Consumer Goods & Lifestyle
NEWS & STORIES
Wilson’s Highly Engineered Airless Basketball Releasing At Retail
Wilson creates first airless basketball in partnership with General Lattice, EOS and DyeMansion
DyeMansion announces new products, partners and production lines at Formnext 2021
Case Study | You Mawo: scanning, 3D printing & finishing the key to custom eyewear
Verkaufsstart für Wilsons ersten 3D-gedruckten, luftlosen Basketball ‚Airless Gen1‘ steht bevor
Wilson stellt den ersten 3D-gedruckten Airless-Basketball vor
Dyemansion und Siemens gehen Partnerschaft zur Industrialisierung von AM ein
BRINGING MORE COLOR TO LIFESTYLE AND CONSUMER PRODUCTS
SPORTS
Case study: Bauer Hockey
The Story behind the MyBauer Reakt Helmet - 3D Printed Helmet liners
©DyeMansion, BAUER
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Additive Manufacturing has been used in the production of consumer products for many years. However, it has only rarely been used in the arena of professional sports. BAUER, one of the biggest hockey brands in the world tackled this challenge. Their parts need to meet specific needs, uphold a certain style and achieve an unparalleled performance value. Professional hockey players need a product that not only reduces drag and provides protection but can also have direct skin contact during hours of intense game time.
The Powerfuse S with its VaporFuse Surfacing brings a lot of value to the product: It takes the porous TPU material to a sealed surface with no worries about abrasion and water or moisture absorption in the part. With our DeepDye Coloring, the parts get their blue color – with many parts all being processed at the same time and getting a consistent color result each time.
The MyBauer Reakt helmet was the first helmet to use 3D printing for individualized helmet inlays and therefore enabling a better fit. Today, the helmet with its fully customizable liner offers an optimal fit and great ventilation. It can be customized via a scan and therefore tailor-made for each player’s head.
The project partners BAUER, DyeMansion, EOS, Twikit and nTop have enabled a previously unseen workflow for the production of a hockey helmet with 3D printing: From scanning and automated data creation of a 3D output file to printing and post-processing, this documentary shows how players received helmets that were customized to their needs, allowing for a perfect fit and better airflow, keeping them cool on the ice.
POLYSHOT CLEANING
POWERSHOT C
VAPORFUSE SURFACING
POWERFUSE S
DEEPDYE COLORING
DM60
“We take the parts to our Powershot C for the cleaning. And then the real portion of it is when we take the parts to the Powerfuse S, which seals he parts. This was a must for us, since the parts are against your skin. So it brings all the value of the product.”
SPORTS
Case study:
WILSON AIRLESS GEN1
How our DeepDye Coloring & VaporFuse Surfacing helped to bring the first 3d printed basketball to the market.
Post-processing steps | ©DyeMansion
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Learn all about the post-processing of the Airless Prototype
The main obstacle is the combination of new technology and a proprietary material, resulting in a ball with a completely unique surface texture that differed from rubber or composite materials. Particularly when it comes out of the printer, it is white and has a finish that isn’t necessarily favorable for the player. The end-user was going to be an athlete, and for them comfort, appearance, and tactile experience are crucial. While we can experiment with aesthetics and design, if the athlete doesn’t feel at ease with the ball, the application willl never succeed. Therefore, a very important step was to transform the printed part into a product that closely resembled what the athlete was accustomed to, ensuring a more familiar and satisfying experience.
With General Lattice’s Computational Design Services, the final design was found using precise settings of various parameters. EOS was able to find the specific, high-performance material and the right printing solution. To go from the raw, printed part to a playable product, DyeMansion’s VaporFuse Surfacing and DeepDye Coloring is used. The Powerfuse S and the process known as VaporFuse Surfacing, is introducing a solvent via vapor form into the process chamber and onto the ball itself via a unique sequence. This way it’s creating condensation on the ball itself. As that process transforms, the system creats iterative cycles to repeat that process over and over via very specific parameters that can be defined based on the smoothness level that is being aimed for. In the final stages the system is removing all of the residual vapor off the part. After the process there’s a ready-to-go product straight out of the system that can then be colored in the next step. With the DM60 a dye pigment is introduced into the part. This dye is chemically bonded to the polymer links themselves, which means the process is impacting into the part itself and therefore not leaving anything on the surface that’s residual.
