Additive Manufacturing: An Overview of the Technology and Its Promise
www.madeinalabama.com/2017/06/additive‐manufacturing‐2
TURI Spring Continuing Education Conference April 25, 2018
Prof. Chris Hansen Associate Professor, UMass Lowell [email protected] Presentation Outline
• What is Additive Manufacturing? • Why are people interested? • Types of technologies • Who are the players in Additive Manufacturing? • Markets and applications • Future trends Types of Manufacturing
Additive Manufacturing Subtractive Manufacturing Forming
Cutting
Stratasys Certification Learning Content 3 Subtractive vs. Additive
Stratasys Certification Learning Content 4 Subtractive vs. Additive
Stratasys Certification Learning Content 5 Additive Manufacturing: Definition
• A process of making a three-dimensional solid object by adding material
• ASTM F2792: Additive manufacturing is defined as the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.
• Additive Manufacturing is often abbreviated as AM
6 AM vs. 3D Printing
• 3D Printing is defined as the fabrication of objects through the deposition of a material using a print head, nozzle, or other printer technology
• The term is often used synonymously with AM
• 3D printing is often abbreviated as 3DP
7 3D Printing: Video
8 Other Terms …
In addition to Additive Manufacturing (AM and 3D Printing (3DP), you may hear: • Direct Digital Manufacturing (DDM) • Rapid Prototyping (RP)
All of these terms and definitions touch on the advantages of this technology AM Advantages
• Design freedom • Design iterations • Time savings • Cost savings
10 Design Freedom
Stratasys Certification Learning Content 11 Design Iterations
Prototyping helps catch and correct problems early
Cost to correct a problem increases exponentially with time
12 Design Iterations
Enhance quality and design https://formlabs.com/blog/ultimate‐guide‐to‐rapid‐prototyping/ 13 Time Savings
Mold for LEGO® Production 4 to 6 MONTHS!
http://mindtribe.com/2016/08/how‐long‐does‐it‐take‐to‐manufacture‐a‐hardware‐product/ 14 Cost Savings
Conventional manufacturing manufactured
3D printing unit per
Cost
Units manufactured (volume)
Small production runs become cost effective http://www.digitaleng.news/de/numbers‐3d‐printing/ 15 Types of AM Technologies
American Society for Testing Materials (ASTM) (committee F42) defines seven process categories for Additive Manufacturing technologies:
Material Extrusion Sheet Lamination Binder Jetting
FDM Fused Deposition Modeling UC Ultrasonic Consolidation CJP ColorJet Printing
FFF Fused Filament Fabrication LOM Fused Filament Fabrication PP Plaster‐based 3D Printing
Vat Photopolymerization Powder Bed Fusion Material Jetting
SLA Stereolithography SLS Selective Laser Sintering MJP MultiJet Printing
DLP Digital Light Processing DMLS Direct Metal Laser Sintering PJ PolyJet
Scan, Spin, & Selectively 3SP EBM Electron Beam Melting Photocure Directed Energy Deposition
Continuous Liquid Interface CLIP SHS Selective Heat Sintering Production LMD Laser Metal Deposition
Adapted from Stratasys Certification Learning Content 16 Types of AM Technologies
Today will focus on these as more heavily used technologies:
Material Extrusion Binder Jetting
FDM Fused Deposition Modeling CJP ColorJet Printing
FFF Fused Filament Fabrication
Vat Photopolymerization Powder Bed Fusion Material Jetting
SLA Stereolithography SLS Selective Laser Sintering MJP MultiJet Printing
DLP Digital Light Processing DMLS Direct Metal Laser Sintering PJ PolyJet
EBM Electron Beam Melting
Stratasys Certification Learning Content 17 Fused Filament Fabrication/Fused Deposition Modeling
Process Overview • Strands of material are melted and extruded onto a platform • Strands weld to one another to form solid part • Support material is broken or dissolved away 18 Fused Filament Fabrication/Fused Deposition Modeling
Strengths Weaknesses • Fast prototypes – desktop printers • Surface roughness due to layering • Inexpensive relative to alternatives • 330‐178 m (0.013 ‐ 0.007”) layer thickness
• Limited materials & properties 19 Commercial FDM Machines
Materials
Machines
20 Consumer FDM Machines
MakerBot Rep Rap •Build size up to 12” x 12” x 18” •Large variety of companies •Materials: ABS and/or PLA •Maker Gear 8” x10” x 8” build •List price: $2,000 to $6,500 •List price: $1,800
