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1 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
AM Capabilities for Thermal Management with a comprehensive study of IN625 Powder Reuse* and the effect on tensile properties
Frederick Claus
Business Development Manager – Aerospace and Defense
Stratasys Direct Manufacturing
* STUDIED ACROSS SEVEN (7) EOS M280 MACHINES OVER THE
COURSE OF EIGHT MONTHS WITH MORE THAN 800 BUILDS
High Efficiency High Temperature Modular Power Utilizing
Innovative Designs, Materials, and Manufacturing Techniques
2 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
AGENDA
• Stratasys Direct Manufacturing – Technologies and Services
• Validating Additive Metals Process for Production Parts
• Additive Capabilities for Thermal Management
• Applications
• Challenges and Future Work
3 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Stratasys Direct Manufacturing is
one of the largest providers of
additive and conventional
manufacturing solutions:
• 7 U.S. manufacturing facilities
• 12 manufacturing technologies
• 600+ employees
• Certifications: ISO 9001, AS9100
• ITAR registered
• Over 25 years experience
About Stratasys Direct Manufacturing
4 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Our experienced team of project engineers is committed to your success with:
• Design support for additive manufacturing
• Technical direction and recommendations
• Material, technology and build optimization for quality,
speed and reduced cost
• Material and Manufacturing Process development
Your Team
5
Stratasys Direct Manufacturing Technologies and Services
6 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Technologies
ADDITIVE
CONVENTIONAL
PolyJet & Stereolithography
Photo-curable ResinsFused Deposition Modeling
Plastic extrusion
Laser Sintering
Laser Based Plastic Powder Bed FusionDirect Metal Laser Sinter
Laser Based Metal Powder Bed Fusion
7 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Product Development Cycle
Concepts
Design &
Engineering
Prototype
Low Volume
Production
Full Scale
Production
CONVENTIONAL
ADDITIVE
8
Stratasys Direct Manufacturing Additive Metals Capacity and Capabilities
9 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Additive Metals Capacity and Capabilities
Two (2) Facilities located in: Austin and Belton, TX
Seventeen (17) Laser Powder Bed Fusion Machines
8 M280’s, 1 M270, 1 M400 in Austin, TX
4 M280’s and 3 M290 in Belton, TX
Ten (10) Metal Alloys
Staff: Programmers, Machine Technicians, Finishers,
Machinists, Design Engineers, Application Engineers
and Manufacturing Process Engineers
Post AMM Support
Five (5) CNC Mills; 3, 4, and 5-axis
Two (2) CNC Lathes
Two (2) Wire EDM and Drill EDM
Surface grinder, Stress-relief kiln, Down
draft tables, shot peen blast cabinets,
multiple tumbling machines
Outsource: Abrasive flow machining,
Mechanical-Chemical PolishingAMM Inspection
Metallographic Mount and Polisher, hardness tester, Zeiss CMM, Flow bench, High resolution scale,
Profilometer
10 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY10
ADDITIVE METALS PRODUCTION FACILITIES
Austin, TX
Belton, TX
Austin and Belton, TX - Similar Capacity,
Redundant Capability
1111 S T R A T A S Y S D I R E C T M A U F A C T U R I N G / C O N F I D E N T I A L
Current Alloy Offerings1. SS 17-4 PH*2. SS316L3. IN 625* 4. IN 718* 5. IN718 API-std6. CoCrMo7. Monel K-5008. Invar-369. AlSi10Mg10. Ti 6-4 Gd5*
* Powder chemistry ordered to meet respective AMS standards.*
Standard Text = Performance Super Alloys
Bold Text = Quick Turn Alloys
Alloys sourced directly from multiple established atomizers.
IN625: -45um +10um, Unused
SS17-4: -45um +10um, Recycled
Additive Manufacturing Metal AlloysFeedstock = Argon gas atomized powder.
All materials are kept in airtight,
color-coded containers
Materials are batched and blended to ensure full
traceability
1212 S T R A T A S Y S D I R E C T M A U F A C T U R I N G / C O N F I D E N T I A L
Stress Relief
Plate-Part Separation
Part Serialization
In-process Inspection
HIP
SHT, PHT
Dimensional Inspection
RadiographicInspection
Performance Inspection
Stratasys Direct, In-house
Powder Removal
This is the only Additive Step
Dimensional InspectionCMM, Faro, Surface Roughness
Radiographic InspectionX-ray, CT scan
Performance InspectionHydrostatic Pressure, Air Effective Area
Heat Treating Vendor Radiographic Testing Vendor
Post Machining
Outsourced operations are executed by strategic partners where SDM programs take priority.
Cutup Metallography
DMLS
DMLS is only an incremental step in Additive Manufacturing. SDM offers the total solution.
Additive Manufacturing includes the Conventional
13
ANSWERING PROCESS QUESTIONS
Industry claims powder degrades with time and exposure.
• Companies are forming around the fear.
• Customer’s specs call for no part to be built with any powder
older than 90 days.
The mechanical and material properties trended against Blend
Composition will answer industry’s question of powder degradation.
Addressing the Industry-Wide Question; Does AM Feedstock degrade with time and exposure?
IN625: -45um +10um, Unused
SS17-4: -45um +10um, Recycled
14
IN625 Powder Recycle and
Reuse Study* ANALYSIS ACROSS SEVEN (7) EOS M280 MACHINES OVER THE COURSE OF EIGHT MONTHS WITH MORE
THAN 800 BUILDS
1515 S T R A T A S Y S D I R E C T M A U F A C T U R I N G / C O N F I D E N T I A L
Powder Reuse StudyAddressing the industry wide question.
Material Property Study - Insight into Powder Life Cycle
Tensile and Microstructure
Industry claims powder degrades with time and exposure.
Companies are forming around the fear
Customer’s specs call for no part to be built with any powder older than 90 days.
SDM’s answer:
- 7 machines building the same material
- 2 tensile bars and 1 metallographic coupon positioned per plate
- over 60 builds/machine
Material properties trended against Blend Composition will answer industry’s
question of powder degradation.
IN625 – As Built Microstructure
16 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Configuration
Back Left
Front Left Front RightFront Left
Front Right
Back Left
3 Sacrificial Cylindrical Blanks, >800 Builds
17 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Processing
Additive
Manufacturing (94hour build, >2800
Layers)
Stress Relief(1925F for 120min)
Plate Part Separation(Saw)
HIP(1950F @ 14.5ksi for 4hrs)
Solution Heat
Treatment(2175F for 60min)
Machining (Per ASTM E8 cylindrical
bars)Testing
(Per ASTM E8 cylindrical
bars)
Tensile Blanks were process alongside
component
Coupons represent relieved component.
18 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
7 Machines, 2 Material Providers, 8 Material Lots, >55 Builds per
Machine
210 tensile bars, 14 Chemical, 20 Metallography
Comparisons:
Material Provider
Build Location
Machine to Machine Consistency
Powder Composition
What was Involved
19
Implemented a digital system providing a resolution in powder composition unmatched by industry.
Logging and minding powder composition over time.
Fundamentals
Workbench - BuildIt / Powder ReportDigital means to log and mine powder composition
2020 S T R A T A S Y S D I R E C T M A U F A C T U R I N G / C O N F I D E N T I A L
Material Recycle and ReusePowder Composition is in a constant state of f lux.
• SDM Recycles 100%
material
• The majority of powder
has been recycled.
• No test method is
identified to qualify
recycled powder
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Axi
s Ti
tle
Times Recycled
Theoretical IN625 Batch Composition Over 30 Recycles
90 Day Limit Build 31
Build 26 Build 21
Build 12 Build 11
Build 6 Build 1
% of Original Batch
21 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
UTS (ksi) Yield (ksi) Modulus (Msi) Elongation (%) Reduction of Area (%)
Perc
enta
ge
Str
ength
(ksi, M
si)
Build Plate Location - Tensile Property Comparison
BL FL FR
n = 66 , 74, 70
Build Location – Machine to Machine – Powder Composition – Material Provider
Build Location Comparison
22 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
UTS Yield Mod Elogation RA
Perc
ent
Str
ength
(ksi, M
Si)
Tensile Property
Machine Comparison - Tensile Property Comparison
SI1849 SI1476 SI2001 SI2006 SI1848 SI1989 SI1991 - Sup. 1
Machine To Machine ComparisonBuild Location – Machine to Machine – Powder Composition - Material Provider
23 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Powder Evolution / Life Cycle Build Location – Machine to Machine – Powder Composition – Material Provider
0 10 20 30 40 50
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 50 100 150 200 250
Times Recycled
Str
ength
(ksi)
Age of Oldest Powder (days)
SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)
Elongation (%) RA (%)
% Virgin % Original Blend
24 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Tensile Properties Overlaid Onto Powder CompositionBuild Location – Machine to Machine – Powder Composition – Material Provider
0 10 20 30 40 50
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 50 100 150 200 250
Times Recycled
Str
ength
(ksi)
Age of Oldest Powder (days)
SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)
Elongation (%) RA (%)
% Virgin % Original Blend
25 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
0 10 20 30 40 50
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 50 100 150 200 250
Times Recycled
Str
ength
(ksi)
Age of Oldest Powder (days)
SI1476 - Vertical Tensile Properties UTS (ksi) Yield (ksi)
Elongation (%) RA (%)
% Virgin % Original Blend
Introduction of Separate Powder LotsBuild Location – Machine to Machine – Powder Composition – Material Provider
Lot 30 Lot 32 Lot 33 Lot 34 Lot 35
26 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Microstructure Over TimeBuild Location – Machine to Machine – Powder Composition – Material Provider
0 10 20 30 40 50 60
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 50 100 150 200 250 300
Times Recycled
Str
ength
(ksi)
Age of Oldest Powder (days)
SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)
Elongation (%) RA (%)
% Virgin % Original Blend
A B C
A (xy)
8e-3inB (xy)
8e-3inC (xy)
8e-3in
27 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Microstructure Different OrientationsBuild Location – Machine to Machine – Powder Composition – Material Provider
A (xy)
8e-3inB (xy)
8e-3inC (xy)
8e-3in
A (xz)
8e-3in
B (xz)
8e-3in
C (xz)
8e-3in
28 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
0 10 20 30 40 50 60
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 50 100 150 200 250 300
Times Recycled
Str
ength
(ksi)
Age of Oldest Powder (days)
SI1849 - Vertical Tensile PropertiesUTS (ksi) Yield (ksi)
Elongation (%) RA (%)
% Virgin % Original Blend
Material Chemistry Over TimeBuild Location – Machine to Machine – Powder Composition – Material Provider
29 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Material Chemistry Over TimeBuild Location – Machine to Machine – Powder Composition – Material Provider
0.0
0.5
0 50 100 150 200 250 300
Weig
ht (%
)
Powder Age (days)
IN625 Chemisrty SI1991 Sup. 1 SI1849 Sup 1 Limit
Times Recycled
20.021.022.023.0
0 50 100 150 200 250 300
8.0
9.0
10.0
0 50 100 150 200 250 300
3.0
4.0
5.0
0 50 100 150 200 250 300
3.0
4.0
0 50 100 150 200 250 300
Cr
Mo
Nb+Ta
Al
Fe
10 20 30 40 50 60
30 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Material Provider Comparison
0%
5%
10%
15%
20%
25%
Ultimate Tensile Strength (ksi)
Ultimate Strength Material Provider Comparison, Uts
0%
7%
14%
21%
28%
35%
Yield Strength (ksi)
Yield Strength Material Provider Comparison, Yts
Material Provider 1, n = 180
Material Provider 2, n = 30
Build Location – Machine to Machine – Powder Composition – Material Provider
31 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
UTS Yield Mod Elogation RA
Perc
ent
Str
eng
th (
ksi, M
si)
Tensile Property
Material Provider - Mechanical Property Comparison
Provider A Provider B
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
n = 180 n = 30
32 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
UTS Yield Mod Elogation RA
Perc
ent
Str
enth
(ksi, M
Si)
Tensile Property
Machine Comparison - Tensile Property Comparison
SI1849 SI1476 SI2001 SI2006
SI1848 SI1989 SI1991 - Sup. 1 SI1991 - Sup. 2
33 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 2 machines
34 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 2 machines
35 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 3 machines
36 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 4 machines
37 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 5 machines
38 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 6 machines
39 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 10 20 30 40 50 60 70
Str
ength
(ksI)
Times Recycled
Material Strength vs. Times Recycled, 6 machines , 2 atomizers
40 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
The different chemistries produced by different suppliers produced statistically different ultimate
tensile strength.
SupplierSupplier 1
(% by Weight)
Supplier 2 (% by Weight)
Al 0.32 0.14
Cr 21.02 21.54
Mo 9.2 9.1
Nb+Ta 3.66 3.73
Fe 0.04 3.90
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
Material Chemistry
41 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Build Location – Machine to Machine – Powder Composition – Material Provider
Material Provider Comparison
0.0
0.5
0 50 100 150 200 250 300
Weig
ht (%
)
Powder Age (days)
IN625 Chemisrty SI1991 Sup. 1 SI1849 Sup 1 SI1991 Sup. 2 Limit
20.0
22.5
0 50 100 150 200 250 300
8.0
9.0
10.0
0 50 100 150 200 250 300
0.0
2.5
5.0
0 50 100 150 200 250 300
3.0
4.0
0 50 100 150 200 250 300
Cr
Mo
Nb+Ta
Al
Fe
42 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Out of the 220 Bars, 2 Appeared “Different”
0 10 20 30 40 50 60 70
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
0 50 100 150 200 250 300
Times Recycled
Str
ength
(ksi)
Age of Oldest Powder (days)
SI1989 - Vertical Tensile Properties UTS (ksi) Yield (ksi)
Elongation (%) RA (%)
% Virgin % Original Blend
Build 51334
Build 50814
BL
FL
FL
FR
43 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Tensile Results Build 50814
0
10
20
30
40
50
60
70
80
0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% 0.70%
Str
ess (
ksI)
Strain (%)
50814-FR
50814-BL
50814-FL
44 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Tensile Comparison, Build 51334 & 54747
0
10
20
30
40
50
60
70
80
90
0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% 0.70%
Str
ess (
ksi)
Strain (%)
51334-FR
51334-FL
51334-BL
54747-FL
54747-BL
45 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Solution Heat Treated, HIP’ed, Stress Relieved, Additive IN625 (100x)
z
x
y
z
x
y
Stress Relieved, Additive IN625 (100x)
Metallographic Comparison, Build 51334 & 54747
46 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
SDM’s mission to control, track, and develop the AM production process has
lead to vertical integration of multiple post process operations and
inspection techniques providing the industry with
• The most efficient and economic powder management process.
• Decreased response time to process drift and potential defect parts.
• Increased confidence in DMLS material/part quality
• Separation from SDM’s competition.
• Increased customer confidence.
• Insight into powder lifecycle
Conclusion
47 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
AM Capabilities for Thermal Management
48 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Next-generation thermal management demands:
• Increased performance with minimum pressure loss
• Reduced size and weight
• Affordable, modular, scalable
Part Consolidation
• Eliminate thermal resistance between components
• Reduce assembly time and weight
Tool-less, Digital Inventory
• Easily iterate through the design/build/test cycle
• Reduced lead times
• Simplified supply chain
WHY CHOOSE AM FOR THERMAL MANAGEMENT?
49 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Design freedom enables increased performance
• Few tooling constraints
• Cost does not scale with complexity
• Nonlinear, tapered, optimized variable geometries
• Extended surfaces: fins, vanes, blades
• Heat pipe capillary wicking structures
• Conformal internal passages
• Thermal topology optimization
WHY CHOOSE AM FOR THERMAL MANAGEMENT?
50 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Additive Applications
51 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
Known thermal management applications include:
• 3D modeling for concept validation
• Integral regenerative cooling of rocket engines
• Optimized wicking structures for passive heat pipes
• Microchannel and jet impingement strategies for
microelectronic device cooling
• Lattice structures for integral thermal shielding
• Conformal cooling for injection molds
• Thin-film cooling
• Pin-fin heat exchangers
ADDITIVE THERMAL MANAGEMENT APPLICATIONS
52 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
3D printing provides vibrant, informative models to:
• Serve as a “proof of concept”
• Conduct flow analysis
• Communicate business value
• Illustrate product enhancements
PROOF OF CONCEPT MODELS
53 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
• Phase II SBIR
• Manufacture advanced combustion liners with shaped film cooling holes for gas turbine engines
• Take advantage of complex internal passages and inlet/outlet geometry without post-machining
THIN-FILM COOLING
54 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
• An optimal process was developed with CTS to apply TBC to the effusion hole surfaces
• Successful adhesion and acceptable porosity in TBC layer
• Experimental testing at research institution
THERMAL BARRIER COATING
55 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
CHALLENGES AND FUTURE WORK
56 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
• Process capabilities
• Wall thickness and feature detail
• Surface finish
• Support design and removal
• Powder removal
• Limited material selection
• Metals: Various copper and aluminum alloys
• Plastics: Still under development
LIMITATIONS OF AM FOR HEAT EXCHANGERS
57 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
DESIGN CONSIDERATIONS: HORIZONTAL HOLES
1-
5mm0.05in - 0.19in
6-
9mm0.20in - 0.35inOver
9mm
0.36in
1-5 mm 6-9 mm Over 9 mm
0.05-0.19
in 0.20-0.35
in
58 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
DESIGN CONSIDERATIONS: TRAPPED SUPPORTS
59 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
• Lower limit bounded by laser spot size, ~100 μm or 0.004”
• Practical lower limits are defined by thermal stress
• Geometry and material dependent
• Warpage mitigated by support structure design
WALL THICKNESS
60 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
• Current materials: AlSi10Mg and C18150
• Thermal conductivity, specific heat, and mechanical properties similar to wrought
• Material availability driven by industry demand, gas atomizer capacity
• We are actively evaluating further Al and Cu alloy blend
• Further characterization of geometry capabilities on a per-material basis
MATERIALS
61 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
• Additive metal manufacturing empowers designers to
create the next generation of thermal management systems
for improved functionality
• Unparalleled geometric freedom without traditional tooling
constraints
• Reduce cost, lead-time, and assembly time
• Integration of multiple components into efficient,
modular, scalable systems
• Maintain digital inventories and iterate quickly
SUMMARY
62 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY
THANK YOU
Andrew Carter
Process and Manufacturing Engineer
Stratasys Direct Manufacturing
Austin, TX
[email protected] | 512-655-5019