inside3dprinting_brentstuckerworkshop
DESCRIPTION
3dprintconfny14TRANSCRIPT
![Page 1: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/1.jpg)
Additive Manufacturing
Reshaping Manufacturing: Understanding 3D Printing Processes
Prof. Brent StuckerFounder & CEO, 3DSIM, LLC
Edward R. Clark Chair of Computer Aided EngineeringDepartment of Industrial Engineering, University of Louisville
Inaugural Chairman, ASTM F42 Committee on Additive Manufacturing
![Page 2: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/2.jpg)
Additive Manufacturing
AM has the potential to enable anyone to make many things they
require, anywhere!
![Page 3: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/3.jpg)
Additive Manufacturing
AM enables…
…an advanced manufacturing facility to be set up using only electricity, some raw materials, and a computer.
![Page 4: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/4.jpg)
Additive Manufacturing
AM enables…
…an entrepreneur to start selling a new product without ever needing to buy a machine, purchase a tool or prove out a mold; and start shipping products the day after the design is finalized.
![Page 5: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/5.jpg)
Additive Manufacturing
AM is used for the…
…automatedmanufacture of hearing aids so that you simply scan the ear, print out a custom-fitted hearing aid, insert electronics, and ship them by the millions.
![Page 6: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/6.jpg)
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
![Page 7: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/7.jpg)
Additive Manufacturing
University of Louisville’s Involvement in AM
• One of the best equipped additive manufacturing (AM) facilities in the world
• Performing Basic and Applied Research, since starting with SLS in 1993
• Over 20 people focused on AM• Close partner of leading AM users
– Boeing, GE, DoD, service bureaus, etc.
• Over 70 member organizations in our RP Center– Includes Haas Technical Education Center
![Page 8: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/8.jpg)
Additive Manufacturing
Typical AM Process Chain
1. Create CAD Solid Model
2. Generate STL File3. Verify File & Repair4. Create Build File
1. Orientation, Location2. Slicing3. Support Material
Generation5. Build part layer-by-
layer6. Post-processing
Click for Movie
![Page 9: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/9.jpg)
Additive Manufacturing
What is an STL Model File?
• Represents 3D solid models using groups of planar triangles– Describe each triangle by
• 3 vertices & unit normal vector– No topological information
• Enumerate all triangles • No special order
– Better accuracy = smaller triangles = larger files
• Set triangle accuracy relative to accuracy of machine used
• Holes between triangles, overlapping triangles, and inverted vectors can be problems
• No knowledge of dimensions (mm or inches)
Facet 1
Facet 2
Facet 3
![Page 10: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/10.jpg)
Additive Manufacturing
New Additive Manufacturing File Format
• AMF– Additive Manufacturing Format– Additive Manufacturing File
![Page 11: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/11.jpg)
Additive Manufacturing
General Concept(XML)
• Parts (objects) defined by volumes and materials– Volumes defined by triangular mesh – Materials defined by properties/names
• Color properties can be specified– Color– Texture mapping
• Materials can be combined– Graded materials– Lattice/Mesostructure
• Objects can be combined into constellations– Repeated instances, packing, orientation
![Page 12: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/12.jpg)
<?xml version="1.0" encoding="UTF-8"?><amf units="mm">
<object id="0"><mesh>
<vertices><vertex>
<coordinates><x>0</x><y>1.32</y><z>3.715</z>
</coordinates></vertex><vertex>
<coordinates><x>0</x><y>1.269</y><z>2.45354</z>
</coordinates></vertex>...
</vertices><region>
<triangle><v1>0</v1><v2>1</v2><v3>3</v3>
</triangle><triangle>
<v1>1</v1><v2>0</v2><v3>4</v3>
</triangle>...
</region></mesh>
</object></amf>
Basic AMF Structure
Addresses vertex duplication, leaks of STL & UNITS
![Page 13: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/13.jpg)
Additive Manufacturing
Compressibility
Comparison for 32‐bit Floats; need to look at double precision
![Page 14: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/14.jpg)
CURVED PATCH(Curved using vertex normals)
PLANNAR PATCH
Optionally add normal/tangent vectors to some triangle mesh vertices
to allow for more accurate geometry.
