Differences Between Fused Granulate Fabrication (FGF) and Fused Filament Fabrication (FFF) 3D Printing

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3D printing technology has revolutionized manufacturing, and understanding the differences between Fused Granulate Fabrication (FGF) and Fused Filament Fabrication (FFF) is crucial for choosing the right method for your projects. This article delves into the unique properties, applications, and cost considerations of FGF and FFF 3D printing techniques.

What is FGF 3D Printing?

FGF printer Suitable-for-More-Materials

Fused Granulate Fabrication (FGF) is a 3D printing technology that uses plastic pellets as the primary material. This method involves feeding granulated thermoplastic into an extruder, which melts the granules and deposits the molten material layer by layer to create the final object. FGF is known for its ability to print large-scale objects quickly and affordably, making it ideal for industrial applications.

FGF stands out because it can utilize a wide variety of thermoplastic materials, including recycled plastics, which significantly reduces material costs. The use of pellets instead of filaments allows for high throughput, making FGF suitable for large-scale production. Additionally, the ability to use recycled and lower-cost materials makes FGF an environmentally friendly and economically viable option for many manufacturers.

What is FFF 3D Printing?

Fused Filament Fabrication (FFF), also known as Fused Deposition Modeling (FDM), is a more common 3D printing technique that uses spooled filaments of plastic as the feedstock. The filament is fed into a heated nozzle, melted, and extruded to build the object layer by layer. FFF is widely used due to its simplicity, accessibility, and versatility.

FFF printers are popular for producing detailed, high-resolution prints. They are suitable for a wide range of applications, from prototyping to small-batch production. The variety of available filaments, such as PLA, ABS, PETG, and specialty materials, adds to the versatility of FFF printing. Furthermore, the ease of use and widespread availability of FFF printers and filaments make them an excellent choice for hobbyists, educational institutions, and professional applications alike.

What is the Difference Between FGF and FFF?

Print Resolution

When comparing FFF vs. FGF, print resolution is a critical factor. FFF typically offers higher print resolution and finer detail, making it ideal for applications requiring precision and intricate designs. The smaller nozzle sizes and controlled filament feed in FFF printers allow for detailed prints with smooth surfaces. This makes FFF suitable for producing small, detailed prototypes, models, and parts with complex geometries.

In contrast, FGF printers, while capable of producing large objects, generally have lower resolution due to the larger nozzle sizes and higher material flow rates. This makes FGF more suitable for large, less detailed prints where speed and material cost are more important than fine detail. However, advancements in FGF technology are continually improving the resolution and surface finish of printed parts, expanding its potential applications.

Print Speed

Print speed is another important consideration in the FFF vs. FGF debate. FGF printers can produce large parts much faster than FFF printers. The use of granulated feedstock and high-flow extrusion systems allows FGF printers to deposit material quickly, significantly reducing print times for large objects. This makes FGF an attractive option for industries needing rapid production of large components, such as automotive, aerospace, and construction.

FFF printers, while slower in producing large parts, excel in printing smaller, high-resolution objects. The controlled extrusion process ensures detailed prints but at a slower rate compared to FGF. This makes FFF ideal for applications where detail and surface finish are more critical than speed, such as in the production of prototypes, functional parts, and consumer products.

Material Compatibility

Material compatibility is a major advantage of FGF 3D printing. FGF printers can use a wide range of thermoplastic materials, including recycled plastics and more affordable pellets. This flexibility makes FGF an economical choice for large-scale production and environmentally friendly projects. Additionally, the ability to use various types of granulates, including high-performance engineering plastics, expands the application possibilities for FGF.

FFF printers also offer a broad range of materials, but they are limited to filament form. While many specialty filaments are available, the cost per kilogram is generally higher than that of pellets used in FGF. However, FFF printers excel in producing prints with specific material properties required for various applications. The diversity of filaments, including composites and flexible materials, allows for tailored solutions in industries such as healthcare, automotive, and consumer goods.

Best Pellet 3D Printers

When considering the best pellet 3D printers for FGF, the following models stand out for their capabilities and performance.

