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Tc manufacturing technologies 2018s_v2_10_30_18_s
- 1. TM Consulting Services ADDITIVE MANUFACTURING FOR3-DIMENSIONAL (3D) STRUCTURES (WITH EMPHASIS ON 3D PRINTING) Jurgen Daniel Teclination Consulting Services San Diego, USA www.teclination.com daniel@teclination.com Technology overview (2017/18) Source: APWorks
- 2. 2TM Consulting Services This slidedeck 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. 3TM Consulting Services Conventional vsAdditive 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
- 4. 4TM Consulting Services Problems withConventional 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
- 5. 5TM Consulting Services Advantages ofAdditive 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
- 6. 6TM Consulting Services Cost Comparison:Additive vs Conventional Source: Deloitte Additive manufacturing
- 7. 7TM Consulting Services AM Stock– “Between Hype and Reality” 3D Systems: DDD ExOne: XONE Stratasys: SSYS 2018 Examples of Public AM Companies Source: etrade.com
- 8. 8TM Consulting Services Market andOpportunities for AM Forging Magazine, March 2018 AM is key to the 4th Industrial Revolution IDTechEx, March 2018 MarketResearchEngine, Jan 2017 Predictions heavily depend on assumptions and included technologies
- 9. 9TM Consulting Services AM ValueChain *Design Tools *Information Services (Conferences / Journals) Source: am.vdma.org and Teclination (*) Tool *Test & Eval Plus:
- 10. 10TM Consulting Services Major Risksin 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
- 11. 11TM Consulting Services AM Sectorsand Technologies Electronic Structures Mechanical Structures Biological Structures Food, etc. • Laminated Object Manufacturing • e.g. CompositesLOM • Fused Deposition ModelingFDM • Selective Laser Sintering • Including Direct Metal Laser SinteringSLS • Electron Beam MeltingEBM • StereolithographySLA • Physical Vapor Deposition • e.g. PlasmaPVD • Material Jetting • e.g. PolyJet ™MJ • Printed Electronics • e.g. CompositesPE • Electrophoretic Deposition EPD • Material ExtrusionME • Pick and PlacePNP • Binder Jet TechnologyBJT • Multi Jet Fusion™MJF …
- 12. 12TM Consulting Services Selected Technologies -Electronics - Source: DuPont, TaktoTek
- 13. 13TM Consulting Services 2.5D Technologies Source:www.mid-tronic.de LDS (Laser Direct Structuring) Hot Stamping laser activation and plating
- 14. 14TM Consulting Services Injection MoldedElectronics (2.5D) Source: DuPont, TaktoTek (www.tactotek.com) Using stretchable conductive ink from DuPont In-Mold Structural Electronics Manufacturing Process
- 15. 15TM 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
- 16. 16TM Consulting Services 3D ElectronicsIntegration 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 See also: commercial printers from Voxel8 and Nano Dimension (without component placement) Source: Science, 30 Sep 2016 3D Structural Electronics
- 17. 17TM Consulting Services 3D PrintedElectronics First on-demand 3D-printed electronics service Printed digital thermometer Source: www.nano-di.com DragonFly 2020 printed circuit board printer Printed electromagnet Conductive silver nanoparticle ink (metal) and insulating ink (dielectric polymer)
- 18. 18TM Consulting Services PolyStrata Process(3D) Photo of RF module Source: www.nuvotronics.com mmWave RF circuits compact, high isolation, low loss PolyStrata transmission lines
- 19. 19TM Consulting Services Selected Technologies -Mechanical Structures - Source: EOS
- 20. 20TM Consulting Services Fused DepositionModeling (FDM) filament heated nozzle Source: Manufacturingguide; Makerbot 3DBenchy PLA model (source: hackaday) FDM nozzle (source:3dnatives) Ultimaker RepRapPro Makerbot Replicator Mini+ Rostock Examples of FDM printers Monoprice MP Select Mini (~$200) ULTEM air duct (source: Stratasys) Examples: Filament Materials: thermoplastic polymers (e.g. PLA, ABS, PI, PEI) e.g. Marlin firmware control:
- 21. 21TM Consulting Services Stereolithography (SLA) FormlabsForm 2 (Laser scanning) ~$3,400 (2018) FDM vs SLA 27x magnificationSource: Formlabs Source: formlabs; sparkmaker3d, www.tth.com • Typically 25-30 micron layer thickness • >40micron resolution Photopolymer (resin) • solidified resin: Ø rigid Ø flexible Ø high temperature Ø dental grade Ø ceramic Ø colored Sparkmaker FHD (LED / LCD projection or Masked SLA) ~$279 (2018) Laser galvo-scanning, DLP or LCD projection Example: Laser galvo-scanning
- 22. 22TM Consulting Services Fast CLIPProcess Source: www.carbon3d.com Example: Adidas Futurecraft 4D midsole printed on a Carbon printer Materials: • Elastomeric polyurethane • Silicone • Rigid Polyurethane • Cyanate Ester • Epoxy • Urethane Methacrylate • Dental Carbon 3D CLIP process (Continuous Liquid Interface Production)
