19.12.2012

3D printing ; from design to production

Kimmo Mäkelä, Jari Mäkelä and Ahti HaapalainenOulu 26.05.2014

VTT

29.12.2012

Definition - What does Additive Manufacturing mean?Additive manufacturing is a manufacturing process through which three-dimensional solidobjects are created. It enables the creation of physical 3-D models of objects using a series ofadditive or layered development framework, where layers are laid down in succession to createa complete, 3-D object.

The technology was formerly known as 3D printing.Additive Manufacturing (AM) is now thestandardized expression, due to that it gives thewider perspective and real meaning of thetechnology used.

(picture; The Great Foodini, a food 3D printer)

39.12.2012

3D printing at the Horizon 2020-program

FoF.NMP.2014-1 Manufacturing processes for complex structures and geometries with efficient use of material – RTD, TRL 4-5, smallAutomated manufacturing of complex geometries can be related to issues such as 3D structured, multi-layered and hybrid materials or thejoint-free realisation of complex shapes.

FoF.NMP.2014-2 Manufacturing of custom made parts for personalised products – RTD, TRL 4-6, SME-targetedDevelopment and integration of advanced design and manufacturing technologies able to transform such new product-service data descriptionsand protocols into manufacturing operations and processes exploiting.

FoF.NMP.2014-6 Innovative product-service design using manufacturing intelligence – RTD, TRL 4-5, SmallToday's ever faster product lifecycles and ever higher quality requirements necessitate manufacturing engineering capability that is able toexploit to the maximum the concurrency of product and service engineering with immediate, cross-disciplinary feedback loops to relevant shopfloor knowledge.

Collaborative management of engineering knowledge and its multi-directional exchange between product design, service design andmanufacturing, enabled by rapid search for design functionality and reusability.- Tools and methodologies to effectively involve customers and suppliers across the value chain.- Multi-disciplinary search, simulation and optimisation of designs.

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FoF.NMP.2015-3 New product functionalities through surface manufacturing processes for mass production, RTD, TRL 4-5, SmallScope:New products with improved performances through functionalization of their surfaces and new approaches are needed to deliverhigh functionality and high-value products in Europe.The use of physical processing techniques (additive manufacturing, laser, jet technologies, 3D printing, micromachining, microforming, photonbased technologies, PVD, etc) or chemical processing (CVD, sol-gel, wet chemistry, electro-chemical, etc)

And others like

NMP 7 - 2015: Additive Manufacturing for tabletop nanofactoriesNMP 18 - 2014: Materials solutions for use in the creative industry sectorNMP 20 - 2014: Widening model applications in materials modellingNMP 36 - 2014: Business models with new supply chains for sustainablecustomer-driven small series productionFoF 1 - 2014: Process optimisation of manufacturing assets: CPS-based processoptimisationFoF 2 - 2014: Manufacturing processes for complex structures and geometrieswith efficient use of materialFoF 10 - 2015: Manufacturing of custom made parts for personalised products

(picture; Dudley the Duck that has 3D printed leg)

59.12.2012

“In two decades, 3-D printing has grown from a niche manufacturing process to a $2.7-billionindustry, responsible for the fabrication of all sorts of things: toys, wristwatches, airplane parts,food. Now scientists are working to apply similar 3-D–printing technology to the field ofmedicine, accelerating an equally dramatic change.” — Popular Science

“3D printing could well rewrite the rules ofmanufacturing in much the same way as the PCtrashed the traditional world of computing” — The Economist

“3D Printing helps you make the product from the core up soyou have less waste The tool is cheaper, the time is faster.If all thought 3D printing could do was shoes, I wouldn’t betalking about it.” — Jeffrey Immelt, CEO, General Electric

(picture ; 14 carat gold jewelry printed by Shapeways)

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Fig. 1. The use of AM for the production of parts 2003–2012. The use of AM for the production of parts for finalproducts continues to grow, as shown in the graph. In ten years, it has gone from almost nothing to 28.3% of the totalproduct and service revenues from additive manufacturing worldwide. Estimate for 2013 is more than 30%

712/06/2014

AM Applications

[Morris Technologies]

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AM ApplicationsAutomotive

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Designing

� Conventional designing methods can be used

� Possibilities to structures that can not bemanufacturing by milling, turning, injectionmoulding, etc.- flow chanels inside parts- honeycomb and cell parts- sharp inside edges- moving parts in one part- very difficult structuresAllways machinable afterwards

