Additive Manufacturing Technology November 2012 www.3trpd.co.uk Phil Kilburn DMLS Sales Manager
Agenda About 3T RPD Ltd Overview of Additive Manufacturing Manufacturing directly in metals Arcam - Electron Beam Melting EOS - Direct Metal Laser Sintering Applications Polymer Additive Manufacturing
About 3T RPD Started trading 1999 Installed 2 x P700 s 2003 DMLS Facility opened 2007 Currently the largest commercial SLS facility in UK, 3 rd largest in Europe 2 nd largest DMLS facility in UK Team 42 Permanent staff
Markets
Quality control 3T Quality standards AS 9100 Rev. C ISO 9001:2008 ISO 13485:2003
Overview of Additive Manufacturing
Overview of Additive Manufacturing Definition of Additive Manufacturing The process of creating 3D objects, layer by layer As opposed to subtractive manufacturing methods
Overview of Additive Manufacturing Additive Manufacturing process Additive Manufacturing Process Subtractive Manufacturing Process
Overview of Additive Manufacturing Additive Manufacturing process Parts are built up from a large number of very thin twodimensional cross sections (layers) By convention the cross sectional layers are the X-Y plane and the model is built up in the Z axis
Overview of Additive Manufacturing Simple example Z CAD model X Y
Overview of Additive Manufacturing Simple example Layers built up in Z axis (accuracy)
Overview of Additive Manufacturing
Overview of Additive Manufacturing Additive Manufacturing process Parts are built up from a large number of very thin twodimensional cross sections (layers) By convention the cross sectional layers are the X-Y plane and the model is built up in the Z axis All processes used in layer manufacturing use STL files (Standard Triangle Language) This is the file format used in open systems Surface is represented by triangles X,Y,Z for each point on triangle and a vector to outside Tolerance of the original surface in relation to triangles is critical
Overview of Additive Manufacturing 0.1 Tolerance 240 triangles 0.01 Tolerance 2,400 triangles 0.001Tolerance 24,000 triangles
Overview of Additive Manufacturing Totally enclosed volume
Overview of Additive Manufacturing Totally enclosed volume (381514 triangles) All triangle are connected and face outwards
Overview of Additive Manufacturing Machines Polymer based + Metal
Overview of Additive Manufacturing Machines Metal Based
Overview of Additive Manufacturing - Metal Additive Manufacturing of Metal products Arcam Electron Beam Welding Renishaw Selective Laser Melting Concept Laser LaserCUSING materials EOS Direct Metal Laser Sintering A range of materials are currently available but not on all machines Stainless Steel Cobalt Chrome Titanium 6Al 4V Inconel Tool Steel Aluminium Gold Silver
Overview of Additive Manufacturing - Arcam Arcam Electron Beam Welding A high energy beam is generated in the Electron Beam Gun The beam melts each layer of metal powder to the desired geometry Extremely fast beam translation with no moving parts Vacuum process eliminates impurities and yields excellent material properties High build temperature gives form stability and low residual stress Low operating costs
Overview of Additive Manufacturing - Arcam ARCAM EBM TECHNICAL DATA (Hot process) Build envelope 200 x 200 x 350 mm (W x D x H) or 300 x 200 mm (Ø x H) Build speed Up to 60 cm 3 /h Layer thickness 50 200µm Vacuum pressure <5 x 10 4 mbar Electron Beam power Up to 4000 W Electron Beam accuracy ±0.05 mm Electron Beam scan speed ~1000 m/s
Overview of Additive Manufacturing - Arcam Materials available Ti6Al4V Ti6Al4V ELI Titanium Grade 2 CoCrMo ASTM F75
Overview of Additive Manufacturing - Arcam
Overview of Additive Manufacturing - Arcam
Overview of Additive Manufacturing - Arcam
Overview of Additive Manufacturing DMLS EOS M280 Key characteristics Build volume: up to 250x250x300mm Up to 400W Yb fibre laser Spot size: 100µm Layer thickness: 20µm to 80µm Build speed Up to 32.4 cm 3 /h Surface finish As built: Ra~4-10µm After polishing: Ra~0.04-0.5µm Minimum wall thickness / feature size 0.04mm Accuracy +/- 0.2mm
Overview of Additive Manufacturing DMLS Definition: Direct Metal Laser Sintering Melting and not sintering
Overview of Additive Manufacturing DMLS Materials Available Maraging steel: 1.2709/M300 Stainless steel: 15-5PH Stainless steel: 316L Cobalt Chrome: UNS R31538 Nickel alloy: In718 Titanium alloy: Ti6Al4V (Grade 5) Aluminium alloy: AlSi10Mg
Microstructure of Metal materials Fine grain structure and dense material X-section Optical micrograph SEM micrograph Optical micrograph SEM micrograph
Microstructure of Metal materials Fine grain structure in Ti6Al4V X-section Optical micrograph Fully dense α/α'-β structure
Microstructure of Metal materials Fine grain structure and dense material Microstructure of heat treated IN718
Overview of Additive Manufacturing - DMLS
