Rapidia – Democratizing high-speed metal 3D printing across diverse industries

Rapidia is a pioneering manufacturer dedicated to democratizing high-speed metal 3D printing across diverse industries. With a vision centered on making Industrial Additive Manufacturing accessible, Rapidia is committed to transforming the landscape of metal part production. Their mission revolves around empowering designers, makers, researchers, and manufacturers, enabling them to independently engage in the production process.

Fueled by a passion for making and a commitment to creative problem-solving, Rapidia channels its dedication into crafting flexible, open platform tools. Positioned as catalysts for change, these tools are envisioned to be instrumental in transitioning the world towards a comprehensive, all-digital metal fabrication workflow. Rapidia's innovative approach aims to redefine the possibilities of metal manufacturing, making high-speed 3D printing accessible to everyone, anywhere.

Conflux 1: A Revolutionary Metal Additive Manufacturing Solution

Conflux 1 emerges as a user-friendly, high-speed, and cost-effective end-to-end metal additive manufacturing solution. This innovative system, driven by Metal Paste Deposition (MPD), transcends traditional limitations, offering a powder-free metal 3D printing process that seamlessly scales from lab-based rapid prototyping to an affordable small-scale production solution.

Scaling Efficiency with MPD Technology: Conflux 1, utilizing the cutting-edge Metal Paste Deposition technology, redefines the landscape of metal 3D printing. Its unique powder-free process accelerates the production of functional metal parts, surpassing conventional methods with remarkable speed.

Swift Production with Unmatched Speed: Most impressively, Conflux 1 significantly reduces production times, completing functional parts in less than half the time required by traditional metal filament methods. Users can expect to obtain fully functional parts in under 24 hours, revolutionizing the pace of metal 3D printing.

Safety at the Forefront of Metal 3D Printing: Conflux 1 prioritizes safety by utilizing metal securely bound in a paste feedstock. The process eliminates the need for chemical solvents or loose powder, minimizing environmental impact and eliminating volatile organic compounds (VOCs). This approach ensures a safer metal 3D printing experience.

Affordability Redefined: Conflux 1 boasts one of the lowest operating costs among metal additive manufacturing systems. This affordability empowers users to maintain lean and agile low-volume part production without compromising on quality or efficiency.

Complete Metal Additive Manufacturing Solution: Conflux 1 offers a comprehensive metal additive manufacturing solution that is ready to use without the need for a dedicated operator or additional equipment for powder handling, stress relieving, support removal, or furnace chilling. It provides a seamless and efficient workflow from printing to sintering, streamlining the entire metal fabrication process.

Metal Paste Deposition: Simplifying Metal Additive Manufacturing

In contrast to laser-based systems relying on melting metal powder, Conflux 1 introduces a game-changing approach known as Metal Paste Deposition. This method entails extruding a water-based metal paste, offering a more accessible and efficient metal additive manufacturing process.

The paste feedstock comprises metal particles securely bound in a diluted mixture of water and binder, with approximately 90% metal solids and 10% liquid by weight. Utilizing a drying lamp during printing, the water component evaporates, leaving behind a green part containing metal particles and less than 1% binder.

Precision in Binder Distribution: The physics of drying ensures precise binder distribution, strategically placing binder only where necessary. As the liquid component decreases, surface tension guides the remaining liquid to the closest points between metal particles. After complete evaporation, the binder is left to perform its function without the need for excessive quantities, distinguishing it from traditional metal filaments and Metal Injection Molding (MIM) feedstocks.

Debinding Shortcut: No Added Time: Metal Paste Deposition eliminates the need for a debinding step, as its feedstocks contain about 90% fewer polymers compared to other bound metal alternatives. This streamlines the process, allowing printed parts to transition directly into the furnace without added time for thermal debinding.

Ensuring Safety and Cleanliness: Metal Paste Deposition prioritizes safety by avoiding loose powder and harmful debinding chemicals. With no contact with hazardous metal powders, the process eliminates respiratory hazards and the potential for explosions. The absence of loose powders also eliminates the need for additional safety equipment.

Unlike competing bound metal feedstocks, Metal Paste Deposition expedites the sintering process, completing it in less than 12 hours. The low binder content allows for faster burn-off, making it suitable for both small and large parts. With minimal binder usage, Metal Paste Deposition enables the printing and sintering of full solid thick sections without the typical restrictions imposed by other metal printing methods. Additionally, users can easily bond multiple green prints together, creating seamless assemblies after sintering. This flexibility allows for optimal print orientations, regardless of the final part's layout.

Exploring 3D Printing Materials: Unlocking Possibilities with Advanced Materials

In the domain of 3D printing, an expansive materials portfolio awaits exploration, providing a plethora of advanced options meticulously tailored to suit diverse applications. This comprehensive selection spans from an array of metals to an inventive evaporative support material, not only facilitating the creation of intricate part geometries but also eliminating the need for arduous support removal processes. Prospective users are encouraged to engage with the expert team to identify and discover the ideal materials tailored to their specific applications.

The commitment to innovation propels an ongoing journey of material development, with the primary objective of expanding the materials portfolio to meet the dynamic demands of evolving industries. Currently undergoing development are materials that include:

• Tool Steel
• Cemented Tungsten Carbide
• Copper

Pioneering Support Material with Dual Extruders

The Conflux 1 printer distinguishes itself with dual extruders, introducing a revolutionary approach by incorporating evaporative support material both inside and outside any metal part. This groundbreaking support material serves dual purposes:

Design Freedom: Leveraging Metal Paste Deposition, an innovative 3D printing technology, the Conflux 1 achieves the printing of overhangs up to 45° without relying on traditional support structures. The addition of evaporative support in the second extruder empowers Conflux 1 to print any overhang, even completely horizontal overhangs.

Effortless Removal: Operating as a release layer between metal surfaces, the evaporative support material prevents bonding during sintering. Particularly beneficial for cantilevered shapes, the support layer ensures stability during sintering. Post-sintering, these supports can be effortlessly removed by hand, streamlining the production process and enhancing efficiency.

Dan Gelbart | Founder and President

Dan is a successful engineer, born innovator, passionate prototyping mentor and well-known Canadian entrepreneur, whose inventions have been documented in 145 US patents. In 1983, he co-founded Creo Products, a technology company that developed innovative products for the printing industry. He served as President and then CTO until July 2005, when Creo was sold to Kodak for $1 Billion. Further, he co-founded Kardium, MDI, Cymbolic Sciences, and Ikomed. While teaching at the University of BC, he created a highly regarded YouTube series on building prototypes, used as course material by universities including MIT. 

“Rapidia is committed to transforming the landscape of metal part production. Their mission revolves around empowering designers, makers, researchers, and manufacturers, enabling them to independently engage in the production process.”