- 23. 23TM Consulting Services Selective LaserSintering (SLS) Source: www.eos.info Source: IOPScience: Shirazi, et al., 2015 Aluminium AlSi10Mg vertical tail plane bracket Build volume: 400 x 400 x 400 mm System Example: EOS M 400-4 (4 x 400W fiber lasers) DMLS (Direct Metal Laser Sintering) Ankle orthosis (source: plus media OT) Metals: Aluminum, steel, titanium, nickel, CoCr alloys Polymers: Polyamides, polystyrenes, thermoplastic elastomers, polyaryletherketones
- 24. 24TM Consulting Services Electron-beam Melting(EBM) Lattice skull implant Metal powders: Ti Al alloys, CoCr Gear box Source: www.arcam.com Advantage: void-free deposition
- 25. 25TM Consulting Services Wire-fed 3DE-beam AM Part requires finish-machining Source: www.sciaky.com Electron Beam Additive Manufacturing (EBAM®)
- 26. 26TM Consulting Services Rapid PlasmaDeposition (RPD) Rapid Plasma Deposition (RPD) Process - also: Wire Additive Manufacturing (WAAM) Source: Aviation Week (Oct 2015) and www.norsktitanium.com; prodways-raf.com Robotic Arc-Welding Concept • 50–100 times faster than powder-based systems • FAA-certified process • Deposition rate: up to 10kg/h Similar concept: Rapid Additive Forging (RAF)
- 27. 27TM Consulting Services Binder Jetting Source:ExOne Binder jetting onto layers of powder De-powdering For metal parts: infiltration (e.g. bronze) (Baking/fusing)Binder curing between layers S-Print (e.g. sand molds) M-Flex (metal parts) Build vol: 800 x 500 x 400mm (~30-60 sec per layer) Build vol: 400 x 250 x 250mm Example of a metal part Process • Metal parts or (sand) molds for casting • Suitable for large parts • No heat applied during printing (less stress) • Often more cost effective than other additive methods • Parts are supported by loose powder Powders: sand, ceramics, metals Binder: Phenolic, aqueous, silicate
- 28. 28TM Consulting Services Metal InkjetPrinting Source: vadersystems.com/ Printing of liquified metal (e.g. Aluminum) Magnet-o-Jet™: electromagnetic pulsing of molten metal 1000 droplets per second
- 29. 29TM Consulting Services Concrete Printer Source:contourcrafting.com USC Viterbi (Prof. Khoshnevis) Contour Crafting
- 30. 30TM Consulting Services MICA FreeformProcess Laser sintering vs MICA freeform Fabrication of parts in assembled state Source: www.microfabrica.com formerly Memgen Materials: (similar to Polystrata process by Nuvotronics) Layering process using plating and planarization
- 31. 31TM Consulting Services Ultrasonic Welding CNCcontour 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
- 32. 32TM Consulting Services Fiber Layering/ Weaving Carbon fiber is braided onto an aircraft component 3D-woven composite and the resin transfer molding (RTM) process (Safran and Albany EC) 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 printer embedding continuous carbon fiber Carbon/ceramic fiber-reinforced composite materials - layered or 3D woven structure -
- 33. 33TM Consulting Services Small-Scale AM Source:www.nanoscribe.de & www.laserfocusworld.com Two-photon Polymerization
- 34. 34TM Consulting Services Large Industrial3D 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 (e.g. 3D retail displays) Selective Lamination Composite Object Manufacturing (Sand) Molds for casting Gel Printing (photo polymeric acrylic gel)
- 35. 35TM Consulting Services Combined Additiveand Subtractive Systems 5-axis powder laser deposition 5-axis milling Source: us.dmgmori.com; www.thermwood.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
- 36. 36TM Consulting Services Free-form AdditiveManufacturing Wire Arc Additive Manufacturing (WAAM) Playhouse structure Metal bridge Source: www.branch.technology; mx3d.com Robotic multi-axis 3D printing technology
- 37. 37TM Consulting Services Selected Technologies -Mechanical Structures - with Full Color Source: Phoenix Children’s Hospital
- 38. 38TM Consulting Services Selective DepositionLamination (SDL) Source: www.mcortechnologies.com/ Removing excess paper Mcor ARKe Process Build material: paper X,Y,Z resolution: 0.1mm Photorealistic color
- 39. 39TM Consulting Services PolyJet Printing J7503D printer from Stratasys (360,000 colors) 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
- 40. 40TM 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)
- 41. 41TM Consulting Services • Averageprinting 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 HP Jet Fusion 3D Printing Source: www8.hp.com/us/en/printers/3d-printers.html HP Jet Fusion 500/300 Series 3D with up to 8 agents for color 3D Price: >$50k - 100,000 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)
- 42. 42TM Consulting Services Inkjet Printingonto Surface 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 -
- 43. 43TM Consulting Services Color Surfaceby 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
- 44. 44TM Consulting Services 3D ColorParts 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)
- 45. 45TM Consulting Services Applications Examples (emphasis on3D printing) Source: Widex
- 46. 46TM Consulting Services Application Areas AreaBenefit 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 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 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
