27
WWW.3DSYSTEMS.COM|NYSE:DDD Direct Metal Printing Services Quickparts 2015
WWW.3DSYSTEMS.COM|NYSE:DDD
Direct Metal Printing Services
Quickparts 2015
Direct Metal Manufacturing Solutions
Technology
DMP Professional Printers
Process
DMP Application & Process Know-how
Service
DMP Contract Manufacturing
Organization 3D Systems DMP
Production Projects
DMP Contract Manufacturing & Services
Sales dept Project
Engineering FastLane
Technology Development
Production
Hardware Software Materials Process
USA - France-Belgium
3D SYSTEMS
BE–UK-USA* UK-BE-NL-DE-FR-IT-USA-BR-AU
3D Systems LayerWise, Leuven, Belgium Fully owned subsiduary
DMP Technology development center DMP Contract manufacturing reference plant
BE-USA*
DEVELOP TECHNOLOGY
DRIVEN BY FOCUSED RESEARCH
USE TECHNOLOGY
ACROSS MARKET APPLICATIONS
CLOSED-LOOP DMP EXPERTISE
DMP Evolution
2001
100% prototyping
4 materials
90 x 90 x 90 mm
First Worldwide 3D Printing of Titanium
90% Volume Manufacturing
18 materials
280 x 280 x 440 mm
Leading DMP manufacturer
technology development & production
Belgium France
ISO 9001 – ISO 13485 Quality Certified
2008 2009 2010 2011 2012 2013 2014
Research Material Parts Quality Productivity
2015
DMP Contract Manufacturing
Increase your added value through advantages of Direct Metal printing
3D Systems offers DMP technology expertise by being technology developer and production company
Market overview
Project Development
Volume Manufacturing
Customer Satisfaction
• Feasibility assessment • Quality plan (PMP) • Supply chain development • Part modeling • Process qualification • Process release
• Raw material release • Process monitoring • Full lot traceability • In-process inspections • Outgoing quality gate • Workstation management
• Customer complaint management • Return material approval process • Annual customer satisfaction survey
Machine / Material release management Supplier quality management
Failure mode & effect analysis
Control plan
Gauge R&R IQ/OQ/PQ 5S
Quality Tools Workstation management
3DS-LayerWise Quality management system
Several materials under development
3D Systems has capabilities to accommodate new materials within a typical timeframe of 3 months
Materials
Stainless steel
Tool steel
Titanium
Aluminium
Super alloy
Exotics
Aero Dental Medical Industrial
• 316L
• SS 17-4
• SS 15-5
• Maraging X3NiCoMoTi 18-9-5
• Ti commercially pure
• Ti commercially pure
• Ti6Al4V ELI
• Ti6Al4V
• Tantalum
• Tungsten
• AlSi10mg
• CoCrMo
• CoCrWMo
• Inconel 718
• Inconel 600
Key
Fe
atu
re
Spec
s M
ater
ials
3
DS
Pro
du
ctio
n
Serv
ice
Cu
sto
mer
Volume Manufacturing Project
Technical AM Products
Fastlane 3D Print Service
3DS Fastlane or Project Teams 3DS Fastlane
Division 3DS Production Division
DM
P M
fg. S
ervi
ces
Lead time is 6 Working days (Or shorter)
Project driven technical expertise
Supply and Quality security
Ti6Al4V Gr5 316L* Aluminum*
Ti6Al4V Grade 1,2,5, Ti6Al4V Grade Eli, 316L, 17-4, 15-5, Maraging, Inconel 718, CoCrMo, CoCrWMo,
Tungsten, Tantalum, AlSi10Mg
(x,y,z)=(250-200-180) mm (9.84-7.78-7.09 inches)
(275-275-420 mm (10.8-10.8-16.5 inches)
DMP Specification
Machine Dimensions 10.8 x 10.8 x 16.5in (275x275x420mm)
Material Density 99-100%
General Tolerances 0.5% with a minimum of +/- 0.008 (0.2mm) on downfacing surfaces
Surface Roughness Basic: Ra 150-275µin (4-7µm) Possible: Ra 0.1µm
Minimal Feature Size 0.005in (0.15mm)
Minimal Wall Thickness 0.008in – 0.01in (0.2 mm – 0.3 mm) gastight, depending on material
Text Dimensions width; height; depth = 0.02; 0.02; 0.006in (0.4 ; 0.4 ; 0.15 mm )
Manufacturing to 2D Plan Post-machining possible
