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3D Printing State of the Art: IndustrialJohn Hornick
April 2016
What Is It?
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What Is It? Not Yoda head
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What Is It? Not Yoda head
The Name Game
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The Name Game AKA:
– 3D printing– Additive Manufacturing
(AM)– Direct Digital Manufacturing– Rapid prototyping
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The Name Game
3D Printing v. AM
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The Name Game
Subtractive v. Additive
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The Name Game
Subtractive v. Additive– old v. new
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The Name Game
Subtractive v. Additive– old v. new– injection molding, casting, weaving
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The Name Game
Subtractive v. Additive– old v. new– injection molding, casting, weaving
old and additive
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The Name Game 3D printing/AM v. “traditional”
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The Name Game 3D printing/AM v. “traditional”
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The Name Game
SLA SLS
DMLSDLP
FFFFDM
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The Name GameBinder jettingDirected energy depositionMaterial extrusionMaterial jettingPowder bed fusionSheet laminationVat photopolymerization
3DP Today
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3DP Today
Price Range:
ASP:
Industrial Base:
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3DP Today
Price Range: $5K to $5M
ASP:
Industrial Base:
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3DP Today
Price Range: $5K to $2M
ASP: $87K ($90K)Industrial Base:
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3DP Today
Price Range: $5K to $2M
ASP: $87K ($90K)
Industrial Base: ~80K
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3DP Today
Binder Jetting
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Binder Jetting aka Digital Part Materialization
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Binder Jetting
Materials: – polymer, metal, glass, sand
Post-processing: curing, sintering, infiltration
Color (in plastic)
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Binder Jetting: Plastics
3D Systems ProJet (US)
acrylate powder infiltrated with cyanoacrylate full color parts $16K to $114K
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Binder Jetting: Plastics
Voxeljet (Germany) continuous build acrylic polymer, sand
room temperature cure (no heat distortion) $150K to $1.8 million
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Binder Jetting: Metals
ExOne (US) 2.5 x 1.6 x 1.3 ft. Bronze, Inconel, iron, stainless steel, tungsten, glass, sand Post-processing: Metal parts:
– sintered – binder burned out– infiltrated with bronze
$145K to $1.6 million
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Binder Jetting: Metals Hoganas (Sweden)
– Small– Precise
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Binder Jetting: Licenses Developed by MIT (“3D Printing”)
– Licensed to: ExOne Z Corp.
–(acquired by 3D Systems)
– Sublicensed: 3D Systems to Voxeljet
Directed Energy Deposition
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Directed Energy Deposition aka:
–Blown Powder AM–Laser Cladding
–$350K to $1.5M
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Directed Energy Deposition Optomec (US)
– Laser Engineered Netshaping (LENS) ≤ 3 x 5 x 3 ft. ≤ 1 kW
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Directed Energy Deposition LENS
– Multi-metals simultaneously graded materials/parts on the fly
– Multi-axis head– Unlimited substrates
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Directed Energy Deposition– Sciaky (US)
Electron beam (EBAM) Wire feedstock 9 x 4 x 5 ft.
Titanium, tantalum, Inconel, SS, Cobalt alloys, Nickel alloys, copper nickel alloys
Fast Very rough parts
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Directed Energy Deposition– Accufusion “Laser
Consolidation”– AM3D– BeAM (Irepa Laser)
“EasyCLAD”– eFesto “Laser
Cladding”
– Honeywell Aerospace “Ion Fusion Formation”
– INSSTek– NASA/Penn State
Radiant Deposition– Trumpf TruLaser– Xi’an Bright Laser
Technologies (China)
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Hybrids DMG Mori Sieki
Germany/Japan
– Laser Deposition Welding DED 5-axis mill 25” x 25” x 22” 2 kW
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Hybrids Yamazaki Mazak
DED
Milling
Interchangeable tool heads
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New on the Block Toshiba:
– 2017– Laser Metal Deposition– 10x PBF– large parts– 110cc/hr
Material Extrusion
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Material Extrusion aka:
– Fused Deposition Modeling (FDM)
– Fused Filament Fabrication (FFF)
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Material Extrusion
Post-processing: removal of supports, surface finishing
Prototypes, simple plastic parts Most-used process
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Material Extrusion Thermoplastics
– ABS– PLA– Polycarbonate– PC/ABS blend– Helian/Eastman
ColorFabb XT– ULTEM
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Material Extrusion Consumer:
– 2009: watershed– ~300– $500 to $5000
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Material Extrusion Stratasys/Objet (US/Israel)
– Filament spools ABS PLA Support material
– $9500 to $500K
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Material Extrusion Arburg (Germany) “Freeformer”
– Stationery nozzle– 3/5 axis– Deposits droplets at high speed
Similar to BPM– Thermoplastic pellets
Material Jetting
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Material Jetting Types:
– Aerosol Jet/Direct write– Cold Spray– Ballistic Particle Manufacturing (BPM)– Polyjet
