Danit Peleg wins purmundus challenge 2017

The purmundus challenge 3D printing design award was presented for the fifth time in Frankfurt as part of the formnext powered by tct exhibition. The purmundus challenge has been rewarding innovative products and projects that break new ground in the field of 3D printing since 2012.

The possibilities of additive production are more varied than they have ever been during the last three decades. There are a wide range of material properties available as well as methods for building up the layers. And, last but not least, it is possible to combine additive and conventional technologies. Only the right selection and combina-tion allow a well-thought-out design to develop its full potential and particular charm.

So why not use an intelligent combination to take advantage of the multi-faceted design possibilities of additive manufacturing?

45 finalists from around the world presented their outstanding designs on the theme of “Fusion – 3D printing intelligently combined” from 14 to 17 November 2017 at the formnext exhibition. The international panel bestowed awards with a total value of 12,000 euros to six win-ners at the award show in Frankfurt. This was the first year in which an “Innovation Prize” was also presented for groundbreaking “visions” – projects that show how 3D printing will continue to change the world of product manufacturing.

This year’s winners are:

1st prize: The Birth of Venus
Danit Peleg 3D I Danit Peleg

2nd prize: FLUID MORPHOLOGY
TU München, Professur für Entwerfen und Gebäudehülle
Moritz Mungenast I Oliver Tessin I Viktoria Blum I Tobias Gutheil I Olga Khuraskina I Luc Morroni

3rd prize: Grasshopper AFO
Mecuris GmbH I Manuel Opitz I Clemens Rieth I Benjamin Els

Special Mention: Dynamic Algae
Dorothea Lang

Innovation Prize: InFoam Printing
Dorothee Clasen I Sascha Praet I Adam Pajonk

Public Choice Award: Ultimate grip
Go3D Ltd I Antti Korpi

1st prize: The Birth of Venus
Danit Peleg 3D I Danit Peleg

This 2017 collection was inspired by the dress that Danit had designed for the Paralympic Opening Ceremony. The collection has 5 looks and is printed using FilaFlex filaments. One of the collection’s garments, the ready-to-wear bomber jacket, is the first fully customizable and personalized 3D printed garment available to purchase online. Printing this collection was 3X faster than Danit’s first collection
thanks to advancement in printing technology.

2nd prize: FLUID MORPHOLOGY
TU München, Professur für Entwerfen und Gebäudehülle I Moritz Mungenast I Oliver Tessin I Viktoria Blum I Tobias Gutheil I Olga Khuraskina I Luc Morroni

3D printed translucent and multifunctional building envelopes

The project was initiated and implemented under the direction of Moritz Mungenast, research assistant at the Chair of Design and Building Envelopes at the Technical University of Munich.

FLUID MORPHOLOGY is the first translucent and multifunctional facade element to be entirely 3D printed. This research project demonstrates the existing potential of 3D printing for the construction sector and building envelopes, as such closing the digital chain – from digital design through digital planning to digital production.
Another innovation is the “functional integration” into one component made from one material – i.e. integration of the following facade functions into FLUID MORPHOLOGY: load transfer, insulation, shading, daylight utilisation, ventilation and sound scattering.

In addition to finding new ways to solve the future global challenges in the construction industry, such as new building materials and energy saving, FLUID MORPHOLOGY’s goal is to reduce building technology, establish a closed material cycle and simplify the construction process by making good use of digital tools.

Other participants: Project Assistant Oliver Tessin and TU masters students Viktoria Blum, Olga Khuraskina, Luc Morroni and Tobias Gutheil. The Chair for Design and Building Envelopes is a member of the Research Lab of the Faculty of Architecture and the TUM group Additive Manufacturing in Construction. Supported by: Rodeca, Picco’s 3D World, Delta Tower.

3rd prize: Grasshopper AFO
Mecuris GmbH I Manuel Opitz I Clemens Rieth I Benjamin Els

An AFO is an externally applied orthotic device which assists patients in regaining a normal walking gait when suffering from drop foot, a condition caused by stroke, cerebral palsy, polio, multiple sclerosis etc. due to muscle weakness in the lower leg. AFO’s account for 26 % of all orthotic devices, making it the most commonly prescribed orthosis.

At present, the most common AFO’s available on the market are custom manufactured thermoplastic AFO’s and prefabricated carbon fiber AFO’s. Thermoplastic AFO’s mimic the anatomy of each individual patient, ensuring a comfortable fit. However, manufacturing of these AFO’s are a lengthy process which takes a minimum of three weeks per AFO. Carbon fiber AFO’s provide superior material qualities such as strength and energy return. These AFO’s are mass produced and are not tailored specifically for each patient.

The grasshopper AFO aims to combine the patient specific qualities of thermoplastic AFO’s with the superior material qualities of carbon fiber. This is achieved through utilizing technologies such as 3D scanning, computer aided design (CAD) and additive manufacturing (3D printing). Carbon fiber is applied to the device in the form of a tape which is fused to the AFO with a hand held tool. At present, the entire process from 3D data capturing to delivering an AFO to the patient takes 10 working days.

Through software automation and the versatility that 3D printing pro-vides, it will be possible to manufacture Grasshopper AFO’s over a shorter time period. A 3D scan of the patient‘s leg will be uploaded to an online platform along with certain technical parameters. This in-formation will then be used to automatically generate an AFO specific to each patient’s needs. This is particularly important in young children who grow at a rapid rate. The customizability of the AFO’s mean that they can also be used on patients with severe deformities. Applying carbon fiber with a handheld device allows orthopedic technicians and clinicians to further customize the AFO’s, adding extra support where needed.

