DSM Additive Manufacturing

Manufacture Tomorrow

Harold van Melick

BRIGHT SCIENCE. BRIGHTER LIVING

DSM Additive Manufacturing“Driving adoption of industrial-scale additive manufacturing with focus on customer’s

applications, through partnerships and innovate business models, while making the

industry sustainable from Day One”

Application-centered

approach

Partnerships New business models

Trend: AM moving from prototyping to industrial manufacturing

Courtesy of

Ultimaker

Page 3

DSM AM: solution provider across technologies

Stereo Lithography (SLA)

SOMOS® brand 30 years of experience

Digital Light Processing (DLP)

Building on SOMOS® portfolio for

higher-wavelengths materials

Selective Laser Sintering (SLS/HSS)

Thermoplastic Engineering Plastics

Powder Portfolio based on innovative

processes

Fused Filament Fabrication (FFF)

Strong portfolio of filaments from

Thermoplastic Engineering Plastics

providing functionality for

applications

Material Jetting

Building on SOMOS® portfolio and

developing alternative chemistries

Fused Granulate Fabrication (FGF)

Strong portfolio of granulates from

Thermoplastic Engineering Plastics

providing functionality for

applications

Additive Manufacturing at K2019

Airflow chamber for a classic Ducati motorbike

Car tail light enclosure for small series

customized production

• Automotive OEMs can generate huge cost savings with 3D printed spare parts

• 30,000 parts on an average car – 36T of spare parts out there

• Research shows that on average spare parts make up approximately 7% of an

automotive OEM’s liquid assets

• Using 3D printing, they can replace their physical warehouse by a digital one

• This saves them millions of dollars as well as resources (energy, material) –

contributing to reducing carbon footprint

Spare Parts transportation

Novamid® for motorbike 3D printed spare part

Lightweight alternative to metal for under-the-hood applications for more cost-efficient spare parts (or parts no longer commercially available)

AIRflowchamber

Novamid®

Id1070 Cf10

Application• Air flow chamber, classic Ducati cooling system

User• Biggelaar, European top-5 Ducati motorbike specialist

Challenge• Biggelaar was rebuilding two classic Ducati 998RS superbikes to make

them race-worthy

• However, no air cooling spare parts…

Solution• Turned to additive manufacturing technology via Switchtec and DSM

• Novamid® ID1030 CF10 for its high stiffness & chemical resistance;

and Arnitel® ID2060 HT for the high temperature resistance

• Easy and fast to print

Benefits• Metal replacement using a thermoplastic material ideal for harsh,

superbike race conditions

• Replicates a classic superbike experience

• Helps build brand reputation as a leading Ducati motorbike specialist

Arnite® PBT powder for 3D printed car tail light enclosure

For small series customized production and faster design prototyping

Tail light enclosure Arnite® PBT Powder

Challenge

• Automotive companies are looking for the right

manufacturing technology to produce small series

and customized cars, as well as ways to quickly

develop new products.

• For functional parts, they need materials that

provide the part the right set of properties –

vibration and temperature resistance, durable,

stiff, high dimensional stability, easy to print

Solution

• Arnite® PBT powder – first PBT powder to be

commercially available for SLS printing

• Easy and fast to print

• Recyclable

Benefits

• Fast product development & prototyping

• Cost-effective small series and customized car

production

• Sustainable material solution for sustainable

manufacturing

Tail light Enclosure Somos® WaterclearUltra 10122

Challenge

• Need for produce small series and customized cars,

as well as ways to quickly develop new products.

• Functional parts printing require materials that

provide the right set of properties – temperature or

moisture resistance, optically clear, etc.

Solution

• Somos® Waterclear Ultra 10122 for SLA printing,

with coating

• Extremely optically clear material for optimal light

transmission

• Superior moisture resistance

• Easy to use and finish

Benefits

• Fast product development & prototyping

• Cost-effective small series and customized car

production

• Sustainable material solution for sustainable

manufacturing

Somos®

PerFORMReflect

Designed for high performance PIV wind tunnel testing

• Excellent detail resolution

• Fast building speed

• Superior high heat tolerance

• Ability to print with superior sidewall quality

• From printed part to PIV test without coating

• Increased flexibility in design

• Saving up to >30% of post-processing time and costs

• Print more accurate parts, faster

Particle Image Velocimetry (PIV)

• In complex shapes, detailed analyses are

performed to find the right geometry for

aerodynamic optimization.

• In wind tunnels Particle Imaging Velocimetry

(PIV) is used to measure the instantaneous

global velocity field in a flowing fluid

Ecosystem of Partnerships – Business Models

Printers Materials Post-processing Distributors

CEAD

HP

Origin

RPS

Stratasys

Ultimaker

Union Tech

Adaptive3D

Chromatic 3D

Fortify

Additive

Manufacturing

Technologies

Formfutura

Matterhackers

Nexeo 3D

Software Services

e-Xstream

Twikit

CHG

SUSTAINABLEPRODUCT PORTFOLIO

RECYCLE

REUSE

BIO-BASED &

BIO-DEGRADABLE

Recycled powders

Recycled PET

filament and

pellets

Bio-based

Bio-degradable

material

development

Design for sustainability

Green product portfolio

Green innovation pipeline

Value chain

Development

Green partnerships

Multi-party partnership programs

Global sourcing possibilities

Association memberships

Use internal DSM links

Materials

Appendix

Link to more info: Plasticsfinder.com

Key Benefits & Properties

• 3D printable at same speed as

unreinforced plastics thanks to low

carbon loading of 10%

• Enables properties close to what is

usually achievable only by injection

molding

• Durable parts with good mechanical

properties due to high interlayer

strength

• Based on DSM Novamid® copolyamide

PA6/66, used in automotive and

electronics for many years

• HDT of 184ºC at 0.45MPa

• Very low warpage compared to

unfilled PA & ABS

Novamid® ID1030 CF10PA6/66 reinforced with short carbon

fibers

Applications

• Automotive under-the-

hood brackets

• Structural jigs & fixtures

• Manufacturing jigs and

fixtures

• Protective and supporting

sports gear

• Medical braces and

prosthetics

• Light weight applications

“no warping“ “can deliver the

performance needed

for professional

use“

“same quality

as the SLS

pieces I make”

Prosthetic socket

Printed by AON3D

Key Benefits & Properties

• First ever high

temperature TPC filament

• A unique balance of

extreme flexibility, high

temperature resistance

and strength,

• Prolonged high

temperature use: 175°C

(1000 hrs), 190°C (500 hrs)

• Excellent UV & chemical

resistance

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Arnitel® ID2060 HTA TPC material

Applications

• Air-fuel management systems for automotive

• Shutter system components for automotive

• Engine shields and covers for automotive

• Front end module components for automotive

• Gaskets and seals for automotive

• End-of-arm tooling for food processing

industry

• Tubes for home appliances

Arnite PBT PowderFirst material from an innovative materials platform

Technical specifications

• Tensile modulus: 2500 Mpa (higher than

incumbent powders such as PA12)

• Melting point: 230ºC

• Printing temperature: 215 – 220ºC

• Wide processing window (30-40ºC)

• PSD: D90 = 100 microns; D50 = < 50 microns

• Density: 0.5 g/cm3

• To be printed on high temperature SLS

machines such as:

• EOS P400 & EOS P800

• Farsoon 252P, SS/HT403P and HT1001P

• Prodways P4500HT

• LSS RAPTOR 22X-S

Application benefits

• High temperature resistance (Lower Thermal Expansion

• High dimensional stability (low moisture uptake)

• Stiffness

• Aesthetic and feel comparable to ceramics

• No warpage in the beta tests conducted so far

• Excellent recyclability* vs incumbent powders: no change

in properties after 30hrs at 280ºC under nitrogen

Processing benefits

• Extremely easy to print compared to other powders such

as PA6.

