A review of 3D printing processes and materials for soft ...
3D Printing Technologies and Materials - GPCA … · GCC Polymer Value Chain: Creating Future...
Transcript of 3D Printing Technologies and Materials - GPCA … · GCC Polymer Value Chain: Creating Future...
• 3D Printing Technologies and
Materials• 3D printing technologies
• SLA /DLP
• CLIP/CDLP
• Material Jetting
• SLS
• FDM
• Near Future
Agenda
GCC Polymer Value Chain: Creating Future Leverage
3D Printing technologies and Materials
There are different 3D printing
technologies and materials you
can print with, but all are based
on the same principle: a digital
model is turned into a solid
three-dimensional physical
object by adding material layer
by layer.
Image Courtesy of Ultimaker
GCC Polymer Value Chain: Creating Future Leverage
3D Printing technologies and Materials
Liquid Materials
- Vat Photopolymerization (plastics)
- Material jetting (plastics, metals and waxes)
- Binder Jetting (ceramics and metals)
Solid Materials
- Material Extrusion (plastics and composites)
- Powder Bad Fusion (plastic and metals)
- Direct Energy Deposition (metals)
- Sheet Lamination (composites and paper)
We can divide the 3D printing by the
type of material and process that is
used
Image Courtesy of Stratasys - Polyjet
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Liquid Materials
Vat Photopolymerization: Photopolymerization occurs when a photopolymer
resin is exposed to light of a specific wavelength
and undergoes a chemical reaction to become
solid.
In general, photopolymers may contain several
components including binders, photoinitiators,
additives, chemical agents, plasticizers and
colorants. However, the three main components
which build the photopolymers are binders
(oligomers), monomers and photoinitiators.Image Courtesy of Formlabs
GCC Polymer Value Chain: Creating Future Leverage
SLA - Stereolithography (laser)
DLP - Digital Light Processing (U.V. projector)
3D Printing – Liquid Materials
Image Courtesy of 3D Hubs
To create a 3D printed object, a build platform is
submerged into a translucent tank filled with
liquid resin. Once the build platform is
submerged, a light located inside the machine
maps each layer of the object through the bottom
of the tank, thus solidifying the material. After the
layer has been mapped and solidified by the light
source, the platform lifts up and lets a new layer
of resin flow beneath the object once again. This
process is repeated layer by layer until the
desired object has been completed.
GCC Polymer Value Chain: Creating Future Leverage
- produce highly accurate parts with smooth
surface finishes and are commonly used
for highly detailed objects
- Low costs
- Desktop printers are available
- Print layer by layer
- Needs post production (washing to
remove not cured resin)
- lower shrinkage
SLA - Stereolithography (laser)
DLP - Digital Light Processing (U.V. projector)
3D Printing – Liquid Materials
Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
- Applications: Small, high detail models,
Jewelry, art, Investment casting, rapid
prototypes, molds, dental, Medical and
health care
- Limitations
Large models
Extensive exposure to UV-light
The resin viscosity can increase over time
Lower HDT
SLA - Stereolithography (laser)
DLP - Digital Light Processing (U.V. projector)
3D Printing – Liquid Materials
Image Courtesy of 3D Systems
GCC Polymer Value Chain: Creating Future Leverage
- Epoxi based photopolymers
- Methacrylic acid esters
(Metacrylated monomers / Metacrylated oligomers)
- Acrylic acid esters
(Acrylated monomers / Acrylated oligomers)
- urethane acrylate
SLA - Stereolithography (laser)
DLP - Digital Light Processing (U.V. projector)
Materials (Thermosets)
3D Printing – Liquid Materials
Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
- Continuous process
- Two stage process: secondary curing by
heat. Improve mechanical properties
- Faster than SLA or DLP
Continuous Liquid Interface Production (CLIP) or
Continuous Digital Light Processing (CDLP)
3D Printing – Liquid Materials
Image Courtesy of Carbon
Image Courtesy of Carbon
GCC Polymer Value Chain: Creating Future Leverage
- Continuous process:
Isotropic properties
3D Printing – Liquid Materials
Continuous Liquid Interface Production (CLIP) or
Continuous Digital Light Processing (CDLP)
Image Courtesy of Carbon
GCC Polymer Value Chain: Creating Future Leverage
- Produce highly accurate parts with
smooth surface finishes and are
commonly used for highly detailed
objects
- Low costs ($$)
- Continuous Print
- Two stage, Needs post thermal curing to
achieve mechanical good properties.
3D Printing – Liquid Materials
Continuous Liquid Interface Production (CLIP) or
Continuous Digital Light Processing (CDLP)
Image Courtesy of Carbon
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Liquid Materials
- Applications: Small, high detail models,
Jewelry, art, Investment casting, rapid
prototypes, molds, dental, Medical and
health care
- Limitations
Large models
Extensive exposure to UV-light
The resin viscosity can increase over time
Continuous Liquid Interface Production (CLIP) or
Continuous Digital Light Processing (CDLP)
Image Courtesy of Carbon
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Liquid Materials
- Materials:
- Rigid, flexible and elastomeric Polyurethane,
- Cyanate Ester,
- Epoxy and Urethane Methacrylate
Continuous Liquid Interface Production (CLIP) or
Continuous Digital Light Processing (CDLP)
Image Courtesy of Carbon
Image Courtesy of Adidas : Futurecraft 4D
GCC Polymer Value Chain: Creating Future Leverage
- PolyJet works by jetting
photopolymer materials in ultra-thin
layers onto a build platform. Each
photopolymer layer is cured by UV
light immediately after it is jetted.