Special mention: Dynamic Algae
Dorothea Lang

In this project, research was conducted on the production of biobased printing material for additive manufacturing from the renewable material algae. Algae are abundant on our planet and have many beneficial properties. They produce oxygen and consume carbon dioxide. A gel-like material was created from a special substance extracted from macro-algae and used as printing material for the 3D printer. The algae-based material has the smart property of reacting to moisture, thus embodying the notion of “4D printing” and “self-assembly” as Skylar Tibbits interprets it, developing systems that change with time and temperature. The movement of the material was shown and the principle clarified in several models with different mechanisms.

Innovation Prize: InFoam Printing
Dorothee Clasen I Sascha Praet I Adam Pajonk

InFoam Printing is a novel technology for manufacturing “smart” foam. Via robotic arm a two-component resin is injected into the foam to built rigid structures. The resin cures within the foam’s cellsstructure to built up complex structures. Depending on the resins compositions this structures can be flexible like rubber, be medium hard or hard as plexiglas. It’s a novel 3D printing technology for flex foam.

The manufacturing process of foam elements is considerably simpli-fied by InFoam printing. Further more it allows free-floating solids to be formed within the foam. Beside that, the technology also opens up completely new possibilities in product design: As the degree of hard-ness within the foam element can be graduall and becomes individu-alizable. Due to the integrated geometries they can also gain totally new abilities and kinetic features: a foam cube, for example, can be programmed with a torsional movement, which can be used for ergo-nomic purposes in upholstery or in ortophilic protectores. Another example would be the integration of a spring-like structure in a foam mattress, a product abilitie that could revolutionize this market.

As foam is used in many products, InFoam Printing offers various applications: mattresses, upholstery, orthopedic shoe sole or car seats. Our first prototype for example, a car seat, contains structures which counteract forces and provide a special grip to the user. Another application would be a mattresses,that can be optimised and be adjusted for each person individually. People soon can have their own mattress manufactured based on 3D body-scans in a way that pressure areas are adjusted to body measurements and sleeping behaviour. Room acoustics and noise reduction also are application areas for InFoam Printing. The injected structures inside the foam cause the sound waves to break and therefore can be absorbed easier.

The initial idea for InFoam Printing was developed on an interdiscipli-nary, 5-day student workshop, organized by Covestro and held at the FH Münster.

Public Choice Award: Ultimate grip
Go3D Ltd I Antti Korpi

Personalized handle for knife!

The product Ultimate grip is a combination of handle made with use of latest technologies and a blade produced with techniques that have been in use for the last century. Design and product development was based on following guidelines:

• Supportless design
• Parts printed directly on a build plate
• Part removal by sawing
• Minimal need for post processing
• Possibility for stacking and optimal print orientation. Full chamber process
• Assembly mechanically without special tools, glues, rivets etc.
• Topology optimization

3D KNIFE is registered trade mark and is known of the following features:

1. Personalized handle. The handle is made by the reference of user´s individual hand print.
a. Enhances grip, safety and ergonomics
b. The sample can be given at desired orientation
c. Designs surrounding individual´s hand print can be designed for task

2. Hollow and thin wall structures. Net shape design.
a. Light weight
b. Unique design
c. Minimal drag (underwater use)
d. Net shape design enhances grip
e. Less material – less energy needed to warm up handle

Net shaped thin wall structure can contain as much as 90% less ma-terial compared to same handle made in solid structure. Wall thick-ness on 3D KNIFE handles made with metal 3D printing vary from 0,4 mm to 0,6 mm. Knife handle made with aluminium weights only 25g!

Good ergonomics, safety and unique design is definitely interesting customers – both end-users and companies using knifes at profes-sional use.

Next year’s edition of formnext is scheduled to take place on 13-16 November 2018 in Frankfurt am Main. The 2018 purmundus challenge award ceremony will take place on 15 November 2018.

More information at purmundus-challenge.com and formnext.de

About purmundus challenge
Since 2012 the purmundus label is inviting designers, engineers and programmers to ex-plore new paths in additive manufacturing by taking part in the ‘purmundus challenge’. The international competition adresses itself to students and design studios that like to meet the challenge of 3D printing. Almost every kind of submission is possible – from a simple concept to a market ready product. Every year the finalists are displayed on a spe-cialized fair where a selected international jury evaluates the submissions. Following this the winners will be rewarded within a festive setting.

About cirp GmbH
purmundus challenge is a trademark of cirp GmbH. Since 1994 the cirp GmbH produces prototypes and small series in polymers with additive manufacturing such as stereo-lithography, laser sintering or polyjet. The cirp GmbH works for many industries with a particular focus on the automotive industry. As a partner in collaborative research projects, the cirp GmbH is also involved to shift and expand the possibilities and limitations of additive manufacturing continuously.

About formnext
formnext powered by tct is the leading trade fair for additive manufacturing and the next generation of intelligent manufacturing solutions. It focuses on the efficient realization of parts and products, from their design to serial production. The conference set to take place alongside the exhibition will also highlight the latest trends and issues in additive manufacturing, along with clever ways in which it can be integrated into process chains in industrial production. The conference’s content is designed by Rapidnews/tct. formnext powered by tct is organized by Mesago Messe Frankfurt GmbH.