specialist manufacturing sme 24 july 2012
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© MHS Consultancy Services
A Quick Thumbnail SketchMark Swan, 24 July 2012
© MHS Consultancy Services
Also known as ‘Additive Manufacturing’
Key Steps:
1. Import a digital designFrom any Computer Aided Design (CAD) tool
2. Slice it into layersAs thin as 16 microns thick (currently)
3. ‘Print’ each layer in turnUsing metal powder, plastic tube or pellets, liquid
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© MHS Consultancy Services
3D Printer Manufacturers Airwolf – USA Fabbster – Germany MakerBot Industries – USA Afinia 3D – USA Objet – Israel EOS – Germany Arcam – Sweden 3D Systems (the Cube – for $1300!!)
3D Print Service Providers Kraftwurx – USA 3T RPD – Newbury, UK Cybaman Technologies – UK
Users EADS – Europe Materialise – Belgium GE – US, UK United Technologies – US, China, Ireland
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Defence
Aerospace
Automotive
Medical
Tooling & Automation
Architectural
Consumer goods
Any prototyping
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Additive Technologies Base Materials
Selective laser sintering (SLS) Thermoplastics, metal powders, ceramic powders
Direct metal laser sintering (DMLS)
Almost any alloy metal
Fused deposition Modelling (FDM) Thermoplastics, eutectic metals
Stereolithography (SLA) Photopolymer
Laminated object manufacturing (OM)
Paper, foil, plastic film
Electron Beam melting (EBM) Titanium alloys
Powder bed, inkjet, & plaster-based
Plaster
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© MHS Consultancy Services
© MHS Consultancy Services
A Telling Graph
Unit Cost
VolumeProduction 3D Printing, or
‘Additive’Manufacturing
Traditional‘Subtractive’Manufacturing
Line of Least Unit Cost
Future Trend
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Next Steps
1. Confidential to my client
2. Confidential to my client
3. Confidential to my client
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Back up Slides
Follow here………….
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Selective Laser Sintering
1. Originally patented at the University of Austin in mid-1980s
2. Uses high power, pulsed laser3. Good for plastic, ceramic and glass
powders4. Full melt, or partial melt5. Does not require support structures
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Direct Metal Laser Sintering
1. Originally developed by EOS in Germany2. Uses high power, fibre optic laser3. Good for metal powder, esp. steel alloys4. Full local melt5. Layers down to 20 microns 6. May require support structures7. May require surface polishing/finishing8. Aerospace, dental, medical
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Fused Deposition Modelling
1. Originally patented by Scott Crump, late 1980s
2. Software by Stratasys (.stl files), also FDM is their trademark; also RepRap project & FFF
3. Extrudes wire or plastic filament4. Nozzle melts material into beads5. Full local melt6. Layers down to 40 microns 7. May require support structures8. Aerospace
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Stereolithography
1. Originally patented by Charles Hull in 19862. Uses concentrated U/V light focused on a vat of
liquid photopolymer3. Commercialised by 3D Systems (Hull’s
company), in Ca4. The U/V light cures and solidifies the molten
polymer5. Layers down to 50 microns 6. Support structures always required7. Manufactured parts require cleaning and curing
as post operations8. Cost in range $100k to $500k / machine9. $80 to $210 / litre of material
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Laminated Object Manufacturing
1. Originally developed by Helisys Inc, now Cubic Technologies
2. Uses a laser to heat layers of adhesive coated paper, plastic or metal laminates
3. Layers down to >50 microns 4. Support structures not required5. Manufactured parts may require waste
removal as a post operation6. Low cost paper models with wood
strength characteristics
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Electron Beam Melting
1. Originally developed by Arcam in Swden2. Metal powder is melted by an electron beam in
a vacuum at 700 oC to 1,000 oC3. Makes very strong components4. Good for Titanium (has high affinity for
Oxygen), and other highly reactive materials5. Layers down to 50 microns 6. Support structures not required7. No additional operations required8. Higher cost than other techniques, e.g. DMLS9. Medical implants, aerospace (turbine blades)
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SummarySLS DMLS FDM,
(aka. FFF)
SLA LOM EBM
Employs Laser Laser Heated extrusion nozzle
U/V light on liquid polymer
Layered adhesive coated
Electron beam, high temp, vacuum
Who? EOS Germany, 3D USA
EOS Germany 3D USA
Stratasys, Ca, Airwolf, Afinia, fabbster, Makerbot, 3D
3D Systems, Objet
Helisys, Ca Arcam, Sweden
Good For Plastic, ceramic, glass
Metal powder
Wire, plastic filament
Polymer Paper, plastic, laminates
Highly reactive metals, e.g. Ti
Melt? Partial Full Full n/a n/a Full
Layers? 20μ 40μ 50μ (Objet claim 16μ)
>50μ 50μ
Support Structures
No Maybe Maybe Yes No No
Costs Low Medium Low Medium Low High
Post Operations?
Polishing Cleaning and curing
Waste removal
None
Applications
Aerospace, dental, medical
Aerospace Automotive, dental, medical
Aerospace, medical
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