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To Read This Handbook Advanced Additive Manufacturing Handbook Prepared by i Deliverable Datasheet Project Acronym: INEX-ADAM Grant Agreement number: 810708 Project title: Increasing Excellence on Advanced Additive Manufacturing Funding scheme: Horizon2020 Twinning Call: H2020-WIDESPREAD-05-2017-Twinning Type of action: CSA Start date of project: 1st September 2018 Duration: 36 months Project website: www.inex-adam.eu Deliverable number: D3.2 – V1.0 Deliverable title: Advanced Additive Manufacturing Handbook Work package: WP3- Raising Knowledge and Excellence on AM Lead beneficiary: UNIZAG FSB/LTH Dissemination level: Public Deliverable summary This handbook is a summary of the training material delivered to UNIZAG FSB by MUL (11-3- 2019 – 5-4-2019), UBRUN (3-6-2019 – 12-6-2019), AIDIMME (23-9-2019 – 4-10-2019) and LTH (4-11-2019 – 15-11-2019) and strategic research topics of all INEX-ADAM project partners. ii Contents Deliverable Datasheet ii Contents iii List of figures vii List of tables xiii Introduction 1 1.1. INEX-ADAM 1 Introduction to Additive Manufacturing 2 2.1. What is Additive Manufacturing 2 2.2. Why do we need Additive Manufacturing 3 2.3. Additive Manufacturing Classification 6 2.4. Vat polymerization 7 2.4.1. Stereolitography SLA 9 2.4.2. Digital Light Processing DLP 11 2.5. Material jetting 12 2.5.1. PolyJet 12 2.6. Binder jetting 16 2.6.1. 3D printing 3DP 17 2.7. Powder Bed Fusion Technologies 20 2.7.1. Introduction to Powder Bed Fusion (PBF) Technologies 20 2.7.2. Electron Beam Technology 22 2.7.3. Laser Melting Technology 25 2.7.4. Selective Laser Sintering (SLS) Technology 27 2.7.5. HP Multi Jet Fusion (HP MJF) Technology 30 2.7.6. Metal Binder Jetting (MBJ) Technology 31 2.8. Material Extrusion Additive Manufacturing (MEAM) Technologies 32 2.8.1. Material extrusion with plungers 33 2.8.2. Material extrusion with filaments 34 2.8.3. Material extrusion with screws 36 2.8.4. Disadvantages of using MEAM 38 References 38 General process workflow in AM 44 3.1. Pre-processing for additive manufacturing 45 3.1.1. File formats used in additive manufacturing 46 3.1.2. Part placement in machine envelope, slicing and machine setup 49 3.2. Build and post-processing 52 References 54 iii Standardisation in AM 55 4.1. Introduction to Standards 55 4.1.1. Significance of Standards 55 4.1.2. Standardisation Bodies 55 4.2. AM Standards 57 4.2.1. Structure of AM Standards 57 4.2.2. ASTM International/ASTM F42 58 4.2.3. CEN/TC 438 59 4.2.4. ISO/TC 261 60 4.3. Reading, Writing and Retrieving Standards 62 4.3.1. Reading Standards 62 4.3.2. Writing Standards 63 4.4. Conclusion 64 4.5. External Resources 65 References 65 Design for AM 67 5.1. The general thought process of DfAM 67 5.2. The economics of DfAM 71 5.2.1. Machine costs 71 5.2.2. Material costs 72 5.2.3. Post-processing costs 72 5.2.4. Time factors that are affected by design 73 5.2.5. Economics Case Study: Metal AM manufactured hydraulic manifold 74 5.3. Polymer design guidelines 78 5.3.1. Designing for material extrusion 80 5.3.2. Designing for polymer powder bed fusion 89 5.3.3. Designing for vat photopolymerisation 96 5.4. Metal design guidelines 100 5.4.1. General design for metal PBF 100 5.5.1. Design for laser powder bed fusion 109 5.5.2. Design for EBM Guidelines 115 References 118 General Process Simulations 119 6.1. Simulation 119 6.1.1. Geometry definition 119 6.1.2. Discretization 120 6.1.3. Material properties 121 6.1.4. Boundary conditions 122 6.1.5. Post-processing results 122 6.2. AM build process simulation 122 6.2.1. Geometry definition 123 6.2.2. Discretization 123 6.2.3. Material definition 124 iv 6.2.4. Build-process parameters 124 6.2.5. Post-processing 124 6.2.6. Limitations 125 6.3. Optimization 125 6.3.1. Topology optimization 125 6.3.2. Define design space 126 6.3.3. Define non-design space 126 6.3.4. Define boundary conditions 127 6.3.5. Define constraints and objectives 127 6.3.6. Define optimization settings 127 6.3.7. Solve 128 6.3.8. Interpret the results 128 6.3.9. Validate 129 6.3.10. Topologic design with Altair software 129 6.3.11. Topologic design with Altair software for EB-PBF 134 6.3.12. Topologic design with Altair software for SLS 135 6.4. Lattice-based topology optimization 137 6.4.1. Lattice type 137 6.4.2. Define the cell size 137 6.4.3. Define the shell thickness 138 6.4.4. Define the minimum/maximum density 138 