufacturing supercluster Next Generation Manufacturing Canada (NGen).

NGen has invested more than $21 million to support a host of manufacturers produce critically needed technologies, equipment and medical devices to fight COVID-19.

Among those manufacturers are Toronto-based Mosaic, a digital manufacturing company using 3D printing technology and multi-material printing processes to produce an array of products, including 45,000 face shield over a three-month period, and Burloak Technologies, a supplier of 3D printed metal parts to the aerospace sector working to develop a full-face shield, which it will produce at volumes of 5,000 per week.

Collaborators at Winthrop University deliver 3D printed face shields

Volunteers at Winthrop University in Rock Hill, South Carolina are 3D printing face shields and face shield mounts for delivery to local healthcare facilities.

Assistant Professor of Biology Courtney Guenther and Fine Arts Instructor Andrew Davis '14 partnered on the project at the university's CreatorSpace where they're now producing these much needed PPE components on a Flashforge Creator Pro extrusion-based 3D printer in PETG.

The CAD designs were shared by iWorx, a company which produces some of the physiology equipment used in Guenther's anatomy and physiology labs. Each shield takes around five hours to print while the protective shields are cut from transparent plastic using a laser cutter in seconds. 

Davis elaborated, "The shields are then attached to the 3D printed mounts via holes cut in the shields. Elastic strips are cut to the proper length and attached to hooks modelled into the mount, and a foam strip is glued to the mount where it rests on the forehead for comfort." 

So far, 12 face shields have been manufactured and delivered to local healthcare providers and the volunteers plan to deliver more soon.  

04/05

Ai Build opens sources face shield design

London-based technology company Ai Build has opened sourced a face shield design that can be produced with desktop 3D printing technology.

The company has deployed its AiSync software to generate machine instructions using freeform multi-axis paths, which produces a curved design of a single strand with variable thickness following the shape of the human head. Per Ai Build, the resulting geometry is faster to produce, more comfortable to wear and stronger.

Daghan Cam, CEO of Ai Build said: “A positive side effect of emergencies is streamlined

innovation. We are extremely excited by the tremendous wave of manufacturers from all around the world turning into additive manufacturing as a response to the Covid-19 emergency. For the first time in history, thousands of 3D printers all around the world are producing millions of products that are in shortage simultaneously. As a technology company, we are doing our part by pushing the boundaries of what is possible with this magical process called 3D printing. Beyond delivering support for some of the short term necessities of our economy during the outbreak, Ai Build continues to innovate aggressively to enable more resilient and sustainable supply chains in the post-pandemic world.”

Formlabs receives emergency use authorisation for 3D printed ventilator adapters

Formlabs has received emergency use authorisation (EUA) from the FDA to additively manufacture bi-level positive airway pressure (BiPAP) adapters designed by New York healthcare provider Northwell Health.

The printed adaptors are small, plastic T-shape parts which convert equipment typically used for patients suffering from sleep apnoea into invasive mechanical ventilators. Formlabs is manufacturing the components at its headquarters in Somerville, MA, where it is allocating 150 printers to produce 3,000 parts a day, and is distributing them throughout the US.

“Prior to the COVID-19 pandemic, the FDA had only authorised a handful of EUAs over a 30=year period. Formlabs’ EUA for BiPAP adapters signifies the need for these components and 3D printing’s unique ability to fill that need,” commented Formlabs CEO Max Lobovsky. “3D printing enables rapid iteration and prototyping of new, innovative medical equipment, while expediting the production process, shortening supply chains, and allowing for localised manufacturing. Hospitals around the country can also use Formlabs’ printers to create these adapters locally under their own practice of medicine, meaning printing the adapters at scale in the hardest-hit areas is as easy as uploading a design and pressing print.”

Cardiff University repurposes 3D printers with DSV to produce PPE for NHS

A suite of 3D printers, including HP's Multi Jet Fusion systems, intended for Cardiff University's new PARC Institute RemakerSpace have been repurposed and relocated for the manufacture of PPE for NHS Wales.

Due to the temporary closure of the university campus amid the COVID-19 outbreak, the team worked with global logistics company DSV to utilise the machines at DSV's ISO9001 healthcare facility in Milton Keynes where it has begun 3D printing visors for use by frontline staff.

Project lead Hrishikesh Pawar, a DSV employee, member of PARC, and additive manufacturing (AM) engineer, said the PARC team has been working to develop a visor that meets NHS guidelines and can be rapidly manufactured in the UK. The first batch of visors are being delivered this week.  

Robyn Davies, Head of Innovation at Cardiff and Vale University Health Board said: "This is a great example of innovation through collaboration. It shows perfectly how health boards, universities and industry partners can work together to deliver innovative solutions in Wales."

Mike Wilson, Executive Vice President for Global Logistics Manufacturing Services at DSV and co-founder of PARC added: "For us, this is just the first step. Now we have the RemakerSpace centre set up, we are looking at other products that we can manufacture to help the NHS in the fight against COVID-19. Not only that, in line with the objectives set out with the creation of the RemakerSpace centre, we want to continue to support the Welsh Government and NHS, with a focus on developing sustainable, multi-use products that help Wales lead the way in the transition to the new circular economies of the future"

The university aims to open the RemakerSpace by the end of this year. 

Scandy and Scale produce PPE prototypes with 3D printing

3D scanning software firm Scandy and sister company Scale have been supporting New Orleans hospitals by 3D printing PPE components.

Leveraging Scale’s fleet of Markforged, Prusa and Formlabs machines, the partners produced prototypes of reusable, sanitizable headbands and face shields, had them evaluated in a clinical setting, and then moved production to a facility in San Antonio to manufacture HDPE headbands, while the cutting of PETG face shield remained local. While Scale’s 3D printing equipment was not able to provide the speed and scale that was required as demand increased fourfold before the first order was even completed, Scandy and Scale did say the technology was ‘essential’ to the prototyping process.

30/04

JMDA switches in-house 3D printing capabilities to produce PPE

UK product design firm JMDA Design is using its in-house 3D printing capabilities to produce PPE supplies for the NHS.

The Worcestershire-based company has put its Ultimaker desktop 3D printer to work, usually reserved for prototyping designs, to produce face shield headbands. Building on an initiative setup by 3D printing specialist SolidPrint3D to help print components for PPE, JMDA Design plans to produce as many headbands as possible over the coming weeks. Once the headbands have been produced, they will be sent off for sterilisation and assembly before being despatched to front line staff. 

Chris Carter, Studio Manager at JMDA Design said, "We've been so moved by the courage of our amazing NHS and keyworkers who are putting their lives on the line everyday to keep us all safe and care for those affected by coronavirus. The least we could do is to help produce headbands on our 3D printer and join many other businesses who are fighting this war together."

MatterHackers and Phillips 66 deliver PPE to LA hospitals and first responders

MatterHackers has teamed with Phillips 66 Los Angeles Refinery to deliver thousands of volunteer-produced 3D printed face shields, meals, and other supplies to Los Angeles Southbay area hospitals and first responders.

As part of a 3 million USD commitment to support COVID-19 relief efforts, including local grants for organisations delivering PPE to first responders in their local plant areas, Phillips 66 awarded MatterHackers with a 25,000 USD grant (through non-profit partner ATHENA Response) to cover costs for PPE to be delivered to the South Bay area of Los Angeles. The grant supports ongoing efforts from the 3D printing specialist which has already delivered over 40,000 3D printed PPE items to hospitals across the US through its volunteer-led Maker Response Hub.

Mara Hitner, Director of Business Development, MatterHackers, said: "Over 4,700 volunteers have been 3D printing PPE across the country for Maker Response Hub hospitals in need for weeks, donating their own time and materials. MatterHackers is grateful for Phillips 66 Los Angeles Refinery's financial support of our South Bay makers so that they can continue to print much needed PPE for local facilities. This crisis is bigger than any one company or organization - we only win when we stand together as a community." - 

Imperial College London develops diagnostic platform for molecular testing with Figure 4

3D Systems is working with Imperial College London to develop a handheld diagnostic platform for molecular testing of COVID-19.

A team led by Dr Pantelis Georgiou developed the Lacewing platform using 3D Systems Figure 4 alongside other technologies. This handheld lab-on-a-chip device is said to enable rapid identification of the virus that causes COVID-19 (SARS-CoV-2) from nasopharyngeal samples in under 30 minutes which will allow front-line staff to quickly assess patients. Results are also synced to the cloud for epidemiological surveillance and mapping of the outbreak.

A first batch of more than 100 units will be produced for validation by clinicians in June at Hammersmith Hospital in London. Production will then be ramped up in the next six months to deliver over 1,000 tests per month to test front-line healthcare staff and patients as a second stage of validation.

Fathom targets a million testing swabs a week

FATHOM is using HP Jet Fusion technology to produce nasopharyngeal test swabs with the ability to manufacture around 100,000 a week. 

Abiogenix, a customer of FATHOM, responded to the company’s call to action in late March and quickly designed the testing swab, which was selected as the most preferred 3D printed swab in an independent clinical validation study at Harvard BIDMC.

The design went through more than 25 iterations over the course of 35 days, with material sensitivity, breakpoint reliability, tip comfort and collection sufficiency all being optimised. Lawrence Livermore National Laboratory, Beth Israel Deaconess Medical Center and the University of Washington Virology Division have all supported FATHOM and Abiogenix in developing the testing swabs.

FATHOM is working to ramp up to a million swabs per week.  

29/04

Zortrax donates 3D printer to hospital-grade lung ventilator project

Zortrax has donated a M300 Dual system to a team of Italian engineers working to build a fully functional, hospital grade lung ventilator using 3D printing.

The Open Breath project has commenced in order to avoid the increased cost and waiting times when ordering standard lung ventilators. The engineers had originally planned to use sheet metal and machined components, but with lengthier lead times and a shorter supply of raw materials and components, the team decided to also incorporate additive manufacturing. Zortrax’s donation of an M300 Dual machine is working alongside a Zortrax M200 printer the engineers already possessed.

“When we heard from the Open Breath people, we immediately knew that we could back them up with the right 3D printer,” commented Mariusz Babula, Vice President of Zortrax. “The 3D printing technology works great when rapid development and fabrication of non-standard solutions is necessary. Various components, that previously had to be made on order at specialised production facilities, now can be 3D printed at home. We are delighted that our products are employed in such important and innovative project aimed at helping people suffering from COVID-19 across the world.”

Zortrax 3D printing equipment is to be used to produce many end-use components, while also being deployed to prototype many of the sheet metal elements. The Open Breath team has ensured to implement all key functionalities in their ventilator, including within their design advanced capabilities like pressure and ventilation rate control. The Open Breath Ventilator can also be used in the SIMV (Synchronized Intermittent Mandatory Ventilation) mode, otherwise known as breath triggering, which is to stimulate the patient’s natural, spontaneous breathing when the artificial ventilation period is close to an end. All ventilation parameters can be monitored remotely to reduce the amount of time the doctors need to spend on visiting each patient.

Nottingham engineers 3D print certified face shields for NHS

Engineers at the University of Nottingham's Faculty of Engineering have designed and 3D printed a CE approved PPE face shield for healthcare workers to use in the fight against COVID-19.

Using equipment at the University's Centre for Additive Manufacturing and working with the help of external collaborators, the team will deliver 5,000 of the face shields with replacement visors to Nottingham's NHS and community healthcare workers.

The shields comprise of a 3D printed headband, a laser cut PET visor (with anti-fog coating) and adjustable strap. The team used in-house laser sintering equipment from EOS and HP's Multi Jet Fusion technology with the support of Matsuura UK. The visor element has been made with the help of local firm Prime Group, and Nottingham Trent University is now ramping up for production of the laser-cut strap.

Building on an open-source headband design from HP, the team made modifications to ensure the face shield could pass a regulatory test by BSI, the UK's national standards body. This involved making the wrap-around visor element wider, and alterations to improve comfort. The face shields successfully passed BSI tests and are CE approved for use as part of PPE for healthcare workers.

Professor Richard Hague, Director of the Centre for Additive Manufacturing, said: "Our primary goal was to ensure that we delivered a PPE solution that was safe and certified so that healthcare workers can have confidence in the equipment they're using. Using the flexibility of additive manufacturing and laser cutting technology, we've been able to arrive at a design, get it tested and approved, and then manufactured and delivered in a very quick timeframe.

"We have also had incredible support from our collaborators in getting these face shields to the NHS - the teamwork and willingness of people to help has been truly heart-warming and we are all extremely proud to be able to contribute to the nation's fight against coronavirus."

Dr James Hopkinson, Local GP and Joint Clinical Chair of NHS Nottingham and Nottinghamshire CCG, said: "We are extremely grateful to the University of Nottingham for developing and supplying the visors which will make a real difference to thousands of healthcare staff working on the frontline of the coronavirus outbreak.

"Packs of the face shields have already been delivered to local GP practices, and we have plans in place to share them with a range of other keyworkers such as people who care for others at home."

