Additive Manufacturing in Manufacturing: A future · PDF fileAdditive Manufacturing in Manufacturing: A future oriented technology with high ... Physics, Chemistry ... Surgical forceps

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Additive Manufacturing in Manufacturing: A future oriented technology with high degree of innovation potentials- are we

ready? Challenges and Chances to handle

Prof. D.Sc. M.Sc. Gideon N. LevyAdditive Manufacturing and

Electro Physical & Chemical Processeswww.cdrsp.ipleiria.pt

18th edition of the AEPR forum 24 -27 June 2013 at Ecole Centrale Paris

Motivation

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How to 3D print your brain Jun.23, 2013

Once you have an MRI image of your head, you can then convert it to a 3D model. intirb uses software FreeSurfer to process the MRI brain scans to obtain the grey matter boundary of brain, intirb suggests to use MeshLab to simplify your .STL file

AM is Hot …published 13.02.2013

“3D printing that has the potential to revolutionize the way we make almost everything“ President Obama

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We are approaching our target…

Agenda I

1. Background

2. Scientific Manufacturing Management

3. Analysis and Synthesis for AM– Economics

– The workflow bottle necks

– TQM Total Quality Management

– TPM Total Productive Maintenance

4. Application Driven

5. Systems, Monitoring and Materials– Performance (productivity, repeatability, accuracy)

– Materials (Plastics, Metals, (Ceramics, Biomaterials))

– Automation

4

Agenda II

6. Pre- /Post Processing – Upstream Processes

– Downstream Processes

7. Business Model– Key users: Experimental validation and certification

– Mainstream users: Service Bureaus

– Modern users: E- Shopping (online / on site)

8. Conclusions

What are Nontraditional Manufacturing processes?

5

More than 25 years ago

08.08.1984 17.10.1986

Patent FDM and EBM

30.10.1989 11.05.1994

6

Patents of SLM and 3DP

12.07.1999 03.05.1999

5 Senses

Why do have AM a great potential?

Ab

stra

ct

Real

Per

cep

tio

n ThinkingSpeakingWritingPrintingPaintingCraftingArt, Music

Virtual realitySoftware Film TVSimulation ModellingScience: Rules and equations Physics, Chemistry Mathematics

Everything we have And more….

7

AM is an Enabling Multidisciplinary Technology

System / Process

Materials

Applications

Up stream/ Down stream

PolymersMetalsCeramicsCompositeBiologic

Application dedicatedAutomation

Part and powder handlingBatch to continues

……………..

Adaptive controlClosed loopProductivityRepeatability………………

Design for AM3DP design

toolPart finishing

Coating Modifications

…………

IndustryAviationAutomotiveJewelry

Medical devicesScaffolds

Organ printing……..

Sirmione – Lago di Garda, Italy (Was layer by layer nature inspired?)

8

Terminology - Process Categories I (2012)

1. Vat Photopolymerization Process Stereolithography, Envisiontec DLP, Micro-SLA, 2 Photon

Liquid Photopolymers,

Ceramic or Metal filled photopolymers

2. Material Jetting Process Multiple nozzles Single nozzles

Thermoplastics, Wax or Photopolymers, Metals,

Optical materials, Electronic materials

3. Binder Jetting process a liquid bonding agent is selectively deposited to join powder materials. Polymer, Metal, Ceramic powders

4. Material Extrusion ProcessFDM Polymers, composite

C

C

C

T

T

CChemical

TThermal

TThermal post processing

T

Terminology - Process Categories II (2012)

5. Powder Bed Fusion Process SLS, SLM, EBM

Polymers, metals & ceramics powder

6. Sheet Lamination Process Bonding, hot melt, glue, US welding

Paper, Metal, Polymers

7. Directed Energy Deposition Process focused thermal energy is used to fuse materials by melting as they are being deposited

Metal, polymers, powder, wireT

T

T

C

CChemical

TThermal

TThermal post processing

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Oversell

Commercialisation

“PhD”

DisillusionmentDevelompment& modification

Evaluation

Standardisation

ACCEPTANCE

Evolution

Need

Pioneers

Scientific“push”

Industrial “pull”

Scientific push and industrial pull

Gartner Hype July 2012

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3DP resourcing (and open sources!)

