Printing in the Third Dimension; Design, Materials ... Tools 1991 –2019 TechLead Corporation 3D...

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1991 – 2019 TechLead Corporation

Printing in the Third Dimension;

Design, Materials, Equipment &

Applications in Electronics

Charles E. Bauer, Ph.D.

Herbert J. Neuhaus, Ph.D.

TechLead Corporation

[email protected]


3D Printing – The Next Additive Approach

• 3D Printing: Digital Model → Physical Object

– Create Successive Thin Layers

– Rapid Prototyping

– Tooling & Custom Parts

2


An Electronics Revolution?

• Making iteration faster, easier

• Mass customization

• Reduced product size

• Eliminate harmful chemicals, waste

• Simplified assembly

• Access to the 3rd dimension


Outline

• 3D Printing Techniques

• Design Tools

• Materials

• Equipment

• Capabilities & Challenges

• Mainstream Applications

• Case Study: Scoliosis

• Emerging Applications

• Opportunities & Recommendations

3


Types of 3D Printing


Additive Manufacturing Technologies

4


3D Construction Technologies

Sculpteo


Methods: Non-Metal Printing

Sculpteo

5


Methods: Metal Printing

Sculpteo


Material Extrusion

• Thermoplastic extrusion

6


Material Extrusion

Composite & Thermoplastic Extrusion


Fiber Composite Deposition

Fiber Deposition

7


Powder Bed Fusion

• Laser fuses powder particles

• Nylon 12 PA650 or PA615-GS (Glass Filled)

Summative


Powder Bed Sintering

• Laser sinters metal powder into 3D parts

• Stainless steel, aluminum, titanium

Khaing, TEC Electronics Singapore

8


Powder Bed Fusion/Sintering

Praxair


Photo Polymerization/Stereo Lithography

• Laser hardens liquid photopolymer to form

solid parts layer by layer

Venkateshan, Slideshare.net

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Photo Polymerization/Stereo Lithography

• Laser hardens liquid photopolymer to form

solid parts layer by layer

Venkateshan, Slideshare.net


Digital Light Synthesis

• Manages a liquid gradient using light and

oxygen to create robust parts

Carbon3D

10


Binder Jetting


Powder Bed Binder Jet

Desktop Metal

11


Sheet Lamination

Polar Instruments


Sheet Lamination

Polar Instruments

12


Sheet Lamination

Polar Instruments


Directed Energy Deposition

Song, Mazumder, University of Michigan

13


Selective Laser Melting

Laser Tech


Direct Metal Deposition (Laser)

TWI

14


Direct Metal Deposition (Weld)

TWI


Material Jetting

3D Hubs

15


Material Jetting

3D Hubs


Material Jetting (Solder Balls on Wafer)

Micro Fab

16


Design Tools


3D Software

• Poser Pro

• PTC

• Rhino 3D

• Sandboxr

• Scenect

• SolidWorks

• TurboCAD

• TinkerCAD

• Zuken

• Alibre

• AutoDesk

(AutoCAD)

• Carrara8

• Blender

• Cimatron Ltd.

• Dassault Systems

• Fusion 360

• Geomagic

17


3DP Software Ecosystem


Materials

18


Most Used Materials 2017-2018

Sculpteo


Additive Materials

Wohlers Associates

19


3DP Organic Materials

• Waxes (extrusion, jetting)

• Food (extrusion, jetting)

• Skin (extrusion, jetting)

• Stem Cell (jetting, extrusion)

• Organ Tissues (jetting, extrusion)

• Structural Tissues (extrusion, jetting)


3DP Ceramics

• Clay (extrusion, binder jetting)

• Porcelain (binder jetting)

• Glasses & Glazes (binder jetting, direct

energy deposition)

• Alumina (binder jetting)

• Mullite (binder jetting)

• Zirconia (binder jetting)

• Silicon Carbide (binder jetting)

