Winner Start-up Challenge 2022
Improved AM composite bonding
SphereCube’s product is a 3D printer designed and assembled to enable the process of 3D printing polymer-based high performance composite materials, or rather thermosetting matrix with continuous fiber reinforcement.
Through the interaction of a heat source with the raw materials involved in the process, SphereCube’s system enables the production of components in composite material with continuous fiber reinforcement and thermosetting matrix. This innovative production process is able to automatically create products using high-performance composite materials, without geometrical limitations.
What makes us different form our competitors? Physics! While other companies are focused on complete curing of the UV thermosetting resin, SphereCube’s system is designed to enhance the wetting and bonding of fiber reinforcements and matrix and also between different 3D printed layers, by curing the thermoset using heat sources.
The MISSION of SphereCube is to get rid of composite processing scraps and molds, in order to reduce the environmental impact of composite production. The VISION of SphereCube is to enhance the sustainability of the entire manufacturing sector, exploiting the fabrication of composite 3D printers being less energy-consuming, able to work with biocompatible materials and more connected, with the aim of building a supply chain 100% sustainable.
Through the interaction of heat sources with the raw materials involved in the process, this system enables the production of components in composite material with continuous fiber reinforcement and thermosetting matrix. The innovative production process is able to automatically create products using high-performance composite materials, without geometrical limitations.
In addition, to facilitate the movement of the fiber along the system, a preparation of the raw fiber material is advised. For this purpose, SphereCube fabricated a system for the pre-Impregnation of the fibers, which takes place in a brand new "binderization" system (figure below). The system proposed by SphereCube is unique since it involves less solvent than usual and keeps the resin/binder ratio constant; this last characteristic is currently impossible to obtain with other systems patented or already on the market, since the fiber is typically immersed in a tank where the solvent undergoes uncontrolled evaporation, unbalancing the solution and modifying the characteristics of the filament during the impregnation process.
Aerospace: Combining the flexibility of Additive Manufacturing with the strength of high-performance composite materials, the production of small batches for the aerospace sector has never been easier, faster and cheaper.
Biomedical: create orthopedic prosthesis with extreme lightness and high resistance at the same time. SphereCube's ground-breaking production process enables parts customization according to the anatomical characteristics of the individual patient, at a lower cost than what can be obtained with traditional composites production technologies.
Sport: Go towards the extreme lightness of composite materials thanks to SphereCube and get unique components fulfilling the needs of each individual athlete. With the Thermal Laser Curing system it is possible to identify the ideal solution and customize it in terms of design, weight and anatomical characteristics, maximizing the performance of each individual athlete in a wide range of sport disciplines.
Shipbuilding: Fabricate parts never seen before in the naval sector and take advantage of the extreme flexibility of Additive Manufacturing combined with the specific performance of composite materials. SphereCube's patented system enables the production of components with shorter delivery times than traditional processes and to have a real-time response to customer needs.
Design: Take advantage of the high mechanical properties of high-performing composite parts and give life to timeless projects. Customize your ideas exploiting of the enormous versatility of SphereCube's innovative system.
“SphereCube is a young startup in the 3D printing field and Formnext will be the very first Expo we will attend as a company. The team looks forward to get in touch with estimated representatives of the 3D printing sector and potential clients, to test the real interest of the public and to attract potential investors.”