Selective Laser Sintering (SLS) with the ProX SLS 6100

Transcription

1 Selective Laser Sintering (SLS) with the ProX SLS 6100 PRODUCTION-READY FOR TOUGH, FUNCTIONAL NYLON PARTS

2 What Can SLS Do For You? MAKE RADICALLY BETTER PRODUCTS GET MORE FLEXIBLE PRODUCTION STREAMLINE YOUR SUPPLY CHAIN Free of the limitations of molding and CNC, design and produce radically lighter weight, higher performance products. Make production-quality parts without tooling. No lead time, and no up front costs to amortize for every design. Consolidate whole assemblies into single parts to reduce BOMs and eliminate assembly labor. SUPERCHARGE YOUR MACHINE SHOP ACCELERATE PRODUCT DEVELOPMENT PERSONALIZE & MASS CUSTOMIZE Free up CNC and machinist time by printing complex plastic geometry instead of multi-setup machining. Go from idea to functional part in hand in a day. Validate designs in 1/10 the time. Skip the limitations of molding and CNC, while achieving exacting mechanical properties and accuracy.

3 SLS Makes 3D Production Real AUTOMOTIVE Compressed product development cycles Functional prototypes that meet heat, strength, accuracy, and mechanical requirements Bridge production Tool-less manufacturing of injection-mold quality parts AEROSPACE Significantly faster time-to-market Lightweight, high value production plastic or cast metal parts Revolutionizing the supply chain Improved assembly through custom jigs & fixtures HEALTHCARE Improved surgical outcomes through patient-specific surgical guides Mass customized production of personalized devices for prosthetics, orthodontics, hearing aids and more INDUSTRIAL COMPONENTS Streamlined supply chains Flexible production, lots of one become economical Rapid customer responsiveness TOOLING 3D printed tooling, including molds, jigs and fixtures is faster and cheaper than traditional tooling FOOTWEAR Mass customized products fit every customer perfectly Lightweight, high-performance shoes give athletes a crucial edge

4 SLS Strength: Real Nylon SIMILAR TO INJECTION MOLDED PARTS With a selection of durable polyamide filled and standard materials, SLS parts perform almost identically to injection molded parts. They are true production grade parts that will last for decades. Prototype housing for functional testing STRONGER THAN OTHER PRINTED PLASTIC PARTS No other 3D printing technology makes plastic parts as strong as SLS. High temperature sintering produces the best mechanical properties, without voids or other artifacts that weaken other 3D printed parts. Low volume production automotive part

5 SLS vs FDM Process Matters Flexural Modulus Flexural Strength Tensile Modulus Tensile Strength SLS Printed Part in DuraForm ProX PA FDM Part in Nylon 12, ZX Orientation* 27 MPa 1650 MPa 1630 MPa 60 MPa 48 MPa 1770 MPa 1950 MPa 50 MPa *FDM parts are non-isotropic (they have different mechanical properties in Z). SLS parts are stronger in the z-axis vs. other 3D technologies. SLS printed part is stiffer SLS printed part is stronger SLS part is far tougher under tension Elongation at Break 3% 22% Impact Strength (unnotched izod) 275 J/m 644 J/m SLS printed part is stronger Heat Deflection Temp 98 C 182 C SLS printed part is superior Based on material datasheets retrieved May 2017

6 SLS Speed THERE'S NO FASTER WAY TO GET PRODUCTION-GRADE PLASTIC PARTS Time to create 250 first article parts 2 x 2 inch (50 x 50 mm) parts 3D Systems SLS FDM Injection Molding 33 hours (warm up + printing + cooldown + breakout) 240 hours (printing + support removal) 360 hours (2 week tooling lead time + 1 day molding)

7 No Supports = Fast & Easy Post-Processing MORE POSSIBILITIES Parts are supported by unsintered powder, you don't need to print support structures, giving you greater design freedom. LOW LABOR COSTS With no support structures to remove, operators & technicians save time. EFFICIENT PRODUCTION Large batches of parts are fast to print and easy to postprocess, making SLS the choice for production-level additive manufacturing. Clean unused powder off parts, and they're done

8 3D Systems SLS Product Line MID-FRAME LARGE-FRAME Smaller Build Volume More Affordable Fine Surface Detail Industrial Grade Large Build Volume Production Ready ProX SLS 6100 spro 60 HD-HS spro 140 spro 230 Priced for prototyping Production capable Functional parts Automatic material management Small scale manufacturing Functional prototypes Repeatable production Large-scale production Large parts for testing Wide body construction Large-scale production Turbine-sized builds Functional testing and manufacturing

