Additive Manufacturing / 3D Printing - Technology Overview 2019

1. TM
Consulting Services
ADDITIVE MANUFACTURING
FOR 3-DIMENSIONAL (3D)
STRUCTURES
(EMPHASIS ON 3D PRINTING)
Jurgen Daniel
Teclination Consulting Services
San Diego, USA
www.teclination.com
daniel@teclination.com
TECHNOLOGY OVERVIEW
Source: APWorks
Update - Summer 2019

2. 2TM
Consulting Services
This slide deck is an overview of technologies related to Additive Manufacturing
with focus on 3D printing. While it covers many recent technology
developments, it is impossible to capture all of them due to the vast variety of
technologies and continuous innovation. Much of the information and the
figures originated from websites as annotated on the slides.

3. Source: www.geaviation.com, cessna.txtav.com
a brand new high-performance turboprop aircraft

4. Source: www.geaviation.com, cessna.txtav.com
1/3 of engine parts are 3D printed
GE's Catalyst™
Advanced turboprop engine
Development started in 2015
Certification expected 2020
855 distinct components down to 12
world’s first turboprop engine with 3D-printed parts

5. Development started in 2015
Certification expected 2020
• Simplified
Ø supply chain logistics
Ø assembly
Ø maintenance
• >100 pounds in weight savings
• Improved fuel burn (20 %)
• 10 percent more power
GE's Catalyst™
Advanced turboprop engine
Source: www.geaviation.com, cessna.txtav.com
1/3 of engine parts are 3D printed

6. 6TM
Consulting Services
Conventional vs Additive Manufacturing (AM)
Source: www.arup.com; mx3d.com; www.halfords.com
Structures carry the same
structural loads and forces
AM bicycle frameConventional bicycle frame
Example 1
Example 2
Conventional Additive Manufacturing

7. 7TM
Consulting Services
Problems with Conventional Manufacturing
High cost for prototyping and small runs
Long design / setup time (Tooling, etc.)
Materials waste in subtractive methods (milling)
Complex assembly required for complex designs
Limited materials combinations
… others
Milling, molding, casting, cutting, sawing, stamping, drilling, …

8. 8TM
Consulting Services
Benefits of Additive Manufacturing
Freedom of complexity (designs difficult to do conventionally)
On-demand production (reduced inventory)
Cost and time savings (for prototyping and small runs) -
no part-specific tooling
Lighter, stronger, better performing, safer parts -
enabled by design optimization software
Reduced waste material
… others
Example: aerospace bracket
(70% lighter while stiffer)
Source: 3D Systems
Directed deposition, e.g. printing, selective lamination, …

9. 9TM
Consulting Services
Cost Comparison: Additive vs Conventional
Source: Deloitte
Additive
manufacturing

10. 10TM
Consulting Services
Market and Opportunities for AM
Forging Magazine, March 2018
AM is key to the 4th Industrial Revolution
IDTechEx, March 2018
Predictions heavily depend on assumptions and included technologies
Global 3D printing revenues: $3.1B in 2020
Deloitte Insights, 2019
3D printing market is expected to grow from
USD 9.9 billion in 2018 to USD 34.8 billion by
2024, at a CAGR of 23.25% (Feb 2019)

11. 11TM
Consulting Services
AM Stock – “Between Hype and Reality”
3D Systems: DDD
ExOne: XONE Stratasys: SSYS
8/2018
Examples of Public 3D Printing Companies
Source: etrade.com
Example:

12. 12TM
Consulting Services
AM Sectors and Technologies
Electronic
Structures
Mechanical
Structures
Biological
Structures
Food, etc.
• Laminated Object Manufacturing
• e.g. CompositesLOM
• Fused Deposition ModelingFDM
• Selective Laser Sintering / Melting
• also Direct Metal Laser Sintering (DLMS)SLS / SLM
• Electron Beam MeltingEBM
• Stereolithography / Digital Light
ProcessingSLA / DLP
• Physical Vapor Deposition
• e.g. PlasmaPVD
• Material Jetting
• e.g. PolyJet ™MJ
• Printed Electronics
• e.g. screen printing, inkjetPE
• Electrophoretic DepositionEPD
• Material ExtrusionME
• Pick and PlacePNP
• Binder Jet Technology
• Including Multi Jet Fusion™BJT
• Directed Energy Deposition
• e.g. Plasma Arc Welding conceptsDED
…
see also: ASTM/ISO standard for AM terminology (ISO/ASTM 52900-15)

13. 13TM
Consulting Services
AM Value Chain
*Design & Fabrication Software Tools
*Information Services (Conferences / Journals)
Source: am.vdma.org and Teclination (*)
Tool
*Test & Evaluation
Plus:

14. 14TM
Consulting Services
Major Risks in AM
Digitalization of physical products
Reliability of mechanical structures
Cyber threats
• reliance on digital files and connectivity
Issues in supply chain
• firmware, network, IT, design, printer/production and
third-party supply chain areas
Counterfeit objects
• easy to produce with a stolen design file
• hackers could build failure points into part design
Material integrity
• machine-to-machine & print-to-print variations
• quality variation of starting material

15. 15TM
Consulting Services
Selected Technologies
- Electronics -
Source: DuPont, TaktoTek

16. 16TM
Consulting Services
2.5D Technologies
Source: www.mid-tronic.de
LDS (Laser Direct Structuring)
Hot Stamping
laser activation and plating

17. 17TM
Consulting Services
Injection Molded Electronics (2.5D)
Source: DuPont, TaktoTek (www.tactotek.com)
Using stretchable conductive ink from DuPont
In-Mold Structural Electronics Manufacturing Process

18. 18TM
Consulting Services
Aerosol Printing – 2.5D Electronics
printed smartphone antennas
Sensor Structures via
Aerosol Jet printing
and
5 axis printing system
printing process
Source: www.optomec.com & www.neotech-amt.com
Printing onto 3D surfaces

19. 19TM
Consulting Services
3D Electronics Integration
Source: Eric MacDonald, Ryan Wickers, et al. (2014) - W.M. Keck Center for 3D Innovation & U Texas, El Paso
Hybrid of AM, robotic component placement and
embedding of conductors
3D printed signal conditioning circuit Source: Science, 30 Sep 2016
3D Structural Electronics
Related process:
commercial printers from
Voxel8 & Nano Dimension

20. 20TM
Consulting Services
3D Printed Electronics
First on-demand 3D-printed electronics service
Printed digital thermometer
Source: www.nano-di.com
DragonFly Pro
printed circuit board
inkjet printer
Printed electromagnet
Conductive silver nanoparticle ink (metal) and insulating ink (dielectric polymer)
Printed 4-layer PCB

21. 21TM
Consulting Services
PolyStrata Process (3D)
Photo of RF module
Source: www.nuvotronics.com
mmWave RF circuits
compact, high isolation, low loss
PolyStrata transmission lines
10x - 100x
improvement
in size, weight, and
power (SWaP)

22. 22TM
Consulting Services
Selected Technologies
- Mechanical Structures
• plastics
• metals
• ceramics
• composites

23. 23TM
Consulting Services
Selected Technologies
Plastic Structures
Source: Formlabs

24. 24TM
Consulting Services
Fused Deposition Modeling (FDM)
filament
heated
nozzle
Source: Manufacturingguide
3DBenchy PLA model
(source: hackaday)
FDM nozzle (source:3dnatives)
ULTEM air duct
(source: Stratasys)
Examples:
Filament Materials:
• thermoplastic polymers
(e.g. PLA, ABS, PI, PEI, PC)
• also metal / ceramic / fiber filler
e.g. Marlin firmware control:
Ultimaker
RepRapPro
Rostock
Examples of FDM printers
Monoprice MP Select Mini
(~$200)
Airwolf3D EVO 22
(~$12k)
(heated
build chamber)
heated
build plate
Filament
DeltaCartesian

