LIGHTFAIR International 2018

Transcription

1 LIGHTFAIR International 2018 Provider Number - Z136 The Value of 3-D Printing in Manufacturing Solid-State Lighting Systems L18SM07 N. Narendran, I.U. Perera May 9, 2018

2 Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. Certificates of Completion for both AIA members and non AIA members are available upon request. This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed d or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion ofthis presentation.

3 Copyright Materials This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited. LIGHTFAIR International 2018

4 Course Description The explosion of solid state lighting (SSL) products in the market and their price erosion has necessitated the search for lower cost materials and manufacturing methods. The automotive, aerospace, and medical industries have recently embraced 3 D printing for manufacturing, a solution that also could allow the lighting industry to offer lower cost, custom SSL systems that are produced on site to achieve on time and on demand manufacturing. This course will describe current 3 D printing technologies and materials and whether they can be used to manufacture the thermo mechanical, electrical, and optical components necessary for SSL fixtures.

5 Learning Objectives At the end ofthe this course, participants will be able to: 1. Learn about current 3 D printing technologies and materials and how 3 D printing of lighting components works 2. Learn about recent research into the thermal conductivity of 3 D printing polymers and their ability to create LED heat sinks 3. Learn about using 3 D printing inks to create electrical traces for solid state lighting 4. Learn about possible 3 D printing technologies for creating optical components

6 The Value of 3 3 D D Printing in Manufacturing Solid State Lighting Systems May 9, :30 am Nadarajah N d j h Narendran N d Indika Perera Lighting Research Center, Rensselaer Polytechnic Institute

7 3 D printing Objects are fabricated by depositing material layer by layer Also known as additive manufacturing (AM) is 3d printing/ SSeverall types t off 3 D 3 D printing i ti processes 7

8 Most common 3 3 D printing processes 1. Thermoplastic extrusion process Fused deposition modeling (FDM) 2 Vat 2. V t photopolymerization h t l i ti process Stereolithography (SLA) Digital Light Processing (DLP) 3. Powder bed fusion process Selective Laser Sinteringg (SLS) Multi jet fusion Direct Metal Laser Sintering (DMLS) Selective Laser Melting (SLM) Electronic Beam Melting (EBM) 4 Material 4. M i l or Binder Bi d jetting j i 8

9 Most common 3 3 D printing processes Source: 3dhubs.com 9 4

10 3 D Printer Manufacturers Printing technology Thermoplastic extrusion Vat photopolymerization 10 Selective laser sintering, M lti j t fusion Multi jet f i Direct metal laser g, Selective laser sintering, melting, and Electron beam melting Materiall and d binder b d jetting Printer Manufacturers XYZprinting, Stratasys, 3DSystems UltiMaker 3DSystems, UltiMaker, Markforged Formlabs, 3DSystems, Carbon, B9Creator 3DSystems, EOS, SINTERIT, hp EOS, GE (Concept Laser and Arcam), ), 3DSYSTEMS,, SLM Solutions Stratasys, 3DSystems, hp, h ExOne, Rize, XAAR,

11 3 D Printer Material Manufacturers Printing technology Material Manufacturers Thermoplastic extrusion BASF, ARKEMA, Covestro, M kf Markforged, d Stratasys, St t P t Proto pasta, colorfabb Vat DSM, SM, Dow ow Corning, Henkel, photopolymerization SARTOMER (ARKEMA), 3DSystems, Direct metal laser ATI Powder Metals, SANDVIK sintering, Selective laser Osprey, Renishaw, Metco, melting, g, and Electron Praxair,, GKN Hoeganaes, g, beam melting Materialise 11 Selective laser sintering, ARKEMA, BASF, Covestro, Material jetting, and Evonik, OPM Binder jetting

12 Expanding Market for 3 3 D Printing Industries that have embraced 3 D printing for manufacturing parts and systems Automotive Aerospace Medical Consumer products 12

13 Reasons for pursuing 3 3 D printing today Prototyping Product P d t development d l t Customization Innovation Reduce stocked inventory Source: 3D printing: The next revolution in industrial manufacturing, UPS and Consumer technology Association,

14 3 D Printing Market Size 3 D printing industry is expected to grow to more than $21 billion in revenue by technology/3d printing i d industry to triple in four years to 21b.html i l i f 21b h l 14

15 Can Solid Solid State State Lighting Benefit from 3 D printing? 15

16 LED Luminaire Market Size LED luminaire market size is projected to reach $45 billion by /issue 5/features/strategies in light 2017/market outlook brightens for leds with new ssl applications emerging.html Philip Smallwood, Strategies in Light

