Additive Manufacturing 101 Advanced Applications Presented by: James Janeteas, Cimetrix Solutions Inc,
Who we are Founded in 1993 Full Line Stratasys Partner for Canada Strong Design / Manufacturing background Service Commercial and Academic verticals Business based exclusively on Stratasys Products
Who we are Dental Specialize: High Requirement Driven Applications Dimensional properties Mechanical properties Process repeatability Predictability Hot/Cold operating conditions Long product service life Automotive Aerospace Defense Medical
Terminology Known by many names 3D Printing Rapid Prototyping Rapid Tooling Rapid Technologies Rapid Manufacturing Advanced Manufacturing Additive Fabrication Additive Layer Manufacturing Direct Digital Manufacturing Direct Manufacturing
Terminology Additive Manufacturing Term covering all technologies Term covering all applications Replacement for RP and Additive Fabrication Definition: Collection of technologies, directly driven by CAD data, to produce 3-Dimensional physical models and parts through an additive process. Defined by ASTM : As the process of joining materials to make objects from 3D model data. Usually layer upon layer as opposed to subtractive methodologies.
Solution Classification ADDITIVE MANUFACTURING 3D PRINTERS Most Affordable Hobby Grade Solution 3D PRINTERS Professional Grade Solution 3D PRODUCTION SYSTEMS Professional Grade Highest Performing Systems $2k - $7k Simple and easy to use Optimized for form $7k - $50k Simple and easy to use Optimized for form, fit and function $50k - $500k & up Optimized for performance Broad application solution High performance materials
Solution Classification 3D PRINTERS 3D PRODUCTION SYSTEMS Performance Requirements Increase Conceptual Models Functional Prototypes Manufacturing Tools End-Use Parts
Technology Assessment Production Series Differentiators Envelope size Materials Accuracy Throughput Resolution Enablers Customization Repeatability Flexibility Complex Part Fabrication
Typical Build Process 1 Pre-Process 2 Manufacture 3 Remove Supports
FDM Process Fused Deposition Modeling : FDM Dual extrusion head technology Deposit liquefied build and support Precise Additive Fabrication Advanced materials Advanced mechanical properties Safe, Simple, Clean process 1 Pre-Process 2 Manufacture 3 Remove Supports
FDM Materials Engineering Grade Thermoplastics Material Options ABS-M30 ABS-M30i ABS-ESD7 Nylon 12 PC-ABS PC (Polycarbonate) PC-ISO Class 6 : Pharmaceutical Ultem 9085 * Polyphenylsulfone PPSF Support Material *Ultem 9085 is a trademark of SABIC Innovative Plastics IP BV.
Technology Assessment POLYJET- Polyjet Matrix Multiple extrusion head technology Deposit liquefied build and support Precise, High Resolution Advanced photo cure materials Composite Material Capability No Post Curing Safe, Simple, Clean process Material Options Vero Family Rigid Opaque FullCure 720 - Rigid Transparent Durus White - Polypropylene like Tango Family - Rubber Like RGD5160-DM - ABS Like RGD525 High Temp VeroDent Dental MED610 Rigid Biocompatible
FDM Materials ULTEM 9085 Aerospace & Defence Grade *Ultem 9085 is a trademark of SABIC Innovative Plastics IP BV. FDM Material Properties SABIC Engineered Certificate of Conformance available High tensile and compressive strength High operating temperature Passes FAR 25.853
FDM Materials Ultem 9085 Aerospace Grade Thermoplastic Passes FAR 25.853 Vertical burn test FST zero rating UL94 V0 Radiant Heat OSU 55/55 PASS Result Limit Off Gassing ASTM E595 Total Mass Loss ( TML) Collected Volatile Condensate Material (CVCM) Water Vapour Recovery Report (WVR) PASS 0.41 % 1.00 % < 0.01% 0.10 % 0.37 Report
Functional Prototypes- End Use Parts Czech Aircraft Company Saves up to 80% of Prototyping and Production Costs Using Fortus With Fortus, we can now develop and test innovative designs - and if necessary change them quickly without halting the production process. This means we no longer need to make functional compromises. Igor Mega, Evektor
Conceptual Models - Functional Prototypes Needed time-to-market reduction CNC Process added too much time to design and prototype process Outsourced parts were big and costly Process did not allow for unplanned projects Fortus for in-house prototypes Large capacity required Ultem 9085 for end use part production such as blow pipes Development Costs reduced up to 80% Accelerated product development Prototyping costs also substantially reduced Can develop more complex and innovative designs make changes without halting production
