rapidshape 3D Printing Solutions for Perfectly Printed Hearing Aids Parts User Manual

3D Printing Solutions for Perfectly Printed Hearing Aids Parts

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HEARING

Andreas Schultheiss CEO
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About 10 years ago, we launched our first printer. Since then, we have been contributing to extraordinary moments in the lives of others: The romantic exchange of rings at the altar, the moving sound experience with the right hearing aid, a radiant smile after a visit to the dentist. We are proud of this, and these moments continue to drive us. The challenges of today are not necessarily those of tomorrow. Intuiting the new ideas originating from our customers, then developing those ideas specifically for them before they even express those ideas to us themselves will always remain our guiding principle. And the next 10 years? The pandemic has taught us a lot. It has also taught us that planning for the future is possible, but not necessarily realistic. But one thing is clear: the world keeps changing and we will all change with it. It is our ideas and decisions that keep us moving forward.
Andreas Geitner CTO
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Shops

Labs

Professional solutions for audio retailers, shops, labs and producers

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Central Manufacturing

Post Processing

Material

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We are Rapid Shape

From a start-up to an international respected company
Our standard

A company from the south of Germany. In 2011, we decided to manufacture our own 3D printers. In this case, we made a virtue out of necessity. Because the offers on the market were simply not satisfactory for our parent company Schultheiss GmbH, which manufactures jewelry casting technology for processing precious metals. So, if nothing fits, something suitable is made. This is how our first printers came about. Today, we employ around 200 people at seven locations in five countries around the world.
Not only to meet our customers` expectations but to exceed them – that has always been our standard. We are constantly developing our products, as well as ourselves, and providing the best solutions for our customers. As a result, our product portfolio has grown enormously since its foundation in 2011.

There’s always a solution
The quality

3D printing should save you time – not rob you of it. This is exactly where our patented solutions come in. For example, our printers have automatic separation units to relieve you of the task of separating the printed parts from the build platform and start the next print job independently. In addition, the automatic refill unit ensures that there is always a sufficiently high level of print material in the reservoir. Manual refilling is no longer necessary. No idle time no cleaning time. *
Before each 3D printer leaves our manufacturing facility, it undergoes several rigorous quality checks. One of the most important steps in this is printing. Validated print jobs are printed on each printer and then they are checked for dimensional accuracy. This ensures that the printers meet our high-quality standards and can be sent along to you.

Andreas Laboratory

Simone Customer Service

Chi Distribution

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Robin Product Management

Placide Technical Service
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• More extras and a complete overview of our solutions can be found starting on page 18.

All over the World
Heimsheim Germany Raleigh, NC USA Tokyo Japan Suzhou China Curitiba Brazil

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Every Machine is an All-rounder

This is how fast it can go*

30 x earmold with cone
printed in approx. 35 minutes
30 x cast for silicone
printed in approx. 35 minutes
33 x integrated faceplate
printed in approx. 30 minutes
33 x custom shell ITE`s
printed in approx. 30 minutes
33 x hearing protection
printed in approx. 30 minutes

Rapid Shape 3D printers for hearing aid parts are extremely versatile. With them, you print validated end products at top speed.

• All times refer to benchmark

models with an HA20+ equipped

with force feedback technology.

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Why we are so fast

Why Vat Polymerization Technology? Why DLP?

There is a huge amount of different 3D-printing technologies available. We made conscious decisions about choosing Digital Light Processing (DLP) for a simple reason: Only by using DLP we can ensure high repeatability over a long period of time when printing high-resolution parts.
DLP is one technical way of vat photopolymerization. Hereby liquid resins are used, the so called photopolymere in this context, which are being cured photochemical by light. As using light as tool, a very precise production is possible. Simultaneously, only lowest energy and resource consumptions are necessary to get from the resin as raw material to the finished printed part. Thereby the highest material turnover rate per time and thus the highest productivity in comparison to other 3D-printing technologies can be achieved. Due to precise manufacturing and smart ideas being developed inhouse, a high rate of resource-efficiency is also an effect of this technology.
All named parameters in combination allow us to produce complex geometries in a cost-efficient, sustainable way and is therefore our technology of choice by conviction.

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Speed and precision with Force Feedback Technology

We were often asked for the reason being that fast – Alongside many causes, especially our patented Force Feedback Technology is an important reason. When separating the very first layer of the part from the reservoir bottom, normally undefinied forces are at work. To prevent the part from being damaged, the separation process has to be proceeded carefully and slowly.

