Transcript Advances in 3D Printing State of the Art and Future Perspectives By D.
Slide 1
Advances in 3D Printing
State of the Art and Future Perspectives
By
D. Dimitrov, K. Schreve, N. de Beer
14 – 15 September 2004, Paris, France
Slide 2
Overview
Introduction
Definition and Classification
Technical and Economic Characteristics
Applications
Main Research Issues
Conclusions
Slide 3
Introduction
Slide 4
Introduction
Growth of 3D Printer sales
Significant sales increase of 3D Printers
compared to RP machines
Slide 5
Definition
and
Classification
Slide 6
3D Printing – Background and Definition
Layer Manufacturing Technologies
Source: Levy et. al.
One of the first developments
Continuous improvement and further
development
Slide 7
Inkjet Printing Technology
Continuous Inkjet Printing
Drop-on-Demand (DoD) Inkjet
Printing
Target properties of printable fluids
Maximise the solid loading of
suspensions
Keep fluid properties within a printable
window
Stabilise suspension against settling
Keep viscosity < 40 mPas
Slide 8
3D Printing - Definition
The ability for subsequent
overprinting leads to the building of
the third dimension, whereby each
layer must solidify.
This allows a multi-layer and multimaterial construction.
Slide 9
Classification of 3D Printing Techniques
Summary of Inkjet techniques and corresponding
technologies
Aimed Deposition
Process
Drop-on-drop deposition
Drop-on-powder (bed)
deposition
Continuous deposition
Technology
3D Plotting
Multi-Jet Modelling
3D Printing
Fused Deposition
Modelling (FDM)
Slide 10
Classification of 3D Printing Techniques
3D Printing
(Ink-Jet Printing Technology)
Continuous Printing
Drop-on-Demand Printing
Drop-on-Drop
Thermal Phase Change
Thermal Phase
Change
Photopolymer Phase
Change
Limited
Materials
Limited
Materials
Specific
Applications
Specific
Applications
Stratasys (Prodigy Plus)
Dimension
3D Systems (ThermoJet)
Objet
Solidscape
Sanders Design International
Drop-on-Powder
(Drop-on-Bed)
Physical Phase Change
Large Variety or
Combination of
Binder/Powder
Large Variety of
Applications
Z Corporation
ProMetal
Soligen
Therics
Slide 11
Technical and Economic
Characteristics
Slide 12
Technical and Economic Characteristics
Slide 13
Observations from Comparison
The hybrid FDM technology is the only
3DP process using continuous material
deposition.
Large variety of machined sizes and build
envelopes – from 1 130 cm3 (3D Systems)
to 843 750 cm3 (ProMetal)
Accuracy capabilities in “±” values.
Achievable accuracy strongly related to
build axes and to resolution.
Surface quality strongly related to layer
thickness
Depending on material used, tensile
strength varies from 0.13 – 43 MPa.
Prices range from $26 000 - $1.2 Million
Slide 14
Applications
Slide 15
Applications – Design
- Conceptual Modelling
Model of manifold displaying finite element analysis information
Source: Z Corporation
Enhances communication,
Error detection,
Non-geometric product information
Slide 16
Applications – Design
- Proof of concept (customer presentation)
Transparent bottles produced for customer presentation
Large possibilities using variety of
combinations with secondary
processes
Slide 17
Applications – Design
- Market research
Prototype of Mop Dryer (courtesy of USABCO)
Efficient way to test the market for
new product entries
Slide 18
Applications – Manufacturing
- Fit and functional models
Simulated Rubber Part
– Gearshift Boot
Function: Testing for
sound damping
Material: zp15e
Infiltrant:
Por-A-Mold Prepolymer
Wall thickness - 2 mm
Size: 200 x 200 x 75
mm
5 Hours printing time
2 Hours post curing and
treatment
Slide 19
Applications – Manufacturing
- Pattern making for casting processes
Automotive Differential
Housing
Starch-based powder & wax
Part built in 4 sections
Size: 264mm236mm281mm
18.5 Hours printing time
12.9 Hours post curing and
treatment
Slide 20
Applications – Manufacturing
- Pattern making for casting processes
Aerospace Part – Gimble
Material: zp15e (wax
infiltrated)
Size: 350 x 440 mm
Wall thickness – 3 mm
11 sections, 8 builds
64 Hours printing time
40 Hours post treatment
and assembly
Achieved tolerances on
casting: ± 0.5 mm
Slide 21
Applications – Manufacturing
- Pattern making for casting processes
Challenge: Meeting accuracy or
surface finish requirements for large
parts and thin walls.