Primary Applications Additive Manufacturing Established / Traditional (Design) Direct Digital Manufacturing (Manufacturing)
Complexity The Sweet Spot Additive Mfg. High Complexity, Low Quantity Specialty End Use Parts Rapid Tooling Low Volume Production Sweet Spot Conventional Mfg. Quantity
Manufacturing Tools Direct benefits Financial gain Lowering costs Increasing profits Time advantages Decreasing time-to-market Decreasing cycle time Indirect benefits Design freedom Product redesign frequency Rapid response
Manufacturing Tools Assembly Aids Examples: Jigs Fixtures Check gauges Drill / rivet guides Go / No-Go gauges Alignment tools & guides Robotics- End of Arm Shot Peen, Grit Blast, Paint masking tools Surrogate Parts
Manufacturing Tools Assembly Aids Benefits: Custom interfaces for complex surfaces Minimize part handling damage Optimized for access without increased costs Light weight ergonomic Enables: Emblem Reduced dependency on external suppliers Overnight fulfillment of new tooling requirements Lights out fabrication Digitally mastered coordinated tooling Resulting in: Reduced cycle times up to 85% Improved Cubing quality Device Headlight Alignment Gage Checker
Manufacturing Tools Manufacturing Jigs and Fixtures with FDM FDM is taking on increasing importance as an alternative manufacturing method for components made in small numbers -Gunther Schmid, BMW
Manufacturing Tools Conventional fixture making Cost and time requirements were high Lack of design freedom reduced productivity FDM used to produce fixtures Have over 400 assembly fixtures Several built on Fortus system FDM enhances ergonomics Organic shapes maximize performance Sparse fill cut weight 72% Method Cost Time CNC Machining Aluminum Fortus system ABS-M30 $420 18.0 days $176 1.5 days Time and cost savings Typical cost reduced from $420 to $176 Typical lead time reduced from 18 to 1.5 days Savings $244 (58%) 16.5 days (92%)
Manufacturing Tools Fabrication Tools Sheet Metal Forming Composite Tooling Fibre Winding Coordinated Tool Families Thermoform Tools Pulp Mould Tooling Tooling Masters & Patterns Injection, Blow Moulds Sand Casting Investment Casting
Manufacturing Tools Piper Reduces the Cost and Leadtime of Hydroforming Tool to Build a personal Jet I can program an FDM part in 10 minutes while typical CNC program takes four hours to write -Jacob Allenbaugh, Manufacturing Engineer, Piper Aircraft
Manufacturing Tools Producing hundreds of aluminum structural components Inner frame components, gussets, brackets, skins etc. FDM as the manufacturing process PC Material 3000 to 6000 psi Ultem 9085 for up to 10,000 psi Hydroform Tooling Produce route, drill and trim fixtures with FDM Program FDM part 10 min vs. 4 hrs CNC No operator attendance Less material waste Aluminum Window Pan (left) FDM Tool Aluminum Window Pan on top of FDM Tool
End Use Parts Direct benefits: Lower cost Shorter lead time Indirect benefits: Design freedom Change freedom Mass customization Weight reductions Part consolidation Supports lean initiatives True JIT (just-in-time) manufacturing Reduced warehouse space/inventory cost
End Use Parts : Case Study FDM End use parts allowed for: Flexibility when designing complex parts Manufacture of less expensive part Weight saving solutions Production of parts that meet FAA regulatory requirements to be installed on aircraft Low volume production No tooling required
End Use Parts Best fit when: Relatively low volumes Short run production Bridge to tooling High part complexity Eliminate expensive tooling Reduce long lead times Part acceptable Aesthetics not critical Finishing processes feasible Physical properties acceptable
End Use Parts : Case Study Applications: End Use Parts To the best of my knowledge, the only additive fabrication technology that meets the stringent requirements for MRI equipment is FDM, Tramm. Virtumed LLC
End Use Parts Virtumed LLC Accelerate Design & Manufacturing Design complexity high Cost of tooling would be very high MR Instruments invested in Fortus system FDM used to build the plastic housings Builds custom appliances to secure patients head Elimination of tooling saves time & money 71% reduction in time vs. CNC 62% reduction in costs vs. CNC 74% reduction in time vs. RTV Moulding 84% reduction in costs vs. RTV Moulding
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