Successful Applications for Additive Manufacturing

March 2, 2021

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• Attended the University of Mississippi

• B.S. Mechanical Engineering

• M.S. Materials Engineering

• Background

• Composite, Rubber, & Plastics Materials

• Injection Molding, Transfer/Compression Molding, some machining techniques, pultrusion, filament winding, and hand layup for composites

• Additive processes – SLA, SLS, FDM, some DMLS, and Carbon

• Caterpillar for 11 yrs

• worked in their Additive Manufacturing group

• Carbon for 3.5 yrs

• Production Development Engineer

• Took the knowledge from the last 5 yrs and helped develop the Carbon Design Program

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Presented by:Brittany Hancock

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Definitions

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• Additive Manufacturing – (3D printing) refers to a collection of technologies where materials are

selectively accumulated to build, grow, or increase the mass of an object layer-by-layer until a three-

dimensional object conforms to its digital model. Objects that are manufactured additively can be

found throughout the product lifecycle, from pre-production (e.g. rapid prototyping) to full-scale

production (e.g. rapid manufacturing), in addition to tooling applications and post-production

customization. ISO/ASTM 52900:2015 – Additive Manufacturing - General principles

• Application – function being performed

• Component / Part – object manufactured to perform in the application

• DLS™ - Digital Light Synthesis™ is a resin based 3d printing technology that produces engineering

grade isotropic plastic parts with good surface finish.

• Manufacturability – as referred to in the presentation – encompasses entire DLS process – print

setup (orientation & support), printing, cleaning, baking

• Manufacturing method – a way to produce a part – any part whether it’s for prototyping, functional

end use testing, or true production. Manufacturing method could be modeling in clay, machining,

molding, or additive manufacturing. Additive offers many tools for the manufacturing toolbox.

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Important Handouts

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Agenda

1. Introduction to Additive Manufacturing (AM)

2. AM Strengths

3. Successful Applications

4. Application Selection Criteria

5. How to Apply the Criteria

6. Designing for AM

7. Summary

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Brief Introduction to Additive Manufacturing

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01

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Additive Manufacturing Processes

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Relationshipwith

Customer

To learn more about these processes:• 3D Hubs – The Complete Engineering Guide 3D Printing• ISO/ASTM 52900:2015 – Additive Manufacturing - General principles• SME – Additive Manufacturing Glossary

Category Types Material

Binder jetting Plastic, Sand, Metal, Ceramic

Directed energy deposition LENS Metal

Material extrusion FDM Plastic

Material jetting Polyjet Plastic

Vat Polymerization DLP, SLA Plastic

Powder bed fusionSLS Plastic

DMLS, SLM Metal

Sheet lamination LOM Plastic

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Process Benefits

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Additive Manufacturing Strengths

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Additive Manufacturing Strengths

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Additive processes offer benefits over traditional manufacturing methods.

Manufacturing Solution

Additive vs Traditional Manufacturing

• Design Freedom• Lattices

• Textures

• Organic designs

• Easy to implement iterations and customizations• User/Patient Specific parts

• Application specific parts

• Easily produce iterations to address issues in the design

• Economic advantages - especially for low volume• Quick turn around times

• No minimum buys

• Part consolidation

Key Concept: Use the additive strengths to drive value to your project (prototypes, parts, manufacturing solutions).

Parts

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DLS™ Strengths

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To be able to decide if DLS™ manufacturing is the right process for the application, it’s important to know process’s strengths.

Design freedom allowed product team to find the perfect shape for performance.

DLS™ vs Machining/Injection Molding• Ability to produce un-moldable geometries

• Part consolidation

• Easy to implement iterations and customizations

• Economic advantages – especially for low volume

DLS™ vs Additive Technologies• Engineering grade materials• Fine features• Cosmetic surfaces• Watertight & Airtight parts with no secondary operation

Key Advantage: Carbon® technology merges engineering grade material properties with all the advantages of additive manufacturing while utilizing the same manufacturing process and material from prototyping to production!

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What makes a successful additive manufacturing

application?

