Marco: Let’s start from the beginning. Tell us a bit about your background and what brought you to open your own 3D printing service?

François: “I studied in industrial engineering, because I was always fascinated by product transformation and manufacturing.

During one of my internships at university, I was lucky to work for a Quality Manager who introduced me to the Quality Principal. And this person pushed me to specialize in Quality Manufacturing at university.

Then I started working for a consulting company specialized in Lean Manufacturing / Six Sigma, where I had the chance to apply the knowledge learned from university in multiple great manufacturing companies: Alcan, Bombardier, Rio Tinto, GE, IBM…

After almost a decade of working in the consulting side, I decided to start my own manufacturing company.

In 2010, I founded Solaxis Ingenious Manufacturing. As a team, we identified opportunities with 3D printing of approved aerospace materials and for end-use part applications beyond prototyping. From the start, we decided to focus on industrial parts / end use parts.

In the last years, several 3D printing patents have expired. So, in 2020, we decided to implement new open-source 3D printing technologies where we could integrate innovative materials, like those from BASF Forward AM, maximize our processes and R&D expertise, and diversify applications.“

Marco: Can you tell us a bit about your 3D printing service? What makes it stand out in the industry, and are there specific sectors you primarily focus on?

François: “At Solaxis, we solve manufacturing problems, when our customers need complex parts. How we stand out in the industry:

• With the industrial 3D printing technologies we are using: robust production systems to offer quality parts, repeatability and reliability.
• With our large-format and large production capacity.
• With our wide range of materials, from standard to high performance, and with our more exotic and innovative materials… to cover several types of applications and requirements.
• With our specialized engineering expertise and industrial R&D capability to solve specific customer problems by analyzing, and offering the best solutions and combination of thermoplastics materials and additive manufacturing processes. Just to give you some examples of the engineering support we can offer:
  • We have customers with critical projects requiring some strength for their parts. For this type of cases, we can print test pieces in different orientations, with BASF Forward AM’s Ultrasint® PA11, and carry out destructive tests (tension, compression, flexion) in our laboratory space at Solaxis. 
  • Some customers have also asked us to help them with the conductivity analysis of their printed parts. Thanks to our certified in-house measuring equipment, we managed to validate the conformity of parts that met surface and volumetric ESD (Electrostatic Discharge) requirements.
• We also stand out with our automated and effective quality management system that assures good management of projects. We have the certifications: AS 9100, ISO 9100, Controlled Goods Program, and a high level of cybersecurity according to the NIST-800-171 standard.

Our main industries are: aerospace, defense, electronics, ground transportation, healthcare and industrial sectors.”

“At Solaxis, we solve manufacturing problems, when our customers need complex parts.”

Marco: Moving onto our partnership, how did you first come across BASF Forward AM, and what motivated you to become a partner?

François: “We first met members of the BASF Forward AM team at events, but at the time we did not have SLS technology. When we acquired our SLS equipment, we were looking for a reliable and established partner who offered materials that could set us apart from the competition. We therefore looked at BASF Forward AM since they offered PA11 with interesting mechanical properties. We have excellent support from their team and they were able to answer our technical questions toward the integration process.”

Marco: Let’s talk about our PA11 portfolio for your SLS 3D Printers. How have they benefited your operations, and what has your experience been with the quality and performance of these products?

François: “The BASF Forward AM materials we use provide a good surface finish and excellent mechanical properties, which allows us to push the limits in terms of possible applications. Yes, we tested some PA12s during the integration of our equipment. However, the Ultrasint® PA11 allows us to obtain better mechanical performance while being simple to use. In addition, the composition of Ultrasint® PA11, which comes partly from castor oil, offers a greener approach compared to PA12 which comes from the processing of petroleum. In short, the Ultrasint® PA11 sets us apart from the SLS industry, where the PA 12 is more common.“

“Yes, we tested some PA12s during the integration of our equipment. However, the Ultrasint® PA11 allows us to obtain better mechanical performance while being simple to use.“

Marco: In which applications do you find our materials to be most advantageous, and which specific uses can benefit the most from this material?

