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Narendran & Perera, SIL 2018 1 3D Printing Opportunities for SSL Components and Fixtures Nadarajah Narendran and Indika U. Perera Lighting Research Center Rensselaer Polytechnic Institute Troy, NY 12180 Session Number: T2 S1 P1

3D Printing Opportunities for SSL Components and Fixtures€¦ · Global 3D printing Forecast Min. 3D printing Global 3D Printing (estimated) Global SSL market Global 3D printing

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Page 1: 3D Printing Opportunities for SSL Components and Fixtures€¦ · Global 3D printing Forecast Min. 3D printing Global 3D Printing (estimated) Global SSL market Global 3D printing

Narendran & Perera, SIL 2018 1

3D Printing Opportunities for SSL Components and Fixtures

Nadarajah Narendran and Indika U. Perera

Lighting Research CenterRensselaer Polytechnic Institute

Troy, NY 12180

Session Number: T2 S1 P1

Page 2: 3D Printing Opportunities for SSL Components and Fixtures€¦ · Global 3D printing Forecast Min. 3D printing Global 3D Printing (estimated) Global SSL market Global 3D printing

Narendran & Perera, SIL 2018 2

What is 3D printing?

3D printing process:• Objects are fabricated by depositing material using print heads, nozzles, or other material deposition or solidification processes using a layer by layer approach with digital information from a computer‐aided design (CAD) model.

• Also known as additive manufacturing (AM)

• Several types of AM processes

http://edition.cnn.com/TECH/specials/make‐create‐innovate/3d‐printing/ Example of vat photopolymerization

https://3dprinting.com/what‐is‐3d‐printing/

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Narendran & Perera, SIL 2018 3

3D printing processes and material

Polymer Metal

Ceramic

Material jettingDirect energy deposition

Vat photopolymerizationMaterial extrusionBinder jetting

Powder bed fusionSheet lamination

Source: Adopted from IDTechEx 2018, Masterclass 7 handoutshttp://www.3ders.org/articles/20170524‐sculpteos‐newly‐released‐state‐of‐3d‐printing‐2017‐report‐shows‐a‐maturing‐market.html

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Narendran & Perera, SIL 2018 4

3D printer and material manufacturers

• 3D Printers• Thermoplastic extrusion

• Stratasys, Ultimaker, RepRap • Selective laser sintering

• 3DSystems, EOS • Vat photopolymerization

• Formlabs, 3DSystems, Carbon 3D• Direct metal laser sintering/Electron beam melting

• EOS, GE (Concept Laser, Arcam)• Binder/Material jetting

• 3DSystems, hp, Stratasys

• Materials• Thermoplastic

• BASF, ARKEMA, COVESTRO

• Vat photopolymerization: • DSM, Dow Corning, Henkel

• Metal powder• SANDVIK Osprey, Renishaw, Advance laser Materials (EOS)

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Narendran & Perera, SIL 2018 5

Expanding market for 3D printing

• Industries who have embraced 3D printing for manufacturing parts and systems

• Automotive

• Aerospace

• Medical

• Consumer products

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Narendran & Perera, SIL 2018 6

Source: ARK investment Management LLC | ark‐investment.com, 2016Source: ARK Investment Management LLC , 2016 |ark‐investment.com

Successful implementation of 3D printing

CFM International’s 3D‐printed fuel nozzle reduces part count from 18 to just 1. (Image source: ge.com)/

3D‐printed parts for the Rolls‐Royce Phantom. (Image source: bmw.com)

Customizable 3D‐printed electric shavers from partnership between Philips, Shapeways and Twikit(Image source: 3dprint.com)

3D‐printed shoes from Adidas and Carbon (Image source: 3dprint.com)

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Narendran & Perera, SIL 2018 7

0

10

20

30

40

2012 2014 2016 2018 2020 2022

Glo

bal r

even

ue ($

Bill

ions

)

Year

Forecast Max.Global 3D printing

Forecast Min. 3Dprinting

Global 3D Printing(estimated)

Global SSL market

Global 3D printing market projections• Global 3D printing market

• $3.1B in revenue in 2013• $12.8B by 2018• $21.0B by 2020.