- 47. 47TM Consulting Services Electronics -Printed Conductors Source: GGI Solutions Flexible Heaters Printed Electrodes Frequency Selective Surfaces Benefits: • Large Area coverage • Thin flexible form factor • Inexpensive / disposable devices
- 48. 48TM 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)
- 49. 49TM Consulting Services Aerospace 3D printedfuel 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
- 50. 50TM Consulting Services Automotive Small seriesturbo impellers (Metalysis) Mass customization (Honda) Rapid development (Hankook tires) • 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
- 51. 51TM Consulting Services Industrial Casting Plasticmold 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
- 52. 52TM Consulting Services Tooling forComposite Lay-up 3D printing tools (for composite lay-up) offer savings in time and material over more traditional methods Source: www.stratasys.com ULTEM FDM printed in ULTEM 1010 polymer
- 53. 53TM Consulting Services Medical 3D printedTi sternum and ribs implant (chest implant) Source: www.materialise.com/en/blog/3d-printed-cast Source: www.rapidreadytech.com/ - Project 3DHEART (Phoenix Children’s hospital) Source: www.anatomics.com Wedge implantes with OsseoTi Porous Metal Technology to facilitate bone –in-growth Source: www.zimmerbiomet.com patient-specific pediatric heart model, 3D-printed in full color. Light-weight patient-specific 3D-printed cast Implants Surgical Planning Orthopedic Casts
- 54. 54TM Consulting Services Clear DentalAligners • ~50-60 stereolithography (SLA) 3D printers from 3D Systems • Medical-grade, FDA-approved polymer • Over 220,000 custom-made clear aligners produced per day, almost 8 million per year • Align Technology: ~$1.3B in sales (91% of revenue from aligners) Sources: www.invisalign.com, www.forbes.com (Forbes, Sept. 14, 2017)
- 55. 55TM 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 -
- 56. 56TM Consulting Services 3D Bioprinting •Polycaprolactone constructs (biocompatible synthetic polymer) • Cells are suspended in a gel composed of biodegradable materials • After two months, infiltration of the constructs with blood vessels was observed, which is attributed to the presence of microchannels in the construct. Source: Nature Biotechnology volume34, pages312–319 (2016); www.wakehealth.edu/WFIRM/ Source: organovo.com Printing of bio-ink building blocks and inert hydrogel material Live cells printed into human-scale constructs representing bone, muscle, and ear tissue Printed 3D tissues that accurately represent human biology
- 57. 57TM Consulting Services 3D-printed Optics Source:Luxexel.com A revolutionary new approach to lens manufacturing No need for polishing Inkjet based fabrication
- 58. 58TM 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 –
- 59. 59TM Consulting Services Exploratory BodyArmor (Ceramics) www.hotendworks.com/ HDfab 3D printer Source: www.3ders.org/articles/20160322-us-army-and-hotend-works-explore-3d-printed-sintered-ceramics-for-soldier-body-armor.html 3-D Printed Sintered Ceramics (e.g. for Body Armor Applications) In initial ballistic tests the printed material still performed slightly worse than conventional armor
- 60. 60TM 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
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- 62. 62TM Consulting Services Wide Varietyof 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 Jet Fusion Binder Jetting Aerosol Extrusion Source material Process liquid powder filament ‘bulk’ Printing 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
- 63. 63TM Consulting Services FDM FilamentMaterials Sources: www.matterhackers.com; www.stratasys.com/materials/fdm; www.esun3d.net/index.aspx ABS Nylon PEI PLA PET TPU filler 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/ABS blend - High impact strength Carbon fiber, metal, ceramic or magnetic particle filled polymer Micro-porous, e.g. for filters or bio- applications + others
- 64. 64TM Consulting Services FDM Materials- Examples Source: all3dp.com/best-3d-printer-filament-types-pla-abs-pet-exotic-wood-metal/ HIPS Wood / Metal PLA Flexible, TPE, TPU, TPC nGen (Eastman Chemical, Amphora(TM) 3D Polymer AM3300, copolyester)
- 65. 65TM Consulting Services Exotic FDMFilament - Examples Source: www.formfutura.com
- 66. 66TM 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) and ultrafine particles (UFPs) released by FDM extrusion process • UL study (2017) identified nanoparticles and VOCs • Styrene, caprolactam, lactide VOCs most significant (but low levels)
- 67. 67TM Consulting Services Materials inNon-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)
- 68. 68TM Consulting Services AM EnablesNovel Materials Ti-6Al-4V to V Gradient Alloy Source: D. Hofmann, et al., Nature Scientific Reports 4, 2014 (www.nature.com/articles/srep05357) and https://authors.library.caltech.edu/50785/1/S0884291414002088a.pdf Metal-matrix compositesGradient alloys Ceramic-reinforced metal matrix composites & Graded composition alloys by SLD process
- 69. 69TM Consulting Services Novel CeramicsResearch Source: Zak C. Eckel, Chaoyin Zhou, John H. Martin, Alan J. Jacobsen, William B. Carter, and Tobias A. Schaedler (2016) “Additive manufacturing of polymer-derived ceramics” Science 351 (6268), 58-62 SLA Silicon oxycarbide ceramic (Pyrolysis process) - high hardness, strength, temperature capability & resistance to abrasion and corrosion - 10 times stronger than ceramic foam
- 70.
- 71. 71TM Consulting Services AM DesignProcess & 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 Creative Colors CAD Design Mesh repair Blender AD Fusion 360 Meshmaker Rhino … 3D Model capture Kinect Fusion Autodesk Recap … Ansys SpaceClaim, Siemens NX, Autodesk Inventor, SolidWorks … Slicer Software For 3D models also design libraries, such as
- 72. 72TM Consulting Services Example –Coil Structure for FDM Source: Teclination Consulting Design and modeling Print conversion (mesh repair, support structures, slicing) Autodesk Fusion 360
- 73. 73TM Consulting Services 3D DesignFile 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
- 74. 74TM Consulting Services Slicer Software Slicercreates: 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
- 75. 75TM Consulting Services Support Structuresin 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
- 76. 76TM Consulting Services DfAM (Designfor 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:
- 77. 77TM Consulting Services AM BuildSimulation 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)
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- 79. 79TM Consulting Services 3D FabricationServices + many others
- 80. 80TM 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
- 81. 81TM Consulting Services 3D Printingwith 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)
- 82. 82TM 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 • Dissolution of support materialJetting SLS: removal of part from powder bed FDM: solvent vapor smoothing of ABS plastic FDM: removal of support structures
- 83. 83TM Consulting Services Surface Finishing Source:www.metal-am.com; www.dlyte.es; www.belairfinishing.com Importance Conventional Methods Before After finishing Example: Corrosion/oxidation resistance Surface friction and wear Bending fatigue Tensile strength Cellular and biofilm adhesion + others Manual sanding/polishing Abrasive flow machining Shot peening / blasting Vibratory grinding Electro-polishingChemical etching CNC Machining Electrodeposition Spray/dip-coating + others
- 84. 84TM 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
- 85. 85TM 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
- 86. 86TM 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
- 87. 87TM Consulting Services Fabrication Challenges Standardizationof 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
- 88. 88TM 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)
- 89. 89TM Consulting Services Data Securityand 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
- 90. 90TM Consulting Services Testing andStandards Source: ASTM
- 91. 91TM 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
- 92. 92TM 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)
- 93. 93TM Consulting Services Other Noteworthy Technologies Source:Advanced Materials / ETH Zürich
- 94. 94TM Consulting Services 3D Pottery Source:www.deltabots.com, www.instagram.com/explore/tags/potterbot 3D PotterBot Clay printer
- 95. 95TM Consulting Services Printed Textiles April2015 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
- 96. 96TM 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
- 97. 97TM 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
- 98. 98TM Consulting Services ‘Open-ended AM’Concept Source: www.dedibot.com 3D printing using Unmanned Aerial Vehicles (UAVs) UAVs as the print extrusion units to break the limitation of size
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- 100. 100TM Consulting Services Additive ManufacturingResources 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
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- 102. 102TM Consulting Services national acceleratorand 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
- 103. 103TM Consulting Services Public 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
- 104. 104TM Consulting Services Corporate Example1: 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
- 105. 105TM Consulting Services Corporate Example2: Siemens New manufacturing facility of Materials Solutions Ltd., Worcester, UKSource: www.siemens.com ~$30M Example: 3D printed blades for gas turbines
- 106. 106TM Consulting Services Corporate Example3: 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
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