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Tru design coatings

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3D Printing and coatings

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Tru design coatings

  1. 1. Coatings that make Additive Manufacturing Work Technology Overview February 27, 2017 1
  2. 2. Background •  Expertise in coatings as applied in the additive manufacturing process. •  Member of Composite Applications Group Consortium, Oak Ridge Carbon Fiber Composites Consortium, and supporting member Institute for Advanced Composites Manufacturing Innovation (IACMI). 2
  3. 3. You May Have Seen the 2015 CAMX Combined Strength Award Winning Printed Shelby Cobra 3
  4. 4. Or The Printed Willys Jeep Body 4
  5. 5. Maybe Even The Printed F-22 5
  6. 6. Or The Printed House & Utility Vehicle 6
  7. 7. ORNL Receives Award For World’s Largest 3D Printed Object Additive Manufacturing Researchers at Oak Ridge National Laboratory have additively manufactured the world’s largest solid 3D printed component. The part took about 30 hours to print, is 17.5’ long x 5’ wide x 1.5’ tall and weighs about 1,650 lbs. 7
  8. 8. Guinness World Record Additive Tool Machined TD Coat RT Surface 8
  9. 9. Digitally Manufactured Molds Successfully Withstand Autoclave High Temperature Tooling Researchers at the MDF- along with 8 industry partners – successfully tested digitally manufactured, high temperature thermoplastic molds that withstood industrial autoclave cycles for the first time ever!
  10. 10. Digitally Manufactured Molds Successfully Withstand Autoclave High Temperature Tooling CAMX 2016 ACE Award Winning Autoclave Tool featuring our TD Seal HT coating.
  11. 11. TD Coat RT 11
  12. 12. As-printed Substrates Are Imperfect •  Near-net as printed •  Dimensional changes result from thermal effects •  Print artifacts such as start / stops, flow instability and slicing issues/irregularities •  Near-net as machined •  Voids •  Broken or lost beads 12
  13. 13. TD Coat RT Allows Rapid Low-Cost Solution To Print Defects •  High-build sprayable 2 component thermoset coating formulated for adhesion to the carbon fiber filled ABS material most commonly used in BAAM printers •  Spray equipment development nearly complete •  Adhesion testing conducted per ASTM D4541 •  Addresses print defects with low labor investment 13
  14. 14. TD Coat RT Sprays Easily •  Sprayable on surfaces at most angles •  Low sag •  Generally sets within 20 minutes of application 14
  15. 15. TD Coat RT Sprays Easily 15
  16. 16. TD Coat RT Post-Processing Options •  Provides stable uniform surface while addressing many print artifacts. •  Machines easily •  Low dust generation •  Repairable 16
  17. 17. TD Coat RT Post-Processing Continued •  Cosmetic parts will require a primer before painting for a Class-A surface •  Tooling gel can be applied immediately or after machining when working with dimensional tolerance constraints 17
  18. 18. TD Coat RT Fits Into Existing Workflows •  Additively manufactured tools seamlessly fit into existing shop work flow keeping current mold maintenance processes unchanged. •  Repairs to tool surface are standard – no special steps are required 18
  19. 19. TD Coat RT on Cincinna- Inc. Cobra Replica 19
  20. 20. Print for TD Coat RT Applica-on Guidelines •  Cosme?c Prototypes •  Print undersized 0.100” for the cosme?c areas unless tolerance on geometry is larger than 0.100” •  This guidance also covers items for Class A finishes •  Dimensional Parts •  Print with an 0.250” inset surface for the coated areas. •  Coa?ng will be applied in 0.5” thickness and returned for machining providing you with 0.25” stock. •  Iden?fy areas where prin?ng needs addi?onal build-up to permit cuQng geometry not efficient to print. •  Must address registra?on needs post coa?ng at the outset. •  Need graphical documenta?on of the surfaces that require coa?ng to guide those applying the coa?ngs 20
  21. 21. TD Seal HT 21
  22. 22. Coating Process Adopted for ACE Award Winning Printed Tool •  Spray Apply TD Seal HT •  Sand and finish •  Prep as usual with composite mold sealer and mold release •  Resulting ACE Award Winning tool and part on display at CAMX 2016 22
  23. 23. Applying TD Seal HT 23

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