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Tc manufacturing technologies 2018s_v2_10_30_18_s
1. TM
Consulting Services
ADDITIVE MANUFACTURING
FOR 3-DIMENSIONAL (3D)
STRUCTURES
(WITH EMPHASIS ON 3D PRINTING)
Jurgen Daniel
Teclination Consulting Services
San Diego, USA
www.teclination.com
daniel@teclination.com
Technology overview (2017/18)
Source: APWorks
2. 2TM
Consulting Services
This slide deck is an overview of technologies related to Additive Manufacturing
with focus on 3D printing. While it covers many recent technology
developments, it is impossible to capture all of them due to the vast variety of
technologies and continuous innovation. Much of the information and the
figures originated from websites as annotated on the slides.
3. 3TM
Consulting Services
Conventional vs Additive Manufacturing (AM)
Source: www.arup.com; mx3d.com; www.halfords.com
Structures carry the same
structural loads and forces
AM bicycle frameConventional bicycle frame
Example 1
Example 2
Conventional Additive Manufacturing
4. 4TM
Consulting Services
Problems with Conventional Manufacturing
High cost for prototyping and small runs
Long design / setup time (Tooling, etc.)
Materials waste in subtractive methods (milling)
Complex assembly required for complex designs
Limited materials combinations
… others
5. 5TM
Consulting Services
Advantages of Additive Manufacturing
Freedom of complexity (designs difficult to do conventionally)
On-demand production (reduced inventory)
Cost and time savings (for prototyping and small runs) -
no part-specific tooling
Lighter, stronger, better performing, safer parts -
enabled by design optimization software
Reduced waste material
… others
Example: aerospace bracket
(70% lighter while stiffer)
Source: 3D Systems
7. 7TM
Consulting Services
AM Stock – “Between Hype and Reality”
3D Systems: DDD
ExOne: XONE Stratasys: SSYS
2018
Examples of Public AM Companies
Source: etrade.com
8. 8TM
Consulting Services
Market and Opportunities for AM
Forging Magazine, March 2018
AM is key to the 4th Industrial Revolution
IDTechEx, March 2018
MarketResearchEngine, Jan 2017
Predictions heavily depend on assumptions and included technologies
9. 9TM
Consulting Services
AM Value Chain
*Design Tools
*Information Services (Conferences / Journals)
Source: am.vdma.org and Teclination (*)
Tool
*Test & Eval
Plus:
10. 10TM
Consulting Services
Major Risks in AM
Digitalization of physical products
Reliability of mechanical structures
Cyber threats
• reliance on digital files and connectivity
Issues in supply chain
• firmware, network, IT, design, printer/production and
third-party supply chain areas
Counterfeit objects
• easy to produce with a stolen design file
• hackers could build failure points into part design
Material integrity
• machine-to-machine & print-to-print variations
• quality variation of starting material
11. 11TM
Consulting Services
AM Sectors and Technologies
Electronic
Structures
Mechanical
Structures
Biological
Structures
Food, etc.
• Laminated Object Manufacturing
• e.g. CompositesLOM
• Fused Deposition ModelingFDM
• Selective Laser Sintering
• Including Direct Metal Laser SinteringSLS
• Electron Beam MeltingEBM
• StereolithographySLA
• Physical Vapor Deposition
• e.g. PlasmaPVD
• Material Jetting
• e.g. PolyJet ™MJ
• Printed Electronics
• e.g. CompositesPE
• Electrophoretic Deposition
EPD
• Material ExtrusionME
• Pick and PlacePNP
• Binder Jet TechnologyBJT
• Multi Jet Fusion™MJF
…
14. 14TM
Consulting Services
Injection Molded Electronics (2.5D)
Source: DuPont, TaktoTek (www.tactotek.com)
Using stretchable conductive ink from DuPont
In-Mold Structural Electronics Manufacturing Process
15. 15TM
Consulting Services
Aerosol Printing – 2.5D Electronics
printed smartphone antennas
Sensor Structures via
Aerosol Jet printing
and
5 axis printing system
printing process
Source: www.optomec.com & www.neotech-amt.com
Printing onto 3D surfaces
16. 16TM
Consulting Services
3D Electronics Integration
Source: Eric MacDonald, Ryan Wickers, et al. (2014) - W.M. Keck Center for 3D Innovation & U Texas, El Paso
Hybrid of AM, robotic component placement and embedding of conductors
3D printed signal conditioning circuit
See also: commercial printers from Voxel8 and Nano Dimension (without component placement)
Source: Science, 30 Sep 2016
3D Structural Electronics
17. 17TM
Consulting Services
3D Printed Electronics
First on-demand 3D-printed electronics service
Printed digital thermometer
Source: www.nano-di.com
DragonFly 2020
printed circuit board printer
Printed electromagnet
Conductive silver nanoparticle ink (metal) and insulating ink (dielectric polymer)
18. 18TM
Consulting Services
PolyStrata Process (3D)
Photo of RF module
Source: www.nuvotronics.com
mmWave RF circuits
compact, high isolation, low loss
PolyStrata transmission lines
25. 25TM
Consulting Services
Wire-fed 3D E-beam AM
Part requires finish-machining Source: www.sciaky.com
Electron Beam Additive Manufacturing (EBAM®)
26. 26TM
Consulting Services
Rapid Plasma Deposition (RPD)
Rapid Plasma Deposition (RPD) Process
- also: Wire Additive Manufacturing (WAAM)
Source: Aviation Week (Oct 2015) and www.norsktitanium.com; prodways-raf.com
Robotic Arc-Welding Concept
• 50–100 times faster than powder-based systems
• FAA-certified process
• Deposition rate: up to 10kg/h
Similar concept:
Rapid Additive Forging (RAF)
27. 27TM
Consulting Services
Binder Jetting
Source: ExOne
Binder jetting onto layers of powder De-powdering For metal parts: infiltration (e.g. bronze)
(Baking/fusing)Binder curing between layers
S-Print (e.g. sand molds)
M-Flex (metal parts)
Build vol: 800 x 500 x 400mm
(~30-60 sec per layer)
Build vol: 400 x 250 x 250mm
Example of a metal part
Process
• Metal parts or (sand) molds for casting
• Suitable for large parts
• No heat applied during printing (less stress)
• Often more cost effective than other additive methods
• Parts are supported by loose powder
Powders: sand, ceramics, metals
Binder: Phenolic, aqueous, silicate
28. 28TM
Consulting Services
Metal Inkjet Printing
Source: vadersystems.com/
Printing of liquified metal (e.g. Aluminum)
Magnet-o-Jet™: electromagnetic pulsing
of molten metal 1000 droplets per second
30. 30TM
Consulting Services
MICA Freeform Process
Laser sintering vs MICA freeform
Fabrication of parts in assembled state
Source: www.microfabrica.com
formerly Memgen
Materials:
(similar to Polystrata process by Nuvotronics)
Layering process using plating and planarization
31. 31TM
Consulting Services
Ultrasonic Welding
CNC contour milling
Rolling ultrasonic welding
20kHz
Aluminum-Titanium
Laminate
SiC fibers embedded in
metal laminate
• Functionally Graded Laminates
• Embedded electronics/sensors
• Metal matrix composite (MMC)
Alumina fibers in
Aluminum (MMC)
process
Source: fabrisonic.com
32. 32TM
Consulting Services
Fiber Layering / Weaving
Carbon fiber is braided onto
an aircraft component
3D-woven composite and the resin transfer
molding (RTM) process (Safran and Albany EC)
LEAP fan blade
Sources: www.airbus.com; www.compositesworld.com/articles/albany-engineered-composites-weaving-the-future-in-3-d; markforged.com
