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Similar to Specialist Manufacturing SME 24 July 2012
Similar to Specialist Manufacturing SME 24 July 2012 (20)
Specialist Manufacturing SME 24 July 2012
- 1. A Quick Thumbnail Sketch Mark Swan, 24 July 2012 © MHS Consultancy Services
- 2. Also known as ‘Additive Manufacturing’ Key Steps: 1. Import a digital design From any Computer Aided Design (CAD) tool 2. Slice it into layers As thin as 16 microns thick (currently) 3. ‘Print’ each layer in turn Using metal powder, plastic tube or pellets, liquid © MHS Consultancy Services
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- 4. 3D Printer Manufacturers Airwolf – USA Fabbster – Germany MakerBot Industries – USA Afinia 3D – USA Objet – Israel EOS – Germany Arcam – Sweden 3D Systems (the Cube – for $1300!!) 3D Print Service Providers Kraftwurx – USA 3T RPD – Newbury, UK Cybaman Technologies – UK Users EADS – Europe Materialise – Belgium GE – US, UK United Technologies – US, China, Ireland © MHS Consultancy Services
- 5. Defence Aerospace Automotive Medical Tooling & Automation Architectural Consumer goods Any prototyping © MHS Consultancy Services
- 6. Additive Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders, ceramic powders Direct metal laser sintering (DMLS) Almost any alloy metal Fused deposition Modelling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (OM) Paper, foil, plastic film Electron Beam melting (EBM) Titanium alloys Powder bed, inkjet, & plaster-based Plaster © MHS Consultancy Services
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- 9. A Telling Graph Volume Traditional 3D Printing, or Production ‘Subtractive’ ‘Additive’ Manufacturing Manufacturing Future Trend Line of Least Unit Cost Unit Cost © MHS Consultancy Services
- 10. Next Steps 1. Confidential to my client 2. Confidential to my client 3. Confidential to my client © MHS Consultancy Services
- 11. Back up Slides Follow here…………. © MHS Consultancy Services
- 12. Selective Laser Sintering 1. Originally patented at the University of Austin in mid-1980s 2. Uses high power, pulsed laser 3. Good for plastic, ceramic and glass powders 4. Full melt, or partial melt 5. Does not require support structures © MHS Consultancy Services
- 13. Direct Metal Laser Sintering 1. Originally developed by EOS in Germany 2. Uses high power, fibre optic laser 3. Good for metal powder, esp. steel alloys 4. Full local melt 5. Layers down to 20 microns 6. May require support structures 7. May require surface polishing/finishing 8. Aerospace, dental, medical © MHS Consultancy Services
- 14. Fused Deposition Modelling 1. Originally patented by Scott Crump, late 1980s 2. Software by Stratasys (.stl files), also FDM is their trademark; also RepRap project & FFF 3. Extrudes wire or plastic filament 4. Nozzle melts material into beads 5. Full local melt 6. Layers down to 40 microns 7. May require support structures 8. Aerospace © MHS Consultancy Services
- 15. Stereolithography 1. Originally patented by Charles Hull in 1986 2. Uses concentrated U/V light focused on a vat of liquid photopolymer 3. Commercialised by 3D Systems (Hull’s company), in Ca 4. The U/V light cures and solidifies the molten polymer 5. Layers down to 50 microns 6. Support structures always required 7. Manufactured parts require cleaning and curing as post operations 8. Cost in range $100k to $500k / machine 9. $80 to $210 / litre of material © MHS Consultancy Services
- 16. Laminated Object Manufacturing 1. Originally developed by Helisys Inc, now Cubic Technologies 2. Uses a laser to heat layers of adhesive coated paper, plastic or metal laminates 3. Layers down to >50 microns 4. Support structures not required 5. Manufactured parts may require waste removal as a post operation 6. Low cost paper models with wood strength characteristics © MHS Consultancy Services
- 17. Electron Beam Melting 1. Originally developed by Arcam in Swden 2. Metal powder is melted by an electron beam in a vacuum at 700 oC to 1,000 oC 3. Makes very strong components 4. Good for Titanium (has high affinity for Oxygen), and other highly reactive materials 5. Layers down to 50 microns 6. Support structures not required 7. No additional operations required 8. Higher cost than other techniques, e.g. DMLS 9. Medical implants, aerospace (turbine blades) © MHS Consultancy Services
- 18. Summary SLS DMLS FDM, (aka. SLA LOM EBM FFF) Employs Laser Laser Heated U/V light on Layered Electron beam, extrusion liquid polymer adhesive high temp, nozzle coated vacuum Who? EOS Germany, EOS Germany Stratasys, Ca, 3D Systems, Helisys, Ca Arcam, 3D USA 3D USA Airwolf, Objet Sweden Afinia, fabbster, Makerbot, 3D Good For Plastic, Metal powder Wire, plastic Polymer Paper, plastic, Highly ceramic, glass filament laminates reactive metals, e.g. Ti Melt? Partial Full Full n/a n/a Full Layers? 20μ 40μ 50μ (Objet >50μ 50μ claim 16μ) Support No Maybe Maybe Yes No No Structures Costs Low Medium Low Medium Low High Post Polishing Cleaning and Waste removal None Operations? curing Applications Aerospace, Aerospace Automotive, Aerospace, dental, dental, medical medical medical © MHS Consultancy Services
Editor's Notes
- As 3D Printing technology improves, so the unit costs will reduce. Manufacturers may choose to switch to 3D manufacturing for ever larger volume runs.