Most consumer-level FFF 3D printers cannot print brackets capable of supporting exceptionally heavy weights. Common filaments like PLA and ABS are durable enough for prototypes and low-impact applications, but it takes a much stronger material to guarantee high performance in the heat and humidity of Suriname.
During a military exercise in South America, crew members needed brackets to support a 20 kg signal amplifier so it could be mounted near the top of a 25-meter pole. This placement reduced the need for long cables and boosted the antenna signal. Without the necessary brackets on hand, the crew used an INTAMSYS printer to create them out of PEKK-CF, a high-performance material requiring extrusion temperatures of at least 350°C. Weaker materials would have buckled under the heavy weight and compromised safety.
A naval ship or submarine contains numerous valves for regulating pressure and fluid flows, controlling everything from fresh water to hydraulic systems. These valves have wheels that allow manual adjustments and are regularly removed for cleaning and maintenance. However, they sometimes break or get lost, necessitating spares.
Due to the diversity in valve wheel types and sizes, DMI workers have been using their INTAMSYS 3D printers to fabricate wheels on demand rather than carrying numerous prefabricated aluminum/steel spares. Valve wheels printed in high-strength materials are durable, resistant to overheating, and can even be installed permanently.
Ships and machines aren’t the only things that require maintenance on long missions. Crew members can suffer injuries in the field, and ships aren’t always within reach of a medical center.
DMI’s additive specialists have been collaborating with Radboud University Medical Center on a research project to develop custom orthotics. Using a mobile 3D scanning application developed by Belgian company Spentys, technicians can design and 3D print custom-fit orthotics to treat minor injuries. A variety of materials can be used, including PEKK, ABS, and PP. The devices can be adjusted over time with straps as the injury heals.
