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

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

Feb 22, 2022 | Case History, News Prosilas, TPU - SLS Material

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.

Biocompatible material for 3D printing: Polycaprolactone

Biocompatible material for 3D printing: Polycaprolactone

Jul 30, 2021 | Case History, News Prosilas

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

Jul 2, 2021 | Case History, News Prosilas

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.

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

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.
[dsm_text_badges main_text=”NEW!” badges_text=”2024″ badges_background_color=”gcid-06befb97-b7d4-43d6-82dd-9c3832e40560″ _builder_version=”4.24.0″ _module_preset=”default” header_text_color=”gcid-06befb97-b7d4-43d6-82dd-9c3832e40560″ header_font_size=”29px” global_colors_info=”{%22gcid-06befb97-b7d4-43d6-82dd-9c3832e40560%22:%91%22header_text_color%22,%22badges_background_color%22%93}”][/dsm_text_badges]

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.
Data Sheet
Production equipment ( molds ) in PA2200 with 3d printing

Production equipment ( molds ) in PA2200 with 3d printing

Jan 8, 2021 | Case History, Pa2200 - SLS Material

Prosilas and DUEPì join forces to revolutionize the production of silicone components.

The present article outlines a successful case study arising from the collaboration between Prosilas, a leading 3D printing company, and DUEPì Automazioni Srl, a company specializing in the design and manufacturing of industrial automation.

The shared objective? Harnessing the capabilities of 3D printing in PA2200 to create molds in short timeframes and at affordable costs, revolutionizing the production process of silicone components.

Silicone Components through 3D Printed Molds

The two companies collaborated on the production of molds in PA2200 using Selective Laser Sintering (SLS) technology.

The choice of PA2200 as the printing material was based on its excellent mechanical and chemical properties, combined with biocompatibility (certified according to EN ISO 10993-1 and USP/level VI/121°C).

Stampo in silicone 3d

Creation of the PA2200 Mold

DUEPì handled the design of the mold geometries, while Prosilas took care of their 3D printing using SLS technology.

The synergy between the two companies allowed for the optimization of the mold geometries, significantly reducing production times and costs.

Production Technologies

Prosilas’ industrial 3D printers, based on SLS technology, ensure the production of individual parts and batches of ready-to-use products.

Laser sintering on polymeric powders currently stands as the most efficient solution for the production of industrial applications.

stampa 3d silicone stampi

Materials for 3D Printing: PA2200 and Its Exceptional Properties

PA2200, or polyamide 12, stands out as an excellent choice among 3D printing materials. Its characteristics make it a versatile and high-performance material, suitable for a wide range of applications.

  • A resilient and versatile material

PA2200 boasts high mechanical and chemical resistance, making it ideal for the production of robust components resistant to impacts, wear, and tension. Its rigidity and toughness make it suitable for bearing heavy loads and for use in various industrial environments.

  • Biocompatibility and safety

The biocompatibility of PA2200, certified according to EN ISO 10993-1 and USP/level VI/121°C regulations, makes it safe for contact with the human body. This makes it an ideal material for the production of medical and food components, where safety and hygiene are fundamental requirements.

  • Flexibility and printing performance

The versatility of PA2200 extends to 3D printing. The material can be used for printing complex and intricate geometries, offering high resolution and a premium surface finish. The ability to print in a variety of colors further expands creative and applicative possibilities.

PA2200 (nylon) utilizzata come materiale di produzione nella stampa 3D, in particolare nella tecnica di stampa SLS (Selective Laser Sintering).

Advantages for Mold Production

3D printing of molds in PA2200 offers a series of significant advantages compared to traditional technologies. Firstly, it allows for a drastic reduction in production costs, up to -180% compared to CNC machining or vacuum casting. This is achieved through the optimization of mold geometries and the reduction of material waste.

Secondly, 3D printing enables the production of molds in significantly shorter timeframes compared to traditional technologies. The speed of production allows for the creation of prototypes and finished products in a short time, ensuring greater flexibility and responsiveness to market needs.

Design flexibility and sustainability

3D printing in PA2200 provides extensive design freedom, allowing for the creation of complex and customized geometries. This results in molds optimized for specific applications, with the possibility of integrating various functionalities into a single mold.

Furthermore, 3D printing in PA2200 aligns with sustainability goals, thanks to the reduction of material waste and the production of lightweight and durable components.

From CNC to 3D SLS: advantages

From CNC to 3D SLS: advantages

Dec 15, 2020 | Case History, Pa2200 - SLS Material

Industrial Revolution: Performance and Design Optimization with SLS 3D Printing

 

3D printing as a viable alternative to CNC

Additive manufacturing and 3D printing technologies are emerging as effective alternatives to traditional CNC industrial systems.

In the following case study, we will explore how the use of our Selective Laser Sintering (SLS) 3D printing systems has allowed for the redesign and improvement of the performance of an industrial application.

New Industrial Application:

The goal was to design a new gripping and handling component based on the principle of the suction pad with differentiated vacuum chambers, intended for the automatic machinery sector.