CURVED PATCH(or curved using edge tangents)
Curved patches
![Page 15: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/15.jpg)
Additive Manufacturing
Multiple Materials
Micro-structureGradient
Materials
![Page 16: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/16.jpg)
Additive Manufacturing
Print Constellation
• Print orientation• Duplicated objects• Sets of different objects• Efficient packing• Hierarchical
![Page 17: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/17.jpg)
Additive Manufacturing
Metadata
<metadata type=“Author”>John Doe”></metadata><metadata type=“Software”>SolidX 2.3”></metadata><metadata type=“Name”>Product 1></metadata><metadata type=“Revision”>12A”></metadata>
<object id=“1”><metadata type=“Name”>Part A ></metadata>
</object id=“1”>
![Page 18: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/18.jpg)
Additive Manufacturing
How do we build parts using AM?
• 7 Process Categories– ASTM/ISO Standard terminology, categories &
definitions will be used
• What are the secret limitations you might not be aware of?
• What types of materials can you use?• What is each process good for?
![Page 19: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/19.jpg)
Additive Manufacturing
Vat Photopolymerization
• An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. – Stereolithography– Envisiontec DLP– Micro-SLA– 2-photon lithography– …
![Page 20: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/20.jpg)
Additive Manufacturing
Projection Systems
• Use a projector (LED or DLP) to illuminate the cross-section – Resolution limited by
pixels of projector– Typically faster per
layer– Common for micro-
stereolithography
http://www.cmf.rl.ac.uk/latest/msl.html
![Page 21: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/21.jpg)
Additive Manufacturing
Envisiontec Perfactory
www.ajm-magazine.com www.crdm.co.uk
![Page 22: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/22.jpg)
Additive Manufacturing
Developments in Vat Photopolymerization
• Increased proliferation of DLP/LCD/LED technology to cure entire layers at once.
• New photopolymer materials which mimic engineering photopolymers
• Expiration of initial stereolithography patents are opening up the marketplace
• Renewed interest in 2-photon polymerization for nano-scale components
![Page 23: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/23.jpg)
Additive Manufacturing
Secrets of Vat Photopolymerization
• Always need supports– Thus, we must remove them– Downward facing surfaces are inferior
• Photopolymers do not have long-term stability in the presence of light– They continue to react and degrade over time.
![Page 24: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/24.jpg)
Additive Manufacturing
Materials in VP
• Over 20 years of photopolymer research, including by major chemical companies, has led to many resins which you can buy
• No materials are “standard engineering-grade” polymers– Specially-formulated to mimic engineering polymers
![Page 25: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/25.jpg)
Additive Manufacturing
What is VP best for?
• High accuracy parts that don’t have stringent structural requirements
• Patterns– Investment casting– RTV molding– …
![Page 26: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/26.jpg)
Additive Manufacturing
Material Jetting
• An additive manufacturing process in which droplets of build material are selectively deposited– Wax or Photopolymers– Multiple nozzles – Single nozzles– Includes
• Objet• 3D Systems Projet• Stratasys Solidscape machines• Several Direct Write machines• Etc…
![Page 27: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/27.jpg)
Additive Manufacturing
Single-Droplet
• Solidscape Modelmakers– 0.0005” layers – small, accurate parts made slowly
![Page 28: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/28.jpg)
Additive Manufacturing
Multi-Droplet
• Thermojet and Actua from 3D Systems– Prints waxy-like materials
• No longer in production, but still serviced
![Page 29: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/29.jpg)
Additive Manufacturing
Developments in Material Jetting
• New Stratasys/Objet Connex 500– Multi-material & Multi-color
• Many traditional “2D printing” companies are investigating 3D printing– Thermoplastics are difficult
• Viscosity issues
– Metals are starting to be publically discussed
• Significant interest in printed electronics– Major industry interest at the intersection between 2½D
& 3D geometries
![Page 30: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/30.jpg)
Additive Manufacturing
Secrets of Material Jetting
• Always need supports– Thus, we must remove them– Downward facing surfaces are inferior (particularly true
if secondary support materials are not used)
• Secondary support materials make support removal easier– Water Soluble– Different Strength– Different Melting Temp
![Page 31: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/31.jpg)
Additive Manufacturing
Material Jetting Materials
• Only commercial materials are wax-like materials or photopolymers– Need low viscosity– Waxes melt at low temperature, but solidify quickly– Photopolymers are cured using light just after
deposition
• No materials are “standard engineering-grade” polymers– Specially-formulated to mimic engineering polymers
![Page 32: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/32.jpg)
Additive Manufacturing
What is Material Jetting best for?
