3d printing, material and application - fhki printing, material and application alan yu ... “we...

1 STRATASYS / THE 3D PRINTING SOLUTIONS COMPANY

3D Printing, Material and Application

Alan Yu

Application Consultancy Leader APJ


FDM builds concept models, functional prototypes and Production

Parts in standard, engineering-grade and high-performance

thermoplastics. Parts are unrivaled in mechanical, thermal

and chemical strength.

STRATASYS TECHNOLOGIES

PolyJet technology is a powerful additive manufacturing method

that produces smooth, accurate prototypes, Production Parts

and tooling. It can produce thin walls & complex geometries

using the widest range of materials.


INDUSTRIES

Industrial Aerospace Automotive Military Architecture

Consumer Medical Dental Jewelry Education

Consumer

Products

Entertainment


PROTOTYPING APPLICATIONS


FORM

“Thanks to the accuracy of the 3D models

printed on the Connex 3D printer, we have

almost-real products in our hands which we

test and use the same way as end products”

Ladislav Skoda, Chief Designer


FIT

Karsten Aagaard, user experience designer

“We had some issues with a mouse in production, so

we built a four up size one so we can actually see the

physical movement of the mouse.”

“We are able to load

components and do testing.”


FUNCTION

“We can also provide customers

conceptual models, end-user parts,

functional prototypes, and even in-

house manufacturing jigs and fixtures.”

“Minimizer continues to grow and succeed because we want to make

bold investments like our new Stratasys prototyping machine that

help move our company forward and create innovation in our

industry”.

“Now we have the ability to offer customers

short-run parts without the expense of

injection molding or CNC machining.”

Craig Kruckeberg, Chief Visionary


Do you need a Transparent part?

With Fine details?

And Great surface Finish?

IT DEPENDS ON YOUR APPLICATION


And if you want a Tough, Strong and Flexible product?



• Do you need to print end use parts?

• That are tough enough to endure rough conditions?



• Combining a Rigid material and a Flexible material?

• Reach different levels of Flexibility?


Multiple Materials

Digital Materials


DIGITAL MANUFACTURING APPLICATIONS


DIGITAL MANUFACTURING | BASIC AND ADVANCED

Jigs and Fixtures | PJ

Jigs and Fixtures | FDM

End-Use-Parts

Sand Casting

End Of Arm Tooling

Silicon Molding | PJ

Blow Molding

Injection Molding

Liquid Silicone Rubber

Basic Manufacturing

Advanced Manufacturing

Rubber Molding


• Direct production on PolyJet system

Complex, organic shapes are feasible

Integrate tool ID, part number, guides

• Size & quantities required:

1 to 100s

1 to 30 cm (0.4 to 11 in)*

• Manufacturing requirements:

Temperatures up to ~90 °C (194 °F)

Moderate mechanical loads (70 MPa [10.1 ksi])

No chemical exposure

• Design elements:

Moderate to thick walls (5 – 13 mm [0.2 – 0.5 in])

Frequent replacement or alteration

Complex, intricate

JIGS AND FIXTURES | PJ

FC720 fixture printed with TangoBlack™ interfaces.

Method (In-house) Time Cost

CNC 3 days $1,500

PolyJet 1 day $900

Savings 2 days (67%) $600 (40%)

Multi-material printing allows incorporation of

text for fixture labeling.


JIGS AND FIXTURES | PJ CASE STUDY


• Quantities

1 to 1,000

Prototypes for evaluation

Short-run production

• Small to mid-sized parts

1 ml to 1 liter (0.03 to 35 oz.)

BLOW MOLDING | DETAIL

Method Time Cost

CNC machining 20 days $2,500

PolyJet blow

mold2hours $280

Savings18days

(90%)

$2,220

(89%)


BLOW MOLDING | CASE STUDY


• Quantity

5 to 100 castings**

• Size

6 mm (0.25 in) to 300 mm (12 in)*

• Design

Complex, intricate

Revisions likely

LIQUID SILICON RUBBER | DETAIL

PolyJet mold made with Digital ABS.

