Hands-on Workshop: Basics of 3D Printing · Advantages of 3D Printing –Freedom of design...
Transcript of Hands-on Workshop: Basics of 3D Printing · Advantages of 3D Printing –Freedom of design...
Hands-on Workshop:
Basics of 3D PrintingIntroduction
Ville Kukko-Liedes IdeaSquare 3.-4.11.2018
Ville Kukko-Liedes
• MA student of Product Development and Machine Design• 3D PrintShop manager in Aalto Design Factory
• Hobbyist 3D printing, 2012• Rapid Prototyping and model making services, 2013• Product development consulting services, 2014• Design Factory PrintShop, 2014
Own DIY machines:
• Mendel Max 1.5, 2012 - 2014
• RepRap Industrial Mini ‘PaPa’, 2014 -->
• RepRap Industrial 2014 --> SOLD
• RepRap Industrial DF ‘NuNu’, 2014 -->
• CoCo, 2017 -->
+ other smaller projects
Saturday
• What is 3D printing and where it can be used?
• Understanding 3D Printing methods
• FDM & SLA technologies
• Getting started with 3D printing
• Hands-On 3D Modeling & printing
• Understanding 3D Printing methods
• Advanced methods
• Hands-On 3D Modeling & printing continues
Sunday
What is 3D Printing?
What is 3D Printing?
Additive Manufacturing (AM):
Construction of physical
objects directly from 3D CAD
data – usually layer upon layer
(CAD = Computer Aided Design)
What is 3D Printing?
Additive Manufacturing (AM):
Construction of physical
objects directly from 3D CAD
data – usually layer upon layer
(CAD = Computer Aided Design)
What is 3D Printing?
As opposed to e.g.
subtractive manufacturing
(milling, turning etc.)
Additive Manufacturing (AM):
Construction of physical
objects directly from 3D CAD
data – usually layer upon layer
(CAD = Computer Aided Design)
What is 3D Printing?
As opposed to e.g.
subtractive manufacturing
(milling, turning etc.)
Additive Manufacturing (AM):
Construction of physical
objects directly from 3D CAD
data – usually layer upon layer
(CAD = Computer Aided Design)
Principle- Stacking two-dimensional layers to form three-
dimensional objects
- Producing 2D layers is relatively simple
- Parts usually need to be supported from below
Principle
STL file – From CAD,
3D-scan, etc.
“Slicing” to multiple layers,
toolpath
calculated for each
Part production
using calculated
paths
Advantages of 3D Printing– Freedom of design – complexity is free
Form optimization, pre-assembly, easy customization..
– No need for toolingNo cost from design changes & cheap small volume prod.
– No need for inventory
On-demand manufacturing, minimal investment,
– Fast lead times & responsivenessQuick alteration in design to respond to customer needs
– Localized manufacturingManufacturing where needed, savings in logistics
– Wide material range – seamless transitions
Innovation potential with new opportunities
– Affordable low volume productionPrice per piece constant regardless of production size
Uses: Rapid Prototyping
- The original and still much used application
of 3D printing
- Commercialized in the 80s
(SLA by 3D Systems)
- Extremely popular in product development:
- Fast testing of form, fit, function,
ergonomics..
- Accurate representation of intended
material properties and function possible
- Affordable and quick to produce
prototypes provide early feedback
- Fail faster to succeed earlier!
Uses: Rapid Prototyping - Concept wireless
charging station for a
plush toy / nightlight
Uses: Rapid Manufacturing
- Use of AM to produce end-use parts and
products
- Expansion during the last 13 years
- From 4% (2003) to 35% (2014)
- Result of process and material
development & media hype
- Notable in medical and aerospace industries
- Medical: Personalized solutions
- Aerospace: Weight optimization
- Potential in multiple fields, but still restricted
to low volume or customized production of
high-end products
- Lacking standards & false assumptions hinder
adoption
3D printed metal parts in BMW i8 convertible
Customized parts in MINI cars
Uses: Rapid Tooling
- Use of AM for indirect production:
- Masters for sand & silicon casting
- Lost wax casting
- Printing sand, metal & plastic molds
- Fixtures for drilling
- Jigs
- Endless number of uses..