Rajant leverages in-house 3D printers to produce protective face masks

During the COVID-19 pandemic, Rajant Corporation, a provider of private wireless networks and equipment based in Malvern, Pennsylvania, has dedicated its resources to produce vital protective face masks to aid healthcare workers’ efforts.

The Rajant team followed the online protocols for “3D Printing Of Personal Protective Equipment And Repurposing Of Common Household Air Filters” and used Rajant's two ‘Ender Pro 3’ 3D printers to produce masks in PLA. These two printers, commonly used by Rajant to create fixtures for the ES1 and DX2 network nodes before COVID-19, quickly doubled to four, and orders for raw materials were put into process.

Rajant-produced masks cannot claim to be a replacement for N95 masks because filtration abilities have not been legally verified. However, they offer the same level of protection as normal surgical masks, which fills a significant need for the general population.

Volunteers from Rajant’s extended family, like Laurie Barry and her 83-year-old father Gary, carefully sanded and cleaned every single unit before boxing. Rajant is producing 24 masks a day and will begin shipping completed masks in bulk to those who have expressed interest.

“It is hard to boil down what is most meaningful about working on this project as it is but a small effort in a sea of very large, complex problems,” said  Giana Schena, one of the Rajant volunteer team. “I feel hopeful that our efforts can bring some light to a dark time, and I feel determined that we will see the results of this project improve people’s lives. I hope we can continue to get the word out about the ease of 3D printing PPE, and in doing so, convince more people to donate equipment to the people who most need protection in this trying time.”

Rajant has also donated its wireless network to Glen Mills School, a federal emergency medical centre in Philadelphia, to aid those working and recuperating at the site during the crisis. 

27/04

ExOne 3D prints reusable metal filters for Pitt designed respirator cartridges

ExOne is collaborating with the University of Pittsburgh to 3D print reusable metal filters which fit into specially designed plastic respirator cartridges to enable sustainable long-term use of much needed devices such as respirators and ventilators. 

The filter was designed for compatibility with a respirator cartridge created by the Mechanical Engineering & Materials Science department at Pitt's Swanson School of Engineering. ExOne additively manufactured the filter using its metal binder jet technology in 316L stainless steel and copper, due to its antibacterial properties, to examine different porosities, airflows and filtration capabilities. Initial tests are being undertaken using CT scanners to analyse the microstructure and porosity of the filters with the overall goal of optimising to an N95 respirator standard. ANSYS is also providing additional computer simulation support to analyse and optimise the performance of the filters.

"Our team has been working urgently to expedite this promising and reusable solution for medical personnel on the frontlines of fighting the COVID-19 pandemic," said John Hartner, ExOne CEO. "Our customers routinely print porous metal filters for a variety of purposes, and we are confident that we'll have a solution soon that can enable medical personnel to sterilise metal filters for repeated reuse, eliminating waste. Once approved, we can print these filters in a variety of sizes for respirators, ventilators, anaesthesia masks or other equipment."

Speaking about the benefit of using binder jet to create specific porosity levels, Markus Chmielus, Associate Professor of Mechanical Engineering and Materials Science at the Swanson School, added: "The advantage of binder jet 3D printing over other additive manufacturing methods for this filter application is the ability to utilise the porosity of the printed part and then fine tune it during the high temperature densification or sintering process to achieve optimum filtering and airflow performance."

Boom Supersonic mobilises 3D printing capacity for face shield production

Boom Supersonic is running 3D printers around the clock to produce headband components for physician face shields in support of the Colorado-based MakeForCovid initiative.

The aerospace company has so far contributed more than 700 units to the efforts, at a rate of 40 units per day, leveraging its Stratasys F370, F450 and F900 platforms. In line with Boom Supersonic’s mobilisation of its fleet of 3D printers, Stratasys is denoting filament.

“There’s a critical equipment shortage for Colorado’s healthcare workers,” commented Nick Sheryka, Boom’s Principal Flight Test Engineer, who is leading the companies COVID-19 response. “MakeForCovid has enabled us to get necessary PPE into the hands of those who need it most. We’ve printed and shipped more than 700 pieces of equipment. We are getting better at printing these parts and thankful for the opportunity to contribute to frontline healthcare workers in a meaningful way.” 

Mercedes Benz 3D printing Prusa face shields

The German automotive leader announced it is donating 3D printed masks for free while the company behind the design, Prusa Research, surpassed a major milestone reporting 100,000 face shields printed and donated around Czechia. 

PrintLab and PrintCity launch lesson plan to inspire COVID-19 solutions

3D printing curriculum developer PrintLab, together with Manchester Metropolitan University's PrintCity digital manufacturing centre, have launched a free lesson plan focused on developing COVID-19 solutions.

The project is designed to teach students about the transmission of viruses on common touch surfaces and challenges them to design products which can be readily attached to surfaces to help reduce the spread of infectious droplets. The idea was inspired by the Armie hands-free device created by PrintCity which allows users to open doors or drawers hands-free.

The 'Pandemic Products' lesson plan provides a range of materials including explainer videos and TinkerCAD and Fusion 360 tutorials to inspire new functional products which could be 3D printed.

Mark Chester, Innovation Development Manager at PrintCity, added: "Over the last couple of weeks it's been inspiring to see how quickly designers, engineers and manufacturers have responded against the short-term impacts of COVID-19 through the production of PPE and ventilators. We feel this free resource provides a fantastic platform for students to learn new skills around design and additive manufacturing which they can apply to the current pandemic."

Jason Yeung, Co-Founder at PrintLab, said: "We're now giving students the opportunity to join the fight against COVID-19 by using their creativity to keep key workers safe. We're confident in the ability of students to step up to this design challenge and we're excited to see their innovative solutions come to life!"

23/04

Stratasys supports Origin in distribution of 3D printed nasopharyngeal swabs

Origin and Stratasys have signed an agreement that will see Stratasys market and promote Origin’s 3D printed nasopharyngeal swabs to healthcare and testing centres throughout the United States.

As a result of the partnership, Origin will see its testing swabs endorsed by Stratasys, who has a wide network of healthcare partners and contacts through its own supply of 3D printing hardware, as well as a supply of 40,000 face shields in recent weeks to 100 frontline organisations.

Origin has seen its nasopharyngeal swabs tested in clinical trials by Beth Israel Deaconess Medical Center, with each Origin One platform able to print a batch of 1,500 swabs per build. With the implementation of a ‘streamlined process’, plus the support of Stratasys and other partners, Origin is working to reach the capacity to produce 190,000 per day or 1.3 million per week.

“We believe widespread testing can help save lives and get our economy going again, and we’re confident that our Origin One technology and simple material requirements will be able to produce millions of swabs to meet the need,” commented Origin CEO Chris Prucha. “We’ve been impressed by the speed with which Stratasys has been able to provide thousands of shields to healthcare systems across the country and believe they are the right partner for helping get millions of swabs where they are most needed.”

“We have tremendous confidence in Origin’s 3D printing technology and we’re confident in our ability to help bring them to market efficiently,” added Stratasys Americas President Rich Garrity.

Updates from HP as they see ‘a decade of change in weeks’

HP has revealed the extent to which its Jet Fusion 3D printing technology has been deployed in the last month as manufacturers and partners mobilised facilities to produce more than 150,000 parts.

Among the applications are face shield components, masks, mask adjusters, wrist covers to protect exposed skin, hands-free door openers, Continuous Positive Airway Pressure (CPAP) connectors and nasopharyngeal swabs.

HP has partnered with Beth Israel Deaconess Medical Center to design and clinically validate the testing swabs and is now looking to mobilise its global partner and customer network to help additively manufacture them at scale.

This group of partners and customers has already been manufacturing large numbers of PPE and medical equipment, including thousands of face shield parts. HP last week received EN1666 certification on its own face shield design and has produced 8,000 of the parts at its Barcelona facilities since March 23^rd, despite knowing ‘nothing about face shields on the morning of Saturday March 21^st’.

Another notable development is in the additive manufacture of CPAP connectors, which have been in use since April 6^th after receiving approval for Spanish hospitals. On March 23^rd, HP received an email from a nursing supervisor at Prícipe de Asturias Hospital just outside of Madrid, who emphasised how doctors didn’t have enough respirators to treat every COVID-19 patient and were already having to make tough decisions as to who lived and who didn't. The hospital ICU team had designed a part that could connect standard equipment to create a CPAP device, which can help increase patients’ blood oxygen levels to above 90% without the need for a ventilator, but no way of manufacturing them. Within two days, HP had a printed part sent to the hospital for validation and has so far produced 500 more connectors, with capacity now scaled up to deliver 10,000 per week.

“Across HP, there has been a huge commitment to help in the COVID-19 battle, and the organization has gone above and beyond to transform how we design and quickly scale up production for critical medical items,” commented Fabio Annunziata, Head of Strategy and Planning for HP’s 3D Printing & Digital Manufacturing business, and lead of HP’s 3D Printing COVID-19 taskforce.

22/04

iMakr sets up 3D printing farm to support Guy’s and St Thomas’ NHS trust

Nexa3D hit pause on everyday printing service to focus on PPE & testing swabs

Nexa3D is using its NXE400 stereolithography 3D printing systems to manufacture PPE components and testing swabs.

The company has installed additional capacity over the last few weeks to enable it to produce parts for 10,000 face shields per week. It is also in the process of supplying nasal test swabs to healthcare facilities and testing labs at volumes of up to 500,000 per week.

Face masks are being manufactured in two versions: the XShield and the more durable XShield Pro, both of which use components printed with lightweight, flexible materials.

Nexa has remained in close contact with various universities and health care systems across the United States, with face shields being delivered to frontline healthcare workers at the Cottage Health System in Santa Barbara County and the non-profit disaster recovery organisation Santa Barbara Bucket Brigade.

“We believe that the additive manufacturing industry is uniquely positioned to deliver practical, urgent and scalable solutions during this unprecedented crisis that address the severely broken supply-chain,” said Nexa3D CEO Avi Reichental. “We are extremely proud of the innovative, hard-working members of our team that are applying themselves to deliver much needed parts and services during this unprecedented period.”

XYZprinting sets up 3D printer farm to manufacture face shield components

XYZprinting Inc. has teamed up with volunteer students at Beckman High School in Irvine, California to 3D print face shield components for local frontline healthcare workers. 

The project saw the 3D printer manufacturer set up a print farm of more than 20 desktop da Vinci 1.0 Pro systems, which have so far produced over 500 face shield headbands for donation to Hoag Hospital in Newport Beach, CA. 

Vinson Chien, Managing Director at XYZprinting US, who initiated the project, said: "The dynamic nature of 3D printing is a great way of problem solving, especially in dire times like these. We are not only hoping to relieve medical workers in our beautiful sunshine state, but also inspire younger folks to help our local community."

ARRK leverages 3D printing to support NHS Trusts in Gloucester and Teesside

Imaginarium now mass producing protective face shields

Imaginarium has announced it said to be dedicating the entirety of its advanced manufacturing facility for the manufacture of PPE to support healthcare workers during the COVID-19 crisis.

The company, which operates one of India's largest rapid prototyping and advanced manufacturing centres, says it is mass producing a unique face shield to provide complete coverage of the face and has already catered to 50,000 frontline workers. 

Kamlesh Parekh, MD, Imaginarium, explained, "There have been multiple efforts at the grassroots level in response to the supply chain challenges for PPE availability. We've come up with a unique concept to protect the entire face of an individual by creating a face shield that provides complete coverage of the face, ears and neck. With an ergonomic, lightweight design, it is a product designed for comfortable usage during long working hours. The Face Shield is the first in a line-up of products shortlisted by our team for design and manufacturing during this time."

The lightweight face shield has been designed to protect the face from all respiratory droplets. It can be worn comfortably without any elastic bands and is said to be easy to assemble and wash. Parekh added that the company is also working on the development of safety goggles, aerosol intubation boxes, ventilator components and other critical supplies.

21/04

America Makes announces two 3D printing challenges to address COVID-19

Following the launch of its online repository to support 3D printing efforts against COVID-19, America Makes has announced two rapid response additive manufacturing challenges to address the shortage of equipment for frontline workers.

Click here for the full story. 

Proto21 develops face shields for Dubai Police

Dubai Police is providing its officers and several ambulance teams with face shields produced with the help of 3D printing.

The face shields have been developed in collaboration with Proto21, who has leveraged its fleet of FDM machines to print reusable top head mounts. These head mounts secure a visor in place to act as an added layer of protection, with face masks also worn by frontline personnel.

20/04

Ferrari deploys 3D printing to produce respirator valves and fittings

Ferrari is using additive manufacturing to produce respirator valves and fittings for protective masks with additive manufacturing technology.

The company typically uses 3D printing to produce prototypes inside its Maranello plant, but is harnessing the technology to help supply much needed medical and protective equipment.