17 Price Erosion for LED Lighting Fixtures Industry trend LED lighting fixtures are manufactured overseas and shipped to U.S. US Commodity (low cost) Increased carbon footprint p Lighting trends for 2018 Lighting fixtures with more functionality will have sensors, radios for wireless connectivity, processors for increased intelligence to conserve energy or deliver intelligence, tailored light, etc. (IoT ready) 3 D printing could further add value custom lighting fixtures, made on site, on demand 17

18 Why 3 3 D printing for SSL fixtures? Today: Prototyping (form factor only) Potential benefits if complete fixtures can be printed in the future Custom fixtures Improved p visual appeal pp and functions Reduced fixture cost Heat sinks with tailored thermal properties Print and assemble optics (one step) One step process for all components Reduce stored inventory of systems and parts Reduced carbon footprint: Manufacturing on site on site (3 D (3 D printing) 18

19 3 D printing for Lighting Some lighting companies are already exploring the benefits of AM for lighting Philips Lighting Telecaster: Philips New Venture for 3D Printed Architectural Lighting Repro light Consortium aims Repro light to Revolutionize the Lighting Industry by

20 Vision for SSL and 3 3 D Printing Change Architectural Lighting Practice se%c3%b1ado_para_el_mar.jpg Fixture design 20 Custom fixtures Credit: Lighting Research Center On demand, On site manufacturing

21 Lighting Research Center Studies Goal: To investigate if functional thermo mechanical, electrical and optical components can be electrical, fabricated using current 3 D printing technologies and materials to manufacture complete SSL li h i fixtures lighting fi [LRC 2017] Credit: Lighting Research Center 21 Credit: Lighting Research Center

22 3 D Printing Processes Investigated 22

23 Material extrusion Material is selectively dispensed through a nozzle Fused deposition modeling (FDM [term and abbreviation trademarked b Stratasys, by S Inc.]). ]) Thermoplastic material through heated extruder Fused filament fabrication (FFF) (Equivalent to FDM) Continuous fiber fabrication (CFF) 23 Source: cturing/materialextrusion//

24 Vat photopolymerization Produce parts from photopolymer material in a liquid state cured using either: Stereolithography (SLA) Selectively cure material using lasers Digital light processing (DLP) Cure photopolymer material using digital light projectors Source: Wallace et al., Validating continuous digital light processing (cdlp) additive manufacturing accuracy and tissue engineering utility of a dye initiator package, Biofabrication, 2014, 6,

25 Mechanical Components

26 Mechanical Component Heat sink To keep LED junction temperature low Drawbacks: D b k Heavy, H EExpensive, i O Overdesigned d i d thermal management 26

27 Estimated Tj for heat sink κ LED heat sink LED package Parameter Value 1,2, 5, 10W 10 C/W 12.7 mm 10.0 cm 10.0 cm 2.5 mm C Thermal conductivity of aluminum~200 W m-1 K-1 27 Credit: Lighting Research Center

28 Study Objectives To investigate potential use of thermoplastic filament in 3 D printing heat sinks for LED applications To characterize and quantify 3 D printed components with commercial filament Build orientation and infill percentage To quantify and compare 3 D printed heat sinks with aluminum heat sink of similar geometry To T investigate i ti t heat h t sink i k geometry t effects ff t on LED performance p profile p Temperature Temperature gradient 28

29 Preparation of 3 3 D printed test samples 20.0±0.1 mm Cross section of deposited material Voids (air) 10.0±0.10 mm L Layer 3 Layer 2 Layer 1 In plane Layer 3 Layer 2 Layer 1 Credit: Lighting Research Center 29 Cross plane

30 Methodology and setup for thermal characterization Steady state heat equation (Fourier s law); Assuming constant heat flux; Credit: Lighting Research Center 30

31 Thermal characterization Credit: Lighting Research Center Reference: Perera, I.U., N. Narendran, V. Terentyeva Thermal characterization of three dimensional printed components for light emitting diode lighting system applications Opt. Eng 57(4), manuscript in press. 31

32 Thermal characterization Temperature gradient per unit length In pane < Cross plane Additives decreased temperature gradient per unit length Improvement in material required for comparable performance to Aluminum heat sinks Credit: Lighting Research Center Reference: Perera, I.U., N. Narendran, V. Terentyeva Thermal characterization of three dimensional printed components for light emitting diode lighting system applications Opt. Eng 57(4), manuscript in press. 32

33 Thermal characterization Build orientation along the heat transfer direction Increased infill percentage decreased temperature difference Decreasing thermal resistance in the 3 D printed sample 33

34 Thermal performance of heat sinks To understand how composite polylactic acid or polylactide (PLA) filaments with thermally conductive additives affect thermal conductivity of printed heat sinks. 34 Credit: Lighting Research Center

