Rapid Prototyping Technologies

• What is Rapid Prototyping• RP Technologies• Applications• How machine looks & Specs• Aero Engines• Pros & Corns • Conclusion

What is Rapid Prototyping

• 3D printing is a process of making three dimensional solid objects from a digital file, typically by laying down many successive thin layers of a material.

• Also known as Additive Manufacturing (AM), Rapid Prototyping (RP), Solid freeform fabrication, etc.,

• The technology for printing physical 3D objects from digital data was first developed by Charles Hull in 1984.

• He named the technique stereolithography and obtained a patent for the technique in 1986.

• The same year, he founded 3D Systems and developed the first commercial 3D Printing machine.

• How Nature buildsLarge 10 1 m

Small 10 -9 m

Technologies

Selective laser sintering (SLS) /Melting (SLM)

Stereo lithography (SL)

Fused deposition modeling (FDM)

Laminated object manufacturing (LOM )

Materials Options for 3D Printing

Metallic materials – Plain Carbon Steel, Tool Steel, Stainless steel, Aluminium, Copper, Titanium, Bronze, Nickel Alumides

Polymers and Polymeric Composites - ABS, Nylon (Polyamide), Polycarbonate, PP, Epoxies, Glass filled polyamide, Windform, Polystyrene, Polyester, Polyphenylesulfone

Others - Sand, Ceramics, Elastomers, Tungsten, Wax, Starch, Plaster

Bio Compatible Materials - Polycaprolactone (PCL), polypropylene-tricalcium phosphate, (PP-TCP), PCL-hydroxyapatite (HA), polyetheretherketone-hydroxyapatite, (PEEK-HA), tetracalcium phosphate (TTCP), beta – tricalcium phosphate (TCP), Polymethyl methacrylate (PMMA)

Prototyping technologies and their base materials

• 3D Printing (3DP): Various materials, including resins

• 3D Ceramic Printing: Various clay and ceramic materials

• Selective laser sintering (SLS): Thermoplastics, metals, sand and glass

• Fused Deposition Modeling (FDM): Thermoplastics• Stereolithography (SL): Photopolymer• Laminated object manufacturing: Laminate sheets,

often paper, and glue• Electron Beam Melting (EBM): Titanium alloys

Selective Laser Sintering

• This is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal, ceramic or glass powder into the desired 3-D shape.

• The laser selectively fuses the material by scanning cross sections generated from a 3-D digital description of the part, for example a CAD file.

Fused Deposition Modeling

• FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle. The nozzle is heated to melt the material and can be moved horizontally and vertically. The part, or model, is produced by extruding mall beads of thermoplastic material to form layers and the material hardens immediately after extrusion from the nozzle

Stereolithography

• Stereolithography is a process for creating

three-dimensional objects using a computer-

controlled laser to build the required

structure, layer by layer. It does this by using a

resin known as liquid photopolymer that

hardens when in contact with the air.

Selective Laser Sintering (SLS)/Melting(SLM)

1. Piston of the part built chamber lower by one layer;

2. Piston of powder cartridges raise up;

3. Roller spread powder evenly over the built surface;

4. Laser beam scan over the top of the part, melting the powder and fuse it to the previous layer;

5. Loop through the four steps to build the next layer.

LaserScanningMirror

Roller

Piston

Part

Supp

ort

Powdercartridges

BuildChamber

Cont..• Direct Metal Laser Sintering (DMLS)/ DMLM• Direct metal laser sintering (DMLS) is an additive

manufacturing technique that uses a laser as the power source to sinter powdered material (typically metal ), aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure. It is similar to selective laser sintering (SLS).

SLM & DMLS Videos

• 3D metal printing machine EOS M 290 - Rapid.Tech 2014.mp4

• Additive Manufacturing - The Next Industrial Revolution.mp4

• Direct Metal Laser Sintering.mp4• Direct Metal Laser Sintering (DMLS) Technolog

y.mp4

Rapid Prototyping

Aerospace

Automobile

Medical

Reverse Engineering

Games & Entertainme

nt

Food

Fashion& Retail etc.,

Do It Yourself

Machine looks

SpecificationMachine Build volume

(mm x mm x mm)

Build speed Layer Thickness

Laser Power

Materilas

SLM 500 500x280 x320 105 ccm /h 20µm -200µm

1000 M or 2x400

SS, Ti , Nickel alloys etc

EOSM 400 400 x 400 x400 2 -20 mm3/s 2µm -100µm 1000W SS, Ti , Nickel alloys etc

Concept Laser M2

250 x250 x 280 2 -20 cm3/h 20µm -80µm SS, Ti , Nickel alloys etc

Sratasys Fortus 900mc

914 x610 x914 >178µm Thermoplastic

Note: Among all material capability is the top most priority.

