3D Printing. Yesterday! Today! Tomorrow?????????????????????? Shane Rolton (BE Mech) Shane Rolton Wysiwyg3d.com.au ProZ3d.com.au

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1 3D Printing Yesterday! Today! Tomorrow?????????????????????? Shane Rolton (BE Mech) Shane Rolton 3D and ProZ 3D

2 Background Presenter A Cadet Engineer with Hawker De Havialland Engineering Manager New Dawn Design Founded Wysiwyg 3D D Scanning services provider Formed ProZ 3D , a collaboration of 3 industry leading companies Wysiwyg 3D, Qubic, and CNC Engineering. 3D Printing Solutions provider! Backgound in Manufacturing, CAD, toolmaking, machining, 3D scanning and metrology, and 3D printing. We can do it Attitude!

3 3D Printing Additive Manufacturing History 3D Systems (3DS), Stratsys Main Players! 3DS invented 3D printing with its Stereolithography (SLA) printer and was the first to commercialize it in Scott Crump invented FDM (Fused Deposition Modelling) in 1991 Now Stratasys 3DS 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 D printing has been used in Australia since mid 1990 s!

4 3D Printing Additive Manufacturing What is it? Back to the Basics It is the construction of a 3 dimensional object by depositing material layer by layer controlled by a computer, defined by CAD! Compared with CNC machining the removal of material layer by layer, controlled by a computer, defined by CAD! How? What Processes are involved? Ink jet, gluing, melting, welding, chemical fusion, curing, spraying!

5 The Range? 3D Printers for Every Need Lower price points Higher Performance

6 SLA (Stereolithography) Shane Rolton 3D and ProZ 3D

7 SLA Technology Overview Shane Rolton

8 SLA Is Used for the Broadest Range Of Applications Ceramic Casting Tough Clear Ceramic Ceramic Durable Bio-Compatible Durable Optically Clear Shane Rolton High-Temp

9 SLA Delivers Accuracy Frequency Standard Deviation < 15 microns 3 Sigma Accuracy +/- 45 μm Difference form nominal in microns

10 Accuracy and Precision 0.25 mm

11 SLA Delivers Fine Features mm walls, holes and features

12 Print Large Parts, Accurate from End-to-End up to 1500 x 750 x 550 mm while still preserving minute detail, high accuracy and repeatability Shane Rolton 12

13 3D Systems SLA Printers Maximum Build volume Accuracy Maximum Resolution ProJet 6000 ProJet 7000 ipro 8000 ProX x 10 x 10 in (250 x 250 x 250 mm) inch ( mm) per inch of part dimension mm, mm layers 15 x 15 x 10 in (380 x 380 x 250 mm) inch ( mm) per inch of part dimension mm, mm layers 26 x 30 x 22 in (650 x 750 x 550 mm) inch ( mm) per inch of part dimension mm, mm layers 59 x 30 x 22 in (1500 x 750 x 550 mm) inch ( mm) per inch of part dimension mm, mm layers

14 SLA Materials Shane Rolton

15 SLA Materials Shane Rolton

16 ProX 500 SLS 3D Printer Shane Rolton 3D and ProZ 3D

17 How it works SLS Selective Laser Sintering Shane Rolton

18 ProX 500 Economically manufacture injection molding-grade plastic parts for demanding end-use applications

19 SLS and Additive Transforms Manufacturing Consolidate parts, reduce labor and eliminate tooling Traditional manufacturing: 15 parts 5 SKU s 3 custom tools 10 assembly checks

20 SLS and Additive Transforms Manufacturing Consolidate parts, reduce labor and eliminate tooling SLS additive manufacturing: 1 part 1 SKU 0 custom tools 1 assembly check

21 SLS Transforms Design and Manufacturing No Tooling + Complete Design Freedom And Optimized parts!

22 SLS Patient Specific Instrumentation (Mass Customization) Implant instrumentation Reduced sterilization and inventory costs Disposable system delivered in a single pre-sterilized box Minimal instrumentation required Reduced Operating Room and Surgeon time Better Fit, minimally invasive, faster recovery

23 SLS Mass Customized Industrial Design Shane Rolton 23

24 SLS Functional Prototypes SLS parts can mimic injection molded plastic performance Production SLS Printed Performance sensor data almost identical

25 ProX 500 Benefits High Speed &Throughput baby car seat and recliner 240 Mobile printer covers 24 bridges for Car for handicaped people 34 hours build time 80 hours build time 52 hours build time

