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Additive Manufacturing
International Trends in Additive Manufacturing
Prof. Brent StuckerClark Chair of Computer Aided Engineering
Department of Industrial Engineering, University of Louisville
Chairman, ASTM F42 Committee on Additive Manufacturing TechnologiesFulbright Scholar, VTT Technical Research Center, Finland
Additive Manufacturing
University of Louisville’s Involvement in AM
• One of the best equipped additive manufacturing (AM) facilities in the world
• Performing Basic and Applied Research, since starting with SLS in 1993
• Over 20 people focused on AM• Close partner of leading AM users
– Boeing, GE, DoD, Integra, service bureaus, etc.• Over 70 member organizations in our RP Center
– Includes Haas Technical Education Center
Additive Manufacturing
Just This Year…
• Newspapers, magazines, TV shows and technical publications have all become fully immersed in the hype surrounding 3D printing and additive manufacturing
• President Obama & Vice-President Biden have spoken about the potential and it played a role in presidential politics– U.S. Department of Defense (including DARPA), Department of
Energy, National Institute of Standards and Technology and other agencies are actively funding AM research & development
• Mergers & acquisitions are in full-swing• Most major manufacturers are spinning up R&D
Additive Manufacturing
National Additive Manufacturing Innovation Institute (NAMII)
• Youngstown Ohio-based collaboration between institutions in Ohio and Pennsylvania (both key swing states in the 2012 election)
• Recently announced $4.5M (+$5M) in funding– Three FDM-related projects– Tool and die repair using directed energy deposition– High-temp SLS maturation– Thermal imaging for DED– Modeling and qualification of metal powder bed fusion
Additive Manufacturing
Other U.S. Government funding
• Joint Defense Manufacturing Technology Program exploring DoD-wide standards for metal AM
• DARPA Open Manufacturing program funded a Manufacturing Demonstration Facility (MDF) and several AM modeling proposals
• DOE funded a large Oak Ridge National Laboratories MDF
• AFRL is actively funding small businesses and universities in many areas
• NIST is funding several Universities
Additive Manufacturing
Other International Observations
• China is poised to spend a significant amount of money on AM ($300M+)
• Europe is fully embracing the hype– EU bureaucracy is pushing standards– New funding is on the way
• Stock valuation is very high right now…• Lots of misinformation
Additive Manufacturing
International Standards
• Standardized process categories adopted by both ASTM and ISO– Majority of my talk uses this structure
• New file format (AMF)• Location/Orientation Standard• Process standards for Ti64
Additive Manufacturing
Vat PhotopolymerizationProcess
• An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. – Stereolithography– Envisiontec DLP– Micro-SLA– …
Additive Manufacturing
Developments in Vat Photopolymerization
• Increased proliferation of DLP/LCD/LED technology to cure entire layers at once.
• New photopolymer materials which mimic engineering photopolymers
• Expiration of initial stereolithography patents are opening up the marketplace– DSM/3D Systems patent infringement and anti-trust
lawsuit over open versus closed machine architecture were settled
• Renewed interest in 2-photon polymerization
Additive Manufacturing
Material Jetting
• An additive manufacturing process in which droplets of build material are selectively deposited– Wax or Photopolymers– Multiple nozzles – Single nozzles– Includes
• Objet• 3D Systems Projet• Stratasys Solidscape machines• Several Direct Write machines• Etc…
Additive Manufacturing
Developments in Material Jetting
• Stratasys merged with Objet• Many traditional “2D printing” companies are
investigating 3D printing– Thermoplastics
• Viscosity issues
– Metals– Color
• Significant interest in printed electronics
Additive Manufacturing
Binder Jetting
• An additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials. – Zcorp– Voxeljet– ProMetal/ExOne– …
Additive Manufacturing
Developments in Binder Jetting
• 3D Systems purchased Zcorp and has changed marketing
• ExOne is pushing “sand printing” and builds metal parts for Shapeways
• Voxeljet, fcubic and others makes the marketplace very dynamic right now– Expiration of patents will open up the marketplace– Continuous build platform design has major
ramifications
Additive Manufacturing
Material Extrusion
• An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice– Based on Stratasys FDM
machines– Office friendly– DIY community– Best selling platform– …
Additive Manufacturing
Developments in Material Extrusion
• Expiration of initial FDM patents has led to a vast proliferation of do it yourself machines– More “DIY” machines sold today than “manufacturing”
machines• 3D Systems offers their own platform• Stratasys focusing on the engineered component
marketplace– New materials, fiber-reinforced composites, etc.– People seem to be taking it more seriously than a few
years ago
Additive Manufacturing
Powder Bed Fusion
• An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed– SLS, SLM, DMLS, EBM, BluePrinter, etc. – Polymers, metals & ceramics
Additive Manufacturing
Developments in Powder Bed Fusion
• First ASTM F42 Ti6/4 Standard– Covers all thermal sources (lasers & electron beams)
• Many metal laser sintering machine manufacturers– SLM Solutions, ConceptLaser, EOS, Phenix, Renishaw, Realizer
• Limited polymer machine manufacturers– 3D Systems & EOS– New companies quietly entering the marketplace
• Significant R&D investments• Open versus Closed machine architectures• High Speed Sintering soon?• GE Bought Morris Technologies
Additive Manufacturing
Sheet Lamination
• An additive manufacturing process in which sheets of material are bonded to form an object.– Paper (LOM)