- For both prototypes & end-use parts
- Takes advantage of low investment cost, fast
process, and AM introduced benefits such as
contouring cooling channels in injection molds
Masters for silicone casting
DIY petrol motor for a surf board
3D Print
Finished
3D print
Cast
Finished
cast
Sandcasting
Printed wax masters for precision casting
Cores for Glass/Carbon-fiber parts
Vacuum forming cores
Injection molds printed with plastic
Freedom of design
– No need to Design for Manufacturing & Assembly:
Instead Design for Functionality, Weight, Strength etc
– Minimize part count while optimizing topology
– Pre-built assemblies – minimize labor time & QC
– Customization without additional cost – Every part
can be different from the others, even in same batch
Design for AM – Case: bottle opener
Design for AM –
Case: Buckle
68 grams
Case: Boeing / F-18 air duct system re-design
Case: F-18 cooling air system
– Complete re-design for functionality & weight
– This unit: part reduction from 16 to 1
– Improved air flow
– No assembly required
– No tooling required
– Future improvements with minimal cost
– Spare parts on demand and on location
Case: Align / Invisialign tooth retainers
Case: Invisialign tooth retainers
– Digital pre-planning of each unit, “digital inventory”
– Example of mass customization – 40,000 a day
– AM produced individual molds for thermal forming
– Innovative example of utilizing customizability
– RP machines & processes modified for excessive use
Other medical uses
Inert implants Hearing aids
- Surgical planning, prosthesis, tooth crowns & bridges, tissue growth…
AM as innovation enabler
AM as innovation enabler
– Easy and affordable access to AM
technology encourages innovation
– Multiple new companies forming
around 3D printing
– 3D Printing is bringing young people
back to making physical things
Role of 3D printing in the future
– Disruptive potential in manufacturing – happening already3DP can change product design and manufacturing approaches drastically. Materials and processes are developed more for end-use
production.
– Supply chain renewal – future possibilityAway from traditional towards more centralized, on-demand, rapid manufacturing.
– Flourishing innovation around AMNew applications, AM techniques, & businesses emerge on daily basis
– Will every home have a 3D Printer and traditional manufacturing will end?No – Perhaps for occasional use in hobbies or garage-tinkering
Hands-on Workshop:
Basics of 3D Printing
Break
Principle- Stacked two-dimensional layers form three-
dimensional objects
- Producing 2D layers is relatively simple
- Parts usually need to be supported from below
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
FDM – Fused Deposition Modeling
FDM – Fused Deposition Modeling
www.youtube.com/watch?v=oeJLLC2NJQs
FDM – Fused Deposition Modeling
•Thermoplastic is extruded to ‘draw’ a layer at a time
• Build platform lowers with the part and process
repeats
•Dissolvable support material from second nozzle; not
commonly used in lower end printers
•Materials:
•ABS
•PLA
•Polycarbonate
•Nylon
• + Many Others! (PEEK, PETG, composites)
•Manufacturers:
•Stratasys, Tiertime, +multiple lower end
Extrusion lines visible
RepRap Project and its effects
Open Source, community driven, self REPlicating RAPid prototyper
- Founded 2005 by Andrew Bowyer, University of Bath, UK
- First RepRap 3D printer to print parts for itself, 2006
- Reprap inspires Makerbot, first commercial hobby printer, 2009
- Stratasys and 3DSystems both hit consumer market also
- 2016: hundreds of different “consumer 3D printers” available
- Most still hobbyist and DIY maker targeted
as they fail to meet user’s expectations
Not all 3D printers are the same
~200€ ~900,000€
Not all 3D printers are the same
General perception of all levels of 3D printing
Reality
E-Nable prosthetics – Community based project
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape“Designer”: Rhino, Maya, Zbrush“Easy-to-use”: TinkerCAD, Google SketchUp
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape“Designer”: Rhino, Maya, Zbrush“Easy-to-use”: TinkerCAD, Google SketchUp
3D files to print
1. CAD software – Model yourself
2. 3D scan an existing object – Modify or replicate as is
3. Download existing files – Free and commercial sites available
3D files to print
1. CAD software – Model yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Thingiverse, Youmagine, GrabCADmodifiable with Meshmixer
STL file format – triangulated mesh approximation
Remember to set good tolerance!