26 ProX 500 Benefits Breakthrough Plastic Material New high performance plastic material: DuraForm ProX Produces smoother surfaces and injection moldinglike part quality, with resolution and edge definition that surpasses existing alternatives

27 ProX 500 Benefits Functional Performance Highly elastic Enables living hinges Easy fit Strong, flexible material

28 ProX 500 Tech Specs Build size Powder layout Layer thickness Imaging system Scanning speed Volume build rate 381 x 330 x 457 mm (15 x 13 x 18 in) Variable Speed Counter Rotating Roller mm ProScan DX Digital High Speed Fill m/s (500 in/s) Outline- 5 m/s (200 in/s) 2 L/hr

29 ProX 100, 200 and 300 EOS, and MTL plus others Fully functional METAL parts in hours Not Just for Printing GUNS!!!!!!! Shane Rolton 3D and ProZ 3D

30 ProX Direct Metal Printing Movie Shane Rolton

31 ProX 100, 200, 300 Direct Metal Production Printers High density, metal printed parts from a large choice of materials with the highest detail and precision

32 Large choice in standard metal alloys and ceramics 9 alloys available directly from 3D Systems CoCr- Cobalt Chrome 17-4PH Stainless Steel Maraging Steel AlSi12 Aluminium Alloy Ti6Al4V Titanium Alloy Inconel 718 Hastelloy X 316 L stainless Alloy Inconel 625 Additional metals, ceramics, and precious metals can also be printed on ProX DMP AI 2 O 3 AlSi12 Inconel 718 Pure Cu Pure Cu

33 Unmatched design and manufacturing freedom Manufacture the Un-manufacturable!!!! Shane Rolton

34 High density parts Density> 99% of theoretical part

35 Highest accuracy, best detail resolution 150 micron wall thickness

36 Smallest Parts detail resolution 2mm gear with 20 teeth C- clamp holding 16 thou wire

37 Excellent Tolerances & Repeatability Repeatability ~20 microns in all 3 axes

38 Aerospace Jet Engine Fuel Nozzles

39 Dental Dental partials manufacturing in CoCr

40 Jewelry Shane Rolton

41 Tooling Blow Mold with conforming holes

42 Patient Specific Implants and Devices Custom acetabular cup for hip replacement surgery

43 ProX 100, 200 and 300 Direct Metal Printers ProX 100 ProX 200 ProX 300 Build volume 3.94 x 3.94 x 3.15 in (100 x 100 x 80 mm) 5.51 x 5.51 x 3.94 in (140 x 140 x 100 mm) 9.84 x 9.84 x in (250 x 250 x 300 mm) Laser power 50W 300W 500W Loading Manual Semiautomatic Automatic Recycling System Optional external system (PX BOX) Optional external system (PX BOX) Automatic Dental version available Dental version available

44 ProJet 5500X Variable Engineered Composite 3D Printer Shane Rolton 3D and ProZ 3D

45 ProJet 5500X Intro Movie Shane Rolton

46 Multiple engineered composite materials Rigid, ABS-like white plastic Rubber-like black tires Moderately flexible front wing

47 Multi-material benefits Shane Rolton

48 Composite material choices The 5500X mixes materials on the fly, so you can choose virtually any number of combinations to get the properties you want Flexible Rigid Black White Clear

49 Accurate parts Shane Rolton

50 Easy post-processing Supports are printed in wax No special water hookups needed Wax simply melts away

51 New VisiJet Composite Materials VisiJet CR-WT Rigid White ABS-like Material Durable Rigid High temperature resistance

52 New VisiJet Composite Materials VisiJet CF-BK Black Rubber-like Material Rubber-like look and feel Extreme flexibility Absorbs shocks and impacts to enhance durability

53 New VisiJet Composite Materials VisiJet CR-CL Clear Polycarbonate-like Material See-thru clarity when polished Simulates polycarbonate or glass Functional durability resists scratching

54 ProJet 5500X tech specs Build size Selectable print modes Print resolution Warranty Printer dimensions 550 x 393 x 300 mm (21.6 x 15.5 x 11.8 in.) HD Mode: 32µ layer thickness 375 x 375 DPI resolution UHD Mode: 29µ layer thickness 750 x 750 DPI resolution Prints extreme fine features down to 0.01 (0.25mm) 5-year print-head warranty 1700 x 900 x 1650 mm (67 x 35.4 x 65 in.)

