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DynaFlex Expands Capacity Integrating 3D Metal Printing with 3D Systems ®DMP Flex 200
DynaFlex is proud to announce the integration of the DMP Flex 200, a next-generation metal 3D printer from 3D Systems, into its digital manufacturing lineup. “Thanks to our trusted partners at Nota3D and 3D Systems, we’ve expanded our metal printing capabilities with the powerful DMP Flex 200—boosting production speeds by up to 80%,” said Matt Malabey, Director of Operations at DynaFlex. With a powerful 500W laser source, enlarged build platform, and industry-leading surface finish, the DMP Flex 200 is designed for high-precision, small-part dental applications—including components like 3D printed bands and other custom fixed appliances. The system’s ability to print with fewer supports and less material reduces post-processing and cost per part—while also accelerating turnaround times for practices nationwide. Key highlights of the DMP Flex 200 include: • Faster Production Times: Up to 80% improvement in print speed for 3D metal printed bands used with fixed appliances. • Enhanced Workflow Automation: Integrated Oqcam Software automates orientation, nesting, labeling, and support generation. • Cleaner, Safer Operation: Advanced chamber sealing and powder-handling design minimizes contamination and improves user safety. • Broader Material Capability: Compatibility with high-performance dental alloys such as LaserForm® CoCr, Stainless Steel 316L, and Ti Gr23. Darren Buddemeyer, Owner and President of DynaFlex, added: “This upgrade supercharges our capacity, ensuring on-time delivery and uncompromising quality for every fixed appliance we produce. With this technology, we’re more equipped than ever to meet our customers’ needs with speed, precision, and reliability.” Malabey continued, “The latest laser technology, automation tools, and improved onboarding features allow us to scale smarter and faster. It’s a strategic step forward for DynaFlex that enhances both quality and speed while optimizing every touchpoint in our workflow.” As DynaFlex continues to lead in orthodontic and dental manufacturing innovation, the addition of the DMP Flex 200 reflects its ongoing commitment to empowering labs and practices with faster, more reliable, and highly precise solutions. This initiative is proudly supported by American innovation—DynaFlex, Nota3D, and 3D Systems are all U.S.-based companies, underscoring our commitment to American-made excellence and locally sourced technology.
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Metal 3D Printing in Aerospace and Defense
Forging the Future of Additive Manufacturing The aerospace and defense industries have always been at the forefront of innovation and technological advancement. As the demand for lighter, stronger, and more efficient components continues to grow, metal 3D printing has emerged as a game-changer in these sectors. The applications of metal 3D printing in the aerospace and defense industries are vast and transformative. This technology empowers engineers to design and produce components that were once deemed impossible, all while reducing costs and increasing efficiency. In this blog, we'll explore the fascinating world of metal 3D printing and its applications in aerospace and defense. 9 Applications of Metal 3D Printing in Aerospace and Defense: 1. Lightweight Structures for Aircraft: One of the most remarkable applications of metal 3D printing in aerospace is the creation of lightweight, complex structures. Traditional manufacturing methods often rely on subtractive processes that waste material and increase component weight. Metal 3D printing, on the other hand, allows engineers to design intricate structures that reduce weight without compromising strength. This leads to more fuel-efficient aircraft, increased payload capacity, and improved overall performance. Metal 3D printing enables the creation of intricate and lightweight components with the use of lattice infill structures that are difficult to manufacture using traditional methods. For instance, GE Aviation has used additive manufacturing to create fuel nozzles that are 25% lighter and five times more durable, reducing fuel consumption and maintenance costs. 2. Complex Geometries: Metal 3D printing enables the production of parts that were previously impossible to manufacture through traditional methods. From turbine blades and heat exchangers to intricate brackets and nozzles, 3D printing offers unprecedented design freedom, resulting in enhanced performance and efficiency. The defense industry often requires tailored solutions for specific applications. Metal 3D printing allows for the production of intricate engine components with complex geometries. For example, the U.S. Army Research Laboratory is using 3D printing to develop customized, high-temperature alloy components for gas turbine engines that offer improved performance and reliability. 