Introducing the Pellet Feed System

10x Cheaper Material on Your AM1

After a year in development, Cosine is excited to release our Pellet Feed System and will begin manufacturing this product for the AM1. By switching to pellet, we are capable of running a wider variety of polymer resin systems at an increased deposition rate of up to 10 lbs/hr. Printing with pellets is 10x faster and 10x cheaper than printing with filament. Existing customers can extend the capabilities of their AM1 by upgrading to the Pellet Feed System. Contact for more information.


Pellet Head - 1.jpg

Cosine at the Additive Manufacturing for Defense and Government

Geoff Nordloh, CFO, Cosine Additive


Meet Cosine at The Additive Manufacturing for Defense and Government in Washington, DC. Our CFO, Geoff Nordloh, will be there July 13-14. He will present our recentbreakthroughs, collaborations, and upgrades to our AM1 platform. Through our partnerships with NSWCC andOakridge National Lab (ORNL), we are expanding our reach into the government sector. Contact Geoff for an opportunity to see our AM1 installation at NSWC-Carderock


Cosine already has established relationships with the SAIC. By the end of the year, our equipment and services will be obtainable through the GSA Multiple Awards Schedule.


Oarkridge signing August 2016


We’re collaborating with Oakridge National Lab (ORNL) and NSWCC to develop new technologies and improve methods in the 3D printing industry with our Cosine AM1.

In these projects:

  • NSWCC requested improved data collection, and Cosine's solution was to develop and install a new bleeding edge motion system .

  • ORNL requested to develop a new pellet feed system. Cosine delivered a pellet extruder capable of printing 10 lbs/hr, allowing for a higher deposition rate and cost reduction with our open material platform.

Trim Tool Case Study

Complex surface geometries can mandate expensive and time consuming tooling solutions. Traditional solutions include CNC machining and composite tooling. Machined tooling is a trade space between raw material costs and CNC capacity. Offloading tooling work from heavily burdened CNC’s can open up capacity for higher value products. Composite tooling requires a series of pattern tools and back up structures(plywood crates or welded tubular frames) that can induce a variety of challenges. These processes can result in increased expenses, long lead times, consume valuable resources (CNC machine time), and families of patterns that need to be tracked and maintained in addition to the tools themselves. 

Additive manufacturing enables users to create complex geometries from a variety of tough thermal polymers. Solid models are used to fabricate complex geometries directly, without the need for any secondary patterns. Often, the design rules for optimized additive manufactured tooling can be leveraged to provide ergonomic fixtures that simplify part processing and employ lower cost manufacturing solutions. 


Fiberglass Splash Tool

• CAD/Reverse Engineer.
• Produce pattern for fiberglass layup
  (CNC, splash or Egg Crate).
• Support frame fab.
• Fiberglass layup and frame integration.
• Finish tool (edge clean up].







Fiberglass Splash Tool


Cosine Manufactured Tool 

Ready to Print
• Up to 1 lb/hour Material Deposition Rate.
• $8.40/hour Machine Utilization Cost                (5yr amortization). 
• $0.60/hour Electrical Cost.


Material Cost (choose one):
• $1/hour Base Polymer Pellet Material Cost.
• $8/hour Base/Neat Filamentized
  Material Cost.
• $33/hour Filled Filamentized Polymer               Material Cost.



Manufacturing Method Comparison

Cosine Machine Utilization Cost to Owners


Casting Industry Case Study

Current Methods

Traditional pattern methods are the most time consuming and complex processes in the casting industry.

Long lead time due to materials and many complex steps.

160 HRS

160 HRS

Expensive and
resource intensive



30% of patterns received have mistakes and need to be reworked.

Single Shot-01.png

Skilled labor
Dying Trade

high skilled labor-01.png

Cosine's Solution

The AM1 allows for faster, cheaper, and more efficient pattern creation.

28 HRS

28 HRS

Two day turn around.



Total cost to make a
pattern with the AM1.

part icon-reiterations-01.png

Making revisions is as simple as hitting print.

general labor-01.png

Anyone can manufacture with the AM1’s intuitive quick-start process.

