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3D Printing, Material and Application
Alan Yu
Application Consultancy Leader APJ
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FDM builds concept models, functional prototypes and Production
Parts in standard, engineering-grade and high-performance
thermoplastics. Parts are unrivaled in mechanical, thermal
and chemical strength.
STRATASYS TECHNOLOGIES
PolyJet technology is a powerful additive manufacturing method
that produces smooth, accurate prototypes, Production Parts
and tooling. It can produce thin walls & complex geometries
using the widest range of materials.
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INDUSTRIES
Industrial Aerospace Automotive Military Architecture
Consumer Medical Dental Jewelry Education
Consumer
Products
Entertainment
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PROTOTYPING APPLICATIONS
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FORM
“Thanks to the accuracy of the 3D models
printed on the Connex 3D printer, we have
almost-real products in our hands which we
test and use the same way as end products”
Ladislav Skoda, Chief Designer
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FIT
Karsten Aagaard, user experience designer
“We had some issues with a mouse in production, so
we built a four up size one so we can actually see the
physical movement of the mouse.”
“We are able to load
components and do testing.”
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FUNCTION
“We can also provide customers
conceptual models, end-user parts,
functional prototypes, and even in-
house manufacturing jigs and fixtures.”
“Minimizer continues to grow and succeed because we want to make
bold investments like our new Stratasys prototyping machine that
help move our company forward and create innovation in our
industry”.
“Now we have the ability to offer customers
short-run parts without the expense of
injection molding or CNC machining.”
Craig Kruckeberg, Chief Visionary
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Do you need a Transparent part?
With Fine details?
And Great surface Finish?
IT DEPENDS ON YOUR APPLICATION
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And if you want a Tough, Strong and Flexible product?
IT DEPENDS ON YOUR APPLICATION
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• Do you need to print end use parts?
• That are tough enough to endure rough conditions?
IT DEPENDS ON YOUR APPLICATION
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• Combining a Rigid material and a Flexible material?
• Reach different levels of Flexibility?
IT DEPENDS ON YOUR APPLICATION
Multiple Materials
Digital Materials
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DIGITAL MANUFACTURING APPLICATIONS
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DIGITAL MANUFACTURING | BASIC AND ADVANCED
Jigs and Fixtures | PJ
Jigs and Fixtures | FDM
End-Use-Parts
Sand Casting
End Of Arm Tooling
Silicon Molding | PJ
Blow Molding
Injection Molding
Liquid Silicone Rubber
Basic Manufacturing
Advanced Manufacturing
Rubber Molding
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• Direct production on PolyJet system
Complex, organic shapes are feasible
Integrate tool ID, part number, guides
• Size & quantities required:
1 to 100s
1 to 30 cm (0.4 to 11 in)*
• Manufacturing requirements:
Temperatures up to ~90 °C (194 °F)
Moderate mechanical loads (70 MPa [10.1 ksi])
No chemical exposure
• Design elements:
Moderate to thick walls (5 – 13 mm [0.2 – 0.5 in])
Frequent replacement or alteration
Complex, intricate
JIGS AND FIXTURES | PJ
FC720 fixture printed with TangoBlack™ interfaces.
Method (In-house) Time Cost
CNC 3 days $1,500
PolyJet 1 day $900
Savings 2 days (67%) $600 (40%)
Multi-material printing allows incorporation of
text for fixture labeling.
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JIGS AND FIXTURES | PJ CASE STUDY
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• Quantities
1 to 1,000
Prototypes for evaluation
Short-run production
• Small to mid-sized parts
1 ml to 1 liter (0.03 to 35 oz.)
BLOW MOLDING | DETAIL
Method Time Cost
CNC machining 20 days $2,500
PolyJet blow
mold2hours $280
Savings18days
(90%)
$2,220
(89%)
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BLOW MOLDING | CASE STUDY
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• Quantity
5 to 100 castings**
• Size
6 mm (0.25 in) to 300 mm (12 in)*
• Design
Complex, intricate
Revisions likely
LIQUID SILICON RUBBER | DETAIL
PolyJet mold made with Digital ABS.