9 3D Systems SLS Product Line ProX SLS 6100 spro 60 HD-HS spro 140 spro 230 Maximum Build Volume 15 x 13 x 18 in (381 x 330 x 460 mm) 15 x 13 x 18 in (381 x 330 x 460 mm) 22 x 22 x 18 in (550 x 550 x 460 mm) 22 x 22 x 30 in (550 x 550 x 750 mm) Material Options DuraForm ProX PA DuraForm ProX EX BLK DuraForm ProX GF DuraForm ProX HST DuraForm ProX AF+ DuraForm ProX FR1200 DuraForm PA DuraForm EX BLK DuraForm GF DuraForm HST DuraForm EX Natural DuraForm FR1200 DuraForm TPU DuraForm Flex CastForm PS DuraForm PA DuraForm EX BLK DuraForm GF DuraForm HST DuraForm EX Natural DuraForm PA DuraForm EX BLK DuraForm GF DuraForm HST DuraForm EX Natural Layer thickness range: in ( mm) build rate 2.7 l/hr 1.8 l/hr 3.0 l/hr Recycling & Handling Automatic Manual (enables material changeovers) Automatic Automatic

10 What is the ProX SLS 6100? Production Quality, Priced for Prototyping The Mid-Frame SLS printer that has excellent surface finish and fine detailing, ideal for production quality, but priced for prototyping Optimizes price-per-part to deliver a competitive Total Cost of Operation (TCO) Automatic material handling and feeding system saves time and money 3D Sprint software easily plans the builds to maximize space and part orientation 3D Connect capable for proactive and preventative remote diagnostics

11 Unmatched Part Quality Excellent surface finish Highest resolution and edge definition High accuracy and repeatability Uniform part properties

12 Lower Part Cost 20% LOWER TOTAL COST OF OPERATION Automated production tools High throughput 95% material efficiency Optimized workflow

13 Material Quality Control System The Single MQC User-Interface screen lets you define material blend ratio in 5% steps Integrated remote cooling station Material tracking data capture Downdraft to reduce airborne materials Automated Dynamic powder blending Supports only one ProX SLS 6100 printer Reject and Re-capture powder chutes Remote installation up 100M effective length from printer

14 Material Quality Control System The Dual MQC The Dual MQC does offer more control over the powder recycling blend allowing you to set the ratio in 1% steps It has 2 material bins for fully automatic blending and recycling Can support 2 printers at once

15 Production-Grade Materials FOR A BROAD SET OF APPLICATIONS DuraForm ProX AF+: Aluminum/mineral filled Nylon 12 material DuraForm ProX EX BLK: Nylon 11 black material DuraForm ProX FR1200: Nylon 12 flame retardant material DuraForm ProX PA: Nylon 12 white, biocompatible and food grade DuraForm ProX GF: Nylon 12 with glass fibers for flexibility and durability DuraForm ProX HST: Nylon 12 with high temperature resistance

16 DuraForm ProX AF+ MINERAL AND ALUMINUM FILLED NYLON 12 BASED POWDER Aesthetic metallic surface finish Functional strength at an affordable cost Repeatable mechanical properties Easily machined and polished Excellent stiffness to weight ratio Lower costs with higher recyclability

17 DuraForm ProX AF+ APPLICATIONS Housing and enclosures Plastic parts requiring a metallic finish and good appearance High rigidity components and functional assemblies Wind tunnel testing parts where stiffness and light weight are needed Jigs and fixtures where high rigidity is required Automotive styling parts where a metallic look is needed (knobs, bezels etc.)

18 DuraForm ProX EX BLK NYLON 11 BASED POWDER Outstanding durability for long-life Excellent impact resistance Fatigue resistant Fuel and oil resistance Uniform black coloring Derived from sustainable non-petrochemical based plastics Replaces injection molded ABS and polypropylene For use in real life environments

19 DuraForm ProX EX BLK APPLICATIONS Housing and enclosures Vehicle dashboards and grilles Automotive bumpers Snap-fits, living hinges and connector type parts Short production consumer goods/sporting equipment Complex designs, especially custom ductwork Exhaust and duct systems for aerospace and automotive uses Impellers

20 DuraForm ProX FR1200 NYLON 12 BASED FLAME RETARDANT POWDER FAR compliant Passes AITM smoke density and toxicity requirements Excellent flame retardancy at 12 and 60 second exposures High accuracy and repeatability needed for manufacturing Non-halogenated formulation Excellent surface quality

21 DuraForm ProX FR1200 APPLICATIONS Direct production of aerospace, transportation and consumer goods application where reliable fire retardancy and reduced smoke and toxicity are required Direct 3D production of aircraft interior parts Accelerate changes in cabin designs for in service aircraft Eliminate tooling and minimize spare part stocking costs Reduce fuel costs with weight optimized design enabled by additive manufacturing

22 DuraForm ProX PA NYLON 12 BASED POWDER Strong, tough thermoplastic material Excellent mechanical properties Outstanding surface smoothness Stable dimensional and mechanical properties Exceptional recyclability Very high part density Biocompatibility: ISO and ISO capable Food safe