• Using glue
– Plastic• Using glue or heat
– Metal• Using welding or bolts• Ultrasonic AM…
Additive Manufacturing
Examples of Sheet Lamination
• Laminated Object Manufacturing– Paper
• Ultrasonic Consolidation (Ultrasonic Additive Manufacturing)– Metal sheets and foils
• CAM-LEM– Ceramic and metal tapes
Additive Manufacturing
Developments in Sheet Lamination
• Fabrisonics formed as a Joint Venture between EWI and Solidica– Selling 3 new platforms based upon their higher power
sonotrode designs• Renewed interest in paper-based machines at the
low-end by Mcor and others
• Other solid state AM methods are being investigated
Additive Manufacturing
– Wire & Powder Materials– Lasers & Electron Beams– Great for feature addition & repair
Directed Energy Deposition
• An additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited
Additive Manufacturing
Developments in Direct Energy Deposition
• Electron Beam with wire seems to be the leading process right now
• Manufacturers are exploring marketing their laser deposition heads as add-ons to existing machine tools
• Increasingly being used for overhaul and repair• New Mil-standard just published
Additive Manufacturing
Hybrid AM
• Direct Write electronics plus AM
• AM plus subtractive milling
Additive Manufacturing
AMF File format
• .AMF– Additive Manufacturing Format– Additive Manufacturing File
• Open source license-free implementation– amf.wikispaces.com
• Next step is to work with software providers (like Microsoft & Materialise) to refine and implement the standard
Additive Manufacturing
Basic AMF Structure
<?xml version="1.0" encoding="UTF-8"?><amf units="mm">
<object id="0"><mesh><vertices>
<vertex><coordinates>
<x>0</x><y>1.32</y><z>3.715</z>
</coordinates></vertex><vertex><coordinates>
<x>0</x><y>1.269</y><z>2.45354</z>
</coordinates></vertex>...
</vertices><region>
<triangle><v1>0</v1><v2>1</v2><v3>3</v3>
</triangle><triangle><v1>1</v1><v2>0</v2><v3>4</v3>
</triangle>...
</region></mesh>
</object></amf>
Addresses vertex duplication and leaks of STL & Units!
Additive Manufacturing Compressibility
Comparison for 32-bit Floats; need to look at double precision
CURVED PATCH(Curved using vertex normals)
PLANNAR PATCH
Optionally add normal/tangent vectors to some triangle mesh edges to allow for more accurate geometry.
CURVED PATCH(or curved using edge tangents)
Curved patches
Additive Manufacturing
Multiple Materials
Micro-structureGradient
Materials
Additive Manufacturing Color and Graphics
• Can be assigned to – A material– A region– A vertex
• Specified– Fixed RGBA values– By formula– By reference to an image
Additive Manufacturing Print Constellation
• Print orientation• Duplicated objects• Sets of different
objects• Efficient packing• Hierarchical
Additive Manufacturing
Testing
• Testing Terminology Standard– Standardized part orientation and location within a
build– Based on basic coordinate systems as per ISO 841
+Y
+X
+Z
+C+B
+A
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Coordinate Systems w.r.t Platforms
+Y
+X
+Z
Front of machine
Build volume origin (0,0,0)
Buildplatform
+Y
+X
+ZFront of machine
Build volume origin (0,0,0)
Buildplatform
(translucent)
For downward building machine architectures
Additive Manufacturing Location and Orientation of
Parts
Additive Manufacturing Location and Orientation of
Parts with Simplified Notation
Z
XY
XYZ
Z
XY
Z
XY
Z
XY
Z
XY
Z
XY
YXZ
ZXY
XZY
YZX
ZYX
Additive Manufacturing Location and Orientation of
Parts with Simplified Notation
Z
XY
Z
XY
ZX Z
Additive Manufacturing
Business Developments
• Business models used for 2D printing, such as for photographs, are starting to be applied in 3D– Print your parts at home, at a local “Staples,” or
through an on-line store (e.g. Shapeways)• 3D Systems continues their buying and merger
spree. • 3D printing is a major investment category now• Marketplace is exploding in almost every
direction, except new materials
Additive Manufacturing
Web 2.0 + AM = Factory 2.0
• User-changeable web content plus a network of AM producers is resulting in new entrepreneurial ventures– Shapeways.com– Freedom of Creation– FigurePrints– …and more
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Additive Manufacturing
Modeling, Process Control & Part Quality Verification
• Significant investments in trying to better understand AM processes– Numerical models which describe the relationship
between process parameters, material microstructure and part properties
• Everyone wants better process monitoring and control– Closed software platforms have a very negative
reputation rights
Additive Manufacturing
Possible Societal Implications
• Additive Manufacturing may have the potential to:– Make local manufacturing of products normative
• Small businesses can successfully compete with multi-national corporations to produce goods for local consumption
• Parts produced closer to home cost the same as those made elsewhere, so minimizing shipping drives regional production
– Reverse increasing urbanization of society • No need to move to the “big city” if I can design my product
and produce it anywhere– Make jobs resistant to outsourcing
• Creativity in design becomes more important than labor costs for companies to be successful
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Additive Manufacturing
The Future of International Collaboration?
• We are at a turning point in our industry1. We are big enough that people care about us
• Nationalism is increasingly apparent• Financial markets are starting to pay attention to us
2. Monopolies are disappearing as patents expire• New companies and new countries can compete in the
global marketplace, but old monopolies fight hard to dominate
• I see companies and countries trying to lock other companies/countries out of certain AM technologies– and standards development activities
• Will they succeed? I hope not!