Development of pattern
equipment for sand
casting for large
components and
complicated core
systems.
Scaled down core system
Slide 22
Applications – Manufacturing
- Pattern making for casting processes
Marine Gear Casing –
Pattern & Core Boxes
Size: 640 x 580 x 24mm
28 sections, 10 builds
8 Cores printed
62 Hours printing time
50 Hours waxing,
assembly, sizing and cavity
Estimated time for
modelling in conventional
way: 180 hours (contrast
62 hrs)
Slide 23
Applications – Manufacturing
- Direct Rapid tooling
Source: Griffin Industries
Sand moulds obtained directly from CAD file
Metal tooling inserts also directly from CAD file
(ProMetal)
Slide 24
Applications – Manufacturing
- Indirect Rapid tooling
Foundry equipment for sand casting of a hydraulic
component
Source: Griffin Industries
Pattern created with zp102 (plaster) material
Cores and inserts created in ZCast500 (ceramic)
material
Slide 25
Applications – Medical Field
Surgical aids
Drug delivery systems
Bone implants & tissue engineering
Organ printing
Surgical planning and preparation
Source: Dr. F. Urrutia
Slide 26
Applications – Architecture
Architectural Model
Source: Maslowski et. al.
3DP models as visualization tools
Difficulties
Reproducing ornate details
Free standing structures
Uniform scaling of 3D CAD models
Slide 27
Main Research Issues
Slide 28
Basic Research Activities
Material improvement
Improvement of existing materials
Development of new materials and material
combinations
Development of biomaterials
Process improvement
Improvement of basic process capabilities
regarding accuracy and surface finish
Advanced control strategies
Local composition control
Adaptive slicing control
Slide 29
Applied Research Activities
Expansion of application range
Improvement of existing applications
Exploration of new challenges
Improved design aids with emphasis on FEA
Optimized process chains for indirect and
direct rapid tooling
Conformal cooling issues
Rapid manufacturing
Tissue engineering (scaffold configurations)
Architectural modelling
Slide 30
Applied Research Activities
Customer satisfaction
Development of capability profiles of working
RP equipment
Accuracy
Strength
Build Time
Surface Finish
Elongation
Cost
Slide 31
Applied Research Activities
Customer satisfaction
Researching the influencing factors and
modelling their internal relationships
Printing technique
Material used
Binder and binding mechanism
Nominal dimensions
Build orientation
Geometric features and topology
Post treatment procedures
Infiltration Agent
Slide 32
Conclusions
Slide 33
Strengths of 3DP for RPD
High speed (DoB concept)
Cost-effectiveness of 3DP parts
Possibility for processing of functionally graded
materials (FGM parts)
Established colouring technology for nongeometric product information
In general, no need for support structures. Still,
substantial inaccuracy may occur due to
squashing of support powder
Commercial 3DP systems have some of the
largest build volumes
Office friendly and non-toxic materials
Highly suitable for post treatment procedures
Slide 34
Weaknesses of 3DP for RPD
Porosity
Accuracy
Surface finish
Relatively (at least currently) less
materials available in contrast to e.g.
SLS. Therefore limited range of
mechanical properties
One or two secondary stages are
needed to make most functional parts
Slide 35
In General
Geometric independence and possibility to
produce FGM parts creates a new paradigm in
product design
Detailed information of material properties still
need to be made available to designers
Process capability profiles need to be developed
in a standard format reflecting most important
manufacturing characteristics
Suitable software tools need to be developed for
design and analysis
Suitable combinations of manufacturing methods
need to be researched and developed
Slide 36
In General
Utilisation value of 3D Printers as concept modellers
Source: Levy et. al.
Slide 37
Future Perspective
Where is the place for 3D Printing among other LM technologies?
T e c h n o lo g y
3D P
SLS, SL A, FDM
SLM , 3D P
P la s tic
20%
1 0 '0 0 0
M e tal
40%
Q u a n tity
1 '0 0 0
M e tal
0%
M e tal
80%
P la s tic
100%
10
1
P la s tic
100%
C M C oncept
M o d e lle r
R P R a p id P ro to typ in g
R T R a p id T o o lin g
R M R a p id
M a n u fa c tu rin g
A p p lic a tio n
Consolidation forecast for LM technologies up to 2010
Source: Levy et. al.
