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Luke Rodgers dives into an innovative material  that offers superior resilience, affordability, and functionality compared to traditional materials. This episode highlights its unique properties, applications, and the excitement surrounding its potential impact on the industry.

• Discussion of the material 
• Comparison with traditional materials 
• Benefits of focusing on resilience and fatigue resistance 
• Applications in various industries beyond prosthetics 
• How PK5000 was developed and its future commercialization plans

Special thanks to Advanced 3D for sponsoring this episode.

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Show Transcript

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Welcome to Season 10 of the Prosthetics and Orthotics Podcast.

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This is where we chat with experts in the field, patients who use these devices, physical therapists and the vendors who make it all happen.

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Our goal To share stories, tips and insights that ultimately help our patients get the best possible outcomes.

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Tune in and join the conversation.

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We are thrilled you are here and hope it is the highlight of your day.

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Hello everyone, my name is Joris Peebles and this is another edition of the Prosthetics and Orthotics podcast with Brent Wright.

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How are you doing, brent?

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Hey, Joris, I'm doing well.

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I tell you what.

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We had so much content come out from AOPA.

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It's like I'm still buried in that, you know yeah, totally, man, without it was.

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I was like that was crazy how much you recorded that when you were there.

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Man, I really missed being there.

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That's first off, I really need to go and uh, it was a lot in a very short time, but then I missed the kind of the regular cadence of talking to you every week and doing this every week.

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So it's kind of like a double kind of thing.

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On the one hand, it was amazing to have so much content and that whole random thing where we did, where just random people would come and just keep coming to join us, was completely crazy and a lot of fun.

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So I enjoyed it.

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But yeah, I do miss our regular episodes.

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I'll say yeah, yeah, well, we'll get this one out and I'm really excited about this one, but I did want to just share.

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Uh, you know, duane scott put on an amazing conference, the cd fam conference in brooklyn, and it was.

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It was really great.

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Yeah, it's amazing how far in really I say, a relatively short amount of time.

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But like the computational design, machine learning, all that stuff, and what was neat is a lot of the people kind of defined what was going on.

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You know, what is AI?

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What is machine learning?

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Do we believe in AI?

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What are we doing?

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And the bottom line that I took away from it is there's still a human aspect to it.

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Right, it's.

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What can the humans input to get results that you want?

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But you know, for really from anything.

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There was a that started off doing computational design, but they started with like jewelry, with like it looks like leaf veins, you know, and so they had this algorithm that creates these leaf veins that are uber-realistic and each piece is different.

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But then a surgeon saw what they were doing and said, hey, that looks like human veins.

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And so now they've completely, they still do some of the art stuff, but now they're using these algorithms to print tissues and vascularize these systems and it's going pretty well.

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They're trying to miniaturize, miniaturize, but it's just amazing where that goes okay, super cool man, and I know I've been hearing good things about the conference from other people.

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But who's it for?

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Is it really for people who are really deep into this, this 3d printing, dfam, design stuff, or what kind of people should go to that conference next year?

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Yeah, so I can imagine it's kind of like, I mean, the early days of AMUG, where it was like these are the people that are down in the trenches and you actually have access to them to talk with them at lunch breaks and you know the breaks and such.

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It's a very small, intimate group, but these are the people that are literally writing the software, creating these ideas.

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They're architects.

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You know some in healthcare, the shoe space.

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So I would say for the time being, like if you're interested in that stuff, you know you may get something out of it, but it gets into the weeds pretty quick, and so I could definitely see somebody that's not even really 3D printing or doing much of anything on the software side really getting lost in a hurry and it wouldn't be very beneficial.

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But for those that are actually in it, I think it will open your eyes but then also connect you to people that are doing really great things.

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Okay, and if I'm working in software in any kind of way, if I'm day-to-day in front of a car doing additive or if I'm making a software package, I should totally 100% be there, right 100%.

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Yeah, especially if you're wanting to look at how are you going to automate, how are you going to train things.

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And this is the first conference.

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I wanted to do a post about this, but I didn't know how to put it all together.

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That's kind of funny, like things that you see at CDFAM, and it's like people taking notes and coding their software program at the same time.

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You know they're like in the audience, and then I looked over and there's a guy playing chess and listening, you know.

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So these this is not like the normal conference.

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These are like uber smart people Like I was definitely not among did you feel like?

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did you feel out of your depth?

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We were like, oh, my God, it was an outkicking of the coverage on my side of things, but I got to talk to a lot of cool people.

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Okay, that's good.

