Inside 3D Printing: Reshaping Manufacturing: Understanding the 3D Printing Process
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This workshop will delve into the overall process of making three-dimensional solid objects from digital designs and explore the various powders, binders and support materials that allow for the geometric flexibility inherent to additive manufacturing. We’ll also examine the course of moving from original concept via virtual blueprint (CAD or animation modeling software) to finished product along with all the pre-preparation and post processing steps required to make a quality printed piece.
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Inside 3D Printing: Reshaping Manufacturing: Understanding the 3D Printing Process
- 1. Reshaping Manufacturing Understanding the 3D Printing Process
- 2. Christina Chun 3D Printing & 3D Design Evangelist christina.chun@sculpteo.com @christinachun
- 3. ●History ●Today ●Processes ●How to get started ●Questions
- 4. are familiar with the
- 6. Ford Model T Assembly Line -December 1, 1913
- 7. The first 3D Printed part was made and Chuck Hull of 3D Systems invented a process called Stereolithography.
- 8. is.... the way weand ideas
- 14. ●Raised $34k ●3D Printed Enclosure ●Batch Printing
- 15. ●Raised $99k ●3D Printed Enclosure ●Batch Printing
- 16. “Thanks to 3D printing, pieces are really quickly available, which means we can test them within a few days, and make changes reactively.”
- 17. “3D Printing is an obvious solution for a start-up, especially if you follow the lean start-up approach. It allows you to cut time and resources on prototyping, thus to achieve a minimum viable product in no time.”
- 19. ●Unlike CNC machining which is a subtractive process, 3D Printing or Additive Manufacturing is an additive process. ●Layers of material are laid down or built upon, layer by layer to build the object.
- 20. vs
- 21. &SLA ●Resolution ●Build Volume ●Material ●Finish Quality ●Cost ●Support Structures ●Parts Cleaning ●Low Temp Melting
- 22. & ●Gradient Light ●Maintenance ●Material ●Printer Size ●Support Structures ●Parts Cleaning
- 23. ●Powder ●Laser ●Vacuum ●Sandblasted
- 24. &SLS ●Resolution ●Build Volume ●Materials ●Lightweight ●Cost ●Hollow to save money ●Plastic is Non-recyclable ●Texture
- 25. ●High Detail Resolution ●Metal Powders ●Complex Geometries ●Aerospace, Dental, Medical and more
- 26. & ●Rapid Prototype ●Small/Complex Parts ●Metals ●High Cost ●Support Material ●Labor Intensive Finishing
- 27. ●Powder ●Liquid Binder ●Vacuum ●De-powder ●Infiltration Process
- 28. & ●Fragile ●Color Issues ●Not Food Safe ●Full Color ●Life-like Models ●Sculptural
- 29. vs
- 30. & ●Clogged Nozzles ●Visible Layers ●Support Removal ●Functional Prototypes ●Maintenance ●Materials
- 31. ●High Detail Resolution ●Metal Powders ●Complex Geometries ●Aerospace, Dental, Medical and more ●Knife ●Heat/Glue ●Machined Drilled Peel off
- 32. ●High Detail Resolution ●Metal Powders ●Complex Geometries ●Aerospace, Dental, Medical and more& ●Material Cost (Paper) ●Thick layers & Fast ●Niche Applications ●Stair Stepping/Layers ●Absorbs Moisture ●Accuracy
- 33. High Detail Resolution Metal Powders Complex Geometries Aerospace, Dental, Medical and more ●Metal Powder ●Vacuum System ●Reactive Materials ●Requires Support ●Fully Dense ●Void-free ●Strong
- 34. ●High Detail Resolution ●Metal Powders ●Complex Geometries ●Aerospace, Dental, Medical and more& ●High Density ●Less Thermal Stress ●Niche Applications ●Time/Cost ●Limited ●Surface Quality
- 37. ●Professional CAD Software ●Popular 3D Modeling Packages ●Open Source, Free & Cloud Apps
- 38. Find a Visit
- 39. ●Sketches ●Technical Drawings ●Concept Artis better thannothing!
- 41. not
- 43. Check the actual size!