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03

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Application Successes – Categorized by Value

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Design Freedom Economic Advantages Part Consolidation

Personal Customization Low Volume

Iterations & Short Deadlines

3 to 1

BIOLASE

Rails o

f Sheffield

Un-moldable Geometries

Becton, Dickinson, and Company (BD)

6 to 1

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What’s the secret?

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Recipe for success:

• Material that meets the needs of the application

• Business Case

• A team with:- A vision and inspiration

- Ability to design to the function of the component• Knowledge of the chosen application

• Knowledge of the chosen manufacturing method

- Implementation strategy

- Good relationships with customers

TEAM

Vision

Inspiration

Strategy

Design to function

Manufacturing Method

Relationshipwith

Customer

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Application Selection Method

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04

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Additive Manufacturing

Evaluation Criteria

Material Specs

ValueManufacturability

AM

$$$

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Material Selection

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Selecting a material:• Material type? Rigid or

Elastomeric

• Temperature requirements

• Chemical resistance

• Biocompatibility needs

• Mechanical performance

$$$

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Value

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Exploring the value (business case) utilizing an additive process for your application:

What strengths can be utilized?

• What design freedoms become available?

• What performance improvements could be made?

• Could the manufacturing process of the component or assembly be streamlined?

What economic advantages can be utilized with AM manufacturing?

• Can you eliminate tooling cost?

• Can you eliminate minimum order buys (quantities and cost)?

• Do you have a short timeline? Need to iterate quickly?

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Defining Advantages of DLS™ Manufacturing:• Engineering grade materials

combined with the advantages of additive

• Same material and process from beginning to end

Design Freedom Part Consolidation Economics

3 Categories of a Compelling Business Case:

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Manufacturability

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DLS™ Manufacturability Specific Factors:• Quantity on build platform

• Post Processing- Support removal

- Cleaning

- Baking

$$$

Manufacturability encompasses the entire process of physically producing the part/component including printing and post processing (cleaning and bake).

The part design can greatly affect this category of the evaluation. Design principles for the process chosen can be applied to create a manufacturable part.

Does the part fit in the build envelop?

Can the part be optimized for the process?

Z

X Y

M2

X189 mm(7.4 in)

Y118 mm (4.6 in)

Z326 mm(12.8 in)

~50 mm

~80 mm

~25 mm

For Production Application:

• Ideally ~10 to 20 parts to build

LEGACY6-PART DESIGN

Tens of thousand deployed in stores across U.S

NEW SINGLE-PART DESIGN

DLS

™ E

xam

ple

Approximate part Size:

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Applying the Application Selection Method

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What you need:

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Identifying Good Fits for AM

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Part Consideration

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Good Fits for AM

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Customization

Un-moldable GeometriesFine features

Design Freedom Part Consolidation Economics

3 Categories of a Compelling Business Case:

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Not a fit for AM

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Locked designs

Parts easily made by other processes

High volumes

High dimensional accuracy

Simple geometries

Material requirements

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Designing for Additive Manufacturing

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Design Principles

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Principles:

• Consistent wall thickness

• Gradual geometry changes

• No trapped volumes

• Self supporting

• CleanabilityARaymond Case Study

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Design Principles – Why apply

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Reasons to apply the design principles:

• Design to function can provide market advantage

• Eliminating human error

- Reducing handling time to post process (support removal, cleaning, baking preparation)

• Helps remove variation and creates a more repeatable process

• Minimizing cost to produce

- Reduction in development time

- Reduction in potential defects

$$$

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Recommended Minimum Feature Sizes

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Other:

• Radius – 0.5 mm (min, I prefer 1 mm)

• Fillets – Exterior corners - 0.5 mm + wall thickness

• Minimum thread size = M4

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Consistent Wall Thickness

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Consistent Wall Thickness Reduces:

• Warping

• Shrink lines

• Large changes in print forces

- Heat

- Suction

- Resin flow

Concept

Design Recommendations:

• The same wall thickness throughout the part is not always possible, in this case make the thickness change very gradual. Curves and organic changes from thick to thin.

• For walls at minimum thickness, keep the height as short as possible.

