layered manufacturing technologies u powder solidification l 3d printing (3dp) l selective laser...

SFFSFF Layered Manufacturing Technologies Layered Manufacturing Technologies

Powder Solidification 3D Printing (3DP)

Selective Laser Sintering (SLS)

Additive With Sacrificial Supports Stereolithography (SLA) {= Liquid solidification}

Thermoplastic deposition

Fused Deposition Modeling (FDM)

Solid Object Printing w/ Multi-Jet Modeling (MJM)

Solidscape’s ModelMaker {previously: Sanders}

“Subtractive” Laminated Object Manufacturing (LOM)

SFFSFF Layered Solidification ProcessesLayered Solidification Processes

Liquid-Based Approaches

Stereolithography(latest process needs almost no “supports”)

Powder-Bed Based Approaches

3D Printing (Z-Corporation)

Selective Laser Sintering

SFFSFF Stereolithography (SLA)Stereolithography (SLA)

First commercial layered manufacturing technology (1988)

Photo-curable liquid resin

www.3dsystems.com

SFFSFF Stereolithography (SLA)Stereolithography (SLA)

UV laser beam solidifies the top layerof a photosensitive liquid.

Build Stage

UV Laser Beam

Photopolymer

SFFSFF Stereolithography: ApparatusStereolithography: Apparatus

SFFSFF StereolithographyStereolithography

Pre-process:

Orient part.

Choose slice thickness.

Slice parts and plan supports.

SFFSFF StereolithographyStereolithography

Process:

Position build platform (stage)just below liquid resin surface.

Smooth surface with re-coater blade.

Scan the outline of the current slice, loosely hatch part interior with laser.

Lower the build platform for next layer.

SFFSFF StereolithographyStereolithography

Post-process: Raise part and drain out liquid.

(except liquid trapped by loose hatch)

Break off supports.

Rinse in isopropanol and water.

Dry with air hose.

Post-cure (strengthen) in UV oven.

SFFSFF StereolithographyStereolithography

Characteristics: Slow process

Supports must be removed by hand

Lab environment necessary (gasses!)

Needs trained operator

Laser lasts 2000hrs, costs $20’000!

Little material choice, ($700 per gallon)

Parts can be brittle, fragile

SFFSFF StereolithographyStereolithography

Characteristics (cont.):

High accuracy Layer thickness 0.001 - 0.006”

Minimum feature size 0.003 - 0.012”

Large build volume Up to 20 x 20 x 23”

SFFSFF Powder-based ApproachesPowder-based Approaches

Key Properties:

Needs no supports that must be removed!

Uniform bed of powder acts as support.

This powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part.

SFFSFF 3D Printing -- Principle3D Printing -- Principle

Selectively deposit binder droplets onto a bed of powder to form locally solid parts.

Powder Spreading Printing

Build

Feeder

Powder

Head

SFFSFF 3D Printing: Some Key Players3D Printing: Some Key Players

Z Corporation: http://www.zcorp.com/Plaster and starch powders for visualization models.

Soligen: http://www.zcorp.com/Metal and ceramic powdersfor operational prototypes.

ProMetal: http://www.prometal-rt.com/Metal sintering processfor operational prototypes and art work.

Therics Inc.: http://www.therics.com/Biopharmaceutical products,tissue engineering.

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

The Z402 3D Printer Speed: 1-2 vertical inches per hour

Build Volume: 8" x 10" x 8"

Thickness: 3 to 10 mils, selectable

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

Digging out

SFFSFF Optional Curing: 30 min. @ 200ºF Optional Curing: 30 min. @ 200ºF

Keep some powder in place

<-- Tray for transport

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

Cleaning up in the de-powdering station

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

The finished part

Zcorp,

6" diam.,

6 hrs.

SFFSFF 120 Cell -- Close-up120 Cell -- Close-up

SFFSFF Parallel Projection of the 4D 120-CellParallel Projection of the 4D 120-Cell

Zcorp,

6" diam.,

6 hrs.

SFFSFF Morin SurfaceMorin Surface

This is the half-way point of a sphere eversion (without causing creases or tears).

3D-Print6" diam.5 hrs.

SFFSFF 3D 3D ColorColor Printing: Z Corporation Printing: Z Corporation

The Z402C 3D Color Printer

Differences compared to mono-color printer: Color print head with: Cyan, Yellow, Magenta,

Black, and Neutral.

Smaller build area.

Specs: Speed: 0.33 - 0.66 vertical inches per hour

Build Volume: 6" x 6" x 6"

Layer Thickness: 3 to 10 mils, selectable

Color depth: 80 mils below surface

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

Use compressed air to blow out central hollow space.