Slide 38
Thank You
Advances in 3D Printing
State of the Art and Future Perspectives
By
D. Dimitrov, K. Schreve, N. de Beer
14 – 15 September 2004, Paris, France
Slide 2
Overview
Introduction
Definition and Classification
Technical and Economic Characteristics
Applications
Main Research Issues
Conclusions
Slide 3
Introduction
Slide 4
Introduction
Growth of 3D Printer sales
Significant sales increase of 3D Printers
compared to RP machines
Slide 5
Definition
and
Classification
Slide 6
3D Printing – Background and Definition
Layer Manufacturing Technologies
Source: Levy et. al.
One of the first developments
Continuous improvement and further
development
Slide 7
Inkjet Printing Technology
Continuous Inkjet Printing
Drop-on-Demand (DoD) Inkjet
Printing
Target properties of printable fluids
Maximise the solid loading of
suspensions
Keep fluid properties within a printable
window
Stabilise suspension against settling
Keep viscosity < 40 mPas
Slide 8
3D Printing - Definition
The ability for subsequent
overprinting leads to the building of
the third dimension, whereby each
layer must solidify.
This allows a multi-layer and multimaterial construction.
Slide 9
Classification of 3D Printing Techniques
Summary of Inkjet techniques and corresponding
technologies
Aimed Deposition
Process
Drop-on-drop deposition
Drop-on-powder (bed)
deposition
Continuous deposition
Technology
3D Plotting
Multi-Jet Modelling
3D Printing
Fused Deposition
Modelling (FDM)
Slide 10
Classification of 3D Printing Techniques
3D Printing
(Ink-Jet Printing Technology)
Continuous Printing
Drop-on-Demand Printing
Drop-on-Drop
Thermal Phase Change
Thermal Phase
Change
Photopolymer Phase
Change
Limited
Materials
Limited
Materials
Specific
Applications
Specific
Applications
Stratasys (Prodigy Plus)
Dimension
3D Systems (ThermoJet)
Objet
Solidscape
Sanders Design International
Drop-on-Powder
(Drop-on-Bed)
Physical Phase Change
Large Variety or
Combination of
Binder/Powder
Large Variety of
Applications
Z Corporation
ProMetal
Soligen
Therics
Slide 11
Technical and Economic
Characteristics
Slide 12
Technical and Economic Characteristics
Slide 13
Observations from Comparison
The hybrid FDM technology is the only
3DP process using continuous material
deposition.
Large variety of machined sizes and build
envelopes – from 1 130 cm3 (3D Systems)
to 843 750 cm3 (ProMetal)
Accuracy capabilities in “±” values.
Achievable accuracy strongly related to
build axes and to resolution.
Surface quality strongly related to layer
thickness
Depending on material used, tensile
strength varies from 0.13 – 43 MPa.
Prices range from $26 000 - $1.2 Million
Slide 14
Applications
Slide 15
Applications – Design
- Conceptual Modelling
Model of manifold displaying finite element analysis information
Source: Z Corporation
Enhances communication,
Error detection,
Non-geometric product information
Slide 16
Applications – Design
- Proof of concept (customer presentation)
Transparent bottles produced for customer presentation
Large possibilities using variety of
combinations with secondary
processes
Slide 17
Applications – Design
- Market research
Prototype of Mop Dryer (courtesy of USABCO)
Efficient way to test the market for
new product entries
Slide 18
Applications – Manufacturing
- Fit and functional models
Simulated Rubber Part
– Gearshift Boot
Function: Testing for
sound damping
Material: zp15e
Infiltrant:
Por-A-Mold Prepolymer
Wall thickness - 2 mm
Size: 200 x 200 x 75
mm
5 Hours printing time
2 Hours post curing and
treatment
Slide 19
Applications – Manufacturing
- Pattern making for casting processes
Automotive Differential
Housing
Starch-based powder & wax
Part built in 4 sections
Size: 264mm236mm281mm
18.5 Hours printing time
12.9 Hours post curing and
treatment
Slide 20
Applications – Manufacturing
- Pattern making for casting processes
Aerospace Part – Gimble
Material: zp15e (wax
infiltrated)
Size: 350 x 440 mm
Wall thickness – 3 mm
11 sections, 8 builds
64 Hours printing time
40 Hours post treatment
and assembly
Achieved tolerances on
casting: ± 0.5 mm
Slide 21
Applications – Manufacturing
- Pattern making for casting processes
Challenge: Meeting accuracy or
surface finish requirements for large
parts and thin walls.