More triangles = Better results
STL file format – triangulated mesh approximation
Remember to set good tolerance!
More triangles = Better results
Orientation and support material
Complicated support structuresare difficult remove
Avoid overhangs Consider overhang angles whendesigning and orienting
Orientation and support material
Orientation and support material
Orientation and support material
Parts are weakest between layers
Design for FDM Example
Objective: Design and print an object
designed for FDM, which doesn’t need
supports and showcases possibilities of FDM
Features:•Overhangs
•Bridges
•Interlocking parts
•Inserts
•Customizability
•Internal features
Considerations:•Tolerances
•Overhang angles
•Minimized warping
•Orientation
Warping – Due to poor attachment to bed
Happens to PLA and ABS in open printers
Insert
Design for FDM printing
Slicers – Software that link 3D file with printers movement
- Software depends on the printer or user prefence- Makerbot Makerbot Print
- Ultimaker Cura
- Other printers Slic3r, Cura, Simplify3D…
- Many are free and even open source
Settings Checklist for Slicer software
- Material
- Temp (ABS ~230’C, PLA ~190’C)
- Diameter (Usually 1,75mm or 3mm)
- Orientation of model - before “slicing”
- Layer height
- 0,1- 0,3mm usually
- Perimeter thickness (‘shell’ of the part)
- Infill percentage (how dense/hollow the part is)
- Supports (if needed)
Before starting print
- Check Printers build platform
- Is it clean?
- Does it have proper adhesion applied?
- PLA: gluestick, (hairspray, blue tape)
- ABS: Kapton tape, BuildTak
- Check Printers material & nozzle
- Is there plastic? Does it need to changed?
- Always observe first layers of printing – They are most crucial!
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
SL – Stereolithography
SLA printers are more accurate than
FDM, but have their drawbacks.
Strong parts: SLA < FDM
Big parts: SLA < FDM
Need supports: SLA < FDM
Post-processing: SLA < FDM
Harmful chemicals: SLA < FDM
Complex parts: SLA > FDM
Small parts: SLA > FDM
Precise parts: SLA > FDM
https://formlabs.com/support/printer
s/form-2/quick-start-guide/
SL – Stereolithography
SL – Stereolithography
•UV laser cures resin
•Build platform lowers with the part into the resin
vat (or rises from it in some cases)
•New layer of resin is cured and process
repeated
•Materials:
•UV curable resins
•Waxes
•Ceramic
•Manufacturers:
•3D Systems, DWS, Lithoz,
+few hobbyist oriented
For Software: Preform (formlabs.com)
Next – Consider:
•Would you like to learn 3D modeling?
•Which software would be most suitable for you?
•Should you use and modify existing files instead?
•How could you use 3D printing?
•In your work? Hobby? As a new skill?
•Which technology would be better for your application?
•What requirements do your prints have?
•SLA or FDM?