The additively manufactured valves have been developed by diving equipment manufacturer Mares to support patients suffering from respiratory failure in emergencies.

Ferrari is planning to manufacture hundreds of the parts in the next few days and is working with the Italian Civil Protection to distribute the components to a number of Italian hospitals and health workers.

3T 3D printing 20,000 face shield bands per week for NHS and frontline staff

3T Additive Manufacturing, a UK-based service provider, is 3D printing 20,000 face shield headbands per week for use by frontline workers fighting the COVID-19 pandemic.

The company is using its fleet of EOS selective laser sintering machines to print the parts, which can be attached to a piece of clear acetate to form a protective shield. The effort follows the launch of EOS's 3D Printing Against Corona hub which is designed to share knowledge, data and downloadable files to help combat the virus. 

3T is working directly with NHS trusts across the UK, as well as various medical distribution companies to supply face shields to UK health workers and is expected to produce more than 100,000 headbands over the next few weeks. 

The CAD for the headband and also a hands-free door gripper can be downloaded for free via 3T's site for anyone to use or modify.

Daniel France, Chief Commercial Officer at 3T: "We've already seen countless examples of how 3D printing is helping people stay protected and fight the virus globally. It was of paramount importance for us, as a business, to play a role in this, and that's why we are manufacturing these for as low a cost as we can to support.

"Working closely with our partners, we've been able to produce tens of thousands of parts using EOS' powder-based 3D printing technology, which ensures frontline health workers are protected. The demand is far greater than one company can provide, but we will continue to do as much as we can to add to the supply."

17/04

5000 face shields needed for Johanniter-Unfall-Hilfe e.V.

The MGA initiative (Mobility | Medical goes Additive) is putting a call out for 5,000 protective face shields to be donated to voluntary humanitarian organisation Johanniter-Unfall-Hilfe e.V.

The international network, which aims to push 3D printing to industrial series production maturity, has described the urgent need for protective equipment for the organisation’s more than 23,000 full-time staff and 40,000 volunteers operating in almost 300 regional, district and local bodies throughout Germany

MGA is calling on 3D printer manufacturers, service providers and makerspaces to produce protective face shields, which are applied during in-house trainings to protect those providing daily care. The face shield design was developed by 3dk.berlin for FDM printing and is made up of two parts.

Last month, MGA set up its virtual 3D Printing fights Corona initiative to gather expertise from hospitals and the 3D printing industry on relevant application developments and requirements from those working on the frontline. MGA is also part of an initiative with Airbus, Volkswagen and DB Schenker which recently delivered 2,000 face shields in Spain.

SmileDirectClub delivers 35,000^th face shield

SmileDirectClub has announced the delivery of 35,000 face shields to healthcare professionals and other key workers with the help of its additive manufacturing capacity.

The face shields have been delivered to the likes of St. Luke’s Health System in Idaho, Dr. Pepper/Keurig in Texas, Sick Kids Foundation in Toronto, University of California San Francisco, Brookdale Senior Living and TN Emergency Management Agency (TEMA), both in Tennessee where SmileDirectClub is headquartered.

In addition to the manufacture of face shields, SmileDirect is also supporting HP to work towards a validated, 3D printed reusable respirator mask with a replaceable filter, which could act as an alternative to a disposable N95 mask.

“We are fortunate to be able to help those in need at this time in many different ways and I thank our team members and partners who took action quickly to coordinate efforts and keep our manufacturing operational so that we can bring much needed supplies to the medical community and others,” commented Dan Baker, Head of Global Supply Chain at SmileDirectClub.

SIARE 3D prints lung simulators with Automobili Lamborghini

SIARE Engineering International Group, an Italian provider of anaesthesia and resuscitation equipment, is working in collaboration with Automobili Lamborghini for the co-engineering and 3D printing of lung simulators.

As the demand for new ventilators grows, there is now also an increasing need to strengthen products in the pre-testing phase including lung simulators, which simulate the characteristics of adult human lungs to test the functionality of ventilators before undergoing final inspection with certified instruments.

SIARE worked with Automobili Lamborghini's 3D printing lab to produce a set of lung simulators using HP's Multi Jet Fusion technology, allowing engineers to print at an accuracy of 0.08 mm.

"The challenge of this cooperation was to redesign and simplify the simulator without losing neither its functionality nor its reliability. The result was a fully printable 3D printing object with an unusual, almost motoristic design," Giancarlo Marisaldi of SIARE Engineering International Group explained. "In just a couple of weeks, Automobili Lamborghini R&D Department's colleagues were able to design, manufacture and validate the simulator, optimising the components and allowing the production of 18 pieces per week in conjunction with the development of facial screens in which we are likewise involved with Automobili Lamborghini's 3D printing laboratory."

Is 3D printing a magic bullet for supply chain at the time of COVID-19 pandemic?

The COVID-19 pandemic put the flexibility of supply chains to a major test by causing a significant shift in consumer demand in many industries—a spike in "essential items" and a reduction in "non-essential items." On March 27, General Motors Company was ordered through the invocation of the Defense Production Act to retool for the production of much-needed ventilators.

On March 30, Ford Motor Company and GE Healthcare announced a plan to produce 1,500 ventilators by the end of April and to deliver 50,000 ventilators in 100 days. Although 100 days may seem like a rapid retooling and a production ramp-up in the world of conventional manufacturing, it still falls behind the acceleration rate of new daily infections. The daily number of confirmed cases in the United States grew by about 26% and reached 26,365 on March 31 based on data from the Johns Hopkins University’s Coronavirus Resource Center.

Among advances in digital technologies, 3D printing is a new manufacturing method that enables us to create whatever we can conceive by using the digital file and the right material. With the growing importance of 3D printing and with the current COVID-19 crisis, we aim to answer two questions related to the implication of 3D printing in the fight against the COVID-19.

How can 3D printing help in humanity’s fight against the COVID-19 pandemic? And what are the limitations of 3D printing in the fight against the COVID-19?

Read the full article, penned by Aalto University's Siavash H. Khajavi & Alireza Jaribion and former GE Additive CEO Mohammad Ehteshami, here. 

Asiga shares open source files for 3D printable PPE

Asiga has set up an internal COVID-19 task force to combat the shortage of PPE.

Working with local government, the stereolithography machine manufacturer is sharing design files for open source PPE devices which can be 3D printed at its manufacturing facility in Sydney or by anyone with a 3D printer.

Asiga has released a number of designs including a face shield frame which can be printed in three parts on its MAX UV 3D system in under 17 minutes. The parts can be easily snapped together and assembled with off-the-shelf clear film to form the visor. The company has also released couple of designs for ‘ear defenders’ which can be worn by health workers to relieve pressure on the back of the ear from face mask elastic.

Asiga is urging its users to check-in with local hospitals, clinics, healthcare services to ascertain whether they have a need.

#36 Additive Insight: How 3D printing is helping to combat COVID-19

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16/04

3D Systems Figure 4 could 3D print 18,000+ test swabs a week

3D Systems says it has the capacity to 3D print 18,345 swabs per week on a single Figure 4 system.

The company, which has already deployed its technology for the manufacture of PPE and ventilator components, is now extending its efforts to address the shortage of nasopharyngeal (NP) swabs to test COVID-19 patients.

3D Systems says it is now working with clinicians to validate the materials and process for NP swabs printed on its resin-based Figure 4 system, stating that the technology’s autoclavable and biocompatible material set is ideal for the rapid mass manufacture of swabs. Based on output from a single Figure 4 system, 3D Systems believes it can print 273 swabs in 2.5 hours, which equates to 34 seconds per swab.

The company has already published a Material Technology Overview Chart to identify the best printer-material combinations for which either Class VI and/or ISO 10993 certifications are possible for COVID-19 applications.

Athletics 3D joins COVID-19 response effort

French sports equipment manufacturer Athletics 3D has developed an interactive map to allow 3D printing users, hospitals and other organisations to pin their locations and indicate their availability or equipment needs to fellow users of the map.

This allows designs of parts, such as for visors, masks or other medical equipment, to be sent to a nearby printer and produced locally.

Athletics 3D is using its own 3D printing capacity, as well as laser plotters to cut plexiglass, to manufacture dozens of visors everyday. The company, however, has sought to encourage other 3D printing users to leverage their machines to help supply PPE and other equipment in the fight against COVID-19.

“This solution eliminates the need to transport the equipment over long distances. The design is transmitted digitally and the printing is performed at or near the final destination. The visor design developed by Zortrax and published in the Zortrax library is now available to everyone [and] is printed and used also in France.”

The Barnes Group Advisors teams with US Veterans Health Administration to support development of 3D printed solutions

Advanced manufacturing consultancy The Barnes Group Advisors (TBGA) has signed an agreement with the US Department of Veterans Affairs, Veterans Health Administration Innovation Ecosystem (VHAIE) to provide a collaboration framework for the deployment of 3D printing technologies in response to COVID-19.

This Corporate Research & Development Agreement (CRADA) is intended for the co-development of technologies to ensure VA medical professionals have access to solutions to support care for veterans.

TBGA and medical industry veteran Andy Christensen has led the initiative using a “requirements-based approach” to help tackle the shortage of PPE for healthcare workers. So far, the effort has resulted in the preliminary validation of two face mask designs which TBGA said have “significant potential.” Christensen also helped facilitate distribution of the designs to Dr. Beth Ripley; Director of the VH 3D Printing Network with the VA Health Care Systems.

Mr. Christensen commented, “This is a significant partnership focused on tackling a realtime problem. The seasoned engineers at the Barnes Group Advisors bring creative solutions and rapid design iterations based on the feedback from the frontline VA team. Our frontline healthcare workers not only need quick solutions, but professional ones that are based on real performance requirements to ensure they are adequately protected.”

As part of the agreement, TBGA is said to be providing resources to design 3D printable items as well as actively participating in the engineering, design, and prototyping of additional printable objects.

Meanwhile, the VHA Innovation Ecosystem will provide resources including engineers for design, run testing, and to communicate with FDA regarding ultimate clearance of the design. They will also provide training for healthcare workers to safely use these 3D printed solutions as needed, in addition to sharing models, best practices and learnings.

15/04

First tests carried out on respirator made with HP's Multi Jet Fusion

A consortium in Spain has successfully carried out the first tests for a respirator featuring HP Multi Jet Fusion printed parts.

The Leitat1 respirator is the result of an alliance between the Consorci de la Zona Franca (CZFB), HP and Leitat (Tecnio) together with CatSalut, through the Consorci Sanitari de Terrassa (CST) and the Hospital Parc Taulí in Sabadell. The first tests were carried out with ICU patients affected by the COVID-19 virus at Hospital Parc Taulí

The respirator, dubbed Leitat1.3, was designed by Leitat to include volumetric sensors, pressure sensors or oxygen alarms, among other features to guarantee functionality for a longer period of time in assisted breathing for severe coronavirus patients. 

The respirator is made up of parts 3D printed with HP's MJF technology and the design is said to allow production of 50 units per day at a cost 10 times lower than that of a conventional respirator.

After initial tests, clinical testing is set to begin with several hospitals including Parc Taulí, Vall d'Hebrón, Hospital del Mar, Consorci Sanitari de Terrassa and Hospital General de Granollers. Tests and refinements have been carried out in Applus with Leitat´s technicians to guarantee the safety of the respirators and ensure they are ready for certification by the Spanish Agency of Medicine and Sanitary Products.

Once approved, production is set to begin at the CZFB headquarters with HP production teams and support from the 3D Factory Incubator and IAM3DHUB. The Bosch Siemens Home Appliance (BSH) company has also joined the project, while Airbus is said to be on-hand to provide technical knowledge for further development.

COVID-19 impact could make 2020 a difficult year for 3D printer shipments

3D printing companies are said to be refocusing their efforts away from printer sales towards service bureau models to produce products related to COVID-19 relief.

According to a report by CONTEXT, 3D printer manufacturers across the globe are shifting their businesses to provide services following weak 3D printer shipments in Q4 2019 and expected constraints in supply-and-demand.

Chris Connery, VP of global analysis at CONTEXT said this could make 2020 a difficult year for sales: “While COVID-19 had not yet had an impact, global 3D printer shipments were already unseasonably weak in Q4 2019. For many manufacturers – particularly those focused on Industrial* or Design* price-class printers – this slowdown was associated with a weak automotive market, a generally weak manufacturing sector and sluggish Asian and European economies.”

* 3D printer price classes: Industrial ≥ $100K, Design = $20K–$100K, Professional = $2.5K–$20K, Personal ≤ $2.5K (excludes DIY kit printers)

SPEE3D 3D printed copper proven to kill SARS-CoV-2 virus

Australian metal 3D printing company SPEE3D is said to have successfully developed and tested a fast and affordable way to 3D print anti-microbial copper, which can kill the COVID-19 virus, onto metal surfaces.

The process, known as ACTIVAT3D copper, has been achieved by modifying SPEE3D’s technology to allow existing metal parts to be coated with copper, harnessing the material's ability to eradicate bacteria, yeasts and viruses on contact by breaking down the cell wall and destroying the genome.

Tests have shown that surfaces modified by the process ‘contact kills’ 96% of SARS-CoV-2, the virus that causes COVID-19, in just two hours. Australian NATA accredited clinical trial speciality laboratory, 360Biolabs ran tests on live SARS-CoV-2 in their Physical Containment 3 (PC3) laboratory. The results showed that 96% of the virus is killed in two hours and 99.2% of the virus killed in 5 hours. Stainless steel, the material most commonly used in hygiene environment, showed no reduction in the same time frame.

The aim is to use the process for common touch items like door handles, rails and touch plates in hospitals, schools and other public places. Using SPEE3D’S technology, it is possible to coat a stainless-steel door touch plate or other handles in just 5 minutes. Fixtures have already been installed by SPEE3D partners at Charles Darwin University (CDU) in Darwin, Swinburne University in Melbourne, the University of Delaware in the USA and in Japan.

SPEE3D CEO, Byron Kennedy said, “The lab results show ACTIVAT3D copper surfaces behave much better than traditional stainless, which may offer a promising solution to a global problem. The technology can be used globally addressing local requirements, be they in hospitals, schools, on ships or shopping centres.”

14/04

Update from BCN3D

After setting itself a target to 3D print over 2,000 face shields for use by healthcare workers in Spain, BCN3D has now reported it has manufactured more than 4,000 in the last two weeks.

The shields have been validated for safe re-use by their intended hospitals, which are all set to take delivery of the devices by the end of this month.

Titan Robotics 3D prints PPE for Colorado healthcare workers

Titan Robotics is using its pellet extrusion 3D printing technology to manufacture face shield halos for healthcare workers in Colorado.

Leveraging its large-format Atlas machine, Titan says it is able to print parts both faster and at a lower price point than desktop extrusion printers, with each halo taking 5.5 minutes to print at a cost of less than 50 cents. Titan cites material flexibility as a key benefit to using pellets as feedstock. For this particular device, the main body is printed in PETG pellets while the strap is produced using TPU.

The company says it is working with local and national organisations to distribute parts to hospitals across the U.S.

AddiFab develops adapter for diving mask

AddiFab has been collaborating with The Ocean Reef Group to manufacture an adapter which can turn a diving mask into a piece of PPE to protect frontline workers.

The additive manufacturing company worked with emergency medicine specialist Michael Mølmer to create the MiMo Face Mask Adapter, which allows bidirectional bacterial/viral

removal filters with gas outlets conforming to ISO 5356-1 to be mounted on a full-face Ocean Reef diver’s mask.

The part was made using AddiFab’s Freeform Injection Moulding platform in materials which are said to be approved by necessary regulatory entities.

Within four days, AddiFabb was able to prototype and deliver 12 parts to a Danish hospital and by day six, was ready to scale up final parts for manufacturing in Europe and the U.S. Currently, the company’s showroom is said to be able to produce 100-150 units a day but AddiFab says it is collaborating with Mitsubishi Chemical to mass-produce the adapter if necessary.

trinckle teams with MyMask to deliver personalised face masks

German software company trinckle has teamed up with a non-profit project which aims to address the shortage of N95 and surgical masks with 3D scanning and 3D printing.

The MyMask project was founded by volunteers in Silicon Valley, Boston and NYC, who have created an app that produces a 3D printable model of a face masks personalised to the wearer. The app leverages trinckle’s paramate software, which is already being used by the likes of Ford to automate the design of 3D printed jigs and fixtures, to combine scan data with morphing algorithms to match the original mask design with the wearer’s face shape.

The 3D model can then be downloaded for free and printed at home or via one of their partners at-cost. MyMask is in beta test mode and currently testing the masks with a small group of users. They are also seeking further support to expand to Europe.

Prodways customers print 5,000+ face shields

Prodways is rallying its network of 3D printer customers to manufacture face shields for use by healthcare workers.

The company says a dozen customers across Europe and North America have now manufactured over 5,000 face shields using their Prodways printers over the last three weeks. Prodways has been providing customers with the design files and optimal print parameters to optimise production.

"Our priority was to act quickly with the greatest possible impact by providing our support for the supply of face shields for medical staff while ensuring the safety of our employees", explained Olivier Strebelle, Chief Executive Officer of Prodways Group "At the heart of our contribution, we are particularly concerned about safety, reliability and the certification required to ensure that the solutions produced can be used safely by healthcare workers ".

Prodways says it is also in discussion with several players in the medical devices field to provide industrial services and solutions for the design and manufacture of parts under emergency situations to fight COVID-19. The projects are currently being certified.

FIT develops 3D printed filter carrier mask for general public

German additive manufacturing specialist FIT AG has developed a special filter carrier which can be combined with almost any filter material to create an emergency mask.

The device has been designed for use by the general public in a bid to combat the shortage of protective masks and reduce the spread of infection to those without protection. The FiT filter carrier is said to be dishwasher safe and can be reused by simply changing the filter material. This can include items such as handkerchiefs, cotton tissues or professional non-woven materials. Based on a study from 2013 by the University of Cambridge, the effectiveness of filtering the smallest particles out of the air depends on which filter material is inserted. Compared to surgical masks, vacuum cleaner bag proved most effective.

The design, which has been optimised for SLS machines, can now be downloaded for free and FIT says it is currently working on a smaller version for children. FIT is making its first production of carriers available free of charge to citizens in its home town of Lupburg. An enhanced design of the mask is also now available, which can be produced on mass with injection moulding.

Carl Fruth, CEO of FIT AG, said: "We are fully aware that our filter carrier cannot protect healthy people from infection. We simply want to improve the protection of others, i.e. reduce the risk of infected people infecting others by droplet infection. In this way we want to contribute to a slowing down of the infection rate. And that's all that matters at the moment.”

3D Systems On Demand 3D prints ventilator parts for Project Pitlane

3D Systems On Demand team in the UK has produced 720 sets of parts for Project Pitlane, a coalition of UK-based Formula One teams and medical companies setup to rapidly design and manufacture ventilators to support the NHS.

A total of 2,880 parts were printed last weekend using selective laser sintering in medical grade nylon.

News you may have missed over the weekend ...

3D printing consortium to deliver millions of test swabs

A consortium of 3D printing companies and academic institutions have come together to deliver millions of additively manufactured nasopharyngeal swabs for testing of COVID-19.

The collaborative effort from additive companies Carbon, Formlabs, EnvisionTEC and Origin, along with The Wyss Institute, Harvard Medical School/Beth Israel Deaconess Medical Center, Stanford Medical Center, University of South Florida Medical School, Ohio State University, and the US Army Natick Soldier Systems Laboratory, has led to the development of wholly 3D printed, Class 1 FDA registered swabs. Desktop Metal CEO Ric Fulop is also leading the task force alongside Ramy Arnaout, MD, PhD, Assistant Professor, Harvard Medical School, and Prof. Kit Parker, Prof. Harvard University, LTC U.S. Army: Program Management.

The swabs can be manufactured on mass with a network verified as ISO13485 facilities across the U.S. which are said to be able to rapidly produce up to 4 million per week. Hospitals and healthcare providers are being urged to visit www.PrintedSwabs.org to request immediate supplies.

Commenting on the collaboration, Chris Prucha, co-founder and CEO of Origin said, "Origin is proud to join together with teams of experts across technology, healthcare and academia to help fast-track efforts to get durable and safe medical devices in the hands of healthcare professionals.

"These are unprecedented times that require unprecedented measures. Given this, Origin has made the decision to focus its efforts solely on developing medical devices and PPE during this crisis.

SLM sets up Additive Alliance Against Corona and prints face shield mould tools

Metal additive manufacturing company SLM Solutions has launched the Additive Alliance Against Corona initiative which aims to combine knowledge from the AM industry to manufacture much-needed medical components.

The company plans to leverage machines and processes which have already been certified to current European "Medical Device Regulation" (MDR) and ISO 13485 guidelines to produce medical components and tooling to help with the shortage of equipment.

SLM says its Selective Laser Melting systems are already being used in the U.S. to produce metal injection moulding tools for face shield production. The company is now inviting more organisations, which can provide support across production, development or logistics, to join this new alliance.

Medical University of Gdańsk uses Zortrax 3D printers to produce masks

Machines from Polish 3D printer manufacturer Zortrax are being put into action to manufacture PPE.

The Medical University of Gdańsk (GUMed) is using its in-house 3D printer farm, which includes several Zortrax systems, to print protective masks and visor components. Currently, GUMed says it has the capacity to print 50 visors per day, or 36 while prototyping further devices.

Dr. Jarosław Meyer-Szary of the Clinic of Pediatric Cardiology and Congenital Heart Defects of GUMed, said: “We are testing and modifying various designs to find the most effective and convenient solutions for their users. Ordinary surgical masks do not provide much protection because they are not tight enough. Unfortunately, the use of such masks fails to eliminate the risk of infection due to small gaps that occur between the mask and the wearer’s face through which the virus may be transmitted. The masks that we are currently testing will be used by healthcare professionals, especially those who are most at risk and who remain in direct and long-term contact with sick patients.”

Zortrax itself is also using its 140 printer capacity to help and has already delivered 100 masks to the Polish Red Cross. Printed in Z-GLASS and Z-PETG filaments, the visors can be easily sterilised and Zortrax has also highlighted the benefit of being able to print in different filaments to colour-code and identify teams in an emergency situation.  

Mariusz Babula, Vice-President of Zortrax, added: “The ability to quickly recalibrate the printer and handle it in a simple and intuitive manner makes the creation of protective equipment possible for everyone. Users who until recently printed unique jewelry, car or motorcycle parts or who designed interior elements can now, in a matter of hours, become producers of articles necessary for medical professionals.”

09/04

Markforged printing testing swabs at scales of 10,000 a day

Markforged has announced it is producing 10,000 3D printed nasopharyngeal testing swabs a day with plans to scale up to 100,000 per day.

A testing study of the swabs was done in parallel with commercial swabs with 50 volunteers being re-tested across a period of between three and fourteen days. All of those re-tested with the 3D printing swabs came back positive. The 3D printed swab features a nylon base with a wrapped rayon tip to gather the viral specimens and is being produced on Markforged’s Industrial series of printers.

The 3D printed swabs were designed and developed in collaboration with the San Diego Covid Research Enterprise Network (SCREEN) Initiative, Neurophotometrics, Rady Children’s Hospital-San Diego, the Scripps Research Institute and the University of California San Diego, and have completed clinical validation with the institutional review board at Rady’s Children’s Hospital and the University of California San Diego this week. Rady Children’s Hospital has ordered 30,000 of the swabs to test patients within its facility.

“Once again, 3D printing is changing the paradigm of medical advancements and device development,” said Justin Ryan, PhD, director and research scientist at the 3D Innovations Lab at Rady Children’s. “We saw an urgent need for swabs for testing, and quickly formed a partnership between academia and industry to come up with designs and test them — and it’s incredible what has been achieved in such a short period of time.”

Forecast 3D launches line of 3D printed PPE equipment

Forecast 3D has announced a line of readily-available PPE products, which have been developed with HP’s Multi Jet Fusion technology.

The product line includes face shields, stopgap masks and nasopharyngeal swabs for testing. These parts are said to all fall under CISA guidelines for manufacturing and are ready to print and ship immediately. More than 3,000 of these medical parts are being printed each day.

“We are proud to be doing our part to help provide critical supplies to the healthcare workers on the front lines of the COVID-19 battle,” said Ken Burns, Commercial Vice President at FORECAST 3D. “One of the benefits of additive manufacturing is its ability to adapt to changing product needs. Once we had FDA-approved or NIH-endorsed designs, we accelerated production on these much-needed supplies.”

GE Additive & TriHealth develop adaptor to convert hard hats into face shields

GE Additive has produced a 3D printed an adapter component that converts a standard hard hat and visor into a face shield.

The company has had a COVID-19 task force working with medical firm TriHealth over a number of weeks and, judging the additive manufacture of full face shields to be a too-lengthy process compared to the urgent need of protective equipment, decided instead to develop the adaptor. The resulting part allows visors and helmets to be joined together within a minute, while the user can also raise and lower the visor as required.

Using a high-temperature ABS material, the adaptors are produced on an extrusion-based machine, with each part taking around 15 minutes to print. GE

08/04

3D Systems develops 3D printed emergency stopgap mask with Veterans Health Administration

3D Systems has introduced another item to its resource of 3D printable COVID-19-related devices. The files for an emergency stopgap face mask (SFM) have been created in collaboration with engineers and clinicians at the Veterans Health Administration and are now available to download.

Given the current shortage of FDA-cleared masks and respirators, the SFM is designed for use in medical purposes when standard PPE is unavailable or for less critical non-medical environments that do not require compliant PPE. The design is made up of a 3D printed mask and filter cover, two elastic trips and a rectangular patch of filter material. It is available in different sizes and can be printed in biocompatible nylon using selective laser sintering and reprocessed using disinfectants or autoclaving.

The SFM design has undergone review in a clinical setting and is recommended for use when manufactured according to the guidance and used as instructed in the IFU.

Carbon: One million testing swabs & support from adidas in PPE face shield production

Carbon has said it is producing more than one million nasopharyngeal swabs a week to support COVID-19 testing, while adidas is lending some of its additive manufacturing capacity to produce PPE face shields in North America.

In vitro diagnostic and medical device manufacturer Resolution Medical is providing distribution support on the nasopharyngeal swab side, with Carbon suggesting it can scale up further if required.

In partnership with adidas, PPE face shields are being produced with Carbon’s additive manufacturing equipment and the same custom material that is used to print the midsoles for the Futurecraft 4D footwear collection. Carbon is currently producing more than 18,000 PPE face shields per week, with the capacity to ramp up to 50,000 per week using its global network of manufacturing partners. The company has made the face shield design open-source and available on its website.

Blue Origin volunteers are 3D printing face shield components

Aerospace manufacturer and sub-orbital spaceflight services company Blue Origin is using its in-house 3D printing capabilities to produce face shield visors for delivery to hospitals around the U.S. 

The efforts are being run by volunteers, with just one person working in the print farm at any one time to adhere to social distancing. 

In a video posted to its LinkedIn page, which shows FDM machines from Stratasys and Raise 3D being used to print the visors, the company says it has the ability to print with around 38 different thermoplastic materials. 

Queen's University Belfast deploys 3D printing to produce face visors

Queen’s University Belfast is deploying 3D printing equipment usually used to manufacture a range of drug delivery systems and medical devices to print parts for protective face visors.

Researchers from the university’s school of pharmacy have modified designs developed by a group of Spanish engineers to support Belfast Trust healthcare workers in their treatment of patients with COVID-19. More than 800 of the visors have been donated so far, with researchers in the School of Mechanical and Aerospace Engineering also working to produce PPE face shields with laser-cutting technology.

07/04

Manchester universities unite to 3D print headbands for protective face shields

The University of Manchester has joined forces with neighbouring University of Salford and MMU to use 3D printing to design and make headbands for protective face masks worn by frontline NHS medical staff.

With a print capacity of near 50 machines, the university is aiming to produce around 500 additional mask headbands per week. The face shield is being laser cut by regional commercial suppliers and assembled at Salford Royal Hospital NHS Trust, part of the Northern Care Alliance. NHS staff will collect the masks from the University campus on a daily basis to help resupply their essential stock of PPE.

Professor Brian Derby is coordinating the 3D printing response at The University of Manchester, he said: “3D printing has allowed the Greater Manchester-based team to progress rapidly from concept, to prototypes, which allowed infection control teams to validate the design and enable the production of PPE acceptable for use in the regions hospitals.”

Sought after personal protective equipment (PPE) is also being donated by the University in the midst of a global shortage including 47,660 pairs of nitrile gloves and 200 pairs of protective goggles.

Meanwhile, MMU is re-opening its PrintCity facility to commence production on additional visors, with a goal to print around 1,000 headbands per week.

BigRep offers up free 3D printing filament to customers printing face shields

Large-format 3D printer manufacturer BigRep is urging its community to help with the additive manufacture of protective equipment for people in their local areas.

The company has published a design for a printable face shield which can be printed in batches of up to 24 units on a BigRep ONE machine, and has already donated several to local organisations to provide protection from the novel coronavirus. To encourage more users to participate, BigRep is offering a complementary 2.3kg spool of PLA in exchange for video footage of the equipment being produced on BigRep 3D printers and donated locally, which it says it will use to continue its call to action.

Renishaw update: Mass-production begins on ventilator components

Global engineering company Renishaw has commenced mass-production on critical components for medical ventilators to support the NHS.

The news follows the UK government’s call out to manufacturers last month to assist with the production of thousands of crucial devices in the fight against COVID-19. Renishaw says it has dedicated a significant part of its manufacturing sites in Gloucestershire and South Wales to produce precision-machined components for two different ventilators manufactured by the VentilatorChallengeUK consortium.

Marc Saunders, Director of Group Strategic Development, said, “Ventilators are sophisticated medical devices and we felt that our capabilities would be best applied to helping scale up the production of designs with existing technologies. We soon realised that many other industrial companies were thinking the same way and that we would need our combined capacity and capabilities to achieve this enormous endeavour.”

Renishaw has joined companies in the aerospace, automotive, medical device and motorsport sectors to form the consortium under the leadership of Dick Elsy, CEO of the High Value Manufacturing Catapult, to boost production of two proven ventilators selected by the NHS and manufactured in the UK by Penlon and Smiths Medical.

Dick Elsy explains, “Penlon and Smiths ordinarily have combined capacity of between 50 and 60 ventilators per week. However, thanks to the scale and resources of the wider consortium, we are targeting production of at least 1,500 units a week of the Penlon and Smiths models combined within a matter of weeks. Ventilators are intricate and highly complex pieces of medical equipment and it is vital that we balance the twin imperatives of speed of delivery with the absolute adherence to regulatory standards that is needed to ensure patient safety.”

Gareth Hankins, Director of Group Manufacturing Services at Renishaw, commented: “The consortium’s key message is that ‘Every ventilator produced is a life saved’ and Renishaw is proud to be playing its part in this vital endeavour.”

Omni3D delivers first batch of face shields to hospitals

Polish 3D printer manufacturer Omni3D has refocused its team’s efforts to 3D print components for protective face shields.

The company says it is currently producing 120 shields daily using its Omni500 LITE and ABS-42 filament but technicians are working on increasing the capacity to 150 units.

Paweł Robak, CEO of Omni3D said: “Omni3D delivered the first batch of face shields to hospitals, and they have passed the practical test. ER department staff, nurses and doctors in surgery departments have received the shields, among others. The hospital staff expressed appreciation and acceptance for our project. We have heard that the face shields are much better than those normally supplied to hospital staff.”

The improved solution includes a movable protective shield, which has been designed to improve convenience for the wearer. The entire mask is said to allow for easy decontamination, aided by a 3D printed attachment at the back made of TPU-93A filament to replace where similar masks on the market are employing a piece of elastic material to close at the back.

Tomasz Banasiewicz, Head of the General, Endocrinological and Oncological Surgery Department at the Święcicki Hospital in Poznań, commented:  "Face shields help our employees stay safe every day, which is extremely important in this difficult time for all of us. The face shield design from Omni3D gives us additional comfort of use thanks to the raisable protective shield, and the materials used make it possible to carry out effective disinfection, which is a very valuable solution."

The mask design has been made available for free.

Fast Radius to deliver 10,000 face shields kits per day

Fast Radius has shipped 1,500 face shield kits to healthcare workers and is getting ready to ramp up production to 10,000 a day.

The advanced manufacturing company says it has created an improved design for the face shield to lower production costs and increase sustainability. The 3D printed “halo,” or headband, allows for universal use with any industry-standard PETG/PC shield, and can withstand typical hospital cleaners and disinfectants. Furthermore, the halo itself is reusable which Fast Radius believes can expand the life span of a shield kit by 5 to 10 times, adding that with proper use, this could extend to months.

“The global crisis demands a rapid response by the manufacturing industry, and Fast Radius is working with other companies and medical professionals to answer the call,” said Fast Radius CEO and founder Lou Rassey. “Recent innovations in industrial additive manufacturing have increased our flexibility and response time, and we’re putting those to use for the public good.”

Fast Radius is actively seeking orders for its face shields from healthcare providers and those working in close contact with the public. The company has also is donated 250 face shield kits to Swedish Hospital, close to its headquarters in Chicago.

3D Systems introduces Materials Technology Overview Chart

3D Systems is addressing concerns related to the manufacture of medical devices with non-biocompatible materials by releasing a Material Technology Overview Chart to identify the best printer-material combinations for COVID-19 related components.

The materials chart highlights the best printer-material candidates for which either Class VI and/or ISO 10993 certifications are possible, including potential solutions to applications in emergency situations. Though, 3D Systems cautions that these materials are not Class VI and/or ISO 10993 certified and said customers should conduct their own testing.

The FDA has recently issued several emergency use authorisations for PPE for healthcare providers which is enabling companies to get clearance more quickly. The company, which has a long history in the manufacture of FDA compliant medical devices, says it is working with guidance from the FDA, VA, America Makes & CDC on its COVID-19 relief efforts.

In another update, 3D Systems added that the design files for its Face Shield Frame, released last month, have been downloaded more than 1,000 times. The company also said its On Demand business is currently involved with approximately 50 different COVID-19 related projects include printing face shields, face masks, ventilator components, disposable valves to convert scuba masks to emergency ventilators, and door openers. In one case, the company is said to have designed, manufactured and delivered disposable valves for emergency ventilator masks at an Italian Hospital in just eight hours.

06/04

Materialise develops oxygen mask with 3D printing to support short supply of ventilators  

Materialise has developed a 3D printed connector designed to convert standard hospital equipment into a non-invasive PEEP mask (NIP) that can be connected to oxygen supply to support patients struggling to breath.

The company says the masks will help to reduce the time patients need to spend relying on mechanical ventilators, meaning more people fighting the COVID-19 virus will have access to the equipment.

Materialise’ NIP connector combines a non-invasive mask, a filter and a PEEP valve to create a non-invasive PEEP mask and help to provide positive pressure on the lungs when connected to a supply of oxygen. Broad availability of the printed part is projected to be available by the middle of April, with manufacturing to take place in Materialise’s ISO 13485-certified facilities in Belgium and Michigan, while regulatory registration in Europe and the United States is to be fast tracked. The company is also supporting a clinical triat to test the clinical impact of the device on COVID-19 patients, with first results expected to be available within a fortnight.

“3D printing is playing a crucial role in fighting the global coronavirus pandemic by making it possible to develop innovative solutions and have them available worldwide very quickly,” said Brigitte De Vet, Vice President of Materialise Medical. “At the same time, it is crucial that the medical products we put on the market are safe and effective. Materialise has decades of experience in certified medical 3D printing which allows us to bring 3D printed devices to the market quickly and safely.”

3T delivers 16,000 parts in five days

Update from Prusa

The desktop 3D printer manufacturer says it has now donated 40,000 face shields across Czechia and is urging the community to direct their 3D printing efforts to vulnerable people in care homes and key workers.

Prusa, which was one of the first desktop companies to release design files for PPE to help combat the coronavirus pandemic, says it is now seeking medical certification for the mask and working on an injection moulded variant. 

03/04

Pop-up production line now 3D printing PPE for NHS 

UK-based 3D printing company EduMaker is donating its machines to provide PPE to the NHS.

The company has set up a pop-up production line with over 30 printers donated from its own print capacity and by members of the local community. The line has been setup in collaboration with Cisco, which has loaned its Green Park office in Reading for the 24/7 manufacture of protective face visors for healthcare providers across 19 NHS organisations.

Working alongside RACE, a business unit of the UK Atomic Energy Authority, and Reading University and Oxford Academic Health Science Network, the collaboration has already produced 500 visors and plans to ramp up production to 300+ a day. Cisco says 113 volunteers have been trained over the last week to produce the visors in shifts.

They have also worked with independent Good Manufacturing Practices (GMP) consultants to document and approve the manufacturing procedures and processes so that they can be made open source for other printer users to start making.

So far, 17 local General Practitioners (GP) surgeries are now using the face visors and distributing them to other health service providers in the area.

Update from Protolabs: 3,000 parts 3D printed for ventilator manufacturer 

Essentium producing protective mask for non-medical use

Essentium is entering production of a protective mask kit comprising of a reusable 3D printed mask frame and filtration media for non-medical use.

The Texas-based firm is following up the 30 pilot units it delivered to the Pflugerville Police and Fire Department this week with a run of 500 next week. Essentium is hoping to reach a weekly production capacity of 5,000 masks, which see a single-use replaceable filtration media attach to a reusable frame printed with Essentium’s TPU74D material.

The design of the mask is freely available through the National Institute of Health (NIH) open source model, but is intended for non-medical use - not in the diagnosis or treatment of disease – based on FDA Emergency Use Authorization, when FDA approved masks are unavailable.

Essentium CEO Blake Teipel said: “The concept of a first responder changes overnight for our nation. As well as our medical, police and emergency services, there is now an extended family of first responders, such as grocery store workers, delivery personnel and refuse collectors who have stepped up to keep us safe in our homes. I am humbled by their dedication. While Essentium cannot be a first responder, we can be a second-tier responder. Where the supply chain or PPE is faltering, we can, and we have stepped in.”