Cube 3Doodler •Build size: 6” x 6” x 6” •Build size: dictated by person •Materials: ABS or PLA •Materials: ABS or PLA •List price: $1,300 •List price: $100
21 Vat Polymerization
Process Overview • UV laser cures photopolymer to create part (thin supports also built) • Parts cured in UV oven • Support material cut away 22 Vat Polymerization
Strengths Weaknesses • Highly accurate models (150 to 50 • Not as fast as FDM micron, 0.006“ to 0.002” layers) • More costly equipment • Hard to keep clean 23 Commercial SLA 3D Systems ®
Carbon ®
EnvisionTec ®
Material Options • ABS, PP, PC like • High temperature • Bio-compatible • Transparent Opaque • Ceramic reinforced composite 24 Binder Jetting
Process Overview • A liquid binder agent is deposited by inkjet printhead onto a powder bed • The powder bed is lowered and a new layer of powder is applied • The part can be post-processed to increase its strength 25 Binder Jetting
Strengths Weaknesses • Wide variety of powder materials • Limited mechanical properties • Multi-color is possible • Difficult to switch between • Relatively fast and inexpensive materials between production runs 26 Commercial Binder Jetting
27 Material Jetting
Process Overview • Melted wax is ejected from inkjet print heads • The material solidifies upon cooling • Supports are needed for overhangs 28 Material Jetting
Strengths Weaknesses • Good accuracy • Limited material choices • Good surface finish • Limited mechanical properties
29 Photopolymer Jetting
Process Overview • Liquid photocurable resin is ejected from inkjet print heads • The material solidifies upon UV exposure • Supports are needed for overhangs 30 Photopolymer Jetting
Strengths Weaknesses • Multiple materials, ‘digital’ materials • Low material stability over time • Great surface finish • Expensive • Good accuracy • Relatively slow production 31 Commercial Photopolymer
Polyjet under Stratasys’ Objet® brand name
2004. 2007. 2014. Connex 1/2/3 2016. J750 Eden Connex 3 Materials 6 Materials 1 2 Material Material Stratasys introduces the first‐ The world’s only full color, s ever color and multi‐material multi‐material, high resolution Highly accurate, finely 3D printer 3D printer detailed models with ultra‐ The world's first multi‐ thin walls material 3D printer
32 Powder Bed Fusion
Process Overview • Laser beam (or e-beam) used to reach powder sintering/melting point • The bed is lowered and a new layer of powder is added • No support is needed 33 Powder Bed Fusion
Strengths Weaknesses • Can manufacture metals directly • Relatively expensive • Can manufacture semi-sintered • Tolerances limited ceramics 34 Post‐Processing Steps
Processes that can be applied to a 3D printed parts after print to provide:
Look and Feel / Finishing Mechanical Properties Seal Adaptation
Mass Finishing Composite method Coating
Painting Thermal treatment Bio Computability
Transparency Gluing
Material mimic
Smoothing
Support removal BEFORE AFTER BEFORE AFTER
Adapted from Stratasys Certification Learning Content 35 Markets & Applications
Aerospace Automotive Consumer Medical Dental Manufacturing Products
In 2017: $6.06 Billion Industry, 17.4% Annual Growth
36 Automotive: BAAM
• BAAM: Big Area Additive Manufacturing
Printed the car structure in 44 hours
https://vimeo.com/146030156 37 Aerospace: Rocket Lab
“3D printed primary components. Rutherford is the first oxygen/hydrocarbon engine to use 3D printing for all primary components including its engine chamber, injector, pumps and main propellant valves. Using this process, Rocket Lab’s engineers have created complex, yet lightweight, structures previously unattainable through traditional techniques, reducing the build time from months to days and increasing affordability”
https://youtu.b /2indPcalm‐A
38 Dental: Invisalign Example
Scan teeth for ‘Digital Impression’ Series of part files created Printed at central factory
https://youtu.be/sDsIfaA5n1s 39 Manufacturing
Rapid Tooling for Injection Molding • Utilize additive manufacturing for mold inserts – Objet, EOS, 3D Systems, others • Advantages – Eliminates need to machine inserts – Faster turn-around time & reduced cost • Disadvantages – Objet jetted photopolymer process • Long cycle time – 6+ minute to cool • Limited production volume: less than 100 parts – EOS direct metal process • Metal remains porous with high surface roughness • Ejection issues – Dimensional issues Who’s Who in AM?
