uv.eb West 2015 Dr. Mike J. Idacavage

PL Industries A division of Esstech, Inc.

March 10, 2015

Agenda •  Intro to 3D Printing •  Overview of 3D Printing Technology •  UV Curable 3D Printing •  Strength, Weaknesses, Applications

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Types of 3D Printing Type Technology Examples

Subtractive manufacturing Using cutting tools to remove unwanted material

CNC Milling

Forming reshapes a work piece without reducing or adding material

Vacuum forming molding

Additive Manufacturing adding material rather than removing it.

Stereolithography (SLA)

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What is 3D Printing? •  3D printing - the building of a three dimensional object by adding

successive layers of the desired material. This is usually done using a computer file as the data source.

•  3D printing is also known as Additive Manufacturing •  The major components of 3D printing are:

–  Computer modeling –  Fabrication –  Finishing

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3D Printing Market Size

Lux Research 2014 5

Technology Market Comparison

IDTechex 2014 6

3D Printing Material Market Growth

IDTechex 2014 7

Other Market Data

•  $310 MM for Plastics (FFF) per Smarttech Publishing marketing report

•  >$200 MM photopolymers per Wohlers Associates/Gartner

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Global 3D printing Market

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Consumer vs. Industrial 3D Printers

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3D Printing Classification

Dr. Timothy Long & Dr. Christopher Williams, Virginia Tech 2015

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Alternative Classification

Lux Research 2014 12

Types of Additive Manufacturing Type Technology Example Typical Materials

Extrusion Fused filament fabrication (FFF) (Fused deposition modeling (FDM))

Thermoplastic, clay, edible materials

Powders Selective laser sintering (SLS)

Plastics, metals, ceramics

Lamination Laminated object manufacturing (LOM)

Paper, metal foil, plastic film

Photopolymerization Stereolithography (SLA) Methacrylates, Acrylates

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Fused Filament Fabrication (FFF)

•  The name Fused Deposition Modeling (FDM) has been trademarked by Stratasys. Fused Filament Fabrication (FFF) is the legal common name.

•  A filament (typically plastic) is melted and extruded through a nozzle. Parts are built by laying down layer-by-layer.

•  Typical plastic materials that are used in FFF are ABS, Polycarbonate, Polylactic Acid, Polystyrene, etc.

Mech Mecca.blogspt.com

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Fused filament fabrication (FFF)

•  Most widely used 3D printing method in the world

•  Simple to use and consumer friendly

•  Examples of FFF/FDM printers: 3D System's Cube, MakerBot's Replicator and Stratasys' Mojo

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Powder (SLS) •  A thin layer of plastic powder is selectively melted by a laser. The parts

are built up layer by layer in the powder bed. •  An alternative method is to jet a binder on the layer of powder . •  When the model is complete, unbound powder is automatically and/or

manually removed in a process called "de-powdering" and may be reused

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ELECTRON BEAM MELTING (EBM)

•  A thin layer of metal powder is selectively melted by an electron beam. The parts are built up layer by layer the in the powder bed.

•  Typical materials used are metals, composites and ceramics

•  High density metal parts can be made. However, the process is slow, expensive and can only be used with a limited number of metals.

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Laminated Object Manufacturing •  Layers of adhesive-coated paper, plastic, or metal laminates are successively

glued together and cut to shape with a knife or laser cutter. Objects printed with this technique may be additionally modified by machining or drilling after printing.

•  Low cost due to readily available raw material

•  Available in both industrial and consumer printers.

•  Used primarily for scale models (architecture) and conceptual prototypes

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3D Printing with UV - History

•  The first use of UV curable chemistry in 3D printing was Stereolithography (SLA)

•  Chuck Hull was the first to file for a patent on the technology in 1986

•  The first 3D SLA Printing company, 3D Systems released the first printer in 1987

•  Objet Geometries (Israel) introduced a 3D inkjet printer that deposited and cured UV curable resins to generate the 3D form.

•  EnvisionTEC (Germany) demonstrated the first DLP 3D Printer in 2001

•  Shapeways introduced the business model of serving as a third party 3D Printer service in 2008

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3D Printing with UV - Types •  Stereolithography

–  A three-dimensional printing process that makes a solid object from a computer image by using a computer-controlled laser to draw the shape of the object onto the surface of liquid plastic.

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3D Printing with UV - Types •  Digital Light Processing (DLP)

–  DLP uses a DLP projector to project an image onto the liquid photopolymer.

–  This causes a 2 dimensional plane to harden at the same time.

–  The printer then moves the cured plane slightly away from the previous image plane and the projector then photo cures a new plane adjacent to the first.

–  Frequently, a commercial standard DLP projector used in presentations serves as the light source.

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3D Printing with UV - Types

•  UV Inkjet systems –  In this process, an object is

slowly build up by jetting a small drop on the build plate followed by UV curing.

–  Similar to standard 2D UV inkjet systems, the printer head then moves to the new location and the process is repeated.

–  The Inkjet head will then go over a previously cured area and deposit and cure additional material.

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3D Printing with UV – Types •  Color can easily be added in the 3D build. •  In order to support the object as it is being built, an additional print

head can be used to jet wax or similar material as the support. The key requirement is the support material must be easily removable by heat, solvents or other methods.

•  The Objet Polyjet printer is an example of this technology.

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Advantages of 3D Printing with UV •  Highest level of build resolution •  Smooth surfaces without requiring finishing •  Typically stronger in the z directions from chemical bonding

between layers •  Wide range of materials available for the resins •  Faster builds when using more powerful lasers •  Able to make clear objects •  Ability to make moving parts •  Easy to finish or paint

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Disadvantages of 3D Printing with UV

•  Safety concerns with handling the light source (especially SLA lasers) and uncured resins

•  Cost of formulated resins •  Performance of the cured object is limited by the materials

used in the formulation •  Machine costs can be higher than other 3D Printing

technologies •  In some systems, the cured resin can absorb moisture thus

changing the properties such as stiffness.

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Applications

•  Prototypes •  Medical Models •  Custom Manufacturing •  Marketing Tools •  Engineering Research •  Patterns and Molds •  Art •  And Many More…..

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Thank You

Contact information: Dr. Mike J. Idacavage VP Business Development PL Industries, a Division of Esstech Inc. 48 Powhattan Avenue Essington, PA 19029 United States 1-610-442-6589 Mike.Idacavage@esstechinc.com

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