A jet nozzle where 22 differentparts were combined andmanufactured as one part

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Facilities available at VTT: 3D printer

3D – PRINTER OBJET EDEN 270 V (2010)� 3D-printer based on UV-curable inkjettable polymer� “Plastic and rubber” with various densities and colors� Maximum part size 260 x 260 x 200 mm� Accuracy: X-axis 42 ȝm, Y-axis 42 ȝm, Z-axis 16 ȝm� Wall thickness > 0.6 mm� Layer thickness 16 ȝm or 30 ȝm� Making inner geometries is possible� Supported file types STL (and SLC)� Accuracy on manutacttured

parts now ±0,03 mm

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Facilities available att VTT: Metalsintering

- picture on left; a bike frame by Renishaw- right; NASA’s Jet Propulsion Laboratoryhas printed copy´s of rocks found at Mars

129.12.2012

On the optomechanical designing of AM parts, some samples

This was the start point

• Optics was design on thealmost ready state

• Around the optics mechanicsand a housing was designed

• Then the electronics is added

Main goal was to get to test fullyfunctional assembly as soon aspossible

139.12.2012

Optical housings

• We deliver the customer fully functionalapparatus

• To design and manufacture mechanicstakes time

• Optical structures are DEMANDING

• The space is all ways very limited

• Very strict tolerances

• Solutions is at precision mechanics

Prototyping eludes expensive mistakes !

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Final structure is Optical frame

• A very cost effective way to makedifficult assemblies

• Delivered on timetable = designingand manufacturing on 3 days

• Flushing goes circular aroundoptics

• Hight 30 mm

• Diameter 40mm

159.12.2012

Issues on AM designing• Errors on 3d drawingsand especially

stl files

• “Just push the button and the AMmachines makes it. Simple”. (ABIG mistake)

• When designing think supports

• Why everyone talks about whathappens at the machine, when theproblems are before and after themachine ? Machine all ways doeswhat you ask it to do. The beforeand after are more difficult issues.

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Internal Structures(Most narrow curved channel 1x1mm)

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Thin Wall Ring with Printed Threads(0,4-0,8mm)

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Case: Valve Holder(nicknamed Terttu)

First Idea

Final Version

1912/06/2014

209.12.2012

Fames and housings

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Experiments

3D-Printed Test setup 3D-printing on substrate 3D-printed optics

Laser cut test CNC-milled surface Silver coated surface

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Finishing

- Machining- Threads- Painting- Polishing- Inserts- etc

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In the future

� Ready consumer products� Optics (lenses, mirrors)� Electronics and jigs for it (can take the heat ofdrying process)� Medical componets for real use (can stand heatand clening fluids)� Moulds� Mould inserts for injection moulding

� What next ? The development is currently almostexponential.

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Some possiblities

� Look alike models and toys is yesterday. Now realparts and assemblys� Silicon mould masters� Prototypes� Moulds� Jigs� Small parts, small series� Manufacturing plants allready exixts, especially on car

manufactures, aeroplanes and medical sector.Jewellery industry comes fast� Parts that are impossible to manufacture with

conventional methods

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Some perspectives

� The ultimate aim of 3D bioprinting is to replicate live 3-dimensionaltissue cultures which may be used for a number of purposes.

Dr Wendy Kneissl, IDTechEx- The global market for 3D printing is set to reach $7 billion by 2025, as

forecasted by IDTechEx.

269.12.2012

Issues• Materials and their fast development• Porousness, especially on softer materials• Supports and removing them• Parts almost all ways need some kind of after treatment• The constant need of more accuracy• The more designers et al lear about AM, the more difficult the

parts are coming. Yes ; there is a limit !• The ”old school”. You are toy makers.• Who teaches AM design ?• Still some disbelief in industry

(picture; a dress (?) by Shapeways to Victoria's Secret FashionShow )

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Benefits

�Cheap and fast !� Flexible� Manufacturing costs in general� Accuracy� Versatile� A lot of possibilities after part has been made� Complex, difficult and almost impossible features and structures� Unmanned production� Freedom to design !

(picture from Taiwan; On the front of the trike is a shredder, which turns the plastic cup into a sortof plastic powder, which in turn is placed into a filament extrusion device and then into a 3D printerwhere their plastic cup is transformed before their very eyes. Though the trike is pedal poweredthe RepRap and recycling)

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More

2912/06/2014

VTT creates business from A M -technology