High-strength break levers: 3D composite
printer embedding continuous carbon fiber
Carbon/ceramic fiber-reinforced composite materials
- layered or 3D woven structure -
34. 34TM
Consulting Services
Large Industrial 3D Printing
industrial thermoplastic reinforced woven composite 3D printer
Source: envisiontec.com, massivit3d.com, www.voxeljet.com
build up rate of 14 in/hr for super-size partssaves up to 75% in sand casting costs
up to 4,000 x 2,000 x 1,000 mm
(e.g. 3D retail displays)
Selective Lamination Composite Object Manufacturing
(Sand) Molds for casting Gel Printing (photo polymeric acrylic gel)
35. 35TM
Consulting Services
Combined Additive and Subtractive Systems
5-axis powder laser
deposition
5-axis milling
Source: us.dmgmori.com; www.thermwood.com
Print an object to near net shape and trim the part to net shape with CNC router
Laser build-up process with 5-axis milling
FDM process with 5-axis milling
38. 38TM
Consulting Services
Selective Deposition Lamination (SDL)
Source: www.mcortechnologies.com/
Removing excess paper
Mcor ARKe
Process
Build material: paper
X,Y,Z resolution: 0.1mm
Photorealistic color
39. 39TM
Consulting Services
PolyJet Printing
J750 3D printer from Stratasys
(360,000 colors)
over 10 million colors and translucent
objects (but different materials properties)
Similar technology:
Inkjet printing of UV curable polymers
3D printer jets and instantly UV-cures
tiny droplets of liquid photopolymer
40. 40TM
Consulting Services
ColorJet Printing (CJP)
formerly: Z Corporation
ProJet CJP 660Pro
Source: www.3dsystems.com & www.3dnatives.com
Solidifying and coloring a powder with a binder
• Uses thin layers of white support powder (gypsum)
• Inkjet printed color binder material
• Powder bed helps to avoid the need for printing supports
• Requires post-processing (clean up of excess powder)
41. 41TM
Consulting Services
• Average printing cost per part is half the average
cost of comparable FDM & SLS printer solutions
• 10 times faster than FDM and SLS
• Very strong and durable parts
HP Jet Fusion 3D Printing
Source: www8.hp.com/us/en/printers/3d-printers.html
HP Jet Fusion 500/300 Series 3D
with up to 8 agents for color 3D
Price: >$50k - 100,000
Similar to binder jetting
(however not binder but fusing agent)
process
Phoenix Children’s Hospital
Heart of Jemma
Strong thermoplastic
chain link
Now also metal parts via sintering!
(HP Metal Jet)
42. 42TM
Consulting Services
Inkjet Printing onto Surface
Source: www.xyzprinting.com
3D PLA FDM printer plus color inkjet
Xyz print da Vinci and XYZmaker modeling software;
- process uses special filament to which ink adheres -
43. 43TM
Consulting Services
Color Surface by Hydro-dipping
Source: learn.adafruit.com/hydro-dip-3d-prints/overview
Adding graphics to 3D parts: by inkjet printing onto water transfer
paper (PVA based) and hydro dipping
44. 44TM
Consulting Services
3D Color Parts by Thermoforming
Gypsum mold because of thermoforming process (PLA would melt)
Example: Plastic food
Source: C. Schueller, et al. , Siggraph 2016
process
process (side-view)
Computational Thermoforming (ETH Zurich, Disney Research)
46. 46TM
Consulting Services
Application Areas
Area Benefit Example
Prototyping Faster, less expensive, allows complex designs Maker community, R&D, product design
Aerospace Light weight, complex design, spare parts, … GE fuel injector nozzle for LEAP engine
Automotive Faster design cycles, Cost & time savings for small
series production, spare parts for rare vehicles
Turbine for Koenigsegg sports car
Medical / Dental Patient-specific design, optimized textures for
bone ingrowth,…
Transparent Invisalign braces, hearing
aids, implants
Military Simpler logistics, spare part availability in remote
areas or on-ship
USS Essex printer installation
Jewelry Faster design cycles, unique and complex designs Many examples of jewelry designers
Industrial Faster and less expensive, complex designs
possible
Turbine blades for generators by Siemens
Construction / Architecture Logistics, simplified transport, unique designs Metal bridge by MX3D in Amsterdam
