Additive Manufacturing for Production Components Friday 8 th June 2012 www.3trpd.co.uk
Stuart Offer SLS Sales Manager
About 3T RPD 3T RPD Ltd 35 permanent staff 2 University Placement students 3 YinI (Year in Industry) students UK Based in Newbury Doubled in size over last 4 years
About 3T RPD Principles Quality Service Delivery
About 3T RPD Started trading Installed 2 x P700 s in 1999 2003 New Building DMLS Facility opened UK s first M 280 machine installed 2006 2007 Nov 2011 Currently the UK s largest commercial SLS facility, 3 rd largest in Europe 2 nd largest DMLS facility in UK
Markets
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 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 - SLS Selective Laser Sintering SLS
Overview of Additive Manufacturing DMLS EOS Direct Metal Laser Sintering
Plastic Additive Manufacturing SLS Process
Plastic AM - Workflow Customer sends 3D CAD data to 3T
Plastic AM - Workflow 3T experts review the data, liaise with customers and pack parts
Plastic AM - Workflow Projects Team quote for the parts
Plastic AM - Workflow CAD Team plan the build chamber partially packed build
Plastic AM - Workflow CAD Team plan the build chamber fully packed build
Plastic AM - Workflow Convert CAD data into slice file
Transfer data to machine Plastic AM - Workflow
Manufacture of 3D Part Plastic AM - Workflow
Build completed Plastic AM - Workflow
Plastic AM - Workflow Build chamber removed and cooled
Plastic AM - Workflow Parts broken out from build chamber
Plastic AM - Workflow Parts cleaned and post processed
Our Machines Machine: Quantity: Build Chamber: Machine: Quantity: Build Chamber: Machine: Quantity: Build Chamber: EOS P730 3 off 700 x 380 x 580mm EOS P380 2 off 340 x 340 x 620mm 3D Systems 2500 HiQ Plus 1 off 320 x 280 x 427mm
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 PEEK * Standard at 3T
Plastic Additive Manufacturing The benefits you can achieve
Benefits from Plastic AM Almost unlimited range of part design
Benefits from Plastic AM Reduced part count/assembly time by integrating parts into one SLS part (A) Conventional Duct fabricated from Vac Formed plastic Part Count = 16 (plus glue) (B) Component modified and consolidated for fabrication via SLS Part Count = 1 Source - Econolyst
Benefits from Plastic AM Integrate several parts into one Source - Econolyst
Benefits from Plastic AM No Tooling
Benefits from Plastic AM Allows for product personalisation
Benefits from Plastic AM Customisation
Benefits from Plastic AM Customisation Customisation can be for 1 off Bespoke Hearing Aid
Benefits from Plastic AM Functional testing Intake Manifold tested in Climatic Chamber Cycling in 1½ hour cycles ramping up to 100ºC, remaining at and then cooling 20 day cycle for testing Intake Manifold fitted to engine and tested at 6,000-7,000 rpm
Benefits from Plastic AM Functional testing Intake Manifold filled with Low Melt Alloy Approximate weight of 135kgs!!! Alloy melted out in boiling water to prove melt out process for production unit
Plastic Additive Manufacturing Designing for Plastic AM
Designing for Plastic AM Complexity is not an issue
Designing for Plastic AM Minimum wall thickness Wall thicknesses > 1mm Accuracy Typical accuracy to be within: Dimensions <100mm +/- 0.3mm Dimensions >100mm +/- 0.3%
Designing for Plastic AM Holes Holes undersize Change CAD Ream Hole Threads Small as M3 Tap material Threaded inserts
Designing for Plastic AM
Designing for Plastic AM Southampton University Laser Sintered Aircraft Unmanned Aerial Vehicle (SULSA UAV) Project started: 5 th May SULSA Flight: 8 th June Article published in New Scientist
Designing for Plastic AM Southampton University Laser Sintered Aircraft Unmanned Aerial Vehicle (SULSA UAV) Ailerons built in SLS weight less than 2.0kg Internal structures for strength
Plastic Additive Manufacturing Finishing for Plastic AM
Finishing for Plastic AM Vibro Finishing Vibro Finishing Machine Parts up to 300 x 300 x 300mm
Finishing for Plastic AM Permanent Surface Colouring
Painting Finishing for Plastic AM