Development of pattern
equipment for sand
casting for large
components and
complicated core
systems.
Scaled down core system
Slide 22
Applications – Manufacturing
- Pattern making for casting processes
Marine Gear Casing –
Pattern & Core Boxes
Size: 640 x 580 x 24mm
28 sections, 10 builds
8 Cores printed
62 Hours printing time
50 Hours waxing,
assembly, sizing and cavity
Estimated time for
modelling in conventional
way: 180 hours (contrast
62 hrs)
Slide 23
Applications – Manufacturing
- Direct Rapid tooling
Source: Griffin Industries
Sand moulds obtained directly from CAD file
Metal tooling inserts also directly from CAD file
(ProMetal)
Slide 24
Applications – Manufacturing
- Indirect Rapid tooling
Foundry equipment for sand casting of a hydraulic
component
Source: Griffin Industries
Pattern created with zp102 (plaster) material
Cores and inserts created in ZCast500 (ceramic)
material
Slide 25
Applications – Medical Field
Surgical aids
Drug delivery systems
Bone implants & tissue engineering
Organ printing
Surgical planning and preparation
Source: Dr. F. Urrutia
Slide 26
Applications – Architecture
Architectural Model
Source: Maslowski et. al.
3DP models as visualization tools
Difficulties
Reproducing ornate details
Free standing structures
Uniform scaling of 3D CAD models
Slide 27
Main Research Issues
Slide 28
Basic Research Activities
Material improvement
Improvement of existing materials
Development of new materials and material
combinations
Development of biomaterials
Process improvement
Improvement of basic process capabilities
regarding accuracy and surface finish
Advanced control strategies
Local composition control
Adaptive slicing control
Slide 29
Applied Research Activities
Expansion of application range
Improvement of existing applications
Exploration of new challenges
Improved design aids with emphasis on FEA
Optimized process chains for indirect and
direct rapid tooling
Conformal cooling issues
Rapid manufacturing
Tissue engineering (scaffold configurations)
Architectural modelling
Slide 30
Applied Research Activities
Customer satisfaction
Development of capability profiles of working
RP equipment
Accuracy
Strength
Build Time
Surface Finish
Elongation
Cost
Slide 31
Applied Research Activities
Customer satisfaction
Researching the influencing factors and
modelling their internal relationships
Printing technique
Material used
Binder and binding mechanism
Nominal dimensions
Build orientation
Geometric features and topology
Post treatment procedures
Infiltration Agent
Slide 32
Conclusions
Slide 33
Strengths of 3DP for RPD
High speed (DoB concept)
Cost-effectiveness of 3DP parts
Possibility for processing of functionally graded
materials (FGM parts)
Established colouring technology for nongeometric product information
In general, no need for support structures. Still,
substantial inaccuracy may occur due to
squashing of support powder
Commercial 3DP systems have some of the
largest build volumes
Office friendly and non-toxic materials
Highly suitable for post treatment procedures
Slide 34
Weaknesses of 3DP for RPD
Porosity
Accuracy
Surface finish
Relatively (at least currently) less
materials available in contrast to e.g.
SLS. Therefore limited range of
mechanical properties
One or two secondary stages are
needed to make most functional parts
Slide 35
In General
Geometric independence and possibility to
produce FGM parts creates a new paradigm in
product design
Detailed information of material properties still
need to be made available to designers
Process capability profiles need to be developed
in a standard format reflecting most important
manufacturing characteristics
Suitable software tools need to be developed for
design and analysis
Suitable combinations of manufacturing methods
need to be researched and developed
Slide 36
In General
Utilisation value of 3D Printers as concept modellers
Source: Levy et. al.
Slide 37
Future Perspective
Where is the place for 3D Printing among other LM technologies?
T e c h n o lo g y
3D P
SLS, SL A, FDM
SLM , 3D P
P la s tic
20%
1 0 '0 0 0
M e tal
40%
Q u a n tity
1 '0 0 0
M e tal
0%
M e tal
80%
P la s tic
100%
10
1
P la s tic
100%
C M C oncept
M o d e lle r
R P R a p id P ro to typ in g
R T R a p id T o o lin g
R M R a p id
M a n u fa c tu rin g
A p p lic a tio n
Consolidation forecast for LM technologies up to 2010
Source: Levy et. al.
Slide 38
Thank You