Basics of 3D Printing Introduction

Home , 3D printing, Cobalt (CAD program), RepRap Project, ZBrush

Hands-on Workshop: Basics of 3D Printing Introduction Ville Kukko-Liedes IdeaSquare 3.-4.11.2018 Ville Kukko-Liedes [email protected] • MA student of Product Development and Machine Design • 3D PrintShop manager in Aalto Design Factory

• Hobbyist 3D printing, 2012 • Rapid Prototyping and model making services, 2013 • Product development consulting services, 2014 • Design Factory PrintShop, 2014 Own DIY machines:

• Mendel Max 1.5, 2012 - 2014 • RepRap Industrial Mini ‘PaPa’, 2014 --> • RepRap Industrial 2014 --> SOLD • RepRap Industrial DF ‘NuNu’, 2014 --> • CoCo, 2017 --> + other smaller projects Saturday

• What is 3D printing and where it can be used?

• Understanding 3D Printing methods • FDM & SLA technologies

• Getting started with 3D printing • Hands-On 3D Modeling & printing

Sunday

• Understanding 3D Printing methods • Advanced methods

• Hands-On 3D Modeling & printing continues What is 3D Printing? What is 3D Printing?

Additive Manufacturing (AM): Construction of physical objects directly from 3D CAD data – usually layer upon layer (CAD = Computer Aided Design) What is 3D Printing?

Additive Manufacturing (AM): As opposed to e.g. Construction of physical subtractive manufacturing objects directly from 3D CAD (milling, turning etc.) data – usually layer upon layer (CAD = Computer Aided Design) What is 3D Printing?

- Producing 2D layers is relatively simple

- Parts usually need to be supported from below Principle

STL file – From CAD, “Slicing” to multiple layers, Part production 3D-scan, etc. toolpath using calculated calculated for each paths Advantages of 3D Printing – Freedom of design – complexity is free Form optimization, pre-assembly, easy customization..

– No need for tooling No cost from design changes & cheap small volume prod.

– No need for inventory On-demand manufacturing, minimal investment,

– Fast lead times & responsiveness Quick alteration in design to respond to customer needs

– Localized manufacturing Manufacturing where needed, savings in logistics – Wide material range – seamless transitions Innovation potential with new opportunities

– Affordable low volume production Price per piece constant regardless of production size Uses: Rapid Prototyping - The original and still much used application of 3D printing - Commercialized in the 80s (SLA by 3D Systems) - Extremely popular in product development: - Fast testing of form, fit, function, ergonomics.. - Accurate representation of intended material properties and function possible - Affordable and quick to produce prototypes provide early feedback - Fail faster to succeed earlier! - Concept wireless Uses: Rapid Prototyping charging station for a plush toy / nightlight Uses: Rapid Manufacturing - Use of AM to produce end-use parts and products - Expansion during the last 13 years - From 4% (2003) to 35% (2014) - Result of process and material development & media hype - Notable in medical and aerospace industries - Medical: Personalized solutions - Aerospace: Weight optimization - Potential in multiple fields, but still restricted to low volume or customized production of high-end products - Lacking standards & false assumptions hinder adoption 3D printed metal parts in BMW i8 convertible Customized parts in MINI cars Uses: Rapid Tooling - Use of AM for indirect production: - Masters for sand & silicon casting - Lost wax casting - Printing sand, metal & plastic molds - Fixtures for drilling - Jigs - Endless number of uses.. - For both prototypes & end-use parts - Takes advantage of low investment cost, fast process, and AM introduced benefits such as contouring cooling channels in injection molds Masters for silicone casting DIY petrol motor for a surf board Sandcasting

3D Print

Finished 3D print Cast

Finished cast Printed wax masters for precision casting Cores for Glass/Carbon-fiber parts Vacuum forming cores Injection molds printed with plastic Freedom of design – No need to Design for Manufacturing & Assembly: Instead Design for Functionality, Weight, Strength etc

– Minimize part count while optimizing topology – Pre-built assemblies – minimize labor time & QC

– Customization without additional cost – Every part can be different from the others, even in same batch Design for AM – Case: bottle opener Design for AM – Case: Buckle

68 grams Case: Boeing / F-18 air duct system re-design

Case: F-18 cooling air system – Complete re-design for functionality & weight

– This unit: part reduction from 16 to 1

– Improved air flow

– No assembly required

– No tooling required

– Future improvements with minimal cost

– Spare parts on demand and on location Case: Align / Invisialign tooth retainers Case: Invisialign tooth retainers – Digital pre-planning of each unit, “digital inventory”

– Example of mass customization – 40,000 a day

– AM produced individual molds for thermal forming – Innovative example of utilizing customizability – RP machines & processes modified for excessive use

Other medical uses

Inert implants Hearing aids - Surgical planning, prosthesis, tooth crowns & bridges, tissue growth… AM as innovation enabler AM as innovation enabler – Easy and affordable access to AM technology encourages innovation

– Multiple new companies forming around 3D printing – 3D Printing is bringing young people back to making physical things Role of 3D printing in the future – Disruptive potential in manufacturing – happening already 3DP can change product design and manufacturing approaches drastically. Materials and processes are developed more for end-use production.

