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Smart Parts: Additive Manufacturing for Integrated Electro-mechanical Devices
The document discusses Stratasys's integration of additive manufacturing technologies, specifically Fused Deposition Modeling (FDM) and aerosol jet printing, to create advanced electro-mechanical devices. It covers the advantages of these technologies, including reduced part count, increased functionality, and cost savings, alongside specific projects like the UAV wing. Future work aims to enhance design rules and performance expectations while expanding applications across various industries.
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Smart Parts: Additive Manufacturing for Integrated Electro-mechanical Devices
- 1. Smart Parts: Additive Manufacturingfor Integrated Electro-mechanical Devices
- 2. Who is Stratasys? FDMTechnology + Inkjet Technology
- 3. Today’s Event Host Kim Killoran Stratasys,Inc. Presenters Jeff DeGrange Vice President of Direct Digital Manufacturing Bill Macy Application Development Lead
- 4. Smart Parts/Smart Tools Additivemanufacturing (AM) • Integrated electro-mechanical devices • Printed structures & printed electronics Will cover: • Process • Applications • Advantages • Considerations • Future
- 5. Overview Marrying two AMtechnologies • Fused Deposition Modeling (FDM) • Aerosol Jet Fully printed hybrid structures • Game changer • Streamline production Joint development project • UAV wing • Research & feasibility • In-situ, single process
- 6. Industries & Applications Aerospace Automotive Consumerelectronics Medical • Devices • Appliances
- 7. Advantages Revolutionary • Weight balanced •Reduced part count • Fewer failure modes •AM benefits • Complex structures with more functionality • Less waste • Fewer process steps • Accelerate manufacturing • Flexibility • Cost reduction
- 8. Process Fused Deposition Modeling(FDM) • Thermoplastic materials
- 9. Process Fused Deposition Modeling(FDM) • Thermoplastic materials
- 10. Process Fused Deposition Modeling(FDM) • Thermoplastic materials Process CAD File Manufacture Completed Part
- 11. Process Aerosol Jet • Atomized& collimated • High-velocity stream
- 12. Process Aerosol Jet • Atomized& collimated • High-velocity stream
- 13. Process Aerosol Jet • “Inks”that can be aerosolized • Nano-particle suspensions • Metal complexes • Carbon nanotubes • Organic conductors • Dielectrics • Adhesives • Sensor materials
- 14. UAV Wing FDM material •ULTEM* 9085 • High HDT and Tg • Mechanical strength •Aerosol Jet materials • Nano-particle silver ink (Cabot CSD-23) • UV-curable dielectric (Sun Chemicals 97B)
- 15. Process Design • Part • Electronics Build– FDM • FDM structure Surface Prep • Sand • Soda blast Fixture Surface Prep Print – Aero. Jet • FDM-built fixtures • Self-leveling compound, printed • Conductive ink Sinter Ink • Oven processing Overcoat • Global seal coat • Localize printed coating
- 16. Printed Electronics Sensors/Devices •Circuits • Resistancetemperature detectors (RTD) • Power • Resistive heating elements • Ground planes • Antennas • RF strip lines • Strain gauges • Chemical sensors •Electronic components • Resistors • Capacitors • Inductors • Surface mount connections • Signal
- 17. UAV Printed Electronics Sensors/devices •Antenna • Strain gauge •Circuits • Power • Signal
- 18. Results Signal circuit • LED:printed traces/connections • 100 x 20 μm •Power circuit • 1,000 x 60 μm • Powered 20 V, 0.5 amp motor Details < 30 minutes CTE mismatch cracks
- 19. Results Antenna • Large surfacearea with 0.40 mm gaps • > 1 hour • Transmitted real-time video feed •Strain gauge • 100 μm • Fine conductive traces • Could not bridge surface defects
- 20. Advantages •New design strategies •Electro-mechanical design at digital level •Flexibility • Design optimization • Design change •Cost reduction • Smaller BOM; fewer processes • Eliminate tooling and labor Cycle time reduction • Product development and manufacturing
- 21. Demonstrator •13.5-inch wing •Functional • FDM– 6 hours • Motors (propeller) • Aerosol Jet – 1 hour • LED signal lights • Slot antenna • Integrated contacts
- 22. R&D •Considerations • Surface finish •Surface energy • CTE mismatch • High-temp structure (secondary sintering) • Shift electronic design approach Future work • Design rules • Interface requirements • Performance expectations • Supportability methods
- 23. Future •Technology integration • In-situprocess •Expand applications and industries •Revolutionize products • Biomimicry, organic shapes • Bone | FDM • Nervous system | Aerosol Jet • “We have the technology. We can make him better...stronger...faster”
- 24. More Information www.stratasys.com/webinar_smartparts • Downloadwebinar slides • View webinar on demand Applications • Optomec: Ken Vartanian - kvartanian@optomec.com • Stratasys: DDM Group - ddm@stratasys.com
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