Materials and Technologies

How additive manufacturing revolutionizes the SMEs' approach to business and product design

Additive Manufacturing for Design - P1

Stefano Lionetti

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Reasons Why

AM (Additive Manufacturing) can offer several benefits in creating prototypes and models, bolstering a product’s value by increasing the efficiency and effectiveness of the design process.

In a SMEs these benefits generally arise in three areas:

• Saving time in the development cycle

• Reducing costs in the development cycle

• Enhancing the final product’s quality and design

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

What You Will Learn

• To understand the differences between Addictive Manufacturing and the more traditional manufacturing methods

• To adopt the most useful available technologies on the market

• To select the raw materials available for 3D printing

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Definition

The ASTM International Committee F42 on Additive Manufacturing Technologies defines:

• Additive Manufacturing as the process of joining materials to make objects from 3D data usually layer upon layer.

– Synonymous:

• Additive fabrication, Additive processes

• Additive layer manufacturing

• Freeform fabrication

• 3D printing as the fabrication of objects through the deposition of material using a print head nozzle or similar printing technologies

Even though “3D printing” has a different meaning, it is nowadays the more popular term to indicate these technologies.

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Definition

The Steps to produce a part by means of additive manufacturing are the same whatever the additive technique used. The steps are summarized as follows:

Schematic of Additive manufacturing steps Source: Deloitte University Press

• 3D modeling the object (CAD);

• Triangularization of the surface and generation of a .STL file;

• Generation of a sequence of slices of the object;

• Additive Manufacturing of the part;

• Finishing operations;

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Technology

AM technology is relatively new and the maturity is estimated in 5 to 10 years according to Gartner’s Study:

Source:The Hype Cycle for Emerging Technologies report, Gartner (August 2015)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Technology

3D Printing expectations are different according to the specific area. For example 3D printing of hearing devices seems to be very near to a technology maturity

Source:The Hype Cycle for Emerging Technologies report, Gartner (August 2015)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Pros

Addictive Manufacturing Pros:

• Freedom of design/geometries

• Complexity is not an issue (limited extra costs on complex geometries)

• Rapid reaction to design changes

• Product customization

• Tooling reduction (direct production or tooling optimization)

• Green technology (limited waste, material scrap reduction)

• Lightweight components (by means of FE analysis and topological optimization)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Cons

Addictive Manufacturing Cons:

• Pre/post processing requires particular effort (dimensional accuracy, anisotropy, microstructure)

• Low speed processes

• High process cost (due to low speed and materials costs)

• Lack of standards

• Limited number of available materials (specially for metal technologies)

• High equipment cost for high end manufacturing

• Surface finish to be improved (specially for metal technologies)

• Limited part size (due to the limited dimensions of the building chamber)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Technologies in the Market

Do you see potential benefits for your SME with the adoption of Additive Manufacturing?

What about your current manufacturing process?

What kind of AM technology could be better for you?

Let’s see what is currently available on the market.

Think About It

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Technologies in the Market

Source:: Adapted from Wohlers Report and ASTM

Technology Company/Manufacturer

Material Extrusion Stratatys, Aleph Objects; MakerBot Industries, Ultimaker

Material Jetting Stratasys, Solidscape, 3D Systems, Keyence

Binder jetting ExOne Company, 3D Systems (includes Z corp.), Voxeljet Technology Gmbh (3D Systems)

Sheet lamination Mcor technologies, Fabrisonic

Vat photopolymerization

Envisiontec, Rapid Shape, Prodways, 3D Systems, Lightforge 3D, B9 Creator, Lithoz

Powder bed fusion EOS, 3D Systems, Renishaw, Phenix Systems, Concept Laser, ReaLizer, SLM solutions, Arcam

Directed energy deposition

Optomec, POM Group, Trumpf, BeAM, RPM Innovations

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Material Extrusion

The starting material is a plastic wire and it is heated and extruded through a nozzle. The extrusion head moves on the XY plane to reproduce the section of the object. The next section is reproduced on the top of the previous one.

Example: Fortius 900mc (Stratasys FDM) Build envelope: 914 x 610 x 914 mm (36 x 24 x 36 inches)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

(Source: Stratasys)

Material Extrusion

When is it used? • Non structural objects • Light and hollow components • Low volume production parts • Functional prototypes • Jigs and fixtures Typical materials: polymers and plastics Technology pros: • Relatively low cost process Technology cons: • Poor surface finish • Low speed and accuracy compared to other processes

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Material jetting machine use a print head to jet melted materials on a building platform. After jetting, the material cool down and solidify.