25. 25TM
Consulting Services
Droplet Printing of Polymers
Ø Inexpensive qualified standard injection molding granulates
Ø 2 materials/colors (e.g. hard & soft materials)
Ø Quality lies in-between SLS and FDM
Source: www.arburg.com
Material: ABS, TPU and armat 21
Piezo
actuator
Hot
Polymer
Hannover Messe 2019
• Typically 25-30 micron layer thickness
• >40micron resolution
• Isotropic material / smooth surface
ARBURG Plastic Freeforming (AFP)
Toothbrush
Related concept: polymer-jetting

26. 26TM
Consulting Services
VAT Polymerization: SLA (Stereolithography) / DLP (Digital Light Projection)
Formlabs Form 2
(Laser scanning)
~$3,400 (2018)
FDM vs SLA
27x magnification
Source: Formlabs
Source: formlabs; sparkmaker3d, www.tth.com
• Typically 25-30 micron layer thickness
• >40 µm resolution
• Isotropic material / smooth surface
Photopolymer (resin)
• solidified resin:
Ø rigid
Ø flexible
Ø colored
Ø high temperature
Ø dental grade
Ø ceramic, metal (sintered)
Sparkmaker FHD
(LED / LCD projection)
~$279 (2018)
Laser galvo-scanning, DMD or LCD projection, holography
Example: Laser galvo-scanning &
top-down process
e.g.:
Resin vat
Laser beam
DMD: Digital Mirror Device; LCD: Liquid Crystal Display

27. 27TM
Consulting Services
Other approaches
CLIP (Continuous Liquid Interface Production)
Fast SLA / DLP Processes
Source: www.carbon3d.com, newpro3d.com
Adidas Futurecraft 4D midsole
Riddell custom helmet liner
Continuous printing enabled by a ‘dead zone’ in bottom-up process
Oxygen
permeable
glass
Dead zone
Oxygen inhibits polymerization and creates a dead zone
Continuous Digital Light Manufacturing
Problem in conventional bottom-up SLA: Peeling and repositioning the build platform slows down process
Projector
Lubricant Sublayer Photo-curing (LSPc)
(e.g. silicone oil /PTFE lubricant layer)
(channel partners:
XYZprinting & Bego Dental)
Intelligent Liquid Interface (ILI)
+ others
(transparent wettable membrane)
CLIP process
CLIP process

28. 28TM
Consulting Services
Laser Powder Bed Fusion
Source: www.eos.info; www.plusmedicaot.com
Source: IOPScience: Shirazi, et al., 2015
Build volume: 700 x 380 x 580 mm
System Example: EOS P 770
(2 x 70W CO2 lasers)
Breathable ankle orthosis
Typical powder particle size:
~60 - 90 micron
- suitable for polymers, metals and ceramicsSelective Laser Sintering / Melting (SLS / SLM)
Related system examples:
Fuse 1
Nylon duct
ProX SLS 6100, …
2021 target: LaserProFusion
Polymers
• Polyamides (Nylon)
• Polystyrenes
• Thermoplastic elastomers
• Polyaryletherketones, …
1 million diode laser array
Laser
Powder coater
Lisa

29. 29TM
Consulting Services
Binder jetting / High Speed Sintering (HSS)
“10 to 100x faster than current
industrial 3D printing processes”
Combining binder jetting and selective laser sintering
Related processes:
Multijet Fusion (MJF)
Source: www.voxeljet.com; www.xaar3d.com
System: VX200
Build volume: 290 x 140 x 180 mm
Inkjet printing of IR-light-absorbing ink onto polymer particles and irradiation with IR light
IR light
Sintered
polymer
InkjetInfrarded
absorbing
ink

30. 30TM
Consulting Services
STEP (Selective Thermoplastic Electrophotographic Process)
Source: www.evolveadditive.com
Xerography based high-speed plastic AM
- with added benefit of possible materials variation
- 50x faster than High Speed Sintering
spun out of Stratasys
US Patent 8488994 B2 (2013)
Partnership with Kodak
on imaging technology
3D printing alternative to injection molding

31. 31TM
Consulting Services
Wave Applied Voxel (WAV) Printing
• No large vats to maintain, less waste, rapidly swappable materials
• Small footprint
• Solves the issue of trapped volumes
• Projected speeds of 4x, 8x, 24x+ of the fastest large vat system
Source: www.paxis.com
One-piece Wav-printed
surfboard
WAVTM-printer
Addresses issues of vat-based systems (e.g. SLA process):
Ultracur3DQualified material:

32. 32TM
Consulting Services
Selected Technologies
Metal Structures
Source: Velo3D

33. 33TM
Consulting Services
Laser Powder Bed Fusion of Metals
Source: www.concept-laser.de; www.eos.info; www.slm-solutions.com
Build volume: 800 x 400 x 500 mm3
System: X LINE 2000R
(2 x 1kW fiber lasers)
Metals:
Aluminum, stainless steel,
titanium, nickel, CoCr , Cu, alloys,
+ others
Valve block for a A380: 35% lighter
(titanium alloy)
Selective Laser Sintering / Melting (SLS &SLM)
Similar systems:
+ others
layer thickness of 15 – 500 μm
in vacuum or inert gas
Titanium bracket is 30 percent lighter
affect solidification conditions:
- Microstructure
- Size of dendrites and grains
Critical process parameters:
• Laser power
• Scan speed
• Layer orientation
• Hatch distance

34. 34TM
Consulting Services
Support-free Metal AM by Laser Powder Bed Fusion
Source: www.velo3d.com
Unsupported inner areas!Sample: Aerodef 2019
Intelligent Fusion™ corrects deformation issues and allows true print-to-design
Support-free laser fusion
Non-contact powder bed re-coaterSoftware corrects for deformation
Bottle opener
• Simpler design process
• Less post-processing
In-situ metrology sensors
Two 1kW lasers
VELO3D Sapphire

35. 35TM
Consulting Services
Other approaches:
Rapid Metal Printing
Print speed of 113 kg per day
(target of 1000kg!)
~55 times the market speed
(identified as 1.96 kg of Titanium per day)
Multi-Layer Concurrent Printing (MCP)
Source: www.auroralabs3d.com
“World’s fastest and largest direct metal 3d printer”
Target industries:
oil & gas, mining, shipping
Novel recoating tool: lasing during recoating process
multiple layers deposited and fused in a single pass
cascading layers
of metal powder
4 laser scan heads
Bi-directional binder jet printing
(single pass jetting)
metal
powder recoater
laser
substrate
recoater
123456

36. 36TM
Consulting Services
Electron-beam Melting (EBM)
Lattice skull implant
Source: www.arcam.com
Advantage: void-free deposition of metals
Optimized roughness for bone in-growth
TiAl turbine blades
(for new GE9X engine)
Spectra H
~62 EBM machines operated by GE Aviation (2019)
Build volume:
- 250 mm diameter
- 430 mm height

37. 37TM
Consulting Services
FDM Extrusion Process of Metals
Source: www.desktopmetal.com; markforged.com; www.aim3d.de; www.rapidia.com
Bound Metal Deposition™
• No lasers, no powders!
• Sparse infills possible
• Ceramic support release layers
• Safe for office environment
Related processes:
Office-friendly metal 3D printing system
Bound metal rods
(high metal ratio)
Studio System ~$120,000
Printer Debinder Furnace
316L steel
not filament!
Print Media
example
(Metal X)
- uses injection molding pellets
CEM (composite extrusion modeling)
Water-based binder – no de-binding step
Ultrafuse
316L filament

