zilveren jubileum 1990-2015 25 years of pioneering work in … · 2019. 4. 26. · 1 zilveren...
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Zilveren jubileum
1990-2015
25 years of pioneering work in
Additive Manufacturing
at KU Leuven
Prof. Dr. Ir. Jean-Pierre Kruth
KU Leuven, Belgium
Fellow CIRP, FSME
Bower Awardee / Franklin Institute Laureate
• A whole bunch of techniques to produce “objects” by gradually adding material until the desired 3D geometry is obtained. Material is often added layer upon layer.
What is Additive Manufacturing (AM) or 3D Printing?
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• A whole bunch of techniques to produce “objects” by gradually adding material until the desired 3D geometry is obtained. Material is often added layer upon layer.
• The 1st technologies appeared around 1990.
What is Additive Manufacturing (AM) or 3D Printing?
• A whole bunch of techniques to produce “objects” by gradually adding material until the desired 3D geometry is obtained. Material is often added layer upon layer.
• The 1st technologies appeared around 1990.
• “Additive Manufacturing” is complementing traditional “Subtractive Manufacturing” (drilling, milling, grinding, …) known for centuries and “Forming technologies” (casting, forging, extrusion, deep drawing, injection molding, …) going back to the prehistory.
What is Additive Manufacturing (AM) or 3D Printing?
Milling machine Casting metal
Forging
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• A whole bunch of techniques to produce “objects” by gradually adding material until the desired 3D geometry is obtained. Material is often added layer upon layer.
• The 1st technologies appeared around 1990.
• “Additive Manufacturing” is complementing traditional “Subtractive Manufacturing” (drilling, milling, grinding, …) known for centuries and “Forming technologies” (casting, forging, extrusion, deep drawing, injection molding, …) going back to the prehistory.
• “3D Printing” is a vulgarizing synonymous for “Additive Manufacturing” (ISO/ASTM standards)
What is Additive Manufacturing (AM) or 3D Printing?
• A whole bunch of techniques to produce “objects” by gradually adding material until the desired 3D geometry is obtained. Material is often added layer upon layer.
• The 1st technologies appeared around 1990.
• “Additive Manufacturing” is complementing traditional “Subtractive Manufacturing” (drilling, milling, grinding, …) known for centuries and “Forming technologies” (casting, forging, extrusion, deep drawing, injection molding, …) going back to the prehistory.
• “3D Printing” is a vulgarizing synonymous for “Additive Manufacturing” (ISO/ASTM standards)
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plastic injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: mock-ups, printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
A lot of combinations; many specializations. KU Leuven: powder-based and laser-based AM.
What is Additive Manufacturing (AM) or 3D Printing?
4
Industrial application of AM appeared only around 1990 because it is an automated process, requiring computers and CAD/CAM systems (digital computer model, 1980’s)
How old is Additive Manufacturing (AM)?
From subtractive manufacturing (SM) to additive manufacturing (AM)
Cappadocia
Typical CIM scenario for Additive Manufacturing (AM)
• CIM = Computer Integrated Manufacturing
• Based on: – CAD = Computer Aided Design (in casu “3D Solid Modeller”)
– CAM = Computer Aided Manufacturing
Triangulated/Facetted Model (STL file)
Sliced Model (Contour file)
Part build in slices with support structure
CAD Model
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Examples of Additive Manufacturing processes
Start phase Process Lay-out Layer deposition Phase change Materials
LIQ
UID
Stereo lithography Liquid resin in a vat,
irradiated by UV light (laser) Liquid layer deposition Photo-polymerization
Acrylates, epoxies, filled
resins
Ink jet Printing Droplets of melted material Deposition of droplets
through nozzle Solidification by cooling Polymers, wax
Fused Deposition
Modeling Material melted in a nozzle
Continuous extrusion and
deposition Solidification by cooling (Filled) Polymers, wax
PO
WD
ER
Three-dimensional
printing
Binder projected on powder
in bed
Layer of powder and drop
on demand binder
deposition
No phase change of
powder, solidification by
injection of binder
Ceramics/ metals/
polymers with polymer
binder
Selective Laser
Sintering/Melting
Powder bed, radiation by
laser Layer of powder
Laser sintering and
melting, re-solidifying
while cooling
Polymers, metals (ferro,
non-ferro), ceramics, all
composites (e.g.
cermets, Al-PA, Cu-PA)
Electron Beam
Melting
Powder bed pre-heated
and radiated by electron
beam
Layer of powder
Electron beam
melting, re-solidifying
while cooling
Non-magnetic, non-
ferro metals (Ti, CoCr)
Laser Cladding Powder injected thru
nozzle(s) in laser spot
Continue powder
injection
Laser melting and re-
solidifying by cooling
Metals, metal
composites
SO
LID
Laminated Object
Manufacturing
Feeding, cutting and binding
of sheets
Deposition of sheet
material
Binding by phase change
of solder, glue or
otherwise
Paper, Polymer foam,
composites, metals,
ceramics
GA
S Selective Laser
Chemical Vapour
Deposition
Gas flow in laser Condensation of gas Solidification by chemical
reaction Metals, ceramics
Examples of Additive Manufacturing processes
Photo-polymerisation of liquid polymer (Stereo-lithography) Process only suited for: - Dedicated photo-polymers
(no technical polymers, no metals, etc.)
