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Matthew GriffinDirector of Community Development, Ultimaker [email protected]
Design for FFF 3D Printing
Matthew Griffin
Most common
forms1) Extrusion-based2) Vat photo polymerization3) Powder bed fusion4) Direct energy deposition5) Binder jetting6) Material Jetting7) Sheet lamination
FFF (FDM)SLA
SLS
Most CommonTechnology
Today
Extrusion-based
FFF (FDM)
Aesthetics• Is it a visual product?• What surfaces will be visible?
1h 46min0.8 Nozzle0.3 Layer height
3h 47min0.4 Nozzle0.2 Layer height
7h 27min0.4 Nozzle0.1 Layer height
Product requirements
Why important? Product design process Efficiency – Less iterations Material choice Get the product you have in mind
What questions to ask yourself?
Tension load to layersPart is weaker
Bending load to layersPart is stronger
Tension load parallel to layersPart is weaker
Tension load parallel to layersPart is stronger
Strength, hardness & wear• Is there a load on the product?• Where is the load applied on your product?• When in use, will the part wear?
Current research into Cura settings priorities for certainapplications
Strength
Visual Aspect
Productivity
Dimensional Accuracy
Product Development Manufacturing aids
Standard UM profile Architecture
FinalParts
Also think of…• Accuracy• Operating environment• Ergonomics• Post processing• Assembly• Etc…
1. Nozzle diameter2. Bottom layer3. Support material4. Small details5. Tolerances6. Fast printing7. Modularity
1 2
3
4
5
6
7
• Smaller diameter for high detail printing• Smaller diameter for sharper corners• Minimum wall thickness should be the same
or bigger than the diameter of your nozzle• Fast print -> Design for the right nozzle
Try to avoid fillets onto the build plate
Chamfers are more recommended
Bottom layer surfaceThe bigger the more surface
for adhesion
Try to avoid sharp edges
To avoid warping
Guidelines for Design Features
16
Combining chamfers and fillets for FFF
https://www.fictiv.com/hwg/fabricate/gdt-101-an-introduction-to-geometric-dimensioning-and-tolerancing
Chamfer
Fillet> 45 °
Support materialnot needed
< 45 °Support materialadvised
> 45 °Support material
not needed
< 45 °Support materialadvised
• Try to avoid bridging• If needed, the shorter the better• Use support material if bridge is too big
• Add chamfer if possible
Guidelines for Design Features
19
Ribs and Gussets for additional strength
https://www.fictiv.com/hwg/design/best-practices-for-adding-ribs-and-gussets-to-3d-printed-parts-for-structura l-integrity
Highest load = 12,36 MPa Highest load = 7,67 MpaDecrease of 38 %
Increase load distribution in all directions
Guidelines for Design Features
20
Add ribs and gussets for increased stiffness and strength
https://www.fictiv.com/hwg/design/best-practices-for-adding-ribs-and-gussets-to-3d-printed-parts-for-structura l-integrity
• Use a smaller nozzle diameter• Give the print more time to cool
• Add prime tower• Print multiple parts at once• Minimum layer time• Lift head
• Shrinkage of material filament
How to optimise?• Perform printing tests before
printing the whole model (dimensions)
• Also, think of: Thickness of bottom and top layers• Check calculated print time in Ultimaker Cura
Play with nozzle diameter Use a lower infill percentage Set a bigger layer height in Cura
• Print faster with the use of multiple printers• Bigger models possible than the build volume of the printer• Easy to replace a part (think of wear for example)• Combination of different materials• Iteration on one part at a time
Matthew GriffinDirector of Community Development, Ultimaker [email protected]
3D PrintingMaterials Overview
The S5 Pro Bundle
PLA
▪ Biggest variety of colors▪ Good tensile strength
TPU 95A
▪ High flexibility▪ High impact strength
Nylon
▪ Wear/corrosion resistant▪ High impact strength
PC
▪ High hardness (shore D)▪ Heat resistance up to 110°C
PP
▪ Chemical resistance▪ Fatigue resistance
CPE+
▪ Heat resistance up to 100°C▪ Increased impact strength
ABS
▪ High durability▪ High toughness
CPE
▪ Chemical resistance▪ High toughness
PVA Breakaway▪ Design freedom with
more materials▪ Time and cost-effective
• Water soluble• Easy to print complex
geometries
Materials Properties Reference Overview
Start partnering with materialcompanies to lower barrier for introducing relevant new materials.