Digital pressure gauge inside an LSR boot.
Method Time Cost
CNC mold 14 days $1,000
PolyJet mold 2 days $400
Savings12 days
(86%)
$600
(60%)
* Larger size feasible, may require mold production in multiple pieces
** Higher quantities possible, may require additional mold prints
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LIQUID SILICON RUBBER 液體矽橡膠 | CASE STUDY
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3,800
Berker: Benefits
22,350
3
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Traditional Tooling
3D Printed Tooling
Traditional Tooling
3D Printed Tooling
Time (Days)
Cost (USD)
“This new flexibility enables us to try out two or three different solutions at the same time to get the best result. The confirmed quality of our products produced using these functional prototypes has accelerated our R&D processes.”
Andreas Krause
Head of Technical Department & Manufacturing at Berker
Functional tests include:
• Electrostatic discharge test
• Used to determined whether assembly of electrical parts will produce a charge of electricity.
• Fit tests
• All components of the assembly had to fit properly.
End use materials were necessary to validate tests (PC, ASA, TPU).
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INJECTION MOLDING | CASE STUDY
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• Thermoplastics with:
• Molding temperatures < 300 °C (570 °F)
• Good flow ability
• Candidates: PE, PP, PS, ABS, TPE, PA, POM, PC-ABS
• Glass filled resins
• Low quantities (5 to 100 Parts)
• Mid-sized parts (< 165 ccm, [10 cu. in.])
• Machine type:
• Bench Plastic Injection Molding Machines
• 50- to 100-ton molding machines
3DPIM – Best fit
A: PE, PP, PS, ABS, TPEs
B: PP+G, PA, POM, PC-ABS
C: PA+G, PC, POM+G
D: PC+G, PPO, PPS
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More cost and time effective way of validating the functionality of rubber parts before going to production.
Savings compared to Traditional Process:
• Steel Production Molds:
• 95% cost savings realized
• Months to days
• Aluminum Molds:
• 50-70% cost savings realized
• Weeks to Days
BenefitsMetal Molds
RTV Molding
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3D Print a mold to be used in the compression molding process.
• Produce fully vulcanized parts with real mechanical properties of rubber
• Mold a variety of materials with different shore values
• Silicone, EPDM, Nitrile, Natural Rubber, etc.
• Up to Shore 70
Rubber Molding with Ultem1010
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OEMs and suppliers who design or manufacture elastomeric rubber and foam materials can use this application:
Specified industries include:
• Automotive (seals and gaskets, dampeners, bushings…etc.)
• Footwear (shoe soles)
• Industrial Machinery (safety equipment, boots)
• Oil and Gas (gaskets, seals)
• Aerospace (gaskets, seals)
Industries
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Stratasys Materials
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Average thermal resistance
& toughness
Enhanced thermal resistance
& toughness
Highest thermal resistance
& toughness
WORLD OF PLASTICS
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13 FDM materials in total, in various colors
• Engineering
• FDM Nylon-12
• FDM Nylon- 6
• ST-130
• PC-ABS
• PC-ISO
• PC
• Standard
• ASA
• ABSplus
• ABSi
• ABS-M30
• ABS-M30i
• ABS-ESD7
• High Performance
• Nylon 12 – Carbon Fill
• ULTEM® 9085
• ULTEM® 1010
• PPSF/PPSU
• PEEK ESD
Different platforms support different:
− Materials
− Colors
− Support
FDM MATERIAL SELECTION
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Transparent
Rigid
Simulated
Polypropylene
Vero
(Opaque) Rigid
Vero (Opaque)
Rigid - Colors
Tango
Rubber-likeMedical
RGD720 DurusWhite VeroWhitePlus VeroYellow TangoPlus Biocompatible Clear
