AM more sustainable and responsible ? It’s a  team work!

AM more sustainable and responsible ? It’s a team work!

Vanna Menco, CEO Prosilas @ SPS Italia

Additive Manufacturing for a more responsible and sustainble producution

The satisfaction and reflection. Our participation in the conference “Women in 3D Printing” within SPS Italia was a very important moment, that saw our CEO  Vanna Menco take stock of additive manufacturing as an important element within a sustainable and responsible production system.

Vanna Menco CEO Prosilas alla SPS di Parma con Women in 3D Printing

Sustainability

Sustainability is a keyword of our time and, as such, sometimes not always used appropriately. Certainly, therefore, it is worth dwelling on this issue, which is also a crucial issue for companies, in environmental and economic terms, and it is first of all “a team effort”, as our CEO said.

“Sustainability is not just about measuring carbon footprint or saving energy”

Vanna Menco says: “The real challenge is to carry out concrete actions, certainly not to make a greenwashing of your company or plant trees to compensate for the CO2 emitted by its production. First of all, it is necessary to start from environmental certifications such as ISO14001 to meet the required parameters”.

The integrated approach of Prosilas

As we pointed out at SPS, the idea of Prosilas for sustainability goes above all through a new approach towards customers and suppliers: a shared approach that starts from the company understood as all its individual employees, to pass then to the customers in form of spendable know-how and to the suppliers in form of shared direction. 

Vanna Menco CEO Prosilas alla SPS di Parma con Women in 3D Printing

Prosilas: AM Consulting

As consulting service, Prosilas is committed every day to provide advice to its customers, through the choice of materials, the type of production, technologies and finishing, favor for example:

  • the use of recycled material;
  • the improvement of performance;
  • the use of energy-saving materials.

We therefore accompany the customer in a certain direction and/ or we advise against certain solutions always with a view to sustainability thanks to the countless solutions that Prosilas can implement, from the choice of materials to production, from technologies to finishing.

Creating an environmental balance with suppliers to have a shared environmental policy.

On the subject of sharing, Vanna Menco’s speech also brought a look to the Prototal group of which Prosilas is part and which is moving with a series of alignment meetings between all the heads of units to find a shared and innovative strategy.

In general, in fact, the companies that first will find the correct and concrete answers to the issues of sustainability will be those that will have the opportunity (and the great responsibility) to be pioneers. In this sense, Prosilas is very pleased to accept this challenge, presenting itself as a “matriarch” of change in its sector, given that sustainability is a concept that already permeates every business action.

Sustainability is a team effort, as we have said, that stimulates the growth of the company and the staff: growth and creative evolution, so that companies provide a positive contribution and changes that last over time. 

Prosilas for Philipp Plein, the shoe revolution starts from a 3D sole

Prosilas for Philipp Plein, the shoe revolution starts from a 3D sole

Philipp Plein Case History

Prosilas: AM Service & Consulting 

Since the beginning of our entrepreneurial adventure, in 2003, we have chosen not to specialize in a particular production sector, preferring to offer as a service to customers in different sectors. Thus, we have maintained a flexibility that has proved particularly successful when, in our transition from prototyping service to manufacturing ally, we were commissioned the sole of a shoe for one of the brands symbol of fashion luxury: Philipp Plein.

 

R&D on Tpu 

In 2020 we enabled the use of TPU, a rubber material widely used in the moulding of soles, on our SLS production systems.  This gave us the opportunity to start the collaboration with Philipp Plein, with the aim of creating a capsule collection of footwear in which to combine innovation and luxury, dedicated to a specific niche of the brand’s customers.   At the heart of the work, for us, was the creation of an attractive model in line with the taste of the brand and the development of a product that exceeded a series of requirements of strength and durability.

 3D Sole

In fact, the sole is one of the crucial elements of a shoe and one of the most stressed by the use. We then conducted a detailed study and a deep work on design and process to ensure replicability. For this reason we also supported the company that would then assemble the final shoe, facing and solving together specific processing problems that usually do not concern those who make prototypes.

The result ?

First, we got a sole completely out of the standard of a traditional ones, with a latticed structure; then, the opportunity to innovate the style thanks to the possibilities offered by 3D printing; finally, we opened doors to unique pieces, unthinkable (or infinitely more expensive) when all the process of creation must use injection moulding. 

Thank to a work like this, a progressive set of know-how is created that is completely new but can be used in all subsequent experiments. So, for example, for Philipp Plein shoes, we conducted several tests on the tightness of the colors of the soles, especially white – which should not turn yellow or turn on other shades – and black – which should not shin, so it can not be painted.

How was that possible?

