Caracol’s Heron AM: Large-Scale 3D Printing with a Focus on Sustainability
Violetta Nespola, Chief Marketing & Strategy Officer at Caracol, spoke with us at RAPID + TCT 2024 and walked us through Heron AM, the company’s large-scale 3D printing platform. Heron AM integrates robotics to create parts from thermoplastic composite pellets to help address both efficiency and sustainability in its approach to additive manufacturing.
Maximizing the Sustainability of 3D Printing
Violetta explained that Caracol’s focus on sustainability is central to the development of Heron AM. While 3D printing is often recognized for its efficiency in material usage, Caracol sought to extend these advantages further by optimizing various aspects of the process. One of the most significant decisions made by the company was to use pellets as a feedstock for the printer, allowing for a wider range of material options, including recycled and bio-based materials, as well as the ability to reuse ground-up scrap.
In addition to material flexibility, the design of Heron AM is optimized to minimize material waste by printing only what is required and precisely where it is needed. In cases where CNC machining is required to meet dimensional tolerances, Caracol estimates a reduction of scrap by 70 to 90% compared to conventional processes.
On-Demand Manufacturing and Logistics Efficiencies
Another critical area of focus for Caracol is reducing the environmental impact of logistics. Heron AM is designed as a flexible system that can be set up in various environments, allowing parts to be printed close to their point of use. This capability minimizes the need for large warehouses and long-distance transportation, which typically increases both cost and environmental impact. By manufacturing on demand, near where the parts will be used, Caracol aims to reduce the logistical footprint of its operations.
Open System with a Focus on Quality Control
Heron AM is an open system, meaning it can work with a broad range of materials. However, Caracol has implemented a thorough qualification process to ensure that only materials that meet strict performance criteria are used. This approach allows for greater process control and reduces the potential for printing errors and material waste. Caracol continuously works with multiple suppliers to expand the range of qualified resins available for use with the machine, ensuring that their customers have access to high-quality, reliable materials.
Applications Across Multiple Industries
Heron AM has been adopted by a wide range of industries, reflecting the versatility of the platform. It is used in what Caracol refers to as the “creative industries,” which include design, furniture, architecture, and construction. Additionally, more advanced industrial sectors, such as marine, aerospace, and automotive, are also leveraging the platform for large-scale 3D printing.
The applications for Heron AM continue to grow, with industries increasingly recognizing the advantages of combining the cost-efficiency and lead time reduction of additive manufacturing with sustainability benefits. In particular, the ability to minimize waste and use fewer tools and support materials makes Heron AM an attractive alternative to more traditional production methods, especially when dealing with large-scale parts.
