Additive Manufacturing (3D-printing) Opportunities for the building hardware industry
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1 Additive Manufacturing (3D-printing) Opportunities for the building ARGE ANNUAL CONFERENCE 13th, 14th & 15th SEPTEMBER 2018 ROTTERDAM - THE NETHERLANDS
2 2 AGENDA Introduction AM Applications AM processes and post processes Conclusions
3 4 Promise of Additive Manufacturing You can print anything (even the impossible) - immediately - very fast, very cheap and you do not need any skills!!! Automation print direct from design file Freedom in design Integrated functions in one part Every product can be unique Low initial costs No molds needed Quick startup production?
4 5
5 6 Points of improvement Materials Accuracy, surface roughness Reliability, reproducability and quality Price Speed Standardisation Certification
6 7 Factors in favour of application of AM Prototyping Small series Special (internal) features (internal channels, lattice structures) Design Customised products Special surface structures (e.g. to promote bone ingrowth) Light weight Relative small products Specific materials Marketing value Complex products with integrated functions
7 8 Prototypes for window seals Direct: Stratasys Objet Tango or Agilus 30 Stereo Lithography - ULM 17120; Flexa Selective Laser Sintering - Duraform Flex Material extrusion: NinjaFlex Indirect: Vacuümcasting of PolyUrethane in Silicone mould Shore A possible
8 9 Electronic tools: small series of special dust collectors
9 10 Appealing examples
10 11 Stealth key: 3D printed key with internal features Complex internal structure, inaccessible to cameras, scanners, clay Price approx. $200,- Printed by selective laser melting sources: : CHF : W.A. de Vigier Award, CHF 100,000
11 12 Additive Manufacturing for the building
12 13 Design door handles
13 14 In ear hearing aids Vat photopolymerisation Courtesy of Widex
14 15 In ear hearing aids Swap of production technology in two years
15 16 Invisalign Costa Rica th million patient
16 17 Implants with special surface structure
17 18 Products with integrated functions 1 Onderdeel 16 parts 1 part Courtesy of 3DSystems
18 19 Produced by AM Produced by traditional technologies
19 20 Factors in favour of application of AM Prototyping Small series Special (internal) features (internal channels, lattice structures) Design Customised products Special surface structures (e.g. to promote bone ingrowth) Light weight Relative small products Specific materials Marketing value Complex products with integrated functions
20 21 Application of AM Design Task Manufacturing technologies Milling Design Functional Mechanical Structural AM potential? AM material & process selection Part requirements AM process limits Turning Casting Part Prototype Optimisation Prototype cycle Prototype Forging Final Design Printed sample Adapted from SASAM, Adriaan Spierings, Inspire
21 22 AGENDA General principles Terminology - Trends AM Applications AM processes and post processes Conclusions
22 23 Official definition Additive Manufacturing Process of joining materials to make parts - from 3D model data, - usually layer upon layer, as opposed to subtractive and formative manufacturing methodologies.
23 24 From CAD to slice-file 3D CAD file STL file Slice file Additive Manufacturing
24 25 Additive Manufacturing = Layered Manufacturing CAD model Slice file Part
25 26 Powder based Liquid based Solid based Powder bed fusion SLS/SLM/DMLS EBM Vat photopolymerisation SLA/DLP/CLIP Sheet lamination Binder Jetting Material Jetting PolyJet / MuliJet Directed Energy Deposition WAAM Directed energy deposition Cladding LMD Material extrusion FDM/FFF
26 27 Material extrusion, Fused Deposition modelling (FDM) Most applied in home printers
27 28 Material extrusion Fused Deposition Modelling (FDM) 45 Degrees
28 29 Fused Deposition Modelling (FDM) Typical specs: Build size Accuracy Layerthickness 200 x 200 x 200 mm 900 x 600 x 900 mm +/- 0,2 mm 0,1 0,5 mm Materials (low end): PLA (ABS) Materials (High End): ABS, PC, PPSU, PPSF, PEI (ULTEM)
29 30 Advantages: Simple, affordable and clean concept, Numerous of producers, open communities. Both low-end home printers and high end professional printers Broad range of materials including high end materials like Poly Carbonate and Ultem. Disadvantages: Not the technology to produce fine detailed and thin walled features Use of support structures required
30 31 Properties relative to most other AM technologies Advantages Disadvantages Simple, affordable and clean concept Numerous of producers, open communities Both low-end home printers and high end professional printers Broad range of materials including high end materials like Poly Carbonate and Ultem. One part can be available fast (nota large batch required) Not the technology to produce fine detailed and thin walled features Use of support structures required
31 32 Powderbed Fusion Laser Sintering / melting / cusing
32 33 Handeling of part and powder Unpacking Adidas Future Craft
33 34 Powder Bed Fusion Especially PBF with metals is not a simple & clean process
34 35 Support structures required Essential for Powder Bed Fusion with Metals Latice stuctures Specialized software
35 36 Applications Powder Bed Fusion Products - Assemblies with moving parts - Internal tubing - Hollow parts - Smal series complex parts
36 37 Properties relative to most other AM technologies Advantages Disadvantages High productivity Complex parts possible with no supports Good material properties Many materials available Quite good detailed Long batch time Sensitive process Powder handling Expensive materials & equipment Rough surface (compared to vat photopolymerisation)
37 38 Vat Photopolymerization Stereo Lithography (SLA)
38 39 Vat Photopolymerization Stereo Lithography (SLA)
39 40 Material Jetting
40 41 Material Jetting Objet (Stratasys) - PolyJet (3D-Systems) Typical size Part material Layerthickness Parts max x 800 x 500 mm Fotopolymers mm High accurate form and fit, good surface quality
41 42 Material Jetting Stratasys Objet - PolyJet
42 43 Binder Jetting 3D-Systems (Z-corp), ExOne, VoxelJet
43 44 3D Printing Z-Corp (3D-Systems) Type: Maximum part size: Part material: Layer Thickness: Low end, concept modeller, investment casting 508 x 381 x 229 mm Powders bound together by an adhesive mm Parts: concept models
44 45 Voxeljet Sand printing for metal casting
45 46 Voxeljet PMMA + investment casting
46 47 Binder Jetting ExOne 47 Printen van Inkjet binder op RVS poeder, daarna infiltreren met brons
47 48 AGENDA General principles Terminology - Trends AM Applications AM processes and post processes Conclusions
48 49 Factors in favour of application of AM Prototyping Small series Complex products Special (internal) features (internal channels, lattice structures) Customised products Special surface structures (e.g. to promote bone ingrowth) Light weight Relatively small products Specific materials Marketing value
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