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1 Jukka Tuomi, Aalto-yliopisto
3D Printing –
Applications in Industry and Home
Jukka Tuomi
Aalto University
Finnish Rapid Prototyping Association FIRPA
FRC+ Project
Riihimäki April 15, 2014
6 Jukka Tuomi, Aalto-yliopisto
Additive Manufacturing – 3D Printing
= Additive Manufacturing =
- Rapid Prototyping, RP
- 3D Printing
- Rapid Manufacturing, RM
- Free Form Fabrication, FFF
- Additive Manufacturing, AM (ASTM ja ISO standardit)
Material additive processes
1988 - -
Material removal processes
Stone age (40 000 eaa)*- - - - - - -
Material forming processes
- - - - - Copper age (5 000 eaa)** -- -
*) Aurignasin kulttuuri
**) Sulatettu kupari, taottu aiemmin
7 Jukka Tuomi, Aalto-yliopisto
3D Printing
Materiaalia lisäävä valmistus, 3D-tulostus, Additive Manufacturing, AM (Rapid
Prototyping, RP tai Rapid Prototyping and Manufacturing, RP&M) on yhteinen
nimitys ryhmälle valmistustekniikoita, joilla fyysinen kappale valmistetaan
suoraan numeerisen määrittelyn (3D-CAD) pohjalta nopeasti, täysin
automaattisesti, geometrisilta rajoituksiltaan vapaassa prosessissa.
ASTM International F42 committee on Additive Manufacturing Technologies:
“Additive Manufacturing (AM) is the process of joining materials to make objects
from 3D model data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies.”
a) b)
8 Jukka Tuomi, Aalto-yliopisto
3D Printing – Process1/2
3D-CAD - Ideas
- Pro/E
- Catia
- SolidWorks
- …
.stl file
.stl file RP&M - SLA
- SLS
- DMLS
- LOM
- FDM
- …
Physical part
Layer-by-layer manufacturing
13 Jukka Tuomi, Aalto-yliopisto
Why?
Rapid Prototypig
Rapid Tooling
Rapid Manufacturing
1990 -
1995 -
2000 -
Time to market
Faster Ramp-up
Agile manufacturing and customization
2000
High-end products, production and logistics
”SuperMachines” 2010 -
15 Jukka Tuomi, Aalto-yliopisto
Airbus:
• AM manufactured future airplane
• 60 % cheaper
• 30 % lighter
• Titanium parts
• 1:25 ratio in buy to fly
• 1:25 ratio in CO2 emissions
• Innovation potential
• 3 % of all patents by a team of 9 AM experts in 2008 (0.02 % of total staff of 57 000)
GE Aviation:
• 50% engine weight reduction
16 Jukka Tuomi, Aalto-yliopisto
AM General Issues
- Manufacturing constraints
- Features regardless of their position in the part
- Minimization of number of parts - consolidation
- Elimination of fasteners
- Maximization of product performance
- Complex geometries
- Customized geometry
- To ignore all of the constraints imposed by conventional
manufacturing processes
17 Jukka Tuomi, Aalto-yliopisto
ASTM-Approved AM Process Terms
• Vat Photopolymerization
• Powder Bed Fusion
• Material Extrusion
• Material Jetting
• Binder Jetting
• Sheet Lamination
• Directed Energy Deposition
28 Jukka Tuomi, Aalto-yliopisto
AM Unique Capabilities 1/2
1 Shape complexiti
- part complexity is virtually unlimited
- custom-designed geometries
2 Hierarchical complexity
- nano-scale
- micro-scale
- mesostructures (0.1-10 mm)
- part-scale
- Foams, honeycombs, lattice structures (p)
- Put material only where it is needed
- High strength – low mass
- Energy absorption
- Thermal and acoustic insulation
- Stochastic processes – designed cellular materials
30 Jukka Tuomi, Aalto-yliopisto
AM Unique Capabilities 2/2
3 Functional complexity
- kinematic joints
- inserts
4 Material complexity
- different material properties in different regions
- LENS and DMD
- Objet
33 Jukka Tuomi, Aalto-yliopisto
Additive Manufacturing Networks
Customers
What means customisation
in here?
How do the customers behave?
How do we express the products
for the customers?
Company networks - Design
- Manufacturing
- Logistics
34 Jukka Tuomi, Aalto-yliopisto
Trends 1/2
Component manufacturing
Technical prototypes
3D Printing
Now Future
35 Jukka Tuomi, Aalto-yliopisto
Trends 2/2
DIY – Do It Yourself
Metals
End product manufacturing
AM Standards
New design systems
- Tinkercad
- 3DVIA
- 123D
-
36 Jukka Tuomi, Aalto-yliopisto
Truth?
” EADS produces world’s first bike using
revolutionary ALM technology (Airbike).”
”Soon spare parts for human beings will be printed.”
”Gun has been printed.”
”Soon food will be printed.”
”3D-printing will become general in homes.”
Etc.
37 Jukka Tuomi, Aalto-yliopisto
Thank you!
Jukka Tuomi
0500-713420