G5Ultra Pellet 3d printer

  • Printing Size: 500*500*400mm
  • Features:
    • Nozzle temperature up to 400℃
    • Rapid heating of hot bed up to 120℃
    • Suitable for more materials
    • High-speed printing

The G5Ultra is a high-speed industrial pellet 3D printer designed for desktop use. It utilizes low-cost thermoplastic pellet feedstocks, making it an economical choice for various applications. The G5Ultra’s high-speed printing capabilities and versatility in material use make it ideal for small to medium-sized parts. This printer is particularly suitable for businesses and research institutions looking to explore pellet 3D printing without the need for large, industrial-scale equipment.

G12 Pellet 3d printer

G12 Pellet 3d printer

  • Printing Size: 1200*1000*1000mm
  • Features:
    • Nozzle temperature up to 450℃
    • Rapid heating of hot bed up to 120℃
    • High Flow Screw Extrusion
    • Powerful Servo Motor

The G12  is a large-format pellet extrusion printer capable of printing medium-to-large format parts. Its robust design and high-performance features make it suitable for industrial applications requiring large, durable parts. The high flow screw extrusion and powerful servo motor ensure efficient and consistent printing performance. The G12 is an excellent choice for industries such as automotive, aerospace, and construction, where the production of large, high-strength parts is essential.

Wrapping Up

Fused Granulate Fabrication (FGF) and Fused Filament Fabrication (FFF) offer distinct advantages depending on the application. FGF is ideal for large-scale, cost-effective production with a wide range of materials, while FFF excels in producing high-resolution, detailed prints for smaller objects. Understanding the differences between these technologies helps in selecting the right method and equipment for your specific needs.

Whether you need the versatility and detail of FFF or the cost-effectiveness and speed of FGF, the advancements in 3D printing technology provide a solution for nearly every manufacturing challenge. With top-tier pellet 3D printers like the G5Ultra and G12, businesses can leverage the benefits of FGF to enhance their production capabilities and drive innovation.

FGF and FFF technologies continue to evolve, with ongoing research and development aimed at improving their capabilities and expanding their applications. As these technologies advance, they will become increasingly accessible and affordable, enabling more industries to benefit from the unique advantages of 3D printing. Whether you’re looking to produce large, cost-effective parts with FGF or high-resolution, detailed components with FFF, understanding the strengths and limitations of each technology will help you make informed decisions and achieve your manufacturing goals.

The Benefits of 3D Printed Furniture with Pellet Extrusion

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Additive Manufacturing (AM) is revolutionizing furniture production by enabling unparalleled customization, design flexibility, and sustainability. Among the various 3D printing technologies, pellet extrusion has emerged as the method of choice. This technique utilizes pellets and shredded recycled plastic, offering both financial and environmental advantages for a wide range of applications. You can reduce material costs by over 60%, and it facilitates the production of large-scale pieces quickly and affordably, making end-use furniture production feasible.

Can a 3D Printer Make Furniture?

Absolutely! With advancements in large-scale 3D printing, creating functional and stylish furniture with a 3D printer is not only possible but also increasingly common. By using a pellet 3D printer, manufacturers can produce everything from chairs and tables to intricate home decor. These printers can handle large-scale designs, ensuring that even substantial pieces are printed efficiently.

Large-scale 3D printing has evolved to the point where it can compete with traditional manufacturing methods. The primary advantage is its ability to produce complex geometries that are difficult or impossible to achieve with conventional techniques. For instance, intricate lattice structures that offer both strength and aesthetic appeal can be created with ease using a 3D printer.

Another significant advantage is the reduction in assembly requirements. Traditional furniture often comprises numerous parts that need to be assembled, which adds to labor costs and production time. In contrast, 3D printed furniture can be produced as a single piece or with minimal assembly, streamlining the manufacturing process.

What Material is Used for Pellet 3D Printing Furniture?

When it comes to materials for 3D printed furniture, two popular choices are PETG and ABS pellets.

Plastic pellet Materials 3d printed furniture

PETG Pellets

PETG (Polyethylene Terephthalate Glycol) pellets are known for their strength, durability, and ease of printing. They are ideal for producing robust furniture pieces that can withstand everyday use. PETG is also recyclable, aligning with sustainable production goals.

PETG’s properties make it an excellent choice for furniture that needs to endure everyday wear and tear. It has high impact resistance, ensuring longevity even in high-traffic environments. Moreover, PETG is hygroscopic, meaning it resists moisture absorption, making it suitable for outdoor furniture as well.