• Smooth, accurate parts that don’t have stringent structural requirements
• Mixing of stiff and flexible materials/colors gives tremendous variability in design– Artwork– Full-color mock-ups– Gradient material assemblies– …
![Page 33: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/33.jpg)
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– …
![Page 34: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/34.jpg)
Additive Manufacturing
Developments in Binder Jetting
• 3D Systems purchased Zcorp and has changed marketing to “Colorjet”– Printing sugary food and ceramics (pottery & art)– Announced a color personal 3D printer
• ExOne is pushing “sand printing” and builds metal parts for Shapeways
• Voxeljet, fcubic, etc. make marketplace dynamic– Continuous build platform design has major
ramifications
![Page 35: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/35.jpg)
Additive Manufacturing
Secrets of Binder Jetting
• Parts from starch/plaster look pretty but are quite brittle– Post-process infiltration of these materials by
cyanoacrylate or another material is needed for strength• Infiltration makes these parts very heavy
• Metal parts are not engineering-grade– Mostly applicable to art– Need infiltrated (highest accuracy)
or sintered (shrinks)
![Page 36: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/36.jpg)
Additive Manufacturing
Binder Jetting Materials
• Majority of the build material is the powder– Makes the process very, very fast
• Materials are by nature “composite”• Gradients in color/properties possible by printing
different binders• Any powder which can be spread and then glued,
reacted, catalyzed, or otherwise fused using a binder is a candidate
• Living tissue and dental ceramics are promising
![Page 37: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/37.jpg)
Additive Manufacturing
What is Binder Jetting best for?
• Color parts used for marketing or proof-of-concept.
• Metal parts for artistic purposes or with limited engineering functionality.
• Powder metal green parts• Sand casting molds
![Page 38: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/38.jpg)
Additive Manufacturing
Material Extrusion
• An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice– Based on Stratasys FDM
machines– Office friendly– DIY community– Best selling platform– …
![Page 39: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/39.jpg)
Additive Manufacturing
Developments in Material Extrusion
• Expiration of initial FDM patents has led to a vast proliferation of personal 3D printers– More “personal” machines sold @$1k-$2k than “industrial”
machines for $10k-$200k– Lots of new materials, competitors, etc.– Many ways for consumers to access & buy these machines
• 3D Systems & Stratasys offer personal 3D printers in addition to their industrial offerings
• Renewed interest in “manufacturing” parts via extrusion– High-temp materials, concrete, fiber-reinforced composites, etc.– People seem to be taking it more seriously than a few years ago
![Page 40: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/40.jpg)
Additive Manufacturing
Secrets of Material Extrusion
• Always need supports– Thus, we must remove them– Downward facing surfaces are inferior
• Secondary support materials make support removal easier– Water soluble, easier to remove, etc.
• Fundamental tradeoffs in build style mean you can NEVER be fully dense & simultaneously achieve maximum accuracy without post-processing
![Page 41: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/41.jpg)
Additive Manufacturing
Material Extrusion Materials
• Commercial materials include easy to extrude engineering polymers– ABS, PC, PC/ABS, PPSF, etc.– Chocolate and meltable food products– Many DIY materials being explored
• Syringe & pumped nozzles also available– Pastes, glue, cement– Frosting & other food products
• Need materials which soften under shear load and maintain their shape after deposition
![Page 42: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/42.jpg)
Additive Manufacturing
What is Material Extrusion best for?
