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TM
Consulting Services
ADDITIVE MANUFACTURING:DISRUPTOR, DRIVING THE 4TH INDUSTRIAL REVOLUTION
- TECHNOLOGIES & APPLICATIONS -
Jurgen DanielTeclination Consulting Services
San Diego, USA
www.teclination.com
Source: APWorks
IEEE Consultants’ Network of San Diego, 9 Sept. 2019
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2TM
Consulting Services
3D Printing Example
Source: www.carbon3d.com
Continuous Liquid Interface Production (CLIPTM)
7x speed
(Digital Light Projection / Stereolithography)
movie
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Source: www.geaviation.com, cessna.txtav.com
a brand new high-performance turboprop aircraft
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Source: www.geaviation.com, cessna.txtav.com
1/3 of engine parts are 3D printed
GE's Catalyst™Advanced turboprop engine
Development started in 2015Certification expected 2020
855 distinct components down to 12
world’s first turboprop engine with 3D-printed parts
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Development started in 2015Certification expected 2020
GE's Catalyst™Advanced turboprop engine
Source: www.geaviation.com, cessna.txtav.com
1/3 of engine parts are 3D printed
• 10 % more power
• Improved fuel burn (20 %)
• >100 lb in weight savings
• SimplifiedØ Supply chain logisticsØ AssemblyØ Maintenance
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6TM
Consulting Services
Conventional vs Additive Manufacturing (AM)
Source: www.arup.com;
Structures carry the same structural loads and forces
Example
Conventional Additive
• milling • sawing • drilling• welding• …
• 3D printing• Layering• …
topology optimized
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7TM
Consulting Services
Cost Comparison: Additive vs Conventional
Source: Deloitte
Additive Manufacturing
Conventional Manufacturing
Breakeven Point
Volume (units manufactured)
Cost
per u
nit m
anuf
actu
red
$$$
$
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8TM
Consulting Services
AM: Key to the 4th Industrial Revolution
Disrupting the $12 Trillion Manufacturing Sector
Source: www.weforum.org; data.worldbank.org; www.atkearney.com; www8.hp.com; lcr4.uk; www.allaboutlean.com
Industry
4.0
Cloud Computing
Additive Manufacturing
Autonomous Systems
Internet of Things
Augmented Reality
Big Data Analytics
Cyber Security
Simulation
Systems Integration
1.0 2.03.0
• Computing / IT• Automation
electronics1970s - 2010s
• Assembly line,• Electric power
1870s - 1960s
• Steam power,• Mechanical
production1780s - 1860s
27 Feb 2019
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9TM
Consulting Services
Selected Technologies
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10TM
Consulting Services
AM Categories
LiquidPowder(Granulate)
Filament(Wire/ Rod)
1D0D 2D
Sheet3D
Ceramic
Metal
Functional (electronic, shape memory, …)
Polymer
Composite
Biologic, food, etc. Selective Laser Melting (SLM)Polystrata
• Binder Jetting (BJT)• Directed Energy Deposition (DED)• Material Extrusion (MEX)• Material Jetting (MJT)• Powder Bed Fusion (PBF)• Sheet Lamination (SHL)• Vat Polymerization (VPP)
Fused Deposition Modeling (FDM)
see also: ASTM/ISO standard for AM terminology (ISO/ASTM 52900-15)
Selective Laser Sintering (SLS)
Stereolithography (SLA)
Electron Beam Melting (EBM)
Digital Light Processing (DLP)
Pick and Place (PNP)
Cold-spray (Kinetic Fusion)
+ others
Process Material
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11TM
