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Made by Aliens

Made by Aliens

Case History 

BASF Forward AM + JNORIG + Prosilas 

“ I wish they looked like they were made by aliens” says Javier Giron, creative director of JNORIG.

Exploring Futurism and Sustainability in Fashion

In the heart of Barcelona, where diversity meets innovation, the avant-garde fashion brand JNORIG thrives.

Led by the visionary creative director, Javier Giron, JNORIG challenges conventions, embracing a futuristic aesthetic that celebrates individuality and self-expression.

In a quest to bring otherworldly designs to life, JNORIG embarked on a journey that led to an extraordinary collaboration with Prosilas and BASF Forward AM, resulting in the creation of truly remarkable pieces that seem “made by aliens.”

 

Challenge: Bridging Fashion, Sustainability, and Innovation

Fashion, by its very nature, is a realm of constant exploration and reinvention. It is a space where new ideas merge with cutting-edge technology and sustainable practices. It’s a shared DNA with the 3D printing industry.

When JNORIG expressed their desire for designs that defied convention and embodied sustainability, Prosilas and BASF eagerly accepted the challenge.

The task at hand was to produce jewelry pieces with unconventional shapes using sustainable materials, all while maintaining an impeccable level of surface finishing akin to creations from another world.

This challenge perfectly aligned with Prosilas and BASF’s commitment to pushing the boundaries of 3D printing technology and sustainable manufacturing.

Solution: Ultrasint® PA11 – A Sustainable Innovation

Prosilas, in collaboration with BASF Forward AM, introduced Ultrasint® PA11 into their Selective Laser Sintering (SLS) systems.

Ultrasint ®PA11, made from castor oil, represents a bio-based alternative to traditional materials like PA12.

Its exceptional toughness, high elongation at break, and elasticity make it an ideal choice for creating resilient, impact-resistant parts.

Notably, Ultrasint® PA11’s biocompatibility and safety for human contact make it suitable for a wide range of applications, including medical devices and sensitive sectors.

Moreover, BASF’s commitment to sustainability extends beyond material innovation; they work closely with castor farming communities in India to enhance productivity and reduce environmental impact.

“Partnering with Prosilas on the ‘MADE BY ALIENS’ project highlighted our commitment to sustainability and innovation. Using our eco-friendly Ultrasint® PA11, they pushed the boundaries of 3D printing to bring JNORIG’s futuristic visions to life. This collaboration exemplifies the transformative power of combining cutting-edge technology with creative ambition, breaking the manufacturing boundaries in fashion, and beyond” says Marco Cristofori, Senior Product Marketing Manager, BASF Forward AM

“In the world of fashion, innovation is the engine that drives designers’ creativity beyond limits with a distinguishing passion. For us, this market is a continuous source of inspiration and advancement in processes, constantly searching for new materials and finishes. Collaborating with JNORIG has been an incredibly stimulating experience: their innovative mindset seamlessly blends with the ever-changing demands of a market that evolves continuously, creating a bridge between the physical and digital worlds. It has been a privilege to be the connection between designers’ vision and product realization, transforming ideas into reality with enthusiasm and dedication,” shares Vanna Menco, CEO of Prosilass

Collaboration Process: From Concept to Catwalk

The collaboration between Prosilas, BASF, and JNORIG was characterized by innovation, efficiency, and creativity.

Within just one month from the initial request, the teams transformed JNORIG’s visionary designs into tangible reality.

Using state-of-the-art 3D printing technology and advanced materials, they produced jewelry pieces that transcended conventional boundaries.

The designs, characterized by fluid silhouettes and otherworldly aesthetics, captured the essence of JNORIG’s futuristic vision.

Fashioning a Sustainable Future

The culmination of this collaborative effort was showcased at the Barcelona fashion show on April 10th, 2024.

The jewelry pieces, crafted from Ultrasint® PA11, not only mesmerized the audience with their striking designs but also highlighted the potential of sustainable materials and advanced manufacturing techniques in the fashion industry.

JNORIG’s commitment to sustainability and innovation extends beyond individual creations; it represents a larger movement towards a more responsible and inclusive fashion ecosystem.

Through the fusion of creativity, technology, and sustainability, JNORIG, Prosilas, and BASF are pioneering a new era in fashion—one that is both visionary and conscientious.

In a world where the boundaries between imagination and reality blur, collaborations like these serve as a testament to the transformative power of creativity and innovation. As we venture further into the future, guided by the spirit of exploration and sustainability, the possibilities are as limitless as the cosmos themselves.

