3D SCREEN PRINTING ADDITIVE MANUFACTURING FOR MASS PRODUCTION. Fraunhofer IFAM Dresden

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1 3D SCREEN PRINTING ADDITIVE MANUFACTURING FOR MASS PRODUCTION

2 Ov erv iew Frauhofer

3 Fraunhofer society Itzehoe Lübeck Rostock Bremerhaven Bremen Oberhausen Dortmund Duisburg Schmallenberg St. Augustin Aachen Euskirchen Hannover Braunschweig Darmstadt Würzburg Erlangen St. Ingbert Kaiserslautern Fürth Nürnberg Saarbrücken Karlsruhe Pfinztal Stuttgart Freising Freiburg München Potsdam Berlin Teltow Magdeburg Cottbus Halle Schkopau Leipzig Dresden Jena Chemnitz Ilmenau 67 Fraunhofer institutes and independent research units in Germany employees 10 institutes or branches in Dresden Efringen- Kirchen Holzkirchen 3

4 Fraunhofer in Dresden 11 institutes, largest site of the Fraunhofer-Gesellschaft ~1,300 employees FEP IFAM IIS IKTS Institute for Electron Beam and Plasma Technology Institute for Manufacturing Technology and Advanced Materials Institute for Integrated Circuits Institute for Ceramic Technologies and Systems ASSID IPMS, IKTS-MD, FEP IKTS-MD Institute for Material Diagnostics IPMS Institute for Photonic Microsystems IVI Institute for Transportation and Infrastructure Systems IWS Institute for Material and Beam Technology IWU Institute for Machine Tools and Forming Technology AVV Application Center for Processing Machinery and Packaging Technology ASSID Project group All Silicon System Integration Dresden IWU IVI,EAS AVV FEP, IFAM IKTS, IWS 4

5 Fraunhofer at Winterbergstrasse Fraunhofer IKTS Institute for Ceramic Technologies and Systems IFAM Fraunhofer IWS Institute for Material and Beam Technology Fraunhofer FEP Institute for Electron Beam and Plasma Technology Fraunhofer IFAM Institute for Manufacturing Technology and Advanced Materials, Branch Lab Dres den Area: m² Employees: ~ 830 5

6 Fraunhofer IFAM branch lab Dresden Staff Students Budget Industry funding Public funding FhG funding Investments Area (Budget 2016) Mio. 32 % 54 % 14 % 1.4 Mio m 2 head: Prof. Dr.-Ing. Bernd Kieback 6

7 Activities at IFAM Cellular Metallic Materials Sintered and Composite Materials Fiber Structures Hollow Spheres Metal Foams Lightweight Materials Tribology PM Technologies 3D Metal Printing 3D Wire Structures Porous Metal Paper Therm o- electrics Thermal Management Hightemperature and corrosionresistant Materials Hydrogen Technology Energy and Thermal Management Elektrolysis Storage Hydrolysis Thermal Simulation Analysis Storage Devices 7

8 3D s creen printing

9 3D-screen printing process layout 9

10 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Wall thickness: 100 µm 5 mm 11

11 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production dimensions of openings down to: 80 µm 12

12 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Numerous structures can be manufactured which are otherwise time consuming to prepare with machining 13

13 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Hollow parts can be prepared 14

14 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Overhangs are possible 15

15 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Part made out of sintered tungsten 16

16 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Material combinations possible white: ZrO 2 black: metal 5 mm 17

17 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production Printing additional structures (e.g. pins) on prefabricated plate safes milling time 18

18 3D-screen printing sample structures thin walls (100 µm) openings (80 µm) numerous structures cavities overhangs brittle, hard materials material combinations functionalizing mass production More than parts/yr can be prepared 19

19 3D-screen printing materials metals ceramics Al 2 O 3, ZrO 2 Properties of 3D-screen printing powders d90 < 1/3 of mesh openings not too abrasive compatibility with carrier substance (water, org. solvents) and additives must withstand heat treatment (debindering, sintering) 20

20 3D-screen printing applications micro parts heat exchanger fuel cells electronics implants filter seals jewellery and branding 21

21 Economic Aspects

22 3D-screen printing case study heat exchanger Sample heat exchanger IFAM s screen printer 1, ,9 single shift (two printing tables) big screens small parts cost/part [ ] 0,8 0,7 0,6 0,5 0,4 8 M parts/yr single layer heigth: 15 µm drying time per layer: 20 s part height: 1 mm parts/year fast printing 0, fast curing thick layers 0,2 0,1 three shift (10 printing tables) 24/7 0,0 0,0 0,2 0,4 0,6 0,8 ~350,000 parts/year screen size [m²] 100 M parts/yr

23 3D-screen printing case study heat exchanger Sample heat exchanger cost structure for part (2x3 cm, thickness 1 mm) heat treatment (operation) screen printer (operation) screen printer (maintenance) three shift (>50 Mio parts/yr.) single shift (0.35 Mio parts/yr.) screen printer materials screens heat treatment maintenance deduction heat treatment (maintenance) heat treatment (deduction) material (metal powder) personal screen cost screen printer (deduction) personal portion of total cost [%] 25

24 Thank you. Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung Institutsteil Dresden (Fraunhofer Institute for Manufacturing Technology and Advanced Materials) Winterbergstraße Dresden Germany Telefon