Additive manufacturing (AM) offers a few major benefits to biomedical applications. To improve the knowledge on AM possibilities, Sirris is organizing two different masterclasses. The first will address the technology, materials used and applications, with experts in the matter explaining all relevant aspects.

1. Additive Manufacturing – Market, Trends and Future
Thierry Dormal

2. AM business - World repartition
Architectural
3%
Other:
5%
Military Motor vehicles
6% 20%
Academic institutions
8%
Aerospace
12%
Medical/dental Sirris 22
15%
%
Sirris 29 % Industrial/business machines
11%
Consumer
products/electronics
20%
Source : Wohlers
2011
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 2

3. Trends for AM & 3DPrinting
• Aerospace : large interest to evaluate AM technologies and start
standardisation & certification (Airbus, ESA,..)
• Mega scale free-form of buildings: D-shape (granular sands)
• 3D printing of nanostructures
• 3D bio-printing (organs & tissues)
• Conductive materials incorporated into layered composites
 radar absorbing materials
• Cost of 3D printers down to 500 € but also up to > 1 M€
• Large companies coming on the AM market:
HP with FDM, Fujifilm with Dimatix (DMP) for solar cells,…
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4. • > 120 3D printers available
Low cost 3D printers • Mostly based on FDM, FFF
• From 400 to 1000 €
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5. • > 120 3D printers available
Low cost 3D printers • Mostly based on FDM, FFF
• From 1000 to 2000 €
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 5

6. • > 120 3D printers available
Low cost 3D printers • Mostly based on FDM, SLA, DLP
• 2000 – 7000 €
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 6

7. Large systems : Voxeljet: up to 4 meters.
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 7

8. Voxeljet: Sand & plastic. 600 dpi. 26560 DOD jets.
67 h. for 1000mm (15 mm/h)
VX4000
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013

10. The future of Additive Manufacturing
• Three different ways of using AM technologies
•  Prototyping for visual models or functional parts
•  Direct production of parts (light redesign, only validation)
•  Direct production of parts redesigned for AM
(no way back to conventional production)
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 10

11. Additive Manufacturing Limitations
• Geometrical limitations:
• Wall thickness: 0.3 mm – 1.5 mm
• Length of internal channels (powder removal)
• Max. size: 100 mm  4000 mm.
• Anisotropy (axe Z) for some mechanical properties
• Surface quality (layer thickness, orientation)
• Support structures for 3D building with some AM techniques.
(generation, building, removal)
• Some understanding of the AM processes are required for
• The designer (dimensioning, resolution, wall thickness)
• The manufacturer (part orientation, support generation,
shrinkage factor, warping)
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 11

12. Geometrical Complexity (Polymers)
• No tool required for series production:
•  No draft angle required for demouldability
•  No mould filling problems
Hettich: Rotolavit Blood centrifuge (< 1.000 units / year)
Freedom of Creation 30 % less expensive than with injection moulding
32 components  3 components (2 with LS, 1 with IM)
Manufacturing on demand (customization)
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 12

13. Geometrical Complexity (metal)
• No tool required for series production:
•  No draft angle required for demouldability
•  Internal walls and details
Steel part (Concept Laser) Wim Delvoye / 3DP metal SIRRIS
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14. Less components - Assembly reduction
• Redesign of a laser collimator for space app.:
• 13 components  2 components
• Cooling system and geometry optimization
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 14

15. Integration of functions
• Integration of snap fits, hinges,...
EOS
EBM - Oak Ridge National Lab Materialise MGX
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16. Integration of functions
• The design of a complex part with
several local functions (spring effect,
damping effect) usually requires the
assembly of components in different
materials.
• With AM, this is possible in one step
with bi-material process like the
Connex machine (Objet)
Connex (Objet)
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17. Lightweight parts – Lattices structures
• Weight reduction using lattices structures
with minimal strength reduction
• Local variation of lattice types
 graded porosity
• Shock damping, vibration reduction
• Biomedical implants: bone regeneration
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18. Lightweight parts - Topology optimization
• Automated design based on the applied constraints (Topol)
• Same mechanical properties
SIRRIS redesign (Compolight)
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013 18

19. Stress verification
Lightweight parts - Topology optimization
Free space definition
Flying Cam example
(Compolight project)
Efforts repartition
Smoothing or redesign
based on the STL geometry
STL file
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013

20. Customization – unique parts & short series
• Unique parts for art, aerospace,
biomedical applications
• Mass customization: variants for each
country
Hearing aids
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21. Customization – unique parts & short series
• Olaf Diegel
(Massey University)
Design: presets or user defined
No AM for head, neck & frets
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22. Customization – unique parts & short series
Aline Salmon
3DP metal (Sirris)
Sac féminin haut de gamme
YAMM (200 parts)
Anne Valérie Bribosia
3DP metal (Sirris)
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23. 3D surface texturing
• Library of texturing types available for the designer
• Stone, wood, marble, leather, …
• Visual effect as well as adherence & special grip
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24. Conformal cooling channels - Hipermoulding project
4 injection moulds produced with & without conformal cooling channels
∅4 mm
Drastic reduction of the cycle time (up to 35%)
Enhancement of part quality
Enhancement of tool lifetime
Profitability up to 200.000 euros/year (prod. 6 Mparts)
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Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013

25. Catamaran (Hydrauvision) – Compolight project
Hydraulic units with complex internal channels
Reduction of the weight and size of the original part
3DP Prometal (Sirris)
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26. Functionaly Graded Materials
Example with Ti alloys (source OPTOMEC):
 3 different Ti alloys with 3
specific functions: impact
resistance, fatigue and creep
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27. • AM : huge design freedom
• Some limitations / guidelines need to be known
• AM should be considered from the product conception phase
• An efficient design for AM allows to use these products as end
products rather than prototypes
• AM maturity: large range of cost, performance & applications
Masterclass: Biomedical applications of Additive Manufacturing Organized by SIRRIS the 12th of March 2013

28. Additive Manufacturing
Thanks
Contact: Thierry Dormal thierry.dormal@sirris.be
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