Materials Standards for Additive Manufacturing

Stainless Steel (17-4) Steel 300

Parts made from 3D

• Jet engine loading brackets are a crucial jet engine component, supporting the weight of the engine during handling and they have to endure significant vibrations during flight .

Milling 3D Printing

1.2 kg 0.6 kg

Low Pressure Turbine blade in γ-titanium aluminide. Courtesy of Avio Aero

Overview

Japanese Company 3D Prints a Large Working Jet Engine Replica

Electron Beam Melting (EBM) - Metal 3D Printing

Additive manufacturing allows designers to create parts like this jet engine combustor that would be very difficult to make on conventional machines

Avio 3D-printed LPT blades for the LEAP, GEnx, GE90 and GE9X jet engines - See more at:

Medical• The Future of Medicine: 3D Printing and Bionic Organs!

Eyes on You

New technologies using Unmanned Aircraft Vehicles (UAV) could create a new, cost-effective and reliable monitoring service. Researchers at University of Southampton, UK have created a new 3D printed drone, called 2Seas, that could soon be used by maritime security organizations. The heart of 2Seas – the central wing box, fuel tank and engine mountings – was 3D-printed, the wings and tail are made from carbon fiber.

Defense & Space

Drone It YourselfDefense & Space

Home-built drones are very popular among hobbyists with backgrounds in electronics and robotics. Jasper van Loenen, an independent designer working in the field of interaction design and art, wanted to make the design simpler so anyone could make their own robots. Van Loenen created a custom DIY (Drone It Yourself) v1.0 kit that turns any object into an unmanned aerial vehicle, simply by attaching four motors and a control unit – no technical know-how needed.http://vimeo.com/jasperl/diy

“Liberator”

Defense Distributed successfully test fired the world's first 3D-printed handgun named Liberator.

All 16 parts of the gun are made from a tough, heat-resistant plastic used in products such as musical instruments, kitchen appliances and vehicle bumper bars. Fifteen of those are made with a 3D printer while one is a non-functional metal part which can be picked up by metal detectors, making it legal under U.S. law. The firing pin is also not made of plastic, though it is easily crafted from a metal nail.

Defense & Space

3D-printed Lunar Base

Building a base on the moon could theoretically be made much simpler by using a 3D printer to construct it from local materials. The concept was recently endorsed by the European Space Agency (ESA) which is now collaborating with architects to gauge the feasibility of 3D printing using lunar soil.

“3D printing offers a potential means of facilitating lunar settlement with reduced logistics from Earth,” said Scott Hovland of ESA’s human spaceflight team.

Defense & Space

Advantages of additive Manufacturing

1. Efficient Use of recourses: • Fewer processing steps, net shape, less assembly, less waste material, less

energy.

2. Freedom to Design and Innovate• If there is one thing that product engineers can count on, it is that there will

be modifications and redesigns

3. Optimized Design: • Less material Better function

4. Small lot production: • Even a lot size of 1.

5. Support of Green Manufacturing

Cont…

6. Reverse engineering:• Scan and manufacture parts for legacy systems

7. Complex Part manufacturing• Exotic structures, functionally graded materials,‐

fabricate moving joints, embedded electronics

Aero Engines• This example of a high-pressure turbine blade was made from a cobalt-chrome

alloy on another type of 3D printer, the direct metal laser melting (DMLM) machine.

Courtesy GE Aviation Each Leap engine will contain 19 metal 3D-printed fuel nozzles. The

part is lighter and more durable than traditional parts

Limitations of RP

Cost

Accuracy

Finish

Strength

Material Options

Conclusion

• http://www.newscientist.com/article/dn23781-windows-aims-to-open-up-3d-printing-to-the-masses.html.

• http://www.newscientist.com/article/dn23785-printed-drones-to-hunt-down-drugrunning-boats.html.

