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[company name] – [date] 1 © 2014 Brewer Science, Inc.
Inside 3D Prin@ng 10/23/14
Strategies and Considera@ons in Developing New Materials for 3D Prin@ng
Carlton Washburn Director of Business Intelligence
2 Inside 3D Prin@ng – 10/23/14
Transforming ideas into integrated solu@ons
INVENT MANUFACTURE INTEGRATE
Core competency and excep@onal exper@se in materials science related to advanced polymeric materials and their process integra@on
3 Inside 3D Prin@ng – 10/23/14
• 33 years ago, in 1981… – MTV was launched – Xerox introduced the computer mouse – IBM released the first PC
• Model 5150 with a 4.77-‐MHz Intel 8088 processor • Base price of $1,565 (> $4,000 today) • Used MS-‐DOS, released by Microsoa
– L2 was released by Brewer Science
4 Inside 3D Prin@ng – 10/23/14
Bourell, D. L., et al. "A brief history of addi@ve manufacturing and the 2009 roadmap for addi@ve manufacturing: looking back and looking ahead." US-‐Turkey Workshop on Rapid Technologies. 2009.
Herbert, 3M, 1979 Photopolymer
Kodama, Nagoya, 1981 Photopolymer
Householder, patent 1981 Concrete
At around the same @me…
5 Inside 3D Prin@ng – 10/23/14
Over 30 years of innova@on
3D Prin4ng
1980s 1990s 2000s 2010s
Materials
6 Inside 3D Prin@ng – 10/23/14
All ini@al materials were commercially available
O
N2light
H2O
O OH
+ N2
Base insoluble sensitizer Base soluble photoproduct
7 Inside 3D Prin@ng – 10/23/14
Over 30 years of innova@on
3D Prin4ng
Materials
1980s 1990s 2000s 2010s
8 Inside 3D Prin@ng – 10/23/14
Material model
Off the shelf
Adapt
Time
Value
9 Inside 3D Prin@ng – 10/23/14
How do you adapt a material?
Find suitable materials
Determine specifica@ons
Test
Develop
Commercialize
10 Inside 3D Prin@ng – 10/23/14
Which comes first, materials, processes, or tools?
Work Breakdown Structure Timeline Jan Feb Mar Apr May Jun Jul
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1.0 Project planning 1.1 Determine scope statement 1.2 Select team 1.3 Plan activites
2.0 Specifications
3.0 Prototype
3.1 Review design Build prototype Test A Test B Test C
4.0 Select suppliers
5.0 Verify tool design
6.0 Qualifcation testing
7.0 Redesign contingency
8.0 Commercialization
11 Inside 3D Prin@ng – 10/23/14
Where are we today?
12 Inside 3D Prin@ng – 10/23/14
Processes
Process Polymers Metals Other Vat Photopolymeriza@on (SLA) ✓ Material Extrusion (FDM) ✓ Material Jemng ✓ Binder Jemng ✓ ✓ ✓ Powder Bed Fusion ✓ ✓ Sheet Lamina@on ✓ ✓ Directed Energy Deposi@on ✓
ASTM, Comminee F42 on Addi@ve Manufacturing Technologies, West Conshohocken, Pa., 2009.
13 Inside 3D Prin@ng – 10/23/14
Material extrusion
Material Key Characteris@cs ABS-‐M30, ABSplus
Versa@le, touch
ABS-‐ESD7 Electrosta@c discharge resistant ABS-‐M30i Biocompa@ble ABSi Translucent PC Strong (tension) PC-‐ABS Strong (impact) PC-‐ISO Biocompa@ble ULTEM 9085 Mechanically well-‐rounded, FST cer@fica@on PPSF Resistant, both thermal and chemical Nylon 12 Strong (high fa@gue resistance) PLA Color selec@on, defini@on, plant-‐based
14 Inside 3D Prin@ng – 10/23/14
SLA and SLS
Stereolithography SLA Materials Laser Sintering SLS Materials 1 Accura® 25 CastForm™ PS 2 Accura® 48HTR DuraForm® EX Black 3 Accura® 55 DuraForm® EX Natural 4 Accura® 60 DuraForm® Flex 5 Accura® ABS Black (SL 7820) DuraForm® FR 100 6 Accura® ABS White (SL 7810) DuraForm® GF 7 Accura® Amethyst™ DuraForm® HST Composite 8 Accura® Bluestone™ DuraForm® PA 9 Accura® CastPro™ DuraForm® ProX™ 10 Accura® CastPro™ Free (SL7800) 11 Accura® CeraMAX™ Composite 12 Accura® ClearVue™ 13 Accura® ClearVue™ Free (SL 7870) 14 Accura® e-‐Stone™ 15 Accura® PEAK™ 16 Accura® Sapphire 17 Accura® SL 7840 18 Accura® Xtreme™ 19 Accura® Xtreme™ White 200
15 Inside 3D Prin@ng – 10/23/14
Over 30 years of innova@on
3D Prin4ng
Materials
1980s 1990s 2000s 2010s
16 Inside 3D Prin@ng – 10/23/14
Material model
Off the shelf
Adapt
Time
Value
Immediate Months
Defin
ed
Choice
17 Inside 3D Prin@ng – 10/23/14
Used by permission from taulman 3D
Adap@ng a material
18 Inside 3D Prin@ng – 10/23/14
How was it done?
Adap@ng Nylon
Time
Value
18 Months
Choice
• 4 full-‐@me testers • 4 specialists • 9 months for capability • Learning cycles
19 Inside 3D Prin@ng – 10/23/14
3D printed microbanery
Sun, K., Wei, T.-‐S., Ahn, B. Y., Seo, J. Y., Dillon, S. J. and Lewis, J. A. (2013), 3D Prin@ng of Interdigitated Li-‐Ion Microbanery Architectures. Adv. Mater., 25: 4539–4543.
20 Inside 3D Prin@ng – 10/23/14
Over 30 years of innova@on
3D Prin4ng
Materials
1980s 1990s 2000s 2010s
21 Inside 3D Prin@ng – 10/23/14
Material model
Off the shelf
Adapt
Custom
Time
Value
Immediate Months Months to Years
Defin
ed
Choice
Individu
aliza
@on
22 Inside 3D Prin@ng – 10/23/14
We appear to be at a crossroad
23 Inside 3D Prin@ng – 10/23/14
Market fulcrum
Ver@cal Integra@on
Outside Services
Cost focus
Lower risk Independence
24 Inside 3D Prin@ng – 10/23/14
What needs to happen next for 3D prin@ng materials?
25 Inside 3D Prin@ng – 10/23/14
Avoid locked tools and processes. It’s a pathway that narrows op@ons for innova@on.
26 Inside 3D Prin@ng – 10/23/14
Material model
Off the shelf
Adapt
Custom
Time
Value
Immediate Months Months to Years
Defin
ed
Choice
Individu
aliza
@on
27 Inside 3D Prin@ng – 10/23/14
How is a custom material developed?
Plan project
Determine material specifica@ons
Test
Develop
Commercialize
Feedback
Determine tool & process specifica@ons Test
28 Inside 3D Prin@ng – 10/23/14
Roadmap example
Tools
Processes
Materials
29 Inside 3D Prin@ng – 10/23/14
One op@on
30 Inside 3D Prin@ng – 10/23/14
Market fulcrum
Ver@cal Integra@on
Outside Services
Innova@on Individualiza@on Cost focus
Lower risk Independence
Speed
31 Inside 3D Prin@ng – 10/23/14
Over 50+ years of innova@on
3D Prin4ng
2010s
Materials
2020s 2030s
32 Inside 3D Prin@ng – 10/23/14
Thank you!