Overview of Additive Manufacturing - DMLS General comments about DMLS materials Full melting process = ~100% density Properties of as-built DMLS parts: close to or better than cast Final properties dependent on heat treatment Can be processed like any other conventionally produced alloys Can be used for prototyping applications as well as manufacturing applications
Basic principles of DMLS
Basic principles of DMLS Powder is not self supporting Parts have to be attached to the platform Post-finishing needed
Demonstration part: build angle effect 15-5PH
Demonstration part: build angle effect In718
Support structure Process Orientate part Add finishing stock (+0.1-0.5mm) Automatic creation of support structure in Magics Support structure OK for prototyping work but not for manufacturing
Bike pedal Support structure
Bike pedal Support structure
Bike pedal Support structure
Bike pedal Support structure
Bike pedal Support structure
Aerospace application Stator Ring Material: Cobalt chrome Dimensions: dia160mm x H60mm Layer thickness: 40micron Build time: 40h Finishing (including polishing): 50h Polishing: First Surface (Micro Machining Process) Cost: ~ 4500
Aerospace application Fuel Injector Material: Inconel 718 Designed for DMLS, 8 parts in 1 Dimensions: dia60mm x H160mm Layer thickness: 40micron Build time: (2off) 50hrs Finishing: 3h Cost: ~ 3500 (each)
Aerospace application Swirler Material: Cobalt Chrome Dimensions: dia27mm x H30mm Layer thickness: 20micron Build time: 90h (45 parts) Finishing (including polishing): 30h Cost: ~ 300 (unit cost for 45 parts)
Fully-Automatic Design Within Enhance Current Optimised (by Within) (Build time) + (machining time) 316L 30h + 3h 14h + 1h Weight 100% 30%
Savings Project Seat Belt Weight Reduction Commercial aircraft can have anything up to 850 seat belt buckles Traditionally constructed, airline seat belt buckles weigh between 155g (Steel) 120g (Aluminium).
Savings Project Seat Belt Weight Reduction Manufactured in Titanium using additive manufacturing, weight is reduced to 68g without compromising strength
Overview of Additive Manufacturing Machines Polymer Based Several processes are readily available in the UK Stereolithography SLA Fused Deposition Modelling FDM 3D Printing Z Corp Selective Laser Sintering SLS A range of materials are currently available but not on all machines Epoxy based materials Nylon ABS Wax Polystyrene
Overview of Additive Manufacturing Machines Polymer based Several processes are readily available in the UK Stereolithography SLA Fused Deposition Modelling FDM 3D Printing Z Corp
Overview of Additive Manufacturing Machines Polymer based Several processes are readily available in the UK Stereolithography SLA Fused Deposition Modelling FDM 3D Printing Z Corp
Overview of Additive Manufacturing Machines Polymer based Several processes are readily available in the UK Stereolithography SLA Fused Deposition Modelling FDM 3D Printing Z Corp Selective Laser Sintering SLS
Plastic AM Materials Nylon 12 (Polyamide PA2200) * Glass Filled Nylon 12 (Polyamide PA3200) * Alumide (Aluminium Fleck/Nylon 12) Polystyrene (PrimeCast 101) Carbon Filled Flexible Flame Retardant Nylon 11 PEK * Standard at 3T
Designing for Plastic AM Minimum wall thickness Wall thicknesses > 1mm Accuracy Typical accuracy to be within: Dimensions <100mm +/- 0.3mm Dimensions >100mm +/- 0.3%
Overview of Additive Manufacturing Machines Polymer Based Build chamber fully packed build material is self supporting
Polymer Based applications Models created from CT and MRI data
Polymer Based applications Integration of several parts into a single component Source - Econolyst
Polymer Based applications Living hinges and assemblies built in one
Polymer Based applications Secondary finishing Brass inserts for small diameter threads Larger pars welded together
Finishing for Plastic AM Special Finishes Plating
Stress MPa Finishing for Plastic AM Effects of adding 100 micron nickel layer to SLS Pa bars 80 60 40 20 1 Pa Control 2 Pa Control 3 100micron Ni 3 100micron Ni 0 0 5 10 15 20 Strain %
Finishing for Plastic AM Permanent Surface Colouring
Painting Finishing for Plastic AM
Finishing for Plastic AM Special Finishes Vacuum Metallised
PEK Plastic AM P 800 EOSINT 4 machines only Process controls still being investigated Variation in Mechanical properties Colour Shrinkage
A. ANALYSIS OF SINTERED PEK parts (x, y and z) Conclusions Ultimate Tensile strength in Z direction is 50% of that in X and Y Colour variation is a surface property Darker colours are produced closer to the centre and bottom of the build chamber There is no observed link between colour and tensile strength There is more variation in shrinkage in Z direction than in X and Y In Z direction pale samples show less shrinkage
Open Coil Surface Support Development. 30% open to Helium in XYZ Yield Stress at ~600MPa 0.5mm thick sheet. Hole Dia. ~ 0.12mm
3D printed Ti End Spacers
THANK YOU Phil Kilburn Email: phil@3trpd.co.uk Tel: +44 7919 924838 / +44 635 580284