• Inexpensive prototypes• Functional parts without
stringent engineering constraints– Limited fatigue strength
• Great platform on which to try lots of things– Living tissue– Food– Toys
![Page 43: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/43.jpg)
Additive Manufacturing
Powder Bed Fusion
• An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed– SLS, SLM, DMLS, EBM, BluePrinter, etc. – Polymers, metals & ceramics
![Page 44: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/44.jpg)
CO2 LaserX-Y Scanning
Mirrors
FeedCartridges
PartCylinder
Counter-RotatingPowder LevelingRoller Laser Beam
SelectivelyMelts Powder
SELECTIVE LASER SINTERING
![Page 45: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/45.jpg)
45
Loose Powder
![Page 46: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/46.jpg)
46
Energy is Applied – Laser or Electron Beam Energy
Radiation/Heat from
Energy Source
![Page 47: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/47.jpg)
47
The Powder Begins to Heat Due to Incident Radiation
![Page 48: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/48.jpg)
48
The Outside of the Particles Heat More Quickly than the Inside
![Page 49: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/49.jpg)
49
Smaller Particles Begin to Melt
![Page 50: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/50.jpg)
50
Larger Particles May or May Not Melt Depending Upon Dwell Time of Radiation
![Page 51: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/51.jpg)
51
Melted Portions of the Material Begin to Coalesce (Sinter) Resulting in a Physical Bond and Shrinkage
![Page 52: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/52.jpg)
52
When the Heat is Removed, the Part Cools as a Porous Solid
![Page 53: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/53.jpg)
53
Melting within a Powder Bed Can Lead to Curl
![Page 54: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/54.jpg)
54
Melting within a Powder Bed Can Lead to Curl
![Page 55: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/55.jpg)
55
Melting within a Powder Bed Can Lead to Curl
![Page 56: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/56.jpg)
56
Melting within a Powder Bed Can Lead to Curl
![Page 57: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/57.jpg)
57
Undesirable Shrinkage Controllable Shrinkage Heater Scanning System
Comparison of Shrinkage With and Without Heaters
![Page 58: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/58.jpg)
58
Undesirable Shrinkage Controllable Shrinkage Scanning SystemHeaterHeater
Comparison of Shrinkage With and Without Heaters
![Page 59: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/59.jpg)
59
Undesirable Shrinkage Controllable Shrinkage Scanning SystemHeater
Index
Comparison of Shrinkage With and Without Heaters
![Page 60: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/60.jpg)
60
Undesirable Shrinkage Controllable Shrinkage Scanning SystemHeater
Comparison of Shrinkage With and Without Heaters
![Page 61: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/61.jpg)
Additive Manufacturing
Metal Laser Sintering Methods for Controlling Shrinkage
Complex Scan Patterns Supports
![Page 62: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/62.jpg)
Additive Manufacturing
Electron Beam Melting (EBM) Arcam
• Electrons are emitted from a heated filament >2500° C
• Electrons accelerated through the anode to half the speed of light
• A magnetic lens focuses the beam
• Another magnetic field controls deflection
• When the electrons hit the powder, kinetic energy is transformed to heat.
• The heat melts the metal powder
No moving parts!
