PowerPoint Presentation Advanced Manufacturing Additive Manufacturing Week 4 – Primary Additive 3D printing processes History of AM Topography: 1890: J.E. Blanther suggested a layered method for...

PowerPoint Presentation
Advanced Manufacturing
Additive Manufacturing
Week 4 – Primary Additive 3D printing processes
History of AM
Topography:
1890: J.E. Blanther suggested a layered method for making a mould for topographical relief maps (wax plates)
Photosculpture:
1860: François Willème: 24 cameras around the
object > an artisan carved a 1/24th cylindrical portion of the figure using a silhouette of each photograph
(Bourell et al, 2009)
1951: O.J. Munz:    proposed    a system similar to stereolithography
1972: Pie
e Alfred Ciraud: The    first successful AM    process - a    powder deposition method    with    an        energy beam
1970’s: Housholder (powder laser sintering), Kodama (photopolymers), He
ert (photopolymers)
1986: Charles (Chuck) Hull: obtained a patent for stereolitography (SL) and founded 3D Systems
(
History of AM
)
1987: 3D Systems: SLA-1 (StereoLithography Aparatus 1) - first commercialised AM machine
Good Morning America, TV Show, 1989
(
Ciraud
)(Bourell et al, 2009; Drstvensek 2010)
http:
www.3ders.org/articles/ XXXXXXXXXXhow-far-3d-printing-has-come-since-good-morning-america-1989.html
Rapid prototyping: Additive manufacturing of a design, often iterative, for form, fit, or functional testing, or combination thereof.
Rapid tooling: the use of additive manufacturing or subtractive manufacturing methods (such as CNC milling) to make tools or tooling quickly, either directly, by making parts that serve as the actual tools or tooling components, such as mold inserts, or indirectly, by producing patterns that are, in turn, used in a secondary process to produce the actual tools.
3D printing: The fa
ication of objects through the deposition of a material using a print head, nozzle, or another printer technology. Discussion: Term often used synonymously with additive manufacturing; in particular associated with machines that are low end in price and/or overall capability.
(ASTM, http:
www.astm.org/FULL_TEXT/F2792/HTML/F2792.htm)
(
Terminology
)
· Mock-ups, scale models
· (Functional) prototypes
· Tooling (moulds, patterns)
· End-products
http:
static1.squarespace.com/static/509c281de4b0cd18c7335a a
t/548e134ee4b023e5238feb68/ XXXXXXXXXX
(
Additive manufacturing appl
ications
)
http:
mastergraphics.com/imagingsolutions/wp- content/uploads/2013/12/Projet-x660.jpg
https:
image.architonic.com/img_pro2
-1/111/7752/Quin-chandelier-b.jpg
+
Minuses    -
(Chiu and Yu 2008; Czajkiewicz 2008, Manogharan 2015)
(
Benefits or AM
)
· (
+
)Directly from 3D computer model
· No tooling - mould is not required
· No waste material (only support in some cases)
· Complex shapes (a form in a form)
· Faster design-to-part production
· Small number of stages in a production process
· Much cleaner workshops
· Lower material consumption
· Lower or no process engineering time
· (
-
)Just in time production, on-demand production
Minuses
· Relatively expensive (material, operation costs)
· Limited materials
· Limited size
· For one or a small number of parts
(Chiu and Yu 2008; Czajkiewicz 2008, Manogharan 2015)
(
Additive manufacturing process
1
Conceptualisation and CAD
2
Conversion to STL
3
Transfer to AM machine and STL manipulation
4
Machine setup
5
Build
6
Removal and Cleanup
7
Post-process
8
Application
)
Images:
Project:
Developing a Better Snowboard Binding
Prepared by:
Robert Leen
Supervised by:
Dr Paul Collins
Assistance in the creation of the final prototype:
Dr Clara Usma Alvarez
Thesis prepared for:
SEJ446:
Engineering Project B
SoE, SEBE
Deakin University
(Gibson et al, 2009)
1. Conceptualisation and CAD
3D model:
· Created using 3D modelling
· Created using 3D scanning
· Combination of 3D modelling and 3D scanning
CAD model (Solidworks 2014 modelling software)
Sketch
STL (.stl) is a file format for 3D model data used by machines to build physical parts; STL is the de facto standard interface for additive manufacturing systems. STL originated from the term stereolithography. (ASTM) It was created by 3D Systems.
