Aleph Objects, Inc

Aleph Objects, the makers of LulzBot™ 3D printers received their first NinjaFlex samples in Fall 2013. LulzBot engineers quickly found the extreme flexibility of NinjaFlex made it challenging to extrude through typical extrusion methods. Thus, LulzBot subsequently developed and introduced the Flexystruder, which is optimized to print with flexible filaments. Aleph Objects engineers tested if NinjaFlex would maintain the same dynamic strength and flexibility it has on the spool, after it has gone through the 3D printing process. Using FreeCAD and Slic3r, they created a two-layer thick sheet, approximately five inches by five inches, taking a little over an hour to print. The two-layer sheet used approximately two percent of the standard .75 kg [3mm diameter] NinjaFlex spool, translating to a test cost of around $1.20. The test print was successful, demonstrating both NinjaFlex strength and flexibility. "In order for exciting new materials like NinjaFlex to get to market, filament developers have to know exactly how the 3D printers themselves work, from the firmware down to the bill of materials. This way modifications and tweaks can be made as needed, and new materials can get to market quickly." Beyond flexibility and strength, LulzBot users have found NinjaFlex has a wide variety of applications. "We have seen LulzBot users print with NinjaFlex to prototype shoes, air filters, pipe fittings, tires, treads, and finger pads for prosthetic hands, to name a few," notes Kenny. "We also found it can be used to grip to glass for window and mirror decals." The long-term value for NinjaFlex in its ability to bond with ABS plastic (a more traditional 3D printing filament material). They believe fused parts with multiple materials open a whole new world of possibilities for 3D printing well beyond current applications.