![Page 63: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/63.jpg)
Additive Manufacturing
EBM versus Laser Processes
• EBM Benefits – Energy efficiency– High power (4 kW) in a narrow
beam– Incredibly fast beam speeds
• No galvanometers– Fewer supports
• EBM Drawbacks– Only works in a vacuum
• Gases (even inert) deflect the beam
– Does not work well with polymers or ceramics
• Needs electrical conductivity– Needs larger powder particles
![Page 64: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/64.jpg)
Additive Manufacturing
Developments in Powder Bed Fusion
• The most-used platform for “functional parts” • Significant R&D investments• Many metal laser sintering machine manufacturers
– SLM Solutions, ConceptLaser, EOS, Phenix, Renishaw, Realizer
• Starting to see new polymer machine manufacturers– Several companies entering the marketplace to compete with 3D
Systems & EOS
• Open versus Closed machine architecture battles• GE’s purchase of Morris Technologies (2012) is still
having major ramifications on the metal laser sintering marketplace
![Page 65: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/65.jpg)
Additive Manufacturing
Secrets of Powder Bed Fusion
• An Expert User is the most critical aspect of getting a good part– User-selected trade-offs between speed, accuracy and
strength in polymer laser sintering– Takes about a year to learn enough to consistently make
good parts in metal processes
• Polymers are not 100% recyclable• Metal supports are a huge pain
– $50k-$100k/year per machine waste is common• Blade crashes and/or over-supporting
![Page 66: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/66.jpg)
Additive Manufacturing
Polymer Materials in Powder Bed Fusion
• You can use any material you want, as long as it’s nylon – Or if it meets the
cooling curve
• Opposite of injection molding– Fast heating, slow
cooling
![Page 67: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/67.jpg)
Additive Manufacturing
Metal Materials in Powder Bed Fusion
• Most casting and welding alloys can be processed using metal laser sintering– Very fast melting & solidification times gives unique
properties & challenges– High reflectivity, high thermal conductivity materials
are difficult to process (copper, gold, aluminum, etc.)
• Titanium is the “sweet spot” for EBM
![Page 68: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/68.jpg)
Additive Manufacturing
Other Materials in Powder Bed Fusion
• Ceramics are difficult, but possible to directly process
• Green parts are easy to process– Powder metallurgy, sand casting, etc.
![Page 69: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/69.jpg)
Additive Manufacturing
What is Powder Bed Fusion best for?
• Manufacturing end-use products– Polymer parts from Nylon 11 or 12 (including glass-
filled nylons)– Metal parts from Titanium, Stainless Steel, Inconel
super alloys, tool steels and more
• Prototyping components where functional testing is required on the prototype
![Page 70: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/70.jpg)
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…
![Page 71: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/71.jpg)
Additive Manufacturing
Developments in Sheet Lamination
• Renewed interest in paper-based machines at the low-end by Mcor and others
• Fabrisonics sells 3 platforms based upon metal ultrasonic additive manufacturing
• Other solid state AM methods are being investigated– Friction stir AM, etc.
![Page 72: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/72.jpg)
Additive Manufacturing
Secrets of Sheet Lamination
• Getting rid of excess material is difficult– Cut then Stack – versus –
Stack then Cut– Mechanical properties are
typically quite poor
http://www.cubictechnologies.com/
![Page 73: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/73.jpg)
Additive Manufacturing
Materials in Sheet Lamination
• Paper is used for proof of concept parts– Color printing on the paper gives color parts
• Metal sheets can be cut and stacked for tooling and other applications
• Ceramic tapes can be cut and stacked and then fired for ceramic parts
• Polymer sheets (such as by Solido) can be bonded and cut to form prototypes
![Page 74: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/74.jpg)
Additive Manufacturing
What is Sheet Lamination best for?
• Paper machines make cheap physical representations of your design
• Original LOM-like machines can be used like wood as patterns for sand casting, or as topographical maps, etc.
• Metal laminated tooling reduces the time to build large molds such as for stamping
• Micro-fluidic ceramic parts can be made using ceramic tapes
![Page 75: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/75.jpg)
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
![Page 76: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/76.jpg)
Additive Manufacturing
Developments in Directed Energy Deposition
• Electron Beam with wire seems to be leading for part production currently
• DoD is interested in laser powder deposition for repair (America Makes project)– Manufacturers are marketing
laser deposition heads as add-ons to existing machine tools
![Page 77: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/77.jpg)
Additive Manufacturing
Secrets of Directed Energy Deposition
• Material needs something to land on (supports)– We don’t typically make 3D complex parts, just
complex parts with mostly upward-facing features
• There is a direct correlation between feature size and build speed. – Accurate processes are painfully slow– Fast process are very inaccurate
• Surface finish & accuracy requirements almost always require finish machining
![Page 78: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/78.jpg)
Additive Manufacturing
Materials in Directed Energy Deposition
• Most metal alloys can be deposited with some success– Rapid cooling
affects properties
• Polymers and ceramics rarely used, but possible
Optical Absorption vs Wavelength
Wavelength (microns)
![Page 79: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/79.jpg)
Additive Manufacturing
What is Direct Energy Deposition best used for?