3. Rapid Prototyping and Iteration: Rapid prototyping is critical in both aerospace and defense. Metal 3D printing accelerates the design and development process by allowing engineers to create prototypes and iterate designs more quickly. It empowers engineers to expedite the design and development cycle by offering them the ability to craft intricate prototypes with remarkable efficiency. This acceleration in the development process becomes a lifeline, where responding swiftly to evolving threats, missions, and emergencies is non-negotiable. In these high-stakes environments, the capability to iterate and refine designs in a fraction of the time traditionally required is not just advantageous; it's mission-critical. 4. Cost Reduction: Metal 3D printing can significantly reduce costs in the aerospace and defense industries. By minimizing material waste and streamlining the manufacturing process, organizations can achieve significant cost savings over traditional production methods. This is particularly advantageous for producing low-quantity, high-value components, such as those required for defense applications. Metal 3D printing significantly reduces lead times and production costs by minimizing material wastage and lowering tooling expenses. For instance, SpaceX has employed 3D printing to produce the SuperDraco engines used in their Crew Dragon spacecraft, which has contributed to cost-effective space travel. 5. Repair and Maintenance: Aerospace and defense equipment must undergo rigorous maintenance and repair. Metal 3D printing facilitates the rapid replacement of damaged components, reducing downtime and ensuring that critical equipment is always ready for deployment. Whether it's a fighter jet, a missile system, or a satellite, the ability to create on-demand replacement parts is a game-changer. Maintaining and repairing military aircraft and defense equipment is a complex and costly task. Metal 3D printing allows for on-site repairs and the production of replacement parts, reducing downtime and costs. This is particularly advantageous for remote military operations where quick repairs are crucial. 6. Material Variety: Metal 3D printing is not limited to a single type of metal. The aerospace and defense industries can utilize a wide range of materials, including titanium, aluminum, stainless steel, and more. This flexibility allows engineers to choose the best material for a specific application, optimizing performance and durability. Aerospace and defense applications often require materials that can withstand extreme temperatures. Metal 3D printing can create components from specialized heat-resistant materials like titanium and nickel alloys. This is especially beneficial for military jets and rockets that experience high levels of heat and pressure during operation. 7. Stealth Technology: In the defense sector, stealth technology is crucial for maintaining a tactical advantage. Metal 3D printing enables the production of intricate components and surfaces that can help reduce radar cross-section and enhance the stealth capabilities of military aircraft and vehicles. 8. Satellite Components: The space industry relies on lightweight and highly reliable components for satellites. Metal 3D printing allows for the creation of intricate components that are both lightweight and robust, ensuring the success of space missions. 9. Sustainable Manufacturing: In a world increasingly focused on sustainability, metal 3D printing stands out as an eco-friendly alternative. The technology produces less waste, consumes less energy, and often requires fewer transportation resources, contributing to a greener future for aerospace and defense industries. Metal 3D printing's energy efficiency, compared to conventional manufacturing processes, is a stride towards reducing carbon footprints. The ability to produce components on-site, reducing the need for resource-intensive transportation, is a pivotal step towards a greener future. In a world where ecological considerations are becoming integral to business operations, metal 3D printing is a testament to the aerospace and defense industries' commitment to responsible, sustainable practices. It embodies the promise of achieving both technological excellence and environmental consciousness in the pursuit of a better, more sustainable world. As these industries continue to evolve, metal 3D printing will undoubtedly play a pivotal role in shaping the future of aerospace and defense. It's an exciting time for innovation and advancement in these crucial sectors, thanks to the remarkable capabilities of metal 3D printing. At Nota3D, our team is the most responsive in the industry—solving issues, developing solutions, and delivering materials faster than anyone else on the market. We work tirelessly to bring you what you need when you need it. Finding the right 3D printer might seem complicated at first. That’s why we’re here! Check out some information about the different printers we offer but don’t stop there. Give us a call or contact us by email so we can help narrow down the lineup to options that are the best possible fit for your specific applications.
