3d printing with ptfe - spe automotive
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3D Printing with PTFE
SPE ACCE Conference 2020
Sam Reiss
Application Development Engineer
September 2020
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Sam Reiss
Sam and the additive manufacturing team are leading
the commercialization of the first ever 3D printing
technology that can print pure PTFE parts, enabling
novel customer applications through cost-effective
manufacturing of part geometries unable to be
produced through any other means.
Sam has been with 3M since 2014, in multiple roles
including regulatory and product development. He
holds both a BS and MS in Nuclear Engineering from
the University of Wisconsin – Madison.
Senior Application Engineer
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Why PTFE?
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Properties of PTFE
Nearly universal chemical resistance
Wide service temperature range
of -200°C to +260°C
Excellent dielectric properties
High limiting oxygen index (LOI)
Low surface energy
Low coefficient of friction
Outstanding weathering & UV stability
Atomizing Nozzle
No dripping or flow above its melt
temperature
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3M™ Dyneon™ fluoropolymers portfolio
Fluorothermoplastics
Fluoroelastomers
Polytetrafluoroethylene (PTFE)
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3M™ Dyneon™ fluoropolymers portfolio
Fully fluorinated Partially fluorinated
3M™ Dyneon™
FEP
TFE + HFP
3M™ Dyneon™
PFA
TFE + PPVE
3M™ Dyneon™
ETFE
TFE + Ethylene
3M™ Dyneon™
PVDF
VDF
3M™ Dyneon™
THV
TFE + HFP + VDF
Carbon (C)Oxygen (O)Fluorine (F) Hydrogen (H)
3M™ Dyneon™
PTFE & TFM ™ PTFE
TFE + PPVE (<1%)
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Current Automotive Applications
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3M™ Dyneon™ Fluoroelastomers for fuel, engine,
and driveline sealing
3M™ Dyneon™ Fluorothermoplastics for low-
emission multilayer fuel tubes & hoses
3M™ Dyneon™ PTFE micropowders as polymer
additives for enhanced tribological behavior/
increased wear resistance
PTFE compounds for dynamic seal rings
Fuel Sender Unit Seal
Throttle Body Gasket
Air Intake Manifold Gasket
Crankshaft Seal
Fuel Filler Neck HoseCharge Air Cooler
Gasket
Transmission Shaft Seal
Cylinder Head Gasket
Example Part Images Courtesy A2Mac1
Current Applications for Fluoropolymers in Automotive
Valve Stem Seal
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Why 3D Printing?
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Reducing Limitations
Traditional manufacturing Additive Manufacturing
• Limited design flexibility with traditional techniques
• Start up costs
Design freedom
• Custom, complex parts
• Novel, functional designs
• Part consolidation
• Miniaturization
On-demand
• Enhanced response to customer, market demand
• Eliminate inventory
Digital manufacturing
• Factory of the future and digital thread alignment
Product development
• Accelerated product development cycles
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The Process
Part & supportdesign
Tailored formulation
3D printing Drying Thermal treatment
Finishing
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Process Parameters and Constraints
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Part DimensionsMaximum: 120mm x 80mm x 80mm
Tube Suspension Fixture
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Design for Printability - Wall Thickness, Hollowing & Supports
Minimum: 0.2 mm, Maximum: 7 mm
2-4 mm are recommended
Hollowing Designed-in reinforcements
Coring and fillets
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Aspect RatioMaximum: 4:1
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Holes & Cavities
Gyroid
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Surface Features
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Application Deep Dive
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Static Mixer Application: Liquid Mixing (Static)
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Agitation ImpellerApplication: Liquid Mixing (Dynamic)
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Case Study: Intelligent Imaging Innovations
Original Basic Sample Holder Design
(Machined PTFE)
Enhanced Final Additive Manufacturing Custom
Sample Holder Design
Industry: Laboratory testing equipment
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Case Study: PennState Health Milton S. Hershey Medical CenterApplication: Olfactometry
Original AutoCad Design from Bestgen, A. K., Schulze, P., Kuchinke, L., Suchan, B., Derdak, T., Otto, T., ... & Sucker, K. (2016). An extension of olfactometry methods: An expandable, fully automated, mobile, MRI-compatible olfactometer. Journal of neuroscience methods, 261, 85-96.
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Case Study: Custom Reaction Chamber for Polymer ForgeIndustry: Optoelectronics
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Next Steps
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Visit our website to learn if your application is a good fit for 3D printed PTFE.
Take the Tech Check
Download the Design Guidelines
Submit your designs for quoting and fabrication
Contact us for further support
Contact Sam directly, [email protected]
Are you ready to go 3D?
3m.com/3dprinting 3m.co.uk/3dprinting 3m.de/3dprinting
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Questions?