STL:
· Is a polygonal (mesh) file
· Describes the external closed surfaces of the original CAD model (no history)
· Basis for calculation of the slices
(
2. Conversion to STL
)
(
Connex3 (Objet 500)
)
· Verification if the file is co
ect (normals, shells)
· General part manipulation:
· Part orientation (build height, specific location within the machine)
· Multiple parts (same parts, different parts)
· Scaling (mm, %)
· Adding text (identification)
(
3.
Transfer
to AM machine and STL

manipulation
)
Build parameters:
· Material constraints
· Energy source
· Layer thickness (time vs. accuracy)
· Timings
(
4. Machine setup
)
Superficial monitoring:
· Material (enough material)
· Energy    (power outage)
· Software (e
ors)
(
5. Build
(Automated process)
)
Once the AM machine has completed the build, the parts must be removed.
Interaction with the machine:
· Safety issues: temperatures lower than operating temperatures, no actively moving parts
Interaction with the part:
· May be fragile before post- processing
(
6. Removal and Cleanup
)
· Careful, experienced manual manipulation
· Time consuming
Before parts are ready for use:
· May be weak
· May have supporting features that must be removed (cutting, melting)
Symbolic image - http:
d2rormqr1qwzpz.cloudfront.net
photos/2014/07/09/62427- cleaning.jpg
(
7. Post-process
)
Surface finishing (visual, texture improvements):
· Priming, gap filling (modelling filler / surfacer + sand paper)
· Painting (car paint)
Assembling together with other part or mechanical / electronic components
(
8.

Application
)
VIDEO: Deakin Designs - GripTight
https:
www.youtube.com/watch?v=cudZKafcQHc
Classification of AM
Adapted from Gibson et al, 2009 and Pham’s Layered Manufacturing classification
Liquid Polyme
1D Channel
SLA
(3D Systems)
2x1D
Channels
Dual bean SLA (3D Systems)
A
ay of 1D
Channels    2D Channels
Polyjet (Object)    DLP
(EnvisionTEC), MicoTEC
Discrete Particles
Molten Material
SLS (3D
Systems), LST (EOS), LENS
Phenix, SDM
FDM, DODJET
(Solidscape)
LST (EOS)    3D Printing    DPS
ThermoJet
Solid Sheets    Solido
PLT (KIRA)
Overview over AM technologies
https:
www.additively.com/img/content/learn/process/3d-printing-technologies-overview-en.png
StereoLithography (SL or SLA)
A UV laser is curing a liquid photopolymer in a vat. The part is built by lowering the build platform into the vat.
https:
www.additively.com/en/learn-about/stereolithography
VIDEO: Stereolithography (SLA) Technology
https:
www.youtube.com/watch?v=NM55ct5KwiI
(
StereoLithography (SL or SLA)
)
· Developed by 3D Systems
· Requires support structures for overhangs (same material)
· Very good accuracy and surface finish
· Only photopolymers (not stable over time, have not well defined mechanical properties)
https:
www.stratasysdirect.com/wp- content/themes/stratasysdirect/img/tech_new/stereolithography/gal lery/stereolithography-sla-002.jpg
http:
2biy4djn37s2xoe622u8h9g1.wpengine.netdna-cdn.com/wp- content/plugins/wp-o-matic/cache/34f20_e-stage-2.jpg
http:
2biy4djn37s2xoe622u8h9g1.wpengine.netdna-cdn.com/wp- content/plugins/wp-o-matic/cache
4243_e-stage-4.jpg
Applications?
http:
d2n4wb9orp1vta.cloudfront.net
esources/images/cdn/cms/0808ct-rapid- part2c.jpg
http:
www.3ders.org/images/prox-950-v10-quickcast.jpg
http:
www.georgehart.com/cccg/Image82.jpg
Fused Deposition Modelling (FDM)
A plastic filament is melted and extruded through a nozzle. Parts are built by laying down layer-by-layer.
