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): 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? 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) Principle - Stacking two-dimensional layers to form three- dimensional objects - 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 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 – 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