Powder Bed Fusion Lich. Tech. Jukka Tuomi Aalto University

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1 MEC-E7006 Advanced Manufacturing (2018) Powder Bed Fusion Lich. Tech. Jukka Tuomi Aalto University

2 ISO AM process terms Vat Photopolymerization Powder Bed Fusion Material Extrusion Material Jetting Binder Jetting Sheet Lamination Directed Energy Deposition Process brand names: Selective laser sintering, SLS Laser Melting Direct Metal Laser Sintering, DMLS

3 3D-Printing objects are made out of slices Stacking up 2D images you can make 3D objects Conceptually simple process great for automation

4 Additive Manufacturing, AM - Rapid Prototyping, RP - 3D Printing - Rapid Manufacturing, RM - Free Form Fabrication, FFF - Additive Manufacturing, AM (ASTM and ISO standards) Material removal processes Stone Age Material Forming Processes Copper Age Additive Manufacturing

5 Powder Bed Fusion

6 Sintering process Loose powder is heated above sintering/melting temperature using a laser beam

7 Selective Laser Sintering

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13 Hopper for powder delivery

14 AM Process Chain

15 3D Printing process 1/2 3D-CAD - AutoCAD - Vertex - Catia - SolidWorks -.stl file AM - SLA - SLS - DMLS - LOM - FDM -.stl file Layer-by-layer manufacturing Physical part

16 3D Printing process 2/2 3D model 3D Printing Physical part

17 Plastics 3D Systems, USA EOS, Germany

18 Plastics Powder will support the parts from below => no supports are needed Parts nesting, you can fill the whole part bed

19 Design for function

20 Aerospace: Boeing

21 Plastics Product development applications, rapid prototyping Thermally stable up to 150 C => under the hood applications

22 Plastics Custom design and production applications Freedom of Creation, Janne Kyttänen

23 Fashion

24 Furniture

25 Selective Laser Sintering Powder bed is heated close to the sintering temperature using IR heaters

26 Laser sintering development project Looking funding through Kickstarter Protounits below 20k

27 Powder sintering with polymer binder The metal powder has polymer material mixed in Laser heats the polymer powder above the sintering

28 Powder sintering with polymer binder

29 Direct Laser Melting FIRPA web side Konematriisi

30 Direct Laser Melting The laser heats the metallic powder above the melting point Typically the process chamber is not above room temperature

31 Curl Distortion Gabriel Bugeda, Miguel Cervera, Guillermo Lombera, Eugenio Onate, (1995) "Numerical analysis of stereolithography processes using the finite element method", Rapid Prototyping Journal, Vol. 1 Iss: 2, pp Fundamental problem with 3D-Printing technologies In solidification the top layer shrinks, part curls => potato chips Nonuniform shrinkage Crashes the builds Inaccurate parts

32 Metals Strong supports are needed because of distortions caused by curl phenomena and large thermal gradients Usually tight laser focus and slow build speed

33 Direct Laser Melting Process testing Process map Tight process tolerances

34 Metals Conformal cooling rticle.aspx?id=19126&taxid=1426

35 Airbus: AM manufactured future airplane 60 % cheaper 30 % lighter Titanium parts 1:25 ratio in buy to fly 1:25 ratio in CO2 emissions Innovation potential 3 % of all patents by a team of 9 AM experts in 2008 (0.02 % of total staff of ) GE Aviation: 50% engine weight reduction

36 Fuel Injection Nozzles for Future GE Jet Engines About 15 individual pieces combined into one Lighter structure Better performance 6/features/additive-manufacturing-at-ge-aviation.html

37 Super Efficient Heat Exchangers

38 Gold and Silver Optimization work for different materials takes usually 6 months or longer

39 New Opportunities Weight Optimization In 3D-Printing, complex objects can be made as easily as simple ones complexity comes for free

40 Sintering of Sand Sand Tools for Casting Applications The sand powder has polymer material mixed in Laser heats the polymer powder above the sintering EOS

41 Ceramics Not commercial yet Like sintering of sand with binder Afterwards green sand parts are sintered in oven for fully sintered ceramics and the binder polymer material burns away

42 Electron Beam Melting Like laser melting except the heating source is electron beam 3 kw of e-beam power Resolution not as good as laser melting Vacuum chamber

43 Production method for orthopedic implants Electron Beam Melting

44 HP entering the market Commercial release 2016/2017

45 Blueprinter

46 MEC-E7006 Advanced Production Text book Text Book for 3D Printing Gibson, Rosen, Stucker: Additive Manufacturing Technologies - Rapid Prototyping to Direct Digital Manufacturing Book for laser material processing Lecture notes

47 April 18th-19th 2018 Dipoli, Otakaari 24, Espoo, Finland Aalto 3D Printing Days is an event consisting of Firpa s 20th Anniversary Conference and NORDIC3DEXPO exhibition. Medical and Industrial focus days offer presentations from world s leading experts. FIRPA 20th Anniversary Conference 3D Printing and technology fair! Conference fees (inc. coffee/tea, meals and exhibition) One day 220 (FIRPA members 190 ) Two days 390 (FIRPA members 330 ) Free entry to the exhibition! More Information Kirsi Kukko Kirsi.Kukko@aalto.fi Tel Registration firpa.fi/html/firpa20.html

48 Thank you! Jukka Tuomi Aalto University Department of Mechanical Engineering