- 44. Export your 3D model! File Formats .stl, .ply, .obj, .wrl etc. Texture Images Vertice Color
- 45. ●Watertight ●Wall Thickness ●Stress Areas ●Articulation ●Moving Parts ●Overhangs
- 46. ●Upload ●Auto Repair ●Materials Check
- 49. From Concept to 3D Print ●Change the orientation ●Slice the model. ●Auto generate supports or manually add your own. ●Send the file to the printer to print or upload to a service.
- 51. ●History
- 52. ●History ●Today
- 54. ●History ●Today ●Processes ●How to get started
- 55. ●History ●Today ●Processes ●How to get started
- 56. reshaping the way that we....
- 57. Christina Chun 3D Printing & 3D Design Evangelist christina.chun@sculpteo.com @christinachun
- 58. http://en.wikipedia.org/wiki/Industrial_Revolution http://online.wsj.com/articles/roots-of-a-high-tech-revolution-1409066696 http://www.studiofathom.com #Case © Fathom http://www.thingiverse.com/make:36841 http://www.thingiverse.com/thing:185125 https://www.etsy.com/shop/stylesbyana http://www.sculpteo.com/en/materials http://www.sculpteo.com/en/transferring-3d-file/ http://en.wikipedia.org/wiki/Electron_beam_melting http://en.wikipedia.org/wiki/Selective_laser_sintering http://www.arcam.com/technology/electron-beam-melting/ http://www.cokreeate.com/ https://learn.adafruit.com/2014-halloween-3d-printed-projects-roundup Autodesk -http://www.123dapp.com http://www.vecteezy.com -freevector/PackyArenas/zhaolifeng/VectorizeNow/Shmector iPhone Blueprint © Apple Inc. 3D Printer Images © 3D Systems, Stratasys, Makerbot, Form Labs, Kudo3D, B9Creator, MCor, Arcam, EOS Autodesk, Netfabb
Editor's Notes
- Outline Before we dive deeper into 3d printing and the 3d printing processes, I'd like to discuss the history of manufacturing.
- The 1698 Savery Engine 1785 Power Loom. Used Water Maudslay screw-cutting lathes of circa 1797 and 1800 Nasmyth milling machine 1829-1830 The Industrial Revolution created a demand for metal parts used in machinery. This led to the development of several machine tools for cutting metal parts. Enabled clock, watch and scientific instrument makers to batch-produce small mechanisms. Machines started to help and take the place of artisans with the invention of the Steam Engine, Hydraulic Power, Trains,etc…..
- 1910 Model T Ford, Salt Lake City, Utah. Henry Ford, who perfected the assembly line by installing driven conveyor belts that could produce a Model T in ninety-three minutes
- Optometrist’s eyecup Photopolymer resin cured with UV light or lasers. Created the STL (Stereolithography) file format Created Digital slicing and infill strategies common to many processes today.
- Entrepreneurs, inventors, math/science, marketing, prototypes, direct to market products. Individuals/Groups Schools Small Businesses Startups Companies Governments
- Jewelry, Eyewear, Food, Military, Industrial Deisgn Biotech: Human tissue replacement. Footwear: Nike 3D printed cleats for the NFL Adidas - We Print Originals campaign in Hong Kong Aerospace – Jet engines Food – 3D Printed Chocolate, Pancakes
- #CAST project - customize your broken arm cast with personal messages via social media 3DPCase.com – Customize phone cases using images. Companies would need to create a new mold for every different part they want to produce. Any iterations would need a new mold made. With 3D Printing, you don’t need a mold.
- You can bring a prototype to market much faster than with traditional methods of prototyping. Designers can add their designs to online marketplaces to sell as soon as they’re ready. Companies would need to create a new mold for every different part they want to produce. 3D Print an injection mold. You can update the computer model whenever changes are needed.
- You can bring a prototype to market much faster than with traditional methods of prototyping. Designers can add their designs to online marketplaces to sell as soon as they’re ready. You can update the computer model whenever changes are needed. Mobius strip - 36 interlocking mobius strips that weave. Create shapes that would otherwise be impossible to create with traditional means.
- Quarterly.co – paid subscription Receive a curated boxe by an influential person every 3 months i.e. Pharrell Williams Limited Edition Perspective Chair by Pharrell Williams 1500 3D Printed
- Italian based Startup, Wireless sensor They tried an FDM printer to prototype with but it lacked precision. First series Batch Print - Great material quality & strength. The Italian national Soccoer team used BEAST to monitor the players training for the World Cup.