Material Jetting (MJ)
3D Printing – Liquid Materials
Image Courtesy of Stratasys - Polyjet
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Liquid Materials
Material Jetting (MJ)
Material Jetting 3D Printing works similarly to
inkjet printing, but instead of jetting drops of
ink onto paper, Material Jetting jet layers of
curable liquid photopolymer onto a build tray.
The most precise technologies for a realistic
prototypes with fine details and smooth
surfaces.
Image Courtesy of Stratasys
Image Courtesy of 3D Hubs
GCC Polymer Value Chain: Creating Future Leverage
- Produce highly accurate parts with
smooth surface finishes and are
commonly used for highly detailed
objects
- Hight costs ($$$$)
- Layer by Layer
- producing fully cured models that can be
handled and used immediately, without
post-curing.
3D Printing – Liquid Materials
Material Jetting (MJ)
Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Liquid Materials
- Applications:
Presentation models
Master patterns
Form and fit models
Flexible, rubber-like models
Realistic anatomical models
Prototypes for fittings, valves, and parts with
complex interior features
- Limitations
Large models
Extensive exposure to UV-light
Material Jetting (MJ)
Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Liquid Materials
- Materials:
- Acrylic monomer + Acrylate olygomer
- acrylic compounds
- PP like, ABS like, flexible,
Material Jetting (MJ)
Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Powder bed fusion
Powder bed fusion (PBF) technologies utilize
a thermal source to induce fusion between
powder particles to a prescribed region of a
build area, one layer at a time, to produce a
solid part. For plastics the SLS process is
used
Image Courtesy of 3DSystems
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Selective Laser Sintering (SLS)
A laser maps the first layer of the object in the
powder, which selectively melts – or sinters –
the material. Once a layer has been solidified,
the print bed moves down slightly as the other
bed containing the powder moves up; and a
roller spreads a new layer of powder atop the
object. This process is repeated, and the laser
melts successive layers one by one until the
desired object has been completed.
Image Courtesy of 3D Hubs
GCC Polymer Value Chain: Creating Future Leverage
- produce highly accurate parts with smooth
surface finishes and are commonly used
for highly detailed objects
- Medium costs ($$$)
- Desktop printers are not available
- Print layer by layer
- Needs post production (remove unmelted
powder)
Selective Laser Sintering (SLS)
3D Printing – Solid Materials
Image Courtesy of 3DSystems
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Selective Laser Sintering (SLS)
- Applications: Functional prototyping,
Parts with complex design with intricate
details, Moving and assembled parts
- Limitations
Cavities within design (unless making use
of escape holes) Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Selective Laser Sintering (SLS)
Materials:
For SLS materials must be in powder form
- Nylon 12, Nylon 11
- Mineral fiber-filled Nylon
- polystyrenes
- thermoplastic elastomers,
- PEEK.
Image Courtesy of S. Berretta, O. Ghita,
K. E. Evans, A. Anderson, C. Newman
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Fusion Deposition Modeling - FDM
The most common technology for
desktop 3D printing.
Great for quick and low-cost prototyping.
Cheaper and simple than other
technologies
Image Courtesy of MakerBot
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
The FDM printing process starts with a string
of solid material called the filament. This line
of filament is guided from a reel attached to
the 3D printer to a heated nozzle inside of the
3D printer that melts the material. Once in a
melted state, the material can be extruded on
a specific and predetermined path created by
the software on the computer.
Fusion Deposition Modeling - FDM
Image Courtesy of 3D HubsImage Courtesy of 3Devo
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Fusion Deposition Modeling - FDM
- Applications: low-cost prototyping,
functional prototypes, parts,
Manufacturing aids
Functional prototypes
Low volume production parts
Education, Architecture, Jewelry,
automotive
- Limitations
non isotropic properties,
part quality limitations (strength,
aesthetics, resolution).
Image Courtesy of All3dp
GCC Polymer Value Chain: Creating Future Leverage
3D Printing – Solid Materials
Fusion Deposition Material - FDM
Materials (Thermoplastics):Due to the simplicity of the process and the use of thermoplastics as
printing materials, It is possible to use a wide range of materials, such
as:
- PLA (Polylact Acid), ABS, PC, PC+ABS alloy, Nylon, PP, PET,
PETG, TPU, HIPS, PVA, ASA (Acrylonitrile Styrene Acrylate),
POM (Polyacetal), PMMA, TPC (Thermoplastic copolyester), PEI
(Polyetherimide)
- It’s possible to use composites materials: carbon fiber, wood,
metal (bronze, brass, copper, aluminum and stainless steel), Fibre
reinforces (kevlar or fibreglass), conductive (carbon black,
graphite), magnect, ceramic,
Image Courtesy of Stratasys
GCC Polymer Value Chain: Creating Future Leverage
- SLA : filled materials. Formlabs announced that it is
launching a composite SLA resin with ceramic
- FDM: commodities: PE and PP. Amorphous x Crystalline
Challenge stick materials on table and warping due
crystallization
- Ionomers for FDM filament
Near Future
Image Courtesy of Geeetech Rostock
3D Printing technologies and Materials