The problem-solving business approach was essential

“There are no closed doors,” explains our CEO Vanna Menco, “We always accept challenges, we like to evolve and find solutions”. In this the imprinting of my father was fundamental, because – she continues – he “loves to crack his head on problems” and not by chance he still leads the Research and Development department.

Our transition from suppliers to consulting service  has been made possible by a know-how developed to support the customer at all stages of production, making available our deep expertise in 3D printing. So, we went from consulting at the prototype stage to consulting for all product development, also providing knowledge on specific steps, such as the blend of the material to be used to achieve a certain result.

Our constant commitment to be the best possible consulting service for AM world.

Prosilas is now member of the Prototal Industries GroupProsilas

Prosilas is now member of the Prototal Industries GroupProsilas

The acquisition of Prosilas by the Prototal Industries Group

 

Prosilas s.r.l, a leading European provider of 3D printing services based in Italy, has been acquired by Prototal Industries, a leader in additive manufacturing and polymer injection molding in northern Europe.

 

The acquisition will strengthen Prototal’s operations in Europe and provide existing Prosilas customers with additional production service capabilities. Through the acquisition of Prosilas, Prototal will have one of the largest additive manufacturing capacities in Europe.

Headquartered in the province of Macerata in Italy, Prosilas was founded in 2003 and for almost two decades has provided expert additive manufacturing services to the European market.

“Between 2019 and 2021 we had several interesting proposals but none had the winning features we were looking for. In January 2021 we got in touch with the Prototal Group and a great feeling was immediately established. Even then, I felt that this collaboration could be a winner for Prosilas. Our visions were aligned and have a really good team with which we collaborate in a very natural and dynamic” Vanna Menco, CEO Prosilas

 

la produzione Stampe tre d per produzioni e preserie Prosilas

The company provides end-to-end services

The company provides end-to-end services, from support to design and optimization, prototyping, mass production and post-processing.

The main specialty of Prosilas is in SLS 3D printing and holds quality certifications including ISO 9001:2015 and ISO/IEC 27001 for IT security and ISO 14001:2015.

Prosilas: cutting edge company

The company has seen remarkable growth since 2016, adding industrial AM systems to its fleet and implementing sophisticated solutions, such as automated material management systems, MES software and quality solutions. In recent years, Prosilas has been interested in establishing an industrial partnership with the aim of expanding its reach and customer base across the European continent.

 

Prototal Industries

Prototal, for its part, has an annual turnover of around 50 million euros and a team of experts of over 200 employees in seven locations. In recent years the company has expanded beyond the Nordic region, first with the acquisition of the AM polymer services business of 3T Additive Manufacturing based in the UK and now with the acquisition of Prosilas.

Prosilas Additive Manifacturing and consulting fa parte del gruppo Prototal

Vanna Menco, CEO Prosilas

Through the agreement officially signed on November 15, 2021, Prototal Industries acquired 100% of the capital of Prosilas.

Going forward, Vanna Menco will remain as CEO and General Manager of Prosilas. Giulio Menco, founder of Prosilas, will maintain the role of technical consultant, specialized in the experimental and R&D field. Members of the existing Prosilas team will also remain as part of the acquisition agreement.

 

vanna e giulio menco ceo prosilas

Press Release

3D RUCK –  Prototal kauft italienischen 3D-Druck-Dienstleister Prosilas – 2/11/21

Il Sole 24 Ore – Grimaldi con Prototal Industries AB nell’acquisizione di Prosilas – 3/11/21

Biocompatible material for 3D printing: Polycaprolactone

Biocompatible material for 3D printing: Polycaprolactone

Case History – Medical

Application in the Medical sector realized through the use of biocompatible and absorbable materials – Polycaprolactone – processed with 3D printing technologies and additive manufacturing SLS – Selective Laser Sintering.

 

Polycaprolactone – PCL: biocompatible material for 3D printing

Our team of experts has perfected a particular formulation of material capable of producing functional parts implantable in the human body.

In this specific case we produced a biocompatible and absorbable material composed of Polycaprolactone and Hydroxyapatite. The chemical composition of the material made possible the realization of a special stent that was implanted in a 5 year old child suffering from bronchcomalacia at the Bambino Gesù Hospital in Rome.

Bronchial stent in 3D printing:  design and implementation

The process of producing the stent was the result of 3 years of research and development that Prosilas has faced pro-bono in order to realize the part in question. The realization was possible through a design phase and a production phase.

The design phase of the geometries was performed on the basis of a computed axial tomography (CT) showing the area to be reproduced. The acquired images were useful to create a new geometry completely customized on the patient.

The case study is the first and only in Europe.

Once the geometry was validated, hundreds of tests on 3D printing (SLS) technologies and materials were performed. The right balance between process parameters and chemical composition of the material led to the creation of the stent. 