Hands-on Workshop:
Basics of 3D PrintingDay 2
Ville Kukko-Liedes IdeaSquare 3.-4.11.2018
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
SLS – Selective Laser Sintering
SLS – Selective Laser Sintering
•Powder stock is joined by partial laser melting
•The powder bed lowers with the part
•New layer of powder is added and process
repeated
•Materials:
•PA (6, 11, 12) (Nylon)
•PA GF, CF (fibre composites)
•PA-Al (30% Aluminium)
•Manufacturers:
•EOS, 3D Systems…
(patents expiring now, low cost machines coming)
Method Material For Tolerance
(mm)
Layer
Thickness (mm)
SLS
PA Functionality
+/- 0,15
(+/- 0,15%)0,1PA CF/GC Hi durability
Wax Casting
SL
ClearAppearance,
Casting+/- 0,05-0,1 0,05-0,2
FlexibleDurability,
Appearance
FDM
ABSFunctionality,
prototyping+/- 0,15-0,3 0,1-0,4
PC
Accuracy
- 3D prints are usually always
comparatively inaccurate
dimensionally as well as
geometrically
- FDM for cheap parts,
printers everywhere. SLA for
small & precise. SLS for
ordering durable & precise
parts
All specs vary depending on machine used
Manufacturing in motion: first survey on the 3D printing community, Statistical Studies of Peer Production.
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion – still..
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
SLM – Selective Laser Melting
SLM – Selective Laser Melting
& Binder coated powder SLS
•Powder stock is joined by laser melting
•The powder bed lowers with the part
•New layer of powder is added and process
repeated
•A lot of supports needed in direct melting!
•Materials:
•Two component (binder coated base)
•Single component:
•Ti6Al4V, 17-4 / 15-5 Stainless, Cobalt
chromium, maraging
•Uses: Molds, small series, prototyping in metal
Additive Industries – Metal 3D printing station
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
3DP – Binder Jetting
3DP – Binder Jetting
•Powder stock is joined by deposited binder
•The powder bed lowers with the part
•New layer of powder is added and process
repeated
•Materials:
•Ceramic, composite, Glass, Metal, Plastic..
•Color printers available
•Usually fragile before post processing
•Uses: Visuals, cores & molds, casting patterns
Full color sandstone + binder - Shapeways
Digital Metal – Höganäs, Sweden
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
LOM – Laminated Object Manufacturing
LOM – Laminated Object Manufacturing
•Sheet is joined to the previous part
•Layer shape is cut into sheet
•Platform lowers and process repeats
•Materials:
•Paper, plastic, metal
•Color printers available
•Not accurate with paper or metal
•Laborious manual support removal
•Uses: Visual aids, metal structures with internal
sensors
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
•Sheet is joined to the previous part
•Layer shape is cut into sheet
•Platform lowers and process repeats
•Materials:
•Paper, plastic, metal
•Color printers available
•Not accurate with paper or metal
•Laborious manual support removal
•Uses: Visual aids, metal structures with internal
sensors
DED – Directed Energy Deposition
•Inert shielding gas jet deposits pwder that is
molten to the part with laser
•Platform moves, while nozzle is usually
stationary
•Materials:
•Metal
•Not very accurate ”net shaping”
•Features machined
•Combined DED + CNC exists!
•Uses: Repairs
DED – Directed Energy Deposition
also LENS – Laser Engineered Net Shaping
Categories of 3D printing
•Vat Photopolymerization
•Powder Bed Fusion
•Material Extrusion
•Material Jetting
•Binder Jetting
•Sheet Lamination
•Directed Energy Deposition
Material jetting
•Printhead (just like in inkjets) deposits droplets
of resin that is cured instantly with UV
•Platform moves down, process repeats
•Materials:
•Resins, various simulated plastic & rubber
•Highly accurate
•Multiple material properties, even smoothly
changing
•Uses: High end visual aids & function test
Material jetting
Dragonfly – PCB Prototyping
MicroTec – 3D Chip Sized Packaging
Kalevala – Jewelry
with wax investment casting
Links to videos
•Kinematics Dress by Nervous System
•SLS Selective Laser Sintering
•SLA Stereolithography
•Binder Jetting metals
•LOM - Mcor Paper Printer
•MORI Hybrid 3DP-CNC
•Material Jetting – Stratasys J750
Ville Kukko-Liedes
Thank you
Printers:
Ordbot: ideasquare-3dprinter-1.cern.ch
X400: ideasquare-3dprinter-2.cern.ch
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Password: 3dprint