François: “ BASF Forward AM materials can be used in multiple sectors of activity such as prototypes, end-use parts, robotic grippers and tooling. Ultrasint® PA11 allows use for applications requiring greater mechanical strength than standard PA12. Ultrasint® PA11 is even more important for our customers who are looking for a greener approach as an alternative to PA12.

End-of-arm tooling: 

• Customer: yourbarfactory – Food industry
• Application: End-of-arm tooling for vacuum pick-and-place systems, tooling that connects to the end of a robot arm. The tooling is used to move boxes.
• Technology: SLS technology, ideal for low- and medium-volume production. Solaxis’ SLS printers offer enhanced resolution, surface finish, and faster production times.
• Material: Ultrasint® PA11 CF. Considering the application, the customer needed a very solid part, with great strength and rigidity. The SLS technology and the material provided an excellent surface finish and good sealing, which was necessary for the vacuum.
• The customer being satisfied, we produced different variants of this gripper, according to the different sizes of boxes to be moved.

3D Printing Custom Orthotics:

• Customer: Health sector – Podiatric Clinic
• Application: Custom orthoses manufactured using additive manufacturing technology. The clinic needed durable, personalized orthoses to improve patient quality of life, with each orthosis perfectly matching the patient’s foot or limb.
• Material: Ultrasint® PA11, chosen for its superior mechanical properties and moisture resistance compared to PA12.
• Technology: SLS technology, ideal for low- and medium-volume production. Solaxis’ SLS printers offer enhanced resolution, surface finish, and faster production times.
• Process: Orthoses are produced in small batches (40-100 units every two weeks) with a rapid turnaround time of five to seven days. The design process includes precise scanning to ensure a perfect fit and durability.
• Challenges Addressed:
  • Durability: Orthoses must have excellent mechanical properties and resistance to moisture.
  • Production Flexibility: Just-in-time manufacturing allows for variable production volumes without high initial investments.
  • Technical Support: Essential for initial design testing and ongoing production quality assurance.
• Results: Solaxis provided high-quality orthoses with improved mechanical properties, moisture resistance, and durability, enhancing patient comfort and satisfaction.

3D Printed Protective Case:

• Customer: Ekyrail Entreprises Inc. – Railway sector
• Application: Protective cover for an electrical switch in locomotives, ensuring health and safety for railway workers. The cover restricts access to sensitive electronic components.
• Material: Ultrasint® PA11, selected for its robustness and excellent mechanical properties.
• Technology: SLS (Selective Laser Sintering) 3D printing, suitable for producing parts with complex geometries and small-volume production. Solaxis’ SLS printers provide precise and high-quality parts.
• Process: Production of the protective cover with internal dimensions of 6.73 in. x 3.76 in. x 2.28 in., featuring a complex geometry that includes reinforcements. The cover must be durable, precise, and have a high-quality surface finish, with deep dye red coloring for safety.
• Challenges Addressed:
  • Complex Geometry: Difficult to machine, making SLS printing an optimal solution.
  • Low-Volume Production: Around 100 parts per year, manufactured on-demand.
  • Surface Finish and Coloring: High-quality finish and consistent red coloring achieved through automated dyeing processes.
• Results: Solaxis provided a robust, durable, and precise protective cover, enhancing the safety of locomotive switches. The flexible manufacturing process allowed for easy design modifications and efficient production of small batches.

Marco: Could you share your experiences with any of the specialized services and solutions you utilize? How do these services support your efforts in improving customer satisfaction?

François: “When it comes to finishing/post-processing, we offer deep dye coloring, forced vapor deposition smoothing and conventional spray painting. These surface treatments make it possible to offer a range of even more aesthetic products that meet the various needs of our customers. This also makes it possible to have products suitable for direct sales to consumers and a faster design to market process.”

“Ultrasint® PA11 allows use for applications requiring greater mechanical strength than standard PA12.“