9 3D Printer Kits manufacturer

35 3D Printer Kits Models available

34 3D Printer Fully Assembled Models

/http://www.3ders.org

3Doodler: The World's First 3D Printing Pen

The pen: The 3Doodler pen is 180mm by 24mm. The pen weighs less than 200 grams

Fun Fact: The average 1kg spool of 3mm ABS contains approximately 360-370 feet of plastic. That's approximately 3,960-4,070 feet of 3Doodling, or 3 Empire State Buildings with enough to spare for several more weeks of doodling

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3DP@ Rapid Tech 13.05 2013 Erfurt

CM Equipment sales trend

CM Units/ year

105 160 198335

512 490650

1'032

1'910

2'450

0

500

1'000

1'500

2'000

2'500

3'000

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

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Additive Manufacturing “Machine Tools”

FDM EBM3DP (DoB)

SLASLS

SLM

Metal

The value chain in product creation

CONCEPT MODELING

RAPID PROTOTYPING

Pre-SERIE / BRIDGING

CONFORMAL COOLING / TOOLING

ADDITIVE MANUFACTURINGREVERSE ENGINEERING

The Trend

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US Patents on RP/AM in steady state trend- maturity growth?

Source: www.additive3d.com/home.htm

AM market growth

Systems and Services

Additive Manufactured parts

Materials

14

Agenda I

1. Background









– Automation

AM Manufacturing and SM (subtractive manufacturing) are comparable tasks with new features

Additive manufacturing (AM) is a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.

Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. (ASTM standard F 2792 - 09)

Manufacturing is the use of machines, tools and labor to make things for use or sale. The term is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale.

Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers".

=

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Manufacturing Implemented Scientific Management (Taylorism)

Scientific management is a theory of management that analyzes and synthesizes workflows, with the objective of improving labor productivity.

Total Quality Management (or TQM) is a management concept coined by W. Edwards Deming. The basis of TQM is to reduce the errors produced during the manufacturing or service process, increase customer satisfaction, streamline supply chain management, aim for modernization of equipment and ensure workers have the highest level of training

Lean manufacturing or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination.

Management philosophy derived mostly from the Toyota Production System (TPS)

Source: www.strategosinc.com/

App

licat

ions

App

licat

ions

App

licat

ions

App

licat

ions

Implement scientific manufacturing management (Tylorism)

The first level of industrial usability was reached Numerous applications of AM are success business

cases Modeling, permanent continuous performance advances

are required

Process, System, Materials

Production integration

Plant integration

Standards TQM Automation Productivity

Upstream processes Downstream processing business process or business

method

App

licat

ions

App

licat

ions

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Agenda I

1. Background









– Automation

Part prices (AM vs. Injection) in function of complexity

complexityfor free

complexityfor free

$ / part

AM Design DFF(Design for Functionality)

TraditionalManufacturing

Traditional DFM(Design for manufacturing)

Additive Manufacturing

Source: inspire - irpd Complexity

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Economics behind conceivable future volumes built with AM Technology (SLS).

Number of parts0

4.000-4.500 20.000

Only 20% ofthe material isin the parts

0

Cost [T€]

Motorcycle accessory:Lifetime: 5 years Volume: 10.000

Example Part:

500

Manual finishing required to bring surfaces up to standard for a visible part.

TQM a must for results and confidence in AM

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Fact is that for AM the results “depend” on:

Process / Technology dependent Material dependent Geometry dependent Application dependent System maturity and Equipment maintenance dependent Age and equipment generation dependent Operator skills and experience

AM is reproducible and reliable only under equal well controlled standardized

conditions

Design Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP RM USEDesign Materials Finish ComponentsRP AM USE

The bottlenecks in AM are the challenges

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The AM Field and Research Opportunities and Efforts

Source Road Map ALM 2009 D. Bourell et al.

Part type have different primary requirements and standards!

Decorative

surface structure

Functional

accuracy

Structural

properties

Medical

biocompatible

The wide ranging applications and requirement is a great challenge for manufacturing. Can a universal systems cover it?