- Basically prototyping
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Examples of Additive Manufacturing processes
Extrusion based AM (FDM – Fused Deposition Modelling)
Ultimaker Original
Process only suited for: - Polymers
(technical polymers, like ABS, etc.)
Examples of Additive Manufacturing processes
Powder Bed Fusion (Selective Laser Sintering/Melting – SLS/SLM)
Process suited for: - Polymers - Metals - Ceramics - Composites (metal-metal, metal-ceramic, plastic-
metal, plastic-glass, fibre-reinforced, etc.)
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• Starts from CAD model of the object
• Allow to produce very complex 3D shapes: – 3D complexity decomposed in simple 2D contours
Main features of Additive Manufacturing
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• Starts from CAD model of the object
• Allow to produce very complex 3D shapes: – 3D complexity decomposed in simple 2D contours
– Free-form doubly-curved shapes
– Parts with internal cavities
– Parts requiring assembly of e.g. 20 parts now produced as 1 part
Main features of Additive Manufacturing
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8
• Starts from CAD model of the object
• Allow to produce very complex 3D shapes: – 3D complexity decomposed in simple 2D contours
– Free-form doubly-curved shapes
– Parts with internal cavities
– Parts requiring assembly of e.g. 20 parts now produced as 1 part
Main features of Additive Manufacturing
15
Courtesy: ESA
• Starts from CAD model of the object
• Allow to produce very complex 3D shapes: – 3D complexity decomposed in simple 2D contours: picture
– Free-form doubly-curved shapes
– Parts with internal cavities
– Parts requiring assembly of e.g. 20 parts now produced as 1 part
• Simple/short job preparation: single operation, machine, tool, set-up (no fixtures)
• Simple production: single set-up, no need for many (dedicated) tools
• Fast throughput (mfg. process still slow)
• Ecological mfg.: creates material only where needed, no spooling of material
• Local manufacturing in small mfg. units or quantities: – Counters delocalisation
– Reduce CO2 footprint: no transport of goods (produced e.g. in Japan) across the world
– Production in (war)ship, spacecraft, other planet, at home, etc.
• Single part, customized products: e.g. single plastic part, medical implants.
• New/customized materials: the material is created during part manufacturing
Main features of Additive Manufacturing
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9
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
A lot of combinations; many specializations. KU Leuven: powder-based and laser-based AM.
Applications of Additive Manufacturing (AM) or 3D Printing
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
10
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
10 mm
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures and houses
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
11
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures and houses
– Artwork, fashion, design
– Consumer/prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures and houses
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
12
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: mock-ups, printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: mock-ups, printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
13
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
14
• AM applies very different processes (SLA, SLS/SLM, FDM, LOM, …), often only suited for a very limited set of materials (photo-polymers, technical polymers, metals/alloys, ceramics, composites,…), and for very diverse applications:
– Prototyping: initial application (Rapid Prototyping)
– Tooling: e.g. plasting injection molding (inserts)
– Industrial mfg.: mechanical, automotive, aerospace, electronics, consumer devices, etc.
– Medical: medical models, prostheses, implants, scaffolds, tissue, (organs), etc.
– Dental: see medical, but quite different market
– Architecture and construction: printing structures (and houses)
– Artwork, fashion, design
– Consumer/Prosumer: home application, DIY (Do-It-Yourself), amateurs
– Production of food and medication
Applications of Additive Manufacturing (AM) or 3D Printing
• 1970-1980’s: strong expertise in conventional (milling, grinding,…) and non-conventional (EDM,…) subtractive manufacturing, plastic injection molding (moldmaking), CAD/CAM, etc.