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3DP Polymers

• ABS - Acrylonitrile Butadiene Styrene

• PLA – PolyLactic Acid

• Nylon – Polyamide

• PEEK – PolyEther Ether Ketone

• PET - PolyEthylene Terephthalate

• PETG - PolyEthylene Terephthalate Glycol

• ULTEM – PolyEtherImide

• HIPS - High-Impact PolyStyrene

• PVA - PolyVinyl Alcohol

• Silicone Polymers


3DP Polymers

• ABS (fusion, binder jetting, stereo lithography,

polyjetting)

• PLA (fusion, stereo lithography, laser sintering)

• Nylon (fusion, laser sintering)

• PEEK (fusion, laser sintering)

• PET (fusion)

• PETG (fusion)

• ULTEM (fusion, laser sintering)

• HIPS (fusion, stereo lithography)

• PVA (fusion)

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3DP Metals

Aluminium alloys

• Good mechanical & thermal properties

• Low density

• Good electrical conductivity

• Low hardness

Stainless steel & tool steel

• High wear resistance

• Great hardness

• Good ductility and weldability

Titanium alloys

• Corrosion resistance

• Excellent strength-to-weight ratio

• Low thermal expansion

• Biocompatible

Cobalt-Chrome superalloys

• Excellent wear & corrosion resistanc

• Great properties at elevated temperatures

• Very high hardness

• Biocompatible

Nickel superalloys (Inconel)

• Excellent mechanical properties

• High corrosion resistance

• Temperature resistant up to 1200oC

• Used in extreme environments

Precious metals• Used in jewellery making

• Not widely available


3DP Metals

• Aluminum (direct deposition, binder jetting)

• Stainless Steel (direct deposition, binder jetting)

• Titanium (fusion, binder jetting, direct deposition)

• Cobalt Chromium (laser sintering/melting)

• Nickel/Inconel (fusion, direct deposition, laser

sintering)

• Nitinol (direct deposition, laser sintering/melting)

• Au/Ag/Cu/Bronze (lost wax casting, fusion, direct

deposition, binder jetting)

3dhubs

22


3DP Composites

• ABS & PLA based Conductive Polymers

(fusion)

• Metal Loaded Polycarbonate & PEEK

(fusion)

• Alumide - Al Loaded Nylon (laser sintering)

• Wood – Wood loaded thermoplastics (fusion)

3dhubs


3DP Specialty Materials

• Silicone Gels (direct light, stereo lithography)

• Nano Materials (jetting, direct light)

• Paper (selective lamination)

• Carbon/Glass Fiber (extrusion, laser

sintering)

• Graphite & Graphene (jetting)

• Sandstone (fusion, binder jetting)

3dhubs

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3DP Organic Application Fields

• Waxes (lost wax casting, extrusion support)

• Food (chocolate, meats, fish, etc.)

• Skin (burns, scars, cosmetics)

• Stem Cell (scaffolds to stimulate self repair)

• Organ Tissue structures (liver, kidney, lung,

heart)

• Structural Tissues (cartilage, disc, bone,

blood vessels)


3DP Ceramics Application Fields

• Clay (pottery, art, dishware)

• Porcelain (art, dishware)

• Glasses & Glazes (lenses, art, dishware,

electronics)

• Alumina (electronic packages, waveguides)

• Mullite (medical implants, electronics)

• Zirconia (dental crowns & implants)

• Silicon Carbide (heat sinks, power systems)

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3DP Polymers Application Fields

• ABS (strong, light weight models & precision parts)

• PLA (perishable models, food containers)

• Nylon (models, tooling, braces/forms, art)

• PEEK (automotive, aerospace, medical, chemical)

• PET (functional models, food containers)

• PETG (functional models, food containers)

• ULTEM (automotive, aerospace, medical, chemical)

• HIPS (fabrication support, shipping)

• PVA (fabrication support)

• Silicone Polymers (seals, gaskets, shields)


3DP Metals Application Fields

• Aluminum (functional models, automotive &

aerospace components)

• Stainless Steel (tooling, models, automotive &

aerospace components)

• Titanium (tooling, functional models)

• Cobalt Chromium (medical, aerospace components)

• Nickel/Inconel (oil, chemical, aerospace, automotive

components)

• Nitinol (medical, dental)

• Au/Ag/Cu/Bronze (jewelry, dentistry, art, electronics)

3dhubs

25


3DP Composites Application Fields

• ABS & PLA based Conductive Polymers

(functional models)

• Metal Loaded Polycarbonate & PEEK (art,

models)

• Alumide (functional models, low volume

manufacturing)

• Wood (models, visual arts)

3dhubs


3DP Specialty Materials Application Fields

• Silicone Gels (seals, gaskets, boots, masks)

• Nano Materials (batteries, sensors)

• Paper (architectural & conceptual models,)

• Carbon/Glass Fiber (recreation, automotive

& aerospace components)

• Graphite & Graphene (touch screens, solar

panels)

• Sandstone (visual arts)

3dhubs

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Equipment


Extrusion Machines

Monoprice

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Extrusion Machines

Ultimaker.com


Powder Bed Fusion Machine

3D Hubs

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Powder Bed Sinter Machine

Toshiba Machine Announces High Speed Metal 3D PrinterToshiba


Photo Fusion/Polymerization

Festo

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Photo Polymerization Machine

Rochester Institute of Technology


Sheet Lamination

• Ultrasonic Additive Manufacturing

– Uses sheets or ribbons of metal bound together

using ultrasonic welding

• Laminated object manufacturing

– Similar but uses paper as material and adhesive

RapidSol / Loughborough University

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Digital Light Synthesis Machine

Carbon 3D


World’s Largest 3D Printed Tool

Oak Ridge Labs

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HP MultiJet 3D

Hewlett Packard


Stratasys’ 3D Printers $6,000 – $750,000

Mid Range – Starting at $20K

High End – Starting at $200KLow End – Starting at $6K

www.cati.com

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Most Advanced Industrial 3D Printers (2018)

Industrial 3D Printer Techology Build Volume Materials

Desktop Metal Production System Single Pass Jetting 330 x 330 x 330 Metals

Arcam Spectra H Electron Beam Melting 250 × 430mm (Ø x H) Metals

3D Systems DMP Factory 500 Direct Metal Laser Sintering

(DMLS)

500 x 500 x 500mm Metals

Laser Concept X LINE 2000R Selective Laser Melting 800 x 400 x 500mm Metals

SLM 500 HL Selective Laser Melting 500 x 280 x 365 Metals

EOSINT M 280 Direct Metal Laser Sintering

(DMLS)

250 x 250 x 325mm Metals

Markforged Metal X Atomic Diffusion Additive

Manufacturing

200 x 200 x 250mm Metal Powder,

Thermoplastics

WAAM Wire + Arc Additive

Manufacturing

- Metals

HP Jet Fusion 500/300 Multi Jet Fusion 332 x 190 x 248mm (500), 254

x 190 x 248mm (300)

Plastic

Photopolymers

Stratasys J750/735 PolyJet 350 x 350 x 200mm (J735),

490 x 390 x 200mm (J750)

Plastic

Photopolymers

Stratasys Objet500 Connex3 Jetting 490 x 390 x 200mm Plastic

Photopolymers

all3dp.com


Most Advanced Industrial 3D Printers (2018)

Industrial 3D Printer Techology Build Volume Materials

Carbon M2 Continuous Liquid

Interface Production

(CLIP)

189 x 118 x 326mm Plastic Photopolymers

3D Systems Figure 4 Digital Light Printing

(DLP)

124.8 x 70.2 x 196mm+

(Scalable)

Plastic Photopolymers

EnvisionTEC Perfactory 4 LED

XXL

LED DLP 230 x 144 x 200mm Plastic Photopolymerrs

Prodways ProMaker V6000 MOVINGLight 120 x 157/350/500 x 150mm Ceramic Resin

Impossible Objects Model One Composite-based

Additive

Manufacturing

(CBAM)

- Polymers, Composites

Nano Dimension DragonFly 2020

Pro

Inkjetting 200 x 200 x 3mm Electronics (PCB)

Mcor ARKe Lamination 184 x 168 x 125mm Paper

BigRep One Fused Deposition

Modeling

1005 x 1005 x 1005mm Thermoplastics

Rize One Augmented Polymer

Deposition

300 x 200 x 150mm Thermoplastics, Binder

Ink

DeltaWASP 3MT Industrial Fused Deposition

Modeling (FDM)

1000 x 900mm (Ø x H) Thermoplastics

all3dp.com

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#desktop-metal-production-system

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#arcam-spectra-h

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#3d-systems-dmp-factory-500

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#laser-concept-x-line-2000r

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#slm-500-hl

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#eosint-m-280

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#markforged-metal-x

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#waam

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#hp-jet-fusion-500-300

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#stratasys-j750-735

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#stratasys-objet500-connex3

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#carbon-m2

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#3d-systems-figure-4

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#envisiontec-perfactory-4-led-xxl

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#prodways-promaker-v6000

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#impossible-objects-model-one

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#nano-dimension-dragonfly-2020-pro

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#mcor-arke

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#bigrep-one

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#rize-one

https://all3dp.com/1/best-industrial-3d-printer-professional-commercial-3d-printers/#deltawasp-3mt-industrial

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State of the Art Vis a Vis Mfg.

Bullema, TNO Science and Industry


Printers Segmented by Price

Chamberlin, IBM

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Capabilities & Challenges


Capabilities

• Access to the 3rd dimension

• Miniaturization

• Unique Combinations

• Rapid Verification (Faster design iteration)

• Reduced Material Waste

• Simplified Assembly of Complex Products

• Mass customization

• On Site Repair

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Volvo Construction Equipment Prototyping

• Volvo retooled the design of construction

equipment & engines with 3DP prototypes

• Savings of 18 Weeks and 92% of Costs

Source: Volvo


Challenges

• Throughput

• Market Immaturity

• Part Size Limitations

• Tolerances

• Repeatability

• Standards

• Multiple Material Constructions

• Materials Performance

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Support for Complex Production?

A.T. Kearney


Supply Chain Implications

• Production closer to end user

• Ship designs not products

• Localized manufacturing

• Lean, Agile supply chain

– Stockless supply chain

– Chainless supply chain

– Distributed manufacturing

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Supply Chain Impact


Mainstream Applications

• Prototyping

• Automotive Parts

• Aerospace

• Medical Implants

• Electronics

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$17 Billion by 2020

A.T. Kearney


Industries Embracing 3DP

Source: AT Kearney

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Prototyping: Footwear

Adidas

FutureCraft 4.0


Prototyping: Yacht Hull

3D printed yacht hull -- a proof of concept by Livrea Yacht

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Prototyping: Airplane Seats

• 3D printing common prototyping and

manufacturing technique in the aerospace

• 50% lighter plane seats with magnesium

Autodesk


Automotive: 3D Printing

Application Process Material Features Example part

Under the hood SLS Nylon Heat resistant functional parts Battery cover

Interior accessories SLA Resin Customized cosmetic components Console prototype

Air ducts SLS Nylon Flexible ducting and bellows Air conditioning ducting

Full scale panels Industrial SLA Resin

Large parts with a surface finish

comparable to injection molding that

allow for sanding and painting

Front bumper

Cast metal brackets &

handlesSLA & cast Wax

Metal parts made from 3d printed

patterns

Alternator mounting

bracket

Complex metal

componentsDMLS Metal

Consolidated, lightweight, functional

metal partsSuspension wishbone

Bezels Material jetting Photopolymer End use custom screen bezels Dashboard interface

Lights SLA Resin Fully transparent, high detail models Headlight prototypes

3dhubs.com

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Automotive: Next Day Prototypes

Skorpion


Automotive: Production

3dhubs

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Automotive: Part Design & production

Prodways Technologies


Aerospace: A350 Hydraulic Assembly

Northrup Grumman

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Aerospace: Airfoils

McGill University


Jet Engine Turbines

Chris Shakal, https://grabcad.com/chris.shakal

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Aerospace: GE Prints & Fires Jet Engine

GE


Remote Repair Opportunities

Five 3D Printers on the

International Space Station!

