N A V I G A T I N G T H E D I G I T A L T H R E A D

U n d e r s t a n d i n g A d d i t i v e M a n u f a c t u r i n g f o r

I n d u s t r i a l A p p l i c a t i o n s

Presented by:

David K. Leigh

Senior Vice President of Engineering

Stratasys Direct Manufacturing

O V E R V I E W :

A . M . S E R V I C E S N E T W O R K • Stratasys’ advanced manufacturing services

business unit is the largest provider of additive manufacturing – 9 U.S. Manufacturing Facilities – 150,000 Ft2 Production Space – 12 Primary Technologies – 600+ Employees – ITAR Registered

• ISO 9001 Valencia (2), Poway, Tucson, Phoenix, Austin, Eden Prairie, Belton & Troy

• AS 9100 Valencia, Austin, Eden Prairie, & Belton

• 275+ Industrial AM Systems

• 1,600 unique part numbers

• Over 35K end-use part details and assemblies manufactured in 2014

O V E R V I E W :

L E A R N I N G O B J E C T I V E S

• Introductory assessment of processes capable of direct part production

• What applications each technology is best suited for

• How to integrate additive capabilities into production

• Managing design specifications and tolerance requirements for Laser Sintering

• Review of real-world applications using A.M. technologies

• Capabilities & limitations of CAD systems

• Understanding of new CAD and process modeling capabilities

H I G H P E R F O R M A N C E

A D D I T I V E P R O C E S S E S F O R

D I R E C T PA R T P R O D U C T I O N

P R O D U C T I O N T E C H N O L O G I E S

Selective Laser Sintering

Direct Metal Laser Sintering

Fused Deposition Modeling

CNC Machining

Cast Urethanes

SLS

DMLS

FDM

CNC

CAST

R A N G E O F 3 D P R I N T I N G S Y S T E M S

Consumer-Grade Industrial Mfg. Systems

Novel Widgets

To

Concept Models

Functional Prototypes

To

End-Use Hardware

Few AM processes currently vetted and approved for

flight hardware production

S E L E C T I V E L A S E R S I N T E R I N G

Uses a CO2 laser to fuse thermoplastic powders layer-by-layer to produce highly complex geometries from sliced CAD data

• Batching/Nesting

• Excellent mechanicals and durability

• Lightweight, thin-walled parts

• High strength-to-weight ratio

• Does not require build supports

• Nylon 11s and 12s

• Filled and unfilled materials

• Chemically resistant and flame retardant options available

M AT E R I A L S A N D P L AT F O R M S

• Materials:

– FR Nylon 11

– Nylon 11

– FR Nylon 12

– Nylon 12

– Carbon Fiber Filled Nylon 11 & 12

– Glass Filled Nylon 12

– Carbon Fiber & Glass Filled Nylon 11

– PEEK & PEKK

• .004” - .006” layers • Max. Build Envelope:

– 15”L x 13”W x 18”H (standard platform) – 27”L x 15”W x 22”H (XL platform)

A E R O S PA C E A P P L I C AT I O N S

Additive Manufacturing is opening up design possibilities for ducting applications, including

production of lightweight integrated structures that enable part consolidation.

D I R E C T M E TA L L A S E R S I N T E R I N G

• A layer-additive process that produces rugged metal prototype and production parts.

• Supports required due to high energy process

• Ideal for geometries that can’t be CNC machined, light-weight designs, and part consolidation

• Applications: small functional parts, complex geometries, end-use production parts

M AT E R I A L S & P L AT F O R M S

• Materials:

• Stainless Steel

• Cobalt Chrome

• Inconel 625,718

• Aluminum

• Titanium (coming soon)

• 20-micron to 40-micron layers

• Optimal Build Size: – Up to 4” x 4” x 4”

• Max. Build Envelope: – 9” x 9” x 9”

F I N I S H I N G & P O S T T R E AT M E N T S

Secondary operations can be applied to DMLS parts to meet your specifications.

• Options Include: – Micro Shot-Peened – Brushed – Hand Polished – CNC Machined – Tumbled

• Post Treatments:

– Heat treating – Stress relief – Hot Isostatic Pressing – Aging

Supports Removed – standard Machine Finish

Al Oxide Blast Shot Peened

Filed and Sanded Polished

F U S E D D E P O S I T I O N M O D E L I N G

Thermoplastic filament is heated to a semi-liquid state and extruded across computer-controlled tool paths to build parts layer-upon-layer.

• Produces prototypes as well as end-use parts.

• Very strong and functional

• High strength-to-weight ratio

• Chemically resistant & flame-retardant options available

• Large build volume (36” x 24” x 36”)

• Production-grade thermoplastics

M AT E R I A L S

• ABS – Great durability with a wide variety of

color choices

• ABS-ESD7 – The benefits of ABS with added static

dissipative properties

• ABS-M30 – Stronger than standard ABS with a variety

of color options

• ABSi – Solid and semi-translucent colors with

better impact strength than ABS

• ASA – UV resistance for outdoor commercial

and infrastructure end-use parts

M AT E R I A L S

• PC – Excellent durability and tensile strength

• PC-ABS – Blend with the highest impact resistance

of any polycarbonate

• PC-ISO – ISO 10993 certified, USP Class VI,

Classification 1 for medical applications

• FDM Nylon 12 – Excellent fatigue and chemical

resistance, one of the most popular plastics used in engineering

• PPSF – Best heat and chemical resistance of any

thermoplastic

• ULTEM 9085 – Certified to withstand flame, smoke, and

toxicity (FST)

U LT E M 9 0 8 5

ULTEM 9085 is a flame retardant high performance thermoplastic for DDM. It is ideal for the aerospace and transportation industries due to its high strength-to-weight ratio and its FST rating.

C A S T U R E T H A N E

Liquid silicone rubber is poured around a master pattern. The resulting mold is pulled from the pattern and cured, then subsequently used to cast urethane parts.

• SLA or CNC master pattern

• EMI, RFI shielding

• Cast in color and texture

• Complex over-molding

• Short-run or low volume mfg

• Bridge production

• Composite casting options – Fiberglass

– Graphite

– kevlar

F I N I S H I N G

Hand Finishing/Sanding

Cosmetic Prime and Paint

EMI & RFI Shielding

Textures & Mold-Tech® Finishes

Hardware (inserts, helicoils, etc.)

Assembly

Vapor Polish

Hand Polish (Metals)

ECS Ducting for Bell Helicopter Harvest Technologies produces complex parts for the Environmental Control System (ECS) of multiple Bell helicopters

M A N U FA C T U R I N G C A S E S T U D I E S

DMLS Fuel Nozzle in GE LEAP Engine GE is replacing their previous fuel nozzle (which required 20 small parts to be welded together) with a 3D printed

cobalt chrome nozzle. They expect to implement this nozzle in 2015-16, and produce 25K nozzles annually.

M A N U FA C T U R I N G C A S E S T U D I E S

Metal Plated SLS and Cast Urethane Parts for Emirates Emirates utilized metal plated FR-106 SLS parts for the table lamps in their Super First Class cabin on the A380. They

also chose cast urethane parts for the flower vases.

M A N U FA C T U R I N G C A S E S T U D I E S

A S S E S S I N G W H E R E

A D D I T I V E M A N U FA C T U R I N G

M A K E S S E N S E

M F G T E C H N O L O G Y I N P R O D U C T

D E V E L O P M E N T C Y C L E

F R E E D O M O F A D D I T I V E

M A N U FA C T U R I N G

• Tool-less (no molds, MUD bases, fixturing, cutters, etc.)

• Geometries designed for maximum functionality vs. tooling constraints

• No worries about undercuts, overhangs, gating, venting, etc.

• No need for draft angles, radii, fillets

• Creative contours, internal features, ribbing/stiffening

• Innovative weight savings capabilities (shelling, lattice work, honeycomb, supports)

• Part consolidation

• Green mfg with less waste (no milling away of excess material)

PA R T C O N S O L I D AT I O N

Traditional Manufacture:

16 piece assembly

Additive (LS) Manufacture:

One Contiguous

L I M I TAT I O N S O F

A D D I T I V E M A N U FA C T U R I N G

• Cost of machines & raw materials

• Limited recyclability of used material

• Build anomalies and associated scrap rate

• As-built tolerance lesser than tooled processes

• Necessary post processing for dimensional tolerance & cosmetics

• Anisotropy due to building in layers

• Feature detail and aesthetic qualities

• Limited economies of scale

E C O N O M I C S

( H O W A N D W H E R E T O S AV E )

• Low to mid volume production with no set up

• Virtual inventory, On demand mfg

• Batching & nesting (LS especially)

• Rev’ing designs without tooling modifications

• Effects of “splitting pie” between multiple vendors

– Customer costs: NREs qualifying & maintaining suppliers

– Fixed cost barriers & thresholds for suppliers

R E V I E W : C O M M O N R E A S O N S T O C H O O S E A . M .

• Weight savings

• Part consolidation

• Cost savings for low quantities

• One-offs and spares

• Parts undergoing several revisions or customization

• Faster time to market

• Ease of use/installation

Weight savings and part consolidation result in immediate cost savings to you, the manufacturer, and potential continued cost savings for the end-user over the life

of the product

M A N A G I N G D E S I G N S P E C S

A N D TO L E R A N C E S I N

L A S E R S I N T E R I N G

FA C T O R S A F F E C T I N G

D I M E N S I O N A L C O N T R O L

• Part Strength Requirements

• Global Scaling

• Laser Beam Characteristics

• Part Bed Thermal Control

PA R T S T R E N G T H :

A B A S I C R E L AT I O N S H I P

MECHANICAL STRENGTH ↑

DIMENSIONAL ACCURACY ↓

PA R T S T R E N G T H

• It is easy to build weak parts in LS

• Flight parts require strength validation

• Tensile bars are fabricated next to parts

– Ultimate Tensile Strength (UTS)

– Elongation at Fracture (EAF)

– Individual Tensile Modulus (ITM)

– Offset Yield Strength (OSY)

PA R T S T R E N G T H

PA R T S T R E N G T H :

M AT I N G L S PA R T S

Outer surfaces typically grow .005” (orange)

• Line to line CAD model results in interference • Negative features close

• Positive features grow

G L O B A L S C A L I N G

• Compensates for part shrinkage

• Compensates for mechanical constants

• Global scaling error is cumulative

– .5% error on 3.000” dimension 3.015”

– .5% error on 10.000” dimension 10.050”

• % of dimension is more representative of the process than hard tolerance callout

L S D I M E N S I O N A L D E S I G N

G U I D E L I N E S

• Allow point load application of force for profile conformity.

• Fitment between parts should allow for positive features to grow and negative features to shrink

L A S E R B E A M C H A R A C T E R I S T I C S

Most Noticeable Characteristics

• Laser Beam Diameter (.018”)

• Beam offsets

• Laser On/Off Response

More significant with smaller dimensions

L A S E R B E A M C H A R A C T E R I S T I C S

PA R T B E D T H E R M A L C O N T R O L

L S D I M E N S I O N A L D E S I G N

G U I D E L I N E S

Q U E S T I O N S ?

Thank You

David K. Leigh

Senior Vice President of Engineering

Stratasys Direct Manufacturing

David.Leigh@stratasysdirect.com

www.stratasysdirect.com