9T Labs and Setforge collaborate to bring CFRP additive manufacturing to series production

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9T Labs and Setforge will replace metals with high-performance carbon fiber composites for automotive, aerospace and industrial applications. Additive Fusion Technology enables serial production of carbon fiber-reinforced polymer (CFRP) parts with high fiber volume (60%) and low void content (<1%) at lower cost using the 9T Labs Red Series equipment.

With over 100 years of experience, Setforge, a subsidiary of Farinia Group, is one of the most important global suppliers of high-quality metal components, at high production volumes, mainly in the automotive and aerospace industries. With its partners, Institut de Soudure and the research institute Arts et Métiers, Setforge is working on the development of a new process, called EPITHER, that aims to produce structural composite parts in high series to diversify its historic production.

“Lightweight and sustainability are becoming more and more important,” noted Head of EPITHER program, Damien Felix. “As an innovative company, we need to explore new technologies for the future of digital series production. With 9T Labs’ cost-competitive approach, we can reduce part weight and production costs.”

Setforge will use the Red Series to set up a high-volume production solution for light and strong composite parts. The Red Series subscription is an all-in-one solution that includes hardware, Fibrify software, and application engineering. “Using 9T Labs’ composite engineering support, we will find and develop the right applications,” said Felix. “9T Labs’ software makes the process of designing composite parts much more accessible to companies that have not been working with composites.”

9T Labs and Setforge
The Red Series composites 3D printer by 9T Labs.

The Fibrify software suite uses integrated FEA tools to help quickly define tailored fiber designs optimized per load case, avoiding less-efficient black metal designs. It also allows parts to be structurally validated before being printed, reducing iterations and streamlining development.

“The Red Series subscription provides us with flexibility in process simulation and digital prototyping as well as the potential to extend our patented process to high series production of carbon composites,” said Felix. “

“We needed additional technology to reach our goals. We have found the right level of mastery in both additive manufacturing and post-consolidation with the Red Series and the great support of the 9T Labs Team. This important step will allow us to substitute metals and scale the production of structural composites to thousands of pieces at a cost-competitive structure.”

“Setforge is a great example of an innovative parts manufacturing company creating new market opportunities by substituting metals with structural composites,” explained 9T Labs Co-founder and Chief Business Development Officer, Giovanni Cavolina. “We are extremely proud to support Setforge in this mission. The combination of 9T Labs’ knowledge in composites and Setforge’s expertise in production will enable serial production using Additive Manufacturing of CFRP.”

Research 2022
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Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based 3dpbm. Today the company publishes the leading news and insights websites 3D Printing Media Network and Replicatore, as well as 3D Printing Business Directory, the largest global directory of companies in the additive manufacturing industry.

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