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Design Considerations for Achieving Success in Metal 3D Printing
Revolutionizing Industries With Cutting Edge Technology The advent of 3D printing with metal has revolutionized various industries, unlocking new possibilities and transforming traditional manufacturing processes. This cutting-edge technology holds immense importance due to its unique advantages. First and foremost, it enables the creation of complex and intricate designs that were previously impossible to achieve with conventional methods. This capability not only enhances product performance but also promotes innovative solutions in aerospace, automotive, and medical sectors. Additionally, 3D metal printing allows for the production of customized and personalized components, reducing material waste and optimizing resource utilization. This environmentally-friendly aspect aligns with the growing emphasis on sustainable practices in modern manufacturing. Moreover, the speed and efficiency of metal 3D printing have significantly reduced production times, enabling rapid prototyping and accelerated product development cycles. As this technology continues to advance, its potential for cost-effectiveness and broad-scale application will continue to grow, making it an indispensable tool for shaping the future of manufacturing and engineering. As this innovative technology continues to evolve, designers and engineers must adapt their approach to fully harness its potential. In this blog, we will explore 8 critical design considerations essential for successful metal 3D printing, empowering businesses to unlock new possibilities and achieve exceptional results. 1.Understanding Metal 3D Printing Technologies Before delving into the design process, it is crucial to comprehend the different metal 3D printing technologies available. Common methods include Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), and Electron Beam Melting (EBM). Each technology has unique capabilities, layer thicknesses, and material compatibility. Choosing the right method that aligns with the desired outcome is fundamental to the design process. Selective Laser Melting (SLM): Selective Laser Melting is a powder-based 3D printing process that involves melting and fusing metal powder using a high-powered laser. The metal powder is spread layer by layer, and the laser selectively fuses the powder particles together based on the 3D model's design. As each layer is fused, the build platform moves down, and a new layer of powder is applied, repeating the process until the entire object is formed. SLM is known for producing highly dense and fully functional metal parts, making it suitable for applications that require high precision and mechanical strength. Direct Metal Laser Sintering (DMLS): Direct Metal Laser Sintering is similar to SLM but operates at a lower temperature. Instead of fully melting the metal powder, DMLS uses a laser to sinter the particles, causing them to fuse together without reaching a complete molten state. This process results in a slightly porous structure, which may require additional post-processing steps for improved density and strength. DMLS is commonly used for manufacturing prototypes and end-use parts with complex geometries in aerospace, automotive, and medical industries. Electron Beam Melting (EBM): Electron Beam Melting is another powder-based metal 3D printing technique that utilizes an electron beam to melt and fuse metal powder. Unlike lasers, which can be used in selective laser melting, the electron beam is more powerful and can produce higher energy densities. EBM is performed in a vacuum environment to avoid the effects of air on the electron beam. The process enables faster printing speeds and is ideal for producing large, dense metal components for critical applications like aerospace and orthopedic implants. The key differences between these 3D printing methods with metal lie in their heating mechanisms, the energy source used (laser or electron beam), and the resulting properties of the printed parts (porosity, mechanical strength). Each method has its advantages and is suitable for specific applications, allowing manufacturers to choose the most appropriate technique based on their requirements and desired outcomes. 2. Designing for Additive Manufacturing (DFAM) Designing for Additive Manufacturing (DFAM) represents a transformative shift in the manufacturing landscape, departing from traditional subtractive methods. Metal 3D printing opens up a realm of possibilities, inviting engineers and designers to unleash their creativity by capitalizing on the unique capabilities of this technology. Embracing metal 3D printing means breaking free from the constraints imposed by conventional manufacturing techniques, enabling the realization of unprecedented designs. The flexibility of this process allows for the creation of organic shapes, intricate geometries, and lightweight structures that were once inconceivable or too challenging to fabricate. With DFAM, designers can optimize parts for specific functions and create components that are tailored to exact specifications, thereby reducing material waste and minimizing the need for assembly of multiple parts. Through iterative prototyping and simulations, designers can optimize designs, reducing trial-and-error cycles and accelerating the product development process. 