Dalla prototipazione

alla produzione additiva:

potenzialità attuali dei materiali polimerici e compositi

Dalla prototipazione

alla produzione additiva:

potenzialità attuali dei materiali polimerici e compositi

Prof. Paolo MinetolaDipartimento di Ingegneria Gestionale e della Produzione(DIGEP)

Stampa 3D - Additive Manufacturing: dalla tecnologia al product designCentro Congressi Torino Incontra – 14 novembre 2019

HISTORICAL DEVELOPMENT

1990 2000 2010

Syst

em

dev

elo

pm

en

t

Conceptual, functional and technical prototypes

Tooling and casting applications,pre-series production

End-usableproducts

RP

RT, RC, RM

AM3D

Printing

2

ADVANTAGES OF LAYERED MANUFACTURING

PRODUCT

• Design freedom

• Lightweight structures

(complex hollow shapes)

• Integrated design and assemblies

• Anatomical personalized

• Ergonometric design

• Customization individualization

PROCESS

• One machine, unlimited forms

• No mould required, no special tools

• Jig and fixture not required

• Undercuts admitted

• One manufacturing step

• Reduced operator intervention

• Time and cost only related

to size, not complexity

3

MACHINES

• Limited build rates

• Machine size limits product size

• Machine speed is limited

• Machines able to handle few materials or colors

PRODUCTS

• Overhangs require support structures

• Scarce superficial finish (post-processing required)

• Limited number of commercially available materials

mostly polymers (limited specifications and functionality)

• Most materials are still expensive

even if machines costs are coming down rapidly

DRAWBACKS OF LAYERED MANUFACTURING

Part

4

POLYMER

StratasysDimensionElite

Selective Laser SinteringEOS Formiga

INVESTMENTS

MarkforgedMark Two

Fused Deposition Modeling

MaterialsABS M30ABS ASAPC-ABSPLAHIPSNylon CarbonPA66 GFPETGTPUNylonOnyxCarbon fiberFiberglassKevlar

Stereolithography

MaterialsNylonNylon glass filledNylon Al filledNylon carbon filled

3ntrA4

Polyjet

Direct Ligth Processing

PhotopolymersMaterialsdevelopment

StratasysF370

CHARACTERIZATION

Computer Tomography

INVESTMENTS

SEM MicroscopeScan Box

New design approach

7

€ perpart

Complexity

TraditionalManufacturing

AdditiveManufacturing

Design for Manufacturing Design for Functionality

DESIGN FOR ADDITIVE MANUFACTURING

DESIGN FOR ADDITIVE MANUFACTURING

Analysis of theoriginal component

CAEOptimization

RedesignDesign for AM production

and CNC finishing

Production of conceptualprototyper

Objective: Minimization of the weight of the main bracket of ahinge for car doors by exploiting the potential of AdditiveManufacturing processes

ValidationFinal

validation

-63%

DESIGN EXPLORATION

POLYMERRESEARCH

Case study of

a polymeric component

Injection Moulding (IM) Additive Manufacturing (AM)

POLYMERRESEARCH

Case study of

a polymeric component

Break-even analysis

POLYMERRESEARCH

POLYMERRESEARCH

POLYMERRESEARCH

POLYMERRESEARCH

2015 – CubeSat Challenge

“FoldSat” model printed by Stratasys in ASA material by

means of a Fortus 400 mc system

Among over two hundred projects, the 1st prize was awarded to the "FoldSat" model of PaoloMinetola and Giovanni Marchiandi of the Department of Management and ProductionEngineering of the Politecnico di Torino, members of the Additive Manufacturing research groupcoordinated by Prof. Luca Iuliano.

The goal of this challenge was to design a small satellite frame optimized for additive manufacturing. By using the benefits of design for additive manufacturing (DFAM) principles:

- Mass distributions and materials can be rethought to minimize weight - Part count can be reduced to improve producibility and ultimately, cost can be reduced.

