Applications of 3D Printing (PI)

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Applications of 3D Printing (PI)

  1. 1. Applications of 3D Printing Dr. Ben Wood & Dr. Greg Gibbons© 2012
  2. 2. A couple of questions to start… WHO USES 3D PRINTING? WHAT FOR?© 2012
  3. 3. Architecture© 2012
  4. 4. Marketing/Advertising© 2012
  5. 5. Medical© 2012
  6. 6. Furniture© 2012
  7. 7. Fashion© 2012
  8. 8. Animation© 2012
  9. 9. SME Application • Injection mould tool ~£10,000 – Requires high volume – Difficult to modify – Tool required for each product • Insert tooling – Simpler pocket tool required – 3D printed insert – Lifetime of 10-200 parts – Low insert cost – Easy to modify/replace© 2012
  10. 10. IIPSI 3D Printing Capabilities and R&D Dr. Greg Gibbons© 2012
  11. 11. 3D Printing • Significant capability in commercial 3D Printing technology – FDM • MJM • 400mc (Stratasys) – Connex 260 (Objet) • Dimension (Stratasys) • Laser Sintering • Prusa (RapRep) – EOS P380i – 3DP • EBM • Z450 (ZCorp) – Arcam S12T • Z310+ (Zcorp)© 2012
  12. 12. FDM (Fused Deposition Modelling) • 400mc – Wide range of materials • Thermoplastics • High temperature • High impact – Have in-house facility to manufacture bespoke feedstock • Xtrutech twin-screw extruder • Novel material capability • Metal, ceramic filled - sensors and actuators a possibility© 2012
  13. 13. FDM (Fused Deposition Modelling) • Prusa RepRap – Lowest cost 3D Printing system available – Range of low-cost thermoplastics – Initial test-bed for novel materials – Evaluating system for appropriate applications© 2012
  14. 14. 3DP (3D Printing) • Z450 – Enables full colour printing of working assemblies – Upgraded to ZP150 (stronger and whiter, more vivid colours) • Z310+ – Mono printer – Utilised for materials and applications research© 2012
  15. 15. MJM (Multi-Jet Modelling) • Connex 260 – Multi-material printing – 10 variations in material properties in one build • Stiffness variation • Density variation • Colour variation • Transparency variation – Potential for research • Novel material combinations • Offering new product capability© 2012
  16. 16. LS (Laser Sintering) • P380i – Range of functional thermoplastics • Polyamide 12 • Aluminium / polyamide 12 • Carbon fibre / polyamide 12 • Polyamide 11/12 co-polymer – Polystyrene • Supports direct manufacture of complex investment cores – Potential for research • New materials • New applications© 2012
  17. 17. 3DPrinting Research Activities • In addition, WMG has significant 3DP research activity, supported by a number of technologies – Metallic and metal – Polymeric / composite 3DP composite 3DP • High resolution hybrid polymer / composite • High resolution laser deposition melting • High resolution 3D • Electron beam melting Photocopying • Plasma Transferred Arc / • Medical modelling CNC • Low cost 3DP© 2012
  18. 18. Plasma Transferred Arc / CNC • Hybrid system utilising PTA to deposit metals and alloys, with CNC material removal – 2 powder feeds – 1 wire feed – CNC machine between layers • Advantages – Repair and augmentation of parts – Functionalise parts – Hybridise parts© 2012
  19. 19. Plasma Transferred Arc / CNC© 2012
  20. 20. High Resolution 3D Photocopying • Using laser printing principle for layer-wise addition of functional materials • Advantages: – High rate – High resolution – Multi-material – Low cost© 2012
  21. 21. Medical Modelling • Surgical training – Working with Prof Abrahams in Institute of Clinical Education – Investigating benefit of ‘low cost’ medical models for clinical training – Moving towards more realistic anatomical models using 3D multi-material printer • Surgical procedural planning – Provide service to UHCW for a range of orthopaedic surgical interventions – Developing into a range of areas, including midwifery© 2012
  22. 22. Medical Modelling • AirPROM – FP7 project – 33 partners 0 s 0.3s 0.6s 0.9s – 11 EU countries 1.2s – €12M – 2011-2015 • Developing customised treatment methodology for COPD • WMG leading the physical validation of macro-airway modelling© 2012
  23. 23. Medical Modelling • Compare CFD-PIV – Establish inflow conditions • CFD to test transition length • For fully developed flow: tube-trachea • Upper and lower airway • Compare to MRI Velocimetry© 2012
  24. 24. Low Cost 3DP • Utilising ultra low cost 3DP systems – New materials development and evaluation • Supported by in-house polymeric / composite filament manufacture© 2012
  25. 25. Hybrid 3D Printing • Bespoke system hybridising MJM with syringe deposition – 2 x 512, 14pl nozzle heads, individually addressed – High viscosity liquid dispensing – Continuous flow for deposition of resins with highly suspended solids – SmartPump for deposition of higher viscosity resins and pastes at extremely high resolution© 2012
  26. 26. Day 2 Preview • Physical to Digital – Laser Scanning • Digital to Physical – Prototyping • Adding functionality with novel ALM – Plastic and printed electronics • Low volume manufacturing – Bridging the gap between prototyping and production© 2012
  27. 27. “We can work with you to develop new products using innovative polymer technologies” We’d love to hear your project ideas… DR. BEN WOOD @BENJAMINMWOOD B.M.WOOD@WARWICK.AC.UK© 2012

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