Agenda I

1. Background









– Automation

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Applications arrays divide and focus consequently on different quality issues and standards

Positioning for plastic part AM manufacturing

Positioning for plastic part manufacturing:AM - Addetive Manufacturing; MI - Micro Injection; IM - Injection Moulding (Source: Levy G.N.iRPD)

Siz

e

IMIM

Complexity

M

S

L

XL

Siz

e

LMAMcuttingcutting

IM

low medium high

Qua

ntity

low

medium

high XXL

XS

LMcutting

MIMIMI

AM

IM

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AM direct metal components production relative to usual options

(Source: Meyer E.B., Levy G.N.)

106

105

104

103

102

101

100

Low Medium High

Geometric Complexity

Cutting

PM - Sintering Die Casting

InvestmentCasting

MIM

Layer Manufacturing

106

105

104

103

102

101

100

106

105

104

103

102

101

100

Low Medium High

Geometric Complexity

Qu

anti

ty

Cutting

PM - Sintering Die Casting

InvestmentCasting

MIM

Addtive Manufacturing

Global Adoption Of The Technology -Application

Patterns For PrototypeTooling

12.2% (12.3%)

Direct Part Production19.2% (14.9%)

Fit And Assembly12.1% (13.3%)

Functional Models18.4% (19.3%)

Visual Aids10.1% (12.0%)

Patterns ForMetal Casting8.9% (8.6%)

Presentation Models7.8% ( 8.1%)

Education/Research7% (5.4%)

Tooling Components2.7% (3.1%) Other

1.8% (2.9%)

Source Wohlers Report 2012

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Art and Interior

FO

C h

ttp://

ww

w.fr

eedo

mof

crea

tion.

com

/

23

3DP made Consumer goods will it be successful?

24

Various SLS Ducting, Panels and Covers for F/A-18E/F Manufactured by ODM

Boeing Dreamliner 787

32 SLS manufactured Polyimide air ducts (FR 106)

Functional designEasy to maintain

25

No-Tool production plastic - small parts

Series: 520 parts/year

Material: PA12 SLS made glass pearls blasting

Pries: EUR 4‘082.- / 520 part

Delivery: 3 days ( from Data)

AM PA12 case

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Conformal cooling systems and heat exchanger

A great chance is coming up in moulds!

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AMZ Silverstone Racing July 2010 ( with 21 “flying SLM parts)

http://www.amzracing.ch/http://www.formulastudent.com

Segmented impeller

Source :irpd

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Medical device advanced complexity

Medical and biomedical application

Body External

(non-clinical)

Op Theater Instruments

Surgical forceps

Surgical guides

Scalpels

OP support Jigs

Prosthesis Systems

Reconstructive prosthetic

Dental crown bridges application

Body internal Temporary

(clinical)

Scaffolds

Clinical suture

Degradable screws and plates

Drug delivery systems

Body internal Permanent

(clinical)

Hip implant

Knee implant

Inter verbal spacer

Cardiac pacemaker

Retinal implants

Dental implants

Topology of Bio- Device Manufacturing

DegradableNon-degradable Non-degradableNon-degradable

Use in operation theater ?Patient

specificPatient

matched

No

n-d

egra

dab

le

De

gra

dab

le

No

n-d

egra

dab

le

De

gra

dab

le

Use outside operation theater

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Customization – patient matched SLS made cutting template “My Knee”

Supporting SLM made Implants (Stainless or Titan)

SLM

Par

tsS

ourc

e :ir

pd

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DENTAL (orthodontic, alignments, copings, bridges, implants)

Data AM User

3DP

SLA

SLM

SLS

ALIGN TECHNOLOGY INC.

SLA 40’000 parts per day

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Medical and Life Science a promising future

MCP

Dr. Anthony Atala (USA) : 3D Printing of Body Parts

Institute for Regenerative Medicine in North Carolina

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Technology accomplished allows to build implantable body parts

66

8th July 2011

Logistics and supply chain mangment

Production on Demand

32

AM options in lightweight structures

Lightweight functional steel partAdditive SLS and Composite: no-tool forming

Composites Busch

SLS Micro Parts – also as actuators SMA (shape memory alloy) and ceramics

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The impact of the DirectSpare concept

Obsolete equipment because of unavailability of spare parts becomes useful

Millions of unused spare parts being reduced to scrap...

Ordered spare parts transported around the globe...

Warehouses stacked with spare parts...

