ExOne Direct Material Printing - Binder Jetting Technology
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Transcript of ExOne Direct Material Printing - Binder Jetting Technology
Asia | The Americas | Europe
• ExOne is a leading additive manufacturing company dedicated to the manufacturing sector.
• ExOne is a global supplier of 3D printing systems and offers design and manufacturing services of 3D printed products.
• ExOne systems are able to print in a variety of materials with the largest available build sizes.
• ExOne has Production Service Centers (PSC) throughout the United States, Europe, and Japan.
• ExOne Global Headquarters is located in North Huntingdon, Pennsylvania
Company Overview
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ExOne Global Facility Locations
ExOne
North America
WEST
ExOne
North America
MID-WEST
ExOne
North America
MID-ATLANTIC
ExOne
North America
SOUTH
ExOne
BRAZIL
ExOne GmbH
GERMANY
ExOne
CHINA
ExOne KK
JAPAN ExOne
ITALY Srl
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Classification Technology Description Materials Developers
Binder Jetting 3D Printing Ink-Jetting
Creates objects by depositing a binding agent to join powdered material
Metal, Polymer, Ceramic, Other
ExOne (US) VoxelJet (Germany) 3D Systems (US)
Direct Energy Deposition
Direct Metal Deposition Laser Deposition Laser Consolidation Electron Beam Direct Melting
Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate
Metal: powder and wire
DM3D (US) NRC-IMI (Canada) Irepa Laser (France) Trumpf (Germany) Sciaky (US)
Material Extrusion Fused Deposition Modeling
Creates objects by dispensing material through a nozzle to build layers
Polymer Statasys(US) Delta Micro Factory (China) 3d Systems (US)
Material Jetting
Polyjet Ink-jetting Thermojet
Builds parts by depositing small droplets of build material, which are then cured by exposure to light
Metal, Photopolymer, Wax
Stratasys (US) LUXeXcel (Netherlands) 3D Systems (US)
Powder Bed Fusion Direct Metal Laser Sintering Selective Laser Melting Electron Beam Melting Selective Laser Sintering
Creates objects by using thermal energy to fuse regions of a powder bed.
Metal, Polymer, Ceramic
EOS (Germany) Renishaw (UK) Phenix Sytems (France) Matsuura (Japan) ARCAM (Sweden) 3D Systems (US)
Sheet Lamination Ultrasonic Consolidation Laminated Object Manufacture
Build parts by trimming sheets of material and binding them together in layers.
Hybrids, Metallic, Ceramic
Fabrasonic (US) CAM-LEM (US)
VAT Photopolymerization
Stereolithography Digital Light Processing
Build parts by using light to selectively cure layers of material in a vat of photopolymer.
Photopolymer, Ceramic
3d Systems (US) Envision TEC (Germany) DWS Sri (Italy) Lithoz (Austria)
Additive manufacturing processes, adapted from ASTM, 2012
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Binder Jetting Process
Binder jetting A printhead selectively dispenses binder on a thin layer of powder. Powder layers can be spread by a counter-rotating roller from a supply chamber to the build chamber, or the powder can be spread by a recoater. After the part is completed, the build chamber is removed to a curing oven, after which the part is depowdered and prepared for sintering or infiltration.
Advantages Economics are great. Well suited for large parts. All kinds of powders can be used. Support structures are not needed.
Disadvantages Surface finishes are generally ~400 microinch. Post-processing such as sintering is necessary for processing metals, ceramics, and other materials.
