VX1000 HSS 3D printer sets standards for speed, repeatability, flexibility | VoxelMatters

First unveiled in 2020, the VX1000 HSS platform by voxeljet set a new standard in polymer AM, offering continuous, high-precision production on a large scale. Now, five years later, the machine still stands at the forefront of powder-based sintering technologies and, frankly, it’s not really a surprise why. 

The VX1000 HSS is based on voxeljet’s High Speed Sintering (HSS) process, an inkjet powder bed printing technology that selectively deposits an energy-absorbing ink onto layers of polymer power and then fuses the layers using infrared radiation. This technique has several benefits compared to conventional selective laser sintering (SLS), including significantly faster printing rates, since it does not use a laser to selectively sinter and instead irradiates the entire powder layer at once, after the inkjet print heads have done their work.  

Speed and scale

The VX1000 HSS delivers voxeljet’s HSS technology on a large scale with a build volume of 1000 x 540 x 200 mm. This scale, one of the largest of its kind in the market, enables users to either manufacture large volumes of small polymer components or create large individual parts. Moreover, because HSS uses an inkjet-based printhead, packing density does not influence layer print times—a key scalability bottleneck for SLS platforms. Generally speaking, the 3D printer can reach printing rates of up to 6,500 cm³/h.

The system’s inkjet printhead is central to this capability. Consisting of a bidirectional printhead with around 8,000 nozzles over a one-meter span, the VX1000 HSS’ printhead can deposit ink across the width of the build space rapidly, evenly and with a high level of repeatability. The printhead integrates piezoelectric modules arranged in a comb-like structure, a configuration that allows it to shift laterally by a few centimeters to cover the entire build area on the return pass, further driving efficiency.

Repeatability

Besides speed and large scale, a key selling point of the VX1000 HSS is repeatability. voxeljet explains that the printer’s intelligent self-regulating temperature management system plays an important role in establishing consistency. “The system is designed to ensure uniform heat distribution across the entire build chamber,” the company explains. “It integrates five independent heating zones, including 54 overhead modules in the ceiling, heated side walls and floor within the job box, temperature control in the recoater and a cooled sintering lamp that emits energy at a targeted wavelength for precise thermal input into the inked areas.”

A number of sensors and pyrometers embedded in the 3D printer monitor the temperature closely and gather data that can be analyzed for future process optimization. All data is stored in a SQL-based database that provides users with full traceability for print jobs.

In sum, this system ensures uniform heat distribution across the whole build chamber and uniform part heating, regardless of whether users are printing a series of small components or one large part. This temperature management system also has other benefits, like maximizing powder reuse through the precision targeted energy of the sintering lamp.  

Economic efficiency

voxeljet emphasizes that economic efficiency was also a central goal in the 3D printer hardware’s development. To this end, a contactless automated cleaning system ensures that the printhead’s performance and lifespan is maximized, while the infrared lamp used to irradiate layers of powder comes with a water cooling system that minimizes maintenance requirements and associated costs. The company says: “The combination of a large build volume, constant layer times, and reduced maintenance requirements has a direct positive effect on both unit costs and system availability.”

The VX1000 HSS also comes with an integrated powder recycling system that recouperates all the unsintered loose powder in the build envelope and enables near complete reuse of the material. In more specific terms, the 3D printer supports a recycling ratio of up to 80/20 (used to new), which minimizes material waste significantly and lowers material costs.

Flexible process control

In recognition of the varying needs of different users, voxeljet has made it possible to customize the system’s printing parameters, such as ink application, temperature profiles, layer thickness and powder recycling rates. The ability to tailor print settings gives users a high level of control over the properties of final parts (i.e. elongation at break, tensile strength, surface roughness). Notably, users can control these properties within a single part, integrating different properties in different part zones for optimized performance and—on an efficiency level—ink consumption.

Setting profiles can also be saved within the system, making it easy to implement the correct settings for a given print job and ensure repeatability.

“The ability to configure various print-mode-dependent parameters offers additional optimization potential,” voxeljet says. “For instance, increasing the ink application can improve part strength, though this may reduce ease of unpacking—and vice versa. These adjustable settings not only enhance system flexibility but also enable targeted process optimization tailored to specific applications.”

To this end, the voxeljet HSS network gives users access to a network of research and material partners with the aim of sharing knowledge and promoting collaboration to validate new materials and applications as well as to optimize the process chain. Through this network, over 30 materials have already been tested for use on the HSS platform, including PA 12 , PP, TPU, PEBA and EVA.

VX1000 HSS, a compelling solution

Ultimately, the hardware and software behind the VX1000 HSS have created a system ideal for series production. The system, which overcomes many issues associated with standard SLS processes, has set a new standard in terms of production speed, repeatability, adaptability and economic efficiency, opening up a wide range of applications and round the clock productivity for powder-based plastic AM.