38. 38TM
Consulting Services
Binder Jetting of Metals
Source: ExOne
Binder jetting onto layers of powder De-powdering For metal parts: with or w/o infiltration
(e.g. bronze infiltration)
SinteringBinder curing between layers
(~30-60 sec per layer)
Examples of metal parts
Process
+ Suitable for large parts (e.g. sand molds for casting)
+ No heat applied during printing (less stress)
+ Often more cost effective than other additive methods
+ Parts are supported by loose powder
Powders: sand, ceramics, plastics, metals
Binder: phenolic, aqueous, silicate, etc. Without infiltration
Similar process:
Process for high volume low-cost parts
3-20 µm particles
Stainless steel
With infiltration
(<1% latex binder;
no de-binding needed)
- Sintering process can cause deformation

39. 39TM
Consulting Services
DED (Directed Energy Deposition): Powder-fed
Source: www.beam-machines.com
Focused thermal (laser) energy is used to fuse a metal powder
5 axis of freedom to build/repair
components layer by layer without
the need for support structures
Repair of worn shaft seal
Similar concepts:
Wire & powder-fed
(powder size: 45-75µm)

40. 40TM
Consulting Services
DED: Wire-fed e-beam Metal AM
Part requires finish-machining
Source: www.sciaky.com; Lockheed Martin
Electron Beam Additive Manufacturing (EBAM®)
Titanium dome for satellite fuel tanks

41. 41TM
Consulting Services
DED: Metal Arc-welding
Rapid Plasma Deposition (RPD):
similar to
Tungsten Inert Gas (TIG) welding
Source: Aviation Week (Oct 2015) and www.norsktitanium.com
Wire Arc Additive Manufacturing (WAAM)
• FAA-certified process
• 50–100 times faster than powder-based systems
• Deposition rate: up to 10kg/h
Similar concepts based on Metal Inert Gas (MIG) welding:

42. 42TM
Consulting Services
Cold-Spray Metal Printing
Source: www.titomic.com, www.spee3d.com
• Mitigate oxidation issues - titanium particles
impact to mechanically fuse (no melting)
• No heat-related distortion
• Extremely fast build rates
Deposition speeds of up to 45 Kg of material per hour
(compare to E-beam melting: 9.07 Kg/hr)
Titomic Kinetic FusionTM
1.8 m titanium drone
Similar Concept:
Supersonic 3D Deposition (SP3D)
printer

43. 43TM
Consulting Services
Jet-printing of Nanoparticle Inks for Metals
Carmel 1400 system
Metal Ceramic
Source: xjet3d.com
Nanoparticle JettingTM (NPJ) – metals and ceramics
• Powderless (greater safety!)
• High speed (~5x of SLS)
• Smooth surface finish
• Extremely low shrinkage (~8x less than MIM)
• Isotropic uniformity
• 99.9% density
Printing at ~500degC
Final sintering
Support removal
(water soluble material)

44. 44TM
Consulting Services
Jet-printing of Molten Metal
Source: vadersystems.com/
Printing of liquified metal (e.g. Aluminum)
Magnet-o-Jet™: electromagnetic pulsing
of molten metal 1000 droplets per second
acquired by Xerox (2019)
Al - 660.3°C
Ti - 1,668°C
Fe - 1,538°C
Cr - 1,907°C
Cu - 1,085°C
Melting point comparison:

45. 45TM
Consulting Services
Joule PrintingTM of Metal
Source: www.digitalalloys.com
Precise closed-loop control of melting at the voxel level
Unlike a direct energy deposition system (e.g. arc welding), there is
no dripping or splashing
Fast and low cost:
• prints at 5-10 kg/hour at very low power (<1 kWh per kg)
• uses commodity wire as the raw material
Process
Metal wire

46. 46TM
Consulting Services
MELDTM Metal AM
Source: meldmanufacturing.com
MELDTM makes the material malleable without melting
Open atmosphere operation
Large parts
Fast process
Unweldable materials
Materials without porosity or hot-cracking
Additive manufacturing
Coating
Metal joining
Component repair
Metal Alloy/Composites
Build Rate (cm3/h)
Al Steel
MELD 1020 61
SLS 2.5 5

47. 47TM
Consulting Services
Ultrasonic Welding
CNC contour milling
Rolling ultrasonic welding
20kHz
Aluminum-Titanium
Laminate
SiC fibers embedded in
metal laminate
• Functionally Graded Laminates
• Embedded electronics/sensors
• Metal matrix composite (MMC)
Alumina fibers in
Aluminum (MMC)
process
Source: fabrisonic.com

48. 48TM
Consulting Services
MICA Freeform Process
Laser sintering vs MICA freeform
Fabrication of parts in assembled state
Source: www.microfabrica.com
formerly Memgen
Materials:
Layering process using plating and planarization
Similar process:
Polystrata by
MICA
SLS

49. 49TM
Consulting Services
Selected Technologies
Ceramic Structures
Source: Xjet

50. 50TM
Consulting Services
Direct Writing (Extrusion) of Clay Paste
Source: www.deltabots.com, www.instagram.com/explore/tags/potterbot
3D PotterBot Clay printer
Scara Mini V1

51. 51TM
Consulting Services
Fused Deposition Modeling (FDM)
Source: zetamix.fr; www.rapidia.com
FDM followed by sintering
parts which contain more
than 80%w of ceramic
Debinding in acetone and sintering between 1200°C and 1500°C:
plastic is removed and a pure ceramic remains
Oxide ceramic filament: Alumina, zirconia, ZTA (ZrO2/Al2O3)
Carbide: Silicon carbide (SiC)
Nitride: Silicon nitride (Si3N4)
Metals: Stainless steel and Tungsten carbide
Related processes:
Water-based binder

52. 52TM
Consulting Services
Inkjet Printing of Ceramics
Ceramic drill bit with 2400 connected cooling channels
Alumina and Zirconia ceramicsSource: xjet3d.com, Fabbaloo
Nanoparticle JettingTM (NPJ) followed by sintering
Image: Fabbaloo
Steel-and-ceramic (un-sintered)
Multimaterial print

53. 53TM
Consulting Services
Stereolithography (SLA / DLP) of Ceramics
Castalite® resin molds
after Bronze casting
Example: Investment Casting
Sintered ceramic parts
Resin is a ceramic-filled photopolymer
Source: Formlabs, Tethon3D, Admatec
slurry
Admaflex 130
DLP engine
foil
Many ceramic photoresins for SLA /DLP processes
(also sintered metal possible)
(~ 15% - 20% shrinkage)
Similar processes:
sintered
un-sintered

54. 54TM
Consulting Services
LCM (Lithography-based Ceramic Manufacturing)
Source: www.lithoz.com
Dental restoration
(Zirconia crowns, implants)
Bone augmentation
(Bioresorbable implants:
Tricalcium phosphate, Hydroxy apatite)
Example: Ceramic static mixer
CeraFab 7500
High performance and bioresorbable ceramics by DLP*
Materials
Aluminum oxide
Zirconium oxide
Silicon nitride
Hydroxyapatite
Tricalcium phosphate
Silica-based ceramics
…
*digital light projection
Photocurable slurry
DMD light exposure
Debinding
Sintering

55. 55TM
Consulting Services
Binder Jetting of Ceramics
Source: www.voxeljet.com, matthey.com, kwambio.com, www.exone.com
Silicon Carbide
Alumina
Zirconia
Boron Carbide
Example: Supports for catalytic applications (high surface area)
Ceramic cord box with holes
CERAMO TWO
Juicer
Similar processes:
MJF
Binder
Jetting
(Debinding)
Sintering
Examples:
(by EVERYTHING ELEVATED)

