Professorship in wood and fiber material technology. Additive Manufacturing of wooden composites and furniture

Transcription

1 Professorship in wood and fiber material technology Marschnerstraße Dresden-Johannstadt Deutschland > 45 employees Chair holder: Prof. Dr.-Ing. André Wagenführ Christian Gottlöber Folie 2 1

2 Folie 3 Content 1. Introduction in Additive Manufacturing (AM) 2. Fused Filament Fabrication (FFF) with wood infused filaments 3. Selective Laser Sintering (SLS) substitution of polyamide with lignin 4. Vacuum Casting prototypes made from lignin Folie 4 2

3 Additive Manufacturing (AM) Manufacturing of threedimensional parts layer by layer Generating ofthelayergeometry ismadedirectlyvia CAD-ortheprovidedSTL-files All machines on the market can be provided with the same STL-files Manufacturing processforsinglepiecesand smallerquantities notoolsarerequired Complexgeometries and fillingstructurescanberealised integratedfunctionality 3D printing is suitable for smaller volumes Mechanical properties ar lower compared to the production with compression or injection moulding lowerdensityofthebuildedparts/ non-pressurizedbondingofthelayers Folie 5 Additive Manufacturing ClassificationofAdditive Manufacturing basedon DIN EN ISO liquid, powdered, solid materials Process category Example Material Vat photopolymerization Stereolithography(SL) Bath of liquid photopolymer Material Jetting Polyjet Liquid photopolymer in drop shape Binder jetting 3D printing(3dp) Powder and liquid binders Powder bed fusion Selective Laser Sintering(SLS) Powdered metals and polymers Material extrusion Fused Deposition Modeling(FDM) Liquid Deposition Modeling (LDM) Contour Crafting Thermoplastic filaments Concrete Pastes Directed energy deposition Laser Metal Deposition (LMD) Powdered metals Sheet lamination Laminated Object Modeling (LOM) Plates and foils made of paper, polymers or metals Folie 6 3

4 Example Folie 7 Fused Filament Fabrication (FFF) Working principle Thermoplastic material Feeder and transport unit Heating element Extrusion nozzle Builded part Source: Andreas Gebhardt Folie 8 4

5 Benefits and limitations of Fused Filament Fabrication Benefits Processing a variety of different materials Processing two materials at the same time Low costsforthe3d-printers Low effort for the installation of the machines Limitations not usefulforsmall, compactparts support structuresnecessary rough surface quality high costs for the materials Folie 9 Materials for Fused Filament Fabrication (FFF) Use of synthetic and biodegradable polymers syntheticpolymers: PP, PE, ABS, PA biodegradablepolymers: PLA, PHA Fields of research at HFT: use of cullolosic/ ligno-cellulosic and residual materials from the wood and paper industryforwoodfilledfilaments Wood PlasticComposites (WPC) Aims Development and manufacturing of wood fiber reinforced filaments Evaluation of the processing and the mechanical properties Manufacturing of prototypes with a wooden aesthetic and surface feeling Folie 10 5

6 Production and processing of wood filled filaments 1. Production of particels 2. Compounding of the materials 3. Extruding of the materials 4. Fused Filament Fabrication Folie 11 Production of particels Solid wood Laminated wood Fibreboards (MDF, HDF, OSB) Folie 12 6

7 Compounding Polymers + Additives Wood fibers Heating-cooling-mixer Folie 13 Extrusion of filaments Compound Extruded filament Folie 14 7

8 Fused Filament Fabrication (FFF) Material spool Feeder Heating element Extrusion nozzle Builded part Folie 15 Application possibilities Pinionin woodenaestheticforfurnitures Frame elementsofa bicycletrailer Folie 16 8

9 Application possibilities Parts for a research rocket Folie 17 Application possibilities Design case Cable clamp Chess pieces Folie 18 9

10 Selective Laser Sintering (SLS) Working principle Laser-scanner unit X-Y scanning mirror Sintered part with support structures Building chamber Leveling roller Powder feed supply Source: Andreas Gebhardt Folie 19 Benefits and limitations of Selective Laser Sintering (SLS) Benefits Processing a variety of different materials Good mechanical properties No support structures necessary Useful for first functional tests Residual material can be used again Limitations Rough surface quality High cleaning effort Release of toxic gases while processing Folie 20 10

11 Materials for Selective Laser Sintering (SLS) Use of as well synthetic and biodegradable polymers syntheticpolymers: PA, PS, PEEK biodegradablepolymers: Lignin Fields of reasearch at HFT: use of biopolymers for the production of prototypes Aims Partial substitution of polyamide with lignin Manufacturing of prototypes Folie 21 Manufacturing of specimens Positioning of the specimens in the building chamber Generated test specimens SLS-Composite Folie 22 11

12 Vacuum casting Source: PTZ Dresden Follow-upprocessofAdditive Manufacturing productionofmouldedpartsbasedon polymers Production of master patterns by Additive Manufacturing Generating of silicone moulds from the master patterns Casting of polyurethane under vacuum by using silicone moulds Folie 23 Application possibilities prototypes produced silicone mould Silicone mould filled with casting resin finished component Folie 24 12

13 Application possibilities prototypes functional models Folie 25 Application possibilities prototypes functional models specimens amountofligninupto40 % Folie 26 13

14 Thank you for your attention. Sources 1. Gebhardt, A.: Generative Fertigungsverfahren: Additive Manufacturing und 3D-Drucken für Prototyping Tooling Produktion, München: Carl Hanser Verlag, Breuninger, J.: Generative Fertigung mit Kunststoffen: Konzeption und Konstruktion für selektives Lasersintern, Berlin/ Heidelberg: Springer Verlag, Zäh, M.: Wirtschaftliche Fertigung mit Rapid-Technologien: Anwender-Leitfaden zur Auswahl geeigneter Verfahren, München/ Wien: Carl Hanser Verlag, DIN EN ISO : Additive Fertigungsverfahren Grundlagen, Begriffe, Verfahrensbeschreibungen 5. Folie 28 14