– Supply chain renewal – future possibility Away from traditional towards more centralized, on-demand, rapid manufacturing.

– Flourishing innovation around AM New applications, AM techniques, & businesses emerge on daily basis

– Will every home have a 3D Printer and traditional manufacturing will end? No – Perhaps for occasional use in hobbies or garage-tinkering Hands-on Workshop: Basics of 3D Printing Break Principle - Stacked two-dimensional layers form three- dimensional objects

- Producing 2D layers is relatively simple

- Parts usually need to be supported from below Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition FDM – Fused Deposition Modeling FDM – Fused Deposition Modeling

www.youtube.com/watch?v=oeJLLC2NJQs FDM – Fused Deposition Modeling •Thermoplastic is extruded to ‘draw’ a layer at a time • Build platform lowers with the part and process repeats •Dissolvable support material from second nozzle; not commonly used in lower end printers

•Materials: •ABS •PLA •Polycarbonate •Nylon • + Many Others! (PEEK, PETG, composites) •Manufacturers: •Stratasys, Tiertime, +multiple lower end Extrusion lines visible

RepRap Project and its effects

Open Source, community driven, self REPlicating RAPid prototyper

- Founded 2005 by Andrew Bowyer, University of Bath, UK - First RepRap 3D printer to print parts for itself, 2006 - Reprap inspires Makerbot, first commercial hobby printer, 2009 - Stratasys and 3DSystems both hit consumer market also - 2016: hundreds of different “consumer 3D printers” available - Most still hobbyist and DIY maker targeted as they fail to meet user’s expectations Not all 3D printers are the same

~200€ ~900,000€ Not all 3D printers are the same General perception of all levels of 3D printing Reality E-Nable prosthetics – Community based project 3D files to print

1. CAD software – Create models yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Free and commercial sites available 3D files to print

1. CAD software – Create models yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Free and commercial sites available “Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape “Designer”: Rhino, Maya, Zbrush “Easy-to-use”: TinkerCAD, Google SketchUp 3D files to print

1. CAD software – Create models yourself

2. 3D scan an existing object– Modify or replicate as is

1. CAD software – Model yourself

2. 3D scan an existing object – Modify or replicate as is

3. Download existing files – Free and commercial sites available 3D files to print

1. CAD software – Model yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Thingiverse, Youmagine, GrabCAD modifiable with Meshmixer STL file format – triangulated mesh approximation

Remember to set good tolerance! More triangles = Better results STL file format – triangulated mesh approximation

Remember to set good tolerance! More triangles = Better results Orientation and support material

Avoid overhangs Consider overhang angles when designing and orienting

Complicated support structures are difficult remove Orientation and support material Orientation and support material Orientation and support material

Parts are weakest between layers Design for FDM Example

Objective: Design and print an object designed for FDM, which doesn’t need supports and showcases possibilities of FDM

Features: •Overhangs •Bridges •Interlocking parts •Inserts •Customizability •Internal features

Considerations: •Tolerances •Overhang angles •Minimized warping •Orientation Warping – Due to poor attachment to bed Happens to PLA and ABS in open printers Insert Design for FDM printing Slicers – Software that link 3D file with printers movement

- Software depends on the printer or user prefence - Makerbot  Makerbot Print - Ultimaker  Cura - Other printers  Slic3r, Cura, Simplify3D…

- Many are free and even open source Settings Checklist for Slicer software

- Material - Temp (ABS ~230’C, PLA ~190’C) - Diameter (Usually 1,75mm or 3mm) - Orientation of model - before “slicing” - Layer height - 0,1- 0,3mm usually - Perimeter thickness (‘shell’ of the part) - Infill percentage (how dense/hollow the part is) - Supports (if needed) Before starting print

- Check Printers build platform - Is it clean? - Does it have proper adhesion applied? - PLA: gluestick, (hairspray, blue tape) - ABS: Kapton tape, BuildTak

- Check Printers material & nozzle - Is there plastic? Does it need to changed?

- Always observe first layers of printing – They are most crucial! Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition SL – Stereolithography

SLA printers are more accurate than FDM, but have their drawbacks.

Strong parts: SLA < FDM Big parts: SLA < FDM Need supports: SLA < FDM Post-processing: SLA < FDM Harmful chemicals: SLA < FDM

Complex parts: SLA > FDM Small parts: SLA > FDM Precise parts: SLA > FDM

https://formlabs.com/support/printer s/form-2/quick-start-guide/ SL – Stereolithography SL – Stereolithography •UV laser cures resin •Build platform lowers with the part into the resin vat (or rises from it in some cases) •New layer of resin is cured and process repeated

•Materials: •UV curable resins •Waxes •Ceramic •Manufacturers: •3D Systems, DWS, Lithoz, +few hobbyist oriented

For Software: Preform (formlabs.com) Next – Consider:

•Would you like to learn 3D modeling? •Which software would be most suitable for you? •Should you use and modify existing files instead?

