inside3 d printing_chuckalexander

Copyright © 2013 Solid Concepts Inc.

Industrial ScaleAdditive Manufacturing

Technologies

Chuck AlexanderProduct Manager

Additive ManufacturingSolid Concepts Inc.

3D PRINTING

Source: Gartner 2012 Technology Hype Cycle

Gartner 2012 Technology Hype Cycle

Source: Gartner 2013 Technology Hype Cycle

Gartner 2013 Technology Hype Cycle

3D PRINTING/ ADDITIVE MANUFACTURING

Additive ManufacturingOverview

Mission: To excel in rapid prototyping and manufacturing by providing superior value through quality, delivery, and service.

Product Development(Prototype, Test, Refine)

Pre‐Production(Sales, Market Introduction, Mfg. Line Optimization)

Production (Low Volume, Spares, Service, Product Revision)

Additive ManufacturingTechnologies

PolyJet

Stereolithography (SLA)

Selective Laser Sintering (SLS)

Fused Deposition Modeling (FDM)

ZPrint 3D Color Prints

Direct Metal Laser Sintering (DMLS)

AdditiveManufacturing

PolyJet™

PolyJet is a high precision 3D printing process with layers as thin as 16 microns (0.0006"). Suitable for excellent appearance models and patterns for advanced urethane castings.

Applications: High resolution concept models, low volume over‐molded parts.

PolyJet Video

• Click to play video

http://www.youtube.com/watch?v=Som3CddHfZE

PolyJet

PolyJet HD build (16μm layers) offers finest layer thickness

PolyJet Blue and SCI White

PolyJet offers fast delivery of highly accurate models

SCI White material used to create fine feature detail

PolyJet

PolyJetMaterial Options

Material Build Envelope Resolution/Tolerances

PolyJet WhiteOpaque white, rigid, durable Objet Eden 260V

Objet Eden 500VRecommended:

4" x 4" x 4“(or larger flat objects)

Maximum:19.3” x 15.4” x 7.9”

PolyJet (Fastest Build Speed)30m (~.00118”) layer thickness by

42m (~.00167”) X & Y axis

PolyJet HD (High Definition)16m (~.00063”) layer thickness by

42m (~.00167”) X & Y axis

Tolerance: .005” or .001”/”, whichever is

greater

PolyJet BluePale blue, rigid, durable

PolyJet GrayLight gray, rigid, durable

Amber ClearClear (amber tint), rigid, durable

PolyJet Flex &PolyJet Over‐Mold

Flexible black (Shore 27A‐95A) &Flexible black over rigid PolyJet White

Objet Connex 500Recommended:

4" x 4" x 4“(or larger flat objects)

Maximum:19.3” x 15.4” x 7.9”

PolyJet Flex & PolyJet Over‐Mold30m (~.00118”) layer thickness by

42m (~.00167”) X & Y axis

Tolerance: .005” or .001”/”, whichever is

greater

SLA® (Stereolithography)

SLA (Stereolithography) provides accurate concept models and master patterns in record time. Complete in‐house finishing capability for production‐like prototypes.

Applications: Concept models, form/fit verification, master patterns for cast urethanes, investment casting patterns, ID‐Light lightweight models.

SLA Video


http://www.youtube.com/watch?v=NM55ct5KwiI


Solid Concepts offers a wide variety of photocure materials that were meticulously

selected to meet your project needs.

SLA has been a material of

choice for many wind tunnel

testing project.

Architectural models are often made with SLA

including this scale mock‐up of San

Francisco for a new Transbay Transit Center & Tower.

Accura 60 is a clear material that can be

tinted such as the red lens seen here.


Finishing – Cosmetic Paint


• SLA master patterns were used to create WALL‐E’s body panels.

• This real robot was built for tours, guest appearances, and trade shows.

SLA® (Stereolithography)Lightweight Appearance Model – ID‐Light

SLA® (Stereolithography)Lightweight Appearance Model – ID-Light

SLA® (Stereolithography)Arts & Entertainment

QuickCast™ Investment Casting Patterns Light Weight Patterns • 10 ‐ 35% lighter (in general) than a

standard investment casting pattern

Pattern shown • 0.0980 kg (left) vs. 0.1240 kg (right)• 21% lighter• Volume = 438 cm3• 0.224 g/cc, 0.283 g/cc• 19.98% of vol. occupied by sold mass

(left)• 25.27% of vol. occupied by solid mass

(right)

QuickCast™SC 1000• Material engineered specifically

for investment casting• Low water absorption• High green strength• Excellent face‐coat adhesion• Higher yield

Large part expertise

QuickCast™

The 2011 PAC 12 football trophy utilized both ID‐Light and QuickCast investment

casting patterns.

