TM
Consulting Services
ADDITIVE MANUFACTURING:DISRUPTOR, DRIVING THE 4TH INDUSTRIAL REVOLUTION
- TECHNOLOGIES & APPLICATIONS -
Jurgen DanielTeclination Consulting Services
San Diego, USA
www.teclination.com
Source: APWorks
IEEE Consultants’ Network of San Diego, 9 Sept. 2019
2TM
Consulting Services
3D Printing Example
Source: www.carbon3d.com
Continuous Liquid Interface Production (CLIPTM)
7x speed
(Digital Light Projection / Stereolithography)
movie
Source: www.geaviation.com, cessna.txtav.com
a brand new high-performance turboprop aircraft
Source: www.geaviation.com, cessna.txtav.com
1/3 of engine parts are 3D printed
GE's Catalyst™Advanced turboprop engine
Development started in 2015Certification expected 2020
855 distinct components down to 12
world’s first turboprop engine with 3D-printed parts
Development started in 2015Certification expected 2020
GE's Catalyst™Advanced turboprop engine
Source: www.geaviation.com, cessna.txtav.com
1/3 of engine parts are 3D printed
• 10 % more power
• Improved fuel burn (20 %)
• >100 lb in weight savings
• SimplifiedØ Supply chain logisticsØ AssemblyØ Maintenance
6TM
Consulting Services
Conventional vs Additive Manufacturing (AM)
Source: www.arup.com;
Structures carry the same structural loads and forces
Example
Conventional Additive
• milling • sawing • drilling• welding• …
• 3D printing• Layering• …
topology optimized
7TM
Consulting Services
Cost Comparison: Additive vs Conventional
Source: Deloitte
Additive Manufacturing
Conventional Manufacturing
Breakeven Point
Volume (units manufactured)
Cost
per u
nit m
anuf
actu
red
$$$
$
8TM
Consulting Services
AM: Key to the 4th Industrial Revolution
Disrupting the $12 Trillion Manufacturing Sector
Source: www.weforum.org; data.worldbank.org; www.atkearney.com; www8.hp.com; lcr4.uk; www.allaboutlean.com
Industry
4.0
Cloud Computing
Additive Manufacturing
Autonomous Systems
Internet of Things
Augmented Reality
Big Data Analytics
Cyber Security
Simulation
Systems Integration
1.0 2.03.0
• Computing / IT• Automation
electronics1970s - 2010s
• Assembly line,• Electric power
1870s - 1960s
• Steam power,• Mechanical
production1780s - 1860s
27 Feb 2019
9TM
Consulting Services
Selected Technologies
10TM
Consulting Services
AM Categories
LiquidPowder(Granulate)
Filament(Wire/ Rod)
1D0D 2D
Sheet3D
Ceramic
Metal
Functional (electronic, shape memory, …)
Polymer
Composite
Biologic, food, etc. Selective Laser Melting (SLM)Polystrata
• Binder Jetting (BJT)• Directed Energy Deposition (DED)• Material Extrusion (MEX)• Material Jetting (MJT)• Powder Bed Fusion (PBF)• Sheet Lamination (SHL)• Vat Polymerization (VPP)
Fused Deposition Modeling (FDM)
see also: ASTM/ISO standard for AM terminology (ISO/ASTM 52900-15)
Selective Laser Sintering (SLS)
Stereolithography (SLA)
Electron Beam Melting (EBM)
Digital Light Processing (DLP)
Pick and Place (PNP)
Cold-spray (Kinetic Fusion)
+ others
Process Material
11TM
Consulting Services
Fused Deposition Modeling (FDM)
filament
Source: Manufacturingguide
FDM nozzle
Rostock