• A very forgiving material which does not require long

times between layers while printing

Benefits

• Extraordinary optical clarity

– Refractive values similar to engineered plastics

• Virtually colorless

• Superior moisture resistance

• Easy to print and finish

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Somos® WaterclearUltra 10122

Applications

• Lens prototypes

• Light guides

• Parts requiring high clarity

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Stereolithography materials - Somos®

Page 22

Thermoplastic Materials

Amorphous Semi-crystalline

PE PPPS PVC

ABS PMMA

PEI

PEEK

LCP

PSU

PES

PET

POM

PC

mPPO Blends

PA46

PA4T

TPC

PBT

PA410

PPA

PA6 PA66 P6/66

PPS

PA4T

Hig

h P

erf

orm

ance

• Building on DSM’s extensive

experience

• Six thermoplastic filaments in the

polyamide & polyester families

for FFF technology

• Industrial end-use thermoplastics

for FGF, SLS & MJF technologies

by leveraging strength in semi-

crystalline engineering plastics

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Best printable engineering materialsDSM Filaments: Novamid®, arnite®, and arnitel®

Novamid® ID1030 Novamid® ID1030 CF10 Novamid® ID1070

Polyamide 6/66

• Easy to print for starting with engineered materials

• Engineered material optimized for ductility &

strength

• Material suitable for harsh environment and

temperatures up to 125ºC

• Produces durable parts with high inter-layer

strength and with excellent mechanical properties

Polyamide 6/66 reinforced with short carbon fibers

• 3D printable at same speed as unreinforced plastics

thanks to low carbon loading of 10%

• Enables properties close to what is usually

achievable only by injection molding

• Durable parts with good mechanical properties due

to high inter-layer strength

• HDT of 184ºC at 0.45MPa

• Very low warpage compared to unfilled PA & ABS

Polyamide 6

• Engineered material optimized for ductility &

stiffness

• Parts with high inter-layer strength durable parts

with good mechanical properties

• Unique DSM co-polyamide technology

• High temperature resistant material up to 150°C

• Suitable for harsh environments

Arnitel® ID2045 Arnitel® ID2060 HT Arnite® ID3040

Thermoplastic co-polyester

• Highly elastic material with Shore D34

• 50% of the feedstock is bio-based

• Faster printer (2x) compared to other TPCs

• High UV and chemical resistance compared to TPUs

• Smooth aesthetics

• Certification:• ISO 10993-10 Irritation / Intracutaneous reactivity testing

• ISO 10993-5 Cytotoxicity testing

• USP class VI tests for medical implants

Thermoplastic co-polyester

• Sustained high temperature use TPC filament:

prolonged high temperature performance at 170°C

for 1,000hrs; and at 190°C for 500hrs

• Excellent chemical resistance against, a.o. exhaust

gas recirculation (EGR) condensates

• Hardness of Shore D61

Polyester

• Pure PET material, offering a very balanced

profile of high stiffness & ductility

• Low warpage & high dimensional stability

• Easy to recycle

• Good resistance to weathering

• Accurate printing

• Coatings and/or paints can be applied easily to

parts

Soft ToughRubber® developed by

Adaptive3D

• Combination of silicone feel and mechanical

properties with the resolution and surface finish

enabled by Digital Light Processing® (DLP)

printing

• Applications in medical models & consumer

products such as audio earbuds & footwear

• Commercialized by DSM (production,

distribution, sales)

Digital Light Processing® (DLP)

Products under development

• Somos®PerFORM HW - collaboration Origin

– Optimization of Somos Perform DSM’s unique

photopolymer material for Origin’s

‘programmable photopolymerization’ (P3)

technology

– Improved quality and surface finish

• Magnetically optimized composites

– Collaboration Fortify

– For 3D printing structural parts

– Using Fortify’s fiber processing expertise to

further improve mechanical and

temperature properties of our materials

– Applications in automotive, aerospace,

electronics, rapid tooling, jigs & fixtures.

Digital Light Processing® (DLP)

Products in development in collaboration

with CEAD

• Developing Fused Granulate Fabrication (FGF)

technologies for large-scale, highly filled

polymer 3D printing

• Create new materials and improve processing

and design for FGF

• Target applications: tooling and end-use parts

aimed at the automotive, marine and

infrastructure industries

• DSM is purchasing a CEAD robotic printer, for

R&D purposes in a first instance and open for

commercial projects via a service partner from

September onward.

Fused Granulate Fabrication

BRIGHT SCIENCE. BRIGHTER LIVING.