VeroClear Rigur VeroBlue VeroCyan TangoGray Hearing Aid Family
VeroGray VeroMagenta TangoBlack VeroGlaze
VeroBlackPlus TangoBlackPlus VeroDent
VeroDentPlus
Rigid Flexible Medical
POLYJET MATERIALS | STANDARD PLASTICS SIMULATION
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TANGO FAMILY COMPARISON CHART
TangoGray TangoBlack TangoPlus TangoBlackPlus
Color Gray Black Translucent Black
Rubber Shore A 73-77 60-62 26-28 26-28
Elongation at Break 45%-55% 45%-55% 170%-220% 170%-220%
Memory Speed Low High Mid Mid
Tear Resistance High Low Mid Mid
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Digital Material
Available In Polyjet Only
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• Digital Materials are Composite Materials•
DIGITAL MATERIALS
Composites are formed by combining materials together to form an overall structure that
is better than the sum of the individual components
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Generating Digital Materials
Primary
Rigid or Flexible
Secondary
Rigid or Flexible
Digital
Material
Composition
of Primary
and
Secondary
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EXAMPLE | RIGUR DM’S
6 flex DM’s and 2 Rigid
DM’s with Tango+
6 flex DMs and 6 Rigid DMs
(Gray scale) with TangoBlack+
New Simulated Polypropylene
materials
• Best PJ offering for ‘living hinge’ application
• Excellent solution for Snap fit application
• Available for all Connex 2 & 3 Systems
Rigur
6 flex DMs6 Rigid DMs
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• This is a Digital Material: RGD5160-DM
DIGITAL ABS MATERIAL
High
Temperature
RGD535/531
High Toughness
RGD515
RGD5160-DM
RGD515 RGD535/531
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WHAT DO DIGITAL MATERIALS LOOK LIKE?
—Tango+
—Elong. at break 170-220%
—Shore A 27
—RGD-MY002-DM
—Rigid
—RGD-MY006-DM
—Rigid
—Vero Magenta
—Rigid
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• 14 Colors Pallets
- All rigid
• Up to 46 colors each
• Combinations of
- Black,
- White,
- Cyan,
- Magenta,
- Yellow,
- Clear colors
RIGID COLORS WITH VERO PROPERTIES
Applications
• Final Product Part Realism
• Focus Groups
• Communication Tools
• …and many more!
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• 72 new Digital Materials per Pallet
• Flexible Colors
TANGO+ BASED PALLETS
VeroYellow
Rigid
VeroCyan
Rigid
Shore
95
Shore
35Shore
30 TangoPlus
Shore 27
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FDM & PolyJet Materials – Technical Capabilities
0
50
100
150
200
250
0 50 100 150 200 250
HDT (C)
Impact (J/m)
PolyJet
FDM
Form, Fit & Assembly
Function & End Use Parts
High Temp
High Temp after PT Digital ABS
after PT
Digital ABS
DurusWhite
PC-ABS
ABS-M30
PC
ULTEM 9085
PPSF
VeroWhitePlus
NYLON 12ASA
Rigur
ULTEM 1010/CG
PC-ISO
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3D PRINTERSPROFESSIONAL SYSTEMS IN ALL SHAPES AND SIZES
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Our Solutions
Stratasys offers a full range of 3D printers for every industry and application, including the world’s
most advanced 3D printing technologies, materials and support.
3D Printers and Production 3D Printers
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Stratasys J750:Mature technology, Ground-breaking Capability
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3rd Generation Multi-Material Technology
2004. Eden
1 Material
Highly accurate, finely
detailed models with ultra-
thin walls.
2007. Connex
2 Materials
The world's first multi-
material 3D printer.
2014. Connex 1/2/3
3 Materials
Stratasys introduces the
first-ever color and multi-
material 3D printer.
2016. J750
6 Materials
The world’s only full color,
multi-material, high resolution
3D printer.
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Stratasys J750 Possibilities
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THANK YOU