Post on 11-Mar-2018
© Fraunhofer IFAM Dresden
T. Studnitzky
3D SCREEN PRINTING MASS PRODUCTION OF METALS AND CERAMICS
© Fraunhofer IFAM Dresden
Fraunhofer-Gesellschaft
München
Holzkirchen
Freiburg
Efringen-Kirchen
FreisingStuttgart
PfinztalKarlsruheSaarbrücken
St. IngbertKaiserslautern
DarmstadtWürzburg
Erlangen
Nürnberg
Ilmenau
Schkopau
Teltow
Oberhausen
Duisburg
EuskirchenAachen
St. Augustin
Schmallenberg
Dortmund
PotsdamBerlin
Rostock
LübeckItzehoe
Braunschweig
Hannover
Bremen
Bremerhaven
Jena
Leipzig
Chemnitz
Dresden
CottbusMagdeburg
Halle
Fürth
München
Holzkirchen
Freiburg
Efringen-Kirchen
FreisingStuttgart
PfinztalKarlsruheSaarbrücken
St. IngbertKaiserslautern
DarmstadtWürzburg
Erlangen
Nürnberg
Ilmenau
Schkopau
Teltow
Oberhausen
Duisburg
EuskirchenAachen
St. Augustin
Schmallenberg
Dortmund
PotsdamBerlin
Rostock
LübeckItzehoe
Braunschweig
Hannover
Bremen
Bremerhaven
Jena
Leipzig
Chemnitz
Dresden
CottbusMagdeburg
Halle
Fürth
67 Fraunhofer institutes and
independent research units in
Germany
23.000 employees
12 institutes or branches in
Dresden
4 of these at the Fraunhofer Institute
Center Dresden
© Fraunhofer IFAM Dresden
Fraunhofer IFAM: Branch Lab Dresden
Director: Prof. Dr.-Ing. Bernd Kieback
Permanent staff 62
Student employees 28
Budget 6.8 Mio. €
Industry 32 %
Projects 56 %
Public funding 12 %
Investments 0.8 Mio. €
Area 2470 m2
(Budget 2014)
© Fraunhofer IFAM Dresden
Metal Additive Manufacturing @ Fraunhofer IFAM
Electron Beam Melting (EBM) [DD]
3D Metal Printing -Screen Printing approach(3DMP) [DD]
Laser Beam Melting (LBM) [HB]
3D Metal Printing -Binder Jetting approach(3DP) [HB]
3D Metal Printing -Binder Jetting approach(3DP) [HB]
© Fraunhofer IFAM Dresden
3D with screen printing ?
Additive manufacturing process, patented 1993
2008 first 3D-Screen Printing facility, first machine in R&D worldwide
2014 working group „3D Metal Printing“ with six scientists and one
technician
2014 new groundbreaking machine specially designed for 3D screen
printing
10 mm
© Fraunhofer IFAM Dresden
Process scheme
Flooding, Printing & Hardening
Screen Partners:
PVF (Hall 6, Booth B39)
Koenen Solar (Hall 3, Booth 355)
Lift screen
Optional: screen change
Optional: Different material
Sintering
© Fraunhofer IFAM Dresden
3D stencil printing – new option
Stencil instead of screen
No Moiré effect
Closed frames possible with holding grid
M-TeCK stencil -> Christian Koenen GmbH (Hall A3, Booth 355)
Possible higher layers and larger bridging
M-TeCK stencil Printed options Printed structures
Source: Christian Koenen GmbH
© Fraunhofer IFAM Dresden
© Fraunhofer IFAM Dresden
Achievable geometrical details (screen printing)
Constant wall thickness (minimal 60 µm)
Maximal height of several cm
Constant cell size
Possible bending in the green state
Properties of print:
Wall thickness: 100 µm
Wall height: 1.5 mm
© Fraunhofer IFAM Dresden
Achievable geometrical details (screen printing)
Feature: Bridging up to 1 mm
Undercuts
Hollow structures and channels –without powder removal or supporting structures
Complex inner structures possible
Sieb 1
Sieb 2
Sieb 3
Sieb 1
Sieb 2
Sieb 3
20 mm
100 µm
© Fraunhofer IFAM Dresden
Achievable geometrical details (stencil printing)
Layer thickness > 300 – 500 µm
Bridging > 2-3 mm
Resolution in the range of the layer height
Much higher building rate compared to screen printing
M-TeCK stencil Printed structures
© Fraunhofer IFAM Dresden
3D screen printing - materials
So far: Metals (based on Fe, Cu, Ti, W, La, Mo, Al, Ta, …)
Ceramics?
Materials Combinations?