SLA® (Stereolithography)Material Options


SC 1000Clear, water resistant, rigid,

durable

3D Systems Viper si2, SLA‐500 ,iPro 8000

Max single piece part size:25” x 29” x 21”

Standard Resolution:0.007” Layer Thickness

Standard Tolerances: .015” or .002”/”,whichever is greater

‐ Or ‐

Premium Resolution:0.005” Layer Thickness

Premium Tolerances: .015” or .0015”/”,whichever is greater

SC 4500White, highly accurate, excellent

sidewall characteristics

3D Systems SLA‐500 Max single piece part size:

20” x 20” x 21”

SL 7545White, good durability, slightly flexible with good accuracy

3D Systems SLA‐7000 Max single piece part size:

20” x 20” x 21”

SLA® (Stereolithography)Material Options


SL 7810Very white, good surface finish

resembles ABS. Accurate parts with exceptional elongation to break

and Izod Impact strength3D Systems SLA‐5000, iPro 8000


Premium Resolution:0.005” Layer Thickness

Premium Tolerances: .015” or .0015”/”,whichever is greaterAccura 60 Clear

Clear, Polycarbonate‐like material, durable tough plastic

SC 5500Gray, accurate, durable

3D Systems Viper si2, iPro 9000Max single piece part size:

25” x 29” x 21”

HDSL Resolution:0.005” Layer Thickness


SLS® (Selective Laser Sintering)

SLS (selective laser sintering) produces rugged Nylon 11 and Nylon 12 prototype and production parts and is ideal for Direct Digital Manufacturing. Layer additive, laser sintered nylon powder.

Applications: Concept models, prototypes, production parts.

SLS Video


http://www.youtube.com/watch?v=9E5MfBAV_tA

SLS® (Selective Laser Sintering)

Integrated SLS fuel tanks built without tooling.

Avionics & Automotive Fuel Tanks

SLS® (Selective Laser Sintering)Art & Architectural Models

Architectural ModelsSLS® (Selective Laser Sintering)

SLS® (Selective Laser Sintering)Architectural Models

SLS® (Selective Laser Sintering)Automotive Applications

SLS Nylon 12 GF was used in this underhood application to enhance air flow in the Porsche 928 engine.

This SLS intake plenum was used on a formula style racecar during

competition.

SLS® (Selective Laser Sintering)Transportation – Electric Motorcycle

SLS® (Selective Laser Sintering)Aerospace Applications

SLS Nylon 12 GF was used to create the gimbal seen below

This PEEK aerospace part mixes hot engine air with

cold atmospheric air outside the airframe, providing regulated temperature.

SLS® (Selective Laser Sintering)Unmanned Aerial Vehicles

SLS® (Selective Laser Sintering)Material Options


Nylon 12 PAWhite, general purpose, rugged Nylon material

3D Systems Sinterstation HiQ HS,EOS P 730




Nylon 12 GFAluminum filled Nylon

material, excellent surface finish

Nylon 12 AFGlass filled Nylon Material, increased tensile modulus

3D Systems Sinterstation HiQ HS Max single piece part size:

12” x 10” x 17”



NyTek™ 1200 CFCarbon filled, superior thermal properties

3D Systems Sinterstation HiQ HSMax single piece part size:

12” x 10” x 17”



DuraForm HSTFiber filled, high strength and

high temperature

PA 640 GSL Lightweight, high stiffness and

high temperature



NyTek™ 1100White, high elongation, aerospace applications

3D Systems Sinterstation HiQ HSMax single piece part size:

12” x 10” x 17”Standard Resolution:0.004” Layer Thickness


NyTek™ 1100 BBlack, high elongation, aerospace applications

FR‐106Flame retardant nylon, FAR

25.853 rated

PEEK HP3Flame retardant, FAR 25.853

and UL‐94 VO rated

EOS P800Max single piece part size:

25” x 13” x 12”

FDM (Fused Deposition Modeling)

FDM uses thermoplastic production materials in a layer additive process. FDM produces functional prototypes and production parts.

Applications: Concept models, Direct Digital Manufacturing, functional prototypes, end‐use parts, visual models, manufacturing tools, engineering test models, low volume production, high temperature parts.

FDM Video


http://www.youtube.com/watch?v=WHO6G67GJbM

FDM (Fused Deposition Modeling)

End‐Use PartsShort‐Run Production PartsJigs & FixturesConcept ModelsFunctional Prototypes

FDM (Fused Deposition Modeling)ULTEM 9085

ULTEM 9085 is a flame retardant high performance thermoplastic for DDM. It is ideal for the transportation industry due to its high strength‐to‐weight ratio and its FST (flame, smoke, and toxicity) rating.

Opportunity

FDM (Fused Deposition Modeling)Air Duct – Orbis Flying Hospital

Challenge


Process


As a result of engineering approved by the DER and mfg. audited by a DAR, an FAA 8130‐3 certification of airworthiness ensured that the duct made is ready to fly.

Results

FDM (Fused Deposition Modeling)Largest Integral Parts

FDM parts as large as 36” x 24” x 36” can be built in a

single build. Larger parts can be built in segments and then assembled

together.

FDM® (Fused Deposition Modeling)Material OptionsMaterial Build Envelope Resolution/Tolerances

ABS‐M30Multiple colors and

applications

Fortus 400mc & Fortus 900mc

production grade equipment(from Stratasys)

Max single piece part size:400mc – 16” x 14” x 16”900mc – 36” x 24” x 36”


(also 0.007” & 0.013” layer thickness)


ABS‐ESD7Black, applications requiring electro‐static‐dissapative

properties

PC‐ABSBlack, highest impact

resistance & good stiffness

PC‐ISOWhite, good stiffness & HDT,

ISO cl VI cert.

ULTEM 9085Tan, excellent HDT, Flame retardant, FAR 25.853 &

UL‐94 VO rated

AM – How do you choose?• Application

• Conceptual or Functional• Part size & resolution (minimum

feature size)• Material• Accuracy• Delivery• Budget

Additive ManufacturingPlastic Products Comparison

ZPrint 3D Color PrintsZPrint is the easiest way to quickly turn 3D CAD data

into real colored parts. Parts are created with powdered plaster composite material coupled with a 4 color printing process. Color is printed directly into the part. This type of color finish eliminates the need for post‐processing paint.

Applications: Architectural Models, Avatars, Presentation Models, Concept Evaluations,Student Projects, Space Studies, Training Aids


Color is printed directly into the part utilizing a 4 color printing process, allowing for 390,000 possible color combinations.


Colors define the aerodynamic pressures

on the fuselage

ZPrint 3D Color PrintsMaterial Options

Material Build Envelope

ZPrintwith ZP 150‐Z Bond Material

ZP650 3D color print system

Maximum:10” x 15” x 8”

FINISHING

FinishingMenehune HaleID‐Light/ SLA (Stereolithograph) – process uniquely offered by Solid Concepts

• Hand Finishing/Sanding• Cosmetic Paint• Non‐cosmetic Paint• EMI & RFI Shielding• Textures & Mold‐Tech® Finishes with

Cast‐in Capabilities• Hardware (inserts, helicoils, etc.)• Assemblies• Vapor Polish

FinishingGreen ABS Machine Finish vs Hand Finished with Cosmetic Green Top CoatFDM (Fused Deposition Modeling)

FinishingBulwark Football HelmetSLS (Selective Laser Sintering) | Hand Finished with Cosmetic Top Coat

DMLS (Direct Metal Laser Sintering) DMLS (Direct Metal Laser Sintering) produces rugged

metal prototype and production parts. Layer additive, sintered metal and alloy powdered materials.

Applications: Small functional parts, detailed prototypes, production parts.

DMLS Video


http://www.youtube.com/watch?v=bgQvqVq-SQU

DMLS (Direct Metal Laser Sintering)

DMLS is ideal for geometries that can’t be CNC machined.

Cobalt Chrome MP1 is biocompatible and often used for surgical assist products.