- Completely sealed surface, refraining from dirt and debris uptake
- Surface for a more seamless feel of play by resisting perspiration
- A homogeneous color – which is always reproducible due to a reliable process using cartridges
- Fully automated system that can run lights out when going into larger production volumes
SPORTS
Case study: Modla x Reebook
A 3D-printed mask for altitude training (limited edition)
©Modla, Reebok
POLYSHOT CLEANING
POWERSHOT C
POLYSHOT SURFACING
POWERSHOT S
DEEPDYE COLORING
DM60
EYEWEAR
Case study: YOU MAWO
Pioneers producing the eyewear of the future: Custom made 3D-printed eyewear based on a 3D-scan
©DyeMansion, You Mawo
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YOU MAWO built their whole business on 3D-printing and produces custom made 3D-printed eyewear based on a 3D-scan. Customization, however, can be a challenge as every single frame produced will be slightly different. Additionally, the eyewear will have direct content with UV light, perspiration, and various cosmetics on a daily basis – quite strong external influences that can have an impact on the material and color.
With the DyeMansion Print-to-Product workflow YOU MAWO was able to solve those challenges and even go a step further – scale and develop reproducible results. Now they specialize in mass customization and high-volume production of eyewear frames, thanks to industrial 3D-technologies across the whole value chain.
One of the biggest benefits is for their consumers. The frames are durable and 30% lighter than traditional plastic frames. Another huge benefit comes for YOU MAWO’s opticians. They don’t need to have so many frames on stock. So, all in all:
- short innovation cycles
- a more sustainable production
- superior products with optimized haptics
- ISO-certified colors for daily use on your skin
- industrial scale manufacturing through reproducible post-processing processes
POLYSHOT CLEANING
POWERSHOT C
PolyShot Surfacing
i
Tumbling process before surfacing (3rd party technology)POWERSHOT S
DEEPDYE COLORING
DM60
EYEWEAR
Case study: Fitz Frames
Re-thinking customized prescription eyewear for everyone ages 3+ with Additive Manufacturing
Fitz Frames make customized eyewear for kids. Each pair of their eyewear frames is custom fitted to fit each individual’s face by taking 40,000 measurements. The challenge is to be able to have a consistent result in regards to finish and color each time.
The solutions from DyeMansion are crucial to the business of Fitz Frames and they couldn’t have built their business without their Print-to-Product workflow that gives them reproducible results for finish and color at scale.
Six models, eight colors and limitless options to customize. 3D-printing and the right post-processing technology gives Fitz Frames the chance to continue innovating on a batch-by-batch process and look for more colors, exciting finish options and more styles in the future as well. The Fitz Frames production serves as an impressive demonstration that eyewear can be produced successfully with a PolyShot finish only, done with the Powershot S.
POLYSHOT CLEANING
POWERSHOT C
PolyShot Surfacing
i
Tumbling process before surfacing (3rd party technology)POWERSHOT S
DEEPDYE COLORING
DM60
EYEWEAR
Case study: Götti
How the biggest Swiss eyewear brand stepped into manufacturing
©DyeMansion, Goetti
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In 2014, Götti was one of the first eyewear manufactures to employ industrial 3D-printing. They faced a big challenge, as they wanted to dye 3D-printed glasses in any color of choice with an individually created color palette while using materials which had to be allergen-free, non-irritating to the skin and UV resistant.
The development of a production-ready process using reproducible finishing and dyeing solutions: The successful implementation of the DyeMansion Print-to-Product workflow, consisting of the blasting systems Powershot C and Powershot S, as well as the DM60 coloring system, achieved an ideal surface finish for the frames and homogeneous, reproducible coloration. This resulted in a marketable 3D-printed eyewear collection.
An extensive range of customization options, lightweight and flexible materials, and local on-demand production:
- maximum individuality
- specially designed colors
- bio-compatible & skin-safe frames
- exceptional designs & shorter innovation cycles
- fast reaction to color trends and unlimited color options
POLYSHOT CLEANING
POWERSHOT C
POLYSHOT SURFACING
i
Tumbling process before surfacing (3rd party technology)
POWERSHOT S
DEEPDYE COLORING
DM60
JEWELRY
Case Study: BOLTENSTERN
Fine jewelry. Coded by hand, crafted by technology.
© DyeMansion, Boltenstern, FORMRISE
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How to transform a 3D-printed polyamide part into a real designer piece? First experiments weren’t as promising. The layers from the printing process were visible on the pendants. The thin wall structures broke easily, and the haptics of the parts were not as good as the label imagined them for an end-use product. Color variety was also a huge challenge for BOLTENSTERN when they came up with the idea to do jewelry with Additive Manufacturing.