To face this critical point we have a solution called Force Feedback Technology. By measuring the forces involved directly on the part, we ensure that our 3D-printer can increase his processing speed up to the maximum – but always in a safe way! In addition, support structures can be constructed noticeable thinner what simplifies rework after printing. The results of Force Feedback in sum are faster printing times while having a constant high quality level.

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Fast Low

results entry costs

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Intelligent Connectivity

Intelligent Connectivity ­ Less effort and higher process reliability

The Intelligent Connectivity feature enables the communication between your printer and RS wash and RS cure post processing devices. Once a connection is established between these devices, the printer can forward completed print jobs to the finishing devices for further processing. There, the cleaning and exposure process is carried out on the basis of the transmitted data.

Post processing devices ­ You can rely on the automated validation

You can rely on certified processes between material and system manufacturers. Not only 3D printing but also cleaning and post-exposure are done automatically with validated parameters. The risk of incorrect processing is excluded.

Our Solutions for increased Productivity

Automatic Separation Module (ASM) ­ Less downtime, more productivity and up to 20% material savings

Increase your productivity with seamless, adjacent print jobs, without interruption. The Automatic Separation Module (ASM) allows you to produce multiple print jobs in a self-determined sequence (job queues) without having to remove the build platform from the printer, detaching the print, unload the print job or clean the platform.* Unused material flows back into the reservoir.

Automatic Resin Refill

Is there still enough resin material inside the reservoir? With the Automatic Resin Refill it`s no longer your job to check the filling level. Modern sensor techniques verify the filling level inside the reservoir to the second. Refilling of resin material from the connected resin bottle is automatically started, in the case that the filling level reaches a critical minimum niveau.*

Hearing aid labs
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• Not available

for every type

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of machine.

RFID ­ Tracking for your validated Workflow
Our products support advanced RFID technology to assist you with compliance and workflow tracking. All devices and consumables are equipped with RFID technology. After filling and inserting the material reservoir into the printer, simply scan the bottle and check on the printer display that you have selected the correct material and that the best-before date has not passed.
In addition, when the print process is started, the printer automatically checks whether the material selected in the CAM software matches the material in the reservoir in order to avoid incorrect print jobs.
Material
RFID identification

The resin bottle is scanned at the printer. The material designation and the best-before date of the material immediately appear on the printer’s display.

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HA10+

The easy-to-use solution for fast 3D printing of hearing aid parts in small labs or even in retail stores

The HA10+ makes immediate local availability of validated 3D printed parts possible. Validated workflows and very easy handling allow on-site printing without 3D printing expertise. Local data preparation or cloud connection to labs or design centers enable unique workflows in the process.

Clean and cure your parts directly after printing with the RS wash and RS cure post processing units for an optimal and validated end-result.

RS wash RS cure

Performance parameters
Build volume Native pixel Max. part height Light source Resolution Dimension (W × H × D) Connections Control Consumables

HA10+
90 x 60 mm and 60 x 30 mm (depending on building platform and reservoir) +/­ 34 µm 90 mm 385 nm UV LED 1280 x 720 px 335 x 541 x 349 mm WLAN, TCP/IP, USB 7″ LCD-Display, touch-screen Multiple use possible

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Userfriendly Clean & environmentally friendly disposal Open system
Quick & easy system
Zero cleaning effort
Optional Force Feedback
Certified auto calibration (ACCS)
Remote Access available
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Shops

HA20+

The economical and professional 3D printing solution for hearing aid labs and mid-sized manufacturers

The HA20+ has a print area for approximately 30 pieces and combines the fastest available speed (patented force feedback technology) for immediate patient care with high accuracy and full material choice. With the high- quality, durable DLP printer, you get consistent quality every time – at an attractive price.
Clean and cure your parts directly after printing with the RS wash and RS cure post processing units for an optimal and validated end-result.