6.4.5. Interpret the results 138 6.4.6. Validate 138 6.5. Non-parametric mesh modelling 139 References 142 Applications of AM 144 7.1. AM in toolmaking application 144 7.1.1. AM silicone short-run moulds 146 7.1.2. AM PolyJet bridge moulds 148 7.1.3. AM (steel) hard moulds 154 7.1.4. Efficient AM moulds – Conformal cooling 157 7.1.5. Efficient AM moulds – optimised build time in tooling 165 7.2. AM application in medicine 166 7.2.1. Medical research and development 167 7.2.2. Preclinical testing and planning 167 7.2.3. Production of medical devices 170 7.2.4. AM pharmaceutical application 178 7.2.5. AM for bioprinting/tissue fabrication 180 References 182 Development of material and processing parameters for AM 187 8.1. Development of materials for Material Extrusion AM 187 8.1.1. Compounding of special materials for Material Extrusion AM 189 8.1.2. Differential Scanning Calorimetry of polymeric materials for MEAM 192 8.1.3. High pressure capillary rheometry of polymeric materials for MEAM 194 8.1.4. Rotational rheometry of polymeric materials for MEAM 197 8.1.5. Thermal conductivity of polymeric materials for MEAM 199 v 8.1.6. Filament production for MEAM 200 8.2. Development of materials for PBF technologies 203 8.2.1. Metallic materials 203 8.2.2. Powder manufacture & metal powders for additive manufacturing (AM) 204 8.2.3. Tests for AM powder characterization 210 8.2.4. Processing parameters determination for EB-PBF 213 8.2.5. Qualification of the EB-PBF production 216 8.2.6. Powder recycling for EB-PBF 234 8.2.7. Parts characterizing & qualification 238 8.3. Development of materials for L-PBF 244 8.3.1. Processing parameters determination for L-PBF 244 8.3.2. Qualification of the L-PBF production 247 8.3.3. Powder blending and recycling for L-PBF 248 References 251 Development of FGM and FGAM 256 9.1. Functionally Graded Material (FGM) 256 9.1.1. Benefits of FGM 257 9.1.2. Classifications of FGM 257 9.1.3. Manufacturing Methods for FGM 259 9.2. Functionally Graded Additive Manufacturing (FGAM) 260 9.2.1. The FGAM Process Chain 261 9.2.2. Design and Modelling of FGAM Parts 262 9.2.3. FGAM Technologies 263 9.2.4. FGAM Applications 264 9.3. Conclusion 265 References 265 Conclusion 268 Appendix A – List of AM standards 269 Appendix B – Operating the equipment for developing of materials for MEAM 272 12.1. Appendix B-1: Kneader 272 12.2. Appendix B-2: Cutting mill 272 12.3. Appendix B-3: Differential Scanning Calorimetry (DSC) 273 12.4. Appendix B-4: High pressure capilary rheometer 273 12.5. Appendix B-5: Vacuum press 274 12.6. Appendix B-6: Rotational rheometer 274 12.7. Appendix B-7: Thermal conductivity measuring device 275 12.8. Appendix B-8: Capilary rheometer 275 vi List of figures Figure 2.1. Comparison of production time between classic processing (CNC milling) and additive manufacturing (PolyJet process) 2 Figure 2.2. Justification of the application of additive manufacturing 5 Figure 2.3. Classification of additive manufacturing according to ISO/ASTM 52900 6 Figure 2.4. Polymerization process 8 Figure 2.5. Stereolitography 9 Figure 2.6. Products made by the SLA process: a) transparent Accura Phoenix b) the bridge 10 Figure 2.7. Digital Light Processing 11 Figure 2.8. Application of the DLP: a) in dentistry, b) for jewellery 12 Figure 2.9. PolyJet 12 Figure 2.10. Product made with digital materials 14 Figure 2.11. Injection mould made by PolyJet Matrix 15 Figure 2.12. Product made with digital materials; combination of Vero and Tango materials 15 Figure 2.13. A part printed in half glossy, half matte, showing the difference in surface finish 16 Figure 2.14. 3D print process 17 Figure 2.15. Product with multiple colour combination 18 Figure 2.16. Poly(methyl methacrylate) 19 Figure 2.17. Sand moulds made with binder jetting 19 Figure 2.18. Powder Bed technology scheme. 21 Figure 2.19. EB-PBF overview. 23 Figure 2.20. L-PBF Overview. 26 Figure 2.21. SLS chamber scheme. 28 Figure 2.22. Powder recovery from sls cake. Affected areas. 29 Figure 2.23. MJF technology components. 31 Figure 2.24. Material extrusion additive manufacturing types. 33 Figure 3.1. General additive manufacturing principle: a) Layer buildup, b) Finished product. 44 Figure 3.2. Product created with a) thick layers b) thin layer and c) variable layers 44 Figure 3.3. Systematisation of AM workflow activities 45 Figure 3.4. CAD model 45 Figure 3.5.
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