3D Printing Seminar

PLACE PARTNER’S LOGO HERE
Title of the presentation | Date | ‹#›
Staff Exchange EEN
Sabanci University – Netherlands Chambre of Commerce
PLACE PARTNER’S
LOGO HERE

Program
7th July (Sabancı University)
Touring the university
Presentation: Innovation scan and Syntens methodology
Lunch
Visit to Technopark Istanbul
Presentation: 3D printing and 3D scanning technologies for desing and small scale manufacturing
• 15' intro of EEN / Dutch ecosystem maybe?
• 30' presentation
• 30' Q&A
Back to city via shuttle
8th July (Sabancı University)
Workshop: How to assess the innovation potential of an SME / developing an action plan (sharing the
Syntens experience)
Lunch
Visit to +90 / Rapid prototyping company
Back to city via shuttle

Shaping without restrictions:
New opportunities with Additive
Manufacturing
Alain Dirven

Rapid Manufacturing
e-Manufacturing
Solid Freeform Fabrication
Layered Manufacturing
3D Printing

Rapid Prototyping:
Manufacturing of physical prototypes direct from
3D CAD data by adding material
Rapid Manufacturing:
Manufacturing of functional (end)products & parts
Rapid Tooling:
Manufacturing of molds, dies & tools

Direct Manufacturing
• Design = digitally 3D fixed
• Object is made by addition of material
• Fast production by reduction of processteps
• Complex geometric objects possible
• Low volumes
• No mold or tool is required (reduction of investment & time)
• Design for Function, not for Manufacturing
Makes impossible shapes possible!

New concepts?
(Wat is dit?)

Anything you shape in 3D . . .

. . . can be made!

Unlimited freedom of design!

No restrictions anymore!

Why so interesting?

Title of the presentation | Date | ‹#›3D CAD Modelling 3D
Scanning
MRI or CT
Scanning
Slicing
Manufacturing of
Part
Post Processing
RP Interface (STL)
(Build supports)
Part Completed

Which applications?
1. Rapid Prototyping: Models & Prototypes
2. Rapid Manufacturing: Products
3. Rapid Tooling: Tools & Dies

New services
• Validation 3D CAD-file;
• Functional testmodels
• Aesthetics
• Ergonomy
• Assembly, fitting & form, handling
• Windtunnel, air & waterflow
•To provide customer small series (n= 1-100) without necessarity to
invest in mold;
• For early deliveries before released mold or tool;
• Manufacturing of master (=indirect).
1. Prototyping

New product opportunities
• Integrating multiple functionality into one complex part;
• Custom made product;
• Developing new specific part without necessarity to invest in
mold;
• Less manufacturing steps, fast delivery and less risk on delay;
• Manufacturing of master (=indirect f.e. casting)
2. Products

Productexample

New tool opportunities
•Direct production of complex parts, no milling or grinding
restrictions (Bridge tooling);
• Integration of several separate parts into one integrated design;
•Optimized shapes and dimensions, complex cooling channels;
• Addition of high wear resistant surfaces;
3. Rapid Toolmaking

Powder
systems
Liquid/paste
systems
Deposition
systems
Laser
Cutting
Laser
Sintering
Laser
Curing
Binder
jetting
Thermoplastic
jetting
Photopolymer
jetting
Layered
systems
Laser
Melting
Rapid Manufacturing Familiy Tree

Powder
systems
Liquid/paste
systems
Deposition
systems
Laser
Cutting
Laser
Sintering
Laser
Curing
Binder
jetting
Thermoplastic
jetting
Photopolymer
jetting
LOM
3D Printing
FDM
SLA
Layered
systems
SLS
Laser
Melting
Rapid Manufacturing Familiy Tree

LOM: Laser Object Manufacturing
Proces: Cutting and bonding of coated paper layers
Materials: Layers of impregnated paper
No supports required
LOMLaser Cutting

SLA: Stereo Lithography
Proces: Curing of UV epoxyresin
Materials: UV curable epoxy resins
Laser Curing SLA