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Did you get to speak or not?

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I did got to talk to a lot of cool people.

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Okay, that's good.

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Did you get to speak or no?

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I did, yeah.

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So I got to share what we've got going on with life enabled and some of the automation that we're trying to do to bring prostheses or access to prostheses worldwide and really lower the barrier to entry to get prostheses on people where software is going to be an issue, and then upskilling on the software will be an issue.

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So this I was really excited to be able to share that okay, super cool and did you get a lot of like feedback from people?

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Were a lot of people interested in that, or was it too specific for them, or do they really like the application?

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they really like the application and I got to talk to, yes, a bunch of people afterwards and in I'm going to probably be working with some people doing some finite element analysis using some other structures.

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So I was always curious and I don't know if you've had them on the guys from Spherine.

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No, no, no.

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Oh, my goodness, they have this.

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They've developed this structure.

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That's a circular structure, that's it's.

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It's made more for the powder bed fusion side of things, which might be appropriate for today, but it's stiff in all directions, so like a truly isotropic structure that is developed and so you'll have to uh, I'll put it in the show notes too, but it's called spherine and they just had integrationine and they just had integration into Rhino, they just had integration into Entopology.

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But it's not only stiff, but it can also be used on the heat exchanger side, and they've just made it very easy to make it, and you can do different densities, different wall thicknesses.

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There's a lot of great features that go along with it.

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So I highly suggest you check it out.

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But I was just doing some exercises on my part with it and literally it's up to a 70 percent weight savings wow, that's amazing.

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And what are these guys?

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They're selling the software to make a specific geometry.

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Is that what they're selling, or yeah, so's, it's.

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Yeah, so it's a software to create this specific geometry within a volume.

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But there's oh, this is kind of like dumb meat, Like it's almost like a plugin, I guess you would say, but I'm definitely under-complicating it.

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It's more than a plugin, because there's a lot of other things that are going on, but it allows you to get the structure and put it onto your devices.

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Okay, interesting, that could be interesting for us as well.

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That's cool, man, I'm glad you went to that.

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Yeah, super cool.

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That's also not exactly my part of the fence either.

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So I always feel like, yeah, I should go, but then I don't go.

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I don't know, I don't know.

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We should go at one point I did get to speak with John from 3dprintcom.

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Cool.

00:07:46.716 --> 00:07:48.605
Yeah, yeah, so he hadn't met him in person.

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He goes, hey man, and so we had a good.

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I didn't realize he was from New York and he had come down, so yeah, so that was kind of fun too.

00:07:55.625 --> 00:07:56.026
Awesome.

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I'm glad you met him, dude.

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Yeah, guest though we have a guest.

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Oh my god, the poor guest.

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Who's our, who's our long-suffering guest so this one's going to be an interesting one.

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So this is luke rogers.

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He is the ceo of a newly formed company called lumis polymers, and we have talked about pk 5000 before and he is the brainchild behind it, and so, um, I think we're going to have a lot of fun.

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Thanks for having me, brent, appreciate it.

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That's super cool.

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Welcome to the show, luke, thank you.

00:08:31.095 --> 00:08:38.200
So okay, brent is the number one fanboy worldwide of this PK5000 stuff.

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And just a little bit of like a background or maybe more generally, before Luke can take us a bit further, I would think background or maybe more generally, before Luke can take us a bit further, I would think we've always struggled in powder bed diffusion in particular, but also all other additive manufacturing, 3d printing technologies, to really make really strong, really kind of resilient materials that stand up to the wear and tear of the outside world.

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The stuff that is easy to stick together is not the stuff that is then easily stuck together forever kind of.

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That's always been our problem and so one of the people have been going all sorts of ways with that.

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One thing is to fill your materials.

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One other way is to put lots of additives in them.

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Another way is to use a relatively strong kind of base material or to do culminations of those things, and there have been a lot of work around PEC.

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Another kind of polyether ketone, ether-ether ketone type materials, that kind of polyether ketone, ether ether ether, ketone type materials, that kind of P, a, e, k family.

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It's very difficult to print.

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They're very expensive to print but really high performance.

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And there's been a lot of work on on on polyamide like nylon type, ppa type materials or high performance type of versions of the polyamides we all know.

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And and then there's all of a sudden, there's this PK5000.

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So tell us a little bit about this PK5000, this material.

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Yeah, thanks for letting me talk about it today.

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The PK5000 material.

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And when people think about polyketones in general, they do tend to go right towards the aromatic type that you were just mentioning.