3. Optimizing Part Orientation Part orientation significantly impacts the mechanical properties and surface finish of metal 3D printed components. Designers must carefully consider how the part will be positioned during the printing process to maximize its mechanical properties and surface finish. Proper orientation helps to minimize the occurrence of residual stresses, which can lead to warping or deformation during and after printing. By strategically positioning the part, designers can reduce the need for excessive support structures, reducing post-processing efforts and material wastage. A well-thought-out orientation can lead to superior surface quality, reducing the need for additional finishing steps. However, achieving the ideal part orientation requires a delicate balance between various factors. Optimal orientation might improve strength and performance but could potentially increase the build time, impacting production efficiency and costs. Designers must also consider material usage, ensuring that the chosen orientation does not result in excessive material consumption, which could affect the overall economics of the 3D printing process. By carefully weighing these trade-offs and leveraging simulation tools, designers can find the sweet spot that results in a successful metal part with optimal mechanical properties, excellent surface finish, and efficient production. 4. Material Selection and Properties Selecting the appropriate metal alloy is crucial for the functionality and performance of the final part. Different metals exhibit varying thermal conductivities, melting points, and mechanical properties. Understanding these material characteristics will help designers make informed decisions, ensuring the desired properties are achieved in the finished product. Several types of metals and metal alloys are commonly used in 3D printing with metals, each offering unique properties and characteristics. Some of the most common types of metals used in metal additive manufacturing include: Stainless steel is widely utilized in 3D printing due to its corrosion resistance, high strength, and affordability. It finds applications in industries such as automotive, aerospace, and consumer goods. Titanium is a lightweight, strong, and biocompatible metal used extensively in the medical and aerospace industries. It is known for its excellent strength-to-weight ratio and resistance to corrosion. Aluminum is another lightweight metal commonly used in 3D printing. It offers good strength, thermal conductivity, and is utilized in industries such as aerospace, automotive, and consumer electronics. Nickel alloys, such as Inconel and Hastelloy, are known for their exceptional high-temperature resistance and corrosion resistance. They find applications in industries like aerospace, energy, and chemical processing. Cobalt-chrome alloys, such as CoCrMo, are commonly used in medical and dental applications due to their biocompatibility and excellent mechanical properties. Copper is utilized for its excellent electrical and thermal conductivity. It finds applications in electronics, heat exchangers, and electrical components. Precious metals like gold and silver are also used in metal additive manufacturing, particularly in the production of jewelry, decorative objects, and high-end consumer goods. 5. Wall Thickness and Feature Size Metal 3D printing has undoubtedly opened up new horizons for creating intricate and delicate features in designs, as well as thin walls that were once challenging to achieve through traditional manufacturing methods. However, designers must tread carefully, as the unique capabilities of metal 3D printing also come with certain limitations that must be considered. One critical factor is the wall thickness of the components being printed. While it may be tempting to push the boundaries of design complexity, insufficient wall thickness can lead to print failures or compromise the mechanical properties of the final part. It is imperative to strike a harmonious balance between design intricacy and manufacturability. This involves understanding the capabilities and constraints of the chosen metal 3D printing technology and the material being used. By carefully evaluating the intended application and structural requirements, designers can optimize the wall thickness to ensure that the 3D printed parts meet the desired functionality, strength, and reliability while still achieving the desired intricate features. Collaboration between designers, engineers, and 3D printing experts is instrumental in navigating these challenges and ensuring that the end product is both visually captivating and structurally robust. 6. Designing for Post-Processing Metal 3D printing, while offering numerous advantages, often necessitates post-processing to achieve the desired final form and functional characteristics of the printed parts. Designers must be mindful of these post-processing requirements from the outset of the design phase. One crucial aspect is the removal of support structures used during printing to ensure the part's stability. Designers should consider how to design support structures strategically, making them easier to remove and minimizing the need for extensive manual intervention. Additionally, heat treatment may be necessary to improve the mechanical properties and relieve residual stresses within the part, especially for certain metal alloys. Integrating heat treatment considerations into the design can optimize the component's performance. Moreover, surface finishing, such as machining, polishing, or coating, is often essential to achieve the desired surface quality and functional characteristics. By factoring in these post-processing steps during the design stage, designers can anticipate the specific requirements and ensure that the 3D printed parts can smoothly transition from the printing stage to the final product, streamlining the overall production process and reducing the need for costly and time-consuming adjustments after printing. This proactive approach enhances efficiency, reduces material waste, and ultimately leads to the creation of high-quality metal parts that meet or exceed the desired specifications. 