To achieve improved haptics of the earrings and offer different colors that reach every part of the earring – in a skin-friendly and reproducible way – they partnered with FORMRISE, a DyeMansion Production Partner. They use our whole Print-to-Product workflow onsite. The solutions for automated cleaning, surface finishing and coloring can be used regardless of the part geometry. FORMRISE was able to deliver what Boltenstern needed: Finished and colored polyamide parts with a premium look & feel.
The ability to produce products in a completely new way:
- premium look & feel of the 3D-printed elements
- high value increase of the 3D-printed parts through finish & color
- maximum flexibility with 180 possible combinations for their customers
- fast reaction to color trends
- unlimited color options
POLYSHOT CLEANING
POWERSHOT C
PolyShot Surfacing
POWERSHOT S
DEEPDYE COLORING
DM60
FOOTWEAR
Under Armour Architech
3D-printed architech futurist sneaker with lattice sole
©DyeMansion, Under Armour
Already in 2016, Under Armour was a pioneer for 3D-printed midsoles in the footwear industry. The 3D-printed sneaker in Glacier Grey, dubbed the UA ArchiTech Futurist, is aptly named to fit its next-gen appearance.
FOOTWEAR
iAMfootwear
Non-branded reference production line for footwear
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Additive Manufacturing can add a lot of value to the way we produce footwear in the future. Companies like Under Armour or Adidas proved already that it is possible to produce midsoles with 3D-printing today. But the standards are high in the footwear industry and the transformation to Additive Manufacturing is a huge step.
To inspire and show what is possible today the consortium of the different technology providers Arkema, DyeMansion, EOS, framas, Siemens and Twikit founded the iAMfootwear project.
This end-to-end solution for a sustainable footwear application shows how cost and performance competitive AM is already today. The iAMfootwear consortium can deliver solutions to footwear brands and individually tune the application for design, performance, and cost.
POLYSHOT CLEANING
POWERSHOT C
VaporFuse Surfacing
POWERFUSE S
DEEPDYE COLORING
DM60
OTHERS
Case study: 360bubble
Fully functional high-performance 3D-printed underwater camera housing
©DyeMansion, 360BUBBLE
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Create a perfectly reproducible part that can withstand constant exposure to saltwater, high pressure, and fluctuating temperatures.
Together with DyeMansion Production Partner Incremental Engineering, 360bubble was able to quickly make improvements and adjustments to the design and bring a fully functional high-performance product to the market in a short period of time.
Multiple 360bubble products are currently available on the market and are always made to order, providing full flexibility during production, and eliminating the need for expensive warehouse fees.
POLYSHOT CLEANING
POWERSHOT C
POLYSHOT SURFACING
POWERSHOT S
DEEPDYE COLORING
DM60
OTHERS
Case study: DaM x edLighting
Industrial craftsmanship 4.0 made in Italy meets Additive Manufacturing
©DyeMansion, DAM, EDLIGHTING
With the combination of Additive Manufacturing, DyeMansion post-processing and Made in Italy craftsmanship, Ettore Lariani and Claudio Molinelli, celebrate industrial design by finding in HP®️ Jet Fusion 3D printing technology the maximum freedom in creating unique lights. The result was a line of fully customized light fixtures that had various surface textures and colors and held up to the high standards of the designers.
POLYSHOT CLEANING
POWERSHOT C
POLYSHOT SURFACING
POWERSHOT S
DEEPDYE COLORING
DM60
OTHERS
Case study: SEVENFRIDAY
Luxury Swiss watch company bringing 3D-printed timepieces to the market with the FREE-D watch
©DyeMansion, SEVENFRIDAY
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SEVENFRIDAY wanted to create a timepiece to celebrate the 10th anniversary of the brand, which highlighted their innovate and out of the box thinking. The challenge was to find a way to merge new & innovative design ideas with traditional Swiss watchmaking craftsmanship. The 3D-printed components had to look and feel high quality, be comfortable to wear and last a lifetime.
The DyeMansion Print-to-Product workflow provided the right look and finish that SEVENFRIDAY was looking for when paired with the 3D-printed PA11 components. They partnered with Prodartis, a DyeMansion Production Partner based in Switzerland, who supported with the printing and post-processing and helped bring the vision of the FREE-D watch to life. PolyShot Surfacing provided the right surface finish and DeepDye Coloring provided them with the right color options they desired, even when working with grey-base material.
FREE-D watch is the first watch from SEVENFRIDAY that was developed and produced entirely in Switzerland, thanks to the support of Prodartis. The first limited edition run of the FREE-D watch sold out quickly, and 3D-printed components will now be a part of many more SEVENFRIDAY timepieces in the future.
POLYSHOT CLEANING
POWERSHOT C
PolyShot Surfacing
DEEPDYE COLORING
DM60
Color is true freedom of design
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