Javier Giron, designer JNORIG

FOCUS

JNORIG

JNORIG is a brand dedicated to diversity and breaking societal norms, celebrating individuality regardless of background, religion, or gender. With architecture-inspired designs and gender-fluid silhouettes, they blend cultural elements and opposing concepts for a unique artistic vision. Javier Giron’s innovative garments combine precision, comfort, and sustainability, embodying a futuristic aesthetic. Tailored for different body types, JNORIG’s designs promote confidence and self-expression, inviting wearers into a universe of disruption and mystique.

BASF Forward AM

BASF Forward AM provides 3D printing solutions along the entire Additive Manufacturing value chain: From consultancy and development, through bespoke design, digital simulation and prototype printing, to finishing and exhaustive component testing – Forward AM provides you with exactly what your business needs. Whichever material you require for your specific project, Forward AM offers you the world’s largest selection of 3D printing materials and service solutions.

Prosilas

Established in 2003 and part of the Prototal Group since 2022, Prosilas stands out as an advanced service provider that integrates various technologies, from 3D printing to vacuum casting and injection molding.
With a strong customer focus and proven experience, Prosilas is a reliable, fast, and sustainable partner for the industry. The company is a reference point for series production, with a long-term vision and the commitment to completing the production cycle by satisfying every phase.
Prosilas offers its expertise in industrial processes and polymer materials to meet the new market demands. Prosilas promotes the research of innovation on products and solutions, with the aim of reducing waste and intensifying research in an efficient and sustainable way.

Basf è un partner di Prosilas per la stampa 3d

How 3D printing is beneficial to the medical sector.

How 3D printing is beneficial to the medical sector.

3D Printing in the Medical Sector: Innovation and Life-Saving Applications

In recent years, 3D printing has revolutionized the medical sector, providing customized solutions and contributing to improved clinical outcomes for patients.

This innovation has paved the way for a range of life-saving applications that address critical medical challenges, radically transforming the production of devices and prosthetics.

Customized Prosthetics for Maxillofacial Surgery

An emblematic example of life-saving use of 3D printing is found in maxillofacial surgery. In this field, the technology allows for the creation of titanium prosthetics perfectly tailored to the individual needs of the patient.

These prosthetics, used in complex procedures, restore the patient’s facial structure, giving them new confidence and improving their quality of life even after highly impactful surgeries.

Polymeric Materials for Life-Saving Applications

In addition to metals, 3D printing successfully utilizes polymeric materials.

An example is the 3D bronchial stent made of polycaprolactone, developed by our team in collaboration with Bambino Gesù Hospital in Rome and currently undergoing certification.

This technology has found application in the healthcare sector, enabling the production of customized, high-quality medical devices in small batches.

This makes otherwise expensive or complex solutions accessible, improving efficiency and reducing production times.

3D Printing in Healthcare: Innovation and Accessibility

Thanks to the optimized design made possible by 3D printing, lighter and more efficient solutions are achieved, helping to reduce costs and improve the overall quality of medical devices.

This is particularly evident in orthopedic surgical procedures, where 3D printing enables the production of customized prosthetics and surgical guides.

These tailored solutions reduce surgical times and improve outcomes for patients, increasing precision and reducing the risk of complications.

Photo courtesy of Prototal Damvig

Photo courtesy of 1zu1

Advanced Support for Customized Medical Solutions

Prototal Group, with its centers of excellence (cleanrooms) and specific certifications for medical device production, is committed to supporting companies in need of advanced solutions.

By collaborating with industry experts and adopting the latest technologies, we are able to provide personalized and high-quality solutions to meet the needs of our clients in the medical sector.

 

Photo courtesy of Prototal Sweden

Photo courtesy of Castomade

Prototal Talks: the future of 3D printing is online!

Prototal Talks: the future of 3D printing is online!

Prototal Talks

Prototal Industries is pleased to announce the birth of Prototal Talks, a series of free webinars dedicated to the world of 3D printing.

In an ever-changing world, where technology advances by leaps and bounds, it’s critical to stay up to date with the latest news and trends.

Prototal Talks was born with this goal in mind: to provide all the enthusiasts and professionals of the sector a unique opportunity to deepen their knowledge and discover the latest innovations in the field of 3D printing.

The second event: 3D Printing Technologies, Materials & Applications at Prototal Industries

Lost in the endless offerings of 3D printing technologies, materials and its applications?

Don’t worry, we will have you covered in our latest Prototal Talks the 22nd of May, where Markus Schrittwieser will join us in a deep dive on 3D printing technologies, material selections and its diverse applications!