Consulting Services
Fused Deposition Modeling (FDM)
filament
Source: Manufacturingguide
FDM nozzle
Rostock
Monoprice MP Select Mini (~$200)
Airwolf3D EVO 22 (~$12k)
(heated build chamber)
heated build plate
Filament
Delta
Cartesian
heated nozzle
Common materials:PLA: Polylactic AcidABS: Acrylonitrile Butadiene Styrene
H&S:Some VOC and Ultrafine Particle concern
movie
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12TM
Consulting Services
FDM Materials (Examples)
Polylactic Acid (PLA)
ULTEM (Nylon) air duct
316L steel
Ceramic
(requires debinding + sintering)
Bound metal rods (high metal ratio)
3D composite: FDM with embedded continuous carbon fiber
NYLON 12CF (carbon fiber filled thermoplastic)
Thermoplastic Polyurethane (TPU)
EasyCorkTM
EasyWoodTM
Composites
Metal / Ceramic (particle filled thermoplastic)
Thermoplastics
Filaflex
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13TM
Consulting Services
3D Printing with Support Structures
HydroFill water-soluble FDM support for ABS and PLA parts
Soluble Support Material
Source: pixelpractice.nyc; airwolf3d.com
Cut-away Support Structures
450
No support needed Support needed
General recommendation
<450
ABS
FDM with dual nozzle
Needed in FDM, SLA, jet-printing and metal SLS (metal SLS: for heat distribution and stability during cool-down)
HydroFill
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14TM
Consulting Services
Materials
VAT Polymerization: SLA (Stereolithography) / DLP (Digital Light Projection)
Formlabs Form 2(Laser scanning)~$3,400 (2018)
FDM vs SLA
27x magnification
Source: Formlabs
Source: formlabs; sparkmaker3d, www.tth.com
• ~ 25-30 micron layer thickness• <40 µm resolution• Isotropic material / smooth surface
Sparkmaker FHD(LED / LCD projection)
~$279 (2018)
Laser galvo-scanning, DMD or LCD projection, holographyDMD: Digital Mirror Device; LCD: Liquid Crystal Display
Issue of trapped volumes
Fast (continuous) processes:CLIP:LSPc:
bottom-up process
Projector
UV light
Build platform
Transparent membrane
Resin vat
• rigid • flexible • colored
• high temperature • dental grade
• ceramics, metals (sintered)
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15TM
Consulting Services
Powder Bed Fusion
Layer thickness: ~15 – 500 μm
Powder particle size: ~50 - 100 µm
Laser power: 10s – 100s of Watt
Ti-6242 particles (45-106 µm)
Source: Stratasys; GE
Selective Laser Sintering / Melting (SLS / SLM)
movie
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16TM
Consulting Services
Powder Bed Fusion (Laser or E-Beam)
Source: www.eos.info; www.plusmedicaot.com; www.malvernpanalytical.com
Polymers - metals - ceramics
Selective Laser Sintering / Melting (SLS / SLM)
Nylon duct
Laser
Titanium bracket (30 % lighter)
Parameters:• Laser power• Scan speed• Layer orientation• Hatch distance
Electron Beam Melting (EBM)
~62 EBM machines operated by GE Aviation (2019)
Health/ safety / Powder recycling
Typical powder particle size: ~50 - 100 µm
TiAl turbine blades
layer thickness: 15 – 500 μm
in vacuum or inert gas
Laser power: 10s of Watt (e.g. CO2) Laser power: 100s of Watt (e.g. fiber)
(for new GE9X engine)
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17TM
Consulting Services
Binder Jetting
Source: www.voxeljet.com; www.xaar3d.com
IR light
Sintered polymer
InkjetInfrared absorbing
ink
3-20 µm particles
Steel
High volume low-cost parts
Multi-jet Fusion (MJF)Fusing agent (not binder)
Binder materials: phenolic, aqueous, silicate, fusing agent, etc.