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So the polyether ketones, the polyether ketone ketones, those are the high temperature, high rigidity, expensive polymers that most people think of when they think of polyketones.

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Pk5000 is actually based on aliphatic polyketones, so it's highly flexible backbone, which means it has a lower melting temperature and is much cheaper to make.

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So it's relatively inexpensive compared to the traditional polyketones and is on par with the polyamides that you would be using in your typical SLS systems today.

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In general, polyketone that are aliphatic has some really interesting physical properties.

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When you look at the overall resistances to chemical resistance, the overall toughness of polyketones, those are retained in the aliphatic materials and you mentioned, you know, one piece of the puzzle and we look at actual utilization of additive manufacturing parts and end-use applications.

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It's been really hard for the additive manufacturing industry to put you know, shall I say, a relative data together to be able to compare materials to really understand what their actual damage tolerance is.

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So a lot of us have historically looked at trying to increase just the impact strength of polymers.

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And impact strength is great for comparing how parts are going to fail on a hard impact or if they've got a flaw in them, and it's an important part of actually determining if your part can survive the unused application.

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But one thing that Additive has done a poor job in really comparing is the resilience of materials and it's a little bit harder material property concept to wrap your head around.

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But if you look at the stress strain curves of any plastic, the resilience is really the area under the tensile stress strain curve up to the actual elastic limit of the polymer.

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So when most people look at data sheets, they look at what's the yield strength, what's the impact strength.

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But we really need to understand what the curves look like and start pulling out what exactly is our elastic limit, strain and our elastic limit, tensile stresses to be able to understand what type of damage tolerance these parts can take.

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If you were to compare those curves and we'll put some in the notes of the show if you look at PA11 and PA12, their elastic limit is between 3% and 4%.

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Elongation or strain.

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For the polyketone product, the elastic limit for elongation is around 8% to 10%.

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So there's a lot more area under the curve, a lot more overall energy that can be absorbed by polyketone and it's a really hard concept to wrap our head around but it's quite evident when you look at the stress-strain curves.

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I've always looked at this personally and this is my little mental model for me, right?

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Okay, so I don't know.

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Please correct me if I'm wrong, but this is how I've tried to understand it.

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That impact strength is kind of like some really sharp object hitting a bridge and breaking it, right?

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But what you're describing is really like everyday cars driving up and down that bridge and that bridge kind of responding in line to all the stresses of these cars, putting weight on, putting pressure on and going up and down that bridge and withstanding that pressure day in, day out.

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And that, to me, is the kind of thing that we always like.

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Focus on this, that high-end impact strength.

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But really is what can that?

00:13:26.969 --> 00:13:30.096
Uh bridge is the little mental ball on my head.

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Uh, can that thing sustain day-to-day, uh, you know, just kind of like continuous service temperature, where you're like, no, it's not about when the thing melts or when it starts to melt, but it's about where can we operate this polymer, you know, in a day-to-day kind of conditions?

00:13:44.008 --> 00:13:47.797
Uh, that it kind of will, you know, keep its properties?

00:13:47.797 --> 00:13:48.865
Is that kind of the right way?

00:13:48.865 --> 00:13:51.610
Am I at least in the right ballpark thinking about it like this way?

00:13:51.951 --> 00:13:52.712
You're absolutely right.

00:13:52.712 --> 00:13:55.158
That's a great way of describing resilience.

00:13:55.158 --> 00:14:02.197
It's how much load that part can take continuously without losing its actual shape of the part.

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So a heat cone can take a very large amount of deformation and load carrying capability before it starts to deform.

00:14:11.729 --> 00:14:27.375
So there's a lot of energy under that curve that it can continue to take and have all those repeated uses before it actually deflects Versus, like you said, the impact strength or the impact toughness is really about catastrophic failure, like I get hit by a baseball or something like that.

00:14:27.375 --> 00:14:36.511
Can that part take that impact Versus what's the repeated utilization of that part when I'm running or, or you know, using it to pick up something?

00:14:37.754 --> 00:14:44.702
and and to me always like if we see what we have a problem in within, in powder refusion particularly, and per polymer.

00:14:44.702 --> 00:14:57.229
We have a problem with maintaining young's modules, maintaining kind of our performance and ls's you know these kind of properties on the long term in the, in the, and we also have a problem with fatigue, strength and also a problem with like kind of impact generally, strength generally.