• 2017 AM service providers• 29% Metal and polymer• 20% Metal• 51% Polymer

Source: Adopted from data obtained including Wohlers , Allied Market Research, Canalys, CCS Insight, Freedonia, Gartner, IBISWorld, Business Wire, IDC, Statista market research reports

[ Source: Wohlers Report 2014 ]

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Narendran & Perera, SIL 2018 8

Reasons for pursuing 3D printing

• Prototyping • Product development • Customization• Cost reduction• Weight reduction• Increased efficiency• Innovation

Source: 3D printing: The next revolution in industrial manufacturing, UPS and Consumer technology Association, 2016

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Can SSL Benefit from 3D Printing?

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Narendran & Perera, SIL 2018 10

Vision for SSL and 3D Printing

Building design Construction Interior finishing

Custom lighting fixture design

On‐demand, On‐site custom fixtures

Interior lighting with custom fixtures

Change Architectural Lighting Practice

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Narendran & Perera, SIL 2018 11

Why 3D print of SSL fixtures?

• Custom fixtures• Improved visual appeal and functions

• Faster new product introductions• Rapid prototyping

• Lower cost SSL fixtures• Reduce cost with composite heat sinks with tailored thermal properties• Reduced carbon footprint: Lower cost manufacturing on‐site (3D printing)• One‐step process: Print/integration of components• Reduce stored inventory of systems and parts

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Components of an LED lighting fixture

[LRC 2017]

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Recent studies

• Goal: To investigate if functional mechanical, electrical, and optical components can be fabricated using current 3D printing technologies and materials to manufacture SSL lighting fixtures

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Narendran & Perera, SIL 2018 14

Mechanical Components

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Objective

• LED systems ‐ Metal heat sinks • To keep LED junction temperatures low • Drawbacks:

• Heavy, Expensive, Overdesigned thermal management

• Study objective: • To investigate if custom heat sinks of suitable thermal properties can be printed using fused filament fabrication (FFF) method

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Estimated Tj with 3D printed heat sinks

Parameter ValueThermal power of LED package ( ) 1 ,2, 5, and 10 WLED package thermal resistance ( ) 10°C/WDiameter of LED package ( 12.7 mmHeat sink length ( ) 10.0 cmHeat sink width ( ) 10.0 cmHeat sink thickness ( ) 2.5 mmHeat sink surface emissivity ( ) 0.9Ambient temperature ( 20°C

LED heat sink

LED package

Thermal conductivity of aluminum ~200 W m-1 K-1

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Thermal performance of 3D printed heat sinks

• In this study we investigated how composite polylactic acid or polylactide(PLA) filaments with thermally conductive fillers affect thermal conductivity of printed heat sinks to manage the junction temperature, Tj, of the LED

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Estimated Tj with different heat sinks

4045505560657075808590

0.1 1 10 100 1000

LE

D c

hip

junc

tion

tem

pera

ture

C)

Heat sink thermal conductivity (W/(m·K))

Generic PLACopper infused PLA variant ACopper infused PLA variant BCarbon fiber PLABronze infused PLAGraphene infused PLAAluminum

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Narendran & Perera, SIL 2018 19

Heat sink temperature profile

• Thermal properties of 3D printed heatsink with different materials

19

Aluminum heat sink

100%

Graphene composite PLA

70%

Copper composite PLA

60%

Generic PLA

50%

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Narendran & Perera, SIL 2018 20

Heat sink geometry effects

20

Tc=64 °C Tc=66 °C Tc=70 °C

8 mm

28 mm

5 mm

5 mm

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Predicting composite thermal conductivity

• To identify and verify a model that can accurately predict the composite material thermal conductivity

21

• Model predictions• Epoxy (κ=0.4 W m‐1 K‐1)• Copper (κ=400 W m‐1 K‐1)• Copper particle size=100 μm

• Experiment• Copper average particle sizes 5 and 150 μm in epoxy host material

Terentyeva et al., 2017.

