Selective Laser Sintering (SLS) with the ProX SLS 6100...SUPPLY CHAIN Consolidate whole assemblies...
Transcript of Selective Laser Sintering (SLS) with the ProX SLS 6100...SUPPLY CHAIN Consolidate whole assemblies...
Selective Laser Sintering (SLS)
with the ProX® SLS 6100 PRODUCTION-READY FOR TOUGH, FUNCTIONAL NYLON PARTS
©2018 by 3D Systems, Inc. All rights reserved.
What Can SLS Do For You?
©2018 by 3D Systems, Inc. All rights reserved.
SUPERCHARGE YOUR
MACHINE SHOP
Free up CNC and machinist time
by printing complex plastic
geometry instead of multi-setup
machining.
ACCELERATE PRODUCT
DEVELOPMENT
Go from idea to functional part in
hand in a day. Validate designs in
1/10 the time.
MAKE RADICALLY
BETTER PRODUCTS
Free of the limitations of molding
and CNC, design and produce
radically lighter weight, higher
performance products.
GET MORE FLEXIBLE
PRODUCTION
Make production-quality parts
without tooling. No lead time, and
no up front costs to amortize for
every design.
STREAMLINE YOUR
SUPPLY CHAIN
Consolidate whole assemblies into
single parts to reduce BOMs and
eliminate assembly labor.
PERSONALIZE &
MASS CUSTOMIZE
Skip the limitations of molding and
CNC, while achieving exacting
mechanical properties and
accuracy.
SLS Makes 3D Production Real
©2018 by 3D Systems, Inc. All rights reserved.
INDUSTRIAL
COMPONENTS• Streamlined supply chains
• Flexible production, lots of one
become economical
• Rapid customer responsiveness
AUTOMOTIVE• Compressed product development
cycles
• Functional prototypes that meet heat, strength, accuracy, and mechanical requirements
• Bridge production
• Tool-less manufacturing of injection-mold quality parts
TOOLING
• 3D printed tooling, including
molds, jigs and fixtures is faster
and cheaper than traditional
tooling
AEROSPACE• Significantly faster time-to-market
• Lightweight, high value production
plastic or cast metal parts
• Revolutionizing the supply chain
• Improved assembly through
custom jigs & fixtures
HEALTHCARE• Improved surgical outcomes
through patient-specific surgical guides
• Mass customized production of personalized devices for prosthetics, orthodontics, hearing aids and more
FOOTWEAR
• Mass customized products fit
every customer perfectly
• Lightweight, high-performance
shoes give athletes a crucial
edge
SLS Strength: Real Nylon
SIMILAR TO INJECTION MOLDED PARTS
With a selection of durable polyamide filled and standard materials, SLS parts perform almost identically to injection molded parts. They are true production grade parts that will last for decades.
STRONGER THAN OTHER PRINTED PLASTIC PARTS
No other 3D printing technology makes plastic parts as
strong as SLS. High temperature sintering produces the
best mechanical properties, without voids or other artifacts
that weaken other 3D printed parts.
Prototype housing for
functional testing
Low volume production
automotive part
©2018 by 3D Systems, Inc. All rights reserved.
SLS vs FDM – Process Matters
Flexural Modulus
Flexural Strength
Tensile Modulus
Tensile Strength
Elongation at Break
Impact Strength (unnotched izod)
Heat Deflection Temp
1650 MPa
1630 MPa
60 MPa
48 MPa
1770 MPa
1950 MPa
50 MPa
27 MPa
22%
3%
644 J/m
275 J/m
182 C
98 C
SLS Printed Part in DuraForm ProX PA
FDM Part in Nylon 12, ZX Orientation*
Based on material datasheets
retrieved May 2017
SLS printed part is stiffer
SLS printed part is stronger
SLS printed part is stronger
SLS printed part is superior
*FDM parts are non-isotropic (they have different
mechanical properties in Z). SLS parts are stronger in
the z-axis vs. other 3D technologies.
SLS part is far tougher under tension
©2018 by 3D Systems, Inc. All rights reserved.
SLS Speed
THERE'S NO FASTER WAY TO GET
PRODUCTION-GRADE PLASTIC PARTS
3D Systems SLS
FDM
Injection Molding
Time to create 250 first article parts2 x 2 inch (50 x 50 mm) parts
33 hours (warm up + printing + cooldown + breakout)
240 hours (printing + support removal)
360 hours (2 week tooling lead time + 1 day molding)
©2018 by 3D Systems, Inc. All rights reserved.