Project Objectives:

During the development process, we set several objectives, including improving the production performance of the automated line, reducing the weight of the component, addressing assembly challenges, and shortening the time to market.

  • Improve the production performance (revolutions per minute) of the automated line on which the component is installed.
  • Reduce the weight of the component.
  • Address assembly challenges – monolithic part.
  • Shorten the time to market.

 

Design for Additive Manufacturing:

We have embraced the principles of design for additive manufacturing and 3D printing, focusing on optimizing conventional geometry. This approach has allowed us to fully leverage the capabilities of 3D SLS systems, achieving innovative solutions that would be impossible with traditional techniques.

Throughout the redesign process of the application, we achieved significant results, including the optimization of integrated channel flows for air depression, weight reduction of the component while preserving its mechanical properties, elimination of two air depression grip points, and the integration of threaded metal inserts.

3D SLS Manufacturing Technologies and Materials:

The printing of the application was entrusted to Prosilas’ Selective Laser Sintering machines.

During the process, advanced materials such as polyamide PA2200 (biocompatible according to EN ISO 10993-1 and USP/level VI/121°C regulations, approved for food contact) and reinforced polyamides (e.g., alumide, PA12GF, PA2210 FR…) were employed.

It is possible to choose the optimal printing material for each specific need.

our materials

Advantages of SLS 3D Printing over CNC Systems:

1.Significant Weight Reduction of the Component:

Through a meticulous redesign and optimization process, SLS 3D printing has allowed for a drastic reduction in the weight of the component while maintaining structural integrity and required performance. This lightweight characteristic opens up new possibilities in terms of energy efficiency and dynamic performance.

2.Realization of Complex Geometries for Excellent Fluidodynamic Performance:

The design freedom offered by SLS 3D printing has enabled the realization of complex geometries optimized to enhance the fluidodynamic performance of the component. This ability to create intricate and functional shapes has revolutionized how we conceive and implement engineering solutions.

 

4. Part Consolidation for Simplified Management:

One distinctive feature of SLS 3D printing is the ability to consolidate multiple complex parts into a single monolithic structure. This not only reduces the total number of components in the system, simplifying assembly but also contributes to greater overall efficiency and durability.

5. Elimination of Seals and Simplification of the Connection Interface:

SLS 3D printing has allowed for the elimination of the need for complex seals, simplifying the component’s architecture and improving overall reliability. The machinery connection interface has been optimized, reducing grip points and enhancing overall integration into the automated line.

6. Overall Performance Enhancement and Delivery Time Improvement:

With the adoption of SLS 3D printing, there has been a significant improvement in the overall performance of the automated line.

Additionally, delivery times are considerably reduced compared to traditional machining, allowing for greater flexibility and responsiveness in the industrial context.

The evolution towards SLS 3D printing has proven to be a strategic choice, redefining the paradigms of engineering and industrial production through continuous innovation and unprecedented optimization.

Prosilas and Bambino Gesù Hospital: 3D printed bronchial stent for a 5 year old patient

Prosilas and Bambino Gesù Hospital: 3D printed bronchial stent for a 5 year old patient

Nov 8, 2020 | Case History, News Prosilas

Bronchial Stent

Prosilas in collaboration with the Bambino Gesù Hospital of Rome has realized a 3D printed bronchial stent.

In 2017 Prosilas, already a leading company in additive manufacturing, received a request from a researcher from the Bambin Gesù Hospital in Rome for the realization of a polycaprolactone stent. 

Firmly believing in the project, the company decided to invest in research and development and, after two years of experimentation produces – in just 6 months from the first tests – the first bio-compatible and absorbable stent, making possible the first transplantation of a 3D bronchus in Europe. 

 

 

la produzione Stampe tre d per produzioni e preserie Prosilas

Prosilas: the company

Prosilas was founded in Civitanova Marche in 2003 as a company that offers rapid prototyping services through the use of additive technologies and 3d printing.

It is active in the automotive, motorsports, aviation, medical, footwear and industrial sectors. 

Its production system includes more than 10 additive manufacturing systems with SLS and SLA (Stereolitography) technologies.

Within the company there is a pre-process design and optimization department, an area dedicated to aesthetic and functional post-process treatments, a metrological station for quality control and an area dedicated to research and development. 

A creative “corpus” that makes it able to provide consulting and service for additive manufacutring production.

Bronchomalacia: what is it?

Bronchomalacia is a relatively rare disease. It consists of a congenital or acquired anomaly affecting the large respiratory tract. It most frequently involves the left main bronchus and manifests itself with a yielding or narrowing of the cartilaginous rings that support the bronchial wall, preventing the normal flow of air in the lung and, in the most severe cases, making patients unable to breathe independently.

A 5-year-old boy was affected and the doctors of the Bambin Gesù Hospital were looking for a way to save his life without having to use lifetime a respirator.