Sports / Clothing Individualization, exclusive fashion design Personalized shoe soles (e.g.Nike, Adidas)
Electronics Conformal design, potentially less expensive, large
area electronics, improved performance, …
Antenna and sensor prototypes
+ others
Concept Models End-Use Parts
Functional
Prototypes
Molds / Castings
Tooling, Jigs,
Fixtures
Visualization Aids
Replacement
Parts
Branding /
Promotion
Source: ultimaker.com; Teclination
47. 47TM
Consulting Services
Electronics - Printed Conductors
Source: GGI Solutions
Flexible Heaters
Printed Electrodes
Frequency Selective Surfaces
Benefits:
• Large Area coverage
• Thin flexible form factor
• Inexpensive / disposable devices
48. 48TM
Consulting Services
Electronics - RF / Antennas
• 95% weight reduction
• 20% reduction of production cost
• 75% of non-recurring costs eliminated
Source: 3dprint.com/178724/3d-printed-antenna-one-component/
Ka-band 4×4 monopulse phased array (1 -100GHz)
1part
100 parts
brazing and EDM
(~8months to develop and 3 to build)
3D laser fusion
( ~a few weeks to complete)
49. 49TM
Consulting Services
Aerospace
3D printed fuel nozzle for CFM LEAP engine for Airbus A321 neo
19 nozzles per LEAP engine
5X increase in durability
25% weight savings
20 parts replaced with one
Source: www.ge.com; www.cfmaeroengines.com; www.materialise.com
Reduced weight of components by “bionic” design
3D printed bionic spacer panel
15% lighter through use of
internal lattice structures
50. 50TM
Consulting Services
Automotive
Small series turbo impellers
(Metalysis)
Mass customization (Honda) Rapid development
(Hankook tires)
• On demand production of spare parts, e.g. for old-timersSpare parts
• Parts for special and exclusive car series & motorsportSmall series
• Exclusivity /personalizationCustomization
• Tools/jigs for test & assembly (Cost/time savings )Tooling
• Testing of prototypes before productionQuality Enhancement
• Accelerated design cycles & lowering costs of new productsDesign cycles
Source: 3dprintingindustry.com
51. 51TM
Consulting Services
Industrial Casting
Plastic mold will burn out completely
without any residue at 700°C or more
• build space: 4000 x 2000 x 1000 mm (LxWxH)
• Layer height: 300 micron
Source: www.voxeljet.com
Sand mold and metal part Investment casting:
Plastic model and metal part
Cooling of ceramic casting die
VX4000 PRINTER
Sand and plastic molds (for investment casting) via binder jetting
plastic metal
3D PRINTING SAVES UP
TO 75 % IN SAND
CASTING COSTS
52. 52TM
Consulting Services
Tooling for Composite Lay-up
3D printing tools (for composite lay-up) offer savings in time and
material over more traditional methods
Source: www.stratasys.com
ULTEM
FDM printed in ULTEM 1010 polymer
53. 53TM
Consulting Services
Medical
3D printed Ti sternum and ribs implant (chest implant)
Source: www.materialise.com/en/blog/3d-printed-cast
Source: www.rapidreadytech.com/ - Project 3DHEART (Phoenix
Children’s hospital)
Source: www.anatomics.com
Wedge implantes with OsseoTi Porous Metal Technology to facilitate bone –in-growth
Source: www.zimmerbiomet.com
patient-specific pediatric heart model, 3D-printed in full color. Light-weight patient-specific 3D-printed cast
Implants
Surgical Planning Orthopedic Casts
54. 54TM
Consulting Services
Clear Dental Aligners
• ~50-60 stereolithography (SLA) 3D printers from 3D Systems
• Medical-grade, FDA-approved polymer
• Over 220,000 custom-made clear aligners produced per day,
almost 8 million per year
• Align Technology: ~$1.3B in sales (91% of revenue from aligners)
Sources: www.invisalign.com, www.forbes.com
(Forbes, Sept. 14, 2017)
55. 55TM
Consulting Services
Hearing Aids
Example: SLA parts by Danish hearing aid manufacturer Widex
Source: www.widex.pro
CAMISHA (Computer Aided Manufacturing of Individual Shells for Hearing Aids)
- scanning, modeling, and printing -
56. 56TM
Consulting Services
3D Bioprinting
• Polycaprolactone constructs (biocompatible synthetic polymer)
• Cells are suspended in a gel composed of biodegradable materials
• After two months, infiltration of the constructs with blood vessels
was observed, which is attributed to the presence of microchannels
in the construct.