High Speed Sintering (HSS)
color by inkjet
Plastic
(also metal)
Polymer particles
Process example: High Speed Sintering (HSS)
( + debinding & sintering)Metal process
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18TM
Consulting Services
Jet-printing
Metal Ceramic
Source: xjet3d.com; Stratasys; Optomec, Xerox
Nanoparticle JettingTM (NPJ)
Printing at ~500degC Final sintering
water soluble support material
PolyJet
UV curable polymersrigid & elastomeric
360,000 colors: CMY, white, black, transparent
Magnet-o-Jet™: electromagnetic pulsing of molten metal
Jet-printing of molten metalAerosol Jet-Printing
printed smartphone antennas
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19TM
Consulting Services
DED (Directed Energy Deposition)
Source: www.beam-machines.com
Laser energy used to fuse metal powder
5 axis of freedom
Similar concepts:
Wire & powder-fed
(size: 45-75µm)
Wire Arc Additive Manufacturing (WAAM)
Similar to Tungsten Inert Gas (TIG) welding
FAA certified process
Repair of worn shaft seal
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20TM
Consulting Services
Sheet Lamination
Source: www.mcortechnologies.com; fabrisonic.com; www.impossible-objects.com
print color – print adhesive – laminate – cut layer
X,Y,Z resolution: 0.1mmPhotorealistic color
Ultrasonic welding
Ultrasonic AM
Composite Based AM (CBAM)
Selective Deposition Lamination (SDL)
Build material: paper
Process
Material: (carbon) fiber composite
Material: metal
CNC / laser contour machining
Process
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21TM
Consulting Services
ApplicationsExamples
(emphasis on 3D printing)
Source: Widex
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22TM
Consulting Services
Digital Dentistry - Clear Dental Aligners
Sources: www.invisalign.com, www.prodways.com
3D printing of dental molds for thermoforming
Medical-grade polymer is thermoformed around
3D printed mold
>320,000 clear aligners produced per day
~6-10 incremental molds per patient
~50-60 SLA printers
Dental mold(SLA, MJF)
Clear alignerThermoforming
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23TM
Consulting Services
Hearing Aids
Example: SLA parts by Danish hearing aid manufacturer Widex
Source: www.widex.pro
CAMISHA (Computer Aided Manufacturing of Individual Shells for Hearing Aids)
modeling SLA printing 3D scanning
Mass customization
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24TM
Consulting Services
Medical
Source: www.anatomics.com; www.zimmerbiomet.com ; www.rapidreadytech.com; www.materialise.com
Patient-specific pediatric heart model
Light-weight patient-specific 3D-printed cast
Surgical Planning & Training
Orthopedic Casts
Software requires FDA clearance!
Personalized Medicine
Printlets™ technology
Spinal wedge implants
Implants
OsseoTiPorous Metal
(for bone in-growth)
Lattice skull implant
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25TM
Consulting Services
Jewelry
Wax 3D SLA* printing and lost-wax casting
High wax content SLA photopolymer for clean burnout
Source: envisiontec.com, i.materialise.com; www.dnaindia.com
SLA mold
wax model
metal
Lost-wax casting processplastermold
burnout metalpart
DNA India
faster & lower cost
*Stereolithography
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26TM
Consulting Services
Aerospace - Rockets
Monolithic Thrust Chamber with Internal Cooling Structure
Selective Laser Melting:
• Nickel superalloy IN718 (difficult to CNC machine)
• Minimum post processing needed
Source: www.slm-solutions.com, cellcore3d.com
Complex lattice structure:
Ø Improved coolingØ Lightweight
Combined fuel injector & thrust chamber
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27TM
Consulting Services
Heat Exchange
• 22% lighter • 55 mm smaller
than traditionally manufactured parts
Pure copper heat exchanger:• spiral design (0.5mm wall thickness)• >30% lighter• 35% cost reduction
Complex heat exchanger concept in Al
Lung-inspired Heat exchanger(ARPA-E HITEMMP)
Novel complex (bio-inspired) & more efficient designs
Source: www.metal-am.com; www.3t-am.com
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28TM
Consulting Services
Automotive
Source: 3dprintingindustry.com; yours-customised.min; www.hrewheels.com
US$148 billion in automotive AM product value forecasted for 2030 (Feb 2019)
Small series variable turbo
Rapid development Customization
Spare parts Small series Customization Tooling Quality enhancementDesign cycles
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29TM
Consulting Services
Industrial Tooling
Source: www.voxeljet.com; www.stratasys.com
Sand mold & metal part
Molds for casting
3D PRINTING SAVES UP TO 75 % IN SAND CASTING COSTS
Composite lay-up molds
(ULTEM 1010)
Carbon fiber composite
Binder jetted
also: plastic molds for investment casting
FDM printed
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30TM
Consulting Services
Electronics - RF Antennas
• 95% weight reduction• 20% reduction of production cost• 75% of non-recurring costs eliminated
