Royal3D adapts DAC system inlet production to 3D printing process

3D printing company Royal3D B.V. (Rotterdam, The Netherlands) was part of the creation of direct air capture (DAC) system inlets for Dutch-based Carbyon Go. (Eindhoven) via its CFAM printer and recycled PET-G + 19GF material. Contacted through De Productenmakers (Eindhoven), Royal3D’s task was to adapt the inlet design to the 3D printing manufacturing process.

Royal3D approached the request using its step-by-step development method, progressing from design, through testing, followed by the actual 3D printing process and finishing with post-processing. First, the team created the parametric production model to ensure adaptability for larger DAC systems in the future without any delay. After the inlet model was ready, Royal3D created a couple of test pieces to validate with De Productenmakers. Followed by its approval, the team produced two inlets for the Carbyon Go unit. 

One of the project’s challenge was to 3D print an inlet that weighed less than 25 kilograms per unit. The inlet also had to have minimal warping, while still being aesthetically pleasing. Those were the guiding parameters the team had to follow during the 3D printing manufacturing process.

The printing process took 12 hours, followed by post-processing with a specialized coating by the Royal3D team. Enhanced with UV additives, the components offer enhanced durability and resistance to sunlight-induced degradation. In line with Royal3D’s values and beliefs, the production process was engineered to minimize material waste; any residual material was shredded and recycled back into raw feedstock, ready for reuse in future prints.

Thanks to Royal3D’s experience project, the lead time was within 3 weeks. The project further proves how 3D printing and sustainability can go hand in hand.