Advanced Applications

Presented by:

James Janeteas,Cimetrix Solutions Inc,

Additive Manufacturing 101

• Founded in 1993

• Full Line Stratasys Partner for Canada

• Strong Design / Manufacturing background

• Service Commercial and Academic verticals

• Business based exclusively on Stratasys Products

Who we are

Dental

Automotive DefenseAerospace

Specialize: High Requirement Driven Applications• Dimensional properties

• Mechanical properties

• Process repeatability

• Predictability

• Hot/Cold operating conditions

• Long product service life

Who we are

Medical

Terminology

• 3D Printing

• Rapid Prototyping

• Rapid Tooling

• Rapid Technologies

• Rapid Manufacturing

• Advanced Manufacturing

• Additive Fabrication

• Additive Layer Manufacturing

• Direct Digital Manufacturing

• Direct Manufacturing

Known by many names

Terminology

• Additive Manufacturing

– Term covering all technologies

– Term covering all applications

– Replacement for “RP” and “Additive

Fabrication”

• Definition:

– Collection of technologies, directly driven

by CAD data, to produce 3-Dimensional

physical models and parts through an

additive process.

Defined by ASTM : As the process of joining materials to

make objects from 3D model data. Usually layer upon layer as

opposed to subtractive methodologies.

ADDITIVE MANUFACTURING

Professional Grade

Highest Performing Systems

3D PRODUCTION

SYSTEMS

• $50k - $500k & up

• Optimized for performance

• Broad application solution

• High performance materials

3D PRINTERS

Professional Grade

Solution

• $7k - $50k

• Simple and easy to use

• Optimized for form, fit and

function

Solution Classification

3D PRINTERS

• $2k - $7k

• Simple and easy to use

• Optimized for form

Most Affordable

Hobby Grade Solution

Conceptual

Models

Functional

Prototypes

Manufacturing

Tools

End-Use

Parts

3D PRINTERS

3D PRODUCTION SYSTEMS

Performance Requirements Increase

Solution Classification

• Envelope size

• Materials

• Accuracy

• Throughput

• Resolution

• Customization

• Repeatability

• Flexibility

• Complex Part Fabrication

Differentiators Enablers

Production Series

Technology Assessment

Remove SupportsPre-Process Manufacture1 32

Typical Build Process

Fused Deposition Modeling : FDM• Dual extrusion head technology

• Deposit liquefied build and support

• Precise Additive Fabrication

• Advanced materials

• Advanced mechanical properties

• Safe, Simple, Clean process

FDM Process

Remove SupportsPre-Process Manufacture1 32

FDM Materials

Material Options

ABS-M30

ABS-M30i

ABS-ESD7

Nylon 12

PC-ABS

PC (Polycarbonate)

PC-ISO Class 6 :

Pharmaceutical

Ultem 9085 *

Polyphenylsulfone PPSF

Support Material

*Ultem 9085 is a trademark of SABIC Innovative Plastics IP BV.

Engineering Grade Thermoplastics

POLYJET- Polyjet Matrix

• Multiple extrusion head technology

• Deposit liquefied build and support

• Precise , High Resolution

• Advanced photo cure materials

• Composite Material Capability

• No Post Curing

• Safe, Simple, Clean process

Material Options

Vero Family – Rigid Opaque

FullCure 720 - Rigid

Transparent

Durus White - Polypropylene

like

Tango Family - Rubber Like

RGD5160-DM - ABS Like

RGD525 – High Temp

VeroDent – Dental

MED610 – Rigid

Biocompatible

Technology Assessment

FDM Material Properties

ULTEM 9085 Aerospace & Defence Grade

• SABIC Engineered

• Certificate of Conformance available

• High tensile and compressive strength

• High operating temperature

• Passes FAR 25.853

*Ultem 9085 is a trademark of SABIC Innovative Plastics IP BV.

FDM Materials

Aerospace Grade Thermoplastic

Passes FAR 25.853

Vertical burn test

FST zero rating

UL94 V0

Radiant Heat OSU 55/55 PASS

FDM MaterialsUltem 9085

Off Gassing

ASTM E595

PASS

Total Mass Loss (

TML)

0.41 % 1.00 %

Collected Volatile

Condensate

Material (CVCM)

<

0.01%

0.10 %

Water Vapour

Recovery Report

(WVR)

0.37 Report

Result Limit

“With Fortus, we can now develop and test innovative designs - and if

necessary change them quickly without halting the production process.

This means we no longer need to make ‘functional’ compromises.”Igor Mega, Evektor

Czech Aircraft Company Saves up to 80% of

Prototyping and Production Costs Using Fortus

Functional Prototypes-

End Use Parts

Needed time-to-market reduction

• CNC Process added too much time to design and prototype process

• Outsourced parts were big and costly

• Process did not allow for unplanned projects

Fortus for in-house prototypes

• Large capacity required

• Ultem 9085 for end use part production such as blow pipes

Development Costs reduced up to 80%

• Accelerated product development

• Prototyping costs also substantially reduced

• Can develop more complex and innovative designs – make changes without halting production

Conceptual Models -

Functional Prototypes

Established / Traditional

(Design)

Direct Digital Manufacturing

(Manufacturing)

Additive Manufacturing

Primary Applications

The Sweet Spot

Conventional Mfg.

