P050-15 [663]

Integration and Expansion of Additive

Manufacturing and Its Associated Technologies

Perspective from AM Center of Excellence (COE)

1 May 2015

Adam Naramore and Talbot Thrasher

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Additive Manufacturing (AM): Pre-Initiation

Engineering

Design the Part

Fabrication

Print the Part

Assembly or Delivery

End User

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So You Bought a Machine. . . .

Fortus 400ProJect 7000 HD Objet500 Connex3 Makerbot Replicator

Concept Laser M2 EOS M290 Arcam Q10 Renishaw EVO

Picture credits:

http://www.concept-laser.de/, http://www.arcam.com/technology/products/arcam-q10/, http://www.eos.info/eos-m290,

http://www.arcam.com/, https://www.stratasys.com, http://www.3dsystems.com/3d-printers/professional/projet-7000-hd

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Now Install It

Shop Floor Space Needs

• Actual machine

• Powder feeder

• Cleaning cabinet

• Post-processing machines

− Grinders, mills, wire EDM, worktables

− Peen cabinet

− Inspection area

Electricity, water for cooling, shop air

Materials and Handling

• Plastics

− Storage, staging, scrap

• Metal Powder

− Storage

− Handling: lifts, carts,

− Powder conditioning

Inert gas (argon, nitrogen)

Concept Laser M2 picture credit: http://www.concept-laser.de/

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Additive Manufacturing: The Morning of Day 1

Supply Chain

Supply the Materials

Additional

Resources

All of the Other

Needs to Support

the Team

Fabrication

Print the Part

Engineering

Design the Part

Mission Assurance

Inspect the PartAssembly

End User

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AssemblyEnd User

Additive Manufacturing: Day 2

Supply Chain

Additional

Resources

FabricationEngineering

Mission Assurance

Powder

Electronic

Model

Design Guide

Post-Processing

Design Allowables

Slicing Software

Defect Definition

Part Notes

KPP Features

Material Inventory

Used

Powder

Shop TravelerMachine

Settings

Cleaning

In-Process

Evaluation

Criteria

Process Qual

Plan

Process

Specification

Technician

Training and

Certification

AM

Machine

Samples

Machining

Post-Process

CT

Comparison

Software

Light

Sample

Testing

Powder Inspection

Equipment

Powder Suppliers

Fabricators

Inspection Req’s

Refurbishment

Configuration

Management

Purchasing

Scheduling

Equipment

Maintenance

Safety

Blue Light Process

CT Process

Inspector

Certification

Tooling

Powder Condition

Inspection

Human Resources

Third-Party

Resources

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Designing the Part

Engineering

Electronic

Model

Design Guide

Post-Processing

Design Allowables

Slicing Software

Defect Definition

Part Notes

KPP Features

Things to Consider

• Design for AM

• Analysis for AM

• Material Properties− Anisotropy

− Surface finish

• Design for manufacture− Build direction

− Build orientation

− Location in printer

− Support StructurePicture credits:

http://www.withinlab.com/software/index.php,

http://solidthinking.com/ProductOverview.aspx?item=Inspire%20Overview&category=Products

• Design software

• Slicing software

• Thermal gradients

• Limitations of the process− Channels

− Internal features

− Bridges

− Edges

− Fill

− Wall thickness

− Mesh type

• Material is money

• Time to print

• Inspectability

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Build and Support Materials and . . .

Supply Chain

Powder

Material Inventory

Powder Suppliers

Fabricators

Inspection Req’s

RefurbishmentUsed

Powder

Things to Consider

Vendor coordination

Filament

Powder

• Vendor: OEM vs market

• Order specifics and availability

• Receiving inspection− Inspection procedures

− Certification technicalities

• Storage

• Base plates

• Refurbishing

• Tracking

• Inert gases

• Machining supplies

• Blast media

• Post-processors

− Heat treat

− Surface finishes

− Coatings/finishes

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Safety

Laser Power – High-Voltage Equipment

Heavy Powder and Parts

Inert Gas Cylinders

Aluminum and Titanium Powder

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Building the Part

Fabrication

Shop TravelerMachine

Settings

Cleaning

In-Process

Evaluation

Criteria

Process Qual

Plan

Process

Specification

Technician

Training and

Certification

AM

Machine

Samples

Machining

Post-Process

Assuming you picked the right machine . . .

Machine Settings

• Plastics− It can take a month to make a good first part

− It can take three months to know the machine

− It can take a year to be proficient

• Metals− Start with coupons

− Move to shapes

− It can take a year to make good high-end parts

− Powder reuse

− Explosive nature – clean well!

Technicians

• Training/certification− Courses, organizations

Samples and inspection criteria

In-process inspection techniques

Materials

• Inventory and ownership

• Tracking and usage

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Inspection and Quality

Mission Assurance

Blue Light Process

CT Process

Inspector

CertificationCT

Comparison

Software

Light

Sample

Testing

Powder Condition

Inspection

Powder Inspection

Equipment

Key Feature Identification

Inspection Types

• Surface smoothness

• Inspection methods

• CMM

• White light

• Blue light

• Structured light

• Laser

• Computed tomography

In-Process

• Machine process monitoring

• Custom gauges

• Check fixtures

− 3-D printed

Inspections

• Finished part

• Powder

− Moisture control and content

− Reuse/reject

− Particle size and distribution

− Renovate method

− Sieving

− Oxygen content measurement

− Number of uses

Who is certified to inspect and how?

Software and Data

• Point cloud

• Surface generators

• Comparative data file

• Part to part

• Part to file

• Statistical process control

• Storage and access

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Ancillary Considerations

Additional

Resources

Configuration

Management

Purchasing

Scheduling

Equipment

Maintenance

Safety

Tooling

Human Resources

Third-Party

Resources

Controlling Electronic Data

• Models

• Print files

• New File formats

Coordinating with:

• Purchasing

• Scheduling

• Machine time and part production

• Technician Availability

Maintenance and Obsolescence

• Materials, machines parts, fixtures,

Other Concerns:

• OSHA, EPA

• Untrained personnel

Not Just Parts

• Engineering models

• Prototypes

• Business development

• After work projects

− STEM

− Charities

− Personal

− Management

• Materials usage and tracking

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Not as Simple as It Might Seem

Engineering

Design the Part

Fabrication

Print the part

Assembly or Delivery

End User

Summary:

• Facilities and Infrastructure

• Materials and Supplies

• Design and Design Process

• Machine and Build Process

• Post Processing

• Inspection

• Personnel/Certifications

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Questions