Adding material layer upon layer allows to obtain a complex 3D object. Usually a print head is made of many nozzles to jet more than one material (for example the material to build the part and the material for the supports)

Material Jetting

Example:

Max2 (Solidscape)

Build Envelope: 152.4 X 152.4 X 101.6 mm (6x6x4 in.)

The Max2 is an high precision 3D machine for the manufacturing of wax patterns perfectly castable with no shrinkage.

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

(Source: 3Dprint scandinavia)

Material Jetting

When is it used? • Castings • Tooling • Metal end use parts • Colored prototypes Typical materials: photopolymers and wax Technology pros: • High accuracy • Multiple materials/colours in one process Technology cons: • Only polymers and waxes can be used

Jewels casting Material: Visijet FTX green

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Binder Jetting is an process in which a liquid binding agent is selectively deposited to join powder particles.

The object develops through the layering of powder and binder. Binder Jetting is capable of printing a variety of materials.

Some materials are typically cured and sintered and sometimes infiltrated with another material.

Hot isostatic pressing may be employed to achieve high densities in solid metals.

Binder Jetting

Example:

S- Max (ExOne)

Build envelope: 1800x1000x600mm (70.9x39.4x23.6 inches)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

When is it used? • castings • tooling • Metal end use parts • Colored prototypes

Typical materials: metal, polymers and ceramic

Technology pros: • Works with metals, polymers and ceramics • Colored parts • fast process

Technology cons: • not always suitable for structural parts, due to the use of binder

material • Significant post process work is needed

(Source: ExOne)

Binder Jetting

Component: Metallic rotor Material: stainless/bronze matrix

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

This machine uses paper sheets as starting material. On each sheet (layer) the adhesive is put in the area that will become the final part and then the contour of the section is cut. Less adhesive is put also on the rest of the sheet that has the function of support. Each sheet is put on the previous one in an iterative process.

Sheet Lamination

Example:

Matrix 300+ (Mcor Technologies)

Available materials and dimensions:

− A4 Paper: 256 x 169 x 150mm

− Letter Paper: 9.39 x 6.89 x 5.9 inches

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

When is it used? • Large parts • tooling • Non structural parts

Typical materials: paper, plastic, sheet metals

Technology pros: • Fast process • Low cost process

Technology cons: • Few materials available • Poor surface finish (lot of work to obtain good

finishing)

Sheet Lamination

Design prototype of a shoe (Source: Mcor Technologies)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

A laser beam is focused on the surface of a vat containing a liquid photocurable resin. The laser solidifies the resin selectively in thin layers according to the focus of the laser itself.

After lowering the vat and recoating the resin, the next section is reproduced and at the end of all the iterations the solid model obtained usually has to be post cured in UV chamber.

Vat Photopolymerization

Example:

ProX 950 SLA (3D Systems)

Build envelope: 650 x 750 x 550 mm (25.6 x 29.5 x 21.65 in)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

When is it used? • Form, fit function prototypes • Consumer goods (toys, electronics) • Guides, jigs and fixtures • Anatomical models • Architectural models • Investment casting patterns • Concept models • Urethane casting patterns • Wind-Tunnel Test Models

Typical materials: photopolymers

Technology cons: • Requires post processing • Limited resin availability • Relatively expensive

Vat Photopolymerization

Pitcher for hot liquids Material: Accura PEAK

(Source: 3D Systems)

Technology Pros: • High resolution • High quality parts • Relatively fast process • Large build volumes

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

The laser is focused on a powder bed and selectively melts the powder according to the geometry of the section to be obtained. At the end of the scan a new layer of powder is deposited on the top of the already finished layer and the process starts again. When the part is finished it has to be removed from a base platform and has to be finished.

Supports removal and surface finishing are most common operations to be done

Powder Bed Fusion

Example:

EOS M 400

Build envelope: 400x400x400mm (15.8x15.8x15.8 in)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

When is it used? • Structural parts • Orthopedic and dental implants • Mechanical joints, assemblies • Conformal cooling channels • Rotors and impellers

Typical materials: plastic, metals, ceramics

Technology cons:

• Low speed process • Post processing of parts (metals) • Available machines with limited

building volume • Few materials available (metals)

Powder Bed Fusion

(Source: stratasys)

Technology pros:

• Many materials available (Plastic)

• Relatively inexpensive process (plastic)

• Power acts as supporting structure

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

LENS process produces full dense metallic parts using an high energy laser source. The laser creates a molten pool on the substrate and in the mean time metallic power is injected in the pool. After solidification the next layer is produced above with the same steps.

