Surpassing its own 2019 Guinness World Record for the largest polymer 3D printer, the University of Maine in the US unveiled a next-generation printer that is four times larger than its predecessor to catalyse the future of sustainable manufacturing in a number of industries. Source: Timberbiz
The new printer, dubbed Factory of the Future 1.0 (FoF 1.0), was unveiled at the Advanced Structures and Composites Centre (ASCC). The thermoplastic polymer printer is designed to print objects as large as 96 feet long by 32 feet wide by 18 feet high, and can print up to 500 pounds per hour.
It offers new opportunities for eco-friendly and cost-effective manufacturing for numerous industries, including affordable housing, bridge construction, ocean and wind energy technologies and maritime vessel fabrication.
The design and fabrication of this world-first printer and hybrid manufacturing system was made possible with support from the Office of the Secretary of Defense through the US Army Corps of Engineers.
FoF 1.0 isn’t merely a large-scale printer; it dynamically switches between various processes such as large-scale additive manufacturing, subtractive manufacturing, continuous tape layup and robotic arm operations.
Access to it and MasterPrint, the ASCC’s first world-record-breaking 3D printer, will streamline manufacturing innovation research at the centre. The two large printers can collaborate by sharing the same end-effectors or by working on the same part.
The one-of-a-kind printer will advance various initiatives, including the development of biobased feedstocks from wood residuals abundant in Maine. This technology will advance commercialization efforts such as BioHome3D and the creation of sustainable, affordable housing.
The FoF 1.0 unveiling comes ahead of a planned ground-breaking new 47,000-square-foot research laboratory called the Green Engineering and Materials (GEM) Factory of the Future. Scheduled for an August, the facility is positioned to enhance manufacturing innovation across multiple sectors. Its primary aim is to facilitate and scale up more sustainable manufacturing practices by introducing next-generation solutions and biomaterials, addressing challenges such as a diminishing workforce and strained supply chains with local solutions.
“Maine needs an estimated 80,000 additional homes by 2030, many specifically for households with incomes at or below the area median income. This new technology allows UMaine-ASCC to scale-up its research and production of its innovative biobased 3D printed home technology,” said Maine Housing’s Development Director Mark Wiesendanger.
“This effort creates another means of producing quality affordable housing, while further driving costs down, and using abundant wood residuals from Maine’s sawmills. We look forward to continuing our collaboration with Dr Dagher, the staff and students at UMaine/ASCC in demonstrating how 3D printed homes and other next-generation housing technologies will quickly and effi iently contribute to enhancing Maine’s housing stock.”
The research facility will not only scale up advanced manufacturing processes, but also explore innovative materials systems by prioritizing recycled and biobased materials. Maine, the most forested state in the nation, annually produces more than one million tons of wood residuals in its sawmills, which can be used as feedstock for 3D printing. In addition, UMaine, with the GEM initiative, has prioritized manufacturing workforce development by offering experiential learning and entrepreneurial training programs aimed at nurturing the next generation of leaders.