Copper, steel and MoSi2 Gas atomized copper
© Fraunhofer IFAM Dresden
3D screen printing – Ceramics
Cooperation with Fraunhofer IKTS
Water based slurry based on metal systems
Printed height: ~ 2 mm, 150 – 200 µm wall thickness
Excellent green strength, no warpage
70 mm
Al2O3
70 mm 6 mm
SiC Green part
© Fraunhofer IFAM Dresden
3D screen printing – Multimaterial (adjacent structures)
Two screens with different design used
Two materials: Steel / Ceramic
Sreen change after 5 layers each
Printing of adjacent structures possible
10 mm
190 µm
Process scheme Printed structures Printed structures
© Fraunhofer IFAM Dresden
3D screen printing – Multimaterial (sandwich structures)
Same screen – different materials
Two materials: Steel / Ceramic
Starting with pure ceramic slurry, adding metal slurry during printing
Ste
el
Cera
mic
Sintered graded structure
© Fraunhofer IFAM Dresden
Features of the 2nd generation printing machine at IFAM
Two printing tables
printing area 300 mm x 300 mm
Closed chamber
climate control
water free pastes possible
All printing parameters independently adjustable
UV hardening facility
Process control taken over from industrial production lines
first step towards industrial production machine
ASYS / EKRA -> Hall 3, booth 277
© Fraunhofer IFAM Dresden
3D-Screen Printing – Applications
Electric components
Cooling Systems
µ-Reactor
Heat exchanger
Fuel cell
Filter
Implants
Sealings
Micromechanics
© Fraunhofer IFAM Dresden
Bipolor plate fuel cell
Integrated channels
Goal: Reduction of costs, size and weight
structure sizes < 100 µm
10 mm
© Fraunhofer IFAM Dresden
Example: Micro cooling systems
Design of optimized structures (COMSOL)
Different CAD models transferred onto one screen
© Fraunhofer IFAM Dresden
Example: Microparts
Special tube for electrical application in cooperation with industry
Complex part printed with five screens
~3500 parts printed at the same time on 1st generation lab machine
+700.000 parts per year possible on 1st generation lab machine
© Fraunhofer IFAM Dresden
3D screen printing - concepts for mass production
2nd generation lab machine:
decoupling of printing and curing
1.500.000 parts / year
Possible production machine:
1 printing area / 5 substrate tables
7.000.000 parts / year
Possible production line:
4 printing areas / 12 substrate tables
simplified printing of complex parts
Table size 300 x 300 mm²
Table size 400 x 600 mm²
© Fraunhofer IFAM Dresden
Economical aspects
Technique Built rate Resolution Powder size Tools?
[cm3 / h] [µm] [µm]
3D-Screen Printing (Labmachine IFAM)
80 - 200 80 - 150 < 15 - < 50 Screen
3D-Stencil Printing (Labmachine IFAM)
200 - 600 200 - 500 < 50 Stencil
Screen / stencil Printing(10 table mass production)
>> 1000 100 < 15 - < 50 Screen / Stencil
SLM / EBM 50 - 100 300 > 45 --
FDM 50 400 -- --
© Fraunhofer IFAM Dresden
Economical aspects
Calculation (Screen Printing):
316 L
Printing area 200 x 300 mm
Screen usage 5000 prints (solar industry 10000 - 100000)
90 % good parts
Including:
Personnel costs
Depreciation
Heat treatment
© Fraunhofer IFAM Dresden
Study: µ-Heat exchanger
0,0 0,2 0,4 0,6 0,8
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
Einfluss der Siebfläche auf die Kosten pro Bauteil (2x3 cm)
Koste
n/T
eil
[€/T
eil]
Siebgröße [m²]
Einschichtbetrieb, Ein-Tischanlage
Schichthöhe pro Lage: 15µm
Trocknungszeit pro Lage: 20sBauteilhöhe: 1mm
0
1.000.000
2.000.000
3.000.000
4.000.000
5.000.000
6.000.000
7.000.000
Teile
pro
Jahr
Technikumanlage am IFAM
~400.000 Bauteile pro Jahr
Lab machine IFAM
Parts / year
effektive printing area [m2]
Pa
rts
pe
r ye
ar
Co
sts
pe
r p
art
[€]
© Fraunhofer IFAM Dresden
Economical aspects
© Fraunhofer IFAM Dresden
Process chain: From powder to part
Partner R&D: Fraunhofer IFAM
3D-Printing machines : EKRA / ASYS
Screen / Stencil supplier: Koenen or PVF
Powder: Depending on material
Furnaces: Different, for e.g. MUT
If necessary: Part manufacturer, in negotitian
© Fraunhofer IFAM Dresden
Economical considerations - take home messages
2D screen printing is an established industrial process process control strategies can be transferred to 3D screen printing
Productivity scales inversely with part volume
Many different parts or part variations can be made on just one screen
Parts that require many screens should be avoided or broken up into simplified geometries otherwise tooling cost goes up, time for screen adjustment goes up
Printing directly onto sinter substrate possible easy handling of large numbers of small parts
Low wear of printing screens. Screens are inexpensive, several suppliers exist
Use of commercially available PIM powders recommended powder cost is known
© Fraunhofer IFAM Dresden
Design Tool Manufacturing Postprocessing
Beam assisted Additive Manufacturing of metal parts (SLM, EBM)
No cavitiesHigh freedom of designSupporting structures needed
Limited part numbersPoor surface qualityLimited materials variety
Removal supporting structuresSurface finishing neededAdditional heat treatment (SLM)
Little tooling cost Mass production possibleHigh materials varietyMedium surface quality
Finishing, if neededCavities / Channels possible3D-free form difficultMulticomponent parts
3D-Screen Printing
No tools needed
Quelle: FhG IFAM Quelle: Argen
Quelle: Siebdruckversand
© Fraunhofer IFAM Dresden
Metal Injection Moulding (MIM)
High tooling cost Mass production possibleHigh surface quality
Free outer contourInner contours limitedNo cavities
Typically no finishing needed
Quelle: EC Tech
Quelle: ArburgQuelle: Indo-MIM / Wittmann Battenfeld
Little tooling cost Mass production possibleHigh materials varietyMedium surface quality
Finishing, if neededCavities / Channels possible3D-free form difficultMulticomponent parts
Quelle: Siebdruckversand
Design Tool Manufacturing Postprocessing
3D-Screen Printing
© Fraunhofer IFAM Dresden
Where does 3D screen printing fit in?
© Fraunhofer IFAM Dresden
Summary
3D screen printing offers new possibilities in product design
Possible structure size 60 µm
Bridging possible without supporting structure
3D screen printing is suitable for mass production
Free choice of material
Metals, ceramics, glass
Material combinations possible
Multilayers
Sandwich structures (In printing direction)
Adjacent structures (Perpendicular to printing direction)
Graded structures
© Fraunhofer IFAM Dresden