Dynamic Molding: 3Deus Dynamics Develops Hybrid 3D Printing Process – Interview with CEO Julien Barthès

Founded in October 2020, 3Deus Dynamics is an innovative French startup that has developed the “Dynamic Molding” process, a hybrid of 3D printing and injection molding taking place in a granular environment. This method enables the use of any injectable material without modification, eliminating the need for support structures and allowing limitless shapes. Initially, the company focused on silicone materials and the development of high-tech silicone composites, serving industries like personalised medicine, aerospace, space and defence and energy. In an interview with 3Druck.com CEO and co-founder Julien Barthès shares his insight into the Additive Manufacturing industry.

Dynamic Molding is a new approach in additive manufacturing through material deposition. This innovative process distinguishes itself from conventional additive manufacturing methods by eliminating the constraints of gravity, allowing for unrestricted size and design, without the need for costly chemical reformulation or secondary structures that generate waste. The printing occurs within a controlled granular environment (powder), behaving like a dynamic mold in which the manufacturing materials (inks) are distributed. The granular medium supports the material during printing and self-repairs after each movement of the print head. The granular medium is 100% reusable and derived from recycled products.

This process allows for 3D printing with all existing viscoelastic manufacturing materials, including thermoplastics, elastomers, thermoplastic-elastomer composites and ceramics without any limitation on the material’s initial properties, be they rheological, mechanical, kinetic or related to solidification/curing mechanisms. This innovation also paves the way for unlimited freedom in 3D design complexity.

Moreover, by incorporating specific non-sacrificial powders in the production process, it is possible to create soft silicone composites with unique functional properties such as flame resistance, conductivity, electromagnetic shielding, or mechanical reinforcement.

Diverse fields of application

Possible applications are manifold, extending across a variety of sectors including personalised medicine, space and defence, aerospace or energy.

Within the medical field Dynamic Molding enables the development of patient specific surgical models to simulate and practice ahead of complex surgeries as well as design iteration of medical devices. Other possible areas of application are the production of silicone thermal protections seals withstanding temperatures of up to 1200 °C without flame propagation; silicone seals for electromagnetic shielding or with conductive properties; as well as the development of innovative silicone composites.

Interview with CEO Julien Barthès

In an interview with 3Druck.com, CEO and co-founder Julien Barthès shares his insight into the industry and outlines the areas in which he believes the strengths of additive manufacturing technology lie.

In your opinion, what significance does additive manufacturing have for the medical industry?

Additive manufacturing, particularly with innovative approaches like Dynamic Molding, holds significant implications for the medical industry. One key aspect lies in the creation of patient-specific solutions, leveraging imaging data to fabricate implants that precisely conform to an individual’s anatomy. This tailored approach enhances the effectiveness of medical interventions and fosters personalised care, marking a paradigm shift in the way healthcare is delivered.

The iterative design capabilities facilitated by Dynamic Molding play a crucial role in the development of medical devices across various classes. This allows for rapid exploration and iteration of designs without the need for extensive reformulation, reducing both time to market and associated costs. For practitioners, this means a better preoperative understanding through ultra-realistic replicas of pathological organs, enabling them to simulate and train for complex surgeries in advance, ultimately reducing complications during procedures.

In terms of supply chain dynamics, the utilisation of additive manufacturing, especially with a focus on patient-specific solutions, leads to a reduction in stock requirements. This not only streamlines the supply chain but also has a positive impact on the environment by minimising material waste. Furthermore, the reduction of stocks and streamlined production processes contribute to a more sustainable approach in medical manufacturing, aligning with the growing emphasis on eco-friendly practices.

Moreover, in the field of aeronautics, aerospace and defense sector, Dynamic Molding contributes to the creation of specialised composites, such as silicone thermal protection seals. These seals can withstand extreme temperatures and exhibit properties like flame resistance, addressing critical needs in these sectors. Additionally, the fabrication of silicone seals for electromagnetic shielding or with conductive properties opens avenues for advanced technologies in specialty industries, ensuring flexibility, high performance, and compliance with stringent standards, including those in the military sector.

Additive manufacturing has continuously developed in recent years. Which innovations or technological breakthroughs do you consider to be particularly important for the industry?

