Rapid Manufacturing Using Composite Stereolithography Technology

Transcription

1 Rapid Manufacturing Using Composite Stereolithography Technology Rapid Manufacturing de toekomst nu Evoluon, Eindhoven Anna Hoiss / Heavy R&D Investment in Materials Technology 1 DSM Corporate Research Multidisciplinary Basic Research 35 Years of Radiation Curable Material Development DSM Desotech UV Curable Resin R&D >2 Patent Families in Radiation Curable Materials DSM Somos UV Curable Resin Development for Solid Imaging 1

2 DSM Somos : Leading Supplier of Innovative UV Curable Materials 2 Somos among earliest SL pioneers (1988) Integrated Systems know how >5 SL Patents Broadest UV Curable Solid imaging resin portfolio Recognized Innovator: 7% of current portfolio commercialized in last 4 years Stereolithography : A Major Facilitator of RM 3 Stereolithography remains the dominant solid imaging technology Per 26 Wohler s Report photopolymers represented 53% of total materials ( $151MM ) used in additive manufacturing Includes Digital Light Processing, Inkjet Printing SL has largest installed base Best established solid imaging technology Widest material selection Large global service bureau availability SL Materials have longer term transferability to alternate solid imaging technologies 2

3 Agenda 4 How the capabilities of DSM Somos Composite SL resins are expanding RM possibilities Stereolithography and RM today RM Applications with Somos Composite SL Resins Additive technologies MC² Metal Clad Composites Rapid Tooling with Somos Composite SL Resins Stereolithography & RM Today 5 Materials remain primary rate determining gate for RM Mechanical property capabilities shape process capability Equipment and Processing Technology will become a secondary hurdle as material capabilities advance Ultimate RM material goal for SL: A material that exhibits Engineering Thermoplastic performance 3

4 Today s SL Technology Landscape : Neat Resins 6 1 Flexural Modulus (MPa) S-712 S-1212 S-1412 S-1112 S Elongation at Break (%) S-812 S-112 Today s s SL Technology Landscape 7 1 NanoTool Flexural Modulus (MPa) S-712 NanoForm 1512 S-1212 S-1412 S-1112 S Elongation at Break (%) S-812 S-112 4

5 Mass Custom Manufacturing 8 Hearing aids Direct manufacture of hearing aid shells (SL, SLS, DLP) Invisible braces ( Align Technology ) Dental scans converted to pattern for thermoformed final product Large scale operation established >5 years SL offers speed, accuracy, detail Composite Material Construction Opens New Frontiers to Expanded Performance 9 Filled Material (Composite) O O Si Coupling Three Phases Interface Resin Filler Interface 5

6 New Applications Potential 1 Design: Ergonix, Italy Production: Delta Prototipi, Italy Material: Somos NanoForm 1512 Image courtesy of Ergonix PreProduction Development 11 Design: Siemens Production: VG Kunststofftechnik, Germany Material: Somos NanoForm 1512 Direct Manufacture enabled Siemens to meet schedule for winter testing and save 4. on tooling costs Image courtesy of Siemens/VG Kunststofftechnik 6

7 MC 2 Technology : Metal Clad Composite 12 Proprietary compositions of a composite SL core and an electroplated nickel skin MC 2 Type is based on Metal content by Volume of approximately 5 to 25% psi unplated MCC FLex and Tensile Strength Flexural Strength Tensile Strength MCCtype1 MCCtype2 MCCtype3 MC 2 Technology : Metal Clad Composite 13 MCC Flexural Properties x1 psi Modulus, ksi Strength,psi unplated MCCtype1 MCCtype2 MCCtype psi x1psi MCC Tensile Properties Modulus, ksi Strength,psi unplated MCCtype1 MCCtype2 MCCtype psi 7

8 Application Of MC 2 Technology 14 Developing a Customer friendly interface to spread metal clad composite concept MC 2 concept is to create a branded composite that can be executed by SBs Ni-plated SL Part from Pitney Bowes Application Of MC 2 Technology With Somos Composite SL Materials 15 Technology Demonstrator: Compressor Production: FineLine Prototyping, (USA) Composite SL parts plated with.7 of metal were used to mimic die-cast products with dynamic parts The compressor generates 1 psi at 3 rpm The gear reduction brings the pump down to 1 rpm Image courtesy of FineLine Prototyping 8

9 Application Of MC 2 Technology With Somos Composite SL Materials 16 Bio-Chip Reader Design: SMARTEC Production: Alphaform AG, Germany Image Courtesy of SMARTEC and Alphaform AG Rapid Tooling Applications Development 17 Attempted with unfilled resins >5 years ago Previous failure due to Material properties: strength, stiffness, temperature resistance Insufficient mold redesign knowledge Lack of experience handling SL tools DSM Somos Applications Development Produced commercial injection molded parts ranging from 2 to >5 in TPE s and glass filled Nylon Ranging from TPE s to glass filled Nylon 9

10 Rapid Tooling Applications Development PreProduction Validation 18 Industrial Air Grinder Production: Paramount Industries, USA Lead Time: < 2 weeks Resin: Nylon 33% GF Injection pressure: bar Images Courtesy of Paramount Industries Molding Temp: o C Rapid Tooling Applications Development PreProduction Validation 19 Highest pressure at gate area GF Nylon hard on even metal tools Added steel gate to Somos SL Composite mold Parts were well within +/-.5 spec 1

11 Rapid Tooling Applications Development PreProduction Validation 2 RT Route Phase Tool design CAM programming Net Shape Benchwork Sample Tool Labour and machine hrs SL resin cost Purchased material Lead Time SL $45 $ wk CNC $25 3 wk View To The Future 21 Rapid Manufacturing will, at least initially, have two specific sub-segments Direct Additive Manufacturing Rapid Tooling Alternative technology carriers must find their niche Materials Technology will be key DSM will continue to be a major player in Radiation Curable Materials innovation and applications development. 11