https:
www.additively.com/img/content/learn/process/additive-manufacturing-fused-deposition-modeling-en.png
VIDEO: Fused Deposition Modeling (FDM) Process - 3D Printe
https:
www.youtube.com/watch?v=b-J9nJtbc6M
(
Fused Deposition Modelling (FDM)
)
· Developed by Stratasys
· Requires support structures for overhangs (same -
eak-away / different – soluble material)
· Fully functional parts in standard plastics (ABS, PC)
· (
https:
makearchitecture.files.wordpress.com/2010/03/photo-10.jpg
)Parts with good mechanical properties, durable over time
· (
https:
solidoodletips.files.wordpress.com/2012/07/p XXXXXXXXXXjpg
)Surface has a step-structure and fine details cannot be realised
http:
1.bp.blogspot.com/- jOHle_CYriY/UZxxfrkSmKI/AAAAAAAABDc/ 2YJCbXsk3vk/s1600/IMG_0708-owl.JPG
Applications?
http:
eprap.org/mediawiki/images/thum
d/dc/Prusa_Diamond_yellow.JPG/300px-Prusa_Diamond_yellow.JPG
Fused Deposition Modelling (FDM)
Laser Sintering (LS) (Selective Laser Sintering, SLS)
A thin layer of plastic powder is selectively melted by a laser. The parts are built up layer by layer in the powder bed.
https:
www.additively.com/img/content/learn/process/additive-manufacturing-laser-sintering-en.png
VIDEO: How sls 3d printing works
https:
www.youtube.com/watch?v=0sLcobtfHFY
(
Laser Sintering (LS)
)
· Developed by DTM (later 3D Systems)
· No support required (powder!)
· Parts in standard plastics (PA) with good mechanical properties
· Parts do not have exactly the same properties as injection moulded parts
· Rough surface finish
https:
gigaom.com/wp-content/uploads/sites/1/2014/04/screen-shot XXXXXXXXXXat XXXXXXXXXXpm-804x532.png
http:
s3.amazonaws.com/cideas- assets/images/processes_SLS/sideba
ProcessSLSplaneart.jpg
https:
i.materialise.com
log/wp-content/uploads/2015/12/laser-sintering-3d- printer.jpg
Applications?
https:
s-media-cache-ak0.pinimg.com/736x/85/a5/57/85a5578870bdf6162f49133fda013b3d.jpg
http:
assets.nydailynews.com/polopoly_fs/ XXXXXXXXXX XXXXXXXXXX!/img/httpImage/image.jp g_gen/derivatives/article_750/3d-printing.jpg
Laser Melting (LM) (Direct Metal Laser Sintering, DMLS)
A thin layer of metal powder is selectively melted by a laser (or multiple lasers). The parts are built up layer by layer in the powder bed.
https:
www.additively.com/img/content/learn/process/additive-manufacturing-laser-melting-en.png
VIDEO: Direct Metal Laser Sintering (DMLS) Technology
https:
www.youtube.com/watch?v=bgQvqVq-SQU
(
http:
www.ha
ec.com/wp-
content/uploads/2014/08/img_3141

660x445.jpg
http:
www.objective3d.com.au/wp-content/uploads/2016
04/556.png
)
Laser Melting (LM)
· DMLS developed by EOS
· Requires support structures (anchor parts and overhanging structures). This enables the heat transfer away where the laser is melting the powder.
· Parts in standard metals with high density - above 99% (can be further processed as any welding part)
· Good mechanical properties (comparable to traditional production technologies)
· Slow and expensive
· Tolerances and surface finishes are limited (can be improved in post-processing)
Applications?
(
Laser Melting (LM)
)
http:
www.industrial-lasers.com/content/dam/ils/online- articles/2016/03/slm_1.jpg
http:
d2n4wb9orp1vta.cloudfront.net
esources/ images
cdn/cms/Golf_Tool_Insert--resized.jpg
http:
www.makepartsfast.com/wp-content/uploads/2012/03/GPI-prototype-3D- printing-parts-7.jpg
http:
serkov.su
log/wp-content/uploads/2014/10/Medical-Modeling.jpg
Electron Beam Melting (EBM)
A thin layer of metal powder is selectively melted by an electron beam. The parts are built up layer by layer the in the powder bed.
https:
www.additively.com/img/content/learn/process/additive-manufacturing-electron-beam-melting-en.png
VIDEO: Direct Manufacturing: ARCAM
https:
www.youtube.com/watch?v=M_qSnjKN7f8
(
http:
d2n4wb9orp1vta.cloudfront.net
esources/i
mages/cdn/cms/AM1112_Military_Image2.jpg
)
· Developed by Arcam
· Limited number of standard metals with high density (above 99%): Cobalt-chromium alloys, Nickel-based alloys, Titanium
· Parts with good mechanical properties (comparable to traditional production technologies)
· Slow and expensive process
· EBM produces less thermal stress in parts and therefore requires less support structure than LM
· Not so good surface finishes as LM (more post-processing – better tolerances)
http:
www.arcam.com/wp-content/uploads/Arcam_EBM_System_A2X.jpg
(
Electron Beam Melting (EBM)
)
Applications?
