Transcript Applications: - NAE Website

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
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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
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
an additive manufacturing process in which liquid
photopolymer in a vat is selectively cured by
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selectively dispensed through a nozzle or
orifice
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
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Increase Product Potential, Reduce Waste (Time, Materials…Cost)
Background: Potential Benefits
• 1st: Affordability
– Reduce tooling, waste
– Complexity = Simplicity
• 2nd: Smart(er)
Manufacturing
Traditionally: 9 piece
welded duct assembly
AM: 2-piece bonded
assembly
– Integrate processes
– Support RP & production
• 3rd: Optimize Product
Design
– Reduce weight, support
modularity
– Multi-functional parts
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F-35 Representative Parts
Oak Ridge National Lab
With Additive You Can Design for Functionality
Agenda
• Introduction
• Technology Background
• Applications
– Snap Shot
– Industrial Examples
– Industrial Diversity
• Paths-Forward
• NAMII
• Summary & Conclusion
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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
Creates Difficult to Machine Shapes
• Metallic Components
– Laser and Electron Beam Melting
• Implants, replacements
• Aerospace components
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Enables Hybrid Uses
Improves Performance Provides Similar Mechanical
Properties (NGC)
(Courtesy EOS & WITHIN)
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
Hot Air Mixer (UCAS-D)
~8” (20.3cm)
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Post Machining and NDI
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
Courtesy of Northrop Grumman Corp. and
CalRam Inc.
Applications: Industrial Diversity
Sensors
Antennae
Functional Apparel
Traditional
Machined
Casting
Large Structures
Additive Selectively Builds
Weight Reductions
Multi-Functional
Parts
Toys & Model Hobbyists
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Complex Parts
Functional Furniture
Additive Manufacturing: An Enabler for Next-Gen Production
Agenda
• Introduction
• Technology Background
• Applications
• Paths-Forward
– Research Potential
– Business Potential
• NAMII
• Summary & Conclusion
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Paths-Forward: Research Potential
• Processing
– Thermal control
– In situ sensor feedback
– Melt pool dynamics
• Materials
– Increased functionality
– AM-specific formulation
– Nano-materials
Nylon CNF with Poor Dispersion
• Model-Based Enterprise
Courtesy of Paramount Industries
– Physics-based simulation
– Enabling digital thread
– Improved design tools
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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”
Trending From Prototyping-Only To Now Include Production
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Agenda
• Introduction
• Background
• Applications
• Paths-Forward
• NAMII
• Summary & Conclusion
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• 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: 1st Project Awards
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• 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
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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
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Additive Is A Compliment to Current Manufacturing
Contact Information
Tim Shinbara
Technical Director, AMT
[email protected]
703.827.5243 (desk)
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Questions?