Join us for an exclusive and free webinar specifically tailored to our in-house offerings and how applications can inspire you to get involved in and benefit from the cutting-edge of Additive Manufacturing.

See you online!

 

Date: May 22, 2024
Time: 10:30 a.m.
Duration: 1 hour (präsentation + Q&A session)
Topic: 3D-printing technologies and materials in the Prototal Group
Language: English
Lecturer: Markus Schrittwieser

Markus Schrittwieser from 1zu1 will be the rapporteur.

 

To participate in the webinar, you must register at the following link: https://mailchi.mp/prosilas.com/mq7mds5j30

Do not miss this unique opportunity to stay updated on the world of 3D printing!

Register now for the first Prototal Talks event!

 

Markus Schrittwieser

MarkusSchrittwieser has been the 3D-Printing and Additive Manufacturing manager at 1zu1 Prototypen since 2012.

He oversees the implementation of 3D printing processes, manages Additive Manufacturing projects, and monitors research and technological development.

He shares his knowledge in 1zu1onlinetalk and seminars (Austrian 3D-Printing Seminars, workshops at FH Vorarlberg and ZHAW in Winterthur) to facilitate entry into additive thinking.

With over 11 years of experience in mechatronic product development, he studied Mechatronics at FH Vorarlberg and obtained a master’s degree in Mechanical Engineering and International Sales at FH Konstanz. 

 

Why attend the Prototal Talks?

The advantages of participating in our webinars are many:

  • Learning from industry experts: Our speakers will be among the best experts in 3D printing at national and international level, ready to share their knowledge and experience with you.
  • High quality content: Webinars will be structured to provide accurate and up-to-date information on a wide range of topics, from rapid prototyping to mass production.
  • Interaction and networking: You can interact directly with speakers and other participants, asking questions and sharing your experiences.
  • Free training: All webinars will be completely free and accessible to everyone.
Certifications: The journey towards excellence and responsibility

Certifications: The journey towards excellence and responsibility

Prosilas: High-Quality Standards and Corporate Responsibility.

Certifying our company is not just a formal act but a tangible demonstration of our commitment to high-quality standards and corporate responsibility.

Certifications such as ISO 9001 and ISO 14001 have become the cornerstones of our approach to daily work, defining our way of operating and inspiring a culture of continuous improvement.

ISO 9001: A fundamental framework for operational excellence

ISO 9001 was the first certification obtained by Prosilas, serving as the foundation upon which we built our quality management system.

Beyond mere compliance, this certification has guided us in implementing procedures that standardize every aspect of our workflow.

Every member of our team is involved and trained to handle work according to stringent guidelines, ensuring consistent quality and fueling our ongoing pursuit of improvement.

ISO 14001: Active Commitment to a Sustainable Future

Our commitment to a healthy and sustainable environment is embodied by our ISO 14001 certification.

Beyond compliance with environmental regulations, we challenge ourselves to continuously measure and improve our environmental impact. From safety to consumption, emissions to noise, every aspect is carefully assessed and enhanced.

This certification is not just a requirement but a tangible demonstration of our dedication to a more sustainable future, aligning with the expectations of our environmentally-conscious customers.

Prototal and the Environment

The attainment of these certifications aligns with Prototal Industries‘ commitment to environmental sustainability.

Our promise by 2030 is to provide cutting-edge, future-oriented solutions that generate positive impacts on customers, society, and the environment, aiming to establish a high industrial standard.

Through innovation, we will pursue the goal of fully integrating into a 100% circular value chain. We believe that sustainability is not only a corporate responsibility but a crucial element for the long-term success of our business.

Towards New Horizons: IATF and TISAX

Looking to the future, we are working towards obtaining IATF (International Automotive Task Force) and TISAX (Trusted Information Security Assessment Exchange) certifications by 2024, thus entering the realm of global regulations in the automotive industry.

IATF standards represent global procedures and regulations required by the automotive industry for its supply chain.

This investment not only ensures compliance as suppliers but empowers the entire organization by transferring advanced skills.

Rigorous staff training and the adaptation of the facility workplaces are essential requirements, leading to a transformation that extends beyond the automotive sector and can be applied to other industrial fields.

Beyond Certifications, Toward a Future of Excellence

Each certification is a crucial step in our corporate journey. Certifying our company is not just stamping a seal on a document; it is our commitment to building an organization that is excellent, conscious, and dedicated to continuous improvement.

