Smart Parts: Additive Manufacturing for Integrated Electro-mechanical Devices

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3D-printed electronics deliver benefits that mirror those of 3D-printed mechanical parts. Integrate the two processes into one hybrid solution to amplify the advantages in time savings, cost reduction and design flexibility to achieve unmatched efficiencies and create revolutionary products. Join us to discover what is possible when you integrate electro-mechanical design and manufacturing.
In this webinar you will learn:
How the hybrid process works
What types of integrated electronics are possible
What are the advantages and considerations
What the future holds

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Smart Parts: Additive Manufacturing for Integrated Electro-mechanical Devices

  1. 1. Smart Parts: Additive Manufacturing for Integrated Electro-mechanical Devices
  2. 2. Who is Stratasys? FDM Technology + Inkjet Technology
  3. 3. Today’s Event Host Kim Killoran Stratasys, Inc. Presenters Jeff DeGrange Vice President of Direct Digital Manufacturing Bill Macy Application Development Lead
  4. 4. Smart Parts/Smart Tools Additive manufacturing (AM) • Integrated electro-mechanical devices • Printed structures & printed electronics Will cover: • Process • Applications • Advantages • Considerations • Future
  5. 5. Overview Marrying two AM technologies • Fused Deposition Modeling (FDM) • Aerosol Jet Fully printed hybrid structures • Game changer • Streamline production Joint development project • UAV wing • Research & feasibility • In-situ, single process
  6. 6. Industries & Applications Aerospace Automotive Consumer electronics Medical • Devices • Appliances
  7. 7. Advantages Revolutionary • Weight balanced • Reduced part count • Fewer failure modes •AM benefits • Complex structures with more functionality • Less waste • Fewer process steps • Accelerate manufacturing • Flexibility • Cost reduction
  8. 8. Process Fused Deposition Modeling (FDM) • Thermoplastic materials
  9. 9. Process Fused Deposition Modeling (FDM) • Thermoplastic materials
  10. 10. Process Fused Deposition Modeling (FDM) • Thermoplastic materials Process CAD File Manufacture Completed Part
  11. 11. Process Aerosol Jet • Atomized & collimated • High-velocity stream
  12. 12. Process Aerosol Jet • Atomized & collimated • High-velocity stream
  13. 13. Process Aerosol Jet • “Inks” that can be aerosolized • Nano-particle suspensions • Metal complexes • Carbon nanotubes • Organic conductors • Dielectrics • Adhesives • Sensor materials
  14. 14. UAV Wing FDM material • ULTEM* 9085 • High HDT and Tg • Mechanical strength •Aerosol Jet materials • Nano-particle silver ink (Cabot CSD-23) • UV-curable dielectric (Sun Chemicals 97B)
  15. 15. Process Design • Part • Electronics Build – FDM • FDM structure Surface Prep • Sand • Soda blast Fixture Surface Prep Print – Aero. Jet • FDM-built fixtures • Self-leveling compound, printed • Conductive ink Sinter Ink • Oven processing Overcoat • Global seal coat • Localize printed coating
  16. 16. Printed Electronics Sensors/Devices •Circuits • Resistance temperature detectors (RTD) • Power • Resistive heating elements • Ground planes • Antennas • RF strip lines • Strain gauges • Chemical sensors •Electronic components • Resistors • Capacitors • Inductors • Surface mount connections • Signal
  17. 17. UAV Printed Electronics Sensors/devices • Antenna • Strain gauge •Circuits • Power • Signal
  18. 18. Results Signal circuit • LED: printed traces/connections • 100 x 20 μm •Power circuit • 1,000 x 60 μm • Powered 20 V, 0.5 amp motor Details  < 30 minutes  CTE mismatch  cracks
  19. 19. Results Antenna • Large surface area with 0.40 mm gaps • > 1 hour • Transmitted real-time video feed •Strain gauge • 100 μm • Fine conductive traces • Could not bridge surface defects
  20. 20. Advantages •New design strategies • Electro-mechanical design at digital level •Flexibility • Design optimization • Design change •Cost reduction • Smaller BOM; fewer processes • Eliminate tooling and labor Cycle time reduction • Product development and manufacturing
  21. 21. Demonstrator •13.5-inch wing •Functional • FDM – 6 hours • Motors (propeller) • Aerosol Jet – 1 hour • LED signal lights • Slot antenna • Integrated contacts
  22. 22. R&D •Considerations • Surface finish • Surface energy • CTE mismatch • High-temp structure (secondary sintering) • Shift electronic design approach Future work • Design rules • Interface requirements • Performance expectations • Supportability methods
  23. 23. Future •Technology integration • In-situ process •Expand applications and industries •Revolutionize products • Biomimicry, organic shapes • Bone | FDM • Nervous system | Aerosol Jet • “We have the technology. We can make him better...stronger...faster”
  24. 24. More Information www.stratasys.com/webinar_smartparts • Download webinar slides • View webinar on demand Applications • Optomec: Ken Vartanian - kvartanian@optomec.com • Stratasys: DDM Group - ddm@stratasys.com
  25. 25. Questions? More information: www.stratasys.com/webinar_smartparts

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