Monoprice MP Select Mini (~$200)
Airwolf3D EVO 22 (~$12k)
(heated build chamber)
heated build plate
Filament
Delta
Cartesian
heated nozzle
Common materials:PLA: Polylactic AcidABS: Acrylonitrile Butadiene Styrene
H&S:Some VOC and Ultrafine Particle concern
movie
12TM
Consulting Services
FDM Materials (Examples)
Polylactic Acid (PLA)
ULTEM (Nylon) air duct
316L steel
Ceramic
(requires debinding + sintering)
Bound metal rods (high metal ratio)
3D composite: FDM with embedded continuous carbon fiber
NYLON 12CF (carbon fiber filled thermoplastic)
Thermoplastic Polyurethane (TPU)
EasyCorkTM
EasyWoodTM
Composites
Metal / Ceramic (particle filled thermoplastic)
Thermoplastics
Filaflex
13TM
Consulting Services
3D Printing with Support Structures
HydroFill water-soluble FDM support for ABS and PLA parts
Soluble Support Material
Source: pixelpractice.nyc; airwolf3d.com
Cut-away Support Structures
450
No support needed Support needed
General recommendation
<450
ABS
FDM with dual nozzle
Needed in FDM, SLA, jet-printing and metal SLS (metal SLS: for heat distribution and stability during cool-down)
HydroFill
14TM
Consulting Services
Materials
VAT Polymerization: SLA (Stereolithography) / DLP (Digital Light Projection)
Formlabs Form 2(Laser scanning)~$3,400 (2018)
FDM vs SLA
27x magnification
Source: Formlabs
Source: formlabs; sparkmaker3d, www.tth.com
• ~ 25-30 micron layer thickness• <40 µm resolution• Isotropic material / smooth surface
Sparkmaker FHD(LED / LCD projection)
~$279 (2018)
Laser galvo-scanning, DMD or LCD projection, holographyDMD: Digital Mirror Device; LCD: Liquid Crystal Display
Issue of trapped volumes
Fast (continuous) processes:CLIP:LSPc:
bottom-up process
Projector
UV light
Build platform
Transparent membrane
Resin vat
• rigid • flexible • colored
• high temperature • dental grade
• ceramics, metals (sintered)
15TM
Consulting Services
Powder Bed Fusion
Layer thickness: ~15 – 500 μm
Powder particle size: ~50 - 100 µm
Laser power: 10s – 100s of Watt
Ti-6242 particles (45-106 µm)
Source: Stratasys; GE
Selective Laser Sintering / Melting (SLS / SLM)
movie
16TM
Consulting Services
Powder Bed Fusion (Laser or E-Beam)
Source: www.eos.info; www.plusmedicaot.com; www.malvernpanalytical.com
Polymers - metals - ceramics
Selective Laser Sintering / Melting (SLS / SLM)
Nylon duct
Laser
Titanium bracket (30 % lighter)
Parameters:• Laser power• Scan speed• Layer orientation• Hatch distance
Electron Beam Melting (EBM)
~62 EBM machines operated by GE Aviation (2019)
Health/ safety / Powder recycling
Typical powder particle size: ~50 - 100 µm
TiAl turbine blades
layer thickness: 15 – 500 μm
in vacuum or inert gas
Laser power: 10s of Watt (e.g. CO2) Laser power: 100s of Watt (e.g. fiber)
(for new GE9X engine)
17TM
Consulting Services
Binder Jetting
Source: www.voxeljet.com; www.xaar3d.com
IR light
Sintered polymer
InkjetInfrared absorbing
ink
3-20 µm particles
Steel
High volume low-cost parts
Multi-jet Fusion (MJF)Fusing agent (not binder)
Binder materials: phenolic, aqueous, silicate, fusing agent, etc.