Source: Nature Biotechnology volume34, pages312–319 (2016); www.wakehealth.edu/WFIRM/ Source: organovo.com
Printing of bio-ink building blocks and inert
hydrogel material
Live cells printed into human-scale constructs
representing bone, muscle, and ear tissue
Printed 3D tissues that accurately
represent human biology
58. 58TM
Consulting Services
Textiles, Fashion, Footwear
Source: ceramics.org/ceramic-tech-today/innovation-on-the-
ground-3-d-printed-shoes-offer-custom-fit-perfect-cushion
Source: www.wired.com/2017/05/the-shattering-truth-of-3d-printed-
clothing/
Gabi Asfour & Stratasys: BIOMIMICY collection (2016)
Personalized shoe soles 3D printed dresses
Laser-sintered airy midsoles in
thermoplastic polyurethane (TPU)
– one size fits one –
59. 59TM
Consulting Services
Exploratory Body Armor (Ceramics)
www.hotendworks.com/
HDfab 3D printer
Source: www.3ders.org/articles/20160322-us-army-and-hotend-works-explore-3d-printed-sintered-ceramics-for-soldier-body-armor.html
3-D Printed Sintered Ceramics (e.g. for Body Armor Applications)
In initial ballistic tests the
printed material still performed
slightly worse than
conventional armor
60. 60TM
Consulting Services
Culinary Printing
Source: www.miamfactory.com/ Source: www.3dsystems.com/culinary Source: http://open-meals.com/
Pixel food printer: 3D printer capable of
producing edible and pixelated 8-bit sushi
3D printed chocolate 3D printed sugar Pixilated sushi
66. 66TM
Consulting Services
Materials Safety – Fumes in FDM
• PLA – regarded as safe
• ABS – releases carcinogens (styrene)
Caution should be used when operating a 3D printer in small
office spaces and hazardous filaments should be avoided
volatile organic compounds (VOCs) and ultrafine particles (UFPs)
released by FDM extrusion process
• UL study (2017) identified
nanoparticles and VOCs
• Styrene, caprolactam, lactide VOCs
most significant (but low levels)
68. 68TM
Consulting Services
AM Enables Novel Materials
Ti-6Al-4V to V Gradient Alloy
Source: D. Hofmann, et al., Nature Scientific Reports 4, 2014 (www.nature.com/articles/srep05357) and
https://authors.library.caltech.edu/50785/1/S0884291414002088a.pdf
Metal-matrix compositesGradient alloys
Ceramic-reinforced metal matrix composites &
Graded composition alloys by SLD process
69. 69TM
Consulting Services
Novel Ceramics Research
Source: Zak C. Eckel, Chaoyin Zhou, John H. Martin, Alan J. Jacobsen, William B. Carter, and Tobias A. Schaedler (2016) “Additive manufacturing of
polymer-derived ceramics” Science 351 (6268), 58-62
SLA Silicon oxycarbide ceramic (Pyrolysis process)
- high hardness, strength, temperature capability & resistance to abrasion and corrosion -
10 times stronger than ceramic foam
71. 71TM
Consulting Services
AM Design Process & Tools
Cura,
Repetier Simplify 3D
Slicer for Fusion
…
Netfabb
AD Meshmixer
Meshlab
…
For added Color and Texture:
e.g. Blender or proprietary software such as Stratasys Creative Colors
CAD Design Mesh repair
Blender
AD Fusion 360
Meshmaker
Rhino
…
3D Model
capture
Kinect Fusion
Autodesk Recap
…
Ansys SpaceClaim, Siemens NX, Autodesk Inventor, SolidWorks …
Slicer
Software
For 3D models also design libraries, such as
72. 72TM
Consulting Services
Example – Coil Structure for FDM
Source: Teclination Consulting
Design and modeling