Digital pressure gauge inside an LSR boot.

Method Time Cost

CNC mold 14 days $1,000

PolyJet mold 2 days $400

Savings12 days

(86%)

$600

(60%)

* Larger size feasible, may require mold production in multiple pieces

** Higher quantities possible, may require additional mold prints


LIQUID SILICON RUBBER 液體矽橡膠 | CASE STUDY


3,800

Berker: Benefits

22,350

3

28

Traditional Tooling

3D Printed Tooling

Traditional Tooling

3D Printed Tooling

Time (Days)

Cost (USD)

“This new flexibility enables us to try out two or three different solutions at the same time to get the best result. The confirmed quality of our products produced using these functional prototypes has accelerated our R&D processes.”

Andreas Krause

Head of Technical Department & Manufacturing at Berker

Functional tests include:

• Electrostatic discharge test

• Used to determined whether assembly of electrical parts will produce a charge of electricity.

• Fit tests

• All components of the assembly had to fit properly.

End use materials were necessary to validate tests (PC, ASA, TPU).


INJECTION MOLDING | CASE STUDY


• Thermoplastics with:

• Molding temperatures < 300 °C (570 °F)

• Good flow ability

• Candidates: PE, PP, PS, ABS, TPE, PA, POM, PC-ABS

• Glass filled resins

• Low quantities (5 to 100 Parts)

• Mid-sized parts (< 165 ccm, [10 cu. in.])

• Machine type:

• Bench Plastic Injection Molding Machines

• 50- to 100-ton molding machines

3DPIM – Best fit

A: PE, PP, PS, ABS, TPEs

B: PP+G, PA, POM, PC-ABS

C: PA+G, PC, POM+G

D: PC+G, PPO, PPS


More cost and time effective way of validating the functionality of rubber parts before going to production.

Savings compared to Traditional Process:

• Steel Production Molds:

• 95% cost savings realized

• Months to days

• Aluminum Molds:

• 50-70% cost savings realized

• Weeks to Days

BenefitsMetal Molds

RTV Molding


3D Print a mold to be used in the compression molding process.

• Produce fully vulcanized parts with real mechanical properties of rubber

• Mold a variety of materials with different shore values

• Silicone, EPDM, Nitrile, Natural Rubber, etc.

• Up to Shore 70

Rubber Molding with Ultem1010


OEMs and suppliers who design or manufacture elastomeric rubber and foam materials can use this application:

Specified industries include:

• Automotive (seals and gaskets, dampeners, bushings…etc.)

• Footwear (shoe soles)

• Industrial Machinery (safety equipment, boots)

• Oil and Gas (gaskets, seals)

• Aerospace (gaskets, seals)

Industries


Stratasys Materials


Average thermal resistance

& toughness

Enhanced thermal resistance

& toughness

Highest thermal resistance

& toughness

WORLD OF PLASTICS


13 FDM materials in total, in various colors

• Engineering

• FDM Nylon-12

• FDM Nylon- 6

• ST-130

• PC-ABS

• PC-ISO

• PC

• Standard

• ASA

• ABSplus

• ABSi

• ABS-M30

• ABS-M30i

• ABS-ESD7

• High Performance

• Nylon 12 – Carbon Fill

• ULTEM® 9085

• ULTEM® 1010

• PPSF/PPSU

• PEEK ESD

Different platforms support different:

− Materials

− Colors

− Support

FDM MATERIAL SELECTION


Transparent

Rigid

Simulated

Polypropylene

Vero

(Opaque) Rigid

Vero (Opaque)