- Several iterations before final batch printing of 40 samples. Batch printing saved 70% per unit. Dimensionally accurate. Fit circuit board in the enclosure.
- Polyamide material - SLS process = High precision parts. To be authorized to fly within city limits drones had to weigh less than 4 kilograms plus parachute. Weight was about 0.9g per printed part. Traditional manufacturing = higher production costs. Can create complicated designs that Hexadrone can’t do with traditional means.
- First bought an injection mold. Parts were wrong Spent a lot of $$$ and didn’t have any $$$ for a new mold. Turned to 3D Printing and within a few iterations, his product was finalized. Sold 2k+ direct to customer. Will not manufacture using traditional means. 3D Printing is the way to go and he won’t change this business model.
- Own a 3D printer? Which one? Do you know anyone who owns a 3D Printer? Have you ever used an Industrial 3D Printer? What did you think of the process?
- Industrial vs Consumer Photopolymer Platform submerges, UV Laser creates parts layer by layer, each cross section is cured. Uses a VAT or container to hold photopolymer liquid. Objet500 Connex/3D Systems Projet 7000 Popular among new entrepreneurs to develop low cost solutions, raising funds via Kickstarter/Indiegogo. i.e. Form 1, Pegasus Touch
- 16microns vs 25 microns Smooth surface, hard/flexible/translucent/opaque, multimaterial color, WAX Complex, Articulated parts, Prototypes Can be casted. 100 degrees F Low Temp Melting Point Flexible Resins can rip if stretched too much.
- Resolution. Cure resin at different levels. SLA can have difficulties changing the laser components. DLP, you can change the bulb. Use same resins as SLA Titan1 & B9 Creator Kickstarters
- SLS - 60-150 microns A build chamber has a layer of powder deposited and a laser draws the cross section layer of the part/item. Uses a laser to sinter powdered material (ie metal alloys). Self supporting powder Polish/Dye/paint
- Thermoplastics, *Metal & Ceramic Powders Plastics can be dyed in various colors, 10 by sculpteo Alumide = Plastic+Alluminum = Less expensive than DMLS but have thick layers. Doesn’t share same characteristics as Metal.
- DMLS was developed by EOS. Down to 20-40 microns layer by layer. Titanium, Aluminum, Inconel, Stainless Steel, Cobalt Chrome Maraging Steel Fiber optic laser to melt the metal powder. Material dispensing platform, a build platform and a recoater blade to move new powder over the build platform. Add powder, level build plate. Oxygen levels must be at a certain level. Support material removal using tools or CNC equipment
- GPIprototype / incept3d.com/ Develop new products faster Create prototypes, molds and functional test parts. Cost effective for small parts vs a larger part that didn’t have complex geometry, traditional means = cheaper Labor intesive to finish the parts i.e. polishing, machined, welded, heat treated, CNC
- Full color - sandstone powder base Thin layer of powder is spread across the build area Inkjet print head moves along a fast axis over a bed of powder, deposits liquid binding material.
- Expensive vs SLS pro Can't be completely solid. Shiny surface. Soluble support. Ultm plastic strength Nylon, flex need a minimum wall thickness of 2mm in order to print
- Makerbot, Cube, UP! Plus, etc.. World’s first 3d printed car by Local Motors Extrusion Thermoplastics (PLA, ABS), HDPE, Sugru, Modeling Clay, Plasticine, RTV Silicone, Precious Metal Clay, Edible Materials, etc. FDM (Fused Deposition Modeling) / FFF (Fused Filament Fabrication) Popular DIY Being sold on Amazon, Radioshack, Walmart, etc. Educators Syringe/Pump Nozzles for frosting, batter, food, paste, glue and cement. Functional Parts, low-cost prototypes. research...
- Flexible, Soluble, Glow in the Dark, Bronze Fill, Woodfill, Opaque, Clear Low cost to print. Support material can be hard to remove depending on the printer. Clogged nozzles or extruder jams due to dirt, switching of multiple materials constantly, etc..
- Feed roll - heat applied, melts coating to bottom. After bonding a knife or laser cuts the sheet of material. Look/Feel like wood. Paper, Metal Foil, Plastic Film, Ceramic tape, Ceramic tape. Paper is used for proof of concept parts. Metal sheets are cut/stacked for tooling. Polymer sheets Metal Foil - Ultrasonic Additive Manufacturing.
