Introduction to Additive Manufacturing (AM)
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1 Introduction to Additive Manufacturing (AM) July 2016 Dhruv Bhate, Ph.D. Senior Technologist, PADT Inc. 1
2 Outline Introduction to PADT AM Processes & Materials Key Drivers for AM Learn More & Get Involved 2
3 INTRODUCTION TO ADDITIVE MANUFACTURING AT PADT 3
4 PADT: What We Do Simulation Product Development Manufacturing Sales Services R&D Training Consulting 4
5 PADT by the Numbers Founded in 1994, 22 years in business 85 employees 19 years average experience, 4 PhDs & 13 Masters degrees R&D labs with $2M in equipment Over 1,700 Customers served Over 100,000 Prototypes & Functional Parts Delivered Over 350 product development projects completed Over 7,200 numerical simulation models run Over 9,900 Support Cleaning Apparatus (SCA) Systems Sold Strong Partnerships: Stratasys Platinum Partner 2015 Concept Laser Consultative Partner ANSYS Channel Partner 13 Small Business Innovation & Research (SBIR) awards since 1999 Tempe, AZ Torrance, CA Albuquerque, NM Phoenix, AZ Littleton, CO Murray, UT 5
6 PADT Capabilities: Additive Manufacturing Fused Deposition Modeling (Fortus 450, 400, 250) Selective Laser Sintering Selective Laser Melting (Concept Laser MLab Cusing R) Arriving Summer 2016 Stereolithography (SLA) Material Jetting (Polyjet) 6
7 PADT Additive Manufacturing (AM) Technology Timeline Stereo lithography SLA 250 Viper Si2 ProJet * FDM 2000 Prodigy Dimension Fortus 400 Fortus 450 Fused Deposition Modeling 1995* 2000* Selective Laser Sintering Sinterstation 2000 plus 1999 HiQ Thermal Sensing Upgrade 2005 Multi-zone Heating Upgrade 2012 Connex 500 Objet 500 Material Jetting (Polyjet) MLab Cusing R Selective Laser Melting (Metal) *retired 7
8 PADT Capabilities: AM Post-Processing & Finishing FDM Support Cleaning Apparatus (Designed, developed and sold by PADT) Powerblast (High Pressure Water Cleaner) Gas vac Blue M Oven Finishing (Support removal, painting, polishing) 8
9 PADT Capabilities: Rapid & Advanced Manufacturing NC Milling & Lathe Injection Molding (at partner site) Chemical Hood & Workspace Customized Testing Lab 9
10 PADT Capabilities: Reverse Engineering & Inspection 3D Scanning (Steinbichler) 3D Scanning (Geomagic Capture) Cross-sectional Scannning (CGI) File Formats (Including Inspection Results) Reverse Engineering Software (GeoMagic Design X) 10
11 PADT Capabilities: Design SolidWorks Pro/Engineer Topology Optimization (ANSYS GTAM) ANSYS SpaceClaim 11
12 PADT Capabilities: Simulation Structural (Statics & Dynamics) Transient Dynamics Multiphysics Simulation Tool Customization, Process Automation High Performance Computing for Simulation 12
13 PADT R&D Focus Area Additive Manufacturing Characterization & Theory Design & Simulation 3 * t cos 1 E1 Es 2 l h 2 sin sin 2 t 1 ( s cot ) l l We seek to address complex problems in Additive Manufacturing that benefit from a combination of experimental, theoretical and numerical approaches 13
14 PADT Recognition & Outreach Highest partner status for commercial resellers America Makes Silver Member Additive Manufacturing Users Group 2012 DINO Award (Brad Palumbo) Voting member, ASTM Standards F42 on Additive Manufacturing Supporting startups at the Center for Entrepreneurial Innovation (CEI) 2011 Governor's Celebration of Innovation Pioneering Award 2011 Spirit of Enterprise Award (Entrepreneurial Leadership) AZ Bio Fast Lane Award 2011 (PADT Medical) Research Awards 13 awards, Commercialization Index of 90, Small Business Innovation Research (SBIR) Grant awarded July 2016 for research on AM lattice modeling (18 months) 14
15 INTRODUCTION TO ADDITIVE MANUFACTURING 15
16 Additive vs Conventional (Subtractive) Manufacturing Conventional Manufacturing 3D Printing (Additive Manufacturing) 16
17 Additive Concept Raw Material Process Technology Product 17
18 Sheet Filament / Wire Liquid Powder Classification of Additive Manufacturing Processes Raw Material Process Technology Laser Fusion/Sintering Electron Beam Melting Binder Jetting Powder + Laser Laser Polymerization Light Projection Polymerization Material Jetting Fused Deposition Wire + Electron Beam Ultrasonic bonding Laser Lamination 18
