3D Printing
News Videos Newsletter Contact us
Home / News / DOE Awards Funding to Develop Tough Resin Tooling
qidi

DOE Awards Funding to Develop Tough Resin Tooling

July 21, 2022

The Department of Energy (DOE) has awarded $3 million in funding to two companies aiming to decarbonize manufacturing with robust, 3D printed resin tooling.

Resin-manufacturer polySpectra and composite material specialist Fortify, along with National Renewable Energy Laboratory, MPI Systems, RePliForm Inc, and ORNL have been funded to develop direct additive automotive tooling with polySpectra’s Cyclic Olefin Resin-based resins.

COR Alpha
COR Alpha resin. Good for tooling. (Image credit: polySpectra)

“Olefin-based thermoset composites have been used for many decades in extremely demanding applications such as wind turbine blades and fuel cell components, because they are among the most durable materials on the planet,” said Raymond Weitekamp, polySpectra founder.

“Under this research grant, we will leverage Nobel-winning chemistry to directly 3D-print these robust composite Cyclic Olefin Resins. The goal of the DOE project is to bring unprecedented materials durability to additive manufacturing, which will provide the industry with immense leverage for the decarbonization and reshoring of the US manufacturing sector.”

Fortify brings to the table their own DCM (Digital Composite Manufacturing) platform which consists of the Flux printer system (with resin mixers to stop the additives from settling) and also the Flux Developer software. Flux Developer is an open materials platform for the development of viscous and filled resins. It enables users to tailor their own photopolymer composites for printing on the Flux machines.

So what’s that about Nobel Prize chemistry and why is an olefin resin different?

polySpectra has a product named COR Alpha, (the COR stands for Cyclic Olefin) which is a resin that cures into rugged and temperature resistant thermoset plastic when printed on DLP printers. The product was developed from research into olefins undertaken by polySpectra’s founder during his PhD at Caltech.

His PhD supervisor PhD advisor, Bob Grubbs, won the Nobel Prize for his work into olefins in 2005. The COR Alpha material shares its heritage from that research.

Typical photopolymer resins are not known for being particularly strong, especially when loads are applied during higher temperatures.

COR Alpha, which is manufactured from an olefinic monomer, a ruthenium catalyst, and functional additives, is unique in that it maintains dimensional stability even when heated.

Other thermoplastics and thermoset polymers tend to trade heat resistance for toughness, as you can see in the graph below.

Graph
Graph of toughness (Image credit: polySpectra)

DOE hopes to decarbonize manufacturing, in particular by reducing the time and energy required for CNC machining tooling. Using metal tooling can be seen as overkill, particularly when low production runs are required.

“More than $8B is spent domestically each year on low-volume injection molding. The work addressed by this DOE award will pave the way for printed injection molding to unlock production applications,” said Josh Martin, CEO & Co-founder at Fortify.

“By combining advanced materials and post-processing with lightweight design principles, there is a significant opportunity to make a dent in the time to market, cost, and performance of part production within the automotive industry and beyond.”
The goal of the project is to develop additively manufactured tooling with orders of magnitude improvements on cost and durability versus traditional CNC tooling with cycle times on par with CNC tooling.

And not only will the tooling benefit, but ultimately, new methods of manufacturing with complex, lightweight geometries and tough plastics that can rival metals, will benefit the end product too.
In this case, the focus is on automotive manufacturing where these lightweighting benefits directly translate to energy savings and emissions reduction.

If you’d like to learn more about the COR Alpha resin (now also available in black) then you can head on over to the product page right here.

And if you’d like to know more about starting your own resin material development workflow, then you can check out the Fortify platform over here.

figure 4 isotropic parts
Related Story
Create Isotropic Parts With 3D Systems’ Figure 4
Share:
WhatsApp Twitter Facebook LinkedIn Buffer Reddit E-mail
About the author | Phillip Keane
Phillip is an aerospace engineer from UK. He is a graduate of Coventry University (UK), International Space University (France) and Nanyang Technological University (Singapore), where he studied Advanced Manufacturing at the Singapore Centre for 3D Printing.
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Latest posts

Fraunhofer, MacLean-Fogg, and Toyota Develop Large-Scale 3D Printing System for Automotive Die Casting Molds

The Fraunhofer Institute for Laser Technology ILT has partnered with powder manufacturer MacLean-Fogg and Toyota to develop a 3D printing solution for manufacturing... read more »

3D Printing Metal
Fraunhofer, MacLean-Fogg, and Toyota Develop Large-Scale 3D Printing System for Automotive Die Casting Molds

