Dr. Thomas BüsgenBayer MaterialScience AG
Plastics for Additive Manufacturing
20th November 2013, 3D Printing & Additive Manufacturing Industrial Applications Summit 2013, London
Sources: voxeljet, Materialise NV, Iris van Herpen
Bayer MaterialScienceProducts and Solutions
PolyurethanesRaw materials for rigid
and flexible foams
Polycarbonates Granules and sheets for a wide variety of applications
Basic chemicalsChlorine production as the backbone for product manufacture
One of the world's leading polymer producers
CoatingsRaw materials for coatings,
adhesives and specialties
High-performance materials for a changing world. Page 2 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London
20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Bayer MaterialScienceInnovations
Page 3
Research for tomorrow´s worldGlobal teams of inventors at Bayer MaterialScience develop new applications for materials and participate to design the future.
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
UV lamp
Photopolymer
Laser
Thermoplast
Plastics for Additive Manufacturing Material selection strongly depends on AM process
Liquid adhesive
Inkjetprint head
Stereolithography
Jetted Photopolymer
Binder Jetting
Selective Laser-Sintering
Fused Deposition Modeling
Low viscous polymer ink Very fine powders
Photo-curable resins Thermoplasts
Filaments
Page 4
Source: custompart.net
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
StereolithographyProcess:Highly focused UV laser traces out successive cross-sections in a vat of liquid photo-polymer�• Curing and solidification by laser�• Post-curing in UV oven Accura
PEAKAccura 60
VisiJetEX200
AccuraAmethyst
AccuraCeraMAX
0
20
40
60
80
100
0 50 100 150 200 250
Tens
ile s
treng
th (M
Pa)
Max. working temperature (°C)
Currently available for AM
Page 5
Source: custompart.net
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Jetted PhotopolymerProcess:Photo-Polymers (build + support material) �• Printed by inkjet head�• cured by UV lamp
UV lamp
Photo
polymer
Currently available for AM
Vero
Tango
VisiJet
0
20
40
60
80
100
0 50 100 150 200 250
Tens
ile s
treng
th (M
Pa)
Max. working temperature (°C)
Page 6
Source: custompart.net
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Binder jettingProcess:Powder bed consisting of polymer, ceramic or metallic particles, respectively �• Jetting of polymer binder�• Subsequent infiltration possible
Liquid adhesive
Inkjetprint head
Currently available for AM
PMMA
ZP 131
Steel infiltr. w/ bronze
0
20
40
60
80
100
0 50 100 150 200 250
InfiltrationTe
nsile
stre
ngth
(MP
a)
Max. working temperature (°C)
3D Systems (ZCorp)
voxeljet
Source: custompart.net
Page 7 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Binder jettingProcess:Powder bed consisting of polymer, ceramic or metallic particles, respectively �• Jetting of polymer binder�• Subsequent infiltration possible
Liquid adhesive
Inkjetprint head
Currently available for AM
PMMA
ZP 131
Steel infiltr. w/ bronze
0
20
40
60
80
100
0 50 100 150 200 250
InfiltrationTe
nsile
stre
ngth
(MP
a)
Max. working temperature (°C)
3D Systems (ZCorp)
voxeljet
500
Source: custompart.net
Page 8 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
PEI
0
20
40
60
80
100
0 50 100 150 200 250
ABS
PC
PEI
PPSFPLA
0
20
40
60
80
100
0 50 100 150 200 250
Process:Filaments of thermoplasts �• 3 mm diameter�• build + support materials�• heated and applied as thin
fibers on a x-y-stage
Fused Deposition Modeling (FDM)Currently available for AM
Page 9
Source: custompart.net
Tens
ile s
treng
th (M
Pa)
Max. working temperature (°C)
Polyphenyl-sulfone
Polyether-imid
Injection molded
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Polyether-etherketone
PA11PS
PEEK
PP
0
20
40
60
80
100
0 50 100 150 200 250
PA11
PS
PEEK
PP
PA12
DuraFormFlex0
20
40
60
80
100
0 50 100 150 200 250
Selective Laser-Sintering (SLS)
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Process:Powder of thermoplastic polymer �• ~ 100 µm particles�• pre-heated just below Tmelt
�• laser-sintered layer-by-layer
Biobased material
Max. working temperature (°C)
Currently available for AM
Laser
Thermoplast
Tens
ile s
treng
th (M
Pa)
Source: custompart.net
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Polyether-etherketone
PA11PS
PEEK
PP
0
20
40
60
80
100
0 50 100 150 200 250
PA11
PS
PEEK
PP
PA12
DuraFormFlex0
20
40
60
80
100
0 50 100 150 200 250
Selective Laser-Sintering (SLS)
Page 11
Process:Powder of thermoplastic polymer �• ~ 100 µm particles�• pre-heated just below Tmelt
�• laser-sintered layer-by-layer
Biobased material
PA11PEEK
EOS Stainless
steel
EOS Cobalt
Chrome
0
200
400
600
800
1000
1200
1400
0 250 500 750 1000 1250Max. working temperature (°C)
Currently available for AM
Laser
Thermoplast
Tens
ile s
treng
th (M
Pa)
Source: custompart.net
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
Cost ComparisonMaterials for AM vs. conventional
SLA Photopolymer resins ~ 175 to 225 $/kg
PolyJet photopolymers ~ 100 to 300 $/kg
SLS powders (PA12) ~ 85 to 100 $/kg
FDM personal 3D printers ~ 15 to 50 $/kg
FDM professional (ABS, PC) ~ 250 $/kg
FDM (PEEK, PEI) > 500 $/kg ABS ~ 2 $/kg
PC ~ 3 $/kg
PA6 ~ 3 $/kg
PA11 7 �– 13 $/kg
PEI 15 �– 20 $/kg
PEEK 34 �– 68 $/kg
Sources:Wohler�’s Report 2013, plasticker.de
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AGPage 12
Summary Material Selection for AM�• All additive manufacturing processes
require specific material classes
�• Final material properties very dependent on used AM technology
�• Usually anisotropic material properties due to layered building
�• Additive Manufactured parts do not match properties of injection molded ones, yet
Today main application in rapid prototyping, visual aids, art,�…
Need for: larger choice in polymer material and properties (e.g. elastic)Scalable processes and competitive prizes
Sources: 3D Systems, voxeljet
Page 13 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG
New Developments:3D printing from polymer pellets
Arburg presents Freeformer
�• Combination of injection molding and FDM technology
�• Uses any kind of thermoplastic pellets (no filament)
�• Printing of several materials
�• No support material by 5 axis building
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AGPage 14
Sources: Arburg.com
New Developments:First Fully-functional Flexible Material in 3D Printing
�• Basis: Thermoplastic Polyurethane (Desmopan®, Bayer MaterialScience)
�• Milled into fine powder of ~100 µm (Desmosint® TPU 92A-1, Lehmann&Voss)
�• Selective Laser-Sintering
Unique properties for AM material:Durable elasticity
High tear resistance
High resistance to dynamic loading
High abrasive resistance
Snappy response
Good temperature range (-20 to 80 °C)
Elongation at break >350 %Sources: Lehmann&Voss, Materialise NV, Iris van Herpen
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AGPage 15
Thomas BüsgenSenior project leader 3D digital printing New Applications EMEABMS-CAS-INN-NAEMEA51368 Leverkusen, Building Q 1+49 214 30 48654 [email protected]
Thank you
3D-Printed Bayer crossSize: 4 cm in diameter, 1.5 mm in height
Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG