Additive Manufacturing Seminar This is NOT a

Additive Manufacturing Seminar • This is NOT a sales seminar!!! • My purpose here is to share information and educate 1

Introduction • What is the term Additive Manufacturing mean? • Additive Vs. Subtractive Manufacturing • In subtractive we start with stock and remove material to get the net shape (traditional machining) • In additive we start with nothing and add material to get the net shape • Our RP goal is to get the best quality parts, in the shortest possible time, at the lowest possible cost. 2

Rapid Prototyping (RP) Introduction of RP – Additive Process Generate a prototype part by Layering Manufacturing Technology - composite material layer by layer Build in one step - directly from model to manufacturing 3

From Concept to full Production 4

Rapid Prototyping - definition (RP) is defined as a group of techniques used to quickly fabricate a model of a part or assembly using three-dimensional computer aided design (CAD) data. Rapid Prototyping , also referred to as solid free-form manufacturing, computer automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for visualization. 5

Prototypes 6

Evolution of Rapid Prototyping 3 D objects were used to demo model since early history Mud, wood, clay and paper was used to create mockups With the industrial revolution machine tools were used to create scaled models The digital era brought a leap step to advanced layer additive prototyping and manufacturing Prototypes are made from solidified liquid, powder, sheets and jetting materials Advanced materials are leading into the future of rapid manufacturing techniques and technology 7

Evolution of Rapid prototyping • Industry started in the mid 80’s • Around 30, 000 products sold world wide. • Great achievements in machine performance and model quality. • Fairly expensive technologies introduced up to date. • Every technology has it’s pros and cons. 8

The fathers of Rapid Prototyping In the early 1980’s Charles Hall developed the liquid polymerization based Stereolithograpy apparatus (SLA) Granted the original patent Considered to be “ the founder” of RP In the late 1987, Carl Deckard developed the powder based Selective Layer Sintering process (SLS) 9

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Technology and operation concept Liquid resin solidification – Stereolithography Powder solidification – Sintering Polymer jetting Fused deposition Laminated objects 14

Stereolithography Stereo – three dimensions Lithography – printing Started with acrylic resins in the early 1980’s Epoxy resins are more common now Very good accuracy $$$, Brittle (originally) UV Laser cure Relatively slow speed Newer resins with improved properties 15

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Supports structure 21

Stereolithography apparatus - SLA 22

UV Laser Depth of penetration Bullet shape cure into resin, energy exposure determine the depth and width of cure pattern Laser 23

UV laser cure into the resin Bullet shape laser beam cure penetration into resin Dp Ec 24

Laser cure on Epoxy resin 25

Building on angle to min. supports 26

SLA 5000 machine 27

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resins can get color by exposure 29

Medical model visualization aid 30

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Assembly part evaluation - SLA 35

SLA parts can be metal plated 36

Selective laser sintering -SLS Developed in late 1980’s Powder base $$$ good accuracy No need for supports – powder is self supporting Shrink and curl challenge Can do short run Rapid Manufacturing without tooling Range of materials nylon to sintered metallic powders 37

Selective Laser Sintering - SLS 38

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SLS Nylon parts 41

Complex assembly – SLS model 42

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SLS Materials (partial list) 45

Fused Deposition Modeling- FDM Developed by S. Scott Crump in the late 1980 s Commercialized in early 1990 s Principle of laying down molten material in layers Nozzle is heated to melt thermoplastics material The print head moves on X-Y Axis to draw the layer The platform drops down on Z for each layer Separate dissolvable support material Several material and color options 46

FDM 47

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Powder Liquid Binding inkjet-like printing head moves across a bed of powder selectively depositing a liquid binding material A fresh layer of powder is added on top of the model can print parts in full color by the binding liquid unbound powder is removed limited application in high accuracy Post cure by glue infilteration parts are fragile and brittle even after post processing The OEM of this Technology is Z-Corporation. 51

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Multijet; Poly. Jet Modeling wax-like thermopolymer plastic models Printing head with multiple spray nozzles (jets) These jetting heads spray tiny droplets of melted material When cooled it hardens on impact to form the solid object Some printers use UV cure process Accuracy depends on printer head resolution DPI Good for investment casting patterns 56

MJM – Thermojet printer 57

MJM 58

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MJM; PJM Printers 60

MJM Click 61

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Object’s MJM printer Click 64

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Rapid prototyping categories Hi End: Above $100 K Mid Range: $40 K – $80 K Low End: Below $20 K

Competitive analysis 67

RP Users 68

Mechanical Properties for RP Strength Elongation / at brake / Elastomer Modulus Toughness Heat deflection temperature Izod notched brake Hardness Clarity 69

Mechanical Properties 70

Mechanical Properties 71

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RP Sequence • CAD solid (surface) model • “water tight” model • Tolerance • ‘. STL’ file • Tessellation and file size • Slicing the file • • Final build data Building (3 D printing) the part Supports removal Post processing 73

CAD Solid Model • Solid model or closed surface model required 74

CAD to STL To produce a model from CAD data, export 3 D CAD model as a STL file. The parameters used to generate this file will directly influence the quality of the model. STL is the standard file type used by all Rapid Prototyping systems. A STL is a triangulated approximation representation of a 3 D CAD surfaced model. You cannot build the model any better or smoother than the STL. So if the STL is coarse and faceted, that's what you will see in the model. 75

. STL File • Software generates a tessellated object description • File consists of the X, Y, Z coordinates of the three vertices of each surface triangle, with an index to describe the orientation of the surface normal 76

. stl – right hand rule - Normals 77

stl with normal vectors 78

Click for the movie 79

. stl 80

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From Art to STL Physical parts can be scanned and output to STL format triangle count of 20, 024, file size of 1, 001, 284 bytes 82

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Watertight STL? ? 84

“Bad” STL 85

“bad” vs. “good” STL 86

Slicing STL file STL Raw Slice Layer data 3 D part 87

Slicing the model –contour line 88

Sliced contour 89

Slicing STL data (. sli) 90

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Rapid Prototyping Applications Design evaluation Physically holding a part vs. viewing it on screen Function verification and tests Form; Fit; Function -- (FFF) Assemblies; wind tunnel; medical; marketing evaluation Master patterns Casting; investment casting; soft tooling Advance to production process Jigs; prototype to metal 94

RP in the Development Cycle Product design Increase part complexity and diversity with little effect on lead time and cost Minimise time-consuming discussion and evaluations of manufacturing possibilities Tool design and manufacturing Minimise design, manufacturing and verification of tooling Reduce parts count and eliminate tool wear 95

RP in Product Development Cycle Product design Increase part complexity and diversity with little effect on lead time and cost Minimise time-consuming discussion and evaluations of manufacturing possibilities Tool design and manufacturing Minimise design, manufacturing and verification of tooling Reduce parts count and eliminate tool wear 96

RP in Product Development Cycle Assembly and test Reduce labour content of manufacturing (e. g. machining, casting, inspection and assembly, etc. ) Reduce material costs (e. g. handling, waste, transportation, spare and inventory, etc. ) Function testing Avoid design misinterpretations mistakes , i. e. what you design is what get) 97

From Prototyping to Tooling Rapid tooling Making the tool from the prototype master Save time and money Soft tooling From 3 to 25 parts per tool Tools made out of Silicon Rubber (soft) plastic Polyurethane parts Range of mechanical properties and colors Wax parts for further Investment Casting 98

Silicone RTV tool 99

Saving time = Saving money 100

RTV – Room Temperature Vulcanization Casting 101

From Prototyping to Tooling Bridge tooling intermediary between Soft Tooling and Hard Tooling From hundreds to few thousands of parts back up materials like Epoxy Resin around the master Metal powder interfiled tools Keltool Production tooling (NOT BY RP) Steel or aluminum machined tools For injection molding machines Millions of parts from each tool 102

Silicone tool casting 103

Composite Tooling (Epoxy Tooling) molds are reasonably fast in comparison to machined molds relatively inexpensive way to create prototype and production tooling. much higher compression strength and heat resistance Good when production material is required Master pattern is by RP 104

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Bridge tooling (epoxy) and (wax)Part 106

Rapid Tooling 107

3 D Keltool Moderate to high volume metal tool RP pattern from which a rubber mold is created The rubber mold is used to cast a steel powder and polymer binder mixture – “green part” Copper infiltrated resulting in a tool with about 70% steel and 30% copper content Advantageous for small, complex molds that would require much time to make with CNC or EDM techniques. 108

3 D Keltool 109

3 D Keltool process 110

Production (traditional) tooling CORE CAVITY 111

Tool Cycle time – Tool Temperature 112

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Thank you 114