Finishing for Plastic AM Special Finishes EMC/RF Shielding Paint
Finishing for Plastic AM Special Finishes Plating
SLS Case Study
Navtech Case Study Navtech Radar W500 automatic surveillance system
Navtech Case Study BRIEF Design change to reduce cost Currently selling 50 off per annum but ramping up to 200 off
Navtech Case Study Outside changed to more economic production methods but internals remained complex and expensive Internal components to be replaced were Rotating Sensor system, support and guidance for the lens and the mounting and location of the emitter reel
Navtech Case Study Extensive test programme Placed the parts in extreme versions of a normal operating environment Simulated over 15 million cycles of the critical components during a two month period Pivot arm became highly polished within a few hours, improving efficiency
Navtech Case Study Durability of the SLS parts lead to Navtech adding new features into their design Flexibility of the material led to creation of built-in springs as a return mechanism for the lens
Navtech Case Study Overall benefits Reduced part count by integrating parts into one SLS part Reduced assembly time New features incorporated into design Flexibility of design now increased
Rapid Manufacturing Considerations
Rapid Manufacturing - Considerations Material & Surface Finish Mechanical Properties; need to design for each material (PA, GFN) Allow for difference in properties with orientation (Anisotropy) Alternative production options Are other forms of RP/ ALM better suited? Is a conventional production route better? Form and Complexity Can you take advantage of the complexity advantage of SLS? Can you combine features, use undercuts?
RM - Design for Packing Same rules as usual for RP SLS plus Packing the Build Chamber the biggest impact on part price! Pack the parts neatly onto the platform Remember the shrinkage allowance!
RM - Design for Packing Consider geometry packing factor e.g. cubes, bowls, spheres
RM - Design for Packing Avoid the Centreline of the build chamber
RM - Design for Packing Maximise the number of stacks
RM - Design for Packing Small changes can have a profound effect a 1mm change in stack spacing increased part price by 11%! Tailfin of plane collision with next shade in pack causing increase in stack height
RM - Design for Packing Max build height Small changes can have a profound effect a 5 mm change in aperture width increased the price significantly!
RM - Design for Packing Consider interleaving
RM - Design for Packing Try fitting other parts into spaces
RM - Design for Packing Try fitting other parts into spaces
Rapid Manufacturing - Design for RM Design for Break-out and Finishing Break-out and Blasting can be a big time stealer It s a tough job design to make it easier Avoid tricky cavities Make the parts easy to handle Design for automation if possible Can Vibratory Finishing be used?
Rapid Manufacturing - Design for RM Packaging and transportation Avoid sharp protrusions Design to make it tough if possible Iterations Communicate with the supplier for any changes, they can have a big effect Batches of parts can be produced to different designs
Rapid Manufacturing - Quality Control Quality RM can result in more accurate parts Repetition offers substantial opportunities You can apply statistical techniques to reduce variability 3T uses Six Sigma quality control methods Dimensional checks methodology affects cost and feedback options Traceability Material batches can be traced (at a cost) Part manufacture data can be captured (at a cost)
Costs Rapid Manufacturing - Benefits Cost Comparison (Sintering vs Tooling): SLS has no initial tooling costs SLS Cost effective SLS Costs Tooling Cost Tool Based Manufacturing Costs N1 = Break-even point
Costs Rapid Manufacturing - Benefits Cost Comparison (Sintering vs Tooling): If part complexity increases, the gap favours Sintering Tooling costs increase to incorporate extra functions SLS Cost effective Complex Tool Manufacturing Costs N1 N2
Questions?
Thank you! www.3trpd.co.uk www.3trpd.co.uk/architecture www.3trpd.co.uk/dmls