Variable Nozzle 3D Extrusion Printer Uses VFGF Processing for Economical Large-Format Additive Manufacturing

Q.Big 3D’s Queen 1 3D printer creates large-volume plastic components through the variable fused granulate fabrication (VFGF) extrusion printing process, offering high build speeds, high-quality surface finishes and high levels of dimensional tolerances with constant gap sizes. 

A key feature — compared to alternative AM strategies such as FDM printing systems — is the use of commercially available plastic granulate without filaments instead of the higher priced polymers with filaments. Using plastic granulates makes large-format 3D printing economical and enables materials with serial properties to be used.

The VFGF process combines speed with precision, which is particularly advantageous for large-volume printing. It thus optimizes the 3D printing process by combining quality with efficiency and optimizing the time-to-market approach. The VFGF process uses adapted process algorithms (predictive flow algorithm) to build up a component at the right time, in the right position with the right amount of material. This makes it possible to print even complex components utilizing undercuts with the help of support structures.

The VFGF system can overcome the previous limitations of conventional manufacturing strategies by offering significantly higher productivity than filament printers. This is due, in part, to the printer’s VFGF printhead, which features a variable nozzle diameter that enables it to print fine surfaces and still be up to 40 times faster compared to 3D printing with filament.

Variable Nozzle

The VFGF process enables precision printing with high resolution in places where fine details are required, such as on the outer surfaces of a component. At the same time, structures on the inside or areas where the resolution is less relevant can be printed more coarsely and therefore faster in a so-called turbo mode. This flexibility of the process enables high build speeds of the 3D components.

The variable nozzle works with a combination of 1.5 mm (detail mode) and 3 mm (turbo mode), and applies the material layer by layer, like a typical 3D printer. This makes it possible to produce very large-volume components economically without the use of molds. This also enables high resolution printing with a short production time — along with lower material costs. The maximum processing speed is 500 mm/sec. with the system enabling an output of 0.15-2.0 kg/hr. 

Detail Mode

The variable nozzle works in detail mode for fine structures or textures. This can be a surface that needs to be accurate for high-gloss painting or for holding fastening elements. It also applies to inclined areas or overhangs with necessary support structures, as well as bridges or thin domes.

Turbo Mode

The turbo mode enables rapid build times needed for very large components. This is a key factor making the process cost-effective compared to conventional processes such as injection molding using granulate material. The turbo mode is selected for in-fill areas or for creating support struts on the back of components in non-visible areas.

Printing Command Validation

During the build, printing commands sent to the Queen 1 system are defined in areas of the component for detail or turbo printing and validated by simulations. For the design engineer, this can open up possibilities for bionic strategies or material savings in the context of lightweight construction.

Full Potential of LFAM

Tool-free manufacturing with an industrial large-format 3D extrusion printer opens up time-to-market strategies for users. The elimination of tool costs and new design strategies for component geometry as well as extremely short amortization periods are also key process benefits.

The VFGF process is suitable for rapid prototyping, replacement components and series production.