Jun 15, 2016 | By Benedict

Cosine Additive LLC, the 3D printer manufacturer behind the Additive Manufacturing 1 (AM1) 3D printer, has partnered with the Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL) to further develop the AM1’s innovative additive manufacturing platform.

The Oak Ridge National Laboratory, the DOE’s 10,000-acre Tennessee tech base, is home to some of the most exciting 3D printing projects in the country. A month ago, the laboratory was working with Boeing for autoclave testing of new 3D printed tools, while 3D printed cars have also driven their way out of massive research facility—and that’s just the tip of the iceberg.

ORNL is showing no signs of slowing down its additive manufacturing endeavors, and recently announced a partnership with Cosine Additive, the Houston-based 3D printer manufacturer behind the Additive Manufacturing 1 (AM1) 3D printer, a large-format, open-source, modular machine with a build area of approximately 4’ x 4’ x 4’ and the ability to print with carbon fiber. By joining forces with ORNL, Cosine is now poised to “develop and demonstrate the enabling technologies for mid-scale additive manufacturing” using the AM1 3D printer.

Both Cosine and ORNL believe that the AM1 could open up new areas of manufacturing for rapid production of medium-size tooling—especially in the transportation, appliance and energy industries—and that the giant 3D printer could help businesses to save money and lead time. The initial focus of the partnership will be on composite materials, as more and more businesses start to see the benefits of carbon fiber 3D printing.

A key aim of the partnership is to increase the AM1’s rate of production. By the end of the project, the two parties hope to have the large-scale 3D printer producing 10 lbs/hr of composite material, and able to print a 50 lb part, measuring at least 30” x 30” x 30”, in under 8 hours.

“We are excited to partner with an innovative small business, such as Cosine Additive,” said Lonnie Love, ORNL group leader of manufacturing systems research. “Our hope is that this partnership, and the ensuing products, will help to excel new applications for additive manufacturing.”

The giant AM1 3D printing platform is fully modular and upgradable, and uses decoupled hardware and software so that businesses can tailor the machine to their own specifications and needs. Additionally, Cosine states that users of the 3D printer could save up to 90% in material supply costs compared to existing industrial polymer filament.

"Cosine Additive's goal is to bring about fundamental change in the additive manufacturing industry,” said Andrew McCalip, Chief Technology Officer at Cosine Additive. “If the technology is to continue its exponential growth, there must be a decoupling of hardware, software, and materials companies.”

Cosine Additive AM1 specifications:

  • Build volume: 1100mm x 850mm x 900mm (43” x 33” x 35”)
  • Print accuracy: .15mm per 100mm
  • Layer resolution: .05mm - 1.5mm
  • Nozzle sizes: .5mm, 1mm, 1.5mm, 2mm, 2.5mm
  • Max flow rate: 3.5 kg / 24hrs



Posted in 3D Printer



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Andrew Miners wrote at 8/4/2016 3:13:26 PM:

Would be interesting to see how this prints and turnaround speeds for serious production. Really interested to hear what this unit can do.

John Stockton wrote at 6/15/2016 7:06:23 PM:

Very nicely done printer. A major step above other FFF printers shown at the RAPiD2016 show.

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