No Supports = Fast & Easy Post-Processing
MORE POSSIBILITIES
Parts are supported by
unsintered powder, you don't
need to print support structures,
giving you greater design
freedom.
LOW LABOR COSTS
With no support structures to
remove, operators & technicians
save time.
EFFICIENT PRODUCTION
Large batches of parts are fast
to print and easy to post-
process, making SLS the
choice for production-level
additive manufacturing.
Clean unused powder off parts, and they're done
©2018 by 3D Systems, Inc. All rights reserved.
Smaller Build Volume | More Affordable | Fine Surface Detail Industrial Grade | Large Build Volume | Production Ready
ProX SLS 6100 sPro 60 HD-HS sPro 140 sPro 230
Priced for prototyping
Production capable
Functional parts
Automatic material management
Small scale manufacturing
Functional prototypes
Repeatable production
Large-scale production
Large parts for testing
Wide body construction
Large-scale production
Turbine-sized builds
Functional testing and
manufacturing
LARGE-FRAMEMID-FRAME
3D Systems SLS Product Line
©2018 by 3D Systems, Inc. All rights reserved.
3D Systems SLS Product Line
ProX SLS 6100 sPro 60 HD-HS sPro 140 sPro 230
Maximum Build Volume
15 x 13 x 18 in(381 x 330 x 460 mm)
15 x 13 x 18 in(381 x 330 x 460 mm)
22 x 22 x 18 in(550 x 550 x 460 mm)
22 x 22 x 30 in(550 x 550 x 750 mm)
Material
Options
DuraForm ProX PA DuraForm ProX EX BLK DuraForm ProX GF DuraForm ProX HSTDuraForm ProX AF+ DuraForm ProX FR1200
DuraForm PADuraForm EX BLK DuraForm GF DuraForm HST DuraForm EX Natural DuraForm FR1200DuraForm TPUDuraForm FlexCastForm PS
DuraForm PA DuraForm EX BLKDuraForm GF DuraForm HST DuraForm EX Natural
DuraForm PA DuraForm EX BLKDuraForm GF DuraForm HST DuraForm EX Natural
Layer thickness range: 0.003 - 0.006 in (0.08 - 0.15 mm)
build rate 2.7 l/hr 1.8 l/hr 3.0 l/hr
Recycling & Handling
AutomaticManual (enables
material changeovers)Automatic Automatic
©2018 by 3D Systems, Inc. All rights reserved.
What is the ProX SLS 6100?
• The Mid-Frame SLS printer that has excellent surface finish and fine
detailing, ideal for production quality, but priced for prototyping
• Optimizes price-per-part to deliver a competitive Total Cost of
Operation (TCO)
• Automatic material handling and feeding system saves time and
money
• 3D Sprint software easily plans the builds to maximize space and part
orientation
• 3D Connect capable for proactive and preventative remote
diagnostics
Production Quality, Priced for Prototyping
©2018 by 3D Systems, Inc. All rights reserved.
Unmatched Part Quality
• Excellent surface finish
• Highest resolution and edge
definition
• High accuracy and repeatability
• Uniform part properties
©2018 by 3D Systems, Inc. All rights reserved.
Lower Part Cost20% LOWER TOTAL COST OF OPERATION
• Automated production tools
• High throughput
• 95% material efficiency
• Optimized workflow
©2018 by 3D Systems, Inc. All rights reserved.
Material Quality Control System
The Single MQC
• User-Interface screen lets you define
material blend ratio in 5% steps
• Integrated remote cooling station
• Material tracking data capture
• Downdraft to reduce airborne materials
• Automated Dynamic powder blending
• Supports only one ProX SLS 6100 printer
• Reject and Re-capture powder chutes
• Remote installation up 100M effective length
from printer
©2018 by 3D Systems, Inc. All rights reserved.
Material Quality Control System
The Dual MQC
• The ‘Dual’ MQC does offer more control
over the powder recycling blend allowing
you to set the ratio in 1% steps
• It has 2 material bins for fully automatic
blending and recycling
• Can support 2 printers at once
©2018 by 3D Systems, Inc. All rights reserved.
Production-Grade MaterialsFOR A BROAD SET OF APPLICATIONS
• DuraForm ProX AF+: Aluminum/mineral filled Nylon 12 material
• DuraForm ProX EX BLK: Nylon 11 black material
• DuraForm ProX FR1200: Nylon 12 flame retardant material
• DuraForm ProX PA: Nylon 12 white, biocompatible and food grade
• DuraForm ProX GF: Nylon 12 with glass fibers for flexibility and
durability
• DuraForm ProX HST: Nylon 12 with high temperature resistance
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX AF+MINERAL AND ALUMINUM FILLED NYLON 12 BASED POWDER
• Aesthetic metallic surface finish
• Functional strength at an affordable cost
• Repeatable mechanical properties
• Easily machined and polished
• Excellent stiffness to weight ratio
• Lower costs with higher recyclability
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX AF+APPLICATIONS
• Housing and enclosures
• Plastic parts requiring a metallic finish and good appearance
• High rigidity components and functional assemblies
• Wind tunnel testing parts where stiffness and light weight are
needed
• Jigs and fixtures where high rigidity is required
• Automotive styling parts where a metallic look is needed
(knobs, bezels etc.)
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX EX BLKNYLON 11 BASED POWDER
• Outstanding durability for long-life
• Excellent impact resistance
• Fatigue resistant
• Fuel and oil resistance
• Uniform black coloring
• Derived from sustainable non-petrochemical based plastics
• Replaces injection molded ABS and polypropylene
• For use in real life environments
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX EX BLKAPPLICATIONS
• Housing and enclosures
• Vehicle dashboards and grilles
• Automotive bumpers
• Snap-fits, living hinges and connector type parts
• Short production consumer goods/sporting equipment
• Complex designs, especially custom ductwork
• Exhaust and duct systems for aerospace and automotive uses
• Impellers
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX FR1200NYLON 12 BASED FLAME RETARDANT POWDER
• FAR 25.853 compliant
• Passes AITM smoke density and toxicity requirements
• Excellent flame retardancy at 12 and 60 second exposures
• High accuracy and repeatability needed for manufacturing
• Non-halogenated formulation
• Excellent surface quality
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX FR1200APPLICATIONS
• Direct production of aerospace, transportation and consumer
goods application where reliable fire retardancy and reduced
smoke and toxicity are required
• Direct 3D production of aircraft interior parts
– Accelerate changes in cabin designs for in service aircraft
– Eliminate tooling and minimize spare part stocking costs
• Reduce fuel costs with weight optimized design enabled by
additive manufacturing
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX PANYLON 12 BASED POWDER
• Strong, tough thermoplastic material
• Excellent mechanical properties
• Outstanding surface smoothness
• Stable dimensional and mechanical properties
• Exceptional recyclability
• Very high part density
• Biocompatibility: ISO 10993-5 and ISO 10993-10 capable
• Food safe
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX PAAPPLICATIONS
• Functional prototyping and low volume production
parts for:
– Automotive
– Aerospace
– Consumer goods
• Housings and enclosures
• Snap fits and complex assemblies
• Connectors
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX GFGLASS-FILLED NYLON 12 POWDER
• Excellent mechanical stiffness and elevated
temperature resistance
• Dimensionally stable
• Easy-to-process
• Excellent surface finish
• Accurate and repeatable parts
• Machinable and paintable for demonstration parts
• Improved isotropic shrinkage due to glass filler
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX GFAPPLICATIONS
• Strong/rigid prototypes that require elevated stiffness and heat resistance
• Low to mid volume direct manufacturing of end-use parts
• Enclosures and housings that require more stiffness
• Aircraft and motorsports parts
• Sporting goods
• Parts requiring machining or joining with adhesives
• Complex production and prototype plastic parts
• Form, fit or functional prototypes
• Parts requiring stiffness
• Thermally stressed parts
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX HSTFIBER-REINFORCED NYLON 12
• Elevated temperature resistance
• High stiffness and strength to weight
• Anisotropic mechanical properties,
just like fiber-filled
• Non-conductive and RF transparent
• Easy-to-finish surface
©2018 by 3D Systems, Inc. All rights reserved.
DuraForm ProX HSTAPPLICATIONS
• Complex, thin-wall ductwork
• Functional prototypes that approach end-use performance properties
• Appropriate for low- to mid-volume rapid manufacturing
• Medical applications requiring USP Class VI compliance or biocompatibility
• Motorsports
• Aerospace
• Housing and enclosures
• Impellers and connectors
• Consumer sporting goods
• Vehicle dashboards and grilles
• Snap-fit designs
• Parts requiring machining or joining with adhesives
©2018 by 3D Systems, Inc. All rights reserved.
3D Sprint for the ProX SLS 6100ADVANCE YOUR WORKFLOW
• High performance auto-nesting
• High density builds
• Sinter Cage structure generator
• Quality check for pre-build verification
©2018 by 3D Systems, Inc. All rights reserved.
Fleet Monitoring
• Customer facing
• Real-time remote monitoring
• Event driven notifications
o Text & email alerts
• Metric rich environment
o Up-time, usage, consumable
use, health of the lasers/print
heads, etc.
Remote Service
• 3D Systems service facing
• Automatically notifies service when
alert conditions occur
• Enables remote investigation for
more precise diagnosis
• No special customer skills set
required
COMING SOON
3D Connect Capable
©2018 by 3D Systems, Inc. All rights reserved.
3D Connect™, A Simplified View
• Edge Gateway synchronizes the
data
• IIOT Platform makes it useful
REMOTE / MOBILECUSTOMER ACCESS
3D SYSTEMS SERVICE TEAM
• LASER HOURS• HEAD PERFORMANCE• SCHEDULED MTC• MORE
Sensor readings
Safe and neutral machine data
Service Tickets
Charts, plots, analytics
Actionable information
COMING SOON
©2018 by 3D Systems, Inc. All rights reserved.
The ProX SLS 6100 in Summary
• Price and performance
– Production quality performance at prototyping price
• Portfolio of 6 production-grade materials
• Strong software platform
– Integrated 3D Sprint and 3D Connect capable
• Automatic material handling, feeding and recycling
through the material quality control (MQC) system
©2018 by 3D Systems, Inc. All rights reserved.
Emirates Uses SLS for Significant Cost
Savings Opportunities of In-Cabin PartsSLS printing with flame retardant nylon material reduces weight of in-cabin video shroud
• Video monitor shrouds are between 9 and 13% lighter
than their conventionally manufactured counterparts
• Emirates optimizes its designs to create fit-for-purpose
parts with an optimized strength-to-weight ratio
• DuraForm ProX FR1200 material:
– FAR 25.853 compliant
– Passes AITM smoke density and toxicity
requirements
– UL certification for consumer goods
• Emirates is in the process of securing Form 1
certification to validate video shroud part design as
approved for aircraft use
©2018 by 3D Systems, Inc. All rights reserved.
Metro Aerospace Introduces 3D Part for Fuel
EfficiencySLS printing provides fuel savings of 4% at cruise with improved aerodynamics
• Metro Aerospace designed microvanes that are
adhesively fastened on both sides of an aircraft’s
fuselage
• Parts designed to reduce drag by reshaping airflow
around the aft cargo door
• Printed with DuraForm® GF, a glass-filled nylon
• Final 3D printed microvanes met the rigorous
standards outlined by the engineers who designed
them
©2018 by 3D Systems, Inc. All rights reserved.
Wiiv Wearables Mass Customization with SLS
100% custom SLS 3D printed production of tens of thousands of shoe soles
• Rapid turnaround of custom shoe soles from
personalized scan data
• SLS build envelope provides the flexibility to stack
parts in a wide variety of configurations
• Enjoy the benefits of 3D production:
– No tooling investment
– Mass customization
– Design freedom
– Fast turnaround
©2018 by 3D Systems, Inc. All rights reserved.
Jay Leno Creates One-of-a-Kind Replacement
Part for EcoJet Concept Car3D Printed Replacement Vent in SLS with high-temperature resistant material
• 3D Systems team helped create a digital workflow to
scan old part and create a design for replacement part
• Printed in Duraform HST, a fiber-filled nylon with
anisotropic mechanical properties
• Ideal for functional prototypes and end-use parts that
require high stiffness and elevated thermal resistance
and has a surface that is very easy to finish
©2018 by 3D Systems, Inc. All rights reserved.
Production Quality with the ProX SLS 6100Transform Your Production Processes with Tool-less Manufacturing
SLS is the 3D printing technology for
real thermoplastic parts without compromise
High performance duct
that's difficult and costly
to mold
Low volume tool-less
manufactured parts
Personalized healthcare
applications
©2018 by 3D Systems, Inc. All rights reserved.
THANK YOU!
©2018 by 3D Systems, Inc. All rights reserved.