3D Printing and Introduction
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The history of early 3D printing technologies included the development of stereolithography in 1984 by Charles Hull, selective laser sintering in 1987 by Carl Deckard, and fused deposition modeling in 1988 by Scott Crump. These founders later started companies like 3D Systems and Stratasys to commercialize these technologies. In 2012, ASTM classified 7 categories of additive manufacturing processes including material extrusion, vat photopolymerization, sheet lamination, material jetting, binder jetting, powder bed fusion, and direct energy deposition. The document then provides examples of how 3D printing is used in the automotive and aerospace industries for applications like prototypes, tooling, and functional end-use parts for weight reduction.
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3D Printing and Introduction
- 1. History of early 3D printing technologies
- 2. Stereolithography Charles Hull invented Stereolithography. He later funded 3D Systems in 1986/ 1983 Selective Laser Sintering Carl Deckard, who was working at the University of Texas, filed a patent in the US for the Selective Laser Sintering (SLS) RP process. He co-founded Desk Top Manufacturing (DTM) Corp. in 1987 which was acquired by 3D systems in 2001. 1987 The early stages of the SLS machine, Betsy Carl Deckard The intermediate parts that Deckard created with Betsy Charles W. Hull Charles Hull demonstrates Stereolithography
- 3. Fused Deposition Modeling Scott Crump invents Fused Deposition Modeling (FDM) FDM. He later co-funded Stratasys in 1989. 1988 MIT developed Three Dimensional Printing process (3DP). 3DP involves spreading a thin layer of powdered material (originally ceramic) on a flat bed, solidifying successive layers with fine jets of binding agent. Z Corporation obtained an exclusive license from MIT in 1995 and was later acquired by 2012. MIT Alpha Machine Printed part emerging from powder 1992 S. Scott Crump FDM Patent Document Three Dimensional Printing process
- 4. Categories of Additive Manufacturing American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive Manufacturing” classified the range of Additive Manufacturing processes into 7 categories in 2012 • Material Extrusion • Vat Photopolymerization • Sheet Lamination • Material Jetting • Binder Jetting • Powder Bed Fusion • Direct Energy Deposition
- 5. Material Extrusion • Process Characteristics • A heated thermoplastic filament is extruded from a capillary die • Thin layers are formed between the die face and previous layer(s) • Parts chamber is heated to minimize stresses and deformation
- 6. • Process Characteristics • Build platform is submersed in liquid photopolymer • Surface polymer is cured using an UV laser to create each layer • Part built between the previous layer and the surface of the photopolymer • Plate descends into the vat of polymer to create each new layer • Parts are then rinsed in solvent and cured in an UV oven. Vat Photopolymerization
- 7. Sheet Lamination • Process Characteristics • Laser cuts thin sheets of material into desired cross- sections • Process is tuned to precisely cut to sheet thickness • Material is thermally fused to the previous layer using a heated roller • Diced material is removed to uncover completed parts
- 8. Material Jetting • Process Characteristics • Array of inkjet print heads to deposit build and support material to form each layer • Material is cured by a UV lamp after each layer is deposited
- 9. Binder Jetting • Process Characteristics • Liquid bonding agent is selectively deposited through inkjet print head to join powder material in powder bed • The difference to Material jetting is the dispensed material is not build material
- 10. Powder Bed Fusion • Process Characteristics • PBF includes Direct metal laser sintering (DMLS) Electron beam melting (EBM) Selective laser melting (SLM) Selective laser sintering (SLS) • A thin layer of material is spread over the build platform • Energy source fuses the layer or the cross section of the model • Further layers or cross sections are fused and added
- 11. Direct Energy Deposition • Process Characteristics • A nozzle delivers metal powder or wire on a surface • Energy sources (Laser, Electron beam, Plasma) melt the material to build a solid object • Can form multi-material parts and graded material interfaces by varying powder composition
- 12. Technologies Plastic Vat Polymerization Material Jetting Binder Jetting Material Extrusion Direct Energy Deposition Power Bed Fusion Sheet Lamination Ceramic Metal Wax Material Selection Materials
- 13. 0.0 200.0 400.0 600.0 800.0 1,000.0 1,200.0 1,400.0 1,600.0 1,800.0 2,000.0 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 Millions SUMMARY FORECAST FOR THE 3DP AUTOMOTIVE INDUSTRY Source: SmarTech’s Annual Market Findings The automotive industry’s adoption of 3D printing is projected to increase from $365.4M in 2015 to $1.8B in 2023, attaining a 19.51% CAGR 3D Printing Automotive Market
- 14. Automotive Industry Application • Accelerating the product design phase of new product development • Customized fabrication of jig and fixture
- 15. • Complex structure designs that drive weight reduction and fuel efficiency Automotive Industry Application Titanium F1 gearbox by CRP Group using rapid casting A F1 car safety hoop/air intake produced in titanium using 3D printing – saving 2kg of weight Energy absorption with 3D printed structure
- 17. 0.0 500.0 1,000.0 1,500.0 2,000.0 2,500.0 3,000.0 3,500.0 4,000.0 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 Millions SUMMARY FORECAST FOR THE 3DP AEROSPACE INDUSTRY Source: SmarTech’s Annual Market Findings 3D Printing Aerospace Market The aerospace industry’s adoption of 3D printing solutions is projected to increase from $723M in 2015 to $3.45B in 2023, attaining an 18.97% CAGR
- 18. GE additively manufactured single part fuel nozzles, which were formerly composed of 20 different parts. Used in GE’s LEAP engines, these nozzles are five times more durable than those produced with conventional methods. It is also the first FAA approved 3D printed component in jet engine. Aerospace Industry Application
- 19. Aerospace Industry Application Airbus Defense and Space 3D printed a space-qualified satellite bracket. The team was able to transform a bracket made up of four main parts and 44 rivets into a single, laser-melted piece that is 40% stiffer and 35% lighter than its predecessor.
- 20. Aerospace Industry Application SpaceX successfully printed and fired a SuperDraco engine chamber using Inconel, a high performance superalloy. The printed chamber resulted in a order of magnitude reduction in lead-time – 3 Month from initial concept to first hot fire.
- 21. NASA tested 3D printed rocket engine injector. Using traditional manufacturing methods, 163 individual parts would be made and then assembled. But with 3D printing technology, only two parts were required. Aerospace Industry Application
- 22. Future of 3D Printing Models PrototypesMater Patterns Plastic Aircraft Parts Consumer Products Mold Inserts Medical Implants Printing in outer space Custom Prosthetics Metal Aircraft Parts Batteries and Electronics Clothing Food Products Living TissuesIntegrated Electronics Smart Structures Human Organ Unimaginable Applications Source: WOHLERS ASSOCIATES
- 23. Future State of 3D Printing Development Source: CSC
- 24. Future State of 3D Printing Source: Stratasys Applications
- 25. Materials Respondents were asked which materials they’d like to see further developed for AM in the future. Metals is the clear leader. Processes Current vs. anticipated future usage of several AM processes among respondent companies. Future State of 3D Printing Source: Stratasys
- 26. Source: WOHLERS ASSOCIATES Future 3D Printing Worldwide Revenue