Advances in 3D Printing State of the Art and Future Perspectives

1. 14 – 15 September 2004, Paris, France Advances in 3D Printing State of the Art and Future Perspectives By D. Dimitrov, K. Schreve, N. de Beer

2. Overview • Introduction • Definition and Classification • Technical and Economic Characteristics • Applications • Main Research Issues • Conclusions

3. Introduction

4. Introduction Growth of 3D Printer sales • Significant sales increase of 3D Printers compared to RP machines

5. DefinitionandClassification

6. 3D Printing – Background and Definition Layer Manufacturing Technologies • One of the first developments • Continuous improvement and further development Source: Levy et. al.

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

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 multi-material construction.

9. Classification of 3D Printing Techniques Summary of Inkjet techniques and corresponding technologies

10. Classification of 3D Printing Techniques

11. Technical and Economic Characteristics

12. Technical and Economic Characteristics

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

14. Applications

15. Applications – Design - Conceptual Modelling Model of manifold displaying finite element analysis information • Enhances communication, • Error detection, • Non-geometric product information Source: Z Corporation

16. Applications – Design - Proof of concept (customer presentation) Transparent bottles produced for customer presentation • Large possibilities using variety of combinations with secondary processes

17. Applications – Design - Market research • Efficient way to test the market for new product entries Prototype of Mop Dryer (courtesy of USABCO)

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

19. Applications – Manufacturing - Pattern making for casting processes • Automotive Differential Housing • Starch-based powder & wax • Part built in 4 sections • Size: 264mm236mm281mm • 18.5 Hours printing time • 12.9 Hours post curing and treatment

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

21. Applications – Manufacturing - Pattern making for casting processes • Development of pattern equipment for sand casting for large components and complicated core systems. • Challenge: Meeting accuracy or surface finish requirements for large parts and thin walls. Scaled down core system

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)

23. Applications – Manufacturing - Direct Rapid tooling • Sand moulds obtained directly from CAD file • Metal tooling inserts also directly from CAD file (ProMetal) Source: Griffin Industries

24. Applications – Manufacturing - Indirect Rapid tooling Foundry equipment for sand casting of a hydraulic component • Pattern created with zp102 (plaster) material • Cores and inserts created in ZCast500 (ceramic) material Source: Griffin Industries

25. Applications – Medical Field • Surgical aids • Drug delivery systems • Bone implants & tissue engineering • Organ printing Surgical planning and preparation Source: Dr. F. Urrutia

26. Applications – Architecture Architectural Model • 3DP models as visualization tools • Difficulties • Reproducing ornate details • Free standing structures • Uniform scaling of 3D CAD models Source: Maslowski et. al.

27. Main Research Issues

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

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

30. Applied Research Activities Accuracy Surface Finish Strength Elongation Build Time Cost • Customer satisfaction • Development of capability profiles of working RP equipment

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

32. Conclusions

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 non-geometric 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

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

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

36. In General Utilisation value of 3D Printers as concept modellers Source: Levy et. al.

37. Future Perspective Where is the place for 3D Printing among other LM technologies? Consolidation forecast for LM technologies up to 2010 Source: Levy et. al.

38. Thank You