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Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided Engineering Department of Industrial Engineering, University of Louisville Chairman, ASTM F42 Committee on Additive Manufacturing Technologies Fulbright Scholar, VTT Technical Research Center, Finland

Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

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Page 1: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

International Trends in Additive Manufacturing

Prof. Brent StuckerClark Chair of Computer Aided Engineering

Department of Industrial Engineering, University of Louisville

Chairman, ASTM F42 Committee on Additive Manufacturing TechnologiesFulbright Scholar, VTT Technical Research Center, Finland

Page 2: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

University of Louisville’s Involvement in AM

• One of the best equipped additive manufacturing (AM) facilities in the world

• Performing Basic and Applied Research, since starting with SLS in 1993

• Over 20 people focused on AM• Close partner of leading AM users

– Boeing, GE, DoD, Integra, service bureaus, etc.• Over 70 member organizations in our RP Center

– Includes Haas Technical Education Center

Page 3: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Just This Year…

• Newspapers, magazines, TV shows and technical publications have all become fully immersed in the hype surrounding 3D printing and additive manufacturing

• President Obama & Vice-President Biden have spoken about the potential and it played a role in presidential politics– U.S. Department of Defense (including DARPA), Department of

Energy, National Institute of Standards and Technology and other agencies are actively funding AM research & development

• Mergers & acquisitions are in full-swing• Most major manufacturers are spinning up R&D

Page 4: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

National Additive Manufacturing Innovation Institute (NAMII)

• Youngstown Ohio-based collaboration between institutions in Ohio and Pennsylvania (both key swing states in the 2012 election)

• Recently announced $4.5M (+$5M) in funding– Three FDM-related projects– Tool and die repair using directed energy deposition– High-temp SLS maturation– Thermal imaging for DED– Modeling and qualification of metal powder bed fusion

Page 5: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Other U.S. Government funding

• Joint Defense Manufacturing Technology Program exploring DoD-wide standards for metal AM

• DARPA Open Manufacturing program funded a Manufacturing Demonstration Facility (MDF) and several AM modeling proposals

• DOE funded a large Oak Ridge National Laboratories MDF

• AFRL is actively funding small businesses and universities in many areas

• NIST is funding several Universities

Page 6: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Other International Observations

• China is poised to spend a significant amount of money on AM ($300M+)

• Europe is fully embracing the hype– EU bureaucracy is pushing standards– New funding is on the way

• Stock valuation is very high right now…• Lots of misinformation

Page 7: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

International Standards

• Standardized process categories adopted by both ASTM and ISO– Majority of my talk uses this structure

• New file format (AMF)• Location/Orientation Standard• Process standards for Ti64

Page 8: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Vat PhotopolymerizationProcess

• An additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. – Stereolithography– Envisiontec DLP– Micro-SLA– …

Page 9: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Vat Photopolymerization

• Increased proliferation of DLP/LCD/LED technology to cure entire layers at once.

• New photopolymer materials which mimic engineering photopolymers

• Expiration of initial stereolithography patents are opening up the marketplace– DSM/3D Systems patent infringement and anti-trust

lawsuit over open versus closed machine architecture were settled

• Renewed interest in 2-photon polymerization

Page 10: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Material Jetting

• An additive manufacturing process in which droplets of build material are selectively deposited– Wax or Photopolymers– Multiple nozzles – Single nozzles– Includes

• Objet• 3D Systems Projet• Stratasys Solidscape machines• Several Direct Write machines• Etc…

Page 11: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Material Jetting

• Stratasys merged with Objet• Many traditional “2D printing” companies are

investigating 3D printing– Thermoplastics

• Viscosity issues

– Metals– Color

• Significant interest in printed electronics

Page 12: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Binder Jetting

• An additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials. – Zcorp– Voxeljet– ProMetal/ExOne– …

Page 13: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Binder Jetting

• 3D Systems purchased Zcorp and has changed marketing

• ExOne is pushing “sand printing” and builds metal parts for Shapeways

• Voxeljet, fcubic and others makes the marketplace very dynamic right now– Expiration of patents will open up the marketplace– Continuous build platform design has major

ramifications

Page 14: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Material Extrusion

• An additive manufacturing process in which material is selectively dispensed through a nozzle or orifice– Based on Stratasys FDM

machines– Office friendly– DIY community– Best selling platform– …

Page 15: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Material Extrusion

• Expiration of initial FDM patents has led to a vast proliferation of do it yourself machines– More “DIY” machines sold today than “manufacturing”

machines• 3D Systems offers their own platform• Stratasys focusing on the engineered component

marketplace– New materials, fiber-reinforced composites, etc.– People seem to be taking it more seriously than a few

years ago

Page 16: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Powder Bed Fusion

• An additive manufacturing process in which thermal energy selectively fuses regions of a powder bed– SLS, SLM, DMLS, EBM, BluePrinter, etc. – Polymers, metals & ceramics

Page 17: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Powder Bed Fusion

• First ASTM F42 Ti6/4 Standard– Covers all thermal sources (lasers & electron beams)

• Many metal laser sintering machine manufacturers– SLM Solutions, ConceptLaser, EOS, Phenix, Renishaw, Realizer

• Limited polymer machine manufacturers– 3D Systems & EOS– New companies quietly entering the marketplace

• Significant R&D investments• Open versus Closed machine architectures• High Speed Sintering soon?• GE Bought Morris Technologies

Page 18: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Sheet Lamination

• An additive manufacturing process in which sheets of material are bonded to form an object.– Paper (LOM)

• Using glue

– Plastic• Using glue or heat

– Metal• Using welding or bolts• Ultrasonic AM…

Page 19: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Examples of Sheet Lamination

• Laminated Object Manufacturing– Paper

• Ultrasonic Consolidation (Ultrasonic Additive Manufacturing)– Metal sheets and foils

• CAM-LEM– Ceramic and metal tapes

Page 20: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Sheet Lamination

• Fabrisonics formed as a Joint Venture between EWI and Solidica– Selling 3 new platforms based upon their higher power

sonotrode designs• Renewed interest in paper-based machines at the

low-end by Mcor and others

• Other solid state AM methods are being investigated

Page 21: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

– Wire & Powder Materials– Lasers & Electron Beams– Great for feature addition & repair

Directed Energy Deposition

• An additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited

Page 22: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Developments in Direct Energy Deposition

• Electron Beam with wire seems to be the leading process right now

• Manufacturers are exploring marketing their laser deposition heads as add-ons to existing machine tools

• Increasingly being used for overhaul and repair• New Mil-standard just published

Page 23: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Hybrid AM

• Direct Write electronics plus AM

• AM plus subtractive milling

Page 24: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

AMF File format

• .AMF– Additive Manufacturing Format– Additive Manufacturing File

• Open source license-free implementation– amf.wikispaces.com

• Next step is to work with software providers (like Microsoft & Materialise) to refine and implement the standard

Page 25: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Basic AMF Structure

<?xml version="1.0" encoding="UTF-8"?><amf units="mm">

<object id="0"><mesh><vertices>

<vertex><coordinates>

<x>0</x><y>1.32</y><z>3.715</z>

</coordinates></vertex><vertex><coordinates>

<x>0</x><y>1.269</y><z>2.45354</z>

</coordinates></vertex>...

</vertices><region>

<triangle><v1>0</v1><v2>1</v2><v3>3</v3>

</triangle><triangle><v1>1</v1><v2>0</v2><v3>4</v3>

</triangle>...

</region></mesh>

</object></amf>

Addresses vertex duplication and leaks of STL & Units!

Page 26: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing Compressibility

Comparison for 32-bit Floats; need to look at double precision

Page 27: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

CURVED PATCH(Curved using vertex normals)

PLANNAR PATCH

Optionally add normal/tangent vectors to some triangle mesh edges to allow for more accurate geometry.

CURVED PATCH(or curved using edge tangents)

Curved patches

Page 28: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Multiple Materials

Micro-structureGradient

Materials

Page 29: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing Color and Graphics

• Can be assigned to – A material– A region– A vertex

• Specified– Fixed RGBA values– By formula– By reference to an image

Page 30: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing Print Constellation

• Print orientation• Duplicated objects• Sets of different

objects• Efficient packing• Hierarchical

Page 31: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Testing

• Testing Terminology Standard– Standardized part orientation and location within a

build– Based on basic coordinate systems as per ISO 841

+Y

+X

+Z

+C+B

+A

Page 32: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Coordinate Systems w.r.t Platforms

+Y

+X

+Z

Front of machine

Build volume origin (0,0,0)

Buildplatform

+Y

+X

+ZFront of machine

Build volume origin (0,0,0)

Buildplatform

(translucent)

For downward building machine architectures

Page 33: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing Location and Orientation of

Parts

Page 34: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing Location and Orientation of

Parts with Simplified Notation

Z

XY

XYZ

Z

XY

Z

XY

Z

XY

Z

XY

Z

XY

YXZ

ZXY

XZY

YZX

ZYX

Page 35: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing Location and Orientation of

Parts with Simplified Notation

Z

XY

Z

XY

ZX Z

Page 36: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Business Developments

• Business models used for 2D printing, such as for photographs, are starting to be applied in 3D– Print your parts at home, at a local “Staples,” or

through an on-line store (e.g. Shapeways)• 3D Systems continues their buying and merger

spree. • 3D printing is a major investment category now• Marketplace is exploding in almost every

direction, except new materials

Page 37: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Web 2.0 + AM = Factory 2.0

• User-changeable web content plus a network of AM producers is resulting in new entrepreneurial ventures– Shapeways.com– Freedom of Creation– FigurePrints– …and more

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Page 38: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Modeling, Process Control & Part Quality Verification

• Significant investments in trying to better understand AM processes– Numerical models which describe the relationship

between process parameters, material microstructure and part properties

• Everyone wants better process monitoring and control– Closed software platforms have a very negative

reputation rights

Page 39: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Possible Societal Implications

• Additive Manufacturing may have the potential to:– Make local manufacturing of products normative

• Small businesses can successfully compete with multi-national corporations to produce goods for local consumption

• Parts produced closer to home cost the same as those made elsewhere, so minimizing shipping drives regional production

– Reverse increasing urbanization of society • No need to move to the “big city” if I can design my product

and produce it anywhere– Make jobs resistant to outsourcing

• Creativity in design becomes more important than labor costs for companies to be successful

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Page 40: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

The Future of International Collaboration?

• We are at a turning point in our industry1. We are big enough that people care about us

• Nationalism is increasingly apparent• Financial markets are starting to pay attention to us

2. Monopolies are disappearing as patents expire• New companies and new countries can compete in the

global marketplace, but old monopolies fight hard to dominate

• I see companies and countries trying to lock other companies/countries out of certain AM technologies– and standards development activities

• Will they succeed? I hope not!

Page 41: Additive Manufacturing International Trends in Additive ... · Additive Manufacturing International Trends in Additive Manufacturing Prof. Brent Stucker Clark Chair of Computer Aided

Additive Manufacturing

Questions & Comments?

[email protected]