RS wash RS cure

Performance parameters
Build volume Native pixel Max. part height Light source Resolution Dimension (W × H × D) Connections Control New features

HA20+
133 x 75 mm +/­ 34 µm 90 mm 385 nm UV LED HD 1920 x 1080 px 335 x 541 x 349 mm WLAN, TCP/IP, USB 7″ LCD-Display, touch-screen Faster print speed Larger LCD screen Touch control

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Tailor-made for small labs Low acquisition cost Open system
Optional Force Feedback
Material identification (RFID)
Certified auto calibration (ACCS)
Remote Access available
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Labs

HA30+

Fast, flexible and semiautomatic thanks to the separation module, intelligent connections and validated workflows

The powerful HA30+ once again sets standards in terms of quality and productivity. Thanks to the integrated, patented Automatic Separation Module (ASM), your printed parts are automatically separated from the build platform after the printing process is finished and then gathered in a collection basket. The next print job is started immediately, without manual intervention.
Clean and cure your parts directly after printing with the RS wash and RS cure post processing units for an optimal and validated end-result.

RS wash RS cure

Performance parameters
Build volume Native pixel Max. part height Light source Resolution Dimension (W × H × D) Connections Control New features

HA30+
151 x 85 mm +/­ 34 µm 155 mm (with ASM: 70 mm) 385 nm UV LED HD 1920 x 1080 px 480 x 690 x 410 mm WLAN, TCP/IP, USB 10″ touch-screen Faster print speed Automatic Separation Module (ASM)

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Automatic Separation Module (ASM) User friendly Open system
Resin temperature control
Integrated Force Feedback
Material identification (RFID)
Certified auto calibration (ACCS)
Remote Access available
Knowledge Center Access
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Labs

HA50+

Highly productive, fully automated standalone printer with large print volume, enables series production and fast print times with consistently high accuracy

The HA50+ is our new workhorse for printing any job. With a printing range three times larger than the HA30+ and the optional, patented separation unit, you can catapult the number of pieces per day many times over. Your printed parts are automatically separated from the build platform after printing is finished and gathered in a big collection basket. The next print job is started immediately, without manual intervention. In addition, the automatic refill unit ensures that there is always a sufficiently high level of print material in the reservoir.
Clean and cure your parts directly after printing with the RS wash and RS cure post processing units for an optimal and validated end-result.

RS wash RS cure

Performance parameters
Build volume Native pixel Max. part height Light source Resolution Dimension (W × H × D) Connections Control

HA50+
231 × 130 mm +/­ 30 µm 300 mm (with ASM: 100 mm) 385 nm LED 4K 3840 × 2160 px 600 × 1660 × 570 mm WLAN, Ethernet, USB 10″ LCD-Display, touch-screen

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Automatic Separation Module (ASM) Automatic Resin Refill unit Open system
Automatic Separation Module (ASM)
Resin temperature control
Automatic door opener
Material identification (RFID)
Certified auto calibration (ACCS)
Integrated Force Feedback
Remote Access available
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Central Manufacturing

HA90+ with ASM

The automated 3D printer for industrial production. With automatic separation module for hearing aid parts

High reliability, high robustness and reproducible quality over time make this device a 24/7 production unit with industrial projection system and internal cooling for system components. Robot-assisted functions are enabled via the Automatic Separation Module (ASM), placing the printed parts either in the cabinet or on a conveyor belt.
Clean and cure your parts directly after printing with the RS wash and RS cure post processing units for an optimal and validated end-result.

RS wash RS cure

Performance parameters
Build volume Native pixel Max. part height Light source Resolution Dimension (W × H × D) Connections Control New features

HA90+
232 x 137 mm +/­ 60 µm 80 mm 385 nm, ultra high power UV LED 4K 3640 x 2160 px XPR 650 x 1080 x 1860 mm incl. cabinet TCP/IP, USB 10″ touch-screen Automation functions High resolution projector Larger print area

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Automatic Separation Module (ASM) Designed for industrial continuous manufacturing Optional with cabinet or conveyor belt Automatic Resin Refill unit
Automatic Separation Module (ASM)
Storing for large quantity of printed parts
Automatic Resin Refill
AC controlled interior for continuous use
Certified auto calibration (ACCS)
Remote Access available
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Central Manufacturing

RS wash

Wireless connectivity to printer
Clean process, no handling of sticky resins
Reduced smell

Post Processing

Give your components the perfect finish- automated and environmentally friendly cleaning

The RS wash automatic cleaning system will impress you with its simple operation and process-controlled connection to your printer – for professional and validated finishing of your printed parts.
Thanks to the automatic selection of the appropriate cleaning program and cleaning medium, cleaning of the printed parts is not only process-safe and simple, but also environmentally friendly, using a 2-step principle with pre- cleaning and final cleaning. We have applied for a patent for this intelligent system.

