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Asia | The Americas | Europe
Direct Material Printing
1
Asia | The Americas | Europe
• ExOne is a leading additive manufacturing
company dedicated to the manufacturing
sector.
• ...
Asia | The Americas | Europe
ExOne Global Facility Locations
ExOne
North America
WEST
ExOne
North America
MID-WEST
ExOne
N...
Asia | The Americas | Europe
Classification Technology Description Materials Developers
Binder Jetting 3D Printing
Ink-Jet...
Asia | The Americas | Europe
Binder Jetting Process
Binder jetting
A printhead selectively dispenses binder on a
thin laye...
Asia | The Americas | Europe
Binder Jetting Process
Droplet Interaction with Powder
Analogous to inkjet paper printer:
(Bi...
Asia | The Americas | Europe
3DP is Basic Powder Metallurgy
Bonded
Partially Sintered
Infiltrated
Highly Sintered
Powder m...
Asia | The Americas | Europe
Advantages of ExOne’s Process
• No extra charge for part complexity
• Offers endless patterns...
Asia | The Americas | Europe
Direct Metal PSC (North Huntingdon, PA)
• ISO 9001: 2008 CERTIFIED
• Reverse design engineeri...
Asia | The Americas | Europe
Industries Served
AUTOMOTIVE AEROSPACE
ENERGY HEAVY EQUIPMENT AND
MACHINERY
GENERAL CONSUMER ...
Asia | The Americas | Europe
General Products
11
Asia | The Americas | Europe
Functional Working Parts
• Print functional working prototypes or production run
quantities f...
Asia | The Americas | Europe
Multiple Part Consolidation
• 27 traditional individual components
reduced to a single piece
...
Asia | The Americas | Europe
Optimization
Traditionally Manufactured Part
14
Part Information
Optimized for 3D Printing – ...
Asia | The Americas | Europe
Certified Materials (PSC Offerings)
316 Stainless Steel
Infiltrated with Bronze
30 or 60 micr...
Asia | The Americas | Europe
Printable Materials
17-4 316 Inconel 718
Cobalt Chrome Iron Chrome Aluminum Tungsten Carbide
...
Asia | The Americas | Europe
420 Stainless Steel Infiltrated with Bronze
17
Asia | The Americas | Europe
316 Stainless Steel Infiltrated with Bronze
18
Asia | The Americas | Europe
Iron infiltrated with Bronze
19
Asia | The Americas | Europe
Inconel 625
20
Asia | The Americas | Europe
Inconel 625 (Highly Sintered)
AS SINTERED PARTS POST PROCCESSED
* Engine Turbine Blade used
f...
Asia | The Americas | Europe
Surface Finishes
Line of Sight Operation
22
Asia | The Americas | Europe
Available Finishes
23
Asia | The Americas | Europe
Case Studies
24
Asia | The Americas | Europe
Case Studies
25
Asia | The Americas | Europe
Process Steps
Print Directly from CAD Depowder
Heat Treatment Final Product
26
Asia | The Americas | Europe
Direct Material Machines
Production
&
Prototyping
Prototyping
&
Production
Research
&
Educati...
Asia | The Americas | Europe
Innovent
28
Asia | The Americas | Europe
M-Flex
29
Asia | The Americas | Europe
Print Platform
30
Asia | The Americas | Europe
Tested and Certified
• Mechanical Testing
– Tensile strength & modulus
– Compressive strength...
Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.
ExOne The Americas
MI...
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ExOne Direct Material Printing - Binder Jetting Technology

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Unique binder-based 3D printing technology was developed at MIT.

ExOne uses Binder Jetting technology to 3D print complex parts in industrial-grade materials. Binder Jetting is an additive manufacturing process in which a liquid binding agent is selectively deposited to join powder particles. Layers of material are then bonded to form an object. The printhead strategically drops binder into the powder. The job box lowers and another layer of powder is then spread and binder is added. Over time, the part develops through the layering of powder and binder.

Binder Jetting is capable of printing a variety of materials including metals, sands and ceramics. Some materials, like sand, require no additional processing. Other materials are typically cured and sintered and sometimes infiltrated with another material, depending on the application. Hot isostatic pressing may be employed to achieve high densities in solid metals.