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors.

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

“Lizard-Frame”: Final Infiltrated Part

SFFSFF Hypercube, Perspective ProjectionsHypercube, Perspective Projections

SFFSFF Two Ways to Make a HypercubeTwo Ways to Make a Hypercube

3D Color Print

Assembly of flat FDM parts ==>

SFFSFFWhat Can Go Wrong ? What Can Go Wrong ? -- -- Parts may brake before infiltrationParts may brake before infiltration

SFFSFF What Else Can Go Wrong ?What Else Can Go Wrong ?

Blocked glue lines

Crumbling parts

SFFSFF What Else Can Go Wrong ?What Else Can Go Wrong ? Some blocked glue lines

Uneven coloring Art ?

SFFSFF Post-Processing for 3D-PrintingPost-Processing for 3D-Printing

Surface is porous, dusty. Seal and strengthen the part:

Dip in wax: Nice smooth finish Needs separate waxing station

Infiltrate with “superglue”: Tedious, dirty manual labor

Spray-paint with a sealant: Polyurethane (yellowish, smelly) Krylon (invisible)

SFFSFF Post-Processing for 3D-PrintingPost-Processing for 3D-Printing

Spray-paint surface with Krylon

SFFSFF 3D Printing: Z Corporation3D Printing: Z Corporation

An Informal Evaluation

Fast !

Running expenses: moderate,(but overpriced powder)

Color print head and tubes need some care in maintenance.

Somewhat messy cleanup !

Lot’s of dust everywhere ...

SFFSFF

Key Points:

Powder gets solidified with a laser.

Powder is kept just below melting point, heat from laser will fuse powder grains.

Un-fused powder acts as support,can easily be removed later.

Many different materials can be used when mixed with a suitable binder:nylon, metal, ceramics …

Selective Laser Sintering (SLS)Selective Laser Sintering (SLS)

SFFSFF SLS: Conceptual ViewSLS: Conceptual View

SFFSFF SLS PlayersSLS Players

3D SYSTEMS Representing the fourth generation of SLS®

(selective laser sintering) technology, Vanguard™ and Vanguard™ HS (High Speed), are the first SLS® systems developed specifically for advanced manufacturing applications.

With the Vanguard system you can move directly from a CAD file to a durable, functional plastic or metal part or tool — in a fraction of the time required for traditional machining and tooling.

http://www.3dsystems.com/products/sls/vanguard/index.asp

SFFSFF SLS from 3D SYSTEMSSLS from 3D SYSTEMS

Use Vanguard or Vanguard HS system for:•  Plastic or metal parts, patterns & prototypes•  Complex metal tooling inserts•  Highly Durable Parts•  Parts with small features•  Short runs of plastic & metal parts

Benefits:•  High part accuracy •  Fast build speed•  Unattended operation•  Uses plastic or metal materials•  Respond to customer demands•  Worldwide service and support

SFFSFF SLS: Laserform PartsSLS: Laserform Parts

SFFSFF The Most Challenging SFF PartThe Most Challenging SFF Part

3rd-order 3D Hilbert Curve: much weight

much length

no supports

only two tube-connectionsbetween the two halves.

SFFSFF Fabricated by ProMetalFabricated by ProMetal

SFFSFF ProMetal ProcessProMetal Process

A ‘green’ part is first formed, composed of stainless steel powder and a selectively applied binder.

This part is built bottom-up, layer-by-layer under direct computer control.

This green part is then sintered, the binder is drained out and replaced by liquid bronze.

ProMetal is a division of ‘The Ex One Company’, Irwin, PA.

SFFSFF The Objet PolyJet ProcessThe Objet PolyJet Process

SFFSFF The Objet PolyJet ProcessThe Objet PolyJet Process

Pointer to the company:

http://www.2objet.com/

See the movie ...

http://www.youtube.com/watch?v=oMQWGBgNCtg

SFFSFF Which Process Should You Pick?Which Process Should You Pick?

Do you need a prototype (not just a model)?

SLS, FDM (for robustness, strength).

Do you need a mold for a small batch?

SLA (for smooth, hard surface).

Does part need multiple colors?

3D Color-Printing.

Does part have convoluted internal spaces?

3D-Print, SLS, SLA (easy support removal).

SFFSFF Informal Process Ratings MatrixInformal Process Ratings Matrix

Hollow Sphere

Hollow Sphere with Drain/Vent

2 Nested, Perforated

Spheres

3D Hilbert

Pipe

Preassembled Gear

Mechanism

LOM (F) F F D F

SLA (F) A B B C

FDM (F) F C C D

3D-P (F) A A C B

SLS (F) A A B B