Rigid - Colors

Tango

Rubber-likeMedical

RGD720 DurusWhite VeroWhitePlus VeroYellow TangoPlus Biocompatible Clear

VeroClear Rigur VeroBlue VeroCyan TangoGray Hearing Aid Family

VeroGray VeroMagenta TangoBlack VeroGlaze

VeroBlackPlus TangoBlackPlus VeroDent

VeroDentPlus

Rigid Flexible Medical

POLYJET MATERIALS | STANDARD PLASTICS SIMULATION


TANGO FAMILY COMPARISON CHART

TangoGray TangoBlack TangoPlus TangoBlackPlus

Color Gray Black Translucent Black

Rubber Shore A 73-77 60-62 26-28 26-28

Elongation at Break 45%-55% 45%-55% 170%-220% 170%-220%

Memory Speed Low High Mid Mid

Tear Resistance High Low Mid Mid


Digital Material

Available In Polyjet Only


• Digital Materials are Composite Materials•

DIGITAL MATERIALS

Composites are formed by combining materials together to form an overall structure that

is better than the sum of the individual components


Generating Digital Materials

Primary

Rigid or Flexible

Secondary

Rigid or Flexible

Digital

Material

Composition

of Primary

and

Secondary


EXAMPLE | RIGUR DM’S

6 flex DM’s and 2 Rigid

DM’s with Tango+

6 flex DMs and 6 Rigid DMs

(Gray scale) with TangoBlack+

New Simulated Polypropylene

materials

• Best PJ offering for ‘living hinge’ application

• Excellent solution for Snap fit application

• Available for all Connex 2 & 3 Systems

Rigur

6 flex DMs6 Rigid DMs


• This is a Digital Material: RGD5160-DM

DIGITAL ABS MATERIAL

High

Temperature

RGD535/531

High Toughness

RGD515

RGD5160-DM

RGD515 RGD535/531


WHAT DO DIGITAL MATERIALS LOOK LIKE?

—Tango+

—Elong. at break 170-220%

—Shore A 27

—RGD-MY002-DM

—Rigid

—RGD-MY006-DM

—Rigid

—Vero Magenta

—Rigid


• 14 Colors Pallets

- All rigid

• Up to 46 colors each

• Combinations of

- Black,

- White,

- Cyan,

- Magenta,

- Yellow,

- Clear colors

RIGID COLORS WITH VERO PROPERTIES

Applications

• Final Product Part Realism

• Focus Groups

• Communication Tools

• …and many more!


• 72 new Digital Materials per Pallet

• Flexible Colors

TANGO+ BASED PALLETS

VeroYellow

Rigid

VeroCyan

Rigid

Shore

95

Shore

35Shore

30 TangoPlus

Shore 27


FDM & PolyJet Materials – Technical Capabilities

0

50

100

150

200

250

0 50 100 150 200 250

HDT (C)

Impact (J/m)

PolyJet

FDM

Form, Fit & Assembly

Function & End Use Parts

High Temp

High Temp after PT Digital ABS

after PT

Digital ABS

DurusWhite

PC-ABS

ABS-M30

PC

ULTEM 9085

PPSF

VeroWhitePlus

NYLON 12ASA

Rigur

ULTEM 1010/CG

PC-ISO

42

3D PRINTERSPROFESSIONAL SYSTEMS IN ALL SHAPES AND SIZES


Our Solutions

Stratasys offers a full range of 3D printers for every industry and application, including the world’s

most advanced 3D printing technologies, materials and support.

3D Printers and Production 3D Printers


Stratasys J750:Mature technology, Ground-breaking Capability


3rd Generation Multi-Material Technology

2004. Eden

1 Material

Highly accurate, finely

detailed models with ultra-

thin walls.

2007. Connex

2 Materials

The world's first multi-

material 3D printer.

2014. Connex 1/2/3

3 Materials

Stratasys introduces the

first-ever color and multi-

material 3D printer.

2016. J750

6 Materials

The world’s only full color,

multi-material, high resolution

3D printer.


Stratasys J750 Possibilities


THANK YOU

3d printing, material and application - fhki printing, material and application alan yu ... “we...

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