Transcript
Kon-15.4126 Production Technology Special Topics (2016): 3D-Printing
Post Processing and Secondary Processes Prof. Jouni Partanen Aalto University
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Kon-15.4126 Prod Tech Special Topics (2016): 3D-Printing •
Lectures on Thursdays 14.15 – 16.00, Lecture hall K1-213 • Jan 7 – Feb 11 • Feb 25 – Mar 31
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Course assignment: • Hands-on-Training • Groups of 4 students? • Exercises will be done in ADDLAB • 3D-design and 3D-printing • 3D object and final report • Course Assistant: Meng Wang • Jan 23 – Mar 15
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Final Exam on Thursday April 7 at 13.00 – 16.00, Lecture hall K1-216 Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Ko-15.4126 Prod Tech Special Topics (2016): 3D-Printing Tentative Schedule for Lectures • • • • • • • • • • • • • •
Jan 7: Jan 14: Jan 21: Jan 28: Feb 4: Feb 11: Feb 18: Feb 25: Mar 3: Mar 10: Mar 17: Mar 24: Mar 31: Apr 7:
Course Introduction History and AM Process Chain Powder Bed Fusion Design for AM and Digital Manufacturing Inigo Flores Ituarte: Software for 3D-Printing Material Extrusion and Directed Energy Deposition no lecture Pekka Lehtinen: Vat Photopolymerization Printing Processes and Sheet Lamination Mika Salmi: Medical Applications of AM Business Aspects Ashish Mohite: 3D-Printing in Architectural and Industrial Design Post Processing and Secondary Processes Final Exam
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
ASTM-approved AM process terms
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Vat Photopolymerization Binder Jetting Powder Bed Fusion Material Extrusion Material Jetting Sheet Lamination Directed Energy Deposition
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Vat Photopolymerization • 3D Systems was founded 1987 • First commercia product SLA-1 (1988) • Photocurable polymer • Good feature definition and accuracy Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Stereolithography • Parts are tacky out of the vat • Parts need to be post cured in an ultraviolet oven for crisp surface finish
www.invisalign.com Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Stereolithography supports
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Stereolithography supports
http://1prototype.com/freeform_parts.html Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Envisiontec • Since 2002 • The photocuring image is done using a DMD (digital micromirrow device) • The object is cured from below
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Binder Jetting • Originally developed and patented by MIT in late 1980s • Licenced to many companies in early 1990s • • •
Z-corp (now part of 3D Systems) Voxeljet ExOne
http://blog.nus.edu.sg/u0804594/common-rp-techniques/d-3dp/
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Binder Jetting
• Powder will support the parts from below => no supports are needed • Parts nesting, you can fill the whole part bed
http://www.growit3d.com/growit-blog/a-vendor-driven-world/
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Z Corporation
Parts are very weak directly out of the machine Infiltration with “Superclue”
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
ExOne
Metals and Sand • Debinding and sintering in high temperature
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
VoxelJet VX-200
VX-4000
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Powder Bed Fusion Technology • Commercial at about 1990 • DTM (acquired by 3D Systems in 2001) • EOS • Plastics and metal materials • Sintering • Melting (early 2000)
http://www.custompartnet.com/wu/images/rapid-prototyping/sls.png
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Plastics
• Powder will support the parts from below => no supports are needed • Parts nesting, you can fill the whole part bed
http://www.growit3d.com/growit-blog/a-vendor-driven-world/
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Powder Bed Fusion Technology - Plastics
Part bed heated just below sintering temperature => Long warmup and cooldown times
http://www.custompartnet.com/wu/images/rapid-prototyping/sls.png
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Powder Bed Fusion Technology - Metals
Room temperature part bed: Lots of energy needed from the laser Large temperature gradients
http://www.custompartnet.com/wu/images/rapid-prototyping/sls.png
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Curl Distortion
Gabriel Bugeda, Miguel Cervera, Guillermo Lombera, Eugenio Onate, (1995) "Numerical analysis of stereolithography processes using the finite element method", Rapid Prototyping Journal, Vol. 1 Iss: 2, pp.13 - 23
• Fundamental problem with 3D-Printing technologies • In solidification the top layer shrinks, part curls => “potato chips” • Nonuniform shrinkage • Crashes the builds • Inaccurate parts
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Metals
• Strong supports are needed because of distortions caused by curl phenomena and large thermal gradients • Usually tight laser focus and slow build speed
http://www.kraftwurx.com