ABS Pellets

ABS (Acrylonitrile Butadiene Styrene) pellets offer excellent mechanical properties and high impact resistance. This material is perfect for furniture that needs to endure significant wear and tear. ABS is also relatively easy to work with, providing a smooth finish for printed items.

ABS is renowned for its toughness and ability to withstand various environmental conditions. It’s commonly used in the automotive industry for similar reasons, which makes it an excellent material for furniture that requires durability. Additionally, ABS can be post-processed easily to achieve a high-gloss finish, adding to the aesthetic appeal of the furniture.

Benefits of 3D Printed Furniture with Pellet Extrusion

Higher Customization Flexibility

One of the standout benefits of 3D printed furniture is the ability to customize designs with ease. Manufacturers can tailor each piece to specific customer preferences, resulting in unique, bespoke items that cater to individual tastes.

Customization goes beyond aesthetics; it includes functionality as well. For example, ergonomic chairs can be designed to fit the exact body dimensions of an individual, providing personalized comfort. This level of customization is challenging to achieve with traditional manufacturing methods without incurring significant costs.

Faster Turnaround Time

Traditional furniture manufacturing can be time-consuming, but pellet 3D printers significantly speed up the process. The ability to produce large-scale pieces quickly means reduced lead times and faster delivery to customers.

Speed is a crucial factor in the modern market, where consumers expect quick turnaround times. 3D printing can reduce the production time from weeks or months to just days, depending on the complexity of the design. This rapid production capability allows businesses to respond swiftly to market demands and trends, maintaining a competitive edge.

Design Freedom - Thinking Outside the Box

3D printing allows designers to experiment with innovative shapes and structures that would be impossible or too costly to achieve with traditional methods. This freedom leads to more creative and functional furniture designs.

For instance, organic shapes that mimic natural forms can be easily produced using 3D printing. These designs not only enhance the aesthetic appeal but also offer functional benefits such as improved structural integrity and material efficiency. The ability to create such unique designs sets 3D printed furniture apart from mass-produced items.

Less Production Wastage

Pellet extrusion is an efficient process with minimal waste. Unlike subtractive manufacturing, which cuts away material, additive manufacturing builds furniture layer by layer, using only the necessary amount of material. This efficiency reduces costs and environmental impact.

Waste reduction is a significant advantage in today’s environmentally conscious world. Traditional manufacturing processes often result in a considerable amount of scrap material, which adds to both cost and environmental burden. 3D printing’s additive nature ensures that almost all the material used goes into the final product, minimizing waste.

Detect Potential Design Flaws

The digital nature of 3D printing enables designers to prototype and test furniture before committing to full-scale production. This capability helps identify and rectify design flaws early, ensuring higher quality final products.

Prototyping is an integral part of the design process, allowing for the testing of various iterations and modifications without the need for expensive tooling changes. By identifying potential issues early in the development process, companies can save time and resources while ensuring that the final product meets the desired specifications and quality standards.

Higher ROI and Lower Production Cost

The cost savings from reduced material waste and faster production times translate into a higher return on investment for manufacturers. Pellet 3D printing is a cost-effective method that lowers overall production costs while maintaining high quality.

In addition to direct cost savings, the flexibility and efficiency of 3D printing enable manufacturers to bring products to market more quickly, capitalize on trends, and meet customer demands with less financial risk. This agility can lead to increased sales and profitability.

More Sustainable

Using recycled plastic pellets in 3D printing aligns with sustainable manufacturing practices. This approach not only reduces reliance on virgin materials but also contributes to waste reduction by repurposing plastic that would otherwise end up in landfills.

Sustainability is becoming increasingly important to consumers, and businesses that prioritize eco-friendly practices can enhance their brand reputation and appeal to a broader audience. 3D printing with recycled materials supports a circular economy, where products are designed with their end-of-life in mind, promoting recycling and reuse.

Best 3D Furniture Printers

G12 Pellet 3D Printer

  • Printing Size: 1200*1000*1000mm
  • Features:
    • Nozzle temperature up to 450℃
    • Rapid heating of hot bed up to 120℃
    • High Flow Screw Extrusion
    • Powerful Servo Motor

The G12 Pellet 3D Printer is a large-format printer ideal for creating medium-to-large furniture pieces efficiently. Its high-temperature capabilities and rapid heating ensure that a wide range of materials can be used, making it versatile for different design requirements.