Leak Tightness 10 E-9 Bar
Project approach
Project Analysis
DfX
Design for Function/Mfg
Project Delivery Validation
Management
Gas Burners
• Material Inconel 718 • Function integration • Integrated cooling channels • Improved performance and lifetime
Quartz bulb burners with
integrated cooling channels
(Courtesy of Havells Sylvania)
ESA in-space satellite engine
In-space satellite engine development
by European Space Agency (ESA) and LayerWise
Injector
Consolidated 5 parts to 1
Eliminated sealing welds
High material density
Design with optimised cooling and thermal isolation
Optimised propellant flow
Combustion chamber
Original design with strut-work ribs
Racing
• Racecar suspension • Structural part • Topology optimization • Hydraulic performance increase
Process Applications
Material 316L
Candy and icecream manufacturing
Production volume 1-1000 part/yr
Tire Technology
150 micron wall thickness
UTS,MPa Yield, MPa Elongation,%
AM* 1030±20 800±35 9.5±1.2
After HT 1330±65 1180±32 10.5±1.5
Quenching + aging 1103 1000 5
Medical Imaging
• Material : pure Tungsten • Collimation • PET & SPECT imaging
DMP Technology
Large size machines
High resolutions
Online quality control
Consistent
Printer Technology
Material Development
Software
In-house material specialists
Best material quality
Chemical stability
Productivity
Traceability
Innovation on 4 levels Materials: high-tech metals like molybdenum, tungsten, copper, …
Productivity: part printed in 2 hours instead of 20 hours
Quality: shape accuracy, finer details, thinner walls, etc.
Build size: increasing the maximum dimensions
Technology development
Direct Metal Printing =
Creating Material AND Product Simultaneously!
≠
Materials
Material development
• Controlled release of materials
• Extensive testing for initial validation and follow-up – Geometric accuracy
– Mechanical testing
– Compositional testing
• Accredited material validation – Fully equipped mechanical & metrology testing lab
– Microscopy (optical, SEM, etc.)
– X-ray (XRD, CT, micro-CT, etc.)
– Compositional analysis
100µm
Powder characterization
• Chemical composition • Particle distribution • Hall Flow
Machine / Material Parameter study
Material / Machine release level
• Prototyping • Static load bearing • Dynamic load bearing
Material Datasheet
• Layer thickness • Laserpower • Scanspeed • Dimensional
• Density
• Mechanical • Thermal
Mechanisms for Robust Quality Control & Traceability
• 1. Raw material intake control – Selection of suitable raw
material supplier – Detailed definition of powder
specification and intake control
– Clear identification numbering of raw material batches
– Dedicated storage location for different powder batches
• 2. AM part production and quality
control – Chemical composition analyses
of powder in accredited laboratories on virgin powder and when mixed
– Fixed cycle running powder sample collection for traceability
– Part production with defined parameters on qualified system for each build
– Density evaluation on each build
• 3. Continuous data collection (QMS database) – Full traceability of materials
from customer back to raw material supplier
– Documentation of all quality information for each material lot in database
• 4. Documentation
– Material lot specific material certificate containing analyses results.
– Delivered with every material delivery in printed and/or digital version
Ordering
Incoming Inspection
Use & storage
Powder Mixing
Material Analysis
Remove
Integrated solutions
Barry Assheton - Head of Sales
3D Systems Europe Ltd
Mob 07931419805
Direct Metal Printing
