ExtraBold Inc.
History of EXF series development from its founding
Extrabold's mission is to realize sustainable manufacturing in a decentralized manner through additive manufacturing (3D printing) technology.
We will introduce the road to the completion of the first mass production prototype and our outlook.
History of founding
Our company's founding dates back to 2017 when we founded Digital Artisan Co., Ltd., which conducts research and development, focusing on manufacturing using 3D technology, human resource development, and joint projects with companies. It started with the idea of "I want to make a large 3D printer that can recycle materials," which I had been considering from the beginning.
Since hardware development requires a large amount of funds, it was incorporated in December 2017 as a separate company from Digital Artisan, and its main business is the use of 3D technology and the research and development of large 3D printers. increase.
The founder, Yuji Hara, has experience in prototyping and CAD design at a major communication device manufacturer. After that, after working as a development manager at a CAD/CAM manufacturer for molds, I have been involved in digital manufacturing for over 30 years, including business related to 3D data and 3D printers as a manager. In the process, we were faced with a business model based on the premise of mass production, mass consumption, and mass disposal. We foresaw that reducing environmental impact and shifting to sustainable manufacturing would be essential for next-generation manufacturing.
As one means of achieving this, we have begun developing a large-scale 3D printer that uses recyclable resin pellets. Problems with conventional FFF (Fused Fused Lamination) 3D printers include the fact that the modeling quality has not reached the industrial grade level and the length of time required for modeling. For this reason, the scenes where 3D printers are introduced are still limited, and they have not spread like general machine tools such as machining centers and laser processing machines.
On the other hand, resin waste generated in the manufacturing process is also a big issue in the manufacturing industry. Companies account for approximately 54%* of the plastic waste generated annually in Japan. Waste plastics discharged by individuals require a number of processes, such as washing and sorting, before they can be reused, but plastics discharged at production sites can be reused in a small number of processes. Hara found a way out in low-cost, reusable plastic waste.
Widespread use of industrial-grade 3D printers in the manufacturing industry, capable of rapid modeling and minimizing resin waste loss. This will accelerate the departure from mass production and mass consumption.
This was our vision.
Source: Plastic Recycling Association "2017 Status of Production, Disposal, Recycling and Processing of Plastic Products"
Company establishment briefing held at the beginning of the company's founding
(2017)
Joint development of the first prototype and organizational change
First, we started developing a prototype, and brought a development plan for a large 3D printer to a venture company of an acquaintance who was already developing and selling 3D printers, and joint development will start in early 2018. Prototype No. 0 "EXF-10" was completed in June of the same year, exhibited at the Design and Manufacturing Solutions Expo (DMS), and became a hot topic as Japan's first large-scale 3D printer. However, although the prototype was completed earlier than originally expected, there were many issues, and it was thought that drastic improvements in modeling quality were necessary in order to introduce it to the production sites of the manufacturing industry. In addition, it became clear that there was a gap between the stances of the two companies, as the venture company that was jointly developing had a business model of custom-made 3D printers for experiments and prototypes.
As a result of discussions on both sides, we came to the conclusion that it would be best for both companies to develop their own 3D printers in order to broaden the base of 3D printers. In this way, the partnership will be dissolved in 2019, and each will develop an ideal 3D printer.
The first developed prototype unit "EXF-10"
There was a need to control the temperature inside the modeling warehouse to suppress the warping of the resin during modeling, so a cardboard case was produced. A temporary chamber room was created and operated using commercially available heaters.
Up to the first mass production prototype "EXF-12"
Having decided to review the design of the prototype from scratch, we set up a development system with a design company, a machine tool manufacturer, and an injection molding product manufacturer, and started development from scratch. In order to realize a 3D printer capable of modeling with the quality and speed that can be introduced at the manufacturing site, it was essential to cooperate with manufacturers who are familiar with industrial products and machine tools.
The development hurdles were extremely high, and there were many situations where we thought it would be impossible to achieve.
However, it never stopped for two reasons.
The first is the high level of attention from manufacturing companies. It was clear from our activities and negotiations up until that point that the large 3D printer we were aiming for had a very high probability of being accepted by the market. In addition, there were no 3D printers on the market that realized UI/UX from the viewpoint of operators at manufacturing sites in Japan, and the demand for domestically produced 3D printers was becoming apparent from that perspective as well.
The second is the thoughts of the development team. During discussions with developers from various manufacturing companies, he said, "If there is a large, recyclable 3D printer, the range of manufacturing will be greatly expanded. The heads of existing machine tools such as CNCs can be turned into extruders for 3D printers." We had a common vision of wanting to be able to replace it.” We were convinced that if we could solve the technical issues mentioned above, 3D printers would spread to manufacturing sites.
And in April 2020, the first mass production prototype "EXF-12" was born.
Assembly of the first mass-produced prototype "EXF-12"
(Around February 2020)
Completed first mass production prototype "EXF-12"
Up to mass production machine "EXF-12"
Along with progress in development, support from domestic companies that share our thoughts has also increased. In order to achieve our ideal performance, high precision is required for each part and module. Collaborating with a Japanese manufacturing company that excels in manufacturing each part has led to a significant improvement in quality. Furthermore, the fact that we were able to raise funds in April 2021 was also a factor in advancing development.
The extruder part that pushes out the resin was realized under the new system. Proprietary head that achieves stable output, large capacity, and high-speed molding. In the future, we have devised a unique mechanism that can be installed as an option on various CNC machine tools and robots. (Patented)
In addition, by adopting a control device made by FANUC, scalability through firmware updates has been greatly improved. In addition, a heat bed that emphasizes maintainability, a chamber room that controls the inside temperature and suppresses warping and deformation during molding as much as possible, an automatic fire extinguisher, a remote control function from the outside, etc. I implemented a lot of functions that seem to be.
Mass production machine "EXF-12" released in September 2021
Customers who have already installed it have told us that they were able to significantly reduce material costs due to the overwhelmingly faster modeling speed and higher stability compared to existing FFF-type large 3D printers. increase.
In addition, Maeda Giken, which develops casting dies and prototypes mainly for automobile parts, has been paying attention to the potential of our EXF-12 from an early stage. In addition to providing advice on development from the user's point of view, he decided to invest in our company along with the introduction of the EXF-12.
We are promoting joint research with universities and research institutes in Singapore, and are conducting advanced development of a completely new 3D print head that achieves further increase in resin ejection volume and stable modeling. In addition, the software is still under development, and we plan to add new functions in parallel with product improvements and updates.
Furthermore, we are also researching and developing a 3D print head (three-dimensional additive manufacturing head) that can be attached to existing machine tools, further accelerating material recycling at manufacturing sites.
Our subsidiary in Singapore
Base of "ExtraBold R&D Singapore"
Creating world-class machine tools with All made in Japan
The EXF-12 was developed as a machine tool for manufacturing and processing industrial grade products. We will continue to push forward with the development of 3D printers and printheads with a view to next-generation manufacturing.
While research and development of additive manufacturing (additive manufacturing) represented by material recycling and 3D printers is progressing overseas, Japan is lagging behind. We aim to be a company that leads next-generation manufacturing through recyclable multi-material 3D printers.
Interior for e-sports created in collaboration with Maeda Giken at the request of D-WEBER
"GT EXPERIENCE CONCEPT
Mechanism for developing young digital human resources
In addition to research and development of 3D printers, we are also promoting human resource development that makes use of a wide variety of backgrounds. A training gym that conducts training and joint research on digital manufacturingBOLD GYM” will be introduced.
We accept interns and secondments from companies and universities that are interested in our activities, and provide a place to learn and practice "digital manufacturing" using EXF-12.