G40 Pellet 3D Printer

  • Printing Size: 3725*2500*1330mm
  • Features:
    • Large working space
    • Workbench design
    • CNC five-axis head
    • High flow screw extrusion design

The G40 Pellet 3D Printer, PioCreat’s largest industrial printer, combines additive and CNC five-axis manufacturing, making it a versatile and reliable option for industrial-scale furniture production. The CNC capabilities allow for precise machining, enhancing the functionality and finish of the printed pieces.

Wrapping Up

3D printed furniture with pellet extrusion is transforming the furniture industry, offering unmatched customization, faster production times, and significant cost savings. By utilizing PETG and ABS pellets, manufacturers can produce durable, sustainable, and innovative furniture designs. The G12 and G40 Pellet 3D Printers exemplify the best in large-scale 3D printing technology, pushing the boundaries of what’s possible in furniture manufacturing.

The future of furniture manufacturing is here, and it’s additive. Embracing 3D printing technology not only enhances production capabilities but also aligns with the growing demand for sustainable and customized products. Whether you’re a manufacturer looking to innovate or a consumer seeking unique and eco-friendly furniture, 3D printed furniture with pellet extrusion offers exciting possibilities.

Piocreat & Pionext Unveils Advanced Dental Solutions at CDS 2024

We’re thrilled to announce the triumphant showcase of Piocreat & Pionext at the highly regarded Chicago Dental Society (CDS) Midwinter Meeting held from February 22nd to 24th, 2024. Founded on the bedrock of pioneering the future of dental technology, piocreat has been steadfast in our commitment to redefining dental solutions through the relentless pursuit of R&D, production, and the distribution of top-tier 3D printers designed explicitly for dentistry. 

Our participation in the prestigious CDS Midwinter Meeting 2024 not only underlines our dedication but also marks a significant milestone in our journey to revolutionize the dental sector.

The spotlight of this year’s exhibition was the unveiling of the latest masterpiece from piocreat –  such as DJ89 Plus,D150 and D158 dental printer . Accompanied by our state-of-the-art biocompatible dental resin, attendees were offered a firsthand encounter with the future of dentistry. These innovations are conceived with perfection and precision in mind, destined to empower dental professionals to exceed the standards of therapeutic and aesthetic dentistry.

Piocreat & Pionext’s venture into the limelight at the CDS Midwinter Meeting 2024 was not just a display of technological marvels but a testament to our unwavering resolve to infuse the dental sector with agile, efficient, and groundbreaking solutions. We extend our heartfelt gratitude to everyone who joined us, sharing in our vision and exploring the vast possibilities that 3D printing holds for dentistry.

The success of PioCreat at the CDS Midwinter Meeting ushers in a new era of dental care, promising an efficient, precise, and personalized approach to dental treatments. For those who couldn’t join us this time, we look forward to connecting with you and introducing you to a world where dental innovations meet exceptional care.

Stay tuned for more exciting developments from Piocreat & Pionext. Together, let’s sculpt the future of dental healthcare, one layer at a time.

Piocreat & Pionext to Ignite Innovation at CDS Midwinter Meeting 2024

Get ready for a 3D printing revolution in the dental industry as PioCreat 3D proudly announces its participation in the CDS Midwinter Meeting 2024.

PioCreat 3D’s offerings result in a lower overall cost of ownership in comparison to major competitors. Our presence at CDS 2024 is your chance to witness firsthand the latest advancements that will shape the future of dental care.

What to Expect from Piocreat at CDS Midwinter Meeting 2024?

  • Machines: Models such as DJ89 Plus 8K LCD 3D printer and D158 surpass rival printers in terms of speed and throughput while maintaining top-tier dimensional precision. With an astonishing print speed of up to 80mm/h, the D150 DLP 3D printer ensures you spend less time waiting and more time creating.
  • Biocompatible dental resin: A portfolio of state-of-the-art dental resins to create products characterized by their robustness, minimal shrinkage, strong biocompatibility, and resistance to wear. This allows users to decrease material consumption and boost output without incurring additional costs.
  • Interactive Showcases: Explore our interactive showcases featuring the latest innovations that are simplifying workflows, enhancing accuracy, and delivering exceptional results in the dental industry.

