Advanced Manufacturing

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Additive Manufacturing

What is it?Why is it such a “hot” area?

How is UL involved?

Brent Stucker, Ph.D.Clark Chair of Computer Aided Engineering

Professor of Industrial EngineeringMechanical Engineering Associate Faculty Member

University of Louisville

ADDITIVE ADDITIVE MANUFACTURINGMANUFACTURING

What is Additive Manufacturing?(3D Printing)

• The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies

Vat Photopolymerization

• An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. – Stereolithography– Envisiontec – Micro-SLA– …

Material Jetting

• An additive manufacturing process in which droplets of build material are selectively deposited– Wax or Photopolymers– Multiple nozzles – Single nozzles– …

Binder Jetting

• An additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials. – Zcorp– Voxeljet– ProMetal/ExOne– …

Material Extrusion

• An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice– From microns to meters– Stratasys FDM machines– Office friendly– DIY community– Best selling platform– …

Powder Bed Fusion

• An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed– SLS, SLM, DMLS, EBM, etc. – Polymers, metals & ceramics

Sheet Lamination

• An additive manufacturing process in which sheets of material are bonded to form an object.– Paper (LOM)

• Using glue

– Plastic• Using glue or heat

– Metal• Using welding or bolts• Ultrasonic AM…

–Wire & Powder Materials–Lasers & Electron Beams–Great for feature addition & repair

Directed Energy Deposition

• An additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited

Engineering & Business Implications

• More Complex Geometries– Internal Features & Structures– Parts Consolidation

• Enables business models used for 2D printing, such as for photographs, to be applied to physical components– Print your parts at home, at a local

“UPS Store” or “Lowes” or order through “Amazon-like” website like Shapeways.com

Web 2.0 + AM = Factory 2.0

• User-changeable web content plus a network of AM producers is already enabling new entrepreneurial opportunities– Shapeways.com– Freedom of Creation– FigurePrints – Spore– …and more

Impact on Logistics

• Eliminates drivers to concentrate production

• “Design Anywhere / Manufacture Anywhere” is now possible– Manufacture at the point of need

rather than at lowest labor location – Changing “Just-in-Time Delivery”

to “Manufactured-on-Location Just-in-Time”

AM is Hot This Year…

• Newspapers, magazines, TV shows and technical publications have all discovered 3D printing via additive manufacturing

• President Obama & Vice-President Biden have spoken about the potential:– The first Institute within the National Network for Manufacturing

Innovation is focused on Additive Manufacturing

• DoD (DARPA), DOE, DHHS, DOC (NIST), NSF and other agencies funding R&D

• Mergers & acquisitions are in full-swing• Most major manufacturers are spinning up R&D

University of Louisville’s Involvement in AM

• One of the best equipped additive manufacturing (AM) facilities in the world

• Performing federally-funded basic and applied research, technology transfer and industry-funded projects in AM since starting with SLS in 1993

• Over 20 people focused on AM• Partner of leading AM users

– Boeing, GE, EWI, Integra, service bureaus, etc.• Over 70 member organizations in our RP Center

– Includes Haas Technical Education Center

AM Equipment at UL

• Polymer Laser Sintering (LS)– 3D Systems (DTM) 2500 plus (with

Multi-zone heating)– 3D Systems (DTM) 2500CI High

Temperature Research Platform• Multi-zone heating• High Speed Scanning

• Direct Metal Laser Sintering (DMLS)– EOS M270 Dual Mode

• Electron Beam Melting (EBM)– Arcam S400

• ExOne 3D Printing– Dental machine

• Ultrasonic Consolidation (UC)– Fabrisonic R200 High Power – Solidica Formation Beta Machine

• Laser Engineered Net Shaping– Optomec LENS 850

• Fused Deposition Modeling– Stratasys uPrint– Several desktop, educational “material

extrusion” machines • Stereolithography

– 3D Systems SLA 250/30• Direct Write

– nScrypt Direct Write head

Why Additive Manufacturing in Kentucky

• U of L has a world-leading capability in additive manufacturing– Laser and electron beam powder bed processes for metals, plastics

and ceramics– Ultrasonic additive sheet lamination and more…

• U of L and other KY institutions can educate & train the needed workforce– Entrepreneurs, designers, engineers, doctors, dentists, technicians,

etc.• The proposed Louisville/Lexington advanced manufacturing

corridor can be a catalyst

Other Louisville/Kentucky Benefits

• UPS could be a key enabler to the distributed, on-demand manufacturing model enabled by AM

• Louisville is a great hub for locating new AM companies and U.S. headquarters for foreign companies

• Louisville is a center for medical innovation

• Northern Kentucky is part of greater Cincinnati’s aerospace infrastructure

Additive Manufacturing Research at UL

• Office of Naval Research Direct Digital Manufacturing – $2.45M grant over 4 years – Investigating Material Properties of parts made using AM

• Office of Naval Research Cyber-Enabled Manufacturing Systems – $1.05M over 7 years– Ultrasonic Consolidation–related funding

• Multi-functional, multi-material parts

– Dislocation Density based Crystal Plasticity Finite Element Modeling (DDCP-FEM)

UL Research continued

• Military SBIR/STTRs – over $500k in subcontracts– High-temp SLS work in support of JSF and more– Naval scale models (magnetic signature)– Modeling of metal powder bed fusion

• Industry-funded projects– 70 members of our Rapid Prototyping Center consortium (19 years

of continuous funding)– Boeing has funded us for more than 10 years

• Dental projects– Porous titanium implants & new materials

UL Research continued:

• GE Aircraft (in contracting)– Layer-by-layer process monitoring of metal powder bed

fusion for process model and part quality validation• NIST (in contracting)

– Modeling of Inconel alloys in metal powder bed processes.

• NSF project– Applying DDCP-FEM to friction surfacing additive

manufacturing

U of L’s Vision for our Additive Manufacturing Institute

U of L Additive Manufacturing

Institute(Engineering,

Medical/Dental, Business, Logistics, etc.)Rapid

Prototyping Center(product

development for industry)

Advanced Materials &

Processes Thrusts(research/

development/modeling of machines & materials)

Bio/Medical Thrusts

(Implants, Tissue Engineering,

Dental Restorations

Medical Devices)

Conclusion

• Additive Manufacturing is poised to transform the production of “physical goods” in much the same way that the internet transformed the production of “informational goods.”

• UL is leading the way in additive manufacturing research and implementation– We are “a” world leader in AM– Targeted investment and recruiting could make us

“the” world leader in AM

Questions?

brent.stucker@louisville.edu

Advanced Manufacturing

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