7. Avoiding Thermal Distortions In metal 3D printing, dealing with thermal distortions presents a significant and common challenge, particularly when printing large and complex parts. The process of metal 3D printing involves melting and solidifying metal powder layer by layer, subjecting the material to intense localized heat. This heat can cause uneven temperature distribution, leading to thermal gradients within the part. As a result, certain areas cool and contract at different rates, potentially causing warping, cracking, or deformation of the printed component. To address this issue, designers must have a deep understanding of the thermal behavior of the chosen metal material. By carefully analyzing the material's thermal properties, including its coefficient of thermal expansion and specific heat capacity, designers can anticipate how the material will respond to the printing process. Armed with this knowledge, designers can then optimize the part's design to minimize the accumulation of heat in critical regions. This can be achieved by strategically placing additional supporting structures or heat sinks, using lattice structures to dissipate heat, or adjusting the printing parameters to control the heat input. By taking these preventive measures, designers can significantly reduce the likelihood of thermal distortions and ensure the successful production of high-quality metal 3D printed parts, even in the face of challenging geometries and large-scale manufacturing. 8. Implementing Support Structures Support structures play a vital role in maintaining the stability of overhanging features and complex geometries during the printing process. As metal powders are selectively fused by the laser or electron beam, any overhangs without support would collapse during printing, compromising the integrity of the final part. Designers must carefully consider the placement and design of support structures to strike a delicate balance. While supports are essential for successful printing, they can also leave unwanted marks or surface irregularities on the final part. Strategic placement of supports can help minimize their impact on the critical surfaces of the component. Moreover, designers should consider the ease of support removal, as precision and care are necessary to ensure that no damage is done to the printed part during this process. Some advanced software tools and simulation techniques can aid designers in optimizing support structures, making them easier to remove while still ensuring proper anchoring during printing. By effectively managing support structures, designers can achieve high-quality metal 3D printed parts with intricate features and overhangs, meeting the desired specifications without compromising the overall integrity of the component. As metal 3D printing continues to redefine manufacturing possibilities, mastering the art of designing for additive manufacturing is becoming increasingly important. Embracing the freedom and flexibility that metal 3D printing offers allows designers and engineers to create groundbreaking solutions previously unattainable through conventional methods. By understanding the intricacies of different metal 3D printing technologies, optimizing part orientation, selecting suitable materials, and integrating post-processing considerations, businesses can achieve remarkable success in metal 3D printing. Embrace the revolution of additive manufacturing, and witness the transformation of design concepts into tangible metal masterpieces. At Nota3D, we pride ourselves on being a resource for our customers to continuously develop internal processes, drive innovation, and increase efficiency by utilizing the finest additive manufacturing technology. We achieve this by being a team of experts for you to partner with and depend on. We help you find clarity in the crowded world of 3D printing and software. Start with Nota3d.
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What Can You 3D Print With Metals?
Examining the Uses and Advantages of Using Metal in 3D Printing Metal can be used for 3D printing through a process called metal additive manufacturing. This innovative technique involves the layer-by-layer deposition of metal powder or wire, which is then selectively melted and fused together using lasers or electron beams. The process begins with a digital design that is sliced into layers, and each layer is sequentially built upon a build plate to create a three-dimensional object. Metal 3D printing offers several advantages, including the ability to create complex geometries, lightweight structures, and highly customized parts. It enables the production of functional metal components with high precision, strength, and durability. Various metals and metal alloys, such as titanium, stainless steel, aluminum, and nickel alloys, can be used for 3D printing, providing versatility and compatibility with different applications across industries ranging from aerospace and automotive to healthcare and consumer goods. Metal 3D printing unlocks new possibilities in design, manufacturing, and rapid prototyping, offering enhanced efficiency, reduced material waste, and increased design freedom. Let’s take a closer look at some of the most common uses for metal 3D printing, and the types of metals that are frequently used. What Can Be 3D Printed Using Metal? 