Source: 3dprint.com/178724/3d-printed-antenna-one-component/
Ka-band 4×4 monopulse phased array (1 -100GHz)
1part100 parts
brazing and EDM (~8 months to develop and 3 to build)
3D laser fusion( ~a few weeks to complete)
metal
e.g. for low SWaP radar on High Altitude, Long Endurance
(HALE) platforms
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31TM
Consulting Services
Art (Example: 3D printed Ceramics)
Sensory Printing Machinethat feels the environment
Image: Galerie VIVID
Extrusion printer
Source: oliviervanherpt.com
Adaptive Manufacturing
Unique ceramic objects
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32TM
Consulting Services
Culinary Printing
Source: www.miamfactory.com Source: www.3dsystems.com/culinary Source: open-meals.com
Pixel food printer: 3D printer capable of producing edible and pixelated 8-bit sushi
3D printed chocolate 3D printed sugar Pixilated sushi
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33TM
Consulting Services
Materials
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34TM
Consulting Services
Novel Materials
Source: D. Hofmann, et al., Nature Scientific Reports 4, 2014 (www.nature.com/articles/srep05357); authors.library.caltech.edu/50785/1/S0884291414002088a.pdf
Graded composition alloys
Related process: Laser Metal Deposition (LMD) / powder nozzle
Laser Deposition process
Metal matrix composites
Ti-6Al-4V to V Gradient Alloy
Multi-Material Objects
e.g. Ti / TiC
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35TM
Consulting Services
Design
Source: Teclination
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36TM
Consulting Services
DfAM (Design for Additive Manufacturing)
Parametric and generative design
Generate (TM) topology optimization
Other examples:
Topology optimization
Lattice structures and biomimicry (bionic design)
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37TM
Consulting Services
AM Build Simulation SoftwareMultiphysics Multiscale Modelling of AM Processes
Source: www.geonx.com; www.3dsystems.com; www.ansys.com; www.alphastarcorp.com; www.e-xstream.com
+ others
Example
Model distortions & residual stresses for processes
Suggest distortion compensation
Model optimal support structures
Minimize number of build tryouts
Minimize risk of printer damage (e.g. re-coater damage)
Predict impact of postprocessing (e.g. heat treatment, HIP,
support removal)
NX & Simcenter
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38TM
Consulting Services
Fabrication Process
Source: i.materialise.com
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39TM
Consulting Services
3D Printing Services
+ many others
HP Digital Manufacturing Network
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40TM
Consulting Services
Process and Postprocess
up to 70% of part cost
• Support removal • Surface finishing• Defect Reduction: Hot Isostatic Pressing
(HIP)• Non Destructive / Destructive Testing
Data Security (Blockchain)
Process Quality Control / Workflow Optimization
Process monitoring &feedback
Standardization
Post Processing
data analytics
SLS part
Melt-pool monitoring
Blacksmith
AI supported process:
+ others
+ others
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41TM
Consulting Services
Wait! - a few more futuristic concepts
Source: Carnegie Mellon University
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42TM
Consulting Services
Small-Scale / Large-Scale AM
Source: www.nanoscribe.de & www.laserfocusworld.com; www.3dwasp.com
e.g. Two-photon Polymerization Contour Crafting
Prof. Behrokh Khoshnevis
Rapid Response Construction (disaster relief)
Photonic materials Metamaterials
Microstents… Extraterrestrial Construction
…
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43TM
Consulting Services
Cooperative Mobile Print Robots
Source: spectrum.ieee.org; gxn.3xn.com
Structures arbitrary in size
crawl – swim – fly
Denmark
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44TM
Consulting Services
The Future - 3D Printed Organs and Tissue
Source: science.sciencemag.org/content/365/6452/482
MRI data of a human heart 3D bioprint collagen & human heart cells
Prof. Adam Feinberg - CMU Bioengineered Organs Initiative
Cardiac ventricles printed with human cardiomyocytes
Freeform Reversible Embedding of Suspended Hydrogels (FRESH) bioprinting
synchronized contractions after 7 days
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45TM
Consulting Services
Resources
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46TM
Consulting Services
AM Information Resources
3dprintingindustry.com
3dprint.com
www.3ders.org
www.rapid3devent.com
www.sme.orgall3dp.com
www.tctmagazine.com
advancedmanufacturing.org
www.3dmpmag.com
additivenews.com
www.metal-am.com
additivemanufacturingtoday.com
… and many more
wohlersassociates.com
www.3dnatives.com
AM News + Info
AM Conferences
formnext.mesago.com
rapid3devent.com
inside3dprinting.com
www.amug.com
www.am-ceramics.dkg.de www.additiveconference.com
www.3dprint-exhibition.com