trends in polymer processing – perception and reality of ......enterprise 3d printing (additive...
TRANSCRIPT
20.10.2014
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Prof. Dr.-Ing. XYZProf. Dr.-Ing. Dietmar Drummer
Institute of Polymer TechnologyUniversity Erlangen-Nuernberg
Am Weichselgarten 991058 ErlangenIn
stitu
te o
f Pol
ymer
Tec
hnol
ogy
–U
nive
rsity
Erla
ngen
-Nue
rnbe
rg
Trends in polymer processing –perception and reality of additive manufacturing
International Conference on Additive Technologies,Vienna, 15. - 17.10.2014
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Medial Interest
Laser andfine powder
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Public Interest
[source: IPO] [source: google]
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Industrial Sectors
[source: Widex]
[source: Stratasys]
[source: EOS]
[source: BMW]
[source: 3dsystems]
[source: EOS]
[source: Fraunhofer Institut]4% of industry revenues, 2013
[source: Wohlers Report]
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Market Research – Megatrends
5 [source: McKinsey Global Institute analysis]
BusinessIndividuals
Government
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Market Research – Megatrends
6 [source: McKinsey Global Institute analysis]
BusinessIndividuals
Government
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Hype Cycle
TechnologyTrigger
Peak ofInflated
Expectations
Trough of Disillusionment
Plateau of Productivity
Slope of Enlightenment
Expectations
Time[source: Gartner]
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Hype Cycle of Megatrends
TechnologyTrigger
Peak ofInflated
Expectations
Trough ofDisillusionment
Plateau ofProductivitySlope of Enlightenment
Expectations
time
Advancedrobotics
Cloud technology
Energy storage
Consumer 3D Printing
[source: Gartner]
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Laminated ObjectManufacturing (LOM)
Fused Layer Modelling (FLM)
Stereolithography(SLA)
3D-Printing (3DP)
9
Hype Cycle
TechnologyTrigger
Peak ofInflated
Expectations
Trough ofDisillusionment
Plateau ofProductivitySlope of Enlightenment
Expectations
time
Advancedrobotics
Cloud technology3D Bioprinting
Energy storage
Selektive Laser Sintering (SLS)Enterprise 3D Printing (Additive Manufacturing)
Consumer 3D PrintingCeramicAdditive Manufacturing
Metal AdditiveManufacturing
[source: Gartner]
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Laminated ObjectManufacturing (LOM)
Fused Layer Modelling (FLM)
Stereolithography(SLA)
3D-Printing (3DP)
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Hype Cycle of Additive Manufacturing
TechnologyTrigger
Peak ofInflated
Expectations
Trough ofDisillusionment
Plateau ofProductivitySlope of Enlightenment
Expectations
time
3D Bioprinting
Selektive Laser Sintering (SLS)Enterprise 3D Printing (Additive Manufacturing)
Consumer 3D PrintingCeramicAdditive Manufacturing
Metal AdditiveManufacturing
[source: Gartner]
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Laminated Object Manufacturing (LOM)
Fused Layer Modelling (FLM)
Stereolithography(SLA)
3D-Printing (3DP)
11
Hype Cycle of Additive Manufacturing
TechnologyTrigger
Peak ofInflated
Expectations
Trough ofDisillusionment
Plateau ofProductivitySlope of Enlightenment
Expectations
time
Selektive Laser Sintering (SLS)
[source: Gartner]
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Additive Manufacturing Processes
3-D (strand, cable, )
Fused Deposition / Layer Modeling
(FDM / FLM)
2-D (sheet, film, )
Laminated Object / Layer Manufacturing
(LOM / LLM)
1-D (floating
medium, )
Stereolithography(SLA)
3D-Printing (3DP)
Selective Laser Sintering (SLS)
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Performance of Additive Manufacturing Processes
13 [Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
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maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
. . . .
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Performance of Additive Manufacturing Processes
14 [Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
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0 0,05 0,1 0,15 0,2
capa
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of p
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[mm
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maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
. . . .
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Performance of Additive Manufacturing Processes
15 [Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
0
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30
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0 0,05 0,1 0,15 0,2
capa
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of p
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[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
. . . .
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Performance of Additive Manufacturing Processes
16 [Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
0
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0 0,05 0,1 0,15 0,2
capa
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of p
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z-di
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[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
. . . .
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Performance of Additive Manufacturing Processes
17 [Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
0
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0 0,05 0,1 0,15 0,2
capa
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of p
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[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
. . . .
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Performance of Additive Manufacturing Processes
18 [Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
0
10
20
30
40
50
60
0 0,05 0,1 0,15 0,2
capa
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of p
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n in
z-di
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[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
*
*
* support structures needed*
*
*
*
*
**
*
. . . .
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0
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20
30
40
50
60
0 0,05 0,1 0,15 0,2
capa
city
of p
rodu
ctio
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z-di
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ion
[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
*
*
* support structures needed*
*
*
*
*
**
*
. . . .
Performance of Additive Manufacturing Processes
material restrictions:
amorphous
semi-crystalline
paper, metal sheetsacrlyic, epoxy, vinyl resins
[Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
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0
10
20
30
40
50
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0 0,05 0,1 0,15 0,2
capa
city
of p
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ctio
n in
z-di
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ion
[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
*
*
* support structures needed*
*
*
*
*
**
*
. . . .
Performance of Additive Manufacturing Processes
0 cm³ 500000 cm³ [materialise]
part size
[Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
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0
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20
30
40
50
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0 0,05 0,1 0,15 0,2
capa
city
of p
rodu
ctio
n in
z-di
rect
ion
[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
*
*
* support structures needed*
*
*
*
*
**
*
. . . .
