Sources: voxeljet, Materialise NV, Iris van Herpen Plastics for Additive Manufacturing Dr. Thomas Büsgen Bayer MaterialScience AG 20 th November 2013, 3D Printing & Additive Manufacturing Industrial Applications Summit 2013, London
Bayer MaterialScience Products and Solutions One of the world's leading polymer producers Polyurethanes Raw materials for rigid and flexible foams Polycarbonates Granules and sheets for a wide variety of applications Coatings Raw materials for coatings, adhesives and specialties Basic chemicals Chlorine production as the backbone for product manufacture High-performance materials for a changing world. Page 2
Bayer MaterialScience Innovations Research for tomorrow s world Global teams of inventors at Bayer MaterialScience develop new applications for materials and participate to design the future. Page 3
Plastics for Additive Manufacturing Material selection strongly depends on AM process Binder Jetting Liquid adhesive Low viscous polymer ink Inkjet print head Very fine powders Jetted Photopolymer Selective Laser-Sintering UV lamp Photo polymer Laser Thermoplast Photo-curable resins Thermoplasts Stereolithography Fused Deposition Modeling Filaments Source: custompart.net Page 4
Stereolithography Process: Highly focused UV laser traces out successive cross-sections in a vat 100 of liquid photo-polymer Curing and solidification by laser 80 Post-curing in UV oven Accura PEAK Accura 60 60 Tensile strength (MPa) 40 20 Currently available for AM VisiJet EX200 Accura Amethyst Accura CeraMAX Source: custompart.net 0 0 50 100 150 200 250 Max. working temperature ( C) Page 5
Jetted Photopolymer Process: Photo-Polymers (build + support material) Printed by inkjet head cured by UV lamp UV lamp Photo polymer Tensile strength (MPa) 100 80 60 40 20 Currently available for AM Vero VisiJet Source: custompart.net 0 Tango 0 50 100 150 200 250 Max. working temperature ( C) Page 6
Binder jetting Process: Currently available for AM Powder bed consisting of polymer, ceramic or metallic particles, respectively Jetting of polymer binder Subsequent infiltration possible Liquid adhesive Inkjet print head Tensile strength (MPa) 100 80 60 40 20 ZP 131 Infiltration Steel infiltr. w/ bronze 3D Systems (ZCorp) Source: custompart.net 0 PMMA voxeljet 0 50 100 150 200 250 Max. working temperature ( C) Page 7
Binder jetting Process: Currently available for AM Powder bed consisting of polymer, ceramic or metallic particles, respectively Jetting of polymer binder Subsequent infiltration possible Liquid adhesive Inkjet print head Tensile strength (MPa) 100 500 80 60 40 20 ZP 131 Infiltration Steel infiltr. w/ bronze 3D Systems (ZCorp) Source: custompart.net 0 PMMA voxeljet 0 50 100 150 200 250 Max. working temperature ( C) Page 8
Fused Deposition Modeling (FDM) Process: Currently available for AM Filaments of thermoplasts 3 mm diameter build + support materials heated and applied as thin fibers on a x-y-stage Tensile strength (MPa) 100 80 60 40 Injection molded PC PLA ABS PEI PEI PPSF Polyphenylsulfone Polyetherimid 20 Source: custompart.net 0 0 50 100 150 200 250 Max. working temperature ( C) Page 9
Selective Laser-Sintering (SLS) Process: Powder of thermoplastic polymer ~ 100 µm particles pre-heated just below T melt laser-sintered layer-by-layer Laser Thermoplast Tensile strength (MPa) 100 80 60 40 20 Currently available for AM PS PA12 PP PP Polyetheretherketone PA11 PA11 Biobased material PEEK PEEK Source: custompart.net 0 PS DuraForm Flex 0 50 100 150 200 250 Max. working temperature ( C) Page 10
Selective Laser-Sintering (SLS) Process: Powder of thermoplastic polymer ~ 100 µm particles pre-heated just below T melt laser-sintered layer-by-layer Laser Thermoplast Source: custompart.net Tensile strength (MPa) 1400 100 1200 1000 80 800 60 600 40 400 20 200 Currently available for AM PS PEEK PA11 PS Polyetheretherketone PA11 EOS PA12 Stainless PA11 steel PP PP DuraForm Flex PEEK EOS Cobalt PEEK Chrome Biobased material 0 0 250 500 100 750 150 1000 200 1250 250 Max. working temperature ( C) Page 11
Cost Comparison Materials for AM vs. conventional SLA Photopolymer resins PolyJet photopolymers SLS powders (PA12) FDM personal 3D printers ~ 175 to 225 $/kg ~ 100 to 300 $/kg ~ 85 to 100 $/kg ~ 15 to 50 $/kg FDM professional (ABS, PC) ~ 250 $/kg FDM (PEEK, PEI) > 500 $/kg ABS PC PA6 PA11 PEI PEEK ~ 2 $/kg ~ 3 $/kg ~ 3 $/kg 7 13 $/kg 15 20 $/kg 34 68 $/kg Sources:Wohler s Report 2013, plasticker.de Page 12
Summary Material Selection for AM All additive manufacturing processes require specific material classes Final material properties very dependent on used AM technology Usually anisotropic material properties due to layered building Additive Manufactured parts do not match properties of injection molded ones, yet Today main application in rapid prototyping, visual aids, art, Need for: larger choice in polymer material and properties (e.g. elastic) Scalable processes and competitive prizes Sources: 3D Systems, voxeljet Page 13
New Developments: 3D printing from polymer pellets Arburg presents Freeformer Combination of injection molding and FDM technology Uses any kind of thermoplastic pellets (no filament) Printing of several materials No support material by 5 axis building Sources: Arburg.com Page 14
New Developments: First Fully-functional Flexible Material in 3D Printing Basis: Thermoplastic Polyurethane (Desmopan, Bayer MaterialScience) Milled into fine powder of ~100 µm (Desmosint TPU 92A-1, Lehmann&Voss) Selective Laser-Sintering Unique properties for AM material: Durable elasticity High tear resistance High resistance to dynamic loading High abrasive resistance Snappy response Good temperature range (-20 to 80 C) Elongation at break >350 % Sources: Lehmann&Voss, Materialise NV, Iris van Herpen Page 15
3D-Printed Bayer cross Size: 4 cm in diameter, 1.5 mm in height Thank you Thomas Büsgen Senior project leader 3D digital printing New Applications EMEA BMS-CAS-INN-NAEMEA 51368 Leverkusen, Building Q 1 +49 214 30 48654 thomas.buesgen@bayer.com