• In 2017, 97 companies selling AM equipment and products
In polymers, top 5: Stratasys, 3D Systems, EnvisionTEC, HP, Carbon In metals, top 5: GE Additive, EOS, SLM, TRUMPF, 3D Systems
https://www.engineering.com/AdvancedManufacturing/ArticleID/16296/Industrial‐3D‐Printing‐Made‐Impressive‐Gains‐in‐2017And‐Things‐Are‐Looking‐Up.aspx 41 Industrial, Government, and Academic Partners
Research projects funded
Innovation Factory & Satellite Location
42 Industry Events
• Science in the Age of Experience – Boston June 18-21 2018!
• RAPID (happening now)
• AMUG – Additive Manufacturing Users Group
Full list: https://3dprintingforbeginners.com/fairs_events/ 43 National Science Foundation I/UCRC: Industry/University Cooperative Research Centers Program
Science of Heterogeneous Additive Printing of 3D Materials
• Cutting‐edge pre‐competitive fundamental research in science, engineering, technology area(s) of interest to industry • Members (Industry, Nonprofits) guide the direction of Center research through active involvement and mentoring Thrust Areas
Achieve unique Design properties through design
Develop novel and enhanced Material materials
Formulate and Modeling validate models
Improve and Printing create new Methods concepts
Emerging Applica‐ applications tions (e.g., biomedical)
45 Planning Meeting Industry Attendees
46 UMass Lowell Site Faculty Team
Alireza Amirkhizi Alkim Akyurtlu Carol Barry Bridgette Budhlall Gulden Camci‐Unal Composites/mechanics Printed meta/electronics Micro/nano processing Adaptive colloids/emulsions Biomaterials & fabrication
Chris Hansen Steve Johnston David Kazmer Joey Mead Nese Orbey Self‐healing materials Product design/molding Machine design/control Elastomers/nano‐materials Structure‐property relations
Ram Nagarajan Meg Sobkowicz‐Kline Scott Stapleton Javier Vera‐Sorroche David Willis Biocatalysis/green polymers Rheology & renewable Modeling & textiles Extrusion & die design Computation fluid dynamics For More Information:
Center Director: Joey Mead, Ph.D. University of Massachusetts Lowell [email protected], 978.934.3446
UML Site Director: UCONN Site Director: GA Tech Site Director: Chris Hansen, Ph.D. Anson Ma, Ph.D. Jerry Qi, Ph.D. UMass Lowell Univ. of Connecticut Georgia Tech [email protected] [email protected] [email protected] 978.934.2932 860.486.4630 404.385.2457
48 Future Trends
The 3rd Industrial Revolution 49 AM As Manufacturing
50 Factory of Tomorrow
51 Mass Customization
https://theplaybook.asia/2017/04/introducing‐adidas‐futurecraft‐4d/ https://www.sculpteo.com/blog/2017/01/11/benefits‐of‐3d‐printing‐mass‐customization/ New markets where customization comes low cost/free 52 Closing Remarks
• Current wave of manufacturing: Additive manufacturing is a digital approach to manufacturing
• Existing impact: AM is HERE … and almost all industries are already using it!
• Future impact: As the technology evolves, the benefit for all industries will grow
53 Questions
UML SHAP3D Site Director: Chris Hansen, Ph.D. UMass Lowell [email protected] 978.934.2932 54