DMLS uses metal and alloy materials to rapidly produce

production parts.

DMLS (Direct Metal Laser Sintering) Thin‐walled Turbine Combustion Chamber – Inconel 718

DMLS (Direct Metal Laser Sintering) Integrated Pressure Taps Stainless Pitot Tubes

DMLS (Direct Metal Laser Sintering) Integrated Cooling Channels for Injection Mold Tooling Insert

DMLS (Direct Metal Laser Sintering) NASS Spinall Implant – Ti6Al4V

DMLS (Direct Metal Laser Sintering) Material Options


Stainless Steel 17‐4 PHWhite, high elongation, aerospace applications

EOS M270 & M280Max single piece part size:

9” x 9” x 7”Optimal max part size:

4” x 4” x 4”

Standard Resolution:20 – 40 micron Layer Thickness


Inconel 625 & 718Black, high elongation, aerospace applications

Colbalt Cromium CoCrSpecialty material

Titanium Ti6Al4VSpecialty material

QuantumCast™ Cast Urethanes

QuantumCast cast urethanes (proprietary advanced casting technology and advanced formula polymers) produce strong pre‐production and short‐run production components.

Applications: Pre‐sales, trade shows, clinical trials, UL/CSA certification, production parts, alpha & beta builds, engineering verification, large part manufacturing, early revenue generation, assembly & quality inspection.

QuantumCastTM Video


http://www.youtube.com/watch?v=rjFdbhCjKPY

Transitioning to Cast UrethanesForeground – SLA (Stereolithography) Master PatternBackground‐ Cast Urethane with cast in texture and cast in color

Cast Urethanes ‐ Time to MarketStar Trac | California Cast Urethane Short Run | Bridge to Production

Cast Urethanes – “Creatures”Dena’ina Civic Center | Alaska | Artist: Ralph HelmickCast Urethane Short Run for 100’s of “creatures” without tooling

HYBRID PROJECTS

Unmanned SubmarineUniversity of Colorado/ National Geographic Multiple Technologies: FDM, Cast Urethanes, SLS

Unmanned Aerial VehiclesArea‐I | Georgia Multiple Technologies: SLS, FDM and CNC, Composites, for fuel tank, ailerons, control surfaces, mounting plates, more…

AerospaceDRS Technologies | Electronics Cooling Duct Designed for Additive Manufacturing SLS (Selective Laser Sintering)

Prosthetics Direct Dimensions Inc. | MarylandPolyJet Master Pattern for Customer Molding Process

QuickCast Investment Casting PatternsKnee Replacement Patterns Created for Individuals – Example of Mass CustomizationSLA (Stereolithography) QuickCast Investment Casting Patterns

DMLS – Direct Metal Laser SinteringDental Copings and Bridges ManufacturingImages & application courtesy of EOS

MotorsportsWithin Technologies | www.within‐labs.com | United KingdomDMLS (Direct Metal Laser Sintering) | Titanium Hood Scoop for Formula 1 Racing

Micro CoolerWithin Technologies | www.within‐labs.com | United KingdomMicrochip level temperature control design requires no supports during Additive Manufacturing build process

Heat ExchangerWithin Technologies | www.within‐labs.com | United KingdomEnhance Software | DMLS

OsseointegrationWithin Technologies | www.within‐labs.com | United KingdomEncouraging ingrowth of bone into an implant

Liquid Lattice Within Technologies | www.within‐labs.com | United KingdomCarrying load while minimizing weight

The Future of AM/3DP Looks Bright

• Opportunities for Market Growth– 3D capture software– Process control– Materials– Finishes– Lower cost of ownership

Questions?

Resources

• Websiteswww.SolidConcepts.com (full service)www.ZoomRP.com (self service)

• Technology Videoshttp://youtube.solidconcepts

• Chuck [email protected](661) 295‐4482

• Thank you to:Within Labs: http://www.within‐lab.com/EOS: www.eos.info

http://youtube.com/solidconcepts

http://www.within-lab.com/

inside3 d printing_chuckalexander

Technology

polyjet fastestbuildspeed

polyjet flexpolyjet

polyjet video clicktoplayvideo

xyaxis tolerance

durable polyjetgray

lowvolume overmoldedparts

highresolution conceptmodels

slavideo clicktoplayvideo