Coatings that make Additive Manufacturing Work

Technology Overview February 27, 2017 1

Background

Expertise in coatings as applied in the additive manufacturing process.

Member of Composite Applications Group Consortium, Oak Ridge Carbon Fiber Composites Consortium, and supporting member Institute for Advanced Composites Manufacturing Innovation (IACMI).

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You May Have Seen the 2015 CAMX Combined Strength Award Winning Printed Shelby Cobra

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Or The Printed Willys Jeep Body

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Maybe Even The Printed F-22

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Or The Printed House & Utility Vehicle

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ORNL Receives Award For Worlds Largest 3D Printed Object Additive Manufacturing

Researchers at Oak Ridge National Laboratory have additively manufactured the worlds largest solid 3D printed component. The part took about 30 hours to print, is 17.5 long x 5 wide x 1.5 tall and weighs about 1,650 lbs.

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Guinness World Record Additive Tool

MachinedTDCoatRTSurface

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Digitally Manufactured Molds Successfully Withstand Autoclave High Temperature Tooling

Researchers at the MDF- along with 8 industry partners successfully tested digitally manufactured, high temperature thermoplastic molds that withstood industrial autoclave cycles for the first time ever!

Digitally Manufactured Molds Successfully Withstand Autoclave High Temperature Tooling

CAMX 2016 ACE Award Winning Autoclave Tool featuring our TD Seal HT coating.

TD Coat RT 11

As-printed Substrates Are Imperfect

Near-net as printed Dimensional changes result

from thermal effects Print artifacts such as start /

stops, flow instability and slicing issues/irregularities

Near-net as machined Voids Broken or lost beads

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TD Coat RT Allows Rapid Low-Cost Solution To Print Defects High-build sprayable 2 component thermoset

coating formulated for adhesion to the carbon fiber filled ABS material most commonly used in BAAM printers

Spray equipment development nearly complete Adhesion testing conducted per ASTM D4541

Addresses print defects with low labor investment

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TD Coat RT Sprays Easily

Sprayable on surfaces at most angles

Low sag Generally sets within

20 minutes of application

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TD Coat RT Sprays Easily

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TD Coat RT Post-Processing Options

Provides stable uniform surface while addressing many print artifacts.

Machines easily Low dust generation

Repairable

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TD Coat RT Post-Processing Continued

Cosmetic parts will require a primer before painting for a Class-A surface

Tooling gel can be applied immediately or after machining when working with dimensional tolerance constraints

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TD Coat RT Fits Into Existing Workflows

Additively manufactured tools seamlessly fit into existing shop work flow keeping current mold maintenance processes unchanged.

Repairs to tool surface are standard no special steps are required

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TD Coat RT on Cincinna- Inc. Cobra Replica

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Print for TD Coat RT Applica-on Guidelines Cosme?cPrototypes

Printundersized0.100forthecosme?careasunlesstoleranceongeometryislargerthan0.100

ThisguidancealsocoversitemsforClassAfinishes

DimensionalParts Printwithan0.250insetsurfaceforthecoatedareas. Coa?ngwillbeappliedin0.5thicknessandreturnedformachiningprovidingyouwith0.25stock.

Iden?fyareaswhereprin?ngneedsaddi?onalbuild-uptopermitcuQnggeometrynotefficienttoprint.

Mustaddressregistra?onneedspostcoa?ngattheoutset.

Needgraphicaldocumenta?onofthesurfacesthatrequirecoa?ngtoguidethoseapplyingthecoa?ngs

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TD Seal HT 21

Coating Process Adopted for ACE Award Winning Printed Tool

Spray Apply TD Seal HT Sand and finish Prep as usual with composite mold

sealer and mold release Resulting ACE Award Winning tool

and part on display at CAMX 2016

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Applying TD Seal HT

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