Print conversion (mesh repair, support structures, slicing)
Autodesk Fusion 360
73. 73TM
Consulting Services
3D Design File Formats
Tesselation: .STL
Free form curves: .OBJ
Encoded colors and textures: .MTL
3D design files may contain data about geometry, color,
texture, and materials
• old and simple format: describes anl object as a
series of linked triangles (Tesselation)
• no info regarding color, texture, material, file
security
.STL
• best for color and high precision printing;
tessellation or free form curves/surfaces
• color and texture stored in a paired .MTL file
.OBJ
• potential new format (ASTM).AMF
• potential new format (Microsoft).3MF
Source: all3dp.com
74. 74TM
Consulting Services
Slicer Software
Slicer creates:
1. a toolpath (more or less intelligently) based on the geometry of the design-file
2. a percentage of infill to save 3D printing time and material
3. support structures, if the geometry is difficult to print
Source: all3dp.com, ultimaker.com
Z-Suite
SliceCrafter
Examples
.stl, .obj, .x3D, 3MF, … .gcode .gcode example
Slicer
75. 75TM
Consulting Services
Support Structures in AM
Source: www.simplify3d.com
Example:
Printed support structures are needed in FDM, SLA, etc.
(processes without a supporting solid powder bed such as SLS)
• General rule of thumb: most extrusion-based printers can
support overhang angles less than 45 degrees.
• Adding support structures with specialized software
76. 76TM
Consulting Services
DfAM (Design for Additive Manufacturing)
Parametric and generative design, topology optimization,
lattice structures and biomimicry (bionic design)
Also: Compensation for shrinkage & warping (e.g. part orientation) and adding support structures
Element design optimization software
Generate (TM) topology optimization
CogniCAD™: Cognitive Computer Aided Design
Platform For Ultimate Lightweighting
Fusion 360 Ultimate generative design
Examples:
77. 77TM
Consulting Services
AM Build Simulation Software
Optimize build-up orientation, support configuration
Verify influence of operating conditions on distortions, plastic strains and residual stresses
Multiphysics Multiscale Modelling of AM Processes
Source: www.geonx.com; www.3dsystems.com; www.ansys.com; www.alphastarcorp.com; www.e-xstream.com
+ others
Example
Model distortions & residual stresses for processes
Suggest distortion compensation
Model optimal support structures
Minimize number of build tryouts
Minimize risk of printer damage (e.g. re-coater damage)
Predict impact of postprocessing (e.g. heat treatment, HIP,
support removal)
80. 80TM
Consulting Services
Cost Example - Shapeways
Not a photo (model)
Natural Sandstone: $29
Orange Plastic: $34
Polished Nickel Steel: $187
Natural Brass: $596 (prices as of Sept, 2018)
Source: www.shapeways.com
Natural Silver: $1,155
18k Gold: $26,896
Platinum: $61,802
Mosaic Egg
2.41 x 1.96 x 1.96 inches
81. 81TM
Consulting Services
3D Printing with Support Structures
HydroFill water-soluble FDM support for ABS and PLA parts
Soluble Support Material
Source: pixelpractice.nyc; airwolf3d.com
Cut-away Support Structures
450
No support needed Support needed
General recommendation
<450
ABS
FDM printing
Needed in FDM, SLA, jet-printing and metal SLS (metal SLS: for heat distribution and stability during cool-down)
82. 82TM
Consulting Services
Post Processing - Examples