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Material Jetting
Aerosol Jet/Direct Write
2.5D
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Material Jetting
Post-processing: heat or chemical treatment
Unlimited:
substrates
shapes
Circuitry
Extreme precision
$200K to $500K
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Material Jetting Direct Write companies:
– Optomec (US) Aerosol Jet– Lawrence Livermore (US)– nScrypt (US)– CamTek (Israel)– Nano Dimension (Israel)– Neotech (Germany)– XJet “Nano Metal Jetting” (Israel)– Argentum (US)
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Material Jetting Cold Spray
– CSIRO
– Flexible Robotic Environments– Trinity College
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Material Jetting Ballistic Particle Manufacturing (BPM)
– Build method: inkjet-like nozzle fires thermoplastic at high speed solidified into desired shape
– Applns: prototyping
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Material Jetting Companies:
– BPM, South Carolina (defunct)– Incremental Fabrication Technologies
(defunct?) metal particles
– Similar to: cold spray Arburg Freeformer
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Hybrids Hermle MPA 40
– Thermal metal spray 3X
– 5 axis CNC– Intermediate milling– Alloys on the fly
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Material Jetting Polyjet
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Material Jetting– Materials: photopolymers, casting materials,
support– Multi and graded materials on the fly
– Post-processing: remove supports, extra powder– Finished parts
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Material Jetting Multi-jet Modeling
– Multi materials in different proportions Some ProJet machines (5500X)
– $60K to $225K
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Material Jetting
J750–Digital materials–6 different resins–360,000 colors–2X
Powder Bed Fusion
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Powder Bed Fusion
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Powder Bed Fusion aka Laser Melting
– Direct Metal Printing (DMP) (3D Systems/Phenix, U.S.)
– Direct Metal Laser Sintering (DMLS) (EOS, Germany)
– Metal Laser Melting (MLM) (Renishaw (UK)) Licensed by EOS for U.S.
– Selective Laser Melting (SLM)(SLM Solutions, Germany) Licensed by EOS for U.S.
– Selective Laser Sintering (SLS) (Fonon, US)
– laserCUSING (Concept Laser, Germany)
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Powder Bed Fusion Other companies:
– Aspect (Japan)– Beijing Longyuan (China)– Blueprinter (Denmark)
(Selective Heat Sintering)– Hunan Farsoon (China)– Realizer (Germany)
(precious metals)– RPM Innovations (US)– Shaanxi Hengtong (China)
– Sisma Spa (Italy)– Trumpf (Germany)– Wuhan Binhu/Huake
(China)– Xi’an Bright Laser
Technologies (China)
Price: $160K to $5.0 million
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Powder Bed Fusion Laser Melting
– Lasers: 400 w to 1 kW– Materials: aluminum, copper, nickel, and titanium
alloys, carbides, SS, tool steels– Post Processing: Heat treating, finishing– Structural finished parts– Complex geometries– Finer finish than EBM
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Powder Bed Fusion Electron Beam Melting (EBM)
– Arcam (Sweden)– same as LM,
but with electron beam– BV: 14” x 14” x 15”– Laser: 3 kW
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Powder Bed Fusion Electron Beam Melting (EBM)
– Materials: Titanium (supported by Arcam)– Faster than laser– Less residual stress than LM– Applns:
structural finished parts, complex geometries– aerospace parts, orthopedic implants
less refined than LM
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Hybrids Matsuura (Japan)
– Powder Bed Fusion – CNC Mill
Mills every ten layers– 400W ytterbium fiber laser– $1 million
OPM Laboratory (Japan) PBF + CNC mill
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Powder Bed Fusion Sintratec
– Switzerland– Nylon– €5K
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Powder Bed Fusion
20:1
25%
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Powder Bed Fusion rtt
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Powder Bed Fusion
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Powder Bed Fusion wfe
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Powder Bed Fusion
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Powder Bed Fusion
http://www.flyingmachine.com.au/studio/
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Powder Bed Fusion
http://www.flyingmachine.com.au/studio/
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Powder Bed Fusion
http://www.flyingmachine.com.au/studio/
Sheet Lamination
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Sheet Lamination Laminated Object Manufacturing (LOM)
–MCor Technologies (Ireland) Full color models $36K to $47K
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Sheet Lamination Ultrasonic Lamination (UL)
–Fabrisonic Ultrasonic Additive Manufacturing (UAM) 72” x 72” x 36” Multi-axis machining Embedded sensors Joining dissimilar
materials
Vat Photopolymerization
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Vat Photopolymerization
1980s
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Vat Photopolymerization
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Vat Photopolymerization Digital Light Processing (DLP)
Envisiontec (Germany) DWS, Lithoz (Ceramic-filled polymer),
Asiga, Rapid Shape Formlabs, Autodesk EMBER, B9,
DWS XFab
Stereolithography (SLA) 3D Systems Lawrence Livermore
– Micro-stereolithography» Ultra-stiff, lightweight parts
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VPP for $86K
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Vat Photopolymerization
Smooth-finish parts, jewelry molds, prototypes
$5K to $600K
Pauline/3D Varius
Game Changers Among Game Changers
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BAAM
ORNLLocal MotorsCincinnati Inc.
