2013 03-12-masterclass-biomedical-applications-of-am sirris-trends

Additive Manufacturing – Market, Trends and Future

Thierry Dormal

Motor vehicles 20%

Aerospace 12%

Industrial/business machines 11%

Consumer products/electronics

20%

Medical/dental 15%

Academic institutions 8%

Military 6%

Architectural 3%

Other: 5%

AM business - World repartition

Source : Wohlers 2011

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Sirris 29 %

Sirris 22 %

Organized by SIRRIS the 12th of March 2013 Masterclass: Biomedical applications of Additive Manufacturing

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Trends for AM & 3DPrinting

• Aerospace : large interest to evaluate AM technologies and start

standardisation & certification (Airbus, ESA,..) • Mega scale free-form of buildings: D-shape (granular sands) • 3D printing of nanostructures • 3D bio-printing (organs & tissues) • Conductive materials incorporated into layered composites

radar absorbing materials

• Cost of 3D printers down to 500 € but also up to > 1 M€ • Large companies coming on the AM market: HP with FDM, Fujifilm with Dimatix (DMP) for solar cells,…


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Low cost 3D printers • > 120 3D printers available • Mostly based on FDM, FFF

• From 400 to 1000 €


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Low cost 3D printers • > 120 3D printers available • Mostly based on FDM, FFF

• From 1000 to 2000 €


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Low cost 3D printers • > 120 3D printers available • Mostly based on FDM, SLA, DLP

• 2000 – 7000 €


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Large systems : Voxeljet: up to 4 meters.


VX4000

Voxeljet: Sand & plastic. 600 dpi. 26560 DOD jets. 67 h. for 1000mm (15 mm/h)


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The future of Additive Manufacturing

• Three different ways of using AM technologies

• Prototyping for visual models or functional parts

• Direct production of parts (light redesign, only validation)

• Direct production of parts redesigned for AM

(no way back to conventional production)


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Additive Manufacturing Limitations

• Geometrical limitations: • Wall thickness: 0.3 mm – 1.5 mm • Length of internal channels (powder removal) • Max. size: 100 mm 4000 mm.

• Anisotropy (axe Z) for some mechanical properties • Surface quality (layer thickness, orientation) • Support structures for 3D building with some AM techniques.

(generation, building, removal)

• Some understanding of the AM processes are required for

• The designer (dimensioning, resolution, wall thickness)

• The manufacturer (part orientation, support generation, shrinkage factor, warping)


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Geometrical Complexity (Polymers)

• No tool required for series production: • No draft angle required for demouldability • No mould filling problems

Freedom of Creation Hettich: Rotolavit Blood centrifuge (< 1.000 units / year) 30 % less expensive than with injection moulding 32 components 3 components (2 with LS, 1 with IM) Manufacturing on demand (customization)


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Geometrical Complexity (metal)

• No tool required for series production: • No draft angle required for demouldability • Internal walls and details

Wim Delvoye / 3DP metal SIRRIS Steel part (Concept Laser)


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Less components - Assembly reduction

• Redesign of a laser collimator for space app.: • 13 components 2 components • Cooling system and geometry optimization


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Integration of functions

• Integration of snap fits, hinges,...

EBM - Oak Ridge National Lab

EOS

Materialise MGX


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Integration of functions

• The design of a complex part with several local functions (spring effect, damping effect) usually requires the assembly of components in different materials.

• With AM, this is possible in one step with bi-material process like the Connex machine (Objet)

Connex (Objet)


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Lightweight parts – Lattices structures

• Weight reduction using lattices structures with minimal strength reduction • Local variation of lattice types

graded porosity • Shock damping, vibration reduction • Biomedical implants: bone regeneration


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Lightweight parts - Topology optimization

• Automated design based on the applied constraints (Topol) • Same mechanical properties

SIRRIS redesign (Compolight)


Free space definition

Efforts repartition

STL file

Smoothing or redesign based on the STL geometry

Flying Cam example (Compolight project)

Stress verification

Lightweight parts - Topology optimization


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Customization – unique parts & short series

• Unique parts for art, aerospace, biomedical applications

• Mass customization: variants for each

country

Hearing aids


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• Olaf Diegel (Massey University)

Design: presets or user defined No AM for head, neck & frets


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Aline Salmon 3DP metal (Sirris)

Sac féminin haut de gamme YAMM (200 parts) Anne Valérie Bribosia 3DP metal (Sirris)


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3D surface texturing

• Library of texturing types available for the designer • Stone, wood, marble, leather, … • Visual effect as well as adherence & special grip


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4 injection moulds produced with & without conformal cooling channels

Conformal cooling channels - Hipermoulding project

∅4 mm

Drastic reduction of the cycle time (up to 35%) Enhancement of part quality Enhancement of tool lifetime Profitability up to 200.000 euros/year (prod. 6 Mparts)


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Catamaran (Hydrauvision) – Compolight project

Hydraulic units with complex internal channels Reduction of the weight and size of the original part 3DP Prometal (Sirris)


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Functionaly Graded Materials

Example with Ti alloys (source OPTOMEC): 3 different Ti alloys with 3

specific functions: impact resistance, fatigue and creep


• AM : huge design freedom • Some limitations / guidelines need to be known • AM should be considered from the product conception phase • An efficient design for AM allows to use these products as end

products rather than prototypes

• AM maturity: large range of cost, performance & applications


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Additive Manufacturing

Thanks

Contact: Thierry Dormal [email protected]


Date post:	18-Nov-2014
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2013 03-12-masterclass-biomedical-applications-of-am sirris-trends

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