Performance of Additive Manufacturing Processes
0 cm³ 500000 cm³
part size
[LKT]
[Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
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0
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0 0,05 0,1 0,15 0,2
capa
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of p
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z-di
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ion
[mm
/h]
maximum resolution [mm]
FDM
LOM
3DP
SLA
SLS
*
* support structures needed*
*
*
*
*
*
. . . .
Performance of Additive Manufacturing Processes
part size
0 cm³ [AUDI]500000 cm³
[Stratasys, EOS, 3D-Systems, Z-Corporation, chip.de]
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Research Activities worldwide (2010)
23
The University of Queensland (AU)
Loughborough UniversityLeicestershire (UK)
University ofMissouri (US)
Utah State University (US)
University of Texas, Austin (US)
NCSU, North Carolina (US)
Overlapping activities:
AMRC Sheffield (UK)
Dansk Teknologisk Institut Forening (DK)
INSA Lyon (FR)
ETH Zürich (CH)
K.U. Leuven (BE)
University Maribor
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Research Activities worldwide (2014)
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AMRC Sheffield (UK)
NCSU, North Carolina (US)
University of Texas, Austin (US)
The University of Queensland (AU)
University ofMissouri (US)
Utah State University (US)
MIT (US)
HuazhongUniversity
Wuhan (CHN)
Chinese Academy ofEngineering
Peking (CHN)
Xi‘an JiatonUniversity Xi‘an
(CHN)
Imperial College (UK)
Virginia State University (US)
University ofNottingham (UK)
University of Exeter(UK)
University ofConnecticut (US)
Penn State University (US)
South Dakota SMT (US)
University ofWaterloo (CA)
ORNL Tennessee (US)
NorthwesternUniversity Illinois (US)
Auckland University of Technology (NZ)
Monash University (AU)
RMIT University Melbourne (AU)
STEM Ohio (US)
University ofMinnesota (US)
Dansk Teknologisk Institut Forening (DK)
K.U. Leuven (BE)
INSA Lyon (FR)
Loughborough UniversityLeicestershire (UK)
ETH Zürich (CH)Zürcher HS (CH)
TU Wien (AT)
Cracow University of Technology (PL)
CSIR South Africa (ZA)
Overlapping activities:
University Maribor
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Research Activities in Germany (2010)
25
Berlin
Paderborn
Erlangen
Duisburg
HamburgBremen
Stuttgart
Overlapping activities: GesellschaftProduktionstechnik
RM PlattformDeutschland
Fraunhofer UMSICHT
DMRC Paderborn
Universität Bremen/BIASFraunhofer IFAM
TU Hamburg-HarburgLaser Zentrum Nord
Universität Duisburg-Essen
Universität Stuttgart/ Fraunhofer IPA
Oberhausen
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Research Activities in Germany (2014)
26
Berlin
Paderborn
Duisburg
Hamburg
TU Hamburg-HarburgLaser Zentrum Nord
DMRC Paderborn
Universität Duisburg-Essen
Universität Bremen/BIASFraunhofer IFAM
Bremen
Fraunhofer UMSICHT
Overlapping activities: GesellschaftProduktionstechnik
RM PlattformDeutschland
Universität Stuttgart/ Fraunhofer IPA
Stuttgart
MünchenFreiburg
Würzburg
DresdenChemnitz
Lemgo
Bonn
Karlsruhe
Darmstadt
Köln
Magdeburg
Deggendorf
Augsburg
Karlsruher Institut für Technologie
HS Ostwestfalen - Lippe
Beuth Hochschule für Technik Berlin / TU Berling
iwb der TU München TH Deggendorf
LF Köln
Fraunhofer IWM
Fraunhofer IPT
HS Bonn-Rhein-Sieg
TU Darmstadt
SKZ / Universität Würzburg
TU Dresden / Fraunhofer IKTS/IWS
TU Chemnitz
Fraunhofer IFF
Fraunhofer IZM
HS Augsburg
Aachen
Oberhausen
Erlangen
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Challenges in Additive Manufacturing exemplary shown on powder based Techniques
27
Powder
Component Process
Component
Boundary Conditions[source: kult-cube]
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Challenges in Additive Manufacturing exemplary shown on powder based Techniques
28
Powder
� powder production
� disposability and price
� material aging
� material requirements (temperature conditions)
� variety of materials
Neumaterial1 cm
cold-wet grinding
orange peel effect
melt emulsification
PBT PA12
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Challenges in Additive Manufacturing exemplary shown on powder based Techniques
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Process
� process and part layout
� machinery
� repeatability of processes
� simulation
� patents
temperature distribution building chamber
delamination due to a missing layer
PowderPowder
Roller Rake
PE-LD PP
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Challenges in Additive Manufacturing exemplary shown on powder based Techniques
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Component
porosity and surface topology of a laser sintered part
� mechanical part properties
� internal stresses / deformation
� anisotropy
� topology optimization
� surface quality
Young‘s modulusBreaking stressElongation
Elon
gatio
n at
bre
ak [%
]
Bre
akin
g st
ress
[N/m
m²]
Youn
g’s
mod
ulus
[N/m
m²]
20 mm
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Challenges in Additive Manufacturing exemplary shown on powder based Techniques
31
Boundary Conditions
� construction
� shaping and education
� legal situation
data preparation
construction
[source: MakerBot]
[source: kult-cube]
orginal scan print
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Summary
[source: FESTO]
PRODUCTIDEA
[source: kult-cube]
Powder Process Component Boundary Conditions
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Genesis of Additiv Manufacturing
33 ground of facts[source: airbus]
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Thank you for your attention