Johnathon Wright Application Engineer Phoenix Analysis & Design Technologies www. PADTInc.com

Transcription

1 Johnathon Wright Application Engineer Phoenix Analysis & Design Technologies www. PADTInc.com

2 PADT is an Engineering Services Company Three Business Groups Simulation Training, Sales & Services Product Development Prototyping Sales & Services Founded in 1994 Four Aerospace Engineers Based on promise of emerging CAE technologies ASU Research Park in Tempe, Arizona Onsite Labs: Clean Room, Medical, General Inspection and Assembly Facilities Machine Shop Training, Seminar and Meeting Space Littleton, CO & Albuquerque, NM office Training Rapid Prototyping 2

3 Introductions What is 3DP/Additive Manufacturing? Brief History Top Five Technologies Industries Best Served Materials Applications Manufacturing Examples Q&A 3

4 Terminology Additive Manufacturing is a class of manufacturing processes that produce 3-Dimensional objects from 3D computer model data by joining thin layers of cross-section of the 3D computer data. AM is also known as Additive Fabrication, Layered Fabrication, Solid Freeform Fabrication, Rapid Prototyping and 3D Printing. Physical Prototype Form: looks, real shape and features Fit: size, ergonomics, precision Function: functionality and performance 4

5 Many Companies and organizations that design and manufacture physical products use AM output from concept to end use product and every step of the product life cycle. The main motivation of using Additive Manufacturing is its unique tooling-less nature that greatly shortens the product development cycle. Another significant advantage of the tooling-less nature of the AM is that it is a perfect fit for personal customized products. (mass customization) 5

6 BIG PLAYERS Stratasys Fdm Polyjet Solidscape Redeye on demand 3D Systems SLA SLS Inkjet (Z print) Cube (Extrusion) Quickparts Metals EOS direct metal laser sintering (DMLS) Arcam electron beam melting (EBM) 6

7 1988 AutoFact in Detroit: First SLA-1 in display 3D Systems (Chuck Hall) 1989 first commercial Stereolithography (SLA) machine sold 1991 Fused Deposition Modeling (FDM) - 3D Modeler introduced Stratasys (Scott Crump) 1992 Selective Laser Sintering (SLS) Sintersation 2000 introduced - DTM Corporation (Carl Deckard, UT Austin) 1993 MIT developed 3 Dimension Printing Emanuel Sachs and Michael Cima 1994 Solidscape Drop on Demand: Wax patterns for investment casting 1995 Z Corporation 1996 Stratasys introduced Genisys 3D Printer 2001: Objet introduced PolyJet technology 2002 SLS metal sintering 2003 EOS metal sintering 2009: Bits from Bytes, MakerBot 7

8 1. CAD - Neutral and Common File for transferring geometry to systems STL file Faceted representation Surfaces are made up of thousands of triangles All CAD tools create STL files 2. TECHNOLOGY/Machine to build your part 3. ONCE THE PART IS DONE support removal, curing etc. 8

9 The first commercially successful technology Uses a liquid that hardens when exposed to ultraviolet light Photo curable polymer Draw on top layer of liquid with ultraviolet laser Supports made from same material Often called SLA Stereolithography Apparatus Largest Vendor: 3D Systems Smaller players in Japan, China, and Europe Now available in 3D Printer level Pricing $15K - $800K Sizes 10x10x10 59 x 30 x 22

10 Strengths Resolution Surface Finish Transparent material Variety of materials Build Speed Mature Technology Weaknesses Post-Process Curing Support removal and Sanding Strength of material Expensive materials 10

11 Fastest Growing Technology 3 times as many Stratasys machines were sold in 2010 than 2 nd place Many low cost systems are FDM based 3D Printing to Digital Manufacturing Biggest Provider is Stratasys, Inc. FDM & Polyjet Prices: $10 k to $500k Build Sizes: 5 x 5 x 5 36 x 24 x 36 Build Platform 11

12 Strengths Material Options Functional Parts Part Strength Ease of Operation Low Cost Materials Digital Manufacturing 3D Printing Platforms Weaknesses Surface Finish Speed 12

13 Dominant Powder Technology Use laser to sinter particles together Uses powder to support Large, durable parts Several Powdered Metal Applications Dominated by 3D Systems A few competitors in Asia EOS in Germany European Laser Melting similar Prices: $150k to $750k Build Size 15 x 13 x 18 13

14 Strengths Large parts Flexible but strong Speed Self supporting Weaknesses Messy powder Surface finish Material options Warp Facility Requirements 14

15 Growing Technology Prints layers of liquid photopolymer then cured with a UV light Jet multiple materials in a single print Combine materials for distinct material properties Flexible materials, over molds Prices: $30k to $500k Build Sizes: 10 x 10 x 6 39 x 31 x 19 15

16 Strengths Speed Resolution Surface finish Digital Material printing Weaknesses Cost of Materials Photopolymer 16

17 Many Players MJM (3D Systems) ZPrinter (Zcorp now owned by 3D Systems) Solidscape (Sanders now owned by Stratasys) Prices $8kto $330k 17

18 Major Press in the past 2 years for maker solutions: DIY Most are based on Fused Deposition Modeling (FDM) RepRap open source machine started it 1,500 machines at the end of 2010 MakerBot, Bits from Bytes, and UP! are derivatives Very popular in incubators and maker labs Some impact in education Lots of buzz But, part quality is very low 18

19 Automotive Aerospace Medical Consumer Products Electronics Toys / Animation Defense Manufacturing

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