56. 56TM
Consulting Services
Laser Powder-Bed Processes for Ceramics
Selective Laser Sintering / Melting (SLS / SLM)
Source: www.mtm.kuleuven.be; global.canon; pdfs.semanticscholar.org
Alumina-based ceramic material
Canon’s new ceramic process: “materials suited to
selective laser melting” (SLM)
Si-SiC part by
Direct SLS
Alumina part with
Indirect SLS
Direct SLS: e.g. used in Si-SiC ceramics (with infiltration)
Indirect SLS: laser melting of a sacrificial organic
binder phase in the polymer-ceramic composite
(resulting in ’green’ parts)
SLM: higher laser energy; lower porosity materials
– but so far limited success in ceramics

57. 57TM
Consulting Services
Directed Energy Deposition of Ceramics
Laser Engineered Net Shaping (LENS)
Source: www.optomec.com
LENS process

58. 58TM
Consulting Services
Selected Technologies
Composite Structures
Source: Airbus

59. 59TM
Consulting Services
Fiber Layering / Weaving
Carbon fiber is braided onto
an aircraft component
3D-woven composite and resin transfer
molding (RTM) process
LEAP fan blade
Sources: www.airbus.com; www.compositesworld.com/articles/albany-engineered-composites-weaving-the-future-in-3-d; markforged.com
High-strength break levers:
3D composite FDM printer embedding
continuous carbon fiber
Carbon / Ceramic Fiber-reinforced Composite Materials
- layered or 3D woven structure -
Related process:

60. 60TM
Consulting Services
Composite-based AM (CBAM)
CBAM 2 printer
Source: www.impossible-objects.com
Stacking and bonding of fiber sheets
1. Printing onto fiber fabric sheets 2. Heat compression
3. Removal of unbonded areas
Process
Related process:
SLCOM

61. 61TM
Consulting Services
Selected Technologies
- Mechanical Structures -
with Full Color
Source: Phoenix Children’s Hospital

62. 62TM
Consulting Services
Selective Deposition Lamination (SDL)
Source: www.mcortechnologies.com/
Removing excess paper
Mcor ARKe
Process
Build material: paper
X,Y,Z resolution: 0.1mm
Photorealistic color

63. 63TM
Consulting Services
PolyJet Printing
J750 3D printer from Stratasys
(360,000 colors: CMY, white, black, transparent)
over 10 million colors and translucent
objects (but different materials properties)
Similar technology:
Inkjet printing of UV curable polymers
3D printer jets and instantly UV-cures tiny
droplets of liquid photopolymer
– rigid or elastomeric polymers –
Source: Stratasys; Mimaki

64. 64TM
Consulting Services
ColorJet Printing (CJP)
formerly: Z Corporation
ProJet CJP 660Pro
Source: www.3dsystems.com & www.3dnatives.com
Solidifying and coloring a powder with a binder
• Uses thin layers of white support powder (gypsum)
• Inkjet printed color binder material
• Powder bed helps to avoid the need for printing supports
• Requires post-processing (clean up of excess powder)

65. 65TM
Consulting Services
• Average printing cost per part is half the average
cost of comparable FDM & SLS printer solutions
• 10 times faster than FDM and SLS
• Very strong and durable parts
Multi-Jet Fusion (MJF) 3D Printing
Source: www8.hp.com/us/en/printers/3d-printers.html
HP Jet Fusion 500/300 Series 3D
Similar to binder jetting
(however not binder but fusing agent)
process
Phoenix Children’s Hospital
Heart of Jemma
Strong thermoplastic
chain link
Now also metal parts via sintering!
(HP Metal Jet)
• Black fusing agent (FA) for light absorption
• Detailing agent (DA) prevents capillary spreading
• Color only around edge
FADA
with up to 8 agents for color 3D
Price: >$50k - 100,000

66. 66TM
Consulting Services
Inkjet Printing of Color Surface layer
Source: www.xyzprinting.com
3D PLA FDM printer plus color inkjet
Xyz print da Vinci and XYZmaker modeling software;
- process uses special filament to which ink adheres -
Similar process:

67. 67TM
Consulting Services
Color Surface by Hydro-dipping
Source: learn.adafruit.com/hydro-dip-3d-prints/overview
Adding graphics to 3D parts: by inkjet printing onto water transfer
paper (PVA based) and hydro dipping

68. 68TM
Consulting Services
3D Color Parts by Thermoforming
Gypsum mold because of thermoforming process (PLA would melt)
Example: Plastic food
Source: C. Schueller, et al. , Siggraph 2016
process
process (side-view)
Computational Thermoforming (ETH Zurich, Disney Research)

69. 69TM
Consulting Services
Applications
Examples
(emphasis on 3D printing)
Source: Widex

70. 70TM
Consulting Services
Application Areas
Area Benefit Example
Prototyping Faster, less expensive, allows complex designs Maker community, R&D, product design
Aerospace Light weight, complex design, spare parts, … GE fuel injector nozzle for LEAP engine
Automotive Faster design cycles, Cost & time savings for small
series production, spare parts for rare vehicles
Turbine for Koenigsegg sports car,
Customization (Mini)
Medical / Dental Patient-specific design, optimized textures for
bone ingrowth,…
Transparent Invisalign braces, hearing
aids, implants
Military Simpler logistics, spare part availability in remote
areas or on-ship
USS Essex printer installation
Jewelry Faster design cycles, unique and complex designs Many examples of jewelry designers
Industrial Faster and less expensive, complex designs
possible
Turbine blades for generators by
Siemens; Tools /fixtures
Construction / Architecture Logistics, simplified transport, unique designs Metal bridge by MX3D in Amsterdam
Sports / Clothing Individualization, exclusive fashion design Personalized shoe soles (e.g.Nike, Adidas)
Electronics Conformal design, potentially less expensive, large
area electronics, improved performance, …
Antenna and sensor prototypes
+ others
Concept Models End-Use Parts
Functional
Prototypes
Molds / Castings
Tooling, Jigs,
Fixtures
Visualization Aids
Replacement
Parts
Branding /
Promotion
Source: ultimaker.com; Teclination

71. 71TM
Consulting Services
Electronics - RF Antennas
• 95% weight reduction
• 20% reduction of production cost
• 75% of non-recurring costs eliminated
Source: 3dprint.com/178724/3d-printed-antenna-one-component/
Ka-band 4×4 monopulse phased array (1 -100GHz)
1part
100 parts
brazing and EDM
(~8months to develop and 3 to build)
3D laser fusion
( ~a few weeks to complete)
metal
e.g. for low SWaP radar on High
Altitude, Long Endurance
(HALE) platforms

72. 72TM
Consulting Services
Aerospace - Aviation
3D printed fuel nozzle for CFM LEAP engine for Airbus A321 neo
19 nozzles per LEAP engine
5X increase in durability
25% weight savings
20 parts replaced with one
Source: www.ge.com; www.cfmaeroengines.com; www.materialise.com
Reduced weight of components by “bionic” design
3D printed bionic spacer panel
15% lighter through use of
internal lattice structures

73. 73TM
Consulting Services
Aerospace - Rockets
Monolithic Thrust Chamber with Internal Cooling Structure
Selective Laser Melting:
• Nickel superalloy IN718
(difficult to CNC machine)
• Minimum post processing needed
Source: www.slm-solutions.com, cellcore3d.com
Complex lattice structure:
Ø Improved cooling
Ø Light weight
Combined fuel injector and
thrust chamber

74. 74TM
Consulting Services
Heat Exchange
• 22% lighter
• 55 mm smaller
than traditionally
manufactured parts
Pure copper heat exchanger:
• spiral design (0.5mm wall thickness)
• >30% lighter
• 35% cost reduction
Complex heat exchanger concept in Al
Lung-inspired Heat exchanger
(ARPA-E HITEMMP)
Novel complex (bio-inspired) & more efficient designs
Source: www.metal-am.com; www.3t-am.com