55 ProJet 5000 Large Plastic 3D Printer Shane Rolton 3D and ProZ 3D

56 How it works MJP MultiJet Printing And Polyjet. Both Brands have these! Shane Rolton

57 57 Large Parts and Lots of Parts!

58 Fine Detail Resolution No stair-stepping on curved sidewalls Micro-fine features; razor-sharp definition Features down to 0.01 inches (0.25mm)

59 ProJet 5000 VisiJet M5 Material Options Select the material that works in your application Choice of clear, high elongation plastic; high-strength, PP-like plastic or rigid, white plastic with high temperature resistance

60 New VisiJet M5 Black Plastic Material High strength PP-like high flex Beautiful, jet-black color Great for Large panels & housings Snap fits & assemblies Tire models Prototypes End use parts

61 VisiJet M5 Black: Mechanical Performance Property VisiJet M5 Black Typical Polypropylene Tensile Strength, MPa Tensile Modulus, MPa Elongation, % High detail on both large and small parts Highly requested jet-black color Functional parts for extended use and testing

62 VisiJet M5 X: Mechanical Performance Property VisiJet M5-X Typical ABS Tensile Strength, MPa Tensile Modulus, MPa Elongation, % High Modulus material, stiff feel Brilliant white finish Large flat panels and other geometries requiring stiff properties

63 ProJet 4500 Full Color Plastic 3D Printer Shane Rolton 3D and ProZ 3D

64 ProJet 4500 Intro Movie Shane Rolton

65 ProJet 4500 Combine the power of vibrant full color with durable plastic parts.

66 The benefits of color combined with strength Which communicates your idea better?

67 High-Quality Full-Color Printing Life-like. Photo-quality. In Three Dimensions. Enhance communication and design Improve marketing Impress customers

68 Applications Customized end-use products

69 Applications Durable concept models

70 Applications Functional prototypes

71 Applications Medical models

72 Applications Digital 3D art

73 Key features Almost 1,000,000 brilliant colors Amazing small feature detail Relative size to model

74 Materials Revolutionary VisiJet C4 Spectrum materials bring full-color capability to plastic parts.

75 ProJet 4500 tech specs Build size Color Print resolution Layer thickness Build speed 8 x 9.5 x 8 (203 x 241 x 203 mm) Continuous-Tone CMY 600 x 600 dpi.004 (.102 mm) Up to ½ in/hour (12mm/hr)

76 VisiJet C4 Spectrum material specs Tensile Strength Tensile Modulus 24.8 MPa 1600 MPa Elongation at Break 3.6% Flexural Strength Flexural Modulus 36.5 MPa 1125 MPa Hardness Shore D 79 Heat Distortion Temperature 57 C

77 ProJet 3500 series for Plastic Parts Precise, User-friendly and Flexible 3D Printing Shane Rolton 3D and ProZ 3D

78 High Performance Materials For More Applications VisiJet M3 X White, injection molded plastic look and feel ABS-like performance VisiJet M3 Black Black, injection molded plastic look and feel High strength and flexibility plastic VisiJet M3 Crystal Transluscent Tough polypro/abslike performance Class VI Certified for medical applications VisiJet M3 Proplast Translucent White Durable plastic performance VisiJet M3 Navy Blue Durable plastic performance VisiJet M3 Techplast Gray Durable plastic performance VisiJet M3 Procast Dark blue for improved surface inspection Castable plastic Advanced Performance

79 Optimized Capacity Stack & nest parts to use entire build volume Take advantage of longer free periods Gain additional thru-put without sacrificing build time Maximize utilization of the available build volume Why print in only 2-dimensions when it s a 3D printer?

80 with Micro-fine Detail Resolution Features down to 0.01 inches (0.25 mm) No geometry limitations

81 Frequency Shane Rolton Accuracy & Precision Tolerances down to +/ inches per inch (+/ mm per 2.54 mm) Difference from nominal in microns

82 Build More Parts, Faster Fast print speed with the wide-pass print head design Combine multiple parts in single build to optimize the build High volume capacity meets peak production demand

83 Automated Process from File to Ready-to-Use Part Fast and easy support removal Wax supports simply dissolve with no support scars Hands-free process saves time and labor No geometry limitations Fine delicate features preserved

84 ProJet 3500 Dental CAD/CAM 3D Printers Precise, User-friendly and Flexible Dental 3D Printing Shane Rolton 3D and ProZ 3D

