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American pioneer 3D printing companies launch ‘Forust’ 3D printing wood products

American 3D printing pioneer companies Figulo, Boston Ceramics, and Emerging Objects have launched Forust 3D printed wood products. The products are primarily based on extensive research conducted over the past decade in the field of hardwood lumber, leading to geometrically complex, elegant finished structures, including tiles, blocks, and panels.

In launching the Forust project, they partnered with Andrew Jeffery, another US industry veteran and 3D printing pioneer is the CEO of the new company. He is the former President of Figulo and Boston Ceramics and also the Director of Ceramic Products at 3D Systems. Mr. Jeffery is one of the leading experts and innovators for ceramics binder jetting and ceramics 3D printing in general in North America.

At Forust, San Fratello is the company’s President and Rael is the COO, have conducted research in binder jetting of several materials leveraging Zcorp/3D Systems binder jetting technology in Emerging Objects. Using an unparalleled selection of materials from ceramics and cement to rubber, sand, and even salt, chocolate, and tea, they have developed unique skills in how to make this process effective in the final parts of mass production.

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Figure 1: Forust wood product Sawdust. Photo: 3dprintingmedia.network

Products include the Sawdust screens made from 3D printed walnut, simulating natural wood grains along the surface to maintain the layering effect from the additive manufacturing process. The screen consists of individual 3D printed wood elements that combine to form a variable dimensional perimeter and surface.

 

In a living tree, the vessels act as a pipeline in the trunk to transport sap into the tree. On the Sawdust screen, vessels serve as an opportunity for visual porosity. The subtle curve of each container raises the lift as a convex or concave aperture which makes the screen both a visual and haptic experience.

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Figure 2: Forust wood product Wood Block. Photo: 3dprintingmedia.network

Wood blocks are an example of 3D printed wood as a potential building material that can be mass-customized. Here too, the production of additive layers of wood blocks produces a grain similar to natural wood, while the wood material itself is made from recycled agricultural waste. The texture and fine cleanliness of the 3D printed wood material give the material warmth, texture, and illumination under certain lighting conditions. It can be used as a screen wall or as a customized masonry unit.

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Figure 3: Forust wood product Burl. Photo: 3dprintingmedia.network

Burl is a product of 3D printing of wood, which explores the form and thickness that makes it possible as an emerging material in additive manufacturing. Like barrels found in nature, these barrels have dense layers of cracks, distortion, and growth rings, a product of layers of manufacturing products.

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Figure 4: Forust wood product Poroso. Photo: 3dprintingmedia.network

Poroso, also shown midway through the page and in a close-up above, is an experiment in block aggregation using a specially formulated wood material. The wood has a higher accuracy and finer finish than previous formulas. It is also stronger and more easily able to be excavated from the print bed.

 

Poroso, shown intimately through and above the page, is an experiment in block aggregates using a specially made wooden material. Wood has higher precision and finer finish than previous formulas. It is stronger and more easily capable of digging from the print bed. Poroso is made with recycled wood fiber and other agricultural waste products.

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