75. 75TM
Consulting Services
Automotive
Small series variable turbo Customization Rapid development
• On demand production of spare parts, e.g. for old-timersSpare parts
• Parts for special and exclusive car series & motorsportSmall series
• Exclusivity /personalizationCustomization
• Tools/jigs for test & assembly (Cost/time savings )Tooling
• Testing of prototypes before productionQuality Enhancement
• Accelerated design cycles & lowering costs of new productsDesign cycles
Source: 3dprintingindustry.com; yours-customised.min; www.hrewheels.com
US$148 billion in AM product value forecasted for 2030 (Feb 2019)

76. 76TM
Consulting Services
Industrial Casting
Plastic mold will burn out completely
without any residue at 700°C or more
• build space: 4000 x 2000 x 1000 mm (LxWxH)
• Layer height: 300 micron
Source: www.voxeljet.com
Sand mold and metal part Investment casting:
Plastic model and metal part
Cooling of ceramic casting die
VX4000 PRINTER
Sand and plastic molds (for investment casting) via binder jetting
plastic metal
3D PRINTING SAVES UP
TO 75 % IN SAND
CASTING COSTS

77. 77TM
Consulting Services
Tooling for Composite Lay-up
3D printing tools (for composite lay-up) offer savings in time and material over more
traditional methods
- but processing conditions are critical: Coefficient of thermal expansion (CTE), curing temperature and pressure -
Source: www.stratasys.com
ULTEM
FDM printed in ULTEM 1010 polymer
e.g. carbon fiber composite

78. 78TM
Consulting Services
Medical
Ti chest implant
Source: www.anatomics.com; www.zimmerbiomet.com ; www.rapidreadytech.com; www.materialise.com
Spinal wedge implants Patient-specific pediatric heart model
Light-weight patient-specific 3D-printed cast
Implants Surgical Planning
Orthopedic Casts
Software requires FDA
clearance!
Personalized Medicine
OsseoTi
Porous Metal
(for bone in-growth)
Phoenix Children’s hospital
Printlets™ technology

79. 79TM
Consulting Services
Clear Dental Aligners
• ~50-60 stereolithography (SLA) 3D printers from 3D Systems
• >220,000 custom-made clear aligners produced per day (~8 million p/year)
• Align Technology: ~$1.3B in sales (91% of revenue from aligners)
Sources: www.invisalign.com, www.forbes.com
(Forbes, Sept. 14, 2017)
SmileDirectClub uses HP’s Multi Jet Fusion to make dental molds
3D printing of dental molds for thermoforming
Medical-grade polymer (SmartTrack) is thermoformed around 3D mold

80. 80TM
Consulting Services
Hearing Aids
Example: SLA parts by Danish hearing aid manufacturer Widex
Source: www.widex.pro
CAMISHA (Computer Aided Manufacturing of Individual Shells for Hearing Aids)
- scanning, modeling, and printing -

81. 81TM
Consulting Services
3D Bioprinting
Source: www.wakehealth.edu; organovo.com; biolife4d.com; www.prellisbio.com
Similar concepts:
Printed biopolymer (hydrogel) and live cells
Fine 3D Vascular bundles
(holographic SLA)
Polycaprolactone construct with
bone, muscle and tissue cells
Printed ‘heart’
(with cardio muscle cells)
• Vascular structures for oxygen and nutrient delivery
(for tissue thicker than 250 µm – oxygen diffusion limit)

82. 82TM
Consulting Services
3D-printed Optics
Source: Luxexel.com
A revolutionary new approach to lens manufacturing
No need for polishing
Inkjet based fabrication

83. 83TM
Consulting Services
Jewelry
Wax 3D SLA printing and lost-wax casting
High wax content SLA photopolymer
for clean burnout
Source: envisiontec.com, i.materialise.com; www.dnaindia.com
SLA mold
wax
model
metal
Lost-wax casting process
plaster
mold
burnout metal
part
DNA India

84. 84TM
Consulting Services
Textiles, Fashion, Footwear
Source: ceramics.org/ceramic-tech-today/innovation-on-the-ground-3-d-
printed-shoes-offer-custom-fit-perfect-cushion
Source: www.wired.com/2017/05/the-shattering-truth-of-3d-printed-clothing/
Gabi Asfour & Stratasys: BIOMIMICY collection (2016)
Personalized shoe soles 3D printed dresses
Laser-sintered airy midsoles in
thermoplastic polyurethane (TPU)
– one size fits one –

85. 85TM
Consulting Services
Art (Example: 3D printed Ceramics)
Sensory Printing Machine that
feels the environment
Image: Galerie VIVID
Extrusion printer
Source: oliviervanherpt.com/
Adaptive Manufacturing
Unique Ceramic objects

86. 86TM
Consulting Services
Culinary Printing
Source: www.miamfactory.com/ Source: www.3dsystems.com/culinary Source: http://open-meals.com/
Pixel food printer: 3D printer capable of
producing edible and pixelated 8-bit sushi
3D printed chocolate 3D printed sugar Pixilated sushi

87. 87TM
Consulting Services
Materials
(emphasis on FDM)

88. 88TM
Consulting Services
Variety of Materials
SLA
Jet-Printing
Plating (Polystrata, MICA)
CLIP
2-photon Polymerization
SLS
E-beam
FDM
Wire-Fed E-beam
Rapid Plasma Deposition
Composite Weaving
SDL
Ultrasonic Welding
Composite Layering
Jet Fusion
Binder Jetting
Aerosol
Extrusion
Source material
Process
liquid powder filament sheet
Manufacturing process determines materials choice
Metals, ceramics, polymers, composites, biomaterials,…
SLA: Stereolithography
SLS: Selective Laser Sintering
FDM: Fused deposition modeling
SDL: Selective Deposition Lamination
CLIP: Continuous Liquid Interface Production

89. 89TM
Consulting Services
FDM Filament Materials
Sources: www.matterhackers.com; www.stratasys.com/materials/fdm; www.esun3d.net/index.aspx
ABS
Nylon
PEI
PLA
PET
TPU
filler
PC,
PC/ABS
porous
PVA
HIPS
novel
Acrylonitrile Butadiene
Styrene
for high temperature
applications, e.g. in cars
Polyetherimide (ULTEM) –
high performance polymer
Poly Vinyl Alcohol - for
support structures – water
soluble (but hygroscopic)
Glass, pH sensitive,
antibacterial material, …
High Impact PolyStyrene -
soluble in limonene (not
hygroscopic)
Thermoplastic Polyurethane -
flexible
Polyethylene Terephthalate,
also PETG
Polylactic Acid –
biodegradable
Polycarbonate, PC/ABS blend
- High impact strength
Carbon fiber, metal, ceramic
or magnetic particle filled
polymer
Micro-porous, e.g. for filters
or bio- applications
+
others
Oxygen absorption
can affect print quality!