High Speed Sintering (HSS)
color by inkjet
Plastic
(also metal)
Polymer particles
Process example: High Speed Sintering (HSS)
( + debinding & sintering)Metal process
18TM
Consulting Services
Jet-printing
Metal Ceramic
Source: xjet3d.com; Stratasys; Optomec, Xerox
Nanoparticle JettingTM (NPJ)
Printing at ~500degC Final sintering
water soluble support material
PolyJet
UV curable polymersrigid & elastomeric
360,000 colors: CMY, white, black, transparent
Magnet-o-Jet™: electromagnetic pulsing of molten metal
Jet-printing of molten metalAerosol Jet-Printing
printed smartphone antennas
19TM
Consulting Services
DED (Directed Energy Deposition)
Source: www.beam-machines.com
Laser energy used to fuse metal powder
5 axis of freedom
Similar concepts:
Wire & powder-fed
(size: 45-75µm)
Wire Arc Additive Manufacturing (WAAM)
Similar to Tungsten Inert Gas (TIG) welding
FAA certified process
Repair of worn shaft seal
20TM
Consulting Services
Sheet Lamination
Source: www.mcortechnologies.com; fabrisonic.com; www.impossible-objects.com
print color – print adhesive – laminate – cut layer
X,Y,Z resolution: 0.1mmPhotorealistic color
Ultrasonic welding
Ultrasonic AM
Composite Based AM (CBAM)
Selective Deposition Lamination (SDL)
Build material: paper
Process
Material: (carbon) fiber composite
Material: metal
CNC / laser contour machining
Process
21TM
Consulting Services
ApplicationsExamples
(emphasis on 3D printing)
Source: Widex
22TM
Consulting Services
Digital Dentistry - Clear Dental Aligners
Sources: www.invisalign.com, www.prodways.com
3D printing of dental molds for thermoforming
Medical-grade polymer is thermoformed around
3D printed mold
>320,000 clear aligners produced per day
~6-10 incremental molds per patient
~50-60 SLA printers
Dental mold(SLA, MJF)
Clear alignerThermoforming
23TM
Consulting Services
Hearing Aids
Example: SLA parts by Danish hearing aid manufacturer Widex
Source: www.widex.pro
CAMISHA (Computer Aided Manufacturing of Individual Shells for Hearing Aids)
modeling SLA printing 3D scanning
Mass customization
24TM
Consulting Services
Medical
Source: www.anatomics.com; www.zimmerbiomet.com ; www.rapidreadytech.com; www.materialise.com
Patient-specific pediatric heart model
Light-weight patient-specific 3D-printed cast
Surgical Planning & Training
Orthopedic Casts
Software requires FDA clearance!
Personalized Medicine
Printlets™ technology
Spinal wedge implants
Implants
OsseoTiPorous Metal
(for bone in-growth)
Lattice skull implant
25TM
Consulting Services
Jewelry
Wax 3D SLA* printing and lost-wax casting
High wax content SLA photopolymer for clean burnout
Source: envisiontec.com, i.materialise.com; www.dnaindia.com
SLA mold
wax model
metal
Lost-wax casting processplastermold
burnout metalpart
DNA India
faster & lower cost
*Stereolithography
26TM
Consulting Services
Aerospace - Rockets
Monolithic Thrust Chamber with Internal Cooling Structure
Selective Laser Melting:
• Nickel superalloy IN718 (difficult to CNC machine)
• Minimum post processing needed
Source: www.slm-solutions.com, cellcore3d.com
Complex lattice structure:
Ø Improved coolingØ Lightweight
Combined fuel injector & thrust chamber
27TM
Consulting Services
Heat Exchange
• 22% lighter • 55 mm smaller
than traditionally manufactured parts
Pure copper heat exchanger:• spiral design (0.5mm wall thickness)• >30% lighter• 35% cost reduction
Complex heat exchanger concept in Al
Lung-inspired Heat exchanger(ARPA-E HITEMMP)
Novel complex (bio-inspired) & more efficient designs
Source: www.metal-am.com; www.3t-am.com
28TM
Consulting Services
Automotive
Source: 3dprintingindustry.com; yours-customised.min; www.hrewheels.com
US$148 billion in automotive AM product value forecasted for 2030 (Feb 2019)
Small series variable turbo
Rapid development Customization
Spare parts Small series Customization Tooling Quality enhancementDesign cycles
29TM
Consulting Services
Industrial Tooling
Source: www.voxeljet.com; www.stratasys.com
Sand mold & metal part
Molds for casting
3D PRINTING SAVES UP TO 75 % IN SAND CASTING COSTS
Composite lay-up molds
(ULTEM 1010)
Carbon fiber composite
Binder jetted
also: plastic molds for investment casting
FDM printed
30TM
Consulting Services
Electronics - RF Antennas