Micro-stereolithography
Laser Curing SLA

SLS: Selective Laser Sintering
Proces: Bonding of powder by heat
Materials: Powders of plastics or coated metal
SLSLaser Sintering:

DMLS: Direct Metal Laser Sintering
Proces: Bonding by sintering of metalpowder
in a powderbed.
Materials: Powders of metals.
DMLSLaser Sintering:

DMLM: Direct Metal Laser Melting
Proces: Melting of metal powder
Materials: Fully dense
Laser Melting: DMLM

Laser Cusing
(Concept Laser)
Proces: Melting of added metal powder
Materials: Titan-, Nikkel-, Kobalt- en Steelalloys
• High small ribs possible
• Materialproperties equal or better
• No material porosity
• Combinatiion of different metals (Functionally
Gradient Materials)
Laser CusingLaser Melting:

DSPC: Direct Shell Production Casting:
Proces: Binder is deposited to bond a bed of
ceramic powder in layerwise cross sections.
Materials: Binding resin
Binder Jetting DSPC 3D Printing

3D Printing
Proces: A liquid adhesive compound is deposited
by a multi-channel jetting head onto the top layer
of a bed of powder object material.
Materials: Wax, Binder
3D PrintingBinder Jetting

FDM: Fused Deposit Modelling
Proces: Addition of molten filament
Materials: ABS, Butyl styrene, PLA
Thermoplastic Jetting FDM
Example of direct digital manufacturing of parts
for end us. With FDM, BMW built this hand-held
assembly tool used in manufacturing cars.

Objet
Proces: Addition of UV cureable photopolymer
Suppliers: Objet
Photopolymer Jetting Objet

Color models
PrototypingApplications

Prototyping: Scale models

Prototyping: SLA indirect

•Operating tools
Applications:Tools
Chirurgy: Tools

•Operating tools
Chirurgy: Tools
Applications:Tools

•Protheses & Inplants
Applications
Medical products

Chirurgical models
MedicalApplications

Health: Hearing aids
MedicalApplications

Interior: Lamps
Applications:Products

Title of the presentation | Date | ‹#›Applications:Products
Additional features

Additional features
Applications:Products

Example of direct digital manufacturing of parts for end
us. With FDM, BMW built this hand-held assembly tool
used in manufacturing cars.
Industry: Tools
Applications

Machine construction: Tools
Applications

Industry: Tools
Robotgrippers met geïntegreerde
luchtkanalen voor zuigcups

Luchtafvoerkanaal koelunit
Applications
Industry: Tools

Afzuigkop voor Bosch schuurmachine
Applications
Industry: Tools

Title of the presentation | Date | ‹#›Applications
Industry: Ceramic parts

Moldmaking: SLA inserts
Applications

Industry: Special parts
Applications

Werkzeugbau
Hofmann
LaserCusing
(Germany)
JB Ventures
(Netherlands)
Applications
Industry: Moldmaking

Industry: Moldmaking
Applications

Industry: Machine parts
Carat Duchatelet Deursloten voor gepantserde voertuigen
(vooraan huidige sloten, achter de vernieuwde versie
Applications

4. 3D Scanning
• Reproduction or copying;
• Scaling;
• Orthopedic products (f.e. protheses)
• Manufacturing of master (=indirect).
Reverse Engineering
Applications

Title of the presentation | Date | ‹#›Applications
3D Scanning: Arts

3D Scanning: Arts

• Surfacequality (stepping, sintering) needs extra
processteps;
• Hardness of material;
• Strong competing developments in HSM,
Aluminium Alloys;
• Large mouldparts expensive, longer leadtime;
• Mouldmaker unknown with addition of material &
properties;
• Better quality but expensive protoparts competing
with high moldinvestment;
Disadvantages/threads
Trends

Serial volume
Functionality
Trends

Title of the presentation | Date | ‹#›Trends

15 metal alloys!
Trends

General
• Cheaper machines, increasing low-end machines;
• Faster, more accurate & reproducible;
• Hybrid techn.: Sintering / Contour milling
• FDM based machines are growing fast;
• Increase of range of materials: Ti, H13, Stainless
Steel, CrCu, WC-Co, Ceramics

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3D Printing Seminar

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