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Summary

• Thermal conductivity of 3D printed PLA components depends on build orientation and filler material properties

• In‐plane thermal conductivity better compared to cross‐plane ; greater than 30%

• Infill percentage increase increased the thermal conductivity of 3D printed components

• Need improved performance filaments to meet thermal conductivity needs of heat sinks for LED systems

In‐plane Cross‐plane

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Electrical Components

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Electrical properties of printed conductive traces • Study objective:

• To investigate if electrical traces can be printed with suitable electrical properties

• In this study we investigated electrical resistivity of the 3‐D printed conductive traces with three types of materials and print orientations:

• Graphene infused PLA• Carbon nanotube based PLA• Conductive carbon black based PLA

• Results:• Graphene infused PLA showed the lowest resistivity

(6.1 x10‐3 Ωm) of tested materials• Copper used PCB traces (1.7 x10‐8 Ωm)

• In‐plane build orientation showed the lowest resistivity (70‐80% lower compared to cross‐plane)

24

Voltage channel

Current channel

3‐D printed trace

V

A

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Summary

• There are commercial inks with resistivity values similar to copper.

• But they cannot be processed using unmodified FFF‐type 3‐D printers.

• Requires paste extruder attachments to benefit from these highly conductive materials

• For example, Yu et al., recently reported a method where 3D printed hollow channels within elastomer structures were filled with injected liquid metal to form electrical traces

https://support.voxel8.co/hc/en‐us/articles/208004096‐Working‐with‐the‐Conductive‐Silver‐Ink‐Solvent

Yong‐Ze Yu, Jin‐Rong Lu, Jing Liua; 3D printing for functional electronics by injection and package of liquid metals into channels of mechanical structures, Materials and Design 122 (2017).

Yu et al. 2017

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Optical Components

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Optical properties of printed components• Study objective:

• To investigate if SLA printing technology and commercially available materials are suitable for printing lenses of appropriate quality for lighting applications.

• Techniques for manufacturing optical components

• Vat photopolymerization, material jetting, and extrusion (glass material)

• In this study we investigated light transmission and scattering distribution as a function of print resolution and print orientation

• Optical samples were prepared at 50 m and 250 m print resolution

• Samples were evaluated for light transmission and scattering

• in‐plane and cross‐plane

Before polishing After polishing

50 m

250 m

laser

In‐plane

laser

Cross‐plane

GE Energy Smart LED Replacement Lamp ‐MR16Secondary lens and holder for LED lighting systems

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Summary• Study results showed that both print resolution and print orientation affect light transmission and scattering distribution

• Polishing the 3‐D printed optical elements improved performance• Increased print resolution 250 μm to 50 μm increased light transmission and decreased light scattering

• In‐plane print orientation had greater light transmission (~ 3 times) compared to cross‐plane print orientation

• Cross‐plane print orientation had greater light scattering compared to in‐plane print orientation

• Requires post‐processing (polishing, heat treating, or coating) to refine and improve optical performance.

• Chien‐Yao Huang et al., in 2017, showed that precise diamond turning and polishing can improve surface roughness of printed components to below 0.05 μm and light transmittance to above 80%.

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Final Remarks

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Narendran & Perera, SIL 2018 30

Final remarks• Opportunities

• Architectural lighting practices• Mass customization

• Custom fixtures (especially for complex geometry design and smaller production runs with unique design changes)• Rapid prototyping and faster new product introductions• Reduce fixture cost

• On‐site manufacturing• Reduce manufacturing cost with manufacturing processes such as 3‐D printing

• Reduce stored inventory

• Challenges• 3‐D printed mechanical, electrical, and optical components

• Component performances need improvement• Components have to be printed separately and integrated separately

• New materials are needed for mechanical, electrical, and optical components to meet performance needs of SSL

• Need strategy for integration of different components• Faster printing speed needed to meet application demand

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Acknowledgments

• Strategies in Light 2018• LRC Faculty, Staff and Students• LRC internal funding• Alliance for Solid State Illumination Systems and Technologies (ASSIST)

• The Federal Aviation Administration (FAA) Cooperative Agreement Number 16‐G‐019

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Thank you

www.lrc.rpi.edu/programs/solidstateEmail: [email protected] (Narendran)

[email protected] (Perera)