Source: www.3dnatives.com; www.3dprinterworld
• Cutting / dissolving of support
• Solvent vapor, sanding, bead blasting, tumbling, coatingFDM
• Removal from powder bed (+ remove support)
• Bead/sand blasting, tumbling, machiningSLS
• Washing, post-cure
• Removal of support, coatingSLA
• Dissolution of support materialJetting
SLS: removal of part from powder bed FDM: solvent vapor smoothing of
ABS plastic
FDM: removal of support structures
86. 86TM
Consulting Services
Defect Reduction (Material Densification)
Hot Isostatic Pressing (HIP) for SLS or EBM
Typical: 5,800 to 30,000 psi
and up to 2,000°C
Source: quintustechnologies.com
Challenge: Defect elimination without coarsening the microstructure (lowering yield strength)
Schematic of a SLS or EBM
printed part
Part has to have a gas-
tight surface!
HIP can achieve 100% of
maximum theoretical density
Eliminate microporosity
Remove (printing) defects
Remove micro-cracks
Improves the ductility and fatigue
resistance of critical, high-
performance materials
+ other processes
87. 87TM
Consulting Services
Fabrication Challenges
Standardization of processes (machine-to-machine and run-to-run variability)
• Consistency of source material
• Process control and error correction
Post processing requirement
• Impact on cost, time and quality)
Certification of parts
• How to distinguish a good part from a faulty one
New potential health hazards to operators
• e.g. particulates, VOCs
Integrity of digital data
• E.g. employ blockchain technology to secure data (‘Cubichain Technologies’)
Protection of Intellectual Property
88. 88TM
Consulting Services
Process / Quality Monitoring
Starting Material
(Specification and Quality)
Post Process Materials
Quality Testing
(NDT, DT)
Dimensional Accuracy
and Surface Finish
(Measurement and post-
processing)
In-situ Part Monitoring
(Melt Pool, Heat Map)
Machine Parameters
(e.g. laser power, nozzle
monitoring)
89. 89TM
Consulting Services
Data Security and Virtual 3D Printing
• Software to manage and protect IP
(shared with vendors during design and manufacturing)
• Enable simpler, secured and more
efficient production process
• Rent virtual printers (representing real physical
printers, or portions thereof)
MAY 14, 2018
JUNE 30, 2018
Virtual Secure Manufacturing Space
Source: www.assembrix.com
91. 91TM
Consulting Services
Materials Testing
Source: Chris Hole (Technology Partnerships) – SpaceTechExpo 4/12/2017; www.testia.com
Melt-pool monitoring
Testing of starting materials quality
• e.g. powder flow, particle size, contaminants, moisture content in plastics
In-situ: e.g. Melt Pool Monitoring (MPM), heat mapping
• MPM: In-process monitoring of SLS melt plume via light beam; spectroscopy of the
plume
Ultrasound and eddy current
• Trusted methods; Eddy current is simple and better at depth than ultrasound
X-ray or CT inspection
• Currently used for critical parts because it can detect internal defects
Penetrant Dye testing
• Standard method to find surface cracks
Process Compensated Resonance Testing (PCRT)
• To identify defective parts (tests part’s resonance frequency)
Fatigue, toughness, shear, tensile tests
• Destructive methods
Non-destructive (NDT) and destructive (DT) methods
+ other test methods
92. 92TM
Consulting Services
Standardization Efforts - Examples
America Makes & ANSI