- Biomedical/Fluidic instruments/components. Stamping Dies, Ceramic Parts. Diagonal cuts to avoid some stair stepping. Inaccurate/warp (moisture)
- Electron Beam Melting - Developed by Arcam AB in Sweden. Controlled vacuum system to maintain a certain level of pressure. Reactive Materials with a high affinity for oxygen - Titanium. Support - moves heat away from where the powder is melted. Reduces thermal stresses/prevents warping. Aerospace, Aeronautic, Biomedical (trabecular structures to maximize bone migration in prostheses), Motorsport (frame construction reduce time for the production of very complex shapes)
- Advantages: extremely complex geometry Metallurgical characteristics similar to heat treated material that allows you to avoid costly heat treatment phases and save time Time to market goes from months (traditional) to a few days (1-2weeks).
- ..do you need to get started?? ...do you do? …..where do you start?
- Contains the data → Printer → Printed Object Data=3D Model → STL, OBJ, WRL, etc. Before you can print, Prepare the file for 3D Printing If you don’t have a 3D file, create one.
- Yourself AutoCad, Solidworks, Catia, Rhino3d, Autodesk Inventor, Alias 3DS Max, Maya, ZBrush, Cinema 4D, Modo Sketchup, Blender, Sculptris, OpenSCAD, FreeCAD, Meshmixer Tinkercad, Autodesk 123D Design, Sculpt, Creature
- Behance, DeviantArt CGTrader, Thingiverse, MyMiniFactory
- Define the project, concept or design brief. Ideas on paper. Define the concept. Refer to. Iterate, make changes. Measurements, clearance issues like hinges or things like buttons etc. Special requirements, etc
- Ideas on paper. Ideas evolve, take shape.
- If you know the material you would like to 3d print in or want to 3d print in a lot of different materials,then you should adhere to the rules of each material.
- post processing - details can be lost wall thickness layer thickness fragility from overhangs or thin areas http://www.sculpteo.com/en/materials
- Build area, if larger, scaled/mult-parts. Assembly. http://www.sculpteo.com/en/transferring-3d-file/
- Build area, if larger, scaled/mult-parts. Assembly. http://www.sculpteo.com/en/transferring-3d-file/
- Minimum .5mm clearance between adjacent parts. Thin areas, areas that bare a lot of weight. 45 degree rule, support material. can change quality of print. Use auto tools from Sculpteo or Netfabb or use Meshlab’s features ie. removing non manifold faces, flipped normals, hole filling http://www.sculpteo.com/upload https://netfabb.azurewebsites.net/ http://meshlab.sourceforge.net/ http://www.sculpteo.com/en/transferring-3d-file/
- Check to see what auto repairs have been done by Sulpteo or you can manually edit/fix your model in a 3d software. http://www.sculpteo.com/en/transferring-3d-file/
- Batch Control – with 20+ units to be printed, you can see how much you can save per unit with this feature. You can see a benefit with 5+ but it’s more significant at 20+. Hollowing – this feature is really helpful in lowering your cost be allowing excess material escape. Only use this if you can live with a few holes in your model.
- View from all angles, inside/out before printing. Algorithm analyzes the models solidity depending on material. Minimum thicknesses + solidity threshold. ie. Sandstone material is more fragile than plastic
- Depending on the printer, you will need to create a build file.
- helmet painted using anthracite gray for metallic parts and clear night blue for the crest. Final touches made by light dry brush strokes using pure white. Sand, glue, Epoxy Resin (strength), mill/drill holes Buttons used an acetone brush-on method of smoothing the ABS. Same with the corral buttons on the right.
- The Industrial Revolution. How these new inventions have helped us grow.
- How tools today have reshaped the way that we manufacture.
- SLA, DLP, SLS, Binder Jetting, DMLS, Laminated Object Manufacturing, Electron Beam Melting The different materials, processes and levels of 3d printing.
- 3D File to 3D Print – Blueprint, Design, Model, Create or Find a designer.
- Best Ideas come to light when we work together. How can we move forward together?
- Feel free to keep in touch and ask me any questions! If I don’t know something, I can try to find out the answer(s) for you!