Electron Beam Melting (EBM)
http:
www.arcam.com/wp-content/uploads/Acetabular_cup_with_SEM- e XXXXXXXXXX560x394.jpg
http:
www.ipmd.net/assets/userfiles/ipmd/images/NEWS/March_2013/arcam_skull.gif
http:
www.arcam.com/wp-content/uploads/hydraulic-manufold.jpg
http:
www.arcam.com/wp- content/uploads/Tu
ine_blade_for_aero
_engine-e XXXXXXXXXX288x416.jpg
Binder Jetting (BJ) (3D printing, 3DP)
Inkjet print heads apply a liquid bonding agent onto thin layers of powder. By gluing the particles together, the part is built up layer by layer.
https:
www.additively.com/img/content/learn/process/additive-manufacturing-binder-jetting-en.png
VIDEO: D2W Multi-Colour 3D Printer in Action
https:
player.vimeo.com/video/ XXXXXXXXXX
(
https:
player.vimeo.com/video/ XXXXXXXXXX
)
· 3DP developed by Z Corporation
· No support required (powder!)
· Almost any material that is available in powder form (plaster, sand, plastic, metal, sugar)
· Fast and cheap
· Parts in full colour are possible
· (
https:
www.digits2widgets.com/3d-
printing/multi-colour-3d-printing
) (
https:
www.digits2widgets.com/wp-
content/uploads/2015/04/Processing- Multi-Colour-3-of-5.jpg
) (
https:
www.digits2widgets.com/wp-
content/uploads/2015/04/Processing
-Multi-Colour-4-of-5.jpg
)Parts directly from the machine are fragile
(
Binder Jetting (BJ)
)
Applications?
Binder Jetting (BJ)
http:
www.3dz.it/wordpress/wp- content/uploads/2016/03/copertina_corvalli s_stampanti3D_italia_3dsystems_artec_to pografia.jpg
http:
tallerdesoluciones.blogs.inti.gob.a
files/2014/01/projet260C.jpg
(
http:
www.wired.com/wp-

content/uploads/2015/02/DOOB3.jpg
)
http:
mastergraphics.co m/imagingsolutions/wp- content/uploads/2013/12
Projet-x660.jpg
Photopolymer Jetting (PJ) (Polyjet    / Multijet modeling)
Inkjet print heads are used to jet liquid photopolymers onto a build platform. The material is immediately cured by UV lamps and solidified which allows to build layers on top of each other.
https:
www.additively.com/img/content/learn/process/additive-manufacturing-photopolymer-jetting-en.png
VIDEO: PolyJet Technology
https:
www.youtube.com/watch?v=Som3CddHfZE
(
Photopolymer Jetting (PJ)
)
· Polyjet developed by Objet
· Multi-material and multi- colour parts: several materials can be jetted at the same time (different shore hardness, translucency)
· UV-active photopolymers (parts are not durable over time, limited mechanical properties)
· Good accuracy and surface finishes
https:
i.ytimg.com/vi/D4Yq3glEyec/maxresdefault.jpg http:
www.formakers.eu/media/ XXXXXXXXXX.jpg
Applications?
http:
www.smg3d.co.uk/images/3d-printed-car-fob_large.jpg
Photopolymer Jetting (PJ)
http:
cdn.shopify.com/s/files/1/0180/7671/products/Me dicalApplicationLR_2_1024x1024.jpg?v= XXXXXXXXXX
http:
www.gxsc.com/images/news
ordered_screwdriver.jpg
Material Jetting (MJ) (Drop on Demand - DOD, Thermojet)
Inkjet print heads are used to jet melted wax materials onto a build platform. The material cools and solidifies which allows to