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Medical: Organs & Tissue

• Heart – patient’s heart tissue ensures

biocompatibility, least challenging as it is a

simple pump

• Skin – all layers, all types (peritoneum, lip,

surface), patient tissue for biocompatibility

• Bone – dissolving biocompatible scaffold

• Cornea – stem cells with alginate & collagen

• Liver – patches for temporary life extension

• Kidney – most challenging due to interaction of

structure & chemical function


Medical: Artifical Heart

• First successfully engineered and printed

complete heart – Differs from earlier organ-on-a-chip approaches

• Bio-ink printed via syringe in gelatinous

support medium– Bio-ink comprises human stem-cell derived cardiac-

muscle cells

Tel Aviv University

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Medical: Implants


Medical: Implants

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Medical: Dental Crown

Sirona


3DP Flexible Materials

Sashi Jain, Intel

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Electronics: Simple Circuits

Xerox


3DP Nanomaterials

• Lithium-ion microbatteries the size of a grain

of sand

• Anode & cathode

inks use lithium

metal oxide

nanoparticles

• Source:

Wyss Institute for Biologically Inspired

Engineering at Harvard

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Electronics: Capacitors

Wu, Z–S. et al. Graphene-based in-plane micro-supercapacitors with high power and energy densities. Nat. Commun. 4:2487 doi:

10.1038/ncomms3487 (2013).

Wu, Max-Planck Institute


Emerging Applications

• Biosensor Devices

• MicroFluidic Devices

• Batteries

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BioSensor Devices

• Combines biological element &

physiochemical transducter

• Detects analytes

• Applications

– Medical

– Environmental

– Agricultural

– Food Industry


Biosensor Elements

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3D Printed Wearable Glucose Sensor

Washington State University


Microfluidic Devices

• Control fluids in micro-channels

• Very low volumes

• Exploit microscale effects

– Surface tension

– Laminar flow

• Applications

– Ink jet printhead

– Nanoliter/picoliter volume handling

– Lab-on-a-chip

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Microfludic Devices

• 3D printed micro-traps capable of catching

motile bacteria from a surrounding liquidScientific Reports volume 7, #: 45897 (2017)


Environmental Monitoring

3D Printing-Based Integrated Water Quality Sensing Systemby Muinul Banna, Kaustav Bera, Ryan Sochol, Liwei Lin, Homayoun Najjaran, Rehan Sadiq and Mina Hoorfar

Sensors 2017, 17(6), 1336

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3D Printed Battery

Printed Wearable Batteries A) Sunglasses with imbedded LED circuit & fully-printed LIB B) Individual battery componentsC) 3D printed battery bracelet with 2 surface mounted LEDs D) Internal 3D printed anode and cathode mounted within the wrist casing

Reyes & Wiley


3D Printed Battery

Graphene 3D Lab

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Case Study

Scoliosis Bracing


Scoliosis = Abnormal Spinal Curvature

Sashi Jain, Intel

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Traditional Braces

Sashi Jain, Intel


First Generation

Sashi Jain, Intel

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First Generation

Sashi Jain, Intel


Capabilities

Sashi Jain, Intel

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Second Generation

Sashi Jain, Intel

1991 – 2019 TechLead Corporation Sashi Jain, Intel

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Enhancing Market Acceptance

Sashi Jain, Intel


Summary

3D Printing – It’s Real!

• Wide range of materials, often in

combination with normally incompatible

materials

• NOT just for prototypes

• Unique capabilities not available with other

manufacturing technologies

• Creating new & expanding markets

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Cost is King, Yield is God!

Sashi Jain, Intel Corporation

Herb Neuhaus, TechLead Corporation

Thank You!

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