Bio inspired AM fabricated systems

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Added Value: Translate process characterization into specific applications

Freedom of Design Lightweight structures (hollow) No-Tool production Assemblies, integrated design Anatomical personalized Ergonometric design Customization individualization Conformal cooling Gradual materials (on the way) Medical scaffolds (on the way) Bio Materials (on the way)

Agenda I

1. Background









– Automation

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Agenda I

1. Background









– Automation

EBM Arcam MultiBeam™

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Up-and-coming Production AM Systems

The 80`s trends in machining is repeating for AM Production oriented design Automation starting point, load unload ease Removable transportable work areas (cylinder, vat etc) Resin regeneration and recycling Production oriented control More process and system control in modern SLS, SLA and SLM

equipment Adaptive control, on-line calibration Closed loop position controls Closed loop laser power controls Closed loop temperature control Reporting Search for efficiency and productivity

[Watch e.g. PRO & EOS System, Prometal S systems, Conceplaser M3]

Continuous Additive Manufacturing

37

3DPContinuous Additive Manufacturing

SLM - Machine size categories

Small dedicated <1

Mid range 15-30

Very large > 100

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China 2013 $80 million investment in AM

An AM-built beam for use in aviation, printed at Northwestern Polytechnical University in China. Courtesy of Guancha Zhe.

Cell seeded scaffolds

A scaffold in tissue engineering serves as a temporary skeleton to accommodate and stimulate new tissue growth

Allow cell attachment, proliferation and differentiation;

Deliver and retain cells and growth factors;

Enable diffusion of cell nutrients and oxygen;

Enable an appropriate mechanical and biological environment for tissue regeneration in an organised way

Das Bild kann zurzeit nicht angezeigt werden.

AM scaffold manufacturing in tissue engineering

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Bio-M dedicated equipment - Biocell Printing all in one system implementation

http://www.cdr-sp.ipleiria.pt/

Scaffold printing stage Scaffold sterilisation chamber Scaffold bioreactor

PhD Work of Marco Domingos

Agenda I

1. Background









– Automation

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Feedback control of Selective Laser Melting

P. Mercelis, J.P. Kruth, J. Van VaerenberghDepartment of Mechanical Engineering, University of Leuven, Celestijnenlaan300B, Leuven, Belgium

Agenda I

1. Background









– Automation

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Direct Indirect

Design ModelsFunctional Models

RP - Prototyping-

Concept modelersPatterns

PartsLong-term use

Thermoforming-Fiber Molding-

ToolingLong-term use

Plastics

PartsLong-term use

Injection molding-Die casting-MIM, CIM

ToolingLong-term use

Metal

Electrical-Medical-

PartsLong-term use

Ceramics

Aviation-

PartsLong-term use

Composite

RM - ManufacturingcomponentsRT - Tooling

inserts

Layer Manufacturing

The structures of biomaterials for AM

Source :irpd

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Interaction manufacturing process material

Traditional processing Non Traditional processing Additive processing

Cast Forming Cuttingmicro

cutting Forming

Electrical

Thermal(e.g.Bea

mEnergy)

chemical (e.g.

Phtopolymer)

AMChemical

AMThermal

AMBiologic

al

Performance

Properties

Bulk (wire, powder liquid)

Preform

Structure

Atom Molecule

ElectronElementary

particle

SLS - Thermoplastics polymers (Red= tried for SLS)

PP

Polymer material choice advances

, iRPD

; EOS

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SLM - materials options

Stainless steel CL 20ES ( 1.4404 ) Hot-work steel CL 50WS ( 1.2709 ) CL 60DG ( 1.2709 ) CL 90RW (1.2083 ) Aluminum CL 30AL ( AlSi12 ) CL 31AL ( AlSi10Mg ) Titanium CL 40TI ( TiAl6V4 ) Nickel-based alloy CL 100NB ( Inconel 718 )

x-y Scanner Laser

Laser Beam

Levelling System

InertGas

Window

Metal Powder

Part

RetractablePlatform

Part

Laser Beam

Powder

x-y Scanner Laser

Laser Beam

Levelling System

InertGas

Window

Metal Powder

Part

RetractablePlatform

x-y Scanner Laser

Laser Beam

Levelling System

InertGas

Window

Metal Powder

Part

RetractablePlatform

Part

Laser Beam

Powder

Some trends and challenges in AM – Materials research

Filled Materials

Multi material

Local alloying

Digital Materials

Gradual Materials

Designed Anisotropy

Designed local property

Optimized metallurgical structures

Ceramics and composite

Medical and Biomaterials

Nano Materials

Micro parts

Memory shape alloys in AM

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9. Gradable materials (on the way)

