ADDITIVE MANUFACTURING: ENABLING ADVANCED MANUFACTURING NAE Convocation of the Engineering Professional Societies Washington, D.C. April 22, 2013 Tim Shinbara Technical Director AMT - The Association For Manufacturing Technology 1
Agenda Introduction Background Applications Paths-Forward NAMII Summary & Conclusion 2
Agenda Introduction Background Terminology Technology Primer Potential Benefits Applications Paths-Forward NAMII Summary & Conclusion 3
Background: Terminology Direct Digital Laser Additive Direct Part Mfg there are standards? 4 Additive Manufacturing is Much More Than Just Printing
ASTM F42 Sub-Committee on Terminology (F2792) 1. Binder Jetting an additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials 2. Directed Energy Deposition an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited 3. Material Extrusion an additive manufacturing process in which material is selectively dispensed through a nozzle or orifice 4. Material Jetting an additive manufacturing process in which droplets of build material are selectively deposited 5. Powder Bed Fusion an additive manufacturing process in which thermal energy selectively fuses regions of a powder bed 6. Sheet Lamination an additive manufacturing process in which sheets of material are bonded to form an object 7. Vat Polymerization 5 an additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization
Background: Technology Primer Additive Manufacturing (AM) materials Polymeric (Nylon, PAEK, ABS-like, etc.) Metallic (Ti-alloys, CoCr, SS 17-4, etc.) Composite, Ceramic, Paper-based AM enables smarter manufacturing 3D Art-to-Part via 2D layer-by-layer Near-net, to net-shape parts Increases the design space Directed Energy Powder Bed Fusion Material Extrusion 6 Increase Product Potential, Reduce Waste (Time, Materials Cost)
Background: Potential Benefits 1 st : Affordability Reduce tooling, waste Complexity = Simplicity 2 nd : Smart(er) Manufacturing Integrate processes Support RP & production Traditionally: 9 piece welded duct assembly AM: 2-piece bonded assembly 3 rd : Optimize Product Design Reduce weight, support modularity Multi-functional parts F-35 Representative Parts Oak Ridge National Lab 7 With Additive You Can Design for Functionality
Agenda Introduction Technology Background Applications Snap Shot Industrial Examples Industrial Diversity Paths-Forward NAMII Summary & Conclusion 8
Applications: Snap Shot Polymeric Components Laser Sintering (LS) Certified and flying (Comm. & Def.) FDA 510(k)-approved Hybrid Applications with Direct Write & Extrusions Embedded sensors / continuous fiber Metallic Components Laser and Electron Beam Melting Implants, replacements Aerospace components Creates Difficult to Machine Shapes Enables Hybrid Uses 9 Improves Performance (Courtesy EOS & WITHIN) Provides Similar Mechanical Properties (NGC)
Applications: Industrial Examples Composite Interface Fitting (JWST) Traditional Manufacturing Additive Manufacturing ~500 CNC machining hours 32 build hours ~16 26 week lead time ~4 day lead time Nominal 60% - 70% cost savings ~10 (25.4cm) As-Fabricated ~8 (20.3cm) Hot Air Mixer (UCAS-D) Traditional Manufacturing Additive Manufacturing Buy-to-Fly ratio 10 20:1 Buy-to-Fly ratio ~2:1 Min. 4-pieces w/ 2 welds 1 piece w/ no welding Nominal 35% - 45% cost savings 10 Post Machining and NDI Courtesy of Northrop Grumman Corp. and CalRam Inc.
Applications: Industrial Diversity Sensors Antennae Functional Apparel Large Structures Traditional Machined Casting Additive Selectively Builds Weight Reductions Multi-Functional Parts Toys & Model Hobbyists Complex Parts Functional Furniture 11 Additive Manufacturing: An Enabler for Next-Gen Production
Agenda Introduction Technology Background Applications Paths-Forward Research Potential Business Potential NAMII Summary & Conclusion 12
Paths-Forward: Research Potential Processing Thermal control In situ sensor feedback Melt pool dynamics Materials Increased functionality AM-specific formulation Nano-materials Model-Based Enterprise Physics-based simulation Enabling digital thread Improved design tools Nylon CNF with Poor Dispersion Courtesy of Paramount Industries 13 Courtesy of EOS http://www.sti-tech.com/fea.html
Paths-Forward: Business Potential Source http://wohlersassociates.com PRODUCTS: Direct Part Manufacturing (19.2%) Functional Models (18.4%) MARKETS: Consumer & Auto ~40% Aero & Medical / Dental Accelerating Wohler s Associates site to order Wohlers Report 14 Trending From Prototyping-Only To Now Include Production
Agenda Introduction Background Applications Paths-Forward NAMII Summary & Conclusion 15
A DMS&T team-led, Multi-agency collaboration between industry, government and universities Public-private partnership Shared facilities open to industry Especially attractive to small businesses Enabling technology transition and commercialization Bridge the gap in Manufacturing Innovation Workforce Development (K-to-Gray) Industrial Commons for Collaborative Innovation Focused on Advancing AM Industry
NAMII: 1 st Project Awards 17 Maturation of Fused Depositing Modeling (FDM) Component Manufacturing Rapid Prototype + Manufacturing LLC (RP+M) Qualification of Additive Manufacturing Processes and Procedures for Repurposing and Rejuvenation of Tooling Case Western Reserve University Sparse-Build Rapid Tooling by Fused Depositing Modeling (FDM) for Composite Manufacturing and Hydroforming Missouri University of Science and Technology Fused Depositing Modeling (FDM) for Complex Composites Tooling Northrop Grumman Aerospace Systems Maturation of High-Temperature Selective Laser Sintering (SLS) Technologies and Infrastructure Northrop Grumman Aerospace Systems Thermal Imaging for Process Monitoring and Control of Additive Manufacturing Penn State University Center for Innovative Materials Processing through Direct Digital Deposition (CIMP 3D) Rapid Qualification Methods for Powder Bed Direct Metal Additive Manufacturing Processes Case Western Reserve University
Agenda Introduction Background Applications Paths-Forward NAMII Summary & Conclusion 18
Summary & Conclusion The Technology Not just a maker movement Enables design for functionality Key piece in digital enterprise (MBE, AME) The Application Need: Increased processing understanding Supports prototyping, functional models, end-use AM discriminator: Knowing how to use AM 19 Additive Is A Compliment to Current Manufacturing
Contact Information Tim Shinbara Technical Director, AMT tshinbara@amtonline.org 703.827.5243 (desk) 20 Questions?