Additive Mfg.

Quantity

Com

ple

xity

Sweet SpotHigh Complexity, Low Quantity• Specialty End Use Parts

• Rapid Tooling

• Low Volume Production

Direct benefits

Financial gain

• Lowering costs

• Increasing profits

Time advantages

• Decreasing time-to-market

• Decreasing cycle time

Indirect benefits

Design freedom

Product redesign frequency

Rapid response

Manufacturing Tools

Assembly Aids

Examples:

• Jigs

• Fixtures

• Check gauges

• Drill / rivet guides

• Go / No-Go gauges

• Alignment tools & guides

• Robotics- End of Arm

• Shot Peen, Grit Blast, Paint

masking tools

• Surrogate Parts

Manufacturing Tools

Emblem Headlight Alignment

Cubing Device Gage Checker

Assembly Aids

Benefits:• Custom interfaces for complex surfaces

• Minimize part handling damage

• Optimized for access without increased

costs

• Light weight ergonomic

Enables:

• Reduced dependency on external suppliers

• Overnight fulfillment of new tooling

requirements

• Lights out fabrication

• Digitally mastered coordinated tooling

Resulting in:

• Reduced cycle times up to 85%

• Improved quality

Manufacturing Tools

“FDM is taking on increasing importance as an alternative manufacturing

method for components made in small numbers”

-Gunther Schmid, BMW

Manufacturing Jigs and Fixtures with FDM

Manufacturing Tools

Conventional fixture making• Cost and time requirements were high

• Lack of design freedom reduced productivity

FDM used to produce fixtures• Have over 400 assembly fixtures

• Several built on Fortus system

FDM enhances ergonomics• Organic shapes maximize performance

• Sparse fill cut weight 72%

Time and cost savings • Typical cost reduced from $420 to $176

• Typical lead time reduced from 18 to 1.5 days

Method Cost Time

CNC

Machining

Aluminum

$420 18.0 days

Fortus

system

ABS-M30

$176 1.5 days

Savings$244

(58%)

16.5 days

(92%)

Manufacturing Tools

Fabrication Tools

• Sheet Metal Forming

• Composite Tooling

• Fibre Winding

• Coordinated Tool Families

• Thermoform Tools

• Pulp Mould Tooling

• Tooling Masters & Patterns

• Injection, Blow Moulds

• Sand Casting

• Investment Casting

Manufacturing Tools

“I can program an FDM part in 10 minutes while typical CNC

program takes four hours to write”

-Jacob Allenbaugh, Manufacturing Engineer, Piper Aircraft

Piper Reduces the Cost and Leadtime of

Hydroforming Tool to Build a personal Jet

Manufacturing Tools

• Program FDM part 10 min vs. 4 hrs CNC

• No operator attendance

• Less material waste

• Producing hundreds of aluminum structural components

• Inner frame components, gussets, brackets, skins etc.

• FDM as the manufacturing process

• PC Material 3000 to 6000 psi

• Ultem 9085 for up to 10,000 psi

• Hydroform Tooling

• Produce route , drill and trim fixtures with FDM

Aluminum Window Pan on top of FDM ToolAluminum Window Pan (left) FDM Tool

Manufacturing Tools

End Use Parts

Direct benefits:

• Lower cost

• Shorter lead time

Indirect benefits:

• Design freedom

• Change freedom

• Mass customization

• Weight reductions

• Part consolidation

• Supports lean initiatives

• True JIT (just-in-time)

manufacturing

• Reduced warehouse

space/inventory cost

FDM End use parts allowed for:

• Flexibility when designing complex parts

• Manufacture of less expensive part

• Weight saving solutions

• Production of parts that meet FAA regulatory requirements to be installed on aircraft

• Low volume production

• No tooling required

End Use Parts : Case Study

Best fit when:

• Relatively low volumes

– Short run production

– Bridge to tooling

• High part complexity

– Eliminate expensive tooling

– Reduce long lead times

• Part acceptable

– Aesthetics not critical

– Finishing processes feasible

– Physical properties acceptable

End Use Parts

Applications: End Use Parts

“To the best of my knowledge, the only additive fabrication technology

that meets the stringent requirements for MRI equipment is FDM,”

Tramm.

Virtumed LLC

End Use Parts : Case Study

Accelerate Design & Manufacturing• Design complexity high• Cost of tooling would be very high

MR Instruments invested in Fortus system• FDM used to build the plastic housings• Builds custom appliances to secure patients

head

Elimination of tooling saves time & money• 71% reduction in time vs. CNC• 62% reduction in costs vs. CNC• 74% reduction in time vs. RTV Moulding• 84% reduction in costs vs. RTV Moulding

Virtumed LLC

End Use Parts

What inspires you is your business

How you make it real is ours.

THANK YOU