02/04

Materialise CEO says 3D printing industry can learn from this crisis

Belgian 3D printing leader Materialise was one of the first companies to develop and distribute novel design files to help prevent the spread of coronavirus. The company's hands-free door opener, which can easily be attached to a door handle to avoid any unnecessary contact, has been printed by a number of companies, not least a leading U.S. healthcare provider, Mayo Clinic. Speaking to TCT in the latest Additive Insight podcast episode, Materialise's founder and CEO Fried Vancraen shared how the file has already received thousands of downloads, and shared how he believes the action being taken by the industry is "a fantastic illustration of the strength of distributed manufacturing and the strength of the 3d printing community."

Further to that, Vancraen said there are also lessons to be learned from this crisis in using AM to tackle future, long-term global challenges.

"I think the positive contribution of the 3D printing industry in this corona crisis will hopefully be an accelerator once the crisis is over, to use it also in the sustainability context because we have this now short-term threat but we have the long-term threat of the climate impact and social disturbance. The way some people are being [...] treated very well by life or treated very poorly in some of the developing countries is something we have to resolve, and that's a long-term crisis that we have to tackle. I think that 3D printing can play a constructive role in this long-term challenge, where sustainability is the answer […] but the corona crisis is the kind of prototyping project, I might call it, for what we need to do in the long-term."

Listen to the podcast in full. 

Nexteer Automotive lends 3D printer capacity to mask and face shield production

Nexteer, a leader provider of intuitive motion control solutions, is leveraging its 3D printing capacity in Tychy, Poland, and Saginaw, Michigan to manufacture medical grade plastic masks and face shields.

The company says it is currently 3D printing 50 face masks and 100 shields a day but is also looking at alternative manufacturing processes including injection moulding to increase output to 1,000.

Engineers in Tychy are producing the shields and working with the Municipal Office to distribute to local medical services. In Saginaw, masks are being printed in two sizes and were reviewed by members of Saginaw’s medical community. As of March 30, more than 150 masks had been given to Michigan Health Improvement Alliance, Inc. to fit with filter material and elastic for ear straps.

“Around the world, our Nexteer team consists of smart, passionate problem solvers, and I’m so proud of how our team members have found creative solutions to help our local communities with much needed medical supplies,” said Robin Milavec, Senior Vice President, Chief Technology Officer & Chief Strategy Officer, Nexteer Automotive. “We will continue to work with local medical and government partners, as well as our suppliers, to provide much needed face masks and shields to help the brave medical teams on the frontlines fighting the COVID-19 pandemic.”

Paragon manufactures thousands of PPE visors for NHS staff

UK-based advanced manufacturing solutions provider Paragon is 3D printing thousands of components for visors for NHS staff in the North East of England.

The company says 5,000 shields have already been provided with another 10-15,000 required by frontline staff, care workers and health workers across the region.

Paragon is a Carbon contract manufacturing partner with access to three Carbon M2 printers and biocompatible resins. The Silicon Valley company began mobilising its network of partners last week to develop designs for face shields and for coronavirus test kit swabs.

Stratasys supporting Paris health care provider

MatterHackers Response Hub delivers 3,500+ 3D printed PPE components

California-based desktop 3D printing specialist MatterHackers is delivering thousands of 3D printed components for PPE through its Maker Response Hub.

The hub, which was set up to assist in the coronavirus crisis, has enlisted 3,500+ volunteers with a total 3D printer capacity of more than 10,000 machines, and features a list of 3D printable models vetted by medical professionals. So far, the initiative has seen 3,500+ PPE components delivered to multiple hospitals across the U.S.

Individuals and print labs can register their machines and start making supplies, while medical facilities and healthcare professionals can register to be supplied with crucial parts. Whenever possible, the Maker Response Hub matches medical requests with local volunteers for safe, contactless curbside delivery.

“This is the perfect demonstration for why 3D printing is so important,” Dave Gaylord, Head of Product at MatterHackers and a former medical device engineer said in a press release. “You can improve on a design and make changes that are implemented immediately - even once production has started - without costly and time-consuming molds. With hundreds of volunteers printing, we simply have to distribute a file and mass production of these important items can begin.”

For those without access to a 3D printer, MatterHackers has partnered with nonprofit ATHENA Rapid Response Innovation Lab to accept donations. The company says one 25 USD donation can produce 10 face shields, from creation to delivery. MatterHackers says it has also been able to connect businesses with their own fleets of desktop printers, including designer lighting company Gantri and architecture firm Bjarke Ingels Group (BIG), with hospitals in need of supplies.

“Making these connections as quickly and efficiently as possible is the entire goal of the Maker Response Hub,” Mara Hitner, Director of Business Development at MatterHackers added. “If we can supply even just one medical professional with life-saving equipment, it will have all been worth it.”

01/04

EOS launches '3D Against Corona' platform

Industrial 3D printing leader EOS has launched an online platform to support 3D printing efforts tackling the coronavirus crisis.

The ‘3D Against Corona’ initiative has been established in the form of a website and LinkedIn group in which EOS is inviting members to share best practices and examples. The company says it is leveraging its global network of suppliers, partners and customers to develop solutions that will help fight further spread of the virus, and through this open platform, will be regularly sharing relevant data, impactful projects, and free files which are available to download and print. So far, the platform provides access to files for Isinnova’s emergency mask for hospital ventilators, hands-free door openers from Materialise and PDR, and face shields provided by EOS North America.

Marie Langer, CEO of EOS, adds: “Improving people’s lives with the help of 3D printing has always been our aspiration. The current pandemic now calls for a joint approach, more than ever before. Today, we are asking all supporters to join us in tackling the challenges that lay ahead of us. Let’s do what our technology is enabling us for: Let’s think differently and push the boundaries of what is possible.”

“We are extremely proud to work alongside so many brilliant minds inside and outside of EOS who are developing and delivering critical solutions for those in need.”

EOS added it is striving to ensure any projects it supports are “effective, lasting and of a quality that is mandatory when human lives have to be saved.” All information and design files shared on the platform will be screened by the company’s engineers first to ensure they meet the high medical standards required.

Rapid Application Group receives orders for 20,000+ 3D printed devices

U.S. additive manufacturing service provider Rapid Application Group says it is working 24/7 to produce PPE gear for local hospitals and first responders.

Last week the company, a Service-Disabled Veteran-Owned Small Business, went into full production for orders of more than 20,000 devices including reusable protective masks using selective laser sintering and 3D Systems Duraform PA material. The mask has been designed to be flexible and features an easy change out filter which can be worn up to six times and sterilised for safe use in hospitals.

According to a post on the company’s LinkedIn page, it has been consulting with local clinics and a non-disclosed large medical company based in Tulsa to refine and test the design before going into full production. RAG added it is working with the FDA on approval.

Beyond PPE, the company says it also plans to expand its 3D printing capabilities to the manufacture of ducts to increase the capacity of ventilators.

31/03

New York doctors unveil 3D printed adaptor to convert BiPAP machines into invasive ventilator systems

New York healthcare provider Northwell Health has found a way to modify and repurpose bi-level positive airway pressure (BiPAP) machines into functional invasive mechanical ventilator with the help of a 3D printed adaptor.

BiPAP machines are non-invasive systems that are deployed to maintain a constant breathing pattern for COPD, congestive heart failure or sleep apnoea patients dealing with symptom flare ups.

With the help of a T-piece adaptor, which has been replicated with 3D printing, and high efficiency particulate air (HEPA) filters at both ends of the oxygen hose, the BiPAP machine can be re-purposed as a pressure controlled ventilator which will be able to support patients with lung disease, whether it has been brought on by COVID-19 or not. The modified machine has been tested with both the original and 3D printed T-piece adaptor, with the protocol designs and 3D print model of the T-piece adaptor set to be shared online.

Northwell Heath is said to have an adequate supply of ventilators for its patients, as well as a good supply of BiPAP machines across its 23 hospitals, but also suggested it could print 150 of the T-Piece adaptors within 24 hours if required.

Superfeet using 3D printing equipment to manufacture PPE mask components

Footwear brand Superfeet and sister company Flowbuilt Manufacturing are working to produce PPE masks with the help of 3D printing technology.

Superfeet mobilised its product development and operations departments within a week to enable the manufacture of masks; 30,000 of which will be distributed to hospitals in the Pacific Northwest.

“We started conversations with local hospitals and healthcare workers last week and discovered a massive need for PPE, as demand has skyrocketed over the past few weeks,” commented John Rauvola, CEO and President of Superfeet. “You can feel the pride our team of employee-owners takes in being able to create something tangible to help combat this pandemic and better protect our community’s first line of defence.”

Evonik donates materials for urgent additive manufacture of medical equipment

Evonik, EOS, 3D Systems and HP are said to be combining their additive manufacturing expertise to support the manufacture of medical components such as masks and ventilator components.

According to a post on Evonik’s website, the specialty chemicals company is donating its polyamide 12 powder material through this partner network for the urgent manufacture of COVID-19 parts.

In an update, 3D Systems says its engineers have created a downloadable 3D file for a face shield frame which can be printed on any SLS machine in autoclavable medical grade nylon. The company added that the file is optimised for high-density manufacturing which means many frames be printed simultaneously within the same build.

Dentists launch 3D Printed COVID19 Parts initiative

A community dentists in the UK are rallying together their 3D printing capabilities in the fight against COVID-19.

The International Digital Dental Academy, which includes over 13,000 dentists and technicians with access to 3D printers, is using its resources to coordinate mass production of essential parts including ventilator splitters, valves, masks and visors to assist the NHS

In a post on the group's Facebook page, Professor Adam Nulty, one of the organisation's co-founders said:

"The Digital Dentistry scene quite possibly has the largest variety and collection of 3D printers outside of engineers. Someone out of the 13,000+ here must know someone who some of us could coordinate with to print the components needed to at least help manufacture. Maybe wishful thinking but if we could speed up the production as required in some capacity working together and with those that need us it would certainly be a great thing to do."

The organisation says it has received several hundred responses so far from individuals and companies wishing to help and has hundreds of printers ready to go. The organisation told TCT it has already successfully supplied visor frames to Lewisham Hospital and Dundee Hospital and is working closely with collaborators to navigate any necessary legal steps.

To support the shipment of parts to frontline works, the IDDA is also hosting a series of fundraising webinars. The sessions are free but donations are welcome to help raise capital towards the purchase of materials, the coordination and production of parts, and shipping to hospitals and medical staff.

Azul 3D leveraging 3D printing to produce 1,000 face shields per 3D printer a day

Chicago-based Azul 3D is producing 1,000 face shields per 3D printer a day with its High Area Rapid Printing (HARP) technology.

Supplying the face shields to local hospitals, Azul is working with a local manufacturer, who is providing the laser-cut clear plastic shields, and another company, who is sanitising and packaging the face shield components into easy-to-assemble kits.

A group of volunteer team members deemed ‘essential workers’ in the State of Illinois are working in six-hour shifts to keep the additive production cycle going round the clock.

“Coronavirus is taking the lives of citizens and healthcare workers in the U.S. and countries around the globe, as hospitals face a shortage of healthcare equipment. We have a technology that allows us to manufacture products quickly, especially in a time of crisis,” said David Walker, CTO and co-founder.

30/03

Ferrovial develops face mask with HP Multi Jet Fusion

Sustainable infrastructure leader Ferrovial is leveraging its 3D printing team to design and print face masks using HP’s Multi Jet Fusion technology.

The company shared images via its Twitter page showing masks including air filters printed in PA12 which are said to be free of surface porosities.

The company says once the masks pass relevant tests from authorities, it will be able to supply 300-400 a day in collaboration with various other companies.

EnvisionTEC teams with healthcare leaders to 3D print ventilation splitters, PPE, and testing swabs

EnvisionTEC founder and CEO Al Siblani says and his team of engineering and applications specialists are working with customers and healthcare leaders to provide solutions for the lack of ventilators, personal protection equipment (PPE), and nasopharyngeal (NP) swabs for coronavirus testing.

The CEO is said to have been collaborating with local hospitals in the Metro Detroit area to provide a functional ventilation splitter which could be 3D printed and used as an emergency solution to allow for multiple patients to receive oxygen from the same ventilator by adjusting the pressure controls.

Elsewhere, EnvisionTEC is helping with the provision of PPE by 3D printing portions of reusable face shields, quickly and in bulk, on its large format stereolithography systems. The company says it also working closely with the Harvard Microbiology Lab within a larger group to combat the shortage of nasopharyngeal collection swabs for testing. EnvisionTEC engineers have designed a collection tip for a flexible nasal swab which was then printed by Brian Nilson of Nilson Laboratories in a batch of 400 on an EnvisionONE cDLM in Class 1 approved material E-Guide in under two hours. The testing process is comprised of a ten stage mechanical testing, a two part absorption test, a biological/chemical testing procedure to ensure the swab absorbs viral RNA particles and does not interfere with PCA/reagents, and a sample collection testing procedure. To pass, a sample needed to use a material that is approved as chemically safe, would bend 180 degrees without breaking, and the design needed to be able to safely collect enough virus particles from the nasal passage to effectively test. E-Guide has already passed some of these tests and is awaiting final IRB testing and approval to determine its suitability for the mass production of the NP swabs for COVID-19 testing.  