• 1990: Start of activities on Rapid Prototyping, dixit AM (polymers):
– Incorporation of Materialise N.V. (Additive Manufacturing of polymers) within KU Leuven labs
– 1st Stereo-Litography Apparatus SLA-250 (3D Systems)
– Own-built SLA machine: Materialiser I, Mammoth SLA, Curtain recoater SLA (patent), Colour SLA (patent)
– Ink jet printing of polymers
• 1991: Start of activities on AM for metals:
– 1st tests with electron beam sintering/melting (EBM)
– 1st tests with selective laser sintering/melting (SLS/SLM)
– Building own SLS/SLM machines (Nd:YAG laser, fiber laser, process monitoring, …)
• 1997: Purchase of DTM Sinterstation 2000+ (100W CO2 laser)
– SLS of polymers, metals (Rapidsteel, Laserform), hardmetals (WC-Co, etc.), titanium,…
• 2008: Incorporation of LayerWise N.V. (AM of metals)
• 2008: Initiating new research on SLS/SLM of ceramics, X-ray CT quality control, …
History of Additive Manufacturing at University Leuven
15
Laser Additive Manufacturing
1st SLA-250 machine installed in 1990
Colour stereolithography (patent)
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dip wait rise sweep(x n)
lower + wait
Dip and blade scraper re-coater (3D System)
Liquid curtain re-coater (K.U.Leuven)
lower sweep
Casting re-coater (EOS)
lower sweep return
inject
Resin sucked byT-shaped bar(Teijin Seiki)
Resin sucked byinterfacial force(CMET)
Variants
Curtain casting head
liquid curtain
v
re-coater head
narrow gap
deposited layer
Q
Scanning behind scraper (Japan)
Variants
LaserbeamBlade
LaserbeamBlade
Opticalflat
Suction re-coater (3D System’s Zephyr/SmartSweep re-coater)
lower sweep
suck
part
liquid resin
Manufacturer : Materialise, Belgium
Process : Mammoth Stereolithography machine (max. dim. 2200x840x640mm)
Product : Ford Mondeo dashboard (2700 layers, 52h build time)
on Rapid-Fit modular fixture
Features Mammoth SLA machine
•Liquid curtain recoating (patent)
•4 parallel scanners, 1 laser
Large stereolithography part - Mammoth SL machine
RapidFit fixture for
Quality Control
Selective Laser Sintering of polymers (SLS)
Digital design from wax imprint SLS production (500 parts) Pigmented shells before & after finishing
Customised hearing aids (Courtesy Materialise – Siemens-Phonak)
Bone scaffolds in PA & PCL
Tibia bone
Components in PA & elastomer
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Selective Laser Sintering of polymers (SLS)
Development of new Polymers for SLS
500% elongation Strong elasticity
11
5 m
m
Very flexible novel material
Development AM novel polymers or reliability existing polymers => Cooperation between KU Leuven (Mech. Eng./PMA and CIT), Materialise and others
Laser Additive Manufacturing
1st SLS/SLM/EBM tests in 1991 (own setups)
to
From
Cooperation KU Leuven PMA + MTM
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• Company: LayerWise N.V., Leuven
• Field: RP & AM of metalic products
• Spin-off of KU Leuven
• Start: 2008 (Founders: CEO P. Mercelis, CEO J. Van Vaerenbergh,
KU Leuven J.P. Kruth)
• Today: 85 persons
• Activities:
– Industrial, medical & dental applications
– Several patents (dental and others)
• 2014: became part of 3D Systems
Additive Manufacturing by SLM of metal powder
10 mm
World’s first full lower jaw produced by SLM in Ti and implanted in patient of 81 years old
(LayerWise, 2012)
LayerWise – Rapid Prototyping & Manufacturing for metals
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Research in SLM of metals
– Expanding material pallet : tuning material, new compositions and alloys
– Improving part and material properties • Density
• Surface quality
• Microstructure
• Strength, Toughness, Fatigue
• Residual stresses: warpage and cracking of parts
• Post-treatment, heat treatment
• Biocompatibility
– Machine and process development (Hardware/Software)
• Building own machines: new lasers, scanners, temperature control, software (scanning, etc.)
• Optimization of processing parameters & window
• Real-time process monitoring and control
• Accuracy
• Speed
– In-line and off-line Quality Control
– Combined additive & subtractive laser manufacturing
– Precision & Micro-manufacturing
– Etc.
Cooperation KU Leuven PMA + MTM
Laser Additive Manufacturing
After polymers and metals, now also ceramics
Emblem statue of Brussels city
Cooperation KU Leuven PMA + MTM
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Need for quality control
• On-line or In-process QC (real-time) Monitoring & control of melt pool using high-speed thermal camera
• Off-line or final QC (accuracy, properties) Use of X-ray CT technology to check dimensional accuracy (outer and inner geometry) and material quality in one measuring inspection job
Quality monitoring & control in Additive Manufacturing
Cooperation KU Leuven PMA + Campus Groep T
Thank you for your attention.
Laser Additive Manufacturing: polymers, metals & beyond