Power of print

A new powder printing process developed by

(DMU) in Leicester could one day be used to cut the cost of manufacturing a variety of customised consumer goods, such as motorcycle helmet liners.

A rapid manufacturing machine using the technology would build a 3D model from a CAD helmet liner design layer by layer at a high production rate. Polymer powders would be specifically selected and sintered for the process.

The process is being tested as part of a European project, Custom-Fit, that aims to produce personalised consumer goods cheaply.

The team is expected to produce sample helmet liners by the end of May.

David Wimpenny, director of the rapid prototyping (RP) and manufacturing group at DMU, said his research group is one of a small number in the world who have successfully produced layers using rapid laser printing techniques.

The challenge, he said, is producing layers fast and high enough. 'A couple of millimetres high was the limit of parts made using laser printing,' said Wimpenny. 'We've broken the 10mm barrier — which doesn't sound like very much, but it's the equivalent of sending a spaceship out of Earth's orbit.'