Schedule a Meeting

Visit Piocreat for more information on our products and solutions. We look forward to welcoming you at CDS Midwinter Meeting 2024!

How to Choose the Best Dental Resin for Dental 3D Printing

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How is 3D printing used in the dental field?

3D printing in the dental field is used for creating various dental products and devices with high precision and speed. Applications include:

Dental Models

Producing accurate models of patients’ mouths, which are used for diagnostics and treatment planning.

Orthodontic

Creating custom aligners, retainers, and other orthodontic devices directly from digital impressions.

Crowns and Bridges

3D printing dental crowns and bridges using materials like ceramics, which provide durability and aesthetic appearance.

Dental Implants and Surgical Guides

Printing surgical guides for dental implants to ensure precise placement and printing of custom dental implants.

Dentures

Fabricating full or partial dentures, allowing for customization and rapid production.

Overall, 3D printing in dentistry enhances customization, reduces turnaround time, and can lower costs while improving patient outcomes.

What is Dental Resin?

In dental 3D printing, dental resin is a type of photopolymeric material that cures (hardens) when exposed to a specific light source, typically ultraviolet (UV) light. These resins are used to create highly detailed and precise three-dimensional objects suitable for dental applications such as crowns, bridges, dentures, orthodontic devices, and surgical guides. Dental resins must be biocompatible, have suitable mechanical properties, and often require regulatory approval for use in patients.
best 3D resin for dental models

Dental Resin for Dental Labs and Orthodontic Practices

PioCreat Dental Resins empower dental labs and orthodontic practices to rapidly manufacture biocompatible surgical guides, splints and models, clear aligner models, and full dentures.

How to Choose the Best Dental Resin for Dental 3D Printing?

Choosing the best dental resin for 3D printing in dentistry involves considering several factors to ensure the material meets clinical requirements and regulations. Here’s a streamlined guide:

1. Biocompatibility: Ensure the resin is biocompatible. It must be safe for intraoral use and should not cause any adverse response in patients.

2. Mechanical Properties: Depending on the dental application (like surgical guides, dental models, crowns, or orthodontic appliances), the resin should have appropriate strength, durability, and wear resistance.

3. Accuracy and Detail: High resolution in resin ensures that the printed dental models or devices accurately reproduce the fine details necessary in dental applications.

4. Color Stability and Esthetics: For prosthetics, look for resins that offer colors matching natural tooth shades and resistance to staining.

5. Certification and Compliance: The resin must comply with local regulatory requirements such as FDA approval in the USA or CE marking in Europe.

6. Print Speed and Ease of Use: Select a resin that provides an optimal balance between print speed and ease of post-processing.

7. Compatibility with Printers: Check if the resin is compatible with your specific 3D printer type (SLA, DLP, or LCD).

8. Vendor Support and Reputation: Choose resins from suppliers with trustful reputations in the industry who provide consistent quality and customer support.

9. Patient-Specific Needs: Consider specific patient needs such as allergies or sensitivities.

10. Cost: Factor in the price, keeping in mind that lower costs should not compromise product quality and patient safety.

Selecting the right dental resin requires a careful combination of these factors tailored to the types of dental applications and devices you plan to produce.

Ortho Model Resin

Specifically formulated for the dental industry, Ortho Model Resin stands as a trusted choice for orthodontic purposes. This biocompatible resin is engineered for compatibility with dental models, It excels with its outstanding print accuracy, heat resistance, substantial hardness, and a silky-smooth finish, all while maintaining the flexibility needed for dental workflows. Its resistance to abrasion contributes to maintaining flawless precision of the models, even after repeated use.

  • High printing speed
  • High edge stability
  • High forming precision
  • High temperature resistant

Temporary Restoration Resin

Temporary Resin is a bio-compatible tooth-colored resin for 3D printing of temporary crown and bridge restorations, inlays, onlays, and veneers. Indicated for up to seven-unit bridges and available in five shades. The material provides greater pressure and impact resistance, wear resistance and corrosion resistance, allowing for excellent marginal adaptation and dimensional stability.

  • Ultra high flexural tensile strength
  • Easy to polish
  • Color selectivity
  • Low water absorption

Surgical Guide Resin

Surgical Guide Resin is a biocompatible material designed specifically for crafting surgical guides. This transparent, Class I resin is perfect for creating precise guide plates essential for implant surgery, as well as orthodontic guides and functional retainers. Developed to facilitate high-precision, implant-guided procedures, Surgical Guide Resin ensures exceptional accuracy and performance.

