Founded in 2019, the French startup Lines Manufacturing is entering the large-format additive manufacturing landscape with its innovative Lines SONIC solution. This FGF (Fused Granular Fabrication) machine stands out due to its impressive printing speed, capable of producing large volumes while ensuring high precision. The company aims to address the needs of the plastics and composites industries by offering a flexible, competitive solution capable of producing thousands of large parts annually. This series approach marks a departure from the conventional role of large-format additive manufacturing, typically limited to prototyping, allowing for expanded deployment of 3D printing advantages.
Anticipated deliveries of the Lines SONIC machines are set to commence in 2025, following extensive industrial trials, such as those conducted with OPmobility (formerly Plastic Omnium) starting in 2022.
Large-format 3D printing often involves a trade-off between part size and quality; as part dimensions increase, printing time also rises. Shortening this duration frequently compromises the quality of the final product due to thick layer deposition. Furthermore, mastering large-format additive manufacturing necessitates specialized knowledge to avoid costly defects during machine setup. Lines Manufacturing addresses these challenges through its industrial expertise.
The SONIC machine boasts print speeds that are 10 to 100 times faster than existing solutions, offering a standard print volume of 3,000 x 2,500 x 2,500 mm and speeds up to 2,000 mm per second (2m/s). The material deposition can reach as high as 80 kg per hour while maintaining fine layer heights starting from 0.4 mm. Lines’ patented polymer pellet extrusion process sets it apart, positioning the SONIC as a viable production mechanism capable of high production rates.
Niels Pernoux, the company’s co-founder and president, describes the SONIC as an "industrialized high-speed additive manufacturing solution" that enables mass production of finished and semi-finished parts with advanced tracking integration—addressing the evolving requirements of high-tech sectors.
The machine is ideally suited for medium-volume production applications in marine, aeronautics, and mobility sectors, including rail and mechanical engineering. Its capability to seamlessly connect unit and mass production processes allows it to fulfill high-volume production needs without tooling.
Lines Manufacturing collaborated with OPmobility on the Smart Polymer Bumper project, focusing on the design of impact-absorbing parts using certified automotive-grade polypropylene. Through simulation and study phases, the team developed 3D-printed absorbers for vehicle front ends, demonstrating that the SONIC machine can mass-produce functional automotive components utilizing innovative lattice structures that outperform traditional foam structures.
Launching the Lines SONIC publicly at Formnext 2024, Lines Manufacturing is backed by leading French industrial groups and has plans to expand its machine range and establish an assembly site in the Grand Est region.
For more details on the Lines SONIC and its industrial applications, visit Lines at Formnext (stand E21, Hall 12.0) or check more information on their website.