85 Print Beautiful Parts No stair-stepping on curved sidewalls Exceptionally Smooth Surfaces

86 with Micro-fine Detail Resolution Features down to 0.01 inches (0.25 mm) No geometry limitations

87 Consistently Sharp Edges and Corners Clean, straight edge definition Exceptional small hole definition

88 Frequency Shane Rolton Accuracy & Precision Tolerances down to +/ inches per inch (+/ mm per 2.54 mm) Difference from nominal in microns

89 High Performance Specialty Materials VisiJet M3 Dentcast Wax-up castable and pressable material Dark green VisiJet M3 Pearlstone Dental models Solid stone appearance VisiJet M3 Stoneplast Dental models Transparent, clear or stone finish, dyeable Class VI Certified for medical applications Engineered Performance

90 ProJet 3500 series for Plastic Parts - Summary Quickly print superior quality dental wax-ups and models High resolution with sharp edges, crisp details and smooth surfaces Intuitive and easy-to-use in your office or remotely High productivity digital dental workflow

91 ProJet x60 Series Fast, Affordable Full Color 3D Printing Shane Rolton 3D and ProZ 3D

92 ProJet x60 Series Shane Rolton

93 Communicate with Color COLOR

94 Communicate with Color +90% of colors in Adobe Photoshop possible High Resolution

95 Communicate with Color 5 Prong 10 Amp Plug Words Picture Model A picture may be worth a thousand words, but how much money is a full color 3D model worth?

96 ProJet 1200 High Precision, Low Cost Professional 3D Printer Shane Rolton 3D and ProZ 3D

97 ProJet 1200 Small, precise parts and casting patterns with micro-sla quality at a breakthrough price

98 ProJet 1200 Intro Movies Dental Jewelry Click videos to play

99 Tough plastic that s castable Use prints directly as casting patterns Cement Crown Sprue Mold 99.99% ash free burnout

100 Prosthodontic 3D printing Full anatomy pressed crowns

101 Revolutionizing digital jewelry production A 3D printer right on your workbench Print casting-ready rings in under 2 hours for less than $1

102 Virtually any small cast metal part Shane Rolton

103 Built-in post processing Built in UV curing chamber

104 How it works micro-sla Build Platform Build Cartridge Mirror Imager Resin is in the bottom of the build cartridge and the build platform is lowered. Resin is cured by imager through the window on the print cartridge and onto the build platform

105 How it works micro-sla Part Repeat the process one 30 micron layer at a time until part the precise part is finished Imager

106 FDM Type Stratsys professional plus 100 s of toy versions! Fused Deposition Modelling Heated Extruder This is where the consumer market is at! Developed 1991 and used in commercial machines, it was the release of this patent that started the home 3D printing trend! $500 to $300,00 plus! All work the same, but you get what you pay for!

107 FDM Type How they work! Shane Rolton

108 The Today! If we compare 3D printing to 2d printing, I feel we are currently somewhere between the 9 pin dot matrix and the 24 pin dot matrix paper printers of the early 1990 s! A time when consumers have cool desktop machines that do a job, but for high quality we still have to use service providers!

109 The Future!!!??????? Lets rewind years! Bespoke manufacturing Craftsman, 1 offs, made to order, slow, expensive, Fully Customized. Rewind to 1910! Henry Ford (Even today this is mainstream) Production line approach, you can have any colour you like as long as it s Black mass production has begun. Manufacture 1000 s of the same items to reduce the cost. Tooling costs are huge, high volumes required. Little choice, very little customization!

110 The Future!!!??????? Future Mass Customization! You can have any combination of colours, shape, materials all made to order but at mass production prices! Ie Hearing Aids Additive in Metal and then finishing! Ie print with material on and grind, or edm. Why not Print the electrode, polish and use in a undersized printed cavity! Especially difficult to machine materials! Challenges ahead Material validation? Process validation? CT, Xray, Simulations, build orientation, material selection, IP, Legals (Police and the Gun Thing),

111 The Future!!!??????? Future Mass Customization! Medical cells in a matrix of protein! Uni Wollongong! Deployable machines to oceans, deserts and space?! Cheaper, higher quality in the home (just like colour laser printers) Complexity comes for FREE! Design for Manufacture Different constraints! What if you combined a standalone 3D printer and a production line? Henry Ford s 3D Printer of the Future!?

112 The Possible Future!!!!!! Shane Rolton

113 Questions????? THANKYOU! Shane Rolton