3D printing with metal allows for the creation of complex, customized, and functional metal parts that were previously challenging to produce using traditional manufacturing methods. Some of the commonly 3D printed metal objects include: Prototypes and Industrial Parts - 3D printing with metals enables the production of prototypes and functional parts for industries such as aerospace, automotive, and engineering. Components like engine parts, turbine blades, brackets, and complex geometries can be manufactured with ease. Jewelry and Fashion Accessories - Precious metals like gold, silver, and titanium can be 3D printed to create intricate jewelry pieces, including rings, pendants, bracelets, and earrings. This technology allows for intricate designs and customization, offering unique and personalized pieces. Medical Implants and Prosthetics - Metal 3D printing has revolutionized the medical field by enabling the production of customized implants and prosthetics. Titanium and other biocompatible metals are used to create patient-specific implants, such as cranial plates, hip and knee replacements, and dental implants, improving patient outcomes. Tooling and Manufacturing Fixtures - Metal 3D printing is utilized to produce complex tooling and manufacturing fixtures, which enhance efficiency and reduce lead times in production processes. These fixtures can be tailored to specific requirements and offer advantages in terms of weight reduction and design flexibility. Art and Sculptures - Artists and sculptors embrace metal 3D printing to bring their creative visions to life. The technology allows for the creation of intricate and detailed metal sculptures, art installations, and decorative objects that were previously challenging to produce using traditional methods. Consumer Goods and Electronics - Metal 3D printing is also utilized to manufacture consumer goods and electronics. Products like custom smartphone cases, high-end audio equipment, watches, and high-performance bicycle frames are some examples where metal additive manufacturing is used. It's important to note that the choice of metal materials for 3D printing varies depending on the application and specific requirements. What Types of Metal Are Used? Several types of metals and metal alloys are commonly used in 3D printing with metals, each offering unique properties and characteristics. Some of the most common types of metals used in metal additive manufacturing include: Stainless steel is widely utilized in 3D printing due to its corrosion resistance, high strength, and affordability. It finds applications in industries such as automotive, aerospace, and consumer goods. Titanium is a lightweight, strong, and biocompatible metal used extensively in the medical and aerospace industries. It is known for its excellent strength-to-weight ratio and resistance to corrosion. Aluminum is another lightweight metal commonly used in 3D printing. It offers good strength, thermal conductivity, and is utilized in industries such as aerospace, automotive, and consumer electronics. Nickel alloys, such as Inconel and Hastelloy, are known for their exceptional high-temperature resistance and corrosion resistance. They find applications in industries like aerospace, energy, and chemical processing. Cobalt-chrome alloys, such as CoCrMo, are commonly used in medical and dental applications due to their biocompatibility and excellent mechanical properties. Copper is utilized for its excellent electrical and thermal conductivity. It finds applications in electronics, heat exchangers, and electrical components. Precious metals like gold and silver are also used in metal additive manufacturing, particularly in the production of jewelry, decorative objects, and high-end consumer goods. The specific metal or alloy chosen for 3D printing depends on the desired properties, functional requirements, and intended application of the printed object. Each metal has its own advantages, limitations, and compatibility with different 3D printing technologies. the choice of materials allows for compatibility with various industries and functional demands. What are the Advantages to Using Metals When 3D Printing? 3D printing with metal allows for the creation of lightweight yet strong structures. Complex internal geometries and lattice structures can be designed to reduce weight without compromising strength, making it suitable for applications where weight reduction is critical, such as aerospace and automotive industries. Metal 3D printing facilitates on-demand production, allowing businesses to manufacture parts as needed, reducing inventory costs, and enabling just-in-time manufacturing. This flexibility is particularly advantageous for low-volume production, spare parts production, and customized manufacturing. Metal additive manufacturing allows for high levels of customization and design freedom. Each printed part can be tailored to meet specific requirements, whether it's the shape, size, or internal features. This flexibility is particularly valuable in industries like aerospace, medical, and automotive, where personalized and patient-specific components are needed. It also enables the creation of complex geometries and intricate designs that are challenging or impossible to achieve with traditional manufacturing methods. This allows for lightweight structures, internal channels, and optimized shapes that can enhance performance and functionality. Nota3D’s mission is to help companies create the best possible products by equipping them with the right 3D technology and supporting their growth. We want to be known as a trusted partner and that is our focus. We listen first, until we have a deep understanding of your need—then we get into what solutions are available to solve it. That’s why several of the nation's top companies come to us to find the right tools for the job. We’ve worked with everyone from garage inventors to the largest medical device companies in the world and the list keeps growing. We test every product ourselves. If it doesn’t meet our rigorous standards, we don’t sell it. To find out more about how we can help, contact us today.
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