By using the Cosine AM1, your company can provide a rapid turn around for your customers, and save money over traditional pattern making techniques.


Traditional pattern making takes 4 weeks and costs an average of $5,000. 
Cosine’s AM1 3D printer allows you to streamline your process with the least amount of hassle. 



Contact us to receive a sample box and start your custom casting project.
We are ready to work with you! 

Part Replacement

Parts will be sent to the client free of charge if the issue is under warranty.

We keep a stocked inventory, so we'll be prepared to send you a new replacement part.



If parts are too large or too complex for customers to install themselves, we will schedule a Cosine engineer to visit your facility to install the part within a week. 

No Downtime Guarantee

While your printer is under maintenance, we will perform your prints at our headquarters. We will send one of our Cosine expert technicians within a one week period. Standardized shipping is covered; however, all we ask of you is to cover materials costs. This warranty will ensure that your prints won't miss their deadline.



Please note that although we ask you to cover costs of materials, be aware that you are normally responsible in covering your own material costs. Standardized shipping will be covered. Faster methods we ask that you cover. 

Payments not covered:

  • Costs to ship faster than ground shipping (expedited)
  • Materials costs

Bleeding Edge Motion Control

Cosine is leading the pack in additive manufacturing by integrating our AM1 with a new motion control system. The new 64 Axis motion controller provides faster file uploads, improved stability, and a feature-rich platform for future product upgrades. The new system increases print head acceleration and has positional accuracy of 50nm, improving the print quality. If you're interested in upgrading your AM1, contact


  • 50nm positional accuracy with Renishaw linear encoders
  • Temperature compensation
  • Input shaping
  • Ethercat enabled
  • Up to 36,000 input/output channels
  • Higher accelerations
  • Higher rapid speeds
  • Higher print speeds / less print time
  • True 3D printing (simultaneous 3-axis printing)

Our Z-Axis Just Got A New Upgrade

After thousands of hours of run time, we've learned a few things we'd like to improve on our AM1. When we added the pellet feed system, we increased the load on our gantry significantly and pushed the gantry framework to its limits. An upgrade was necessary, so we chose the beefiest gearbox we could get our hands on. With our new box, our AM1 can carry up to 60lb loads and move at a faster pace along the Z axis than ever before! Contact us for more information.

3D Printed Dress

Expandable dress designed by Mariale Mora-Sanchez.

Mariale Mora-Sanchez is one of our interns here at Cosine and an industrial design student from the University of Houston. She designed a 3D printed an expandable dress out of flexible material and printed it with our AM1. Here's her presentation about it.

Service Engineer, Felix and Maria, wearing her dress

Service Engineer, Felix and Maria, wearing her dress

Print of the day: Split Patterns for casting valve bodies

What we printed today! Split form patterns for casting a 90lb steel safety valve. We firmly believe that casting is one of the right applications for large format filament printing! 

  • 1mm Nozzle
  • ABS Material
  • 1.8kg
  • 10" x 12" x 6" 
  • 13hr print time
  • 4,400 mm/min
  • 75C chamber temperature


Note the steaming popping in this part. It's due to the ABS picking up moisture during the printing process. We're working on a heated vacuum spool cart to help prevent this problem. It's a tough one!

After one application of Evercoat Featherfill. Never again apply bondo by hand! Take about 10 minutes to spray and 20 minutes to sand. There is a time/resolution tradeoff that is always present with printing. For larger prints, it's often times better to choose a larger layer thickness to save 12+ hours in printing, and perform a half hour of post processing to achieve the final desired surface finish. 









Print of the day. Variable Layer "Time is Money" Tower

This is what we call the "Time is Money" tower.  There is a constant desire to have the best possible surface finish with prints, but it comes at the price of time. We're created a sample that shows this concept very plainly. Each one inch section of the tower is done at a different layer thickness. 

.1mm layer = 360 RMS = 102 minutes

.2mm layer = 590 RMS = 51 minutes

.3mm layer = 720 RMS =  35 minutes

.4mm layer = 950 RMS = 26 minutes

.5mm layer = 1100 RMS = 21 minutes

Web Analytics