CF process allows to customise the tibial component of a total knee implant, that fits the individual anatomy of the patient improving stability of the artificial knee joint

Customise material grading to fit individual patient physiology

Take CT scan of

tibia bone

100% Ti 100% CoCr

GradedCoCr –Ti

materials

Automated designed

tibial baseplate

3DP Digital Materials

100% Material A

100% Material B

75%:25%

50%:50%

25%:75%

Source: SFF 2012, Daniel Dikovsky, Ph.D.

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Agenda II






8. Conclusions

Design for AM e.g. Potential in der Aero industries

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Young Modulus v/s Elongation

SLS Material selection data base I

Tensile Strength v/s Density

SLS Material selection data base IV

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Design considerations on Laser Cusing andfor the EBM process

Design considerations on Laser Cusing andfor the EBM process

48

Topological Optimizations

Topological optimized design results are:• Complex geometries • Conventionally not produce

able• Have to be smoothed

• Highest geometrical freedom• Agile manufacturing• New design concepts

Chances for Layer Manufacturing:

ATKINS Project: a low-carbon footprint manufacturing solution

The £2.7 Million ATKINS Project …

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Post processing options for functional and visual parts enhancements

SLS parts

no surfacetreatment

surface refining

man made

coating

water-tight-repellent

pressure/vac. tight

wear resistance

UV-/ lightprotection

chemical resistance

film finish

flockfinish

laquerefinish

visual/aestheticfunctional

how to do it?Enhancement by finishing

how to do/proof it?

powdercoating

vaporC/PVD

machine made

A. Surface roughnessB. AestheticC. Functional

Best in Class - SLM parts Polishing

50

Engineered surfaces - Engineered Trabecular Structures™

The material can incorporate integrated Trabecular Structures™ and Engineered Surface Porosity™ (ESP).

This enables design for osseointegration and reduces the number of process steps in manufacturing.

Pictures of bone growing into titanium implants with Engineered Surface Porosity, manufactured in the EBM process.

Courtesy of Professor Peter Thomsen, MD, Dept. of Biomaterials, University of Gothenburg, and ARCAM

SLM HIP Hot Isostatic Pressing

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SLM post heat treatments

Agenda II



7. Business Model– Key users: Experimental validation

and certification



– Others?

8. Conclusions

52

Around 30 AM Systems SLA SLS

Harvest Technologies, which was started by David K. Leigh and his father David E. Leigh out of their barn, celebrated the opening of its 40,000 square foot facility

The company that was created, Rapid Quality Manufacturing (RQM), has as its entire focus and business model the creation of higher-volume production parts using DMLS and other additive fabrication technologies. Greg Morris, CEO, Morris Technologies, Inc.

17 M270 und 1 M280 SLM Anlagen

Headquarters: Cincinnati Ohio, United StatesRevenue: $3 MillionEmployees: 75

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Shapeways is a spin‐out of the lifestyle incubator of Royal Philips Electronics

Agenda II






8. Conclusions

54

We are on the right track

Conclusions

The sustainability will be a mayor issue for all of us

The implementation of Scientific Management (Taylorism) is a must

Hybrid systems are in due

Productivity, Automation and quality enhancements are a permanent issue

New application driven manufacturing tasks coupled with product innovations are just around the corner.

Interdisciplinary and complexity are increasing

Additive Manufacturing Processes are a great challenge and chance in manufacturing

5 years to go!

The scientific AM community has to be involved

55

Personalized

Construction of a CUBESAT using AdditiveManufacturing

Additive manufacturing

The sky is the limit !

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Conclusions by Albert Einstein

The formulation of a problem is often more essential than its solution, which may be merely a matter of mathematical or experimental skill.

The process of scientific discovery is, in effect, a continual flight from wonder.

All meaningful and lasting change starts first in your imagination and then works its way out. Imagination is more important than knowledge.

Albert Einstein

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Additive Manufacturing in Manufacturing: A future · PDF fileAdditive Manufacturing in Manufacturing: A future oriented technology with high ... Physics, Chemistry ... Surgical forceps