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Material Extrusion • Commercial at about 1990 • Stratasys • Key patents expired at about 2005 • Many low cost products available today • Largest number of machines in world today
http://www.custompartnet.com/wu/fused-deposition-modeling
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Stratasys
• 3D objects are made by stacking layers from bottom up • Objects need to be supported from below • Easy support removal - soluable support materials Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Reprap • • • •
University of Bath About 2005 Open source community Members from all over the world • Some of the device components are made by the device itself (self replicating) •
499 £ for the kit on the right
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There are many low cost systems (300 - 5000 €) on the market currently http://www.nextdayreprap.co.uk/ Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Material Jetting
• Commercial at about 1995 • 3D Systems • Objet (now part of Stratasys
http://www.makeuseof.com/tag/what-is-3d-printing-and-how-exactly-does-it-work/
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Solidscape
• Solidscape 3D-printer makes parts out of thermopolymer – wax-like material • Parts are encased in soluable support material
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
3D Systems Thermopolymers for investment castings Jewelry industry
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Objet Digital Material
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Sheet Lamination • Commercial at about 1990 • Helisys • went out of business in about 10 years • Laser replaced by knife • Mcor Technologies
http://www.custompartnet.com/wu/laminated-object-manufacturing
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Sheet Lamination • Decubing
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Directed Energy Deposition
http://blog.cafefoundation.org/?p=8410
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
LENS technology
Laser Engineered Net Shaping
• Stacking up 2D images you can make 3D objects • Conceptually simple process – great for automation
http://www.tms.org/pubs/journals/jom/9907/hofmeister/hofmeister-9907.html
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Investment Casting • Technology is very good for jewelry
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Investment Casting: Quick Cast
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Sand Casting
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
RTV Silicon Molding • Room Temperature Vulcanizing
Silicone casting
http://www.met-l-flo.com/gallery.htm http://www.paint-sculpt.com/tutorials/mold-making-tutorial/mold-making-tutorial-overview.html
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Direct Tooling Insert production
Injection/sand mold production
http://www.tctmagazine.com/additive-manufacturing/3d-printing-cuts-tooling-cost-by-97-percent/
http://www.mmsonline.com/articles/adding-to-your-tooling-options
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Rapid Manufacturing • Other denominations include Direct Part Production (DPP) and Direct Manufacturing (DM) among others • Producing a part directly using AM
http://www.yenra.com/rapid-prototyping/metal.jpg
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Kon-15.4126 Prod Tech Special Topics (2015): 3D-Printing Questions for preparation to exam 1. Applications of 3D-printing in tooling. 2. What are those features of a part that can be produced particularly well using Additive Manufacturing technologies as compared to traditional manufacturing technologies? 3. Give the list of the ASTM approved Additive Manufacturing processes and describe one example of each process. 4. (a) Calculate the total cost per part for the case where 25 parts are made in one build using material extrusion process. The height of the parts 5 cm and layer thicknesses are 0,2 mm. Assume average layer cross section to be 2 cm2, extrusion line width to be 0,7 mm and extrusion speed to be 6 cm/s. The wait between extrusion stopping and starting in a new layer is 3 s. Assume preparation time and warm-up time to be 15 min together and cooldown and part removal time to be 10 min together. Weight of each part is about 10 g and material cost is 100 €/kg. Material extrusion equipment cost is 120000 and it is amortized in 6 years. Expected usage is 4000 h in a year. (b) Calculate breakeven quantity between additive manufacturing and injection molding if the injection molding tool is assumed to cost 5 k€ and the production cost for each part is 0,1 € in injection molding. 5. Describe how 3D-Printing can be applied to medical applications. 6. 8 Direct Digital Manufacturing drivers were given in the lectures. Describe all of them. 7. Metallic 3D-Printing: describe methods and challenges relate to them. 8. Describe new potential business opportunities 3D-printing makes possible
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
Thank you! Jouni Partanen Aalto University Department of Mechanical Engineering
[email protected]
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing Prof Jouni Partanen