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ExOne Direct Material Printing - Binder Jetting Technology

  1. 1. Asia | The Americas | Europe Direct Material Printing 1
  2. 2. Asia | The Americas | Europe • ExOne is a leading additive manufacturing company dedicated to the manufacturing sector. • ExOne is a global supplier of 3D printing systems and offers design and manufacturing services of 3D printed products. • ExOne systems are able to print in a variety of materials with the largest available build sizes. • ExOne has Production Service Centers (PSC) throughout the United States, Europe, and Japan. • ExOne Global Headquarters is located in North Huntingdon, Pennsylvania Company Overview 2
  3. 3. Asia | The Americas | Europe ExOne Global Facility Locations ExOne North America WEST ExOne North America MID-WEST ExOne North America MID-ATLANTIC ExOne North America SOUTH ExOne BRAZIL ExOne GmbH GERMANY ExOne CHINA ExOne KK JAPAN ExOne ITALY Srl 3
  4. 4. Asia | The Americas | Europe Classification Technology Description Materials Developers Binder Jetting 3D Printing Ink-Jetting Creates objects by depositing a binding agent to join powdered material Metal, Polymer, Ceramic, Other ExOne (US) VoxelJet (Germany) 3D Systems (US) Direct Energy Deposition Direct Metal Deposition Laser Deposition Laser Consolidation Electron Beam Direct Melting Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate Metal: powder and wire DM3D (US) NRC-IMI (Canada) Irepa Laser (France) Trumpf (Germany) Sciaky (US) Material Extrusion Fused Deposition Modeling Creates objects by dispensing material through a nozzle to build layers Polymer Statasys(US) Delta Micro Factory (China) 3d Systems (US) Material Jetting Polyjet Ink-jetting Thermojet Builds parts by depositing small droplets of build material, which are then cured by exposure to light Metal, Photopolymer, Wax Stratasys (US) LUXeXcel (Netherlands) 3D Systems (US) Powder Bed Fusion Direct Metal Laser Sintering Selective Laser Melting Electron Beam Melting Selective Laser Sintering Creates objects by using thermal energy to fuse regions of a powder bed. Metal, Polymer, Ceramic EOS (Germany) Renishaw (UK) Phenix Sytems (France) Matsuura (Japan) ARCAM (Sweden) 3D Systems (US) Sheet Lamination Ultrasonic Consolidation Laminated Object Manufacture Build parts by trimming sheets of material and binding them together in layers. Hybrids, Metallic, Ceramic Fabrasonic (US) CAM-LEM (US) VAT Photopolymerization Stereolithography Digital Light Processing Build parts by using light to selectively cure layers of material in a vat of photopolymer. Photopolymer, Ceramic 3d Systems (US) Envision TEC (Germany) DWS Sri (Italy) Lithoz (Austria) Additive manufacturing processes, adapted from ASTM, 2012 4
  5. 5. Asia | The Americas | Europe Binder Jetting Process Binder jetting A printhead selectively dispenses binder on a thin layer of powder. Powder layers can be spread by a counter-rotating roller from a supply chamber to the build chamber, or the powder can be spread by a recoater. After the part is completed, the build chamber is removed to a curing oven, after which the part is depowdered and prepared for sintering or infiltration. Advantages Economics are great. Well suited for large parts. All kinds of powders can be used. Support structures are not needed. Disadvantages Surface finishes are generally ~400 microinch. Post-processing such as sintering is necessary for processing metals, ceramics, and other materials. 5
  6. 6. Asia | The Americas | Europe Binder Jetting Process Droplet Interaction with Powder Analogous to inkjet paper printer: (Binder ≡ Ink Powder Layer ≡ Paper) Exception: Binder must penetrate to bond with previous layer 6
  7. 7. Asia | The Americas | Europe 3DP is Basic Powder Metallurgy Bonded Partially Sintered Infiltrated Highly Sintered Powder metallurgy is the process of blending fine powdered materials, pressing them into a desired shape or form (compacting {printing}), and then heating the compressed material in a controlled atmosphere to bond the material (sintering). The powder metallurgy process generally consists of four basic steps: powder manufacture, powder blending, compacting, and sintering. (Wikipedia) Product Forms 7
  8. 8. Asia | The Americas | Europe Advantages of ExOne’s Process • No extra charge for part complexity • Offers endless patterns and part geometry • No support structures needed • Requires no build plate to begin on • Easy optimization of traditional • No tool paths required • Multiple different parts can be built in a single print bed • Parts can be modified on the CAD file in seconds, and reprinted without complicated tooling changes • Use of industrial graded materials • Large build envelopes • High print speed 8