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Binder Jetting Process
Droplet Interaction with Powder Analogous to inkjet paper printer:
(Binder ≡ Ink Powder Layer ≡ Paper) Exception: Binder must penetrate to bond
with previous layer
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3DP is Basic Powder Metallurgy
Bonded
Partially Sintered
Infiltrated
Highly Sintered
Powder metallurgy is the process of blending fine powdered materials, pressing them into a desired shape or form (compacting {printing}), and then heating the compressed material in a controlled atmosphere to bond the material (sintering). The powder metallurgy process generally consists of four basic steps: powder manufacture, powder blending, compacting, and sintering. (Wikipedia)
Product Forms
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Advantages of ExOne’s Process
• No extra charge for part complexity
• Offers endless patterns and part geometry
• No support structures needed
• Requires no build plate to begin on
• Easy optimization of traditional
• No tool paths required
• Multiple different parts can be built in a single print bed
• Parts can be modified on the CAD file in seconds, and reprinted without complicated tooling changes
• Use of industrial graded materials
• Large build envelopes
• High print speed
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Direct Metal PSC (North Huntingdon, PA)
• ISO 9001: 2008 CERTIFIED
• Reverse design engineering (modeling or scanning)
• Prototypes services
• Optimization for additive manufacturing
• Finishing in-house
• Low volume production contract services
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Industries Served
AUTOMOTIVE AEROSPACE
ENERGY HEAVY EQUIPMENT AND
MACHINERY
GENERAL CONSUMER FILTRATION AND MINING
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Functional Working Parts
• Print functional working prototypes or production run
quantities for real life applications
• Possible post processes but not limited to the following:
Machine: 420SS - typically has a tensile strength range of 60-
75 ksi conventionally machining may require slower
speed and feed rates
316SS – can be traditionally machined
Finish: Mass finishing with polishing media
Grind, Sand, Polish
Coat: Clear Coating, plating, powder coat, paint
Weld: Silicone Bronze rod and TIG weld
Silver Solder (Harris Products 45N, stay below 700⁰ C)
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Multiple Part Consolidation
• 27 traditional individual components
reduced to a single piece
• Reduction of documentation and time
• Delivered in weeks not months
• On-the-fly changes are possible
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Optimization
Traditionally Manufactured Part
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Part Information
Optimized for 3D Printing – Pass 1
Optimized for 3D Printing – Pass 2
Name: Nacelle Bracket Application: Aerospace Prototype Printed Material: 420 Stainless Steel and Bronze
Weight = 7.8 lbs.
Weight = 2.8 lbs.
Weight = 1.4 lbs.
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Certified Materials (PSC Offerings)
316 Stainless Steel Infiltrated with Bronze
30 or 60 micron
420 Stainless Steel Infiltrated with Bronze
30 or 60 micron
Inconel 625 (Highly Sintered)
30 Micron
Iron Infiltrated with Bronze
30 micron
Bonded Tungsten Soda Lime Glass
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Printable Materials
17-4 316
Inconel 718
Cobalt Chrome Iron Chrome Aluminum Tungsten Carbide
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Inconel 625 (Highly Sintered)
AS SINTERED PARTS
POST PROCCESSED
* Engine Turbine Blade used
for demonstration piece only *
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Process Steps
Print Directly from CAD Depowder
Heat Treatment Final Product
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Direct Material Machines
Production
&
Prototyping
Prototyping
&
Production
Research
&
Education
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Tested and Certified
• Mechanical Testing
– Tensile strength & modulus – Compressive strength & modulus – Flexural strength & modulus – Fatigue & fracture toughness – Impact strength (Charpy & Izod)
• Metallography & Microscopy
– Specimen Preparation • Mounting, grinding, polishing equipment
– Microscopy • Inverted Light Microscope • Scanning Electron Microscope (SEM) • Image Analysis Software
• Hardness
• Density
– Archimedes, Helium Pycnometry, Bulk • Coefficient of Thermal Expansion (CTE)
SEM Machine
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Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.
ExOne The Americas
MID-ATLANTIC
127 Industry Boulevard North Huntingdon, PA 15642 USA +1 877 773 9663 MIDWEST
2341 Alger Drive Troy, MI 48083 USA +1 248 740 1580 SOUTH
7409 Railhead Lane Houston, TX 77086 USA +1 281 931 0011
ExOne Europe
ExOne GmbH
Daimlerstrasse 22 86368 Gersthofen Germany +49 821 65063-0 ExOne Italy SRL
Via Galileo Galilei 68 Località La Pigna 25015 Desenzano del Garda Brescia, Italy ExOne Asia
161-5 Haneo Odawara-shi, Kanagawa Japan 256-0804 +81 465 44 1303
exone.com +1 877 773 9663
SOUTHWEST 3905 N. Pecos Rd N. Las Vegas, NV 89115 +1 702 487 3977
NORTHWEST 1307 W. Valley Highway N. Auburn, WA 98001 +1 253 394 0357