• 95% weight reduction• 20% reduction of production cost• 75% of non-recurring costs eliminated
Source: 3dprint.com/178724/3d-printed-antenna-one-component/
Ka-band 4×4 monopulse phased array (1 -100GHz)
1part100 parts
brazing and EDM (~8 months to develop and 3 to build)
3D laser fusion( ~a few weeks to complete)
metal
e.g. for low SWaP radar on High Altitude, Long Endurance
(HALE) platforms
31TM
Consulting Services
Art (Example: 3D printed Ceramics)
Sensory Printing Machinethat feels the environment
Image: Galerie VIVID
Extrusion printer
Source: oliviervanherpt.com
Adaptive Manufacturing
Unique ceramic objects
32TM
Consulting Services
Culinary Printing
Source: www.miamfactory.com Source: www.3dsystems.com/culinary Source: open-meals.com
Pixel food printer: 3D printer capable of producing edible and pixelated 8-bit sushi
3D printed chocolate 3D printed sugar Pixilated sushi
33TM
Consulting Services
Materials
34TM
Consulting Services
Novel Materials
Source: D. Hofmann, et al., Nature Scientific Reports 4, 2014 (www.nature.com/articles/srep05357); authors.library.caltech.edu/50785/1/S0884291414002088a.pdf
Graded composition alloys
Related process: Laser Metal Deposition (LMD) / powder nozzle
Laser Deposition process
Metal matrix composites
Ti-6Al-4V to V Gradient Alloy
Multi-Material Objects
e.g. Ti / TiC
35TM
Consulting Services
Design
Source: Teclination
36TM
Consulting Services
DfAM (Design for Additive Manufacturing)
Parametric and generative design
Generate (TM) topology optimization
Other examples:
Topology optimization
Lattice structures and biomimicry (bionic design)
37TM
Consulting Services
AM Build Simulation SoftwareMultiphysics Multiscale Modelling of AM Processes
Source: www.geonx.com; www.3dsystems.com; www.ansys.com; www.alphastarcorp.com; www.e-xstream.com
+ others
Example
Model distortions & residual stresses for processes
Suggest distortion compensation
Model optimal support structures
Minimize number of build tryouts
Minimize risk of printer damage (e.g. re-coater damage)
Predict impact of postprocessing (e.g. heat treatment, HIP,
support removal)
NX & Simcenter
38TM
Consulting Services
Fabrication Process
Source: i.materialise.com
39TM
Consulting Services
3D Printing Services
+ many others
HP Digital Manufacturing Network
40TM
Consulting Services
Process and Postprocess
up to 70% of part cost
• Support removal • Surface finishing• Defect Reduction: Hot Isostatic Pressing
(HIP)• Non Destructive / Destructive Testing
Data Security (Blockchain)
Process Quality Control / Workflow Optimization
Process monitoring &feedback
Standardization
Post Processing
data analytics
SLS part
Melt-pool monitoring
Blacksmith
AI supported process:
+ others
+ others
41TM
Consulting Services
Wait! - a few more futuristic concepts
Source: Carnegie Mellon University
42TM
Consulting Services
Small-Scale / Large-Scale AM
Source: www.nanoscribe.de & www.laserfocusworld.com; www.3dwasp.com
e.g. Two-photon Polymerization Contour Crafting
Prof. Behrokh Khoshnevis
Rapid Response Construction (disaster relief)
Photonic materials Metamaterials
Microstents… Extraterrestrial Construction
…
43TM
Consulting Services
Cooperative Mobile Print Robots
Source: spectrum.ieee.org; gxn.3xn.com
Structures arbitrary in size
crawl – swim – fly
Denmark
44TM
Consulting Services
The Future - 3D Printed Organs and Tissue
Source: science.sciencemag.org/content/365/6452/482
MRI data of a human heart 3D bioprint collagen & human heart cells
Prof. Adam Feinberg - CMU Bioengineered Organs Initiative
Cardiac ventricles printed with human cardiomyocytes
Freeform Reversible Embedding of Suspended Hydrogels (FRESH) bioprinting
synchronized contractions after 7 days
45TM
Consulting Services
Resources
46TM
Consulting Services
AM Information Resources
3dprintingindustry.com
3dprint.com
www.3ders.org
www.rapid3devent.com
www.sme.orgall3dp.com
www.tctmagazine.com
advancedmanufacturing.org
www.3dmpmag.com
additivenews.com
www.metal-am.com
additivemanufacturingtoday.com
… and many more
wohlersassociates.com
www.3dnatives.com
AM News + Info
AM Conferences
formnext.mesago.com
rapid3devent.com
inside3dprinting.com
www.amug.com
www.am-ceramics.dkg.de www.additiveconference.com
www.3dprint-exhibition.com