Part designs submitted to National Institutes for Health 3D Exchange website to be reviewed

America Makes, the US food and Drug Administration (FDA), the Department of Veterans’ Affairs and the National Institutes of Health are now accepting and reviewing 3D print designs via the NIH 3D Exchange website.

Designs submitted through the America Makes submission form will be fast tracked through the review process as the organisations bid to help address supply shortages in the fight against COVID-19.

“We have seen so much innovation throughout the additive manufacturing industry related to the COVID-19 pandemic. The question we’ve repeatedly been asked is ‘are these products safe and reliable in a health care setting?’ The design portion of the repository seeks to put clarity around that question for both manufacturers and providers,” commented John Wilczynski, Executive Director of America Makes. “We believe it is a critical part to allowing the additive industry to effectively meet the needs of front-line health care workers.”

150+ companies join Stratasys coalition to produce face shields with 3D printing

Last week we reported how Stratasys had produced 5,000 face shields, free of charge, in an effort to confront the COVID-19 pandemic. Now, with a coalition of more than 150 companies and universities including Boeing, Toyota Motor Company, Medtronic, Dunwoody College of Technology and more, the company says it will be able to produce more than 11,000 face shields by next week, and another 16,000 the week after.

This mask is comprised of a 3D printed visor and a clear plastic shield which covers the entire face. In Europe, Stratasys says it is serving as a hub to connect service bureaus with those requesting help and has also posted the face shield printing and assembly instructions online for anyone to produce face shields on their own. In the U.S., Stratasys is using its GrabCAD Shop work order management software to assign orders from healthcare systems to each coalition member. The company is also inviting any 3D print shop wishing to help print at least 100 visors to join the effort.

To date, the coalition is serving the needs of more than 30 different health systems, covering hospitals, clinics, academic medical centers, and nursing homes. So far, Stratasys has received requests for 350,000 face shields.

“I have never seen collaboration across our industry the way I’ve been seeing it over the last couple weeks,” said Stratasys Healthcare Segment Leader, Scott Drikakis. “The need is dire, but we are getting the kind of commitments from our coalition partners that will make a real difference and help buy time to scale up the manufacturing of shields and other essential supplies. This rapid, adaptive response is what 3D printing does exceptionally well, and I’m very proud of our employees and partners.”

SmileDirectClub donates face shields to Canadian children's hospital

SmileDirectClub has donated 250 face shields manufactured with 3D printing to the Hospital for Sick Children in Toronto, Canada.

The company says it is capable of printing, assembling and shipping 7,500 face shields per day and is set to ramp production up further. It is also working on the production of test kit swabs and mask respirators.

“We all have a responsibility to ‘help the helpers’ however possible and never before has the need been greater for equipment that can keep people – especially medical personnel working tirelessly to combat this pandemic – safe and healthy,” commented CEO David Katzman. 

27/03

FATHOM helps source much needed medical supplies for local hospitals

Advanced manufacturing company FATHOM is calling upon its community to help source much-needed medical supplies such as protective equipment and critical ventilator components. Since Sunday, the company says it has already connected multiple hospitals to an LA-based face shield manufacturer, which can reportedly produce up to 5,000 shields a day. Internally, it is also said to be using 3D printing to prototype designs for test-kit swabs, and working to locate PPE gear to deliver to local hospitals. So far, FATHOM says it has been able to track down over 100,000 KN95 masks which are now either with or on their way to hospitals.

Additionally, the company is aiming to tackle the shortage of ventilators by collaborating with academic institutions and laboratories to assist in the manufacture of critical components for various low cost and easier to produce ventilators. Watch FATHOM's call to action below.

CRP 3D prints prototypes for emergency valves

CRP Technology has 3D printed a number of prototypes for emergency valves, and link-components for respiratory masks to assist with the treatment of coronavirus patients.

The company said it was able to produce the parts in-house in under 24 hours using High Speed Sintering and its Windform P1 isotropic material.

"Following the intensification of the emergency due to the lack of fundamental devices for the care of patients affected by Covid-19, we want to give a concrete sign of our support,” Engineer Franco Cevolini, Vice President and Technical Director CRP Technology, commented. “We 3D printed emergency valves for ventilations and several 'Charlotte valves'. 'Charlotte valves' are link-components for emergency ventilator mask, realised by Isinnova on Dr. Renato Favero idea and project, adjusting a snorkelling mask already available on the market (Easybreath mask by Decathlon).”

According to CRP, Isinnova is said to be urgently seeking to patent these valves "to prevent any speculation on the price of the component." Isinnova intends to keep the patent as free to use, so that the valves can be accessed by any hospital that may need them.

CRP has stressed that neither the mask nor the link have been certified, and that usage by the patient is subject to signed acceptance of use.

Fortify to prototype parts intended for injection moulding in response to PPE shortages

Boston-based Fortify is working with partnering organisations to create a 3D printed prototype of a mask that will then be manufactured with injection moulding in response to the PPE shortage.

CEO Josh Martin told TCT:

“What we are trying to do is work with some of the leading efforts that are designing different types of masks and swabs using, primarily, 3D printing and converting those into quick turn injection moulding [parts] using our platform and leveraging our contract manufacturing network so that we can quickly validate a moulded device and then spin that up and slingshot it through to a traditional level of throughout on production.

“I guess I’m not too confident that the 3D printing industry is going to be able to meet the level of demand we’re going to see over the next month by 3D printing alone because you’ve got thousands of printers that aren’t necessarily going to have the same outputs. You’ve got to post-process those [parts] which is very human intensive, and these healthcare professionals are relying quite a bit on this.

“And I think for the system to come through the more traditional manufacturing process, injection moulded out of the medical grade material in a process that’s highly repeatable and much easier to ramp up, that’s what we’re trying to enable in the short term.”

Roboze 3D prints hundreds of valves for artificial respirators

Italian-American 3D printer manufacturer Roboze has produced hundreds of respirator valves for hospitals throughout Italy treating COVID-19 patients.

The parts were printed through the company's 3D Parts division and will be supplied free of charge for use with artificial respirators. The company, known for its beltless 3D printing technology and composite material capabilities, says it has also accepted a number of requests from additional Italian hospitals and from around the world.

With the support of Dallara Automobili, an Italian race car manufacturer, Roboze is also said to be putting its network of Roboze 3D Parts centers to work for the production of hospital C-PAP masks for Sub-intensive therapy. The company says it is doing so in collaboration with Isinnova, the same company behind some of those early 3D printed valves which were delivered to a hospital in Italy last week.

"We could not just stand and watch, the role of audience has never been in the spirit of the society. I am proud to address our resources to support who need them and contribute to help those who today are ready to be on the front and fight this invisible monster: the healthcare professionals and hospitals," Alessio Lorusso, Roboze CEO & Founder said in a statement. "Today more than ever, our technology needs to be at complete disposal to those who are looking for components to face this global emergency. We are available for everyone". 

26/03

Freeman Technology creates PPE visors for local NHS trust

Xometry creates hub for open source CAD designs

Manufacturing service provider Xometry says it's joining the fight against the global COVID-19 pandemic with the creation of an online hub where engineers and medical professionals can access open source files for much needed supplies.

The company has created a repository of 3D CAD files for in-demand items such as face shields, face masks, contactless door-opening hooks, hand gel dispensers, and testing equipment, and plans to update the platform regularly with additional resources.

Xometry, which expanded its instant quote 3D printing services to Europe earlier this year, says it has a network of 4,000 manufacturers including CNC machinists, injection moulders, sheet metal fabricators, and industrial 3D printers, to scale up operations for critical, life-saving projects. 

During this time, Xometry said it will expedite any orders related to fighting COVID-19.

Carfulan Group offers 3D printing and metrology services to plug supply chain disruptions

Away from the manufacture of medical devices, UK-based engineering group Carfulan Group is making all 3D printing and metrology systems at its Derbyshire Advanced Innovation Centre available for manufacturers affected by staff shortages and supply chain disruptions amid the COVID-19 crisis.

The group, which incorporates OGP UK, SYS Systems and VICIVISION UK, says in subcontracting its services, it hopes to “play its part in keeping the wheels of UK manufacturing turning,” particularly as a growing number of service providers are being asked to urgently turn their production capacities over to the manufacture of medical equipment.

Carfulan Group Managing Director Chris Fulton said: “It’s important that everyone does their bit and we hope that we can do ours by sharing the expertise of our highly qualified engineers through subcontracting services, ensuring that those faced with fulfilling orders and satisfying customer demand stand the best chance of doing so.”

BCN3D delivers 400 face shields to Spanish hospitals; 2,000 expected in coming days

Following on from the Barcelona-based 3D printing company’s offer to open up its printer farm in response to the coronavirus crisis, BCN3D has delivered 400 face shields to 11 Spanish hospitals.

The company has been using its desktop FDM technology to print parts for protective visors, which use a transparent acetate screen and a rubber back fixture, and are said to have been validated by the centres for safe re-use. A total of 2,000 face shields are expected to be delivered in the next few days.

Arnau Valls, coordinator of the 3D printing unit at Hospital Sant Joan de Déu de Barcelona, which received 60 face shields, commented: "In the current situation, in which adult or general hospitals are treating the highest volume of patients by COVID-19, our role is to support and collaborate with all our means in the management of the coronavirus crisis, in this case, from the innovation in 3D printing of medical material".

Further updates from Origin

Prior to this post, Origin CEO Chris Prucha wrote: 

"It's critically important that our industry can supply tested, validated, and safe 3D-Printed parts to HCPs. The Origin team is happy to report major developments in one of our PPE programs: our team has improved the design of a new PPE face shield (both for safety, comfort, and manufacturability). We're currently testing production and will begin shipping to HCPs and other partners for further testing in the field this week. Pending results, we will roll these out to our production network partners and make them available to HCPs. In addition to the community, I want to thank our close partners for their critical input and support: Stratasys, Henkel, Stanford University School of Medicine and Verify Life Sciences.

"This is just Phase 1; we have other parts undergoing production feasibility and rapid design iterations, including COVID-19 testing swabs and sterilizable respirator components. More work is to be done, but there is line-of-sight on getting there. Stay tuned, focused, and safe!"

3D Systems offers up on-demand 3D printing service and new Simbionix module for lung ultrasound training

3D Systems is appealing to engineering teams with access to 3D printers to help bridge the gap in the supply chain for medical device manufacturers, hospitals, and healthcare providers requiring crucial devices.

The company is exploring the manufacture of face shields, surgical masks, diagnostic swabs, and ventilator components. Those now famous images of additively manufactured Venturi Ventilator Valves from Italian company Isinnova were in fact printed on the ProX 6100 in Medical Grade Nylon, and 3D Systems’ On Demand is said to be engaging with the company to produce additional components from its On Demand facility in Pinerolo, Italy.

Additionally, 3D Systems has developed a new module for its Simbionix software to deliver training for lung ultrasounds. Lung Ultrasound is considered an alternative to chest radiography or CT scanning in COVID-19 patients. The company believes this safe, low-cost, repeatable, radiation-free solution could be critical for the success of COVID-19 management and is offering the module free of charge to current users of Simbionix simulators, including educational institutions, hospitals and healthcare organisations, to help physicians rapidly acquire the necessary skills. The module is planned for general availability from 30 March.

25/03

Voodoo Manufacturing targeting 2,500 protective face masks a week

Voodoo Manufacturing has mobilised its 5,000 square-foot facility to produce emergency Personal Protective Equipment (PPE) for US frontline health workers.

The company is aiming to produce 2,500 protective face shields per week, with room to scale based on demand. Voodoo will be responding to batch orders of protective face shields through CombatingCovid.com.

CEO Max Friefeld commented: “The world was not prepared for an outbreak of this scale and hospitals have been scrambling to save as many people as they can while rationing PPE for their staff. We want healthcare workers to know that their cries are being heard, and like many of our peers in the 3D printing and technology industry, we’re mobilising our resources to help meet demand faster than traditional supply chains can.”

Nagami Design printing 500 face masks a day

Nagami Design has put its furniture production on-hold to additively manufacture protective face masks with a robotic extrusion platform.

Using design files made available by desktop 3D printing vendor Prusa, which have been verified by the Czech Ministry of Health, and a PETG material with robust chemical resistance, durability and high impact strength, the company has sis printing 500 masks per day. Currently, Nagami Design is focusing efforts on Hospital Provincial de Ávila in the city where it is located but is looking to expand to other affected regions later this week, including Madrid.  

“This is by far the most important project we’ve ever worked on, but also one we wish we’d never had to start. Our generation has knowledge and digital tools that have become truly meaningful. There is no product to sell, no market to compete in. This is a challenge for all of us, and we’d like to encourage everyone with tools of any kind to reach out and contribute to helping bring safety back into our world,” commented Manuel Jimenez García, Miki Jimenez García and Ignacio Viguera Ochoa, the founders of Nagami Design.

