Additive Manufacturing (3D-printing) Opportunities for the building hardware industry

Transcription

1 Additive Manufacturing (3D-printing) Opportunities for the building ARGE ANNUAL CONFERENCE 13th, 14th & 15th SEPTEMBER 2018 ROTTERDAM - THE NETHERLANDS

2 2 AGENDA Introduction AM Applications AM processes and post processes Conclusions

3 4 Promise of Additive Manufacturing You can print anything (even the impossible) - immediately - very fast, very cheap and you do not need any skills!!! Automation print direct from design file Freedom in design Integrated functions in one part Every product can be unique Low initial costs No molds needed Quick startup production?

4 5

5 6 Points of improvement Materials Accuracy, surface roughness Reliability, reproducability and quality Price Speed Standardisation Certification

6 7 Factors in favour of application of AM Prototyping Small series Special (internal) features (internal channels, lattice structures) Design Customised products Special surface structures (e.g. to promote bone ingrowth) Light weight Relative small products Specific materials Marketing value Complex products with integrated functions

7 8 Prototypes for window seals Direct: Stratasys Objet Tango or Agilus 30 Stereo Lithography - ULM 17120; Flexa Selective Laser Sintering - Duraform Flex Material extrusion: NinjaFlex Indirect: Vacuümcasting of PolyUrethane in Silicone mould Shore A possible

8 9 Electronic tools: small series of special dust collectors

9 10 Appealing examples

10 11 Stealth key: 3D printed key with internal features Complex internal structure, inaccessible to cameras, scanners, clay Price approx. $200,- Printed by selective laser melting sources: : CHF : W.A. de Vigier Award, CHF 100,000

11 12 Additive Manufacturing for the building

12 13 Design door handles

13 14 In ear hearing aids Vat photopolymerisation Courtesy of Widex

14 15 In ear hearing aids Swap of production technology in two years

15 16 Invisalign Costa Rica th million patient

16 17 Implants with special surface structure

17 18 Products with integrated functions 1 Onderdeel 16 parts 1 part Courtesy of 3DSystems

18 19 Produced by AM Produced by traditional technologies

19 20 Factors in favour of application of AM Prototyping Small series Special (internal) features (internal channels, lattice structures) Design Customised products Special surface structures (e.g. to promote bone ingrowth) Light weight Relative small products Specific materials Marketing value Complex products with integrated functions

20 21 Application of AM Design Task Manufacturing technologies Milling Design Functional Mechanical Structural AM potential? AM material & process selection Part requirements AM process limits Turning Casting Part Prototype Optimisation Prototype cycle Prototype Forging Final Design Printed sample Adapted from SASAM, Adriaan Spierings, Inspire

21 22 AGENDA General principles Terminology - Trends AM Applications AM processes and post processes Conclusions

22 23 Official definition Additive Manufacturing Process of joining materials to make parts - from 3D model data, - usually layer upon layer, as opposed to subtractive and formative manufacturing methodologies.

23 24 From CAD to slice-file 3D CAD file STL file Slice file Additive Manufacturing

24 25 Additive Manufacturing = Layered Manufacturing CAD model Slice file Part

25 26 Powder based Liquid based Solid based Powder bed fusion SLS/SLM/DMLS EBM Vat photopolymerisation SLA/DLP/CLIP Sheet lamination Binder Jetting Material Jetting PolyJet / MuliJet Directed Energy Deposition WAAM Directed energy deposition Cladding LMD Material extrusion FDM/FFF

26 27 Material extrusion, Fused Deposition modelling (FDM) Most applied in home printers

27 28 Material extrusion Fused Deposition Modelling (FDM) 45 Degrees

28 29 Fused Deposition Modelling (FDM) Typical specs: Build size Accuracy Layerthickness 200 x 200 x 200 mm 900 x 600 x 900 mm +/- 0,2 mm 0,1 0,5 mm Materials (low end): PLA (ABS) Materials (High End): ABS, PC, PPSU, PPSF, PEI (ULTEM)

29 30 Advantages: Simple, affordable and clean concept, Numerous of producers, open communities. Both low-end home printers and high end professional printers Broad range of materials including high end materials like Poly Carbonate and Ultem. Disadvantages: Not the technology to produce fine detailed and thin walled features Use of support structures required

30 31 Properties relative to most other AM technologies Advantages Disadvantages Simple, affordable and clean concept Numerous of producers, open communities Both low-end home printers and high end professional printers Broad range of materials including high end materials like Poly Carbonate and Ultem. One part can be available fast (nota large batch required) Not the technology to produce fine detailed and thin walled features Use of support structures required

31 32 Powderbed Fusion Laser Sintering / melting / cusing

32 33 Handeling of part and powder Unpacking Adidas Future Craft

33 34 Powder Bed Fusion Especially PBF with metals is not a simple & clean process

34 35 Support structures required Essential for Powder Bed Fusion with Metals Latice stuctures Specialized software

35 36 Applications Powder Bed Fusion Products - Assemblies with moving parts - Internal tubing - Hollow parts - Smal series complex parts

36 37 Properties relative to most other AM technologies Advantages Disadvantages High productivity Complex parts possible with no supports Good material properties Many materials available Quite good detailed Long batch time Sensitive process Powder handling Expensive materials & equipment Rough surface (compared to vat photopolymerisation)

37 38 Vat Photopolymerization Stereo Lithography (SLA)

38 39 Vat Photopolymerization Stereo Lithography (SLA)

39 40 Material Jetting

40 41 Material Jetting Objet (Stratasys) - PolyJet (3D-Systems) Typical size Part material Layerthickness Parts max x 800 x 500 mm Fotopolymers mm High accurate form and fit, good surface quality

41 42 Material Jetting Stratasys Objet - PolyJet

42 43 Binder Jetting 3D-Systems (Z-corp), ExOne, VoxelJet

43 44 3D Printing Z-Corp (3D-Systems) Type: Maximum part size: Part material: Layer Thickness: Low end, concept modeller, investment casting 508 x 381 x 229 mm Powders bound together by an adhesive mm Parts: concept models

44 45 Voxeljet Sand printing for metal casting

45 46 Voxeljet PMMA + investment casting

46 47 Binder Jetting ExOne 47 Printen van Inkjet binder op RVS poeder, daarna infiltreren met brons

47 48 AGENDA General principles Terminology - Trends AM Applications AM processes and post processes Conclusions

48 49 Factors in favour of application of AM Prototyping Small series Complex products Special (internal) features (internal channels, lattice structures) Customised products Special surface structures (e.g. to promote bone ingrowth) Light weight Relatively small products Specific materials Marketing value