UM Print Profile Assistant
Chemical Companies use print profile assistant to make tuned 3rd party profile based on baseline
UM Cura Marketplace
Ultimaker providesBaseline profiles
Material Partners
COMMERCIAL
HIGH PERFORMANCE THERMOPLASTICS
COMMODITY THERMOPLASTICS
AMORPHOUS SEMICRYSTALLINE
PC/ABS
PEEKPI
PES
PSUPPA
PEI
PE
PVC
mPPO
PS
POM
PC/PBT
PA6PA66
PETPTPC
PVDF
PA6/66
PC
ABSASA
PP
TPUPETG
SAN
PLAPVA
AMORPHOUS SEMI CRYSTALLINES
COMING SOON
Co-polyester (incl. PETG) Standard Reinforced (CF, CNT) Functionalized (ESD)
ABS
PC
HT Co-polyesterPVDFPET
Reinforced (CF)
Elastomers TPU/TPC/TPE ( 85A-100A)
PA ( 6/66, 6 & 12) Standard Reinforced (GF, CF) Functionalized (FR)
PP Standard Reinforced (GF)
ENGINEERING THERMOPLASTICS
PLA Standard Functionalized (tough)
PEKK
PCT
PMMA
IN DEVELOPMENT
PA12
PPSPC/ABS
PMMA ASA
Material Alliance Portfolio
The answer for any requirement existsTo narrow down the material possibilities
Impact resistantTemperature resistant Chemical resistantHigh stiffness Biocompatibility
ESDFlame Retardant Flexibility Optical Clarity Wear resistant
Aesthetic / Visual Food Contact Recycled Post processable Support
Key considerationsTo narrow down the material possibilities
ESD Safe materials:3DXSTAT ESD PETGClariant PC ESDClariant PC+ABS ESDClariant PET-G ESDJabil PET-G ESDJabil TPU ESDKimya ABS ESDLehvoss Luvocom PAHT CF ESD
Flame Retardant materials:BASF Inno FRClariant PA6/66 FRClariant PA6/66-GF20 FRClariant PA6/66-GF20 FR LS (certified)DSM NovamidAM 1030 FR (UL certified)Solef® PVDF AM filament
High Impact resistant materials3R3DTM ABS ELIX HIAll regular PP materialsBASF TPU 85AClariant PLA-HI-GF10Matterhackers NylonGMatterhackers NylonXUltimaker TPU 95ALubrizol ESTANE® 3D TPU F70D-065
(High) Temperature resistant materialsArkema FluorX PVDF (150 ºC)BASF PAHT CF15 (150-180 ºC)BASF PP-GF30DSM Arnitel HT TPC 61D (175-190 ºC)DSM Novamid CF10 (150-180 ºC)DSM Novamid 1070 (150 ºC)DuPont Zytel CF20 (150 ºC)DuPont Zytel GF30 (150 ºC)Lehvoss PaHT CF (150-180 ºC)Luvocom 3F PaHT (120-160 ºC)Luvcom 3F PET CF (125 ºC)Matterhackers NylonG (up to 160 ºC)Polymaker CoPA (180 ºC)Polymaker Pa6-CF (180 ºC)ProtoPasta HTPLA (155 ºC)Ensinger PA 6 GF30 black (150 ºC)Solef® PVDF AM filament (130 ºC)Lubrizol ESTANE® F94A-055
Biocompatible materials3R3DTM ABS ELIX FCArkema FluorX PVDFCopper3D PLActiveDSM Arnitel TPC 34DFibreTuff Medical grade filamentHuntsman IROPRINT F 80213 TPU85ANile Polymers Fluorinar-C PVDF
Food Contact Approved materials3R3DTM ABS ELIX FCCopper3D PLActiveFacilan HTIgus Iglidur I150