90. 90TM
Consulting Services
FDM Materials - Examples
HIPS Wood / Metal PLA
Flexible, TPE, TPU, TPC Nylon 12 Carbon Fiber (Stratasys)
Source: all3dp.com/best-3d-printer-filament-types-pla-abs-pet-exotic-wood-metal/; www.stratasys.com

91. 91TM
Consulting Services
Exotic FDM Filament - Examples
Source: www.formfutura.com; 3dprintmagazine.eu
Ultrafuse 316LX
•Debinding
• Sintering (~1300C)
•~20% shrinkage
316L steel

92. 92TM
Consulting Services
Materials Safety – Fumes in FDM
• PLA – regarded as safe
• ABS – releases carcinogens (styrene)
Caution should be used when operating a 3D printer in small office spaces
and hazardous filaments should be avoided!
Volatile Organic Compounds (VOCs) & UltraFine Particles (UFPs)
• UL study (2017) identified nanoparticles and
VOCs (styrene, caprolactam, lactide,…)
Source: ulchemicalsafety.org/initiatives/3d-printing/
Feb 2019
- released by FDM extrusion process -

93. 93TM
Consulting Services
Materials in Non-FDM Processes
Inkjet Silicones (Wacker ACEO)
Binder jetting: Metals, Ceramics,
Sand (ExOne)
Metals
Plastics, elastomers, (ceramic) filled polymers
Ceramics
Biomaterials, food
Electronic functionality Printing of living cells (Poietis)
3D-printed photodetectors for ‘bionic
eye’ (U. Minnesota)
Important materials factors in power-based processes such as SLS:
• Oxygen content of particles (causing reduced strength of parts)
• Spherical shape and size distribution (flowability and part porosity)
• Particle recyclability (e.g. plasma conditioning)

94. 94TM
Consulting Services
Metal Powder for AM
Sources: www.materials.Sandvik; www.ge.com; tekna.com; www.mimete.com; www.oerlikon.com
("Powder Metallurgy Science",
R.M. German, MPIF)
Ti-6242 particles (45-106 micron)
Available AM Powders (Examples):
Ø Titanium, (stainless) steel, aluminum, (pure) copper
Ø Al alloys (Scalmalloy: Al, Mg, Scandium – strong and crack-free)
Ø Cobalt chrome
Ø Titanium and nickel-based alloys
Ø Gold, platinum, palladium, silver
Concerns: Health, safety (explosion hazard), waste/recycling
For powder bed & blown powder AM processes
• Spherical morphology & high packing density: for good flow
properties
• Low oxygen content: for clean microstructures & lower sintering
temperatures in binder jetting
• Particle size distribution: for good flow and reduced voids
- SLS: ~40-90 micron powder
- Binder jetting: ~9-20 micron metal injection molding (MIM) powders
Important Powder Properties
Gas atomized powder

95. 95TM
Consulting Services
Diamond Composite
SLA with diamond particles in polymer binder
- then binder removal and infiltration with molten Si to form SiC matrix
- possibly also HIP process for densification
Source: www.home.Sandvik; www.freepatentsonline.com
SLA* printed diamond composite
*stereolithography

96. 96TM
Consulting Services
Amorphous Metals (Metallic Glasses)
requires high cooling rates of
over 1000 Kelvin/second (50% weight reduction through design)
irregular, non-crystalline structure
Selective Laser Melting (SLM)
(Zirconium-based alloy)
Source: www.heraeus.com;3dprintingindustry.com
Extreme hardness - High yield strength - High elasticity
2kg
• corrosion resistance
• excellent wear resistance
• elasticity
• (biocompatibility)
Large components enabled
by SLM 3D printing

97. 97TM
Consulting Services
Novel Multi-Material Objects
Ti-6Al-4V to V Gradient Alloy
Source: D. Hofmann, et al., Nature Scientific Reports 4, 2014 (www.nature.com/articles/srep05357);
authors.library.caltech.edu/50785/1/S0884291414002088a.pdf
Metal-matrix compositesGradient alloys
Graded composition alloys
Related process:
Laser Metal Deposition
(LMD) / powder nozzle
Laser Deposition process
Ceramic-reinforced metal matrix composites

98. 98TM
Consulting Services
Novel Ceramics Research
Source: Zak C. Eckel, et al. (2016) “Additive manufacturing of polymer-derived ceramics” Science 351 (6268), 58-62
Silicon oxycarbide ceramic (SLA* & Pyrolysis)
• 10 times stronger than ceramic foam
• withstands temperatures up to 1700C
high hardness, strength, temperature capability &
resistance to abrasion and corrosion
*Stereolithography

99. 99TM
Consulting Services
Materials Selection Database
Source: senvol.com
Database for AM materials and machines
Related products:
AMRS
Granta MI
• Materials
• AM Process
• Properties
- Mechanical
- Physical
- Thermal
• Certifications
Search for

100. 100TM
Consulting Services
Design
Source: Teclination

101. 101TM
Consulting Services
AM Design Process & Tools
Cura,
Repetier Simplify 3D
Slicer for Fusion
…
Netfabb
AD Meshmixer
Meshlab
…
For added Color and Texture:
e.g. Blender or proprietary software such as Stratasys GrabCAD
CAD Design Mesh repair
Blender
AD Fusion 360
Meshmaker
Rhino
…
3D Model
capture
Kinect Fusion
Autodesk Recap
…
Ansys SpaceClaim, Autodesk Inventor, Siemens NX, SolidWorks …
Slicer
Software
Design libraries of existing 3D models, e.g.:

102. 102TM
Consulting Services
Example – Coil Structure for FDM
Source: Teclination Consulting
Design and modeling
Print conversion (mesh repair, support structures, slicing)
Autodesk Fusion 360

103. 103TM
Consulting Services
3D Design File Formats
Tesselation: .STL
Free form curves: .OBJ
Encoded colors and textures: .MTL
3D design files may contain data about geometry, color,
texture, and materials
• old and simple format: describes anl object as a
series of linked triangles (Tesselation)
• no info regarding color, texture, material, file
security
.STL
• best for color and high precision printing;
tessellation or free form curves/surfaces
• color and texture stored in a paired .MTL file
.OBJ
• potential new format (ASTM).AMF
• potential new format (Microsoft).3MF
Source: all3dp.com

104. 104TM
Consulting Services
Slicer Software
Slicer creates:
1. a toolpath (more or less intelligently) based on the geometry of the design-file
2. a percentage of infill to save 3D printing time and material
3. support structures, if the geometry is difficult to print
Source: all3dp.com, ultimaker.com
Z-Suite
SliceCrafter
Examples
.stl, .obj, .x3D, 3MF, … .gcode .gcode example
Slicer

105. 105TM
Consulting Services
Support Structures in AM
Source: www.simplify3d.com
Example:
Printed support structures are needed in FDM, SLA, etc.
(processes without a supporting solid powder bed such as SLS)
• General rule of thumb: most extrusion-based printers can
support overhang angles less than 45 degrees.
• Adding support structures with specialized software

106. 106TM
Consulting Services
DfAM (Design for Additive Manufacturing)
Parametric and generative design, topology optimization,
lattice structures and biomimicry (bionic design)
Also: Compensation for shrinkage & warping (e.g. part orientation) and adding support structures
Element design optimization software
Generate (TM) topology optimization
CogniCAD™: Cognitive Computer Aided Design
Platform For Ultimate Lightweighting
Fusion 360 Ultimate generative design
Examples:
Altair InspireTM topology optimization /
generative design

107. 107TM
Consulting Services
AM Build Simulation Software
Optimize build-up orientation, support configuration
Verify influence of operating conditions on distortions, plastic strains and residual stresses
Multiphysics Multiscale Modelling of AM Processes
Source: www.geonx.com; www.3dsystems.com; www.ansys.com; www.alphastarcorp.com; www.e-xstream.com
+ others
Example
Model distortions & residual stresses for processes
Suggest distortion compensation
Model optimal support structures
Minimize number of build tryouts
Minimize risk of printer damage (e.g. re-coater damage)
Predict impact of postprocessing (e.g. heat treatment, HIP,
support removal)
NX & Simcenter

108. 108TM
Consulting Services
Fabrication Process
Source: i.materialise.com

109. 109TM
Consulting Services
3D Fabrication Services
+ many others
HP Digital Manufacturing Network

