SEAM Research Center uses Epic3D for large-format 3D printing in the construction industry

In the new SEAM Research Center, researchers are concentrating on fully exploiting the potential of Screw Extrusion Additive Manufacturing (SEAM). A central component of the center is the Epic3D portal printer, which enables the production of plastic components in XXL format. The continuous deposition process and the integration of stiffening structures create resilient components, which facilitates the use of the technology for individually designed façade elements and other weather-resistant products in the construction sector.

The collaboration with Wirth & Co. GmbH and Fraunhofer IWU opens up new possibilities in the field of additive manufacturing. The potential of the SEAM process is particularly evident in façade construction, fences and gates. Traditional manufacturing methods often reach their limits with large-volume components, whether due to high tool costs or long lead times. The SEAM process overcomes these hurdles by working without tools and with commercially available plastic granules, which both reduces production costs and increases design flexibility.

Dr. Martin Kausch, Head of the Sustainable Fibre-Plastic Composites department at Fraunhofer IWU, emphasizes: “We make sophisticated design affordable. The very personal touch in façade design can of course also be implemented in the manufactory. But it is only affordable with manufacturing processes such as SEAM.”

The Epic3D system, together with the METROM P1410 and SEAMHex systems, offers high movement flexibility and precision. The hexapod of the SEAMHex system enables fast and accurate positioning, which is particularly advantageous for medium-sized components. This technology allows the production of complex and thin-walled structures that would be difficult to realize with traditional methods.

Florian Stöckel, Managing Director of Wirth & Co. GmbH, adds: “3D printing using the SEAM process opens up completely new design possibilities in façade construction. Together with the Fraunhofer IWU, we are working on optimizing design, materials and the 3D printing process for applications in the construction industry. By investing in the Epic3D gantry system, we are entering the additive manufacturing of elements for the construction industry.”

The SEAM team will be presenting its latest research results at Formnext 2024 in Frankfurt am Main. Visitors can gain insights into the advanced manufacturing techniques and performance of the SEAM process at booths E38 and C29 (Metrom).

By combining innovative technology and practical application, the SEAM Research Center is setting new standards in large-format 3D printing and contributing to the further development of the construction industry. The solutions developed not only offer economic advantages, but also enable a more sustainable and flexible design of building components.