additive manufacturing what is it? why is it such a hot area? how is ul involved? brent stucker,...
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Additive Manufacturing
What is it?Why is it such a “hot” area?
How is UL involved?
Brent Stucker, Ph.D.
Clark Chair of Computer Aided Engineering
Professor of Industrial Engineering
Mechanical Engineering Associate Faculty Member University of Louisville
ADDITIVE ADDITIVE MANUFACTURINGMANUFACTURING
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Additive Manufacturing
What is Additive Manufacturing?(3D Printing)
• The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies
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Additive Manufacturing
Vat Photopolymerization
• An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. – Stereolithography
– Envisiontec
– Micro-SLA
– …
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Additive Manufacturing
Material Jetting
• An additive manufacturing process in which droplets of build material are selectively deposited– Wax or Photopolymers
– Multiple nozzles
– Single nozzles
– …
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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
– …
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Additive Manufacturing
Material Extrusion
• An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice– From microns to meters– Stratasys FDM machines– Office friendly– DIY community– Best selling platform– …
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Additive Manufacturing
Powder Bed Fusion
• An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed– SLS, SLM, DMLS, EBM, etc.
– Polymers, metals & ceramics
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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…
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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
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Additive Manufacturing
Engineering & Business Implications
• More Complex Geometries– Internal Features & Structures– Parts Consolidation
• Enables business models used for 2D printing, such as for photographs, to be applied to physical components– Print your parts at home, at a local
“UPS Store” or “Lowes” or order through “Amazon-like” website like Shapeways.com
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Additive Manufacturing
Web 2.0 + AM = Factory 2.0
• User-changeable web content plus a network of AM producers is already enabling new entrepreneurial opportunities– Shapeways.com– Freedom of Creation– FigurePrints – Spore– …and more
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Additive Manufacturing
Impact on Logistics
• Eliminates drivers to concentrate production
• “Design Anywhere / Manufacture Anywhere” is now possible– Manufacture at the point of need
rather than at lowest labor location
– Changing “Just-in-Time Delivery” to “Manufactured-on-Location Just-in-Time”
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Additive Manufacturing
AM is Hot This Year…
• Newspapers, magazines, TV shows and technical publications have all discovered 3D printing via additive manufacturing
• President Obama & Vice-President Biden have spoken about the potential:– The first Institute within the National Network for Manufacturing
Innovation is focused on Additive Manufacturing
• DoD (DARPA), DOE, DHHS, DOC (NIST), NSF and other agencies funding R&D
• Mergers & acquisitions are in full-swing
• Most major manufacturers are spinning up R&D
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Additive Manufacturing
University of Louisville’s Involvement in AM
• One of the best equipped additive manufacturing (AM) facilities in the world
• Performing federally-funded basic and applied research, technology transfer and industry-funded projects in AM since starting with SLS in 1993
• Over 20 people focused on AM
• Partner of leading AM users– Boeing, GE, EWI, Integra, service bureaus, etc.
• Over 70 member organizations in our RP Center– Includes Haas Technical Education Center
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Additive Manufacturing
AM Equipment at UL
• Polymer Laser Sintering (LS)– 3D Systems (DTM) 2500 plus (with
Multi-zone heating)– 3D Systems (DTM) 2500CI High
Temperature Research Platform• Multi-zone heating• High Speed Scanning
• Direct Metal Laser Sintering (DMLS)– EOS M270 Dual Mode
• Electron Beam Melting (EBM)– Arcam S400
• ExOne 3D Printing– Dental machine
• Ultrasonic Consolidation (UC)– Fabrisonic R200 High Power – Solidica Formation Beta Machine
• Laser Engineered Net Shaping– Optomec LENS 850
• Fused Deposition Modeling– Stratasys uPrint– Several desktop, educational
“material extrusion” machines
• Stereolithography– 3D Systems SLA 250/30
• Direct Write– nScrypt Direct Write head
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Additive Manufacturing
Why Additive Manufacturing in Kentucky
• U of L has a world-leading capability in additive manufacturing– Laser and electron beam powder bed processes for metals,
plastics and ceramics– Ultrasonic additive sheet lamination and more…
• U of L and other KY institutions can educate & train the needed workforce– Entrepreneurs, designers, engineers, doctors, dentists, technicians,
etc.
• The proposed Louisville/Lexington advanced manufacturing corridor can be a catalyst
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Additive Manufacturing
Other Louisville/Kentucky Benefits
• UPS could be a key enabler to the distributed, on-demand manufacturing model enabled by AM
• Louisville is a great hub for locating new AM companies and U.S. headquarters for foreign companies
• Louisville is a center for medical innovation
• Northern Kentucky is part of greater Cincinnati’s aerospace infrastructure
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Additive Manufacturing
Additive Manufacturing Research at UL
• Office of Naval Research Direct Digital Manufacturing – $2.45M grant over 4 years – Investigating Material Properties of parts made using
AM
• Office of Naval Research Cyber-Enabled Manufacturing Systems – $1.05M over 7 years– Ultrasonic Consolidation–related funding
• Multi-functional, multi-material parts
– Dislocation Density based Crystal Plasticity Finite Element Modeling (DDCP-FEM)
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Additive Manufacturing
UL Research continued
• Military SBIR/STTRs – over $500k in subcontracts– High-temp SLS work in support of JSF and more– Naval scale models (magnetic signature)– Modeling of metal powder bed fusion
• Industry-funded projects– 70 members of our Rapid Prototyping Center consortium (19
years of continuous funding)– Boeing has funded us for more than 10 years
• Dental projects– Porous titanium implants & new materials
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Additive Manufacturing
UL Research continued:
• GE Aircraft (in contracting)– Layer-by-layer process monitoring of metal powder bed
fusion for process model and part quality validation
• NIST (in contracting)– Modeling of Inconel alloys in metal powder bed
processes.
• NSF project– Applying DDCP-FEM to friction surfacing additive
manufacturing
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Additive Manufacturing
U of L’s Vision for our Additive Manufacturing Institute
U of L Additive Manufacturing
Institute(Engineering,
Medical/Dental, Business, Logistics, etc.)Rapid
Prototyping Center(product
development for industry)
Advanced Materials &
Processes Thrusts(research/
development/modeling of machines & materials)
Bio/Medical Thrusts
(Implants, Tissue Engineering,
Dental Restorations
Medical Devices)
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Additive Manufacturing
Conclusion
• Additive Manufacturing is poised to transform the production of “physical goods” in much the same way that the internet transformed the production of “informational goods.”
• UL is leading the way in additive manufacturing research and implementation– We are “a” world leader in AM
– Targeted investment and recruiting could make us “the” world leader in AM