Johnathon Wright Application Engineer Phoenix Analysis & Design Technologies www. PADTInc.com

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PADT is an Engineering Services Company Three Business Groups

▪ Simulation – Training, Sales & Services ▪ Product Development ▪ Prototyping – Sales & Services

Founded in 1994 Four Aerospace Engineers Based on promise of emerging CAE technologies

ASU Research Park in Tempe, Arizona Onsite Labs: Clean Room, Medical, General Inspection and Assembly Facilities Machine Shop Training, Seminar and Meeting Space

Littleton, CO & Albuquerque, NM office Training Rapid Prototyping

www.padtinc.com

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• Introductions • What is 3DP/Additive Manufacturing? • Brief History • Top Five Technologies • Industries Best Served • Materials • Applications • Manufacturing Examples • Q&A

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Terminology Additive Manufacturing is a class of manufacturing

processes that produce 3-Dimensional objects from 3D computer model data by joining thin layers of cross-section of the 3D computer data.

AM is also known as Additive Fabrication, Layered Fabrication, Solid Freeform Fabrication, Rapid Prototyping and 3D Printing.

Physical Prototype • Form: looks, real shape and features • Fit: size, ergonomics, precision • Function: functionality and performance

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Many Companies and organizations that design and manufacture physical products use AM output from concept to end use product and every step of the product life cycle.

The main motivation of using Additive Manufacturing is its unique tooling-less nature that greatly shortens the product development cycle.

Another significant advantage of the tooling-less nature of the AM is that it is a perfect fit for personal customized products. (mass customization)

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BIG PLAYERS Stratasys

• Fdm • Polyjet • Solidscape • Redeye on demand

• 3D Systems • SLA • SLS • Inkjet (Z print) • Cube (Extrusion) • Quickparts

Metals • EOS – direct metal laser sintering (DMLS) • Arcam – electron beam melting (EBM)

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1988 AutoFact in Detroit: First SLA-1 in display 3D Systems (Chuck Hall)

1989 first commercial Stereolithography (SLA) machine sold 1991 Fused Deposition Modeling (FDM) - 3D Modeler introduced – Stratasys (Scott

Crump) 1992 Selective Laser Sintering (SLS) Sintersation 2000 introduced - DTM Corporation

(Carl Deckard, UT Austin) 1993 MIT developed 3 Dimension Printing Emanuel Sachs and Michael Cima

1994 Solidscape Drop on Demand: Wax patterns for investment casting 1995 Z Corporation 1996 Stratasys introduced Genisys 3D Printer 2001: Objet introduced PolyJet technology 2002 SLS metal sintering 2003 EOS metal sintering 2009: Bits from Bytes, MakerBot

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1. CAD - Neutral and Common File for transferring geometry to systems

– STL file • Faceted representation

– Surfaces are made up of thousands of triangles

• All CAD tools create STL files

2. TECHNOLOGY/Machine to

build your part

3. ONCE THE PART IS DONE – support removal, curing etc.

• The first commercially successful technology – Uses a liquid that hardens when exposed to ultraviolet light

• Photo curable polymer – Draw on top layer of liquid with ultraviolet laser – Supports made from same material

• Often called SLA – Stereolithography Apparatus

• Largest Vendor: 3D Systems – Smaller players in Japan, China, and Europe – Now available in “3D Printer” level

• Pricing – $15K - $800K

• Sizes – 10x10x10 – 59 x 30 x 22

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• Strengths – Resolution – Surface Finish – Transparent material – Variety of materials – Build Speed – Mature Technology

• Weaknesses – Post-Process Curing – Support removal and Sanding – Strength of material – Expensive materials

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• Fastest Growing Technology – 3 times as many Stratasys machines were sold in 2010 than 2nd place – Many low cost systems are FDM based

• 3D Printing to Digital Manufacturing • Biggest Provider is Stratasys, Inc.

– FDM & Polyjet • Prices:

– $10 k to $500k • Build Sizes:

– 5 x 5 x 5 – 36 x 24 x 36

Build Platform

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• Strengths – Material Options – Functional Parts – Part Strength – Ease of Operation – Low Cost Materials – Digital Manufacturing – 3D Printing Platforms

• Weaknesses – Surface Finish – Speed

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• Dominant Powder Technology – Use laser to sinter particles together – Uses powder to support

• Large, durable parts • Several Powdered Metal Applications • Dominated by 3D Systems

– A few competitors in Asia – EOS in Germany – European Laser Melting similar

• Prices: – $150k to $750k

• Build Size – 15 x 13 x 18

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• Strengths – Large parts – Flexible but strong – Speed – Self supporting

• Weaknesses – Messy powder – Surface finish – Material options – Warp – Facility Requirements

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Growing Technology

Prints layers of liquid photopolymer then cured with a UV light

Jet multiple materials in a single print Combine materials for distinct material properties

• Flexible materials, over molds Prices:

– $30k to $500k Build Sizes:

– 10 x 10 x 6 – 39 x 31 x 19

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• Strengths – Speed – Resolution – Surface finish – Digital Material printing

• Weaknesses – Cost of Materials – Photopolymer

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Many Players – MJM (3D Systems) – ZPrinter (Zcorp now owned by 3D Systems) – Solidscape (Sanders – now owned by Stratasys)

Prices – $8kto $330k

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• Major Press in the past 2 years for “maker” solutions: DIY

• Most are based on Fused Deposition Modeling (FDM)

• RepRap open source machine started it – 1,500 machines at the end of 2010 – MakerBot, Bits from Bytes,

and UP! are derivatives

• Very popular in incubators and “maker” labs

• Some impact in education • Lots of buzz • But, part quality is very low

Automotive Aerospace Medical Consumer Products Electronics Toys / Animation Defense Manufacturing