Market insight from Context's Chris Connery

Daniel O'Connor: In the midst of this it will be interesting to see how the additive manufacturing industry is affected. 3D printing is generating a lot of column inches for the manufacture of PPE and ventilator equipment, one really hopes that much of it is as useful and game-changing as it appears. But what does the market look like in the long-term? Industry Analyst Chris Connery VP Global Research & Analysis at CONTEXT, had this to say:

"Many of the trends you note in your recent State of the Industry piece for Q3’19 carried over into Q4’19 with negative headwinds associated with a weak global manufacturing sector, weak Automotive markets and weak demand in Europe and Asia continuing in the 4th quarter. This resulted in weak printer shipments in almost all of the four segments (Personal, Design and Industrial with the only Y/Y growth seen in the Professional space thanks mostly to Formlabs).  Forecasting for 2020 is the new, big challenge for many with Supply and Demand both coming into play.  It seems that many/most printer companies have rightly shifted their near-term focus for the businesses (if their factories are even still open or operational) on services, seeing how they can be of assistance in printing much needed medical equipment.  Some have reported strong printer demand in Q1’20 but most of this reporting was prior to various “Stay at Home” mandates. Much of the demand in Q1’20 was being supported from stock shipments from the channel or from existing manufacturer inventories. Western (US and European) factories began to close in March but Chinese factories – many of which were closed in Jan/Feb – are reportedly coming back on line. So, for sure there will be issues with component supplies when factories and businesses do come back on-line.  The demand side of the equation now also comes into play with key end markets like Aerospace, Dental, Consumer Products, Movie and Props, Education, R&D and the like all now significantly impacted by fallout associated with closures needed to stop the spread of the disease."

24/03

HP makes design files available with more printed parts in testing 

HP has made a number of part design files freely available to download and also revealed ventilator and mask applications are in the testing and validation phase.

The company says more than 1,000 parts produced with its Multi Jet Fusion 3D printing technology has already been delivered to hospitals as a result of collaborations with its global manufacturing network, governments and health agencies.

So far, a hands-free door opener, a mask adjustor and face shield have been validated and produced, while field ventilator and FFP3 face mask designs are expected to go into production soon once validation is received. The field ventilator includes 3d printed parts for a mechanical bag valve mask that is used as a short-term emergency ventilation for COVID-19 patients, while the FFP3 face mask is needed for the medical professionals providing treatment.

“HP and our digital manufacturing partners are working non-stop in the battle against this unprecedented virus. We are collaborating across borders and industries to identify the parts most in need, validate the designs, and begin 3D printing them,” said Enrique Lores, President and CEO, HP Inc.

Hubs launches COVID-19 manufacturing fund

The 3D printing platform, which currently has a network of 2,300+ machines, has launched two initiatives; one for engineers to get funding and resources to produce COVID-19 related parts, and another for those who wish to donate funds to make these parts a reality. 

Hubs said it will also be donating all profits from COVID-19 related projects back into this fund.

Sintratec joins companies 3D printing Materialise's hands-free door opener

Low-cost selective laser sintering machine manufacturer Sintratec is one of the latest companies to 3D print Materialise's hands-free door opener designed to stop the spread of coronavirus.

The part was produced using the company's Sintratec 2 system and put to use at its office in Switzerland.

The design file can be downloaded for free or printed to order via Sintratec. 

Statement from America Makes

"As the National Additive Manufacturing Innovation Institute, America Makes’ mission is to drive collaboration in our industry to meet the needs of the US government and manufacturing base. This mission couldn’t be more clear and apparent than it is today with the ongoing COVID-19 crisis and pending supply chain shortages throughout the US.

We are actively working on creating a central repository of partners that are ready and willing to assist in this time of crisis. We are collecting their capabilities and capacities so the needs on the front lines can be met effectively and with safe, quality products. We are proud of the incredible innovation that we have seen throughout the industry and will have more information shortly about how to ensure that innovation is meeting the direct needs of America’s health care workers."

https://www.americamakes.us/statement-on-covid-19/

Ford to 3D print at least 1,000 disposable respirators per month

Motor company Ford is leveraging its Advanced Manufacturing Center in Redford, MI to additively manufacture disposable respirators which help to filter the air healthcare workers and first responders breathe.

Ford will initially work to manufacture 1,000 of the respirators per month, once approached by a proper health agency, but intends to ramp up production as quickly as possible. Partnerships with 3M, to manufacture Powered Air-Purifying Respirators (PAPRs), GE Healthcare, to expand production of GE’s existing ventilator design to support patients with respiratory failure or breathing difficulties, and UAW, to assemble more than 100,000 plastic face shields a week, have also been announced.

“This is such a critical time for America and the world. It is a time for action and cooperation. By coming together across multiple industries, we can make a real difference for people in need and for those on the front lines of this crisis,” said Bill Ford, Ford’s executive chairman.

Farsoon makes mask adjustor and safety goggles design files available

Farsoon has made the design files of the facial mask adjustors and safety goggles it helped to additively manufacture in China available to those with SLS, SLA and FDM 3D printing capacity.

The 3D printing vendor has worked closely with some of its industrial partners to fight the COVID-19 outbreak in China and, as the virus continues to spread around the world, is hoping to contribute again.

Working with PEAK Sports, the facial mask adjustor is designed to prevent stress caused by wearing protective facial masks for extended periods of time. The four pairs of hooks at each end of the parts can be adjusted, while the centre of the adjustor strap is textured to improve contact with the isolation suit. Farsoon’s 403P Series was able to produce 1,000 straps per build, with its FS3300PA material enabling the part to be disinfected under high heat and pressure. The design is said to be printable on SLS, SLA and FDM technologies.

The medical safety goggle, meanwhile, was designed and produced by Huaxiang Group in the thousands with testing completed in 10 days. Like PEAK Sports, Huaxing harnessed the 403P Series, printing goggle frames with the FS3300PA material and sealing rings wuth Lehvoss’ TPU material. With an optimised design, the company was able to lightweight the goggles, with users also praising the comfort of the products. The design is available in two sizes and can be printed in SLS, SLA and FDM, with the protective lens outline also included for ease of production.

Design files can be accessed via this link.

Origin champions collaboration as parts sent for testing

Ultimaker to connect 3D printing hubs with hospitals facing tool and part shortages

Desktop 3D printing leader Ultimaker has launched an initiative which aims to make its global network of printers, experts, and designers, available to hospitals in need of tools and parts amid the COVID-19 pandemic.

Through its website, Ultimaker has introduced a "Connect and Print" map which allows hospitals facing acute shortages of critical parts with approved 3D print designs and material specifications to send their requests to local providers. 

In addition, the company has launched a "Design, Check, and Print" service to support hospitals with the design and creation of tools that run out or are in limited supply. Parts will be printed by the nearest 3D print hub and sent to the hospital as soon as possible. After testing and receiving approval of the hospital, the part is available for further 3D printed production.  

Siert Wijnia, Co-founder of Ultimaker, said: "Hospital equipment parts might break or hospitals may run out of particular tools, for example. We are proud to see the 3D printing community come together to immediately print approved designs of objects that hospitals need right now. We hope these initiatives will help all hospitals understand where 3D printers, knowledge, and materials are available, so hospital staff can focus on what matters most: saving lives."

Formlabs to deploy 1,000 3D printers to produce COVID-19 test swabs

Desktop stereolithography leader Formlabs is said to be working with its volunteer network to supply hospitals with 3D printed COVID-19 test swabs. 

According to a post on the company's Twitter account, Formlabs is said to be mobilising its community of users to deploy nearly 1,000 printers to quickly mass-produce swabs and other personal protective equipment (PPE) such as face shields and respiratory masks. Formlabs says its desktop systems are capable of producing 300 test swabs in a single print, allowing for a total of around 75,000-150,000 swabs per day. This development aims to rapidly provide hospitals with access to large quantities of essential COVID-19 test kit components.

The Formlabs team is said to be working with three leading U.S. hospitals, as well as Boston-based medical professor Dr. Ramy Arnaout on the swab design. The company plans to print these swabs in-house and share the design files with its community as well as other health systems across the U.S. 

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SmileDirectClub invites medical companies into 3D printing facility

Clear aligner manufacturer SmileDirectClub has opened the doors of its 3D printing facility to medical supply companies and healthcare organisations to help combat COVID-19.

Working with these partners, the company hopes to assist in the production of additional medical face shields, respirator valves and other medical equipment. SmileDirectClub has a global HIPAA-trained contact centre team and is encouraging medical companies to contact them via resilience@smiledirectclub.com if interested in the offer.

“In times like these, it is incumbent on all of us to do what we can to help those in need however we can,” commented CEO David Katzman. “Reports of medical supply shortages are very concerning and we have the production capacity to help in the printing of plastic materials. Due to recent automations that increased our printing output capacity, we're able to easily add this production to our current clear aligner therapy lines.

“We urge any company or health organisation that could use additional production resources to reach out to us directly.”

Lithoz cancels Innovation Lab opening event

Lithoz has today decided to cancel the opening ceremony of the Lithoz Innovation Lab (LIL) originally scheduled for May 14^th.

It comes amid movement restrictions put in place to slow the spread of COVID-19.

The facility has been designed to enable collaboration between it’s in-house experts and users of its ceramic additive manufacturing technology, while also host training initiatives.

Lithoz says it hopes to host the event at another point in time and that customers will continue to receive suppliers and all machine deliveries will be carried out on time.

Stratasys to manufacture 5,000 full face shields by end of this week

Stratasys is donating its global 3D printing sources to provide thousands of disposable face shields for use by medical personnel.

In the U.S., the company has set itself a target of producing 5,000 face shields by Friday, at no cost to the recipients. This includes both a 3D-printed frame and a clear plastic shield that covers the entire face.

Stratasys said medical technology company Medtronic and Minneapolis-based Dunwoody College of Technology will provide support for the plastic shield material.

"We are humbled by the opportunity to help. We see additive manufacturing as an essential part of the response to the COVID-19 global epidemic," said Stratasys CEO Yoav Zeif. "The strengths of 3D printing - be anywhere, print virtually anything, adapt on the fly - make it a capability for helping address shortages of parts related to shields, masks, and ventilators, among other things. Our workforce and partners are prepared to work around the clock to meet the need for 3D printers, materials, including biocompatible materials, and 3D-printed parts."

Stratasys has set up a page where organisations can request 3D printed products to help with the crisis, offer 3D printing capacity, or request 3D printers or material for medical- or safety-related purposes. 

Stratasys also plans to support the CoVent-19 Challenge led by anaesthesiology residents of Massachusetts General Hospital, which is inviting engineers and designers to help develop a new rapidly deployable ventilator and other innovative solutions to the ventilator shortage. 

Report: How 3D printing companies are responding to the coronavirus crisis

Over in the U.S., Silicon Valley 3D manufacturing company Carbon says it is on hand with its network of contract manufacturing partners using its Digital Light Synthesis technology to print polymeric parts, and believes AM can help overcome the challenges of traditional supply chains, particularly in the face of shut-downs and global transportation disruptions. So far, the company has been developing designs for face shields and swabs for coronavirus test kits. Dr. Joseph DeSimone, Carbon's Co-Founder and Chairman of the Board, cited Carbon’s cloud capabilities and engineering-grade materials as valuable assets in tackling the crisis and urged companies, governments, and others to reach out.

He told TCT: “Adaptable and diversified global supply chains are essential now and into the future as we confront major disruptions caused by pandemics or other significant events like earthquakes or hurricanes. For example, Carbon printers are all connected to the cloud, so when such a disruption occurs, even if one facility goes down, digital designs for parts can easily be shifted to and manufactured at another facility as needed. We are encouraged that manufacturing facilities that house Carbon printers, including facilities in Asia that were recently suffering some of the worst effects of the COVID-19 pandemic, are back up and running.”

Full story here.

Materialise releases free 3D print file for hands-free door opener

Materialise has designed a 3D printed hands-free door opener that makes it possible to open and close doors with your arm.

The 3D printed door opener can be attached to existing door handles without drilling any holes and features a paddle-shaped extension which allows people to open and close doors without using their hands, particularly valuable in environments where does must remain shut for safety reasons.

The first model can be attached to cylindrical handles but Materialise plans to introduce additional designs using different 3D printing technologies.

Anyone with access to a 3D printer can download the design for free and 3D print it locally in a matter of hours or order via the the i.materialise portal.https://www.materialise.com/en/hands-free-door-opener

"The power of 3D printing in combination with Materialise's three decades of 3D printing expertise made it possible to turn an idea into an innovative product in less than 24 hours," says Fried Vancraen CEO of Materialise. "By making the design available digitally, it can be produced on 3D printers everywhere and become available around the world in a matter of hours. In this case, we designed the product in Belgium and people in China, Europe or the U.S. can now 3D print the door opener locally."