110. 110TM
Consulting Services
Cost Example - Shapeways
Not a photo (model)
Natural Sandstone: $29
Orange Plastic: $34
Polished Nickel Steel: $187
Natural Brass: $596 (prices as of Sept, 2018)
Source: www.shapeways.com
Natural Silver: $1,155
18k Gold: $26,896
Platinum: $61,802
Mosaic Egg
2.41 x 1.96 x 1.96 inches

111. 111TM
Consulting Services
3D Printing with Support Structures
HydroFill water-soluble FDM support for ABS and PLA parts
Soluble Support Material
Source: pixelpractice.nyc; airwolf3d.com
Cut-away Support Structures
450
No support needed Support needed
General recommendation
<450
ABS
FDM printing
Needed in FDM, SLA, jet-printing and metal SLS (metal SLS: for heat distribution and stability during cool-down)

112. 112TM
Consulting Services
Post Processing - Examples
Source: www.3dnatives.com; www.3dprinterworld
• Cutting / dissolving of support
• Solvent vapor, sanding, bead blasting, tumbling, coatingFDM
• Removal from powder bed (+ remove support)
• Bead/sand blasting, tumbling, machiningSLS
• Washing, post-cure
• Removal of support, coatingSLA
• Poly-jet: Dissolution of support material
• Binder-jet: de-powdering, (de-binding & sintering)Jetting
SLS: removal of part from powder bed FDM: solvent vapor smoothing FDM: removal of support structures
~70% of part cost can come from post process in (SLS or binder jetting)*
*Wohler report
ABS plastic

113. 113TM
Consulting Services
Simplified Post-processing
Source: www.rize3d.com
Augmented Deposition: material extrusion (FDM) and jetting
RIZE™ ONE
support structures are quickly, easily and cleanly removed
Release ink
Special ink (color)
Support
extrusion
Part extrusion

114. 114TM
Consulting Services
Automated Post Processing
Source: www.postprocess.com; solukon.de
Hybrid DECI Duo
Support removal and surface finishing
SLS part
FDM part
two perpendicular, single-axis jet streams
comprised of compressed air, detergent, and
suspended solids providing targeted blast
Related processes:
(Automated
powder removal)

115. 115TM
Consulting Services
Surface Finishing
Source: www.metal-am.com; www.belairfinishing.com; dyemansion.com
Importance
Methods
before
after finishing
Examples:
Corrosion/oxidation
resistance
Surface friction and
wear
Bending fatigue
Tensile strength
Cellular and biofilm
adhesion
Sanding/polishing/machining
Abrasive flow machining Shot peening / blasting
Vibratory grinding
Electro-polishingChemical etching
Vapor smoothing Electrodeposition
Spray/dip-coating + others
Appearance
automotive colors
color variety
Dyeing

116. 116TM
Consulting Services
Surface Finishing – novel Approaches
Source: www.metal-am.com; www.dlyte.es; www.ilt.fraunhofer.de
Dry Electropolishing
Titanium spinal implant with a smooth surface
finish (right) achieved using DryLyte Technology
Laser-polishing
SLS CoCr knee implant, partially laser-polished
• Selective
• Micro-scratch free
• Fast
• Particle-free
• Reproducible
• Surface densification
SLS: Ra < 7 µm
Polished: Ra <0.3 µmRa < 0.1 µm
• Complex geometries
• Micro-scratch free
• Preserves geometry
• Reproducible

117. 117TM
Consulting Services
Surface Smoothing – Example: RF Antenna
Surface smoothing improves antenna performance
Source: Microwave & RF, October 2018, (Glenn Robb, Antenna Test Lab Co.)
FDM printed RF horn antenna
VSWR
Solvent-vapor
smoothed
PLA plastic coated with
conductive paint

118. 118TM
Consulting Services
Defect Reduction (Material Densification)
Hot Isostatic Pressing (HIP) for SLS or EBM
Typical: 5,800 to 30,000 psi
and up to 2,000°C
Source: quintustechnologies.com
Challenge: Defect elimination without coarsening the microstructure (lowering yield strength)
Schematic of a SLS or EBM
printed part
Part has to have a gas-
tight surface!
HIP can achieve 100% of
maximum theoretical density
Eliminate microporosity
Remove (printing) defects
Remove micro-cracks
Improves the ductility and fatigue
resistance of critical, high-
performance materials
+ other processes

119. 119TM
Consulting Services
Fabrication Challenges
Standardization of processes (machine-to-machine and run-to-run variability)
• Consistency of source material
• Process control and error correction
Post processing requirement
• Impact on cost, time and quality)
Certification of parts
• How to distinguish a good part from a faulty one
New potential health hazards to operators
• e.g. particulates, VOCs
Integrity of digital data
• E.g. employ blockchain technology to secure data (‘Cubichain Technologies’)
Protection of Intellectual Property

120. 120TM
Consulting Services
Process / Quality Monitoring
Starting Material
(Specification and Quality)
Post Process Materials
Quality Testing
(NDT, DT)
Dimensional Accuracy and
Surface Finish
(Measurement and post-processing)
In-situ Part Monitoring
(Melt Pool, Heat Map)
Machine Parameters
(e.g. laser power, nozzle monitoring,
temperature)
Process Environment
(e.g. moisture, airflow)

121. 121TM
Consulting Services
Process and Quality Control Solutions
Process control for metal AM Product Lifecycle Management &
Workflow Optimization
Workflow optimization
Product Lifecycle Management (PLM)
for simplicity and traceability
Examples:
Workflow Software
data analytics: PrintRite3D ANALYTICS®

122. 122TM
Consulting Services
Artificial Intelligence Supported AM
3D Printing Enhanced by Machine Vision and AI
Source: www.inkbit.xyz; markforged.com
Multi-material inkjet printing:
• Digital print record for each layer
• Data used to train a machine learning algorithm
• Voxel-level real-time feedback control
Inkjet printer
Related approach:
Blacksmith

123. 123TM
Consulting Services
Data Security and Virtual 3D Printing
• Software to manage and protect IP
(shared with vendors during design and manufacturing)
• Enable simpler, secured and more
efficient production process
• Rent virtual printers (representing real physical
printers, or portions thereof)
MAY 14, 2018
JUNE 30, 2018
Virtual Secure Manufacturing Space
Source: www.assembrix.com

124. 124TM
Consulting Services
Testing and Standards
Source: ASTM

125. 125TM
Consulting Services
Materials Testing
Source: Chris Hole (Technology Partnerships) – SpaceTechExpo 4/12/2017; www.testia.com
Melt-pool monitoring
Testing of starting materials quality
• e.g. powder flow, particle size, contaminants, moisture content in plastics
In-situ: e.g. Melt Pool Monitoring (MPM), heat mapping
• MPM: In-process monitoring of SLS melt plume via light beam; spectroscopy of the
plume
Ultrasound and eddy current
• Trusted methods; Eddy current is simple and better at depth than ultrasound
X-ray or CT inspection
• Currently used for critical parts because it can detect internal defects
Penetrant Dye testing
• Standard method to find surface cracks
Process Compensated Resonance Testing (PCRT)
• To identify defective parts (tests part’s resonance frequency)
Fatigue, toughness, shear, tensile tests
• Destructive methods
Non-destructive (NDT) and destructive (DT) methods
+ other test methods

126. 126TM
Consulting Services
Standardization Efforts - Examples
America Makes & ANSI
Source:www.ansi.org; www.astm.org
ASTM Committee F42 on Additive Manufacturing Technologies
and focus areas (sub-committees)
ASTM (American Society for Testing and Materials)

127. 127TM
Consulting Services
AM Standards Structure
Source: ASTM

128. 128TM
Consulting Services
Additional
Technology Examples
Source: Advanced Materials / ETH Zürich

