1. Additive manufacturing & Ceramics
a leap forward
Hessel Maalderink
June 7, 2012
themadag Additive Manufacturing

2. 1
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Agenda
• TNO and Additive Manufacturing
• Technologies
• Projects
• Micro stereolithography
• Principal
• Work done at TNO
• Building in highly filled resins, then sintering
• Applications
• Future developments

3. 2
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
TNO in the Netherlands.
Dutch Research Institute.
14 locations
3800 Fte.
Location Eindhoven.

4. 3
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
About TNO.
Research Organisation since 1932
7 Themes & 20 Innovation Areas.

5. 4
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
TNO High-tech systems & Materials.
Department: Equipment for Additive Manufacturing – EfAM.
15 fte on AM.
35 fte supporting technology.

6. 5
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
EfAM - Equipment for Additive Manufacturing.
Specialised in Micro Stereo Lithography and Inkjet Printing.
Polymers and High Filled Resins containing Ceramics & Metals.
High viscous material printing & Multi-Material
©TNO ©TNO
©TNO ©TNO

7. 6
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
High Viscosity Jetting.
Multi Material Printing
Software,
Material,
Process,
Graded.
©TNO ©TNO

8. 7
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
EU Research Projects.
Sixth Framework
CEC made Shoe
Digitex
Stella
Open Garments
Seventh Framework
Custom Fit
Custom IMD
DirectSpare
Compolight
Diginova

9. 8
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
EU Research Projects.
Some Results

10. 9
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Food Lab.
Demonstration of the latest food printing
techniques:
3D printing
Laser sintering
Extrusion
Ink jetting
Encapsulation
Electro spinning
A virtual tour can be found on:
http://www.tno.nl/digitale_bladen/foodlab/index.
cfm ©TNO

11. 10
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Stereolithography
Courtesy CustomPartNet

12. 11
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
uSLA machine principle Spindle
Force feedback
Load cell
Steppermotor Platform
Reservoir
Projector
Mirror
Shutter

13. 12
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro Stereo Lithography
Work flow
3D Cad file STL file Bitmaps µSLA part
To project

14. 13
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Introduction to micro stereolithography
Z-stage
Cured Resin Light curable resin
Glass
DLP Projector

15. 14
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro stereolithography
Z-stage
Cured Resin Light curable resin
Glass
DLP Projector

16. 15
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro stereolithography
Z-stage
Cured Resin Light curable resin
Glass
DLP Projector

17. 16
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro stereolithography
Z-stage
Cured Resin Light curable resin
Glass
DLP Projector

18. 17
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro stereolithography
Z-stage
Cured Resin Light curable resin
Glass
DLP Projector

19. 18
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro stereolithography
Z-stage
Cured Resin Light curable resin
Glass
DLP Projector

20. 19
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
The Lepus® System.
Closed Loop
Force feedback
Licensed to RapidShape

21. 20
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
µ SLA
Development of custom additive manufacturing
systems, in a B2B consortium with industrial partners
Jewelry Dental
Courtesy RapidShape Hearing aid

22. 21
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro Stereo Lithography
Laser
Mask projection
Scale
Laser (2 photon)
Courtesy
Laser Zentrum Hannover
nm µm mm
Voxel size

23. 22
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Micro Stereo Lithography
Applications: Courtesy RapidShape
Prototyping
Master
Rapid Manufacturing
Fields of operation:
Medical Devices
Electronics / Telecom
Sensors
Micro fluidic systems
Mechanical components
Mould making
Jewelry

24. 23
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Roadmap of High Filled µSLA.
High Filled µSLA
Development of additive manufacturing systems for high
filled materials, with partners in industry and research.
Technical
Ceramics
Piezo
Metals
Magnetic
Organic
Biomaterial

25. 24
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Processing highly filled material

26. 25
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Processing highly filled materials

27. 26
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
The Technology.
Highly filled materials.
What are they?
Photopolymer filled with a powder based material (e.g. ceramic), in which
the photopolymer is used as a binder.
Why filled photopolymers?
To go beyond the limited properties of photopolymers, by using the
advanced properties of the filler
Why highly filled?
Minimum of 50 vol% required to sinter powder
Higher filling gives less shrinkage during sintering

28. 27
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Now, why would we like to “print” ceramic
structures ?
Ceramics have some interesting properties….
- Hardness, stiffness
- Chemical resistance
- Wear resistance
- Heat resistance
- Low thermal expansion
- Low Thermal conductivity / High thermal conductivity
- Low weight
…. but are in general not easy to process

29. 28
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Consequences of high filling
Increased viscosity
Non-newtonian behaviour
Changed optical characteristics
Sagging

30. 29
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Rheology
1,0E+06
1,0E+05
Viscosity (mPa.s)
1,0E+04
75wt% no disp
74 wt %
1,0E+03 80 wt %
87 wt %
89 wt %
90 wt %
1,0E+02
1 10 100
Shear rate (1/s)
Highly decreased viscosity through dispersant
Type and amount are critical and binder specific !

31. 30
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Scatter reduction
Light scattering due to ceramic particles influences spatial resolution of the
uSLA process
Important parameters
Particle size distribution
Refractive index of ceramic particle
Refractive index of photopolymer
Absorption coefficient of ceramic particle

32. 31
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Scatter reduction: analysis method
Work done by Hans Wegman
Mask projection
Sensofar

33. 32
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Scatter reduction: model

34. 33
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Preliminary Results: Al2O3
Some Results of Al2O3 Ceramic parts made by TNO.
©TNO
Al2O3
©TNO ©TNO

35. 34
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Preliminary Results: Al2O3
• Highly Al2O3 filled photosensitive resins were formulated (45-50%vol)
• Viscosity around 30 Pa.s
• Small parts were built
• Density OK
• Work in progress: crack reduction

36. 35
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Preliminary Results: SiC
SiC (green)

37. 36
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Roadmap of High Filled µSLA.
Larger parts: New recoater concept to process high viscous material.
Improve material and process for reproducible parts.
Expand material portfolio.
Technical
Ceramics
Al2O3
AlN
ZrO2
SiC
SiO2

38. 37
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
The Hype - 3D Printing.
Gartner Hype Cycle 2011.
Courtesy: Gartner

39. 38
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
The Hype - 3D Printing.
Gartner Hype Cycle 2011
Courtesy: Gartner

40. 39
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
The Media Hype is already started.

41. 40
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Investors.
Hype or not?
ABN Business report 2012.

42. 41
10 januari 2011
M Bouman
TNO Nieuwe huisstijl
Envisioning Emerging Technology.