•How could you use 3D printing? •In your work? Hobby? As a new skill?

•Which technology would be better for your application? •What requirements do your prints have? •SLA or FDM? Hands-on Workshop: Basics of 3D Printing Day 2 Ville Kukko-Liedes IdeaSquare 3.-4.11.2018 Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition SLS – Selective Laser Sintering SLS – Selective Laser Sintering •Powder stock is joined by partial laser melting •The powder bed lowers with the part •New layer of powder is added and process repeated

•Materials: •PA (6, 11, 12) (Nylon) •PA GF, CF (fibre composites) •PA-Al (30% Aluminium) •Manufacturers: •EOS, 3D Systems… (patents expiring now, low cost machines coming)

Accuracy Method Material For Tolerance Layer (mm) Thickness - 3D prints are usually always (mm) comparatively inaccurate dimensionally as well as PA Functionality +/- 0,15 SLS PA CF/GC Hi durability 0,1 geometrically (+/- 0,15%) Wax Casting - FDM for cheap parts, Appearance, printers everywhere. SLA for Clear Casting small & precise. SLS for SL +/- 0,05-0,1 0,05-0,2 Durability, ordering durable & precise Flexible parts Appearance

ABS Functionality, FDM +/- 0,15-0,3 0,1-0,4 prototyping PC

All specs vary depending on machine used Manufacturing in motion: first survey on the 3D printing community, Statistical Studies of Peer Production. Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion – still.. •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition SLM – Selective Laser Melting SLM – Selective Laser Melting & Binder coated powder SLS •Powder stock is joined by laser melting •The powder bed lowers with the part •New layer of powder is added and process repeated

•A lot of supports needed in direct melting!

•Materials: •Two component (binder coated base) •Single component: •Ti6Al4V, 17-4 / 15-5 Stainless, Cobalt chromium, maraging

•Uses: Molds, small series, prototyping in metal

Additive Industries – Metal 3D printing station Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition 3DP – Binder Jetting 3DP – Binder Jetting •Powder stock is joined by deposited binder •The powder bed lowers with the part •New layer of powder is added and process repeated

•Materials: •Ceramic, composite, Glass, Metal, Plastic..

•Color printers available •Usually fragile before post processing

•Uses: Visuals, cores & molds, casting patterns

Full color sandstone + binder - Shapeways Digital Metal – Höganäs, Sweden

Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition LOM – Laminated Object Manufacturing LOM – Laminated Object Manufacturing

•Sheet is joined to the previous part •Layer shape is cut into sheet •Platform lowers and process repeats

•Materials: •Paper, plastic, metal

•Color printers available •Not accurate with paper or metal •Laborious manual support removal

•Uses: Visual aids, metal structures with internal sensors

Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition DED – Directed Energy Deposition

•Sheet is joined to the previous part •Layer shape is cut into sheet •Platform lowers and process repeats

•Materials: •Paper, plastic, metal

•Color printers available •Not accurate with paper or metal •Laborious manual support removal

•Uses: Visual aids, metal structures with internal sensors DED – Directed Energy Deposition also LENS – Laser Engineered Net Shaping •Inert shielding gas jet deposits pwder that is molten to the part with laser •Platform moves, while nozzle is usually stationary

•Materials: •Metal

•Not very accurate ”net shaping” •Features machined •Combined DED + CNC exists!

•Uses: Repairs Categories of 3D printing

•Vat Photopolymerization •Powder Bed Fusion •Material Extrusion •Material Jetting •Binder Jetting •Sheet Lamination •Directed Energy Deposition Material jetting Material jetting

•Printhead (just like in inkjets) deposits droplets of resin that is cured instantly with UV •Platform moves down, process repeats

•Materials: •Resins, various simulated plastic & rubber

•Highly accurate •Multiple material properties, even smoothly changing

•Uses: High end visual aids & function test

Dragonfly – PCB Prototyping

MicroTec – 3D Chip Sized Packaging

Kalevala – Jewelry with wax investment casting

Links to videos

•Kinematics Dress by Nervous System •SLS Selective Laser Sintering •SLA Stereolithography •Binder Jetting metals •LOM - Mcor Paper Printer •MORI Hybrid 3DP-CNC •Material Jetting – Stratasys J750 Printers: Ordbot: ideasquare-3dprinter-1.cern.ch X400: ideasquare-3dprinter-2.cern.ch Login: ideasquare Password: 3dprint

Thank you

Ville Kukko-Liedes [email protected]