The international competition was promoted by the company Stratasys Vertical Solutions -Aerospace in collaboration with the GrabCAD platform. It required to design a frame forCubeSat-type satellites that was optimized for production through additive manufacturing(additive manufacturing) or 3D printing (3D printing) .

Award motivation:«FoldSat is an elegant design that leverages geometries only available with 3D printing. Paolo takes the concept even further by illustratinghow the design also implements DFAM (design for additive manufacturing) best practices. FoldSat also gets a bonus for incorporating allthe common CubeSat features, including PCB mounting slots and features for easy maintenance. Great job!»

http://goo.gl/juPLmH

POLYMERRESEARCH

17

MANUFACTURING

Part material

Support material

POLYMERRESEARCH

The production time by FDM can be cut down to an estimated 40% bymanufacturing the cube in its unfolded configuration together with areduction of about 30% of support material if compared to the foldedconfiguration (cube shape).

POLYMERRESEARCH

Main materials

currently

available

POLYMERRESEARCH

Main materials

currently

available

Material

Sintering (SLS)

Selective LaserFused DepositionModelling (FDM)

Drop on Demand (DoD)

Jetting Photopolymerization

Stereolithography(SLA)

Polyjet / Projet

Extrusion

Powder SolidLiquid

UV Lamp Laser

3 Dimensional

Printing (3DP)

1 Material1 Material+

+ Binder:

Digital Light Processing (DLP)

POLYMERRESEARCH

Multi Jet

Fusion (MJF)

+ Agents:

POLYMERRESEARCH

Performances of AM

polymeric parts

with fillers (Graphene, Carbon fibres, …)

FDM machine with 3 extruder heads

Different strategies for deposition of the graphite filled filament

POLYMERRESEARCH

Inserts(print paused)

POLYMERRESEARCH

Flexible parts

POLYMERRESEARCH

Flexible parts

with lattice structure

Self-supportinglattice by generativedesign

POLYMERRESEARCH

Actuators(one piece sealed parts)

Courtesy of HP

Courtesy of Festo

POLYMERRESEARCH

Heat

exchangers(one piece sealed parts)

POLYMERRESEARCH

Pellet

3D Printer

Pellet dimension:about 3 mm

Extrusion temperature:up to 280 °C

Bed temperature:Up to 90 °C

1. Detaching from the building platform and removal of support structures

2. Post curing: completely polymerization of the part

3. Sand papering and application of coatings

• Basic Step 3: Detachment + Post-curing + Coating

STEREO-LITHOGRAPHY (SLA)

POLYMERRESEARCH

Parameter Value

Return loss ≥ 30 dB

Insertion loss ≤ 0.4 dB

Rejection ≥ 40 dB

Dimension (width x height x length)

30 mm x 30 mm x 48 mm

Weight 16 g

Measured performance of the prototype

• Fifth-order WR51 stub filter in ABS-like

RF BENCHMARK: SLA PROTOTYPES

POLYMERRESEARCH

To 50 Micron Layer Resolution50 – 200microns

100microns

100microns

● Nylon/Onyx

● Fiberglass

● Kevlar

● Carbon Fiber 125microns

Two nozzle heads

One part - thousands ofcontinuous fibers

Markforged patented Technology

CONTINUOUS FIBER FILAMENT (CFF)

Nylon

Fiber

POLYMERRESEARCH

The reinforcement strategy can be changed layer by layer

REINFORCEMENT STRATEGIES

POLYMERRESEARCH

Materials for CFF(by Markforged)

FDM SACRIFICIAL CORES AND MANDRELS FOR COMPOSITE LAYUPS

Potential application: customized sacrificial tooling for repairing

POLYMERRESEARCH

Prof. Paolo Minetola

Associate Professor of Manufacturing SystemsPolitecnico di Torino – DIGEPDep. Management and Production EngineeringC.so Duca degli Abruzzi 24 - 10129 TorinoTel. +39-011-090.7210 or 7254Mob. +39-331-668.49.76 Fax. +39-011-090.7299e-mail: paolo.minetola@polito.itwww: iam.polito.itWinner of “The CubeSat Challenge”http://goo.gl/juPLmH