3D Printing and coatings

1. Coatings that make Additive Manufacturing Work
Technology Overview
February 27, 2017 1

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).
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3. You May Have Seen the
2015 CAMX Combined Strength Award
Winning Printed Shelby Cobra
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4. Or The Printed Willys Jeep Body
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5. Maybe Even The Printed F-22
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6. Or The Printed House & Utility Vehicle
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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.
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8. Guinness World Record Additive Tool
Machined
TD Coat RT
Surface
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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. Digitally Manufactured Molds Successfully
Withstand Autoclave
High Temperature Tooling
CAMX 2016 ACE Award
Winning Autoclave Tool
featuring our
TD Seal HT coating.

11. TD Coat RT 11

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
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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
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14. TD Coat RT Sprays Easily
• Sprayable on surfaces
at most angles
• Low sag
• Generally sets within
20 minutes of application
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15. TD Coat RT Sprays Easily
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16. TD Coat RT Post-Processing Options
• Provides stable uniform surface while addressing many print
artifacts.
• Machines easily
• Low dust generation
• Repairable
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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
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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
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19. TD Coat RT on Cincinna- Inc. Cobra Replica
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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
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21. TD Seal HT 21

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
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23. Applying TD Seal HT
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