19 Materials (Polymers) Thermoplastics (FDM) Photopolymers (Polyjet) 19
20 Materials (Laser-based for Metals) Non-Reactive Metal Alloys Reactive Metal Alloys 316L Stainless Steel Maraging Hot-Work Steel Stainless Hot-Work Steel 30Al/31Al Aluminum Alloy Ti6Al4V Titanium Alloy 17-4 PH Stainless Steel Inconel 718 Inconel 625 Commercially Pure Titanium Biocompatible Ti6Al4V Alloy Bronze Alloy Biocompatible CoCrW Alloy 20
21 Additive Manufacturing Trends AM System Installations by Sector Worldwide AM Revenue (USD, Millions) Services Percentage of AM Revenue from Functional Parts Products 21
22 ADDITIVE MANUFACTURING DRIVERS 22
23 Top 5 AM Drivers 1 Rapid Prototyping and Tooling Design Freedom Lead Time Reduction Manufacturing Cost Reduction 5 New Applications Rolls Royce Trent XWB 23
24 1 Rapid Prototyping Low-cost, rapid manufacturing of one of a kind parts allows for faster product development cycles 50-90% cost reductions 80-95% lead time reductions Wind Tunnel Models (Lockheed Martin Corp.) Mock-Ups & Fit Tests (Lockheed Martin Corp.) Display Models (Lockheed Martin Corp.) 24
25 1 Rapid Tooling Organic Innovation, operators and engineers design and print tooling and improvements at low cost and fast turnaround time and see the results of their ideas C-130 Microvane Tooling (Lockheed Martin Corp.) Drill Jigs (Lockheed Martin Corp.) Layup Tool (Lockheed Martin Corp.) 25
26 2 Design Freedom Internal Features Layer-by-layer manufacturing process allows for more complex geometries design with (almost) no constraints! Fuel Nozzle (GE Aviation) UAV Wing (Aurora Flight Sciences) Space Launch Fuel Nozzle (NASA Marshall) 26
27 2 Design Freedom Strength-Weight Optimization Topology optimization allows for reducing the material requirements for any desired objective (stiffness, strength, extension etc.) AM enables manufacturing of these designs! Topology Optimization (ANSYS) Bracket with 30% weight reduction (Airbus) Seat-belt buckle - 55% weight reduction, estd. 72.5kg on Airbus 380 (EOS) Exhaust Sensor (RSC Engg.) Bracket (Honeywell) 27
28 2 Design Freedom Parts Consolidation Parts previously designed for manufacturing and subsequent assembly can now be printed in a consolidated manner to eliminate assembly costs (labor and parts) Satellite Waveguide, Renishaw (77 parts to 1) Sensor Housing, GE (20 parts to 1) Airbus Fuel Assembly (10 parts to 1) 133 g 53 g 28
29 3 Lead Time Reduction Eliminate Supplier Sourcing Deloitte University Press 2011 Committee on Examination of the U.S. Air Force's Aircraft Sustainment Needs Additive Manufacturing enables point-of-use manufacturing! US Navy Raytheon 29
30 3 Lead Time Reduction Accelerate Development, Replacement & Repair Super Draco Thruster: concept to hot firing in 100 days (Space X) Replacement parts for a 30-year old component within a week (Airbus) Turbine blade repair (DM3D, MT Additive) 30
31 4 Manufacturing Cost Reduction Mass Customization Low Volume, High Mix High Volume Manufacturing 31
32 5 3D Printed Electronics (PEN, Inc.) New Applications Space Construction (ESA) Armor & Exoskeleton On-Orbit Manufacturing (Tethers Unlimited) Bioprinting 32
33 LEARN MORE & GET INVOLVED 33
34 Learn More Online Courses: 3D Opportunity: Additive Manufacturing for Business Leaders : Bioprinting: 3D Printing Body Parts : Reading: European Powder Metallurgy Association (EPMA) Brochure: Introduction to Additive Manufacturing : Wohlers Report (annual, fee): Metal Additive Manufacturing Magazine (free digital editions): Conferences: AMUG: RAPID: SFF Symposium: formnext: America Makes Membership: Online, Living Textbook expected in 2017 (PADT leading effort) 34
35 Arizona Additive Manufacturing Committee (AZ Tech Council) Started June 2016, with goals: Promote AM and educate potential users Act as a forum to influence local regulation Inform progress of national certification and standards organizations Serve as a rallying point for collaboration - 53 individuals representing 34 entities in AZ (and growing) - Next meeting is at PADT (Monday, August 15, 4-5:30pm) - Contact dhruv.bhate@padtinc.com to learn more 35
36 Thank You! 36
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