ASTM International Approves New Standard to Streamline AM Processes

ASTM International's additive manufacturing technologies committee (F42) has approved a new standard designed to help businesses navigate the procurement and delivery of 3D... read more »

News
ASTM International Approves New Standard to Streamline AM Processes

Trek Launches 3D Printed AirLoom Saddle Line

Trek has introduced its first 3D-printed saddle series, the Aeolus AirLoom, featuring what the company calls AirLoom lattice technology. The new design updates... read more »

News
Trek Launches 3D Printed AirLoom Saddle Line

QuesTek Partners with Niobium Producer to Develop High-Temperature 3D Printing Alloy

QuesTek Innovations has partnered with a global niobium producer to develop a high-temperature alloy designed for additive manufacturing. The project targets aerospace and... read more »

3D Printing Metal
QuesTek Partners with Niobium Producer to Develop High-Temperature 3D Printing Alloy

Autodesk Research and Additive Tectonics Develop 3D Printed Floor System with Alternative Materials

Autodesk Research has partnered with Additive Tectonics to develop a new approach to concrete floor construction using 3D printing technology. The collaboration combines... read more »

Construction

NREL Acquires Large-Scale Metal 3D Printer to Advance Marine Energy Research

The National Renewable Energy Laboratory (NREL) has installed a new laser-powered metal 3D printer at its Flatirons Campus to support marine energy device... read more »

3D Printing Metal
NREL Acquires Large-Scale Metal 3D Printer to Advance Marine Energy Research

Apple Adopts 3D Printing for Titanium USB-C Ports in New iPhone Air

Apple’s latest smartphone release marks a quiet but notable step in consumer electronics manufacturing: the company has confirmed that its new iPhone Air... read more »

3D Printing Metal
Apple Iphone 17 air

GKN Aerospace Expands Connecticut Facility for 3D Printed Engine Components

GKN Aerospace announced the expansion of its Newington, Connecticut facility to include a new production line for additively manufactured Fan Case Mount Ring... read more »

Aerospace
GKN Aerospace Expands Connecticut Facility for 3D Printed Engine Components

UltiMaker Launches Secure 3D Printing Line for Defense Applications

UltiMaker has introduced its Secure Line of 3D printing products specifically designed for defense and high-security environments. The initial lineup includes the UltiMaker... read more »

News
UltiMaker Launches Secure 3D Printing Line for Defense Applications

Digital Manufacturing Centre Delivers 90kg 3D Printed Military Vehicle Component

The Digital Manufacturing Centre (DMC) has completed production of its largest additive manufacturing metal component to date - a 90kg suspension and differential... read more »

3D Printing Metal
Digital Manufacturing Centre Delivers 90kg 3D Printed Military Vehicle Component

Social

  • Facebook Facebook 3D Printing
  • Linkedin Linkedin 3D Printing
Join our newsletter

Our newsletter is free & you can unsubscribe any time.

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Fashion
  • Medical
  • Military
  • QIDI Tech X-Max 3

    • - Print size: 325 x 325 x 315 mm
    • - fully enclosed
    More details »
    $799.00 QIDI Store
    Buy Now
  • QIDI Tech Q1 Pro

    • - Print size: 245 x 245 x 245 mm
    • - 600mm/s max speed
    More details »
    $449.00 QIDI Store
    Buy Now
  • QIDI Plus4

    • - Print size: 305 x 305 x 280 mm
    • - print temperature of 370°C
    More details »
    $799.00 QIDI Store
    Buy Now
  • Snapmaker Artisan Premium 3-in-1

    • - Print size: 400 x 400 x 400 mm
    • - comes with enclosure
    More details »
    $2,999.00 Snapmaker
    Buy Now

Company Information

  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing

Blog

  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal

Featured Reviews

  • Anycubic Photon Mono M5s
  • Creality Ender 5 S1
  • The Mole 3D Scanner
  • Flashforge Creator 3 Pro

Featured Industries

  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
2025 — Strikwerda en Dehue
  • Home
  • Join our mailing list
  • Contact us
Blog
  • Latest News
  • Use Cases
  • Reviews
  • 3D Printers
  • 3D Printing Metal
Featured Industries
  • Automotive
  • Aerospace
  • Construction
  • Dental
  • Environmental
  • Electronics
  • Medical
  • Military
  • Fashion
  • Art
Company Information
  • What is 3D Printing?
  • Contact us
  • Join our mailing list
  • Advertise with us
  • Media Kit
  • Nederland 3D Printing