129. 129TM
Consulting Services
Small-Scale AM
Source: www.nanoscribe.de & www.laserfocusworld.com; www.microlight.fr; www.nano-fabrica.com
e.g. Two-photon Polymerization
Photonic Professional GT2
Similar concepts:

130. 130TM
Consulting Services
Microprinting
Volume 28, Issue 12, March 23, 2016
Pages 2311–2315
Source: www.ethz.ch; L. Hirt, et al., Jan 2016, Advanced Materials (ETH and University of Zurich, Zurich, Switzerland)
Deposition by FluidFM technology
(e.g. www.cytosurge.com) ~50µm
3D Microprinting of Metals Using a Force-Controlled
Nanopipette for Layer-by-Layer Electrodeposition
Hollow atomic force microscopy (AFM) cantilevers locally supply metal
ions (e.g. copper) in an electrochemical cell

131. 131TM
Consulting Services
Large Industrial 3D Printing
industrial thermoplastic reinforced woven composite 3D printer
Source: envisiontec.com, massivit3d.com, www.voxeljet.com
build up rate of 14 in/hr for super-size partssaves up to 75% in sand casting costs
up to 4,000 x 2,000 x 1,000 mm
3D retail displays
Selective Lamination Composite Object Manufacturing (SLCOM)
(Sand) Molds for casting Gel Printing (photo polymeric acrylic gel)
Build envelope: 762 x 610 x 610 mm
SLCOM 1

132. 132TM
Consulting Services
Combined Additive and Subtractive Systems
5-axis powder laser
deposition
5-axis milling
Source: us.dmgmori.com; www.thermwood.com; matsuurausa.com
Print an object to near net shape and trim the part to net shape with CNC router
Laser build-up process with 5-axis milling
FDM process with 5-axis milling
Other concepts:
Lumex Avance
SLS and machining during the AM process

133. 133TM
Consulting Services
Free-form Additive Manufacturing
Wire Arc Additive Manufacturing (WAAM)
Playhouse structure
Metal bridge
Source: www.branch.technology; mx3d.com
Robotic multi-axis 3D printing technology

134. 134TM
Consulting Services
Cooperative Mobile Print Robots
Nanyang Technological University, Singapore
Source: spectrum.ieee.org
Robots that can 3D print and move around
Build structures that are more or less arbitrary in size

135. 135TM
Consulting Services
‘Open-ended AM’ Concept
Source: www.dedibot.com; gxn.3xn.com
3D printing using Unmanned Aerial Vehicles (UAVs)
UAVs as the print extrusion units to break the limitation of size

136. 136TM
Consulting Services
Concrete Printing
Source: contourcrafting.com
USC Viterbi (Prof. Khoshnevis)
Contour Crafting

137. 137TM
Consulting Services
Printed Textiles
April 2015
April 2014
Layered Fabric 3D printer
Source: www.disneyresearch.com
Felting printer
Feeding yarn and attachment with
felting needle
Laser cutting and bonding with
heat-sensitive adhesive

138. 138TM
Consulting Services
4D Printing
Source: gatech.edu
Science Advances 12 Apr 2017:
Vol. 3, no. 4, e1602890
Shape-shifting 3D printed parts (Smart memory polymer)
Objects transform
with heat

139. 139TM
Consulting Services
Resources

140. 140TM
Consulting Services
Additive Manufacturing News
3dprintingindustry.com
3dprint.com
www.3ders.org
www.rapid3devent.com
www.sme.org
all3dp.com www.tctmagazine.com
advancedmanufacturing.org
www.3dmpmag.com
www.3dprintforums.com
additivenews.com
additivemanufacturing.com
www.manufacturingtomorrow.com
www.metal-am.com
home.liebertpub.com
additivemanufacturingtoday.com
www.printedelectronicsworld.com
www.printedelectronicsnow.com
… and many morewww.compositesworld.com
wohlersassociates.com
www.3dprintingmedia.network
www.3dnatives.com
www.3dprintpulse.com
www.additivemanufacturing.media

141. 141TM
Consulting Services
AM Conferences and Tradeshows
formnext.mesago.com
rapid3devent.com
www.amug.com
inside3dprinting.com
www.additivemanufacturingforum.de
www.3dprint-exhibition.com
www.rapidtech-fabcon.de www.mpif.org
www.additiveconference.com
www.tctasia.com.cn
+ otherswww.am-ceramics.dkg.de

142. 142TM
Consulting Services
AM Patents

143. 143TM
Consulting Services
“Additive Manufacturing” Patents
Source: www.lens.org
Top applicant companies
2005-2018
Patents/applications (‘publication date') with “Additive Manufacturing” in title, abstract or claims

144. 144TM
Consulting Services
“3D Printing” Patents
Source: www.lens.org
Top applicant companies
2005-2018
Patents/applications (‘publication date') with “3D Printing” in title, abstract or claims

145. 145TM
Consulting Services
AM Investments

146. 146TM
Consulting Services
AM Landscape
Source: amfg.ai/

147. 147TM
Consulting Services
national accelerator and the nation's leading
collaborative partner for technology research,
in additive manufacturing and 3D printing
furthering U.S. development and adoption of
the flexible hybrid electronics
encourages factories across the United
States to deploy digital manufacturing and
design technologies
Program operated by the interagency AMNPO
(Advanced Manufacturing National Program Office)
US Government Investment
consists of multiple linked
Manufacturing Innovation Institutes
(14 institutes / public-private partnerships)
Operates in partnership with the DOD, DOE, NASA, NSF, and the
Departments of Education, Agriculture, HHS, and Labor
…
through
FFRDCs,
Government
Labs,
Agencies

148. 148TM
Consulting Services
Public AM Corporations - Examples
NYSE: DDD NASDAQ: DDYD
NASDAQ: XONE
NASDAQ: MTLS
NASDAQ: ONVO
NYSE: VJET
EPA: PWG
NASDAQ: ADSK
NASDAQ: ALGN
NYSE: PRLB
NYSE: HPQ
FRA: AM3D
NYSE: GE
NYSE: ARNC
see also e.g. (ARK Invest) ETF: PRNT + others

149. 149TM
Consulting Services
Corporate Example 1: GE
• 2016: $39 million Center for Additive Technology
Advancement (CATA) in suburban Pittsburgh
• 2017: became Customer Experience Center (CEC)
– in addition to CEC Munich ($15M)
Example - LEAP engine parts:
19 printed fuel nozzles in the
combustion system (Co-Cr alloy)
• 25% lighter
• Replaces ~20 parts
• ~5x higher durability
2016: GE acquired
ARCAM and Concept Laser
Source: GE, Bloomberg, tctmagazine

150. 150TM
Consulting Services
Corporate Example 2: Siemens
New manufacturing facility of Materials
Solutions Ltd., Worcester, UKSource: www.siemens.com
~$30M
Example: 3D printed blades for gas turbines

151. 151TM
Consulting Services
Corporate Example 3: Arconic
• Arconic Technology Center near Pittsburgh (focus is on
wire or powder for 3D printed aerospace parts)
• AmpliforgeTM Process (combines additive and traditional
manufacturing)
Source: www.arconic.com
3D printed hinge
November 15, 2017
Alcoa Technology Center, Pittburgh
2016
Metal powder

152. 152TM
Consulting Services
Corporate Example 4: HP
• Large scale factory environment for customers and partners to
collaborate on digital manufacturing
Source: www.press.ext.hp.com
“Most advanced research and development facilities
for the next-generation technologies powering
the Fourth Industrial Revolution”
• More than 150,000 square feet of cutting-edge innovation space

153. 153TM
Consulting Services
Contact:
www.teclination.com
daniel@teclination.com