Flexible materials:Arkema/3DXFlex TPE 92-95ABASF Ultrafuse TPU 80A LFBASF Ultrafuse TPU 85AClariant TPU 85AClariant TPU 95ADSM Arnitel HT TPC 61DDuPont Hytrel TPE 60DDSM Arnitel TPC 34DHuntsman IROPRINT F 80213 Neutral TPU85AUltimaker TPU 95ALubrizol ESTANE® 3D TPU F70D-065 Lubrizol ESTANE® 3D TPU F94A-055Lubrizol ESTANE® 3D TPU F98A-030
Key considerationsTo narrow down the material possibilities
Chemical resistant materialsArkema FluorX PVDFBASF PAHT CF15BASF PPGF 30BASF Ultrafuse TPU 85AClariant PET-GClariant PPDSM Arnitel TPC 34DDuPont Zytel CF20DuPont Zytel GF30Nile Polymers Fluorinar-C PVDFJabil PET-GOwens Corning XSTRAND GF30-PPPush Plastic PC-PBTSolef® PVDF AM filamentUltimaker PPUltimaker CPEUltimaker CPE+Ultimaker TPU 95A
High Stiffness materials3D Universe Nylon CF3DXTech CarbonX CF-Nylon Gen 3BASF PAHT CF15BASF PET CF15BASF PPGF 30Clariant PA6/66-GF20 FRClariant PC+ABS GF15Colorfabb XT-CF20DuPont Zytel CF20DuPont Zytel GF30Ensinger TECAMID PA 6 GF30eSUN ePA-CFJabil PETG ESDLehvoss Luvocom 3F PAHT CF15Lehvoss Luvocom 3F PET CF15Matterhackers NylonGMatterhackers NylonXOwens Corning XSTRAND GF30-PP Owens Corning XSTRAND GF30-PA6Polymaker Polymide PA6-CFPush Plastic PC-PBTVartega VartegaFil ABS CF5-10% recycled
UV resistant materials3DXTech 3DXMAX ASAArkema FluorX PVDFBASF PPGF 30DSM ArnitelID2045Filamentive ASAFormfutura ApolloX ASALehvoss Luvocom 3F PET CF15Lubrizol ESTANE® 3D TPU F70D-065Mitsubishi Chemical 3Diakon PMMANile Polymers Fluorinar-C PVDFSolef® PVDF AM filament
Recycled materialsFillamentive ASAFillamentive rPETgFillamentive rPLAFishy Filaments Porthcurno PA6Kimya PLA-RReflow rPETGVartega VartegaFil ABS CF5-10% recycled
Key considerationsTo narrow down the material possibilities
Wear Resistant materialsArkema FluorX PVDFBASF Ultrafuse TPU 85AFluorinar-C PVDFIgus Iglidur I150Igus Iglidur I180Nile Polymers Fluorinar-C PVDFOwens Corning XSTRAND GF30-PA6Polymaker CoPASolef® PVDF AM filament
Aesthetic / Visual materials3D4Makers Facilan C8ColorFabb Color on DemandColorfabb WoodfillFibreTuff Bone-like filamentFormfutura Galaxy PLAFormfutura StonefilProto-Pasta Brass / Bronze / Copper Composite HTPLAProto-Pasta Magnetic Iron PLAProto-Pasta Stainless Steel PLAProto-Pasta Translucent / Sparkly HTPLAThe Virtual Foundry Copper Filamet
Optical Clarity materials (transparency)eSUN PETGClariant PETMitsubishi Chemical 3Diakon PMMAMitsubishi Chemical DURABIOTaulmann TGLASEUltimaker CPE / CPE+Lubrizol ESTANE® 3D TPU F70D-065Lubrizol ESTANE® 3D TPU F98A-030
Post Processable materialsBASF Ultrafuse 316LFibreTuff Bone-like filamentPolymaker PolycastPolymaker PolysmoothThe Virtual Foundry Copper Filamet
Support materialsInfinite solutions Aquasys 120Matterhackers IonicUltimaker PVA
Higher Temp Support
