Collaboration between Alveo3D and Fabbrix®
Alveo3D and Fabbrix® initiated their collaboration in late 2020 with a shared goal: to develop and integrate high-performance filters into Fabbrix’s large-format 3D printing solutions. The partnership sought to address key concerns in air filtration, specifically focusing on filter efficiency, pressure drop, and temperature resistance.
I. Project Initiation
Fabbrix® reached out to Alveo3D in November 2020, inquiring about the feasibility of incorporating custom-designed filters into their 3D printer models ( ELEMENTO v2.1 and ELEMENTO TC ). Their key requirements included:
- High filtration efficiency while maintaining a low-pressure drop.
- Compatibility with existing Fabbrix systems.
- Resistance to a temperature range of 0°C to 80°C.
II. Challenges Encountered
1. Prototype development constraints
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- Initial prototypes encountered difficulties due to the limited thickness available for folding HEPA media. The original design called for folds at 10mm, significantly smaller than the usual 20mm required for standard HEPA configurations.
- To resolve this, Alveo3D proposed using nano-synthetic mesh HEPA (N13) and a cotton-based HEPA (M13) to ensure structural integrity and performance.
2. Airflow & pressure drop adjustments
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- The tests showed that the air pressure loss was substantial. Increasing the filter thickness to 60mm (instead of 30mm) was suggested to enhance filtration efficiency without excessive resistance.
- Fabbrix requested assistance in selecting axial fans that could accommodate the new filter specifications.
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III. Prototyping and Testing
Throughout 2021, Alveo3D provided multiple prototypes, refining the design based on Fabbrix’s testing feedback:
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By early 2021, the first test results were shared, highlighting a need for improvements in airflow dynamics.
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Alveo3D recommended modifications to the filter dimensions to optimize performance.
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Additional testing was performed to assess the impact of temperature variations on filter efficiency.
IV. Final Implementation
This case study highlights the complexities of integrating filtration systems into the industrial 3D printer. After refining the design, Alveo3D successfully delivered a final version of the N13 filter, meeting Fabbrix’s specifications.
- Enhanced Air Quality: Users reported a significant reduction in odors and airborne particles.
- Seamless Integration: The filters fit perfectly into the ELEMENTO and ELEMENTO TC enclosures without modifications.
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