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Gradual Geometry Changes

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Gradual Geometry Changes reduces:

• Warping

• Resin flow bands

• Shrink lines

• Internal stresses that can cause failure points (example: cracking in bake

• Sagging during bake

• Large changes in print forces during print

Concept

Applications

Gradual geometry changes rule of thumb:

• No sharp edges or corners

- Use radius, fillets, chamfers

• Remember the parts are growing from a liquid resin, therefore the parts can be more organic. Use curves and natural changes from thick to thin to make geometry changes instead of steps, corners.

• Apply gradual geometry changes in all directions of the part, not just the printing direction.

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Gradual Geometry Changes

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Design Recommendation:For a given rise T, the transition should run at least T x 2.• Ex: A rise of 3.0 mm would require a 6.0mm run from the base level to the new level.• More gradual transitions are even better.• Keep the maximum overhang angle of 40 degrees in mind as it may come into play

depending on part orientation.T

T X 2Application Example

Design Recommendation

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Self Supporting

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Self supporting parts eliminates/reduces:

• Material usage

• Shift lines

• Handling time after print

• Cleaning

BD – Case Study on how this part was designed

Design Recommendations:

• Use fillets, chamfers to help transition the edges

• Support bosses and other overhang geometries with gussets

• Self supporting can also mean filling in space fillers and brining parts to meet the platform

Requires manual supportsHarder to clean

Original DLS Design

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No trapped volumes

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Venting all volumes will:

• Eliminates suction forces during printing

• High suction forces can cause:

- parts to fall off the platform

- print defects such as holes delamination

- warping during bake due to internal stresses

• Improve cleanability of parts

Section through

example part

LOW PRESSURE

HIGH PRESSURE

Design recommendation:

• Vent volumes with minimum 2 to 3 mm vent holes

• May require more than 1 vent hole

• Vent blind holes for improved cleanability

Unvented Volume Examples

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Cleanability

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Parts that are easy to clean eliminate/reduce:

• Handling time after print

• Human error

• Scrap

• Part inconsistency

• Part overexposure to solvent

Design recommendation:

• Vent all trapped volumes

• Vent blind holes

• Use gradual geometry changes

• No sharp edges – especially internal corners

• Feature spacing – use the bridge and overhand distance as a good starting point

• Self supporting where possible

Salt baked into a part

Resin trapped on part

Application Example

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Example Part - Housing

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These parts were designed for DLS™ technology.

Can you pick out the features?

Prin

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Platform Platform

Prin

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Summary

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Design Summary

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Design Principles:

• Consistent wall thickness

• Gradual geometry changes

• No trapped volumes

• Self supporting

• Cleanability

Design tips to support the principles:

• No sharp edges/corners

• Bring the part to meet the build platform

• Use organic/natural designs

DLS™ specific tips:

• Tie thin/delicate features into your part for stability in bake

• Feature spacing use the maximum overhang or bridge distance

• Threaded holes and metal inserts are usable with Carbon®

When possible design to the function of the application. Try to utilize the design freedoms that additive offers.

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Application Selection Method – Important Concepts

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Strengths:Additive vs Traditional Methods• Ability to produce un-moldable geometries

and textures

• Part consolidation

• Easy to implement iterations and customizations (User and Patient Specific)

• Economic advantages – especially for low volume

DLS™ vs Additive Technologies• Engineering grade materials• Fine features – Logos, Threads• Cosmetic surfaces• Watertight & Airtight parts with no

secondary operation

Material Specs

ValueManufacturability

AM

$$$

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Carbon Website – www.carbon3d.com

• Handouts

• Engineering Handbook

• DLS ™ Design Quick Guide

• Materials

• Technical datasheets available under each material family

• Inspiration

• Meet the Additive MVPs

• Want to learn more?

• Webinars

• Ask an Additive Expert

• Case Studies

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Carbon®Resources

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Online Basics:

Free

• 3D Hubs – The Complete Engineering Guide 3D Printing

• ASME Resources - Resources

• ISO/ASTM 52900:2015 – Additive Manufacturing -General principles

• SME – Additive Manufacturing Glossary

Paid course

• MIT – Additive Manufacturing for Innovative Design and Production

• UL – Additive Manufacturing Training and Education

Certifications:

• SME – Additive Manufacturing Certifications

• Barnes Global Advisors – Additive Manufacturing Certificates for Engineers and Business Professionals

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Other places for training

Thank you