Because of the specific process set up, LENS allows to deposit composites and functionally graded materials

Directed Energy Deposition

Example:

LENS MR-7 (Optomec)

Build envelope: 300x300x300mm

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

When is it used? • Repairing parts • Mechanical components • Structural components

Typical materials: metals (powder and wire)

Technology pros:

• Allows repairing of components • Relatively fast process

Technology cons: • Poor surface finish • Available machines with limited building volume • Limited materials available

Directed Energy Deposition

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

In the last 5 years have appeared on the market many low cost 3D printers (unit price below $5000), with a specific consumer target and so very far from the industrial «additive manufacturing» concept since they are:

• Not for professional use;

• Learning platforms for students;

• For “do it yourself” applications.

Quality and properties of the prototypes do not meet any standard.

Desktop 3D Printers

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Desktop 3D printers

Examples:

Makerbot Replicator 2X

RepRap community machine

Microprinter M3D

M3D Printer

Dimensions: It's a cube, 7.3 in (185 mm) per side

Makerbot Replicator 2X

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

AM Technologies And Materials

What kind of materials are currently used in your manufacturing process?

Are you searching for innovative and more efficient alternatives?

Let’s see the available raw materials for Additive Manufacturing.

Think About It

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

AM Technologies And Materials

Material extrusion

Material jetting

Binder jetting

Vat photopolimeriz.

Sheet lamination

Powder bed

fusion

Directed energy

deposition

Polymers, Polymers blend

x x x x x x

Composites x x x x x

Metals x x x x

Graded/Hybrid metals

x x

Ceramics x x x

Investment casting patterns

x x x x

Sand molds & cores

x x x

Source: Adapted from Wohlers Report

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Materials

Nowadays there are a more than 200 materials available to be processed by AM machines:

Metallic

Polymeric

Organic

Ceramic

Composites

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Materials

• Usually each machine manufacturer aims to obtain a sort of monopoly in the material market since beyond selling the equipment the greatest income is selling raw materials.

• Many companies develop know how in house on processing special materials so that they increase their competitiveness (since they don’t share the results of the research). Some examples:

AVIO AERO (intermetallics)

CRP Technologies (polymer composites)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Materials

Materials are the real issue today, particularly for metal technologies, since there’s the need of understanding:

• the basic science of each additive technology

• which is the microstructure coming out from certain process conditions

• how to modify/enhance the microstructure through thermal treatments

• material properties (need for a complete database)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Materials

Recently developed and available on the market:

• 3D Systems - Visijet elastomer photopolymer

• 3D Systems - FTX cast (wax resin hybrid for jewelry casting patterns)

• Envisiontec – ABS Thoug 3SP, E-Appliance (material for orthodontic modeling)

• DSM Somos – Somos perform (composite resin with high heat tolerance)

• Stratasys – Endur (polypropylene like material)

• Protoplant – PLA filaments filled with stainless steel

• Graphene 3D (and others) – graphene based polymers

• Freeformer – all materials available for injection moulding

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Materials

• Graphene Lab. Inc.

• Envision Tech.

Graphene 3D battery (Source: http://www.graphene3dlab.com )

E-Appliance nanofilled resin (Source: http://www.envisiontec.com)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Materials

Other recently developed and available on the market:

• ARCAM – Inconel 718

• ExOne – Inconel 625

• EOS – Nickel Alloy HX (Similar to Hastelloy x)

• VBN Components – Vibenite 60 (metal matrix with dispersed carbides)

VBN Vibenite 60 hollow gear hobs (Source: vbncomponents.se)

ExOne In625 component

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Applications

Industrial sector Applications

Aerospace & Defence

Structural and non structural parts, spare parts, conceptual models

Healt & Medicine Prostheses and implants, surgery and medical devices, dental implants, hearing devices

Space Lightweight structures

Automotive Conceptual models, prototyping of parts or assemblies (bumpers, wind breakers, etc.), wind tunnel protoypes

Consumer Jewelry objects, watches, customized objects, prototypes

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Applications

Future Applications:

• Nano manufacturing

• Manufacturing of tissues/biological parts/organs

• Manufacturing of bio-composites materials

• Additive manufacturing in space (for space exploration)

• Full scale manufacturing of buildings

3D printed artificial Heart Valve (Source: Cornell University)

Ad

dit

ive

Man

ufa

ctu

rin

g fo

r D

esig

n –

P1

Thinking Additive

Now that you know more about AM, do you think that it could be integrated in your manufacturing process?

In the second part of the module you will learn:

• What changes in the design approach compared to traditional methods;

• How to choose materials and technologies that prioritize the aspects most relevant to your target application;

• How to better design your products thinking additive

CHECK IT!

Thank you for your attention

www.designforenterprises.eu #Design4Enterprises

Materials and Technologies

Additive Manufacturing for Design - P1

andrea.pestarino@dappolonia.it