Carbonmide drone chassis and 3D printing

Carbonmide drone chassis and 3D printing

Case Study: Topological Optimization and 3D Printing for a Lightweight and Durable Drone Frame

 

Drones that are increasingly high-performing and lightweight demand cutting-edge components.

Prosilas presents a case study showcasing the utilization of topological optimization and SLS 3D printing for the production of a drone frame using carbon fiber-reinforced polyamide.

The challenges:

  • Reduce the weight of the frame to enhance the efficiency and autonomy of the drone.
  • Ensure the frame’s strength against stresses and vibrations during flight.
  • Create a complex and optimized geometry that is unattainable with traditional manufacturing methods.

Design and Optimization

The drone frame was designed using topological optimization software.

This software analyzed the stresses and constraints to which the frame would be subjected during flight and generated an optimal geometry that utilizes only the necessary amount of material to meet strength requirements.

Production

The frame was manufactured using Selective Laser Sintering (SLS) 3D printing technology with carbon fiber-reinforced polyamide.

This material was chosen for its high mechanical strength, lightweight properties, and resistance to high temperatures.

Results

The drone frame produced with carbon fiber-reinforced polyamide was found to be 50% lighter than a frame made with a traditional material such as aluminum.

Furthermore, the frame in this material demonstrated superior mechanical strength and better vibration absorption capabilities.

Benefits

The utilization of topological optimization and SLS 3D printing led to a series of benefits for the drone frame:

 

  • Weight Reduction: The frame is 50% lighter than an aluminum frame, improving the efficiency and autonomy of the drone.
  • Increased Strength: The carbon fiber-reinforced polyamide frame exhibits superior mechanical strength and better vibration absorption, enhancing the drone’s durability and reliability.
  • Design Freedom: The use of 3D printing allowed for the creation of a complex and optimized geometry that would not be achievable with traditional manufacturing methods.
  • Cost Reduction: 3D printing helped reduce frame production costs, making it more accessible for a wide range of applications.
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Hyper-Light Carbon: 20% Less Weight

In addition to carbon fiber-reinforced polyamide, Prosilas introduces Hyper-Light Carbon, one of the lightest materials in the world of 3D printing.

The new formulation of PA 12 with carbon fiber provides lightness, strength, and ease of processing. The material features a uniform surface finish, high precision, and an excellent strength-to-weight ratio.

It represents a further evolution for the production of drone frames and components where lightweight is a fundamental characteristic.

Hyper-Light Carbon stands out for its even lower density (0.82 g/cm³), enabling the creation of even lighter and more high-performance frames. This material also offers high mechanical strength, excellent surface finish, and ease of processing.

With Hyper-Light Carbon, you can:

  • Achieve a new level of lightness and performance.
  • Further enhance the efficiency and autonomy of the drone.
  • Attain complex and optimized geometries for improved aerodynamics.
PA12 ALU jigs with SLS printer

PA12 ALU jigs with SLS printer

Innovative Applications in Industrial Tooling:

Custom Mounting Fixtures with PA12 ALU 3D printed

The tooling sector is undergoing a revolutionary transformation thanks to 3D printing technologies and SLS (Selective Laser Sintering) additive manufacturing.

In particular, the combination of freeform design and advanced materials such as PA12 ALU loaded aluminum is enabling the efficient and innovative production of tailor-made equipment for the industrial sector

Freeform Design:

Freeform design represents a crucial step forward, allowing the production of custom parts on demand without the need to maintain a warehouse.

This flexibility is particularly advantageous for the production of dedicated tools for special processes or for complex assemblies.

SLS additive technologies enable the creation of strong and lightweight geometries in a short period, revolutionizing the way industrial tools are conceived and produced.

Practical Application – Assembly Guides:

A concrete example of this innovation can be found in the Prosilas facilities, where assembly guides have been produced using SLS technology.

These guides are crucial for centering and drilling on mechanical parts, enabling more precise and efficient production processes.

dime sls alumide pa12 stampa 3d

Companies can benefit from exceptionally strong and lightweight geometries, contributing to the improvement of efficiency and precision in production processes.

Prosilas remains at the forefront in this continually evolving sector, providing customized solutions through its expertise in the use of advanced materials and industrial 3D printing technologies.

PA12 ALU

PA12 ALU  loaded with aluminum, has established itself as one of the most utilized materials in the manufacturing industry for 3D printing.

Parts produced with SLS technology and PA12 ALU exhibit excellent mechanical performance, high rigidity, abrasion resistance, and good thermal dissipation.

The possibility of surface finishing treatments and post-processing CNC machining provides additional customization options.

Material Characteristics:

  • Good mechanical strength
  • Abrasion resistance
  • Good thermal dissipation
  • Possibility of surface finishing treatments and post-processing CNC machining