00:14:57.229 --> 00:15:15.320
So you're kind of saying that you know, on of these problems we solve very particular ones that are kind of really really helpful if you're trying to make something that's like a kind of a baseball glove, something that you're going to use every day and going to kind of put on the strain every day, right, yeah, so that actually refers to something that's very similar to resilience, which is recoverable work.

00:15:15.904 --> 00:15:22.110
So recoverable work is typically where a part is fatigued to the actual stress that it's going to be utilized at.

00:15:22.110 --> 00:15:28.898
Then what is the energy under the curve of that fatigued state?

00:15:28.898 --> 00:15:46.756
And we'll include some notes about, about typical polyketone recoverable works in the notes as well and that's really where you know that fatigue limit where does the actual part go when it gets to fatigue and how much work can that part do at that fatigue limit.

00:15:46.756 --> 00:15:48.390
That's recoverable work.

00:15:48.390 --> 00:15:51.485
It's also a really important part that we haven't covered well in the additive industry.

00:15:52.168 --> 00:15:54.533
So this is interesting and yours.

00:15:54.533 --> 00:15:57.331
You may speak to this too, but Luke, I'm just kind of curious.

00:15:57.331 --> 00:16:07.159
I mean, so you know, a lot of people are focused on the polyamides PA11, PA12, and even like the polypropylene.

00:16:07.159 --> 00:16:29.653
But it's like to me, while those perform and they perform well for a lot of things, I mean, there's a ton of people out on these with the prostheses that are, that are wearing prostheses and such like, if you bring it to my world, but like it really wasn't, until I heard about some of this other stuff that is important in plastics.

00:16:29.653 --> 00:16:39.065
It's, it's I don't want to say the industry's been, it's not talking about this stuff, but it's the polyamides and the polypropylenes.

00:16:39.065 --> 00:16:45.577
They don't have these features and so you don't necessarily talk about them.

00:16:45.577 --> 00:16:59.094
So it's, it's not a, it's not a story to tell essentially within, you know, within the current state of OEMs and powder bed fusion, Is that a fair statement?

00:17:00.505 --> 00:17:09.599
I would say that all polymers have these properties and any good engineer can design around the properties for a given problem statement.

00:17:09.599 --> 00:17:11.222
For a given problem statement.

00:17:11.222 --> 00:17:31.170
I think what Polyketone, the PK5000 product, does is it gives you better resilience, better recoverable work to allow for more flexibility of your types of designs and a lot more application spaces that maybe couldn't have historically been done in a single article build you can incorporate into a PK5000 build because of the added resilience and added recoverable work of these types of products.

00:17:31.190 --> 00:17:35.484
Okay, so what you're saying is that, yes, you can make pretty much thousand build because of the added resilience and added recoverable work of these types of products.

00:17:35.484 --> 00:17:39.409
Okay, so what you're saying is that, yes, you can make pretty much.

00:17:39.409 --> 00:17:45.527
You can, you can engineer around some of the shortcomings, I guess you would say, of any of the powders, make it thicker, thinner or what have you.

00:17:45.527 --> 00:17:54.847
But sometimes it may be looking for a different tool as well, and what tool is going to make the most sense for your particular product?

00:17:55.449 --> 00:17:55.891
absolutely.

00:17:55.891 --> 00:17:59.125
And you know people are going to sell what they've historically had right.

00:17:59.125 --> 00:18:04.038
So if it's not an option on your end of the platform historically you can't sell for it.

00:18:04.038 --> 00:18:07.733
But as we've seen with you know, altim 9085 and the fdm market.

00:18:07.733 --> 00:18:15.738
You know once that tool gets out there it starts to get adoption for its unique physical and chemical properties yeah, and so talk to us a little bit more about this material.

00:18:15.758 --> 00:18:21.807
All right, we got aromatic right, which is they smell nice, right, and aliphatic, so aromatic they have something with rings.

00:18:21.807 --> 00:18:36.130
Could you explain a little bit that difference a little bit, because between the stuff that people know and you already alluded to, like the difference a little bit with the regular peak and peck and if you're not familiar with them, if you're listening, that's kind of the material everybody asks for if they're looking for high material, high performance.

00:18:36.130 --> 00:18:52.519
It has some really interesting properties at the peak, is inherently flame retardant, has a really high service temperature, but it's really difficult to use, it's really difficult to crystallize and I think on that crystallization front, which is really the problem if you're printing these materials or trying to reuse them, that kind of thing, that's a huge problem.

00:18:52.519 --> 00:18:54.104
That keeps people from making big parts.

00:18:54.104 --> 00:18:58.926
It keeps people from industrializing this because it's super expensive in the first place and then you try to make your part.

