p050-15 integration expansion of additive manufacturing
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P050-15 [663]
Integration and Expansion of Additive
Manufacturing and Its Associated Technologies
Perspective from AM Center of Excellence (COE)
1 May 2015
Adam Naramore and Talbot Thrasher
P050-15 [663] -2-
Additive Manufacturing (AM): Pre-Initiation
Engineering
Design the Part
Fabrication
Print the Part
Assembly or Delivery
End User
P050-15 [663] -3-
So You Bought a Machine. . . .
Fortus 400ProJect 7000 HD Objet500 Connex3 Makerbot Replicator
Concept Laser M2 EOS M290 Arcam Q10 Renishaw EVO
Picture credits:
http://www.concept-laser.de/, http://www.arcam.com/technology/products/arcam-q10/, http://www.eos.info/eos-m290,
http://www.arcam.com/, https://www.stratasys.com, http://www.3dsystems.com/3d-printers/professional/projet-7000-hd
P050-15 [663] -4-
Now Install It
Shop Floor Space Needs
• Actual machine
• Powder feeder
• Cleaning cabinet
• Post-processing machines
− Grinders, mills, wire EDM, worktables
− Peen cabinet
− Inspection area
Electricity, water for cooling, shop air
Materials and Handling
• Plastics
− Storage, staging, scrap
• Metal Powder
− Storage
− Handling: lifts, carts,
− Powder conditioning
Inert gas (argon, nitrogen)
Concept Laser M2 picture credit: http://www.concept-laser.de/
P050-15 [663] -5-
Additive Manufacturing: The Morning of Day 1
Supply Chain
Supply the Materials
Additional
Resources
All of the Other
Needs to Support
the Team
Fabrication
Print the Part
Engineering
Design the Part
Mission Assurance
Inspect the PartAssembly
End User
P050-15 [663] -6-
AssemblyEnd User
Additive Manufacturing: Day 2
Supply Chain
Additional
Resources
FabricationEngineering
Mission Assurance
Powder
Electronic
Model
Design Guide
Post-Processing
Design Allowables
Slicing Software
Defect Definition
Part Notes
KPP Features
Material Inventory
Used
Powder
Shop TravelerMachine
Settings
Cleaning
In-Process
Evaluation
Criteria
Process Qual
Plan
Process
Specification
Technician
Training and
Certification
AM
Machine
Samples
Machining
Post-Process
CT
Comparison
Software
Light
Sample
Testing
Powder Inspection
Equipment
Powder Suppliers
Fabricators
Inspection Req’s
Refurbishment
Configuration
Management
Purchasing
Scheduling
Equipment
Maintenance
Safety
Blue Light Process
CT Process
Inspector
Certification
Tooling
Powder Condition
Inspection
Human Resources
Third-Party
Resources
P050-15 [663] -7-
Designing the Part
Engineering
Electronic
Model
Design Guide
Post-Processing
Design Allowables
Slicing Software
Defect Definition
Part Notes
KPP Features
Things to Consider
• Design for AM
• Analysis for AM
• Material Properties− Anisotropy
− Surface finish
• Design for manufacture− Build direction
− Build orientation
− Location in printer
− Support StructurePicture credits:
http://www.withinlab.com/software/index.php,
http://solidthinking.com/ProductOverview.aspx?item=Inspire%20Overview&category=Products
• Design software
• Slicing software
• Thermal gradients
• Limitations of the process− Channels
− Internal features
− Bridges
− Edges
− Fill
− Wall thickness
− Mesh type
• Material is money
• Time to print
• Inspectability
P050-15 [663] -8-
Build and Support Materials and . . .
Supply Chain
Powder
Material Inventory
Powder Suppliers
Fabricators
Inspection Req’s
RefurbishmentUsed
Powder
Things to Consider
Vendor coordination
Filament
Powder
• Vendor: OEM vs market
• Order specifics and availability
• Receiving inspection− Inspection procedures
− Certification technicalities
• Storage
• Base plates
• Refurbishing
• Tracking
• Inert gases
• Machining supplies
• Blast media
• Post-processors
− Heat treat
− Surface finishes
− Coatings/finishes
P050-15 [663] -9-
Safety
Laser Power – High-Voltage Equipment
Heavy Powder and Parts
Inert Gas Cylinders
Aluminum and Titanium Powder
P050-15 [663] -10-
Building the Part
Fabrication
Shop TravelerMachine
Settings
Cleaning
In-Process
Evaluation
Criteria
Process Qual
Plan
Process
Specification
Technician
Training and
Certification
AM
Machine
Samples
Machining
Post-Process
Assuming you picked the right machine . . .
Machine Settings
• Plastics− It can take a month to make a good first part
− It can take three months to know the machine
− It can take a year to be proficient
• Metals− Start with coupons
− Move to shapes
− It can take a year to make good high-end parts
− Powder reuse
− Explosive nature – clean well!
Technicians
• Training/certification− Courses, organizations
Samples and inspection criteria
In-process inspection techniques
Materials
• Inventory and ownership
• Tracking and usage
P050-15 [663] -11-
Inspection and Quality
Mission Assurance
Blue Light Process
CT Process
Inspector
CertificationCT
Comparison
Software
Light
Sample
Testing
Powder Condition
Inspection
Powder Inspection
Equipment
Key Feature Identification
Inspection Types
• Surface smoothness
• Inspection methods
• CMM
• White light
• Blue light
• Structured light
• Laser
• Computed tomography
In-Process
• Machine process monitoring
• Custom gauges
• Check fixtures
− 3-D printed
Inspections
• Finished part
• Powder
− Moisture control and content
− Reuse/reject
− Particle size and distribution
− Renovate method
− Sieving
− Oxygen content measurement
− Number of uses
Who is certified to inspect and how?
Software and Data
• Point cloud
• Surface generators
• Comparative data file
• Part to part
• Part to file
• Statistical process control
• Storage and access
P050-15 [663] -12-
Ancillary Considerations
Additional
Resources
Configuration
Management
Purchasing
Scheduling
Equipment
Maintenance
Safety
Tooling
Human Resources
Third-Party
Resources
Controlling Electronic Data
• Models
• Print files
• New File formats
Coordinating with:
• Purchasing
• Scheduling
• Machine time and part production
• Technician Availability
Maintenance and Obsolescence
• Materials, machines parts, fixtures,
Other Concerns:
• OSHA, EPA
• Untrained personnel
Not Just Parts
• Engineering models
• Prototypes
• Business development
• After work projects
− STEM
− Charities
− Personal
− Management
• Materials usage and tracking
P050-15 [663] -13-
Not as Simple as It Might Seem
Engineering
Design the Part
Fabrication
Print the part
Assembly or Delivery
End User
Summary:
• Facilities and Infrastructure
• Materials and Supplies
• Design and Design Process
• Machine and Build Process
• Post Processing
• Inspection
• Personnel/Certifications
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