writes copy 04 Oct 2017

Freshmade 3D Debuts Strong New 3D Printing Material AMClad With a 3D Printed Bowling Ball

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I like bowling, even though I’m terrible at it – I think the highest I’ve ever scored in my life was 150. I just find the whole atmosphere of the bowling alley enjoyable. But aside from a 3D printed assistive ramp for disabled children, we don’t often see 3D printing technology combined with bowling. That’s changed now, with a 3D printed bowling ball that Youngstown, Ohio-based 3D printing startup Freshmade 3D created to showcase its new proprietary 3D printing material, AMClad.

(L-R) Freshmade 3D officers Brett Conner, Chief Technical Officer; Rich Wetzel, CEO; and Christopher Tomko, President and Chief Operations Officer. [Image: The Business Journal]

Earlier this week, Freshmade 3D, which offers digital manufacturing services and typically specializes in rare parts when it’s not busy  3D printing life-sized political bobble heads, and is  one of Youngstown Business Incubator’s 30 portfolio companies, successfully hit the lanes with the 3D printed bowling ball ahead of this Friday’s National Manufacturing Day.

After scoring a strike, Rich Wetzel, the startup’s CEO, told The Business Journal, “If you were to do that with a bowling ball [made from traditional 3-D printing materials], it wouldn't be heavy enough and it'd probably shatter on impact.  We wanted to show that this is a strong material that won't break and can withstand several cycles in manufacturing.”

AMClad, a patent-pending isotropic (can withstand forces from all angles) engineered sand composite, or ESC, differs from other 3D printing materials because of its structural strength. The material can bend more, stretch further, and be subjected to more weight, due to its higher compression, flexural, and tensile strengths.

“From an engineering standpoint, it's more tailorable,” said Freshmade President and CEO Christopher Tomko. “In a traditional manufacturing setting, you're bound by the materials. In our case, the particulate we print with is the carrier of the shape and we apply properties to it.”

3D printed sign made with AMClad

AMClad can be used to 3D print a variety of large objects, like prototypes, sculptures, and tools.

“We believe AMClad has great potential in a wide range of applications,” Freshmade Chief Technical Officer Brett Conner said. “With advantages in durability, strength, production speed, and cost, it's something manufacturers will definitely be interested in.”

When manufacturers look for a strong, economical material, they normally choose an ABS polymer, which has a typical tensile strength between 3,000 and 5,000 psi and a flexural strength of around 7,000 psi. AMClad is comparable to ABS, with a  tensile strength of 4,820 psi and flexural strength of 7,940 psi. But the material’s compression strength – capable of handling about 18,000 psi – blows ABS out of the water, making AMClad “structurally sound from all angles.”

Tomko said, “You can crush it. You can park a car on it and it'll stand up.”

“If you hold a [traditional] 3-D printed item in your hand and bend it a certain way, it's prone to crack. It's weaker in that direction where the layers are stacked.”

The startup began developing AMClad when it was commissioned last summer to create life-size bobble heads of President Donald Trump and then-Democratic nominee Hillary Clinton. Freshmade discovered that the materials it was originally going to use would not support the overall weight of the huge statues.

“There wasn't any other solution for us, so we worked backward.  We found an affordable solution that had no strength and then found ways to make it strong,” Tomko explained.

According to Wetzel, while Freshmade continued to work on the development of AMClad, they also began to focus on making it an affordable alternative for manufacturers, through quick project turnaround and decreased materials cost.

“Typically, traditional manufacturing tools can take upward of a year to get made and tens of thousands of dollars,” Wetzel said. “If that iteration isn't good, then you have to start the process over again.  We have a fast turnaround, a variety of finishes and coating,

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