35 Estimated Tj with different heat sinks Increased thermal conductivity reduces LED junction temperature Case temperature is about C C lower than Tj 35 Reference: Narendran, N., I.U. Perera, X. Mou, and D.R. Thotagamuwa Opportunities and challenges for 3 D printing of solid state lighting systems. Proceedings of SPIE 10378, 16th International Conference on Solid State Lighting and LED based Illumination Systems, SPIE Optics + Photonics, San Diego, Calif., August 2017, Paper

36 Measured material thermal conductivity κ [W m 1 K 1 ] Material 36 Generic PLA Copper infused PLA variant A Copper infused PLA variant B Carbon fiber PLA Bronze infused PLA Conductive PLA Graphene infused PLA Copper based liquid Silver based ink In plane In plane Cross Cross plane plane In plane Cross plane l NA NA

37 Heat sink temperature profile Low κ of 3 D printed heat sinks had high resistance From fin base to fin tip cross sectional area temperature gradient < 20 C 100% 28 mm 34 mm 29 mm 9 mm 9 mm 75% Aluminum heat sink Graphene composite PLA 50% 60% C di Li Credit: Lighting hi R Research hc Center Copper composite PLA 37 Credit: Lighting Research Center Generic PLA

38 Heat sink geometry effects Increase in surface area at the high temperature region reduced LED case temperature Tc=64 C Tc=66 C Tc=70 C 38 Credit: Lighting Research Center Credit: Lighting Research Center

39 Thermal conductivity of printed parts Thermal conductivity of 3 D printed PLA components depends on build orientation and filler material properties Compared to cross plane, the in plane thermal conductivity is much better 30% to 131% higher Infill percentage increase increased the thermal conductivity of 3 D 3 D printed components Graphene infused PLA had the highest κ value Still 20 times smaller Need improved performance filaments to meet thermal conductivity needs of heat sinks for LED systems 39

40 Electrical Components

41 Electrical properties Study objective: To investigate if 3 D printed electrical traces have suitable electrical properties Three types of filament Graphene infused PLA CNT infused PLA Carbon black infused PLA Three build orientations Parallel to the current flow Normal to the current flow 45 angled g to the current flow 41 Reference: Narendran, N., I.U. Perera, X. Mou, and D.R. Thotagamuwa Opportunities and challenges for 3 D printing of solid state lighting systems. Proceedings of SPIE 10378, 16th International Conference on Solid State Lighting and LED based Illumination Systems, SPIE Optics + Photonics, San Diego, Calif., August 2017, Paper Credit: Lighting Research Center A 3 D printed trace V Current channel Voltage channel Credit: Lighting Research Center

42 Results and Summary Graphene infused PLA filament Ωm Copper traces ( Ωm) In plane I l b ild orientation build i t ti showed h d th the llowestt resistivity Inks with resistivityy values similar to copper pp are available Cannot be processed using unmodified FFF type 3 D printers. 3 D i t Requires paste extruder materials us/articles/ Working with the Conductive Silver Ink Solvent 42 Credit: Lighting Research Center

43 Optical Components

44 Optical properties of printed components Study objective: To investigate if SLA printing and commercially available materials are suitable for printing lenses Light transmission and scattering as a function of print resolution and print orientation Resolution: 50 μm and 250 μm print Print orientation: in plane and cross plane Secondary lens and holder Before polishing After polishing 50 μm μm 250 μ laser In plane laser Reference: R f N Narendran, d N N., II.U. U P Perera, X X. M Mou, and dd D.R. R Th Thotagamuwa. t Opportunities and challenges for 3 D printing of solid state lighting systems. Proceedings of SPIE 10378, 16th International Conference on Solid State Lighting and LED based Illumination Systems, SPIE Optics + Photonics, San Diego, Calif., August 2017, Paper Cross plane Credit: Lighting Research Center

45 Results and Summary Both print resolution and orientation affect light transmission and scattering distribution Polishing the 3 D printed optical elements improved performance Increased print resolution increased light transmission and decreased light scattering In plane print orientation had greater light transmission (~3 ( 3 times) compared to cross plane cross plane print orientation Cross plane print orientation had greater light scattering compared to in plane print orientation Requires post processing to refine and improve optical performance 45

46 Final remarks Opportunities Change architectural lighting practices Mass M customization t i ti Challenges 3 D printed mechanical, electrical, and optical components cannot be performed on the same platform New materials are needed to meet performance needs of SSL Faster printing speed needed to meet application demand 46

47 Acknowledgments LRC Faculty, Staff, and Students LRC internal funding ASSIST FAA l i d / / lid Thank you 47

48 Please remember to complete the h course evaluations. l i Thank you. 48