We are ready to face the challenges of the modern world with responsibility, awareness, and the determination to pursue excellence in every aspect of our work.

Innovation in Soccer: Study and Implementation of Protective Masks through 3D Printing

Innovation in Soccer: Study and Implementation of Protective Masks through 3D Printing

3D Printing in the Development of Sports Protective Devices

Simone Gallozzi Demonstrates Its Potential in His Thesis

Sport and 3D Print

The world of sports is constantly seeking innovative solutions to enhance athletes’ performance, reduce the risk of injuries, and facilitate recovery.

3D printing, in particular, is emerging as an increasingly popular technology, enabling the production of customizable protective devices such as prosthetics, running shoe soles, helmets, and other safety gear – as exemplified by our Case Study on Lube Volley.

In particular, Simone Gallozzi’s thesis demonstrates the feasibility and details the workflow of a 3D printing application in the field of soccer

Simone Gallozzi protective mask in PA 603 CF

 Lube Volley Athletes

The candidate, in his thesis titled ‘ADDITIVE MANUFACTURING IN THE SPORTS WORLD – Analysis and Production of Facial Protective Masks in Soccer,’ under the guidance of Professor Eleonora Santecchia, conducted a thorough analysis on the application of 3D printing in sports.

His main objective was to explore the production of protective devices through 3D printing, both for the maxillofacial area and other parts of athletes’ bodies.”

Case Study: Maxillofacial Protective Mask

The heart of the thesis is represented by the Case Study, in which Gallozzi,student
of Mechanical Engineering at the Università Politecnica delle Marche, collaborated with our company in the development of a maxillofacial protective mask designed for soccer players.

Material and Printing Technology Selection:

The first step involved choosing the most suitable material and printing technology for the application.

In this case, the chosen material is PA603CF, a composite of PA2200 loaded with carbon fiber.

Its ability to provide high-performance, coupled with its resistance to the stresses typical of the soccer environment, makes it ideal for the production of advanced protective devices.

The selected printing technology is SLS (Selective Laser Sintering), enabling the precise and durable printing of PA603CF parts.

PA603CF materiale caricato con fibra di carbonio per la stampa 3D

PA 603 CF – Carbon filled Polyamide

Exemple of specimens for tensile and flexural tests

Design and Production Workflow

1 – Modeling and Printing of Specimens for Tensile and Flexural Testing:

Prior to the production of the mask, validation tests of the material were conducted, in accordance with UNI EN ISO 527-2, 1A, and ISO 178 standards.

The specimens modeled using Siemens NX passed tensile and flexural tests, confirming the suitability of PA603CF for the maxillofacial protective mask.

2 -Face scanning:

The next phase involves the 3D scanning of the subject’s face for whom the mask has been modeled.

This scanning is performed using a 3D scanner, which captures the shape and size data of the face.

The acquired data is then used to create a 3D model of the mask that perfectly fits the subject’s face using reverse engineering techniques

Scanning phases

Mask 3D model

3 – 3D Modeling:

The 3D model of the mask is created using Siemens NX, a 3D modeling software. The model is designed to protect the most vulnerable areas of the face, such as the cheekbone, jaw, and nose.

Consideration for comfort and lightness was crucial, along with the desire to preserve the athlete’s peripheral field of vision to the maximum extent possible.

4 -Prima realizzazione del prototipo

Prima di procedere con la maschera finale, è stato creato un prototipo in VeroWhitePlus con la stampante 3D Objet30 di Stratasys, che sfrutta la tecnologia di material jetting.

Questo passo preliminare ha consentito di valutare la bontà del design prima di passare alla fase successiva.

First protoype of the mask

Last phase, finally the mask is printed

5 –3D Printing with SLS Technology and PA603CF Material

Once the success of the prototype was confirmed, the 3D printing of the final protective mask in PA603CF was initiated using our company’s SLS 3D printers.

This phase represents the culmination of the thesis work, with the chosen material selected for its intrinsic properties of rigidity, strength, hardness, and lightness.

Post-Printing Phases: Safety and Customization

Simone Gallozzi theoretically discussed post-printing phases, including the need to internally coat the mask with a soft material for skin contact. He proposed the use of strategic supports to avoid contact with the traumatized area.

Surface treatments and aesthetic customizations are considered to enhance the appearance of the mask, completing the process with the addition of elastic bands through designated holes.

 

Simone Gallozzi’s work represents a very interesting application of Additive Manufacturing in the world of sports, highlighting how collaboration between academia and industry can open new perspectives for innovation.

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