What Do You Know About the Eight Additive

Manufacturing Processes?

Thank You To Our Sponsor

q  This webinar will be available afterwards at www.designworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar

Before We Start

Moderator

Leslie Langnau Design World

What do you know about the 8+ additive manufacturing processes?

•  Vat photopolymerization o Stereolithography and DLP

Extrusion

3dp Unlimited

Afinia

Material Jetting Binder Jetting

Multi Jet Fusion

Laser sintering o  Variations: Selective Laser Sintering (SLS), Direct Metal Laser Sintering,

Direct Metal Sintering, Electron Beam Melting, Direct Energy Deposition

•  Laser melting o  Selective Laser Melting (SLM), LaserCUSING, Electron Beam Melting

•  Sheet Lamination

•  Bioprinting

•  Manufacturers: o  3D Systems o  EnvisionTec o  Form Labs o  Others

Vat Photopolymerization

Stereolithography

•  Vat of photo curable liquid polymer •  Light sources: lasers, ultraviolet, LEDs •  Objects often built upside down, top of

part down

Excellent for fine detail, accurate dimensions Layer thickness: 0.002 in. to 0.006 in. Tolerances: +/- 0.002 to +/- 0.005

ProjetX950 uses two lasers. Spot size ranges from 0.005 to 0.030 in.

Digital Light Processing •  Light source is usually

Blue Light from a projector, LEDs, or lasers. Projector optics enable an XY resolution of 16 to 69 microns.

3SP: Scan, Spin, Selectively Photocure

Blue Ray light DLP lasers Layer thickness ranges from 0.002 to 0.004 in. Resolution is 0.004 in.

Extrusion A thermoplastic filament moves through a heated deposition nozzle head and is deposited in layers to build a part. As material hardens, it binds to previous layers. ABS, PLA, and others. Materials often the same as those used in injection molding.

Photo  source:  Zureks

Layer height ranges from 0.01 to 0.016, and is dependent on the type of filament and nozzle size used. Tolerance ranges from +/- 0.005 to 0.10 On the highest-performance Stratasys FDM machines, part tolerance reaches as high as 0.003 in., which rivals injection molding.

Material Jetting Sprays or jets drops of liquid photopolymer onto a build platform or part. Usually UV cured Some systems spray wax material

Material Jetting Finishes tend to be smooth, with fine detail Use multiple nozzles Jetting material can have different durometers For form, fit and function apps

Material Jetting Stratasys with its Objet and Solidscape systems. Layers: between 16 and 30 microns (depending on print speed) Resolution: about 42 microns in each direction. 3D Systems, Potentially Hewlett-Packard, which uses a mix of material jetting and binder jetting

Binder jetting

Photo  source:  ExOne

Binder Jetting Systems jet or spray a binder material onto a layer of powder material. Heat is not always used to help bind the layers. Materials include: ceramic, composites, plastics, sand, and some metals. First technology to introduce color: more than 4,000 colors available.

Binder Jetting Post processing used to produce various properties in the final part, remove the binder material, or to consolidate the core material. Infiltration materials include wax, cyanoacrylate glue, and epoxy 3D Systems, ExOne, Voxeljet

Architectural structure built by Voxeljet

Binder jetting Parts made in this way are usually 99.9% dense Minimum layer thickness is 0.0035 in. Typical tolerance is +/- 0.005 in.

3D Systems binder jetting

Multi Jet Fusion—HP

Seems to use both binder and material jetting technology Multiple fluids consisting of fusing and detailing agents (binder, color, and other)

Multi Jet Fusion Dual carriage arrangement Prints more than 30 million drops per second Initial material: thermoplastics

Metal sintering and melting To avoid patent infringement, companies have resorted to a variety of methods to sinter or melt metal, and have developed different labels for these methods.

Laser Sintering ASTM: Laser sintering is the production of objects from powdered materials using one or more lasers to selectively fuse or melt the particles at the surface, layer by layer, in an enclosed chamber.

Laser Sintering Materials: Plastic or metal in powder form From 99+ to 100% dense parts

Selective Laser Sintering Developed and patented by Dr. Carl Deckard, at University of Texas One or more thermal sources are used to fuse powder particles. Materials include plastic, ceramic, glass, and metal. Layer thickness is about 0.004 in. Tolerance is about +/- 0.007 in.

Direct Metal Laser Sintering Developed by Pierre Ciraud in the 1970s. This is now EOS trademarked technology. DMLS refers specifically to the use of metals as the build material Layer thickness ranges from 20 to 40 microns Pre and post-run tooling not required.

Direct Metal Sintering 3D Systems metal sintering process Creates chemically pure, fully dense metal and ceramic parts. Repeatability is about 20 microns

Direct Energy Deposition Optomec’s version is also called blown powder additive manufacturing Benefits: large build volume, thin layer deposits of 100 nm, feature sizes to 10 microns

Selective Laser Melting In laser melting, the material is fully melted into a liquid form Melting imparts different properties to the final part, including different crystal structure or porosity Renishaw and SLM Solutions

LaserCUSING From Concept Laser, this is a form of laser melting. Main differences: Red Fiber laser Patented exposure strageties Single component metal powders Parts are stress and deformation free and fully dense Layer thickness is between 20 and 50 microns  

ASTM classified EBM as a powder bed fusion technique. EBM is proprietary to ARCAM The power source is an electron beam rather than a laser A true vacuum is needed to build parts, which are fully dense Markets include medical, aerospace, and automotive

Electron Beam Melting

Sheet lamination Traditionally, this has been a process that laminates sheets of paper to create parts. New companies are using lamination to build parts layer by layer using other materials, including metal and carbon fiber composites

Sheet Lamination Mcor Technologies is the most known developer of this technology today. Selective Deposition Lamination (SDL) is the name of its process Standard paper is the material. SDL combines lamination and binder jetting to additively build a part Full-color is available

Sheet Lamination

Bio-printing Organovo and EnvisionTec It’s the process of building spatially controlled cell patterns using 3D printing techniques. Cells are dispensed onto a biocompatible scaffold layer by layer EnvisionTec’s process uses syringes to deposit cell material as the syringes move in three dimensions Still undergoing study

Heart  valve  tissue

Questions? Leslie Langnau Design World llangnau@wtwhmedia.com Twitter: @DW_3DPrinting

Thank You q  This webinar will be available at

designworldonline.com & email

q  Tweet with hashtag #DWwebinar

q  Connect with Design World

q  Discuss this on EngineeringExchange.com