  9. 9. Asia | The Americas | Europe Direct Metal PSC (North Huntingdon, PA) • ISO 9001: 2008 CERTIFIED • Reverse design engineering (modeling or scanning) • Prototypes services • Optimization for additive manufacturing • Finishing in-house • Low volume production contract services 9
  10. 10. Asia | The Americas | Europe Industries Served AUTOMOTIVE AEROSPACE ENERGY HEAVY EQUIPMENT AND MACHINERY GENERAL CONSUMER FILTRATION AND MINING 10
  11. 11. Asia | The Americas | Europe General Products 11
  12. 12. Asia | The Americas | Europe Functional Working Parts • Print functional working prototypes or production run quantities for real life applications • Possible post processes but not limited to the following: Machine: 420SS - typically has a tensile strength range of 60- 75 ksi conventionally machining may require slower speed and feed rates 316SS – can be traditionally machined Finish: Mass finishing with polishing media Grind, Sand, Polish Coat: Clear Coating, plating, powder coat, paint Weld: Silicone Bronze rod and TIG weld Silver Solder (Harris Products 45N, stay below 700⁰ C) 12
  13. 13. Asia | The Americas | Europe Multiple Part Consolidation • 27 traditional individual components reduced to a single piece • Reduction of documentation and time • Delivered in weeks not months • On-the-fly changes are possible 13
  14. 14. Asia | The Americas | Europe Optimization Traditionally Manufactured Part 14 Part Information Optimized for 3D Printing – Pass 1 Optimized for 3D Printing – Pass 2 Name: Nacelle Bracket Application: Aerospace Prototype Printed Material: 420 Stainless Steel and Bronze Weight = 7.8 lbs. Weight = 2.8 lbs. Weight = 1.4 lbs.
  15. 15. Asia | The Americas | Europe Certified Materials (PSC Offerings) 316 Stainless Steel Infiltrated with Bronze 30 or 60 micron 420 Stainless Steel Infiltrated with Bronze 30 or 60 micron Inconel 625 (Highly Sintered) 30 Micron Iron Infiltrated with Bronze 30 micron Bonded Tungsten Soda Lime Glass 15
  16. 16. Asia | The Americas | Europe Printable Materials 17-4 316 Inconel 718 Cobalt Chrome Iron Chrome Aluminum Tungsten Carbide 16
  17. 17. Asia | The Americas | Europe 420 Stainless Steel Infiltrated with Bronze 17
  18. 18. Asia | The Americas | Europe 316 Stainless Steel Infiltrated with Bronze 18
  19. 19. Asia | The Americas | Europe Iron infiltrated with Bronze 19
  20. 20. Asia | The Americas | Europe Inconel 625 20
  21. 21. Asia | The Americas | Europe Inconel 625 (Highly Sintered) AS SINTERED PARTS POST PROCCESSED * Engine Turbine Blade used for demonstration piece only * 21
  22. 22. Asia | The Americas | Europe Surface Finishes Line of Sight Operation 22
  23. 23. Asia | The Americas | Europe Available Finishes 23
  24. 24. Asia | The Americas | Europe Case Studies 24
  25. 25. Asia | The Americas | Europe Case Studies 25
  26. 26. Asia | The Americas | Europe Process Steps Print Directly from CAD Depowder Heat Treatment Final Product 26
  27. 27. Asia | The Americas | Europe Direct Material Machines Production & Prototyping Prototyping & Production Research & Education 27
  28. 28. Asia | The Americas | Europe Innovent 28
  29. 29. Asia | The Americas | Europe M-Flex 29
  30. 30. Asia | The Americas | Europe Print Platform 30
  31. 31. Asia | The Americas | Europe Tested and Certified • Mechanical Testing – Tensile strength & modulus – Compressive strength & modulus – Flexural strength & modulus – Fatigue & fracture toughness – Impact strength (Charpy & Izod) • Metallography & Microscopy – Specimen Preparation • Mounting, grinding, polishing equipment – Microscopy • Inverted Light Microscope • Scanning Electron Microscope (SEM) • Image Analysis Software • Hardness • Density – Archimedes, Helium Pycnometry, Bulk • Coefficient of Thermal Expansion (CTE) SEM Machine 31
  32. 32. Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you. ExOne The Americas MID-ATLANTIC 127 Industry Boulevard North Huntingdon, PA 15642 USA +1 877 773 9663 MIDWEST 2341 Alger Drive Troy, MI 48083 USA +1 248 740 1580 SOUTH 7409 Railhead Lane Houston, TX 77086 USA +1 281 931 0011 ExOne Europe ExOne GmbH Daimlerstrasse 22 86368 Gersthofen Germany +49 821 65063-0 ExOne Italy SRL Via Galileo Galilei 68 Località La Pigna 25015 Desenzano del Garda Brescia, Italy ExOne Asia 161-5 Haneo Odawara-shi, Kanagawa Japan 256-0804 +81 465 44 1303 exone.com +1 877 773 9663 SOUTHWEST 3905 N. Pecos Rd N. Las Vegas, NV 89115 +1 702 487 3977 NORTHWEST 1307 W. Valley Highway N. Auburn, WA 98001 +1 253 394 0357

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