  • Easy to drill
  • High sharp precision
  • High flexural strength
  • Transparent to see drill position

Dental Casting Resin

PioCreat’s Biocompatible castable resin is expertly formulated for dental casting applications, boasting minimal ash and residue upon burning and excellent casting characteristics. This high-precision resin ensures that even the finest details are sharply defined in print. Additionally, its low shrinkage properties mean that printed models maintain their shape and are less prone to deformation. This makes it an ideal choice for creating intricately detailed 3D printed models that are used for casting metal dental crowns, bridges, and brackets.

  • High precision
  • Good texture
  • Fast process
  • High cost-effectiveness

Denture base resin

Piocreat Denture Resins, which are approved Class II biocompatible materials for 3D printing of digital dentures, offer a unique blend of flexibility and stability. This innovative formula sets a new benchmark for denture manufacturing by integrating durability, visual appeal, and patient comfort. Utilize Denture Base Resin for the creation of durable, wear-resistant, and biocompatible denture bases. This method significantly reduces costs compared to conventional techniques. Furthermore, the resulting dentures are built for extended wear, with a lifespan ranging from 1 to 3 years, ensuring patient satisfaction over the long term.

  • Class II biocompatible
  • Perfect Details
  • Low water absorption
  • Durable

DJ89PLUS – Reliability for Dental and Jewelry Professionals

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Overview

The PioNext DJ89 PLUS from Piocreat is a LCD printer aimed at the dental industry, and as you can see in the image below, it is clear that this is an industrial-grade machine.

DJ89PLUS LCD printer

Featuring a 228 × 128 × 100 mm build envelope, it is ideally sized for orthodontic printing tasks that can be performed chairside.

One of the standout features of the PioNext DJ89 PLUS is its high-resolution capabilities, capable of rendering fine details and smooth surfaces with exceptional clarity. This level of precision is crucial in dentistry, where the accurate replication of anatomical features is paramount for successful clinical outcomes. It achieves this thanks to its 8K (7680 x 4320 px) screen resolution, 29 micron XY accuracy and 8x anti-aliasing. It can print at layer heights of 0.01mm-0.1mm ensuring minimal stepping artifacts on prints.

The DJ89 PLUS features 8x anti-aliasing

User Friendly and Robust

Thanks to its 5-inch color touch screen the PioNext DJ89 PLUS boasts a user-friendly interface, streamlining the printing process and allowing dental practitioners to focus their attention where it matters most – on patient care. Additionally, the PioNext DJ89 PLUS features both auto-leveling and auto-feeding, to facilitate a hassle-free printing experience.

The printer’s robust build quality ensures long-term reliability, minimizing downtime and maximizing productivity in dental laboratories and practices. Its durable construction and efficient workflow management make it a valuable asset for any dental facility striving for excellence in patient care. Thanks to its double linear guide and ball screw motion hardware, the rigid structure ensures not only high accuracy in prints, but means the accuracy is consistent time and time again.

Light source technology

Unlike typical parallel light source technology, this innovative advancement achieves a higher level of light uniformity. Traditional parallel light sources project lamp bead light directly onto the LCD screen.

However, this approach often causes repeated block illumination, leading to higher light intensity in specific areas intensified by superposition.Repurposing this drawback, the integrated light features of DJ89PLUS ensures that each light bead evenly illuminates the LCD screen, following the principle of refraction.

Light Uniformity

Combining the benefits of DLP and LCD technology, the PioNext DJ89 PLUS does not suffer from the downsides associated with parallel emission light sources, such as insufficient light uniformity and frequent replacement of light sources.

With its integrated light source technology the PioNext DJ89 PLUS achieves light uniformity up to 95%, and has a lightsource lifespan of 2000 hours, making it a highly cost-effective solution.

dental Overview

Material Compatibility

Another notable advantage of the PioNext DJ89 PLUS is its versatility in material compatibility. It uses 405nm resins to ensure maximum compatibility. With a wide range of biocompatible resins available, dental professionals have the flexibility to choose the most suitable material for their applications, whether it be for surgical guides, Gingiva masks, orthodontic models, and more.

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