Demystifying 3D Printing & Additive Manufacturing

presentation for

Steve Hatten – TechHelpBrian Hoffmann – Intermountain3D

TechHelp and Intermountain 3D

• Empower Idaho’s manufacturing sector with

knowledge and access to high-technology additive

manufacturing tools and processes

• Accelerate growth and adoption rate of additive

manufacturing and rapid prototyping tools and

processes in Idaho

• Raise awareness and educate Idaho’s

manufacturing sector on high-efficiency

manufacturing tools and processes through jointly

held events and seminars

• Create opportunities for current Idaho students to

build skills in the high-tech manufacturing sector which are in demand

…are working together to:

3D Printing: Wiki View

3D printing (or additive manufacturing, AM) is any of various processes used to make a three-dimensional object. In 3D printing, additive processes are used, in which successive layers of material are laid down under computer control. These objects can be of almost any shape or geometry, and are produced from a 3D model or other electronic data source.

3D Printing: Mainstream Media View

• Manufacture at home on your own desktop!

3D Printing: Additive Manufacturing View

• Single piece titanium print

• 18 piece assembly reduced to 1 part

• 25% lighter

• Simpler, 5X more durable/reliable

• 15% reduction in fuel & CO2 emissions

• > $1.5 million in annual fuel savings/plane

• Lightweight composite & AM materials

• > 99.98% dispatch reliability

Aviation Manufacturing

LEAP Fuel Nozzle (19/engine) CFM LEAP Turbine Engine

Direct Metal 3D Printer

(EBM-Electron Beam Melting)

• GE plans to manufacture over 100K aviation parts by 2020

Gartner 2014 Hype Cycle

Commercial 3D Printing/Additive Mfg. has 5-10 year lead on consumer 3D printing.This is why you should care about Additive Manufacturing now!

Consumer 3D Printing

Commercial 3D Printing

3D BioPrinting

Design Cycle

Concept Development

Detail DesignBuild /

TestManufacture /

Ship

Time

Desired Revision Count

Cost per Change

Typical Revision Count

Prototype Early/Inexpensively

Revise Without Retooling

Additive Manufacturing Design Cycle

Design Revision Cost Rule of Thumb

Changes later frequently cost 10x the previous stage1

1 Reinertsen, D. (2009) Principles of Product Development Flow. Celeritas Publishing

FACT

Key Additive Manufacturing Benefits• Faster time to market for product

introductions and revisions

• End-to-end design cycle cost savings

– Concept phase: Inexpensive concept modeling

– Design phase: Design verification & 3D fitment check

– Build/Test phase: Prototyping materials that mimic production parts

– Mfg. phase: Elimination of part/job specific tooling and their own development cycles

Key Additive Manufacturing Benefits

• New design freedoms vis-à-vis elimination of many manufacturing limitations

– Parts that can only be built via AM techniques

• Improved product performance & quality, affordable continuous improvement

• Quick design cycles = more ideas = more breakthroughs = improved designs

• Improved communication = improved decision making & efficiency

Basic Truths About Additive Manufacturing

• There is no single 3D Printing technology that does everything best

• Each technology has strengths and weaknesses, e.g. material properties, speed, equipment cost, post-processing

• 3D printer choice should primarily be driven by intended APPLICATIONS

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The T25 housing is located inlet to the high-pressure compressor and protects the sensor electronics (Photo: GE Aviation)

GE announces first FAA approved 3D-printed engine part

– April 2015

Basic Truths About Additive Manufacturing

• Many companies rely on multiple 3D printer platforms for different applications or they will outsource for applications that their printer fails to satisfy

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Early Melni Connector Concept

• A great 3D printer is not a cure for poor CAD design practices

– CAD training, architecture, review, validation, etc. are important for successful AM

3D Print Technologies Roadmap

Concept Development Detail Design

Build / Test

Manufacture /

Ship

Powder-Metal

Powder-Thermoplastic

Liquid Plastic Photopolymer-UV Laser

Liquid/Gel Photopolymer-Piezo Jetting Printhead

Thermoplastic Filament-Extrusion

Powder-Gypsum/Plastic-Jetting Binder

Paper-Cut/Laminated

Sugar/Chocolate-Extrusion

Ceramic-Extrusion

• Resolution• Engineering applications• Material properties• $$$ Cost

Case Study – Consumer Products• Project: Series of tests to correlate material properties of production parts to 3D

printed parts

• Outcomes: High correlation resulted in change in “go to market” strategy

• Before: Destructive testing with SLA, SLS

• After: Destructive testing with SLA, later SLS

Production Seat SLS Seat

Investment Casting• Investment casting is the use of a pattern to create a single use direct-pour metal mold.

I3D Case Study

• 4 hours per/mold

• $1 material cost/mold

• Setup time (~1 hour)

• Capacity: 5-10 rings/wk

• 2 hours for 7 ring molds

• $0.5 cost/mold

• Setup time (10 minutes)

• Capacity: 50+ rings/wk

• Superior detail in parts

Before After

Custom Jewelry Manufacture(Process: Investment Casting)

CAD Wax Cast Assemble

Melni Connector - 3D Printing Applications

• Early Prototypes

• Product Testing

• Investor presentations

Questions?

BACKUP

CONCEPT PHASE EXAMPLE APPLICATIONS

CONSUMER ELECTRONICS RAPID DESIGN ITERATION

• Create models in hours instead of weeks, at one-fifth the cost

• Keeps the development cycle humming

• More refined, elegant products

Courtesy of Cisco Consumer Business Group, Denmark

“We get prototypes quickly, we refine them quickly, we create new ones, and

we derive our elite designs…”-- Eskild Hansen, Head of Cisco’s

European Design Centre

STAMPS AND WRITING INSTRUMENTS RAPID DESIGN ITERATION

• Time to market reduced by half• Faster, better, more innovative products

development• Improved production efficiency

Courtesy of Shachihata, Japan

FOOTWEAR DESIGN ITERATIONSCourtesy of Timberland, USA

• Dramatic reduction in prototype costs and turnaround time, resulting in more prototyping, better communication, better designs and increased revenue

“3D Systems printers have done exactly that for us, compressing our design cycles,

lowering our costs and helping us produce better products for our customers.”

– Toby Ringdahl, Computer Aided Design Manager, Timberland Company

ENGINEERING COMMUNICATION MODELS

• Evaluation models to match timeline and quality standards

• Marketing models for more effective decision making

Courtesy of Pratt & Miller, USA

Finite Element Result -Corvette GT2 Spindle Stress Colored and Deformation

x1000

LARGE MACHINE SCALED SALES & MARKETING MODELS

• Reduced time and costs for tradeshows displays• Powerful sales tool make the difference• Compressed design cycle by 25 to 30%

Courtesy of Spirax Sarco, USA

A $600,000 sale was closed with this 3D printed scale

model of the EasiHeat heat exchanger

This model weighs six pounds instead of 40, making it easy for sales persons to tote to customer calls

This 1/3 scale 3D printed model of the PTF4 Condensate Pump saves tradeshow labor time and costs

Clash Detection

• Use color to check interferences and remaining space

Courtesy of Shinryo and Team-S, Japan

Plant model – MEP Systems

DETAILED DESIGN PHASE EXAMPLE APPLICATIONS

3D Printing Applications – Design Verification Models

• Check Fitment

• Validate CAD Data

• Identify functional design revisions early

• Test form, fit and assembly

• Hands-on feedback

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Detailed Design Models

• Color and texture for faster approvalof details

Courtesy of Andrew Chary Architect

“BIM doesn’t reach its full persuasive potential on a computer screen. The model comes to life when you hold a 3D print in your hands.”

- Andrew R Chary, Andrew Chary Architect PLLC

TRANSMISSION TOWER DETAILED MODELS

• Better customer understanding with 3D printed models for presentations and communication

Courtesy of Nippon Katan Corporation, Japan

Catenary pole brackets and insulators

FORM & FIT TESTING

3D printed hi-flow exhaust pipe and manifold installed onto the vehicle to

ensure that the shape of the configuration was exactly the right fit

“Our ProJet x60 Printer has been the single biggest step we’ve taken to improve the way we refine concepts, develop products, communicate

with our suppliers and market our products”- Mike Wood

Chief Engineer, Trinity Products

Courtesy of Trinity Products

ASSEMBLY TEST OF WATCH HOUSINGS

• Inhouse prototyping: keeps developments confidential

• Higher Quality

• Flexible use: directly produce assembly fixtures

"With the high-precision 3D printed mock-ups of our wristwatch designs, we improved quality and saved three times the installation costs of our ProJet 3500 HD within

six months." - Mr. Naito

Product Development, Citizen Watch

Courtesy of Citizen

Solar PANEL DEVELOPMENT

• Multi-material design freedom and functionality

Courtesy of SolVilla and CCAT, USA

Building integrated solar examples

3D Printed Serial Plug

Hard Clear Material

Integrated Softer Material

Slide-In Copper Bus

FUNCTIONAL TEST PHASE EXAMPLE APPLICATIONS

Performance sensor data almost exactly the same

EARLY DESIGN TESTING

Production Seat SLS Seat

• Optimize performance of seat designs by testing various ideas with printed prototypes

Applications - Testing

• Material Properties or Post Finishing allow for testing of new designs prior to tooling

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Application - Testing & Validation

Total casting weight 28 Lbs Total casting weight 16.5 Lbs

Before After

Aerodynamic Models With Pressure tappings

Courtesy of the Federal Aerospace Administration, USA

FLUID FLOW IN HARSH ENVIRONMENTS

• Alternative designs for automotive oil tanks • 3D printed test parts withstand oil and other aggressive fluids• Improvement of flow rate

Source: madnesscar.blogspot.it

Save 12 Weeks from Traditional Methods

Speeding up Product Development

“ Our in-house 3D printing capability greatly reduced the lead time for our prototypes as well as the number of iterations needed.

We are saving about $250,000/year on prototype parts. ”

Daniel CopleyR&D Manager at Parker Hannifin

Courtesy of Parker Hannifin RACOR, USA

MANUFACTURING PHASE EXAMPLE APPLICATIONS

Applications - Manufacturing

Consolidate parts, reduce labor and eliminate tooling

Traditional manufacturing:• 15 parts• 5 SKU’s • 3 custom tools• 10 assembly checks

SLS Transforms Manufacturing

Consolidate parts, reduce labor and eliminate tooling

SLS additive manufacturing:• 1 part• 1 SKU• 0 custom tools• 1 assembly check

Application - Digital Manufacturing

• Currently used in– Mater Patterns for Jewelry Flask casting– Dental– Hearing aid shells– Surgical medical models

Tooling for molded pulp packaging

• Fast and economicaltool production

Courtesy of Regale

Molded pulp packaging produced

with a 3D printed tool

Applications – Bridge Tooling

• Accelerate manufacturing start-up• Protect increased investment

– Rapid tooling verification– First run jigs & fixtures– Confidence to make supply-chain

commitments

• Support product launch activities• First article functional products

– Final testing– Early customer placements

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Application- Direct Manufacturing

No Tooling + Complete Design Freedom

MTI – one-off oil pump pulley for racecar in 3 days

"3D printing opens up a whole new way of thinking about the design of

components, where printed parts allow for higher complexity and more complex

features that allow significant weight savings or enhanced flowability for

cooling within the component." Gary Cosmer, CEO, MTI

Satellite combustion chamber

(Courtesy of European Space Agency)

AEROSPACE MASS COMPLEXITY

Applications - Medical

Custom acetabular cup

for hip replacement surgery

Applications - Dental

Dental partials manufacturing

in CoCr

Reduce design to manufacturing by 4 weeks

• Allows for more design iterations

• Improved engine reliability with no design limitations

Courtesy of Honda Performance Development, USA

Oil Filter Housing Exhaust Manifold

ProJet CPX RealWax casting patterns

Electronic box cooling ductLotus F1 Team

17 Million Transparent Dental Aligners/yearCourtesy of Align Technology and their brand Invisalign

SPECIALIZED TOOLING

• 12 inserts in ~50 hours on Pro X300

• Smooth vertical walls with special build style

• Undercuts without supports

Avoid expensive CNC- direct manufacturing of propeller

Same day hydroforming tool

• Die mold printed in 6 hours

• No sign of wear after 100 pieces formed

• Superior surface finish and low investment cost

Same day hydroforming tool

The 3D printed mold

The 3D printed Die and formed part after hydroforming

The 3D printed die mold and cut metal sheet

Patented Roller- Wiper layering System

• Metal wiper lays the powder bed on the build plate and a special roller compacts the metal powder to the desired layer thickness/ density on return.

• Parts from one batch to the next are sintered with consistency and quality• Easier to handle size inconsistency in the metal powder and still achieve better results• Helps to work with smaller metal powder grain size ( down to 3 micron) when extreme• detail is needed• Works successfully with spherical and non-spherical powder particles• Works with Metal and ceramics in the same equipment

Large choice in standard metal alloys and ceramics

• More than 15 materials tested and available

• Steel, CrCo, Inconel, Al and Ti alloys

• Al2O3 ceramic

Inconel 718 AI2O3 AlSi12 Pure CuPure Cu

High density parts

Density> 99% of theoretical part

Smallest Parts – detail resolution

2mm gear with 20 teeth

C- clamp holding 16 thou wire

Applications - Automotive

Tire Molds

Applications - Energy

Microturbinemanufactured

from cermet powder

Applications - Tooling

Blow Mold with conforming holes