Source:www.ansi.org; www.astm.org
ASTM Committee F42 on Additive Manufacturing Technologies
and focus areas (sub-committees)
ASTM (American Society for Testing and Materials)
95. 95TM
Consulting Services
Printed Textiles
April 2015
April 2014
Layered Fabric 3D printer
Source: www.disneyresearch.com
Felting printer
Feeding yarn and attachment with
felting needle
Laser cutting and bonding with
heat-sensitive adhesive
96. 96TM
Consulting Services
4D Printing
Source: gatech.edu
Science Advances 12 Apr 2017:
Vol. 3, no. 4, e1602890
Shape-shifting 3D printed parts (Smart memory polymer)
Objects transform
with heat
97. 97TM
Consulting Services
Microprinting
Volume 28, Issue 12, March 23, 2016
Pages 2311–2315
Source: www.ethz.ch; L. Hirt, et al., Jan 2016, Advanced Materials (ETH and University of Zurich, Zurich, Switzerland)
Deposition by FluidFM technology
(e.g. www.cytosurge.com) ~50µm
3D Microprinting of Metals Using a Force-Controlled
Nanopipette for Layer-by-Layer Electrodeposition
Hollow atomic force microscopy (AFM) cantilevers locally supply metal
ions (e.g. copper) in an electrochemical cell
98. 98TM
Consulting Services
‘Open-ended AM’ Concept
Source: www.dedibot.com
3D printing using Unmanned Aerial Vehicles (UAVs)
UAVs as the print extrusion units to break the limitation of size
102. 102TM
Consulting Services
national accelerator and the nation's leading
collaborative partner for technology research,
in additive manufacturing and 3D printing
furthering U.S. development and adoption of
the flexible hybrid electronics
encourages factories across the United
States to deploy digital manufacturing and
design technologies
Program operated by the interagency AMNPO
(Advanced Manufacturing National Program Office)
US Government Investment
consists of multiple linked
Manufacturing Innovation Institutes
(14 institutes / public-private partnerships)
Operates in partnership with the DOD, DOE, NASA, NSF, and the
Departments of Education, Agriculture, HHS, and Labor
…
through
FFRDCs,
Government
Labs,
Agencies
103. 103TM
Consulting Services
Public Corporations - Examples
NYSE: DDD NASDAQ: DDYD
NASDAQ: XONE
NASDAQ: MTLS
NASDAQ: ONVO
NYSE: VJET
EPA: PWG
NASDAQ: ADSK
NASDAQ: ALGN
NYSE: PRLB
NYSE: HPQ
FRA: AM3D
NYSE: GE
NYSE: ARNC
see also e.g. (ARK Invest) ETF: PRNT + others
104. 104TM
Consulting Services
Corporate Example 1: GE
• 2016: $39 million Center for Additive Technology
Advancement (CATA) in suburban Pittsburgh
• 2017: became Customer Experience Center (CEC)
– in addition to CEC Munich ($15M)
Example - LEAP engine parts:
19 printed fuel nozzles in the
combustion system (Co-Cr alloy)
• 25% lighter
• Replaces ~20 parts
• ~5x higher durability
2016: GE acquired
ARCAM and Concept Laser
Source: GE, Bloomberg, tctmagazine
105. 105TM
Consulting Services
Corporate Example 2: Siemens
New manufacturing facility of Materials
Solutions Ltd., Worcester, UKSource: www.siemens.com
~$30M
Example: 3D printed blades for gas turbines
106. 106TM
Consulting Services
Corporate Example 3: Arconic
• Arconic Technology Center near Pittsburgh (focus is on
wire or powder for 3D printed aerospace parts)
• AmpliforgeTM Process (combines additive and traditional
manufacturing)
Source: www.arconic.com
3D printed hinge
November 15, 2017
Alcoa Technology Center, Pittburgh
2016
Metal powder
