Additive Manufacturinging. from Beginning to now. Manfred Hofmann 3D Systems SA Marly EMPA / SATW Technology Briefing

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1 Additive Manufacturinging from Beginning to now Manfred Hofmann 3D Systems SA Marly EMPA / SATW Technology Briefing

2 3D Systems 3D Systems, Inc. Rock Hill, USA Sales and Sevice Sales and Offices Sevice Sales and Offices Sevice Sales and Offices Service 3D Systems SA Offices Marly, CH Hemel Hempstead, UK D, F, I, UK, JP, HK Materials Development and Production European HQ

3 3D Systems Introduction 3D Systems (NYSE:DDD) is a leading provider of 3D printing centric design-to-manufacturing solutions Leadership Through Innovation and Technology 3DS invented 3D printing with its Stereolithography (SLA) printer and was the first to commercialize it in DS invented Selective Laser Sintering (SLS) printing and was the first to commercialize it in DS invented the ColorJet Printing (CJP) class of 3D printers and was the first to commercialize 3D powder-based systems in DS invented MultiJet Printing (MJP) printers and was the first to commercialize it in Cube Extrusion Printers

4 Large selection of print engines and machine classes On Demand Parts: 3D Systems Quickparts Solutions service Application integration: Design, Medical

5 3D Systems SA Swiss Company owned by 3D Systems Inc. Entity for development & production of AM materials (consumables) Specialized in Photo Polymer Materials Stereolithography and Jet Technologies Located in Marly, Switzerland ~25 employees

6 Definitions of (Rapid) Prototyping Models and unique parts of a new design Representing shape and general aspect of the product Approach look and surface quality of production part Mimic functions of the designed part Rapid Prototyping (RP) Term extended to Rapid Manufacturing Struggling for a name: layered manufacturing Free form fabrication fabbing / fabber

7 Typical Prototypes (FineLine; USA)

8 NEW PRODUCTS AND INNOVATION FUEL GROWTH

9 Body Physical Object 3D Data: a Basis for Additive Manufacturing Product Target Calculation FEM Simulation Digital Mockup CAD Digitizer 3D Scanner 3D Data Model + ancillary product description Post Processor Process specific software Control Data RP / RM Machine MRI Scanner Post Processing RM output CAT Product Documentation Marketing Material User / Service Manuals Deliverable Part

10 Basic Process Steps of Rapid Prototyping Prepare: Input of digital 3D model (create supports) Math: Slice model into thin layers Build: Imaging System Spread a layer of build material (Recoating) Phase change (solidify / attach ) the image of cross section N on the surface Build: 3D Printer Dispense liquid material image-wise as a cross section Phase change (solidify / attach) the surface

11 Rapid Prototyping/Manufacturing Techniques (Commercial) Adding and Structuring Layers Adding material image-wise Stereolithography (photopolymer) MultiJet Modelling (wax; photopolymers) Selective Laser sintering (thermoplastic powder; metals) 3D printing (organic or ceramic powder + binder solution) Layered Object Manufacturing (paper; thermoplastic sheets) cut contours Fused Deposition Modelling (extruded thermoplastic) LENS (metals) Film Transfer Imaging (V-Flash)

12 Drivers for RP / AM technologies Computing power available for data preparation and machine control Increased use of 3D CAD for mechanical design Multi-axis motion control (mechanical or laser beam steering) Material (fluid) metering and MultiJet / inkjet technologies Thermal control of powder bulk and extrusion heads Process specific materials development

13 Stereolithography schematic Lasers: HeCd Ar+/UV SolidState (UV)

14 Details of Layer Forming Laser beam Layer N Resin vat

15 Details of Layer Forming Laser beam Line crossing Overlap Position New Layer <Liquid Resin

16 Stereolithgraphy Materials Selection Criteria Liquid Resin Photo sensitivity / high photo-speed at ambient temperature Low and controlled cure shrinkage Moderate viscosity (for even recoating) Long-term stability (in the machine) Non-hazardous and low odor Low humidity absorption

17 Stereolithgraphy Materials Selection Criteria Cured Polymer / Parts Thermo-mechanical material properties comparable to typical engineering thermoplastics: - Elastic modulus, Tg, impact resistance, HDT High accuracy: compensation of cure shrinkage Spatial resolution: small features laser line-width surface quality: smooth borders and down facing areas low influence of environmental conditions: humidity, temperature (CTE), solvents and grease Color and transparency

18 Typical composition of current SL resins Cycloaliphatic epoxy resins Polymer polyols Poly-hydroxy monomer Cationic Photoinitiator Stabilizer Multifunctional acrylate monomer Radical photoinitiator Dyes or pigments

19 Properties of Commercial SL Materials Accura si 50 SL Tensile Strength ASTM D MPa Tensile Modulus ASTM D 638 2,480-2,690 MPa Elongation at Break (%) D % Flexural Strength ASTM D MPa Flexural Modulus ASTM D 790 2,210-2,340 MPa Impact Strength (Notched Izod) D J/m Heat Deflection Temperature ASTM D 0.45 MPa MPa MPa with Thermal Postcure C

20 Accura 25 Accura Xtreme Accura 50 Accura 55 Accura 60 Accura 40 Accura 10 Accura Bluestone Flexural Modulus (MPa) Elongation at Break (%) Elongation Linked to Modulus % % % % % %

21 Metal parts: Investment casting with SL patterns

22 SL QuickCast pattern for Investment Casting

23 New Application Requirements Very high stiffness (simulate CFC s)

24 Variational Design for Wind Tunnel

25 Challenge for Filled SL Photopolymer Materials Modulus: intermediate between Matrix Polymer and (inorganic) filler Viscosity increase Filler content; type and shape; surface treatment Percolation limit Agglomeration and Sedimentation Particle size distribution; specific gravity (Laser) light scattering Lost Laser Power; linewidth increase Depending on refractive index difference Reaction inhibition / stability decrease Chemical interaction with base resin

26 Filler Sedimentation HPC Bluestone

27 separation [mm] Sedimentation Monitoring Turbiscan Filler limit Bluestone HPC prod time [days]

28 (Laser) Light Scattering / Transparency SLA 7000 Vat Surface

29 Selective Laser Sintering (SLS) schematic

30 ProX SLS Available Materials: DuraForm ProX Extra strong and durable engineered production plastic DuraForm ProX GF Glass filled plastic that is stiffer and offers higher heat deflection DuraForm ProX AF+ A unique aluminum and fiber filled plastic with higher heat deflection and cast-metal appearance

31 SLS Production Printers Machines optimized for Polymer or Metal Powders

32 SLS Application Examples Rigid and durable parts Thermoplastic starting materials Good surface finish Blending with fillers for special properties Medium size build chambers Parts nesting possible

33 Laser Melting

34 RP Technologies: Metal Parts SLS / SLM LENS

35 MJP wax patterns for Investment Casting Features down to 0.25 mm No geometry limitations M3 HiCast

36 3D Application: Lost Wax Metal Foundry Material: Wax formulation for Multijet Printing

37 More Information druck.com wohlersassociates.com Rapid Prototyping Journal (Emerald) Paul F. Jacobs; Rapid Prototyping & Manufacturing; SME: Dearborn, MI, Marshall Burns; Automated Fabrication; PTR Prentice Hall: New Jersey, 1993 Ian Gibson; David W. Rosen; Brent Stucker; Additive Manufacturing Technologies; Rapid Prototyping to Direct Digital Manufacturing, Springer: Heidelberg 2010

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