• Adding features to existing structures– Replace complex forgings with sheet structures that we
build up near-net shape parts on
• Repair & refurbishment of existing components– Qualified for many high-performance applications
![Page 80: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/80.jpg)
Additive Manufacturing
General Comments
• Powder Materials• Modeling• Implications of AM
![Page 81: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/81.jpg)
Additive Manufacturing
Powders
• Small powder particles– Give better feature resolution, surface finish,
accuracy and layer thicknesses– Are difficult to spread and/or feed– Become airborne easily (repel in EBM)– React with oxygen easily
• Spherical powders with a tight PSD are best• Powder morphology, packing density, fines, etc.
make a HUGE difference in some processes
![Page 82: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/82.jpg)
Additive Manufacturing
AM can now enable us to…
…control the overall geometry of a part, which could be made up of a truss network, where each truss has an optimized thickness and could have an individually controllable microstructure or material.
• But we don’t know how to:• Efficiently represent this type of multi-scale
geometry in a CAD environment, or• Efficiently optimize these multi-scale features, or• Efficiently simulate the link between AM
process parameters and microstructure, or• Efficiently compute the effects of changes in
microstructure on part performance
Courtesy David Rosen, Georgia Tech
![Page 83: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/83.jpg)
Additive Manufacturing
Simulation Needs
• We need improved computational design tools for additive manufacturing
• Like those used for injection molding and casting/forging
• But, physics-based tools are inefficient when applied to AM• Requires dramatic simplification of the process and/or geometry
• Instead, AM-industry software focuses primarily on geometry and not process control or performance/quality
• Forces the AM industry to continue the Build/Test/ Redesign cycle of traditional manufacturing.
![Page 84: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/84.jpg)
Additive Manufacturing
• Process simulations that are faster than an AM machine builds a part– Predict residual stress and distortion so we know how to place
supports and how to pre-distort our CAD model
• Material simulations which can predict crystal leveldetails and the resulting mechanical properties
• Lightning fast solutions on GPU-based platforms• We simulate only what we need to get a practical
answer as FAST as possible • Come tomorrow morning to hear more….
![Page 85: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/85.jpg)
Additive Manufacturing
Engineering Implications
• More Complex Geometries– Internal Features– Parts Consolidation– Designed internal structures
• No Tools, Molds or Dies– Direct production from CAD
• Unique materials– Controllable microstructures– Multi-materials and gradients– Embedded electronics
![Page 86: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/86.jpg)
Additive Manufacturing
Business Implications
• Enables business models used for 2D printing, such as for photographs, to be applied in 3D– Print your parts at home, at a local “FedEx Kinkos,”
through “Shapeways” or at a local store• Removes the low-
cost labor advantage• Entrepreneurship
– Patents expiring• New Machines
– Software tools– Service providers Pharmaceutical Manufacturing in China
![Page 87: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/87.jpg)
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
87
![Page 88: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/88.jpg)
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”
![Page 89: Inside3DPrinting_BrentStuckerWorkshop](https://reader036.vdocuments.us/reader036/viewer/2022081403/55490b82b4c90553458b92dc/html5/thumbnails/89.jpg)
Additive Manufacturing
Big Picture Possibilities
• Additive Manufacturing has the potential to:– Make local manufacturing of products normative
• Small businesses can successfully compete with multi-national corporations to produce goods for local consumption
• Parts produced closer to home cost the same as those made elsewhere, so minimizing shipping drives regional production
– Reverse increasing urbanization of society • No need to move to the “big city” if I can design my product
and produce it anywhere– Make jobs resistant to outsourcing
• Creativity in design becomes more important than labor costs for companies to be successful
89