DSM Somos®, a world leader in the development of high performance stereolithography (SL) resins, has announced the winners of its “X-Factor Challenge”—a rapid prototyping design competition highlighting the versatility and unique performance features of Somos’ new high impact SL resin DMX-SL™ 100.

Judging all entries for the competition was a panel of experts chosen for their knowledge of rapid prototyping and rapid manufacturing: Tom Sorovetz, RP Manager, Chrysler Corp, Detroit, MI; Tom Mueller, Co-Owner Express Pattern, Vernon Hills, IL; and Tim Gornet, Manager, RPC Operations,  University of Louisville, Louisville, KY.

Replacement part winner

The Replacement Part Category required part entries to satisfy the demands of a laser-sintered or cast urethane part; demonstrate the advantages of using SL; demonstrate the capability of DMX-SL to stretch conventional limits of the SL process in terms of stiffness and toughness; and simulate the properties of the end-use material (if a prototype).

Winner of the Replacement Part Category was Mark Horner of The Technology House, LTD in Solon, OH, who submitted a “ Discharge Chute” for a small ride-on tractor.  “This was a part that would typically have been made from cast urethane, but Technology House was able to save a few steps by making it directly from DMX,” says Mark Horner. “What impressed judges is that the Discharge Chute went through extensive real world testing without shattering—no other SL resin could have survived.”  Runner-up in the Replacement Part Category was Chris Husmann of Northrop Grumman Corp. El Segundo, CA who submitted a “ Gear Wheel” to replace an injection-moulded ABS/urethane part that kept breaking.

Creative section winner

Criteria for the Creative Category required part entries to: demonstrate creativity not normally found in industrial applications; clearly demonstrate the advantages of using SL, and full optimize the stiffness and toughness properties of DMX-SL 100. 

Winner of the Creative Category was Vince Anewenter of the MSOE Rapid Prototyping Center in Milwaukee Wisconsin for his “ Foosball Man” used in the game of foosball (or table football as it’s known outside North America). Runner-up in the Creative Category was Ian Campbell of Loughborough University in the UK, for his “ Personalised Ergonomic Gaming Joystick.”

“Because DMX-SL™ 100 creates stiff and tough parts that are unique to the SL market, many users are finding equally unique applications for it that push the limits of stereolithography,” says DSM Somos Marketing Manager Eva Montgomery. “We were impressed by the variety of entries received for our competition—it really reflects the ingenuity and creativity of designers working in the RP sector.”

The X-Factor Challenge was designed to introduce prototyping applications in an openly discussable format. All four winning parts from the “X-Factor Challenge” will be displayed at DSM Somos’ trade show booths at upcoming exhibitions, beginning with the 3D SUG User's Group Conference in Costa Mesa, CA April 7-9.