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BAAM
ORNLUTenn
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Voxel8
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CBAM Process Overview
Load CAD slices into
printer and print bitmap of layer on fiber sheet
Remove dry
polymer powder
Feed fiber sheet into
inkjet printer
Stack sheets, heat, and
compress stack to final part
height
Remove un-bonded portions of fiber sheets to net final part
Deposit polymer powder
(1) (2) (3) (4) (5) (6)
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Impossible Objects CBAM
– Functional parts– ≤10x faster/stronger– Strength to weight
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Carbon Continuous Liquid Interface Production (CLIP)
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Figure 4 Platform
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High Speed Sintering/FACTUM
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High Speed Sintering/FACTUM
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s
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Who Else Wants In? New resin-based lamination process
– Fast– Precise
Rapid– Prototyping– Manufacturing
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Who Else Wants In?
November 2015:
PBF (polymers)$50-$150K ???
Patent Landscape
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Patent Landscape USA 60%
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Patent Landscape Top issuing: USA 60%
– 2002 to 2014: 12,000
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Patent Landscape Top issuing: USA 60%
– 2002 to 2014: 12,000
– Pending: ~4000– Issued: ~8000
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Patent Landscape Top issuing: USA 60%
Expiring: – 2003 to 2014: (225)– 2013 to 2014: ~16
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Patent Landscape
Patents
Applns
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Patents Issued 1991 to Early 2014
3D Systems
Univ. of Texas
Electro Optical Systems
Objet
Nanotek
MakerBot
BPM Technology
United Technologies
Z Corporation
Panasonic
VoxelJet
0 50 100 150 200 250201
101616
5785
2519
1324
852
81314
2615
408
2166
# of Patents
# of Patents
The Players
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3D Systems, DTM, & Z Corp US DDD 2001: acquired DTM Corporation 2012: acquired Z Corporation BJ, ME, MJ, PBF, VPP
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Stratasys/Objet Israel (US) SSYS 2012:Merged with Objet 2013:Acquired Makerbot ME, MJ
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Stratasys & MakerBot Consumer/prosumer/RP printers Lower cost machines (~$2000) 2013: acquired by Stratasys in $403M stock deal
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Arcam Sweden AMAVF PBF (Electron Beam)
– Focus: orthopedic implants and aerospace
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Concept Laser Germany PBF
– Laser CUSING
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Electro Optical Systems Germany PBF
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EnvisionTEC Germany VPP
jewelry, hearing aid, dental, consumer, auto manufacturing, and design
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ExOne US XONE Binder Jet
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HP US HPQ Game changer among game changers Multi Jet fusion
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Optomec US DED, MJ
LENS Aerosol Jet
2.5D/parts/repair
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Voxeljet Germany VJET Binder Jet Big printers
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Companies
“Game changing technology” Acquired Morris Technologies
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Companies
“Game changing technology” Acquired Morris Technologies
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Companies
“Game changing technology” Acquired Morris Technologies
Silverbrook Technologies (Australia)– ≥ 40 patents (BPM)
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Colleges and Universities USC: ≥ 26 patents (5)
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Colleges and Universities USC: ≥ 26 patents (5)
MIT: ≥ 21 (31)
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Colleges and Universities USC: ≥ 26 patents (5)
MIT: ≥ 21 (31)
UTA/UTEP: ≥ 8 (7)
Who Else Wants In?
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Who Else Wants In?
Epson: 5 years
–“We want our machines to make anything”
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Who Else Wants In?
Epson: 5 years
–“We want our machines to make anything”
Others ????
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Who Else Wants In?
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Who Else Wants In?
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Who Else Wants In? yuu
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Who Else Wants In?
Embedded ID
Selective curing VPP
Free-moving buildplate
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DisclaimerThese materials are public information and have been prepared solely for educational and entertainment purposes to contribute to the understanding of U.S. intellectual property law. These materials reflect only the personal views of the authors and are not a source of legal advice. It is understood that each case is fact specific, and that the appropriate solution in any case will vary. Therefore, these materials may or may not be relevant to any particular situation. Thus, the authors and Finnegan, Henderson, Farabow, Garrett & Dunner, LLP cannot be bound either philosophically or as representatives of their various present and future clients to the comments expressed in these materials. The presentation of these materials does not establish any form of attorney-client relationship with the authors or Finnegan, Henderson, Farabow, Garrett & Dunner, LLP. While every attempt was made to ensure that these materials are accurate, errors or omissions may be contained therein, for which any liability is disclaimed.
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