Performance parameters
Volume Cleaning time Cleaning medium Connections Dimension (W × H × D)

RS wash
119 x 160 x 99 mm approx 6­8 minutes (depending on material) Isopropanol, ethanol WLAN/LAN 235 x 464 x 270mm (w/o Iso Container) 344 x 464 x 309mm (w/ Iso Container)

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Effective computercontrolled cleaning agent use
Exchangeable liquid container (plug-in system)
Stackable with RS cure
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RS cure

For the perfect finish to your components – 360° curing at the touch of a button

The RS cure automatic exposure system cures your printed parts homogeneously from all sides thanks to powerful LEDs. The integrated vacuum technology enables excellent curing of the materials. This means that materials from many material manufacturers can be processed in a way that is already validated. The process-controlled connection to your
3D printer ensures that the correct program is always selected automatically and that the mechanical properties and biocompatibility of the end product are achieved. The presets are tested and validated in close cooperation with our material partners to ensure process reliability.

Performance parameters
Volume Curing time Connections Dimension (W × H × D) Version

RS cure
179 x 117 x 102 mm approx 6­10 minutes (depending on material) WLAN/LAN 243 x 419 x 269 mm with vacuum

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Wireless connectivity to printer Validated process Compatibel with various material suppliers Works with vacuum
360° illumination in one go
Certified Auto Calibration Sensor (ACCS)
Stackable with RS wash
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Post Processing

We won`t let you down

Our service team

If you have technical problems, we won`t let you down! Our technical service team is spread across five service hubs internationally and will get any downtime up and running again. Whether remotely from the service workshop or directly at your site, we will find a way. You can reach our technical service team by phone, email and, WhatsApp. Or you can use our online appointment booking system and book an appointment of your choice from the comfort of your own home.

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Our experience is your value

No one is born a master

Extensive training in the use of our printers will help you to tailor the print results perfectly to your needs. Afterwards, you will receive a training certificate and will be well-prepared to get started with your 3D printer.

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Know-how for your Job

We like to share

Get access to our knowledge, bundled in our Rapid Shape Knowledge Center! With every product you can dial directly into the Knowledge Center. When you scan the QR code on your device with your smartphone, you will be redirected to the mobile view of the Knowledge Center. * There you can access informative brochures, technical documentation, numerous tutorials and downloads. If you prefer to browse our Knowledge Center from the comfort of your PC, we will send you your individual access data by e-mail.

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*Internet connection required

Showroom at the Headquarter

Heimsheim, Germany

3366

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For best Results

Our material partners

Rapid Shape and the leading material manufacturers combine their strengths for maximum flexibility and unlimited availability. This allows us to support a jointly validated workflow throughout. In close cooperation and at the highest level, new material parameters are created every day that are precisely matched to our products and that bring you the best possible end results.
Over 200 validated materials are available in our material library, each with a tested and approved set of printing parameters. You’ll receive regular material updates for your material library to stay current and have the widest selection available.
Yet one thing always remains the same: You have the choice of which material you want to work with. With the free parameter sets, you can create and manage your own parameter sets.

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Material

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Go your way

Our workflow partners

While the production of 3D-printed parts is always subject to the same workflow, with our strong workflow partners, all avenues are open to you. With the latest version of our Netfabb CAM software, we offer a seamless connection to Dental Wings, 3Shape, and Exocad. That means: Design parameters, data transfer, and print preparation functions are preconfigured and automated.
Material pre-selection, part orientation and positioning on the build platform, adding necessary support structures, and the final creation of the print data – our software does it all for you. What else is there to do? Press “Start.”

Scan

Design

Prepare

Print

Wash

Cure

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We accompany you on your way

Satisfied customers

Over 4,500 satisfied customers worldwide can’t be wrong. This is the best proof of quality and service. We maintain a trusting relationship with our customers. Many have been with us since our company was founded in 2011 and know how passionate we are about developing high-quality 3D-printing machines. Our success is based on this passion, the comprehensive expertise of our engineers and that of all our employees.
We will be happy to advise you individually about your needs.
Rapid Shape GmbH Römerstr. 21 71296 Heimsheim Germany
+49 7033 309878-0
info@rapidshape.de rapidshape.de

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CT // 2022 // RS-HA+// EN-01

Rapid Shape GmbH Römerstrasse 21 71296 Heimsheim Germany +49 7033 309878-0 info@rapidshape.de rapidshape.de
rapidshape.de

References

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