23 DuraForm ProX PA APPLICATIONS Functional prototyping and low volume production parts for: Automotive Aerospace Consumer goods Housings and enclosures Snap fits and complex assemblies Connectors

24 DuraForm ProX GF GLASS-FILLED NYLON 12 POWDER Excellent mechanical stiffness and elevated temperature resistance Dimensionally stable Easy-to-process Excellent surface finish Accurate and repeatable parts Machinable and paintable for demonstration parts Improved isotropic shrinkage due to glass filler

25 DuraForm ProX GF APPLICATIONS Strong/rigid prototypes that require elevated stiffness and heat resistance Low to mid volume direct manufacturing of end-use parts Enclosures and housings that require more stiffness Aircraft and motorsports parts Sporting goods Parts requiring machining or joining with adhesives Complex production and prototype plastic parts Form, fit or functional prototypes Parts requiring stiffness Thermally stressed parts

26 DuraForm ProX HST FIBER-REINFORCED NYLON 12 Elevated temperature resistance High stiffness and strength to weight Anisotropic mechanical properties, just like fiber-filled Non-conductive and RF transparent Easy-to-finish surface

27 DuraForm ProX HST APPLICATIONS Complex, thin-wall ductwork Functional prototypes that approach end-use performance properties Appropriate for low- to mid-volume rapid manufacturing Medical applications requiring USP Class VI compliance or biocompatibility Motorsports Aerospace Housing and enclosures Impellers and connectors Consumer sporting goods Vehicle dashboards and grilles Snap-fit designs Parts requiring machining or joining with adhesives

28 3D Sprint for the ProX SLS 6100 ADVANCE YOUR WORKFLOW High performance auto-nesting High density builds Sinter Cage structure generator Quality check for pre-build verification

29 3D Connect Capable COMING SOON Remote Service 3D Systems service facing Fleet Monitoring Customer facing Automatically notifies service when Real-time remote monitoring alert conditions occur Event driven notifications Enables remote investigation for o Text & alerts more precise diagnosis Metric rich environment No special customer skills set required o Up-time, usage, consumable use, health of the lasers/print heads, etc.

30 3D Connect, A Simplified View COMING SOON Edge Gateway synchronizes the data IIOT Platform makes it useful REMOTE / MOBILE CUSTOMER ACCESS Sensor readings Safe and neutral machine data Service Tickets Charts, plots, analytics Actionable information 3D SYSTEMS SERVICE TEAM LASER HOURS HEAD PERFORMANCE SCHEDULED MTC MORE

31 The ProX SLS 6100 in Summary Price and performance Production quality performance at prototyping price Portfolio of 6 production-grade materials Strong software platform Integrated 3D Sprint and 3D Connect capable Automatic material handling, feeding and recycling through the material quality control (MQC) system

32 Emirates Uses SLS for Significant Cost Savings Opportunities of In-Cabin Parts SLS printing with flame retardant nylon material reduces weight of in-cabin video shroud Video monitor shrouds are between 9 and 13% lighter than their conventionally manufactured counterparts Emirates optimizes its designs to create fit-for-purpose parts with an optimized strength-to-weight ratio DuraForm ProX FR1200 material: FAR compliant Passes AITM smoke density and toxicity requirements UL certification for consumer goods Emirates is in the process of securing Form 1 certification to validate video shroud part design as approved for aircraft use

33 Metro Aerospace Introduces 3D Part for Fuel Efficiency SLS printing provides fuel savings of 4% at cruise with improved aerodynamics Metro Aerospace designed microvanes that are adhesively fastened on both sides of an aircraft s fuselage Parts designed to reduce drag by reshaping airflow around the aft cargo door Printed with DuraForm GF, a glass-filled nylon Final 3D printed microvanes met the rigorous standards outlined by the engineers who designed them

34 Wiiv Wearables Mass Customization with SLS 100% custom SLS 3D printed production of tens of thousands of shoe soles Rapid turnaround of custom shoe soles from personalized scan data SLS build envelope provides the flexibility to stack parts in a wide variety of configurations Enjoy the benefits of 3D production: No tooling investment Mass customization Design freedom Fast turnaround

35 Jay Leno Creates One-of-a-Kind Replacement Part for EcoJet Concept Car 3D Printed Replacement Vent in SLS with high-temperature resistant material 3D Systems team helped create a digital workflow to scan old part and create a design for replacement part Printed in Duraform HST, a fiber-filled nylon with anisotropic mechanical properties Ideal for functional prototypes and end-use parts that require high stiffness and elevated thermal resistance and has a surface that is very easy to finish

36 Production Quality with the ProX SLS 6100 Transform Your Production Processes with Tool-less Manufacturing Low volume tool-less manufactured parts Personalized healthcare applications High performance duct that's difficult and costly to mold SLS is the 3D printing technology for real thermoplastic parts without compromise

37 THANK YOU!