N A V I G A T I N G T H E D I G I T A L T H R E A D

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2 N A V I G A T I N G T H E D I G I T A L T H R E A D U n d e r s t a n d i n g A d d i t i v e M a n u f a c t u r i n g f o r I n d u s t r i a l A p p l i c a t i o n s Presented by: David K. Leigh Senior Vice President of Engineering Stratasys Direct Manufacturing

3 O V E R V I E W : A. M. S E R V I C E S N E T W O R K Stratasys advanced manufacturing services business unit is the largest provider of additive manufacturing 9 U.S. Manufacturing Facilities 150,000 Ft 2 Production Space 12 Primary Technologies 600+ Employees ITAR Registered ISO 9001 Valencia (2), Poway, Tucson, Phoenix, Austin, Eden Prairie, Belton & Troy AS 9100 Valencia, Austin, Eden Prairie, & Belton 275+ Industrial AM Systems 1,600 unique part numbers Over 35K end-use part details and assemblies manufactured in 2014

4 O V E R V I E W : L E A R N I N G O B J E C T I V E S Introductory assessment of processes capable of direct part production What applications each technology is best suited for How to integrate additive capabilities into production Managing design specifications and tolerance requirements for Laser Sintering Review of real-world applications using A.M. technologies Capabilities & limitations of CAD systems Understanding of new CAD and process modeling capabilities

5 H I G H P E R F O R M A N C E A D D I T I V E P R O C E S S E S F O R D I R E C T PA R T P R O D U C T I O N

6 P R O D U C T I O N T E C H N O L O G I E S SLS DMLS FDM CNC CAST Selective Laser Sintering Direct Metal Laser Sintering Fused Deposition Modeling CNC Machining Cast Urethanes

7 R A N G E O F 3 D P R I N T I N G S Y S T E M S Consumer-Grade Novel Widgets To Concept Models Few AM processes currently vetted and approved for flight hardware production Industrial Mfg. Systems Functional Prototypes To End-Use Hardware

8 S E L E C T I V E L A S E R S I N T E R I N G Uses a CO2 laser to fuse thermoplastic powders layer-by-layer to produce highly complex geometries from sliced CAD data Batching/Nesting Excellent mechanicals and durability Lightweight, thin-walled parts High strength-to-weight ratio Does not require build supports Nylon 11s and 12s Filled and unfilled materials Chemically resistant and flame retardant options available

9 M AT E R I A L S A N D P L AT F O R M S Materials: FR Nylon 11 Nylon 11 FR Nylon 12 Nylon 12 Carbon Fiber Filled Nylon 11 & 12 Glass Filled Nylon 12 Carbon Fiber & Glass Filled Nylon 11 PEEK & PEKK layers Max. Build Envelope: 15 L x 13 W x 18 H (standard platform) 27 L x 15 W x 22 H (XL platform)

10 A E R O S PA C E A P P L I C AT I O N S Additive Manufacturing is opening up design possibilities for ducting applications, including production of lightweight integrated structures that enable part consolidation.

11 D I R E C T M E T A L L A S E R S I N T E R I N G A layer-additive process that produces rugged metal prototype and production parts. Supports required due to high energy process Ideal for geometries that can t be CNC machined, light-weight designs, and part consolidation Applications: small functional parts, complex geometries, end-use production parts

12 M AT E R I A L S & P L AT F O R M S Materials: Stainless Steel Cobalt Chrome Inconel 625,718 Aluminum Titanium (coming soon) 20-micron to 40-micron layers Optimal Build Size: Up to 4 x 4 x 4 Max. Build Envelope: 9 x 9 x 9

13 F I N I S H I N G & P O S T T R E A T M E N T S Secondary operations can be applied to DMLS parts to meet your specifications. Options Include: Micro Shot-Peened Brushed Hand Polished CNC Machined Tumbled Post Treatments: Heat treating Stress relief Hot Isostatic Pressing Aging Supports Removed standard Al Oxide Blast Filed and Sanded Machine Finish Shot Peened Polished

14 F U S E D D E P O S I T I O N M O D E L I N G Thermoplastic filament is heated to a semi-liquid state and extruded across computer-controlled tool paths to build parts layer-upon-layer. Produces prototypes as well as enduse parts. Very strong and functional High strength-to-weight ratio Chemically resistant & flameretardant options available Large build volume (36 x 24 x 36 ) Production-grade thermoplastics

15 M AT E R I A L S ABS Great durability with a wide variety of color choices ABS-ESD7 The benefits of ABS with added static dissipative properties ABS-M30 Stronger than standard ABS with a variety of color options ABSi Solid and semi-translucent colors with better impact strength than ABS ASA UV resistance for outdoor commercial and infrastructure end-use parts

16 M AT E R I A L S PC Excellent durability and tensile strength PC-ABS Blend with the highest impact resistance of any polycarbonate PC-ISO ISO certified, USP Class VI, Classification 1 for medical applications FDM Nylