3d printing with ptfe - spe automotive

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, smreiss@mmm.com

Are you ready to go 3D?

3m.com/3dprinting 3m.co.uk/3dprinting 3m.de/3dprinting

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Questions?