Additive manufacturing has experienced continuous development in recent years, with several key innovations and technological breakthroughs shaping the industry. Two particularly noteworthy advancements are the development of innovative materials, such as silicone and ceramics, and the industrialisation focus on metals with versatile applications across multiple markets.

The introduction of innovative materials like silicone and ceramics has expanded the capabilities of additive manufacturing. Silicone, known for its flexibility and versatility, has found applications in various sectors, including healthcare for patient-specific solutions and advanced seals. Ceramics, on the other hand, offer unique properties suitable for applications in electronics, aerospace, and medical devices. The ability to 3D print with these materials opens up new possibilities for creating complex and customised components with enhanced functionalities.

Another critical advancement involves the industrialisation focus on metals within additive manufacturing. Metal 3D printing has gained prominence due to its potential to produce high-strength and durable components with intricate geometries. This breakthrough is particularly relevant across diverse industries, including aerospace, automotive, and healthcare. The capability to print metal components allows for the creation of complex structures, improved performance, and lightweight designs, contributing to more efficient and optimised end-products.

In addition to materials, innovations in multi-market applications of additive manufacturing have played a pivotal role. The industrialisation of 3D printing processes for metals has facilitated the production of metal components at scale, making them applicable across various industries. This versatility is key in addressing diverse market needs, ranging from automotive parts and aerospace components to medical implants.

First Corona and the now high inflation pose major challenges for the entire industry. In your opinion, how do the multiple crises affect the additive manufacturing industry?

The combination of the COVID-19 pandemic and the current high inflation rates poses significant challenges for the additive manufacturing industry. However, amidst these crises, there are notable ways in which the additive manufacturing sector is both adapting and showcasing its resilience.

Firstly, the disruptions caused by the pandemic have accelerated developments in the 3D printing sector. The need for rapid prototyping and manufacturing solutions became even more apparent during the pandemic, as traditional supply chains faced disruptions. Additive manufacturing, with its ability to provide quick and flexible production capabilities, became a crucial tool in responding to urgent demands for medical equipment, components, and prototypes. This spotlight on the versatility and agility of 3D printing has heightened its importance in the industry.

The challenges posed by the pandemic and inflation have also underscored the importance of rethinking production strategies. There is an increased emphasis on relocalising production to ensure a more resilient and responsive supply chain. Additive manufacturing plays a pivotal role in this trend, offering the possibility of shorter and more reactive manufacturing circuits. By reducing dependence on global supply chains, companies can mitigate risks associated with external disruptions and fluctuations in inflation rates.

Furthermore, the crises have stimulated the development of more efficient means of production within the additive manufacturing sector. Companies are investing in research and innovation to enhance the speed, scalability, and cost-effectiveness of 3D printing technologies. This drive for efficiency not only addresses immediate challenges but also positions the industry for long-term growth and sustainability.

What impact do you think additive manufacturing will have on various industries and possibly society as a whole in the coming years?

Additive manufacturing is poised to have a transformative impact on various industries and society as a whole in the coming years. The shift from a standardised society to one tailored to individual needs is one of the most profound changes anticipated. This transition is particularly notable in fields such as healthcare, where patient-specific solutions, enabled by additive manufacturing technologies like Dynamic Molding, are revolutionising treatment approaches.

In the aerospace industry, the impact of additive manufacturing is already evident in the optimisation of designs. This innovation allows for the creation of components with identical or even enhanced performance compared to traditional counterparts but with significantly reduced weight. Lighter aircraft components contribute to lower fuel consumption, subsequently reducing the industry’s overall carbon footprint and environmental impact. As a result, additive manufacturing not only enhances efficiency but aligns with global efforts towards sustainability.

The impact on the supply chain is another critical aspect. Additive manufacturing introduces a paradigm shift in manufacturing processes, allowing for more localized and on-demand production. This, in turn, reduces the reliance on large inventories and extensive warehouses, leading to a streamlined and more responsive supply chain. The implications are far-reaching, with potential benefits ranging from cost savings to increased flexibility in meeting dynamic market demands.

Additionally, the customisation capabilities of additive manufacturing technologies contribute to a more sustainable approach. By producing goods tailored to specific needs, there is a reduction in material waste and energy consumption. This aligns with the broader societal shift towards environmentally conscious practices, making additive manufacturing an integral part of a more sustainable and eco-friendly future.

You can find out more about 3Deus Dynamics and the Dynamic Molding process here.