The child’s bronchus was squeezed between the left pulmonary artery and the descending thoracic aorta. This compression had generated the narrowing of the respiratory duct and the yielding of the cartilage rings that support the wall of the bronchus.
The fundamental problem was constituted by the material and shape of the stents which are usually metallic and are implanted inside the hollow organs.

There was a need for a stent that could act as an external structure, which would support the bronchial walls and allow them to regenerate.
It also had to grow with the child’s body – without breaking or causing hemorrhages – to be absorbable and to facilitate breathing.
Hence the researchers request all European companies that deal with 3D printing for the creation of a biocompatible bronchus, a request that none was able to provide.

la produzione Stampe tre d per produzioni e preserie Prosilas

“In 2017 we received the first request for a polycaprolactone stent from a researcher of the Bambino Gesù Hospital of Rome. Until then we had never heard of Polycaprolactone. Believing in the project, we decided to invest in research and development working on the properties of the material and buying a new machine entirely dedicated to the project”, says Vanna Menco, CEO of the company, because «we realized that we were faced with something so extraordinary that it was worth trying”.

Case Study

The stent was made by combining hydroxyapatite – already an elective material for the construction of devices intended for bone regeneration – and polycaprolactone, a biocompatible polymer that can be completely bio-assimilated within a couple of years and which, up to now, had never been printed in 3D.
The creation of the stent is the result of work that involved various players in the additive manufacturing process. It took 6 months to go to the idea to the realization.
The geometries were created starting from the two-dimensional images (CT) made in the Department of Diagnostic Imaging by dr. Aurelio Secinaro and then co-designed by Dr. Luca Borro of “Unità di Innovazione e Percorsi Clinici.”
For the mechanical resistance tests, we cooperate with the University of Modena and Reggio Emilia and numerous experiments were necessary, especially in terms of sterilization of the device.

    «The geometry allows both the cells not to sink to the bottom where they are unreachable by nutrients, and to guide their
    proliferation and growth»» Vanna Menco, CEO Prosilas

    From 3D to 4D printing

    The creation of the stent with additive manufacturing technologies is a clear example of the very evolution of traditional 3D printing technologies in the so-called 4D printing or bioprinting.
    A fourth dimension is added to the three dimensions to represent the transformation of materials over time. A very challenging evolution that can represent a physiological passage for those who have believed in and worked in the additive manufacturing
    field since the very beginning.
    The experience and determination of Vanna and Giulio Menco and of all the Prosilas staff have been fundamental to the success of the project which projects Italy among the world leaders in 3D printing.

    “Soon other kinds of stents will be completely replace: the easily dislocatable silicone stents and metal stents which, once incorporated into the wall of the airway, are no longer removable and can interfere with the growth of the child’s respiratory system.
    The 3D “bronchus” implanted on our little patient, on the other hand, will disappear from the body within a couple of years. It is reasonable to think that, in the meantime, it will have induced the generation of a peribronchial fibrous reaction which will somehow “replace” the function of the damaged cartilage: the bronchus will thus be able to support itself and will have the possibility to develop and continue to grow”. Explains the heart surgeon Adriano Carotti. 

    The surgery

    The surgery was performed on October 14, 2019 by Dr. Adriano Carotti, head of the “Unità di Funzione di Cardiochirurgia Complessa con Tecniche Innovative,” ‘, in collaboration with the airway surgeons of the Laryngo-Tracheal Team, directed by Dr. Sergio Bottero.
    The implant in the child was possible thanks to the authorization by the Ministry of Health for compassionate use and Prosilas created the device pro bono.

    The child was able to go home one month after the surgery and will
    have a normal life.

    “We are happy to have won an enormous challenge: saving a child’s life. We make our experiences and our process available to the medical world so that they can be a useful tool for improving the lives of people”.
    Vanna Menco, Ceo Prosilas

    Press release

    Il Sole 24 Ore – Prosilas cresce con stampi in 3D nel settore biomedico di Michele Romano  – 25/7/19

    3D4Growth – Prosilas: ritorno alla vita grazie alle tecnologie di Additive Manufacturing  di Francesco Puzzello  – 3/12/19

    Ospedale Bambino Gesù – Blog – Impiantato primo “bronco” 3D su bimbo di 5 anni – 3/12/19

    Ansa.it – Bronco riassorbibile in 3D restituisce il respiro a un bambino di 5 anni – di Silvana Logozzo  3/12/19

    Rai News – Bronco riassorbibile in 3D ridà il respiro a un bimbo – 3/12/19

    Cronache Maceratesi – Bronco in 3D salva la vita ad un bambino  – 3/12/ 19 di Laura Boccanera

    TGcom24 – Bambino Gesù, bronco riassorbibile in 3D ridà il respiro a un bimbo –  3/12/19

    01Health – Stent biocompatibile stampato in 3D per un bambino– 9/12/19

     

     

    “We will continue to work on the development of this type of application by trying to stimulate the scientific community to a greater use of additive manufacturing materials and technologies, we make available to the world of Medical our experiences and our process so that they can be a useful tool to improve the lives of other people”

    Vanna Menco

    CEO PROSILAS