• http://www.psfk.com/2013/07/3d-printed-fashion-show.html.• http://www.stratasys.com/resources/case-studies• http://www.wikihouse.cc/• http://on3dprinting.com/wp-content/uploads/2012/08/20120

806-Infographic-How-3D-Printing-Works-Preview.jpg• http://lunarscience.nasa.gov/articles/building-a-lunar-base-

with-3d-printing/•

http://www.3ders.org/articles/20130706-3d-printable-drone-it-yourself-kit-turns-any-object-into-an-uav.html

• http://creativemachines.cornell.edu/ornithopter • http://www.3ders.org/articles/20130702-3d-printed-drones-t

o-monitor-illegal-operations-at-sea.html

• http://betabeat.com/2013/05/first-fully-3d-printed-gun-created/

References

• Barnatt, Christopher. "3D Printing." Explaining the Future. (2013): n. page. Web. 16 Apr. 2013. <http://www.explainingthefuture.com/3dprinting.html>.

• Cornell, Scott. "Disadvantages of 3-D Printers." azcentral. n. page. Web. 16 Apr. 2013. <http://yourbusiness.azcentral.com/disadvantages-3d-printers-2212.html>.

•  Cubify 3-D Systems. Cubify. Web. 16 Apr 2013. <http://cubify.com/cube/compare.asp&xgt;.

• Evans, Hugh. "3-D Printing: The Game Changer."Connections. n. page. Web. 16 Apr. 2013. <http://individual.troweprice.com/public/Retail/Planning-&-Research/Connections/3D-Printing/The-Game-Changer>.

• "Gartner Says Early Adopters of 3D Printing Technology Could Gain an Innovation Advantage Over Rivals."Gartner. n. page. Web. 16 Apr. 2013. <http://www.gartner.com/newsroom/id/2388415>.

• How to use Cube 3-D Printer and Review. N.d. Video. n.p. Web. 16 Apr 2013. <http://desktop3dprinter.org/how-to-use-cube-3d-printer-and-review/>.

Thank You…

Applications• Aerospace:

-Engines, Interior, UAVs, • Automotive:

-Motor Racing, etc., • Industry:

-Handling & Robotics, etc., • Life style products:

-Jewellery, sports equipments, Foot wear, …• Medical:

-Dental, Orthopedic Technology, Medical Devices,..• Reverse Engineering: • Educational & Research Labs: • Toys:

2 .STEREOLITHOGRAPHY

Stereo lithography is an additive manufacturing process using a vat of liquid UV-curable photopolymer ”resin” and a UV laser to build parts a layer at a time.

• GE Aviation uses additive manufacturing methods such as direct metal laser melting (DMLM) to build 3D-designed production engine components that traditional manufacturing methods are incapable of producing.

• http://www.sparpointgroup.com/news/ge-aviation-speeds-up-production-of-3d-printed-jet-engine-parts-by-25#sthash.mkIJa2vT.dpuf

• By 2020, GE Aviation will produce more than 100,000 additive manufactured components for the LEAP and GE9X engines. GE will install 19 additive manufactured fuel nozzles on every LEAP engine, which has amassed more than 4,500 orders.

• The LEAP fuel nozzle is up to 25 percent lighter and five-times more durable than traditionally manufactured fuel nozzles, leading to big fuel savings.

• Today, Boeing (BA) uses the process to make plastic air-conditioning ducts for its 787 Dreamliner jet, and Nike(NKE) has a football cleat made on 3D printers.

• The 3D printing process has facilitated the building of a more efficient jet engine.

• Last week, the MIT Technology Review reported that a new incarnation of jet engines will mean aircraft use up around 15 per cent less fuel thanks to their lighter components, potentially saving some $1 million (£655,695, €776,217) annually per aeroplane, impacting significantly on carbon emissions.

• Additive manufacturing has the potential to reduce the weight of a single aircraft engine by 1,000 lbs - See more at: http://www.tctmagazine.com/software/ge-unveils-its-10-global-open-innovation-jet-engine-bracket-/#sthash.V9Wff2wx.dpuf

• Ohio-headquartered GE Aviation is using lasers to print fuel nozzles for next-generation jet engines. These nozzles are 25 per cent lighter and as much as five times more hard-wearing than the existing model welded from 20 different parts.

EOS Materials

Rep RapModel:

RepRapPro HuxleyPrice: $599

EventorbotModel: Delta

Micro Up Afinia H-SeriesPrice: $1,500

PrintrbotModel: Printrbot

GOPrice: $1,500

MakerbotModel:

Replicator 2x

Price: $2,800

The Future is

3DModel: Glacier SteelPrice: 3000

3D SystemsModel: CubeXPrice: $3000

FormlabsModel: Form 1Price: $3,300

StratasysModel: U print SE

PlusPrice:

$15,000

• Pressure to develop new and high quality ‐products

• quickly and cost effectively.• Pressure for quick response manufacturing

and• rapid deployment of products into production