00:18:58.926 --> 00:19:01.233
You end up with like kind of like brown sugar kind of thing.

00:19:01.555 --> 00:19:03.390
Where does this aliphatic, aromatic stuff?

00:19:03.390 --> 00:19:05.519
Um, you know, where does that feature?

00:19:05.519 --> 00:19:10.813
And and what are the big differences between, like the peaks we all know and hate well, Good question.

00:19:10.853 --> 00:19:30.007
So when you think of just aromatic versus aliphatic, all it really means is that aromatics have aromatic backbones that are much more rigid and resist deflection of the actual polymer backbone, versus the aliphatics have a very flexible backbone.

00:19:30.007 --> 00:19:34.996
So that's the easiest way to think about it just visually in your mind when you think about chemistry.

00:19:34.996 --> 00:19:46.794
And those very rigid backbones have high TGs, high melting points, versus the ones that have more flexibility it's easier for that polymer to start bending and moving.

00:19:46.794 --> 00:19:55.415
So it then really has a lower modulus, has a lower melting temperature compared to the aromatic type polymer.

00:19:55.415 --> 00:19:58.795
Same thing happens in aromatic polyamides.

00:19:58.795 --> 00:20:05.618
So there's aromatic polyamides that are very high temperature, like PPAs, versus the traditional long chain polyamides that we're used to working with.

00:20:05.618 --> 00:20:18.570
Same thing happens on both of those types of chemistries versus whether it's a polyamide or a polyketone how rigid that backbone is is dependent on the monomers you use to make.

00:20:18.632 --> 00:20:22.585
Okay, and then and then and let's, let's talk to us a bit about where do you see this playing a role?

00:20:22.585 --> 00:20:32.233
I mean because, on the one hand, it should be easier to process and, on the other hand, it's much cheaper, right, and on the other hand, we probably don't need like 420 degree muscle temperature stuff like that.

00:20:32.233 --> 00:20:35.759
The pulsing temperature also means that we can use different printers for this right.

00:20:36.704 --> 00:20:39.294
Yeah, so our polyketone is a powder-based product, right?

00:20:39.294 --> 00:20:43.576
So it's available in powder bed fusion processes that can be inerted.

00:20:43.576 --> 00:20:50.365
It doesn't require an extra environment to be printed so it can be utilized at standard utilization temperatures.

00:20:50.365 --> 00:20:53.776
So it's got very similar melting temperatures to PA12 and PA11.

00:20:53.776 --> 00:20:57.496
So it's commonly available in traditional SLS platforms.

00:20:57.496 --> 00:21:02.116
It doesn't require a high temperature SLS platform to run in, although you can run it in them as well.

00:21:02.116 --> 00:21:09.345
So that lower melting temperature does allow for it to be utilized in all different kinds of fielded systems today.

00:21:09.384 --> 00:21:11.089
Fielded systems today.

00:21:11.089 --> 00:21:29.031
And I would also say that in general, when people switch to polyketone and get it onto their printers, because of those tangible feel of the parts that we just talked about and the resilience and our global work with these types of parts, most of our customers that switch don't switch their printer back to the other materials they were using.

00:21:29.031 --> 00:21:32.025
They usually stay with the polyketone product because it is different.

00:21:32.025 --> 00:21:39.365
Once you get your hands on it it's hard to understand from a data sheet, but when you feel the resilience of the parts you can tell that it's different.

00:21:39.724 --> 00:21:41.538
Okay, and then talk to us about the economics of this.

00:21:41.538 --> 00:22:00.071
Because, okay, if you're looking at peak and ultem and all these kind of things that people use instead of this or partially instead of this, I guess you're using ultem or other materials not be able to recycle anything, so you're printing a whole powder bed.

00:22:00.071 --> 00:22:15.493
All that powder that is supporting that material needs to be thrown away, right, you can't recycle it not once, not at any time, and so that gives us very, very poor economics on if you're trying to make an implant or something like that, and that's really kept this market very small.

00:22:15.493 --> 00:22:22.595
So the most critical aircraft parts, the most critical implants in the body, and are you able to change those economics with the PK material?

00:22:23.545 --> 00:22:34.461
Yes, our PK5000 will have stable physical properties and build conditions at a 40% virgin content refresh rate for powder bed fusion processes.

00:22:34.461 --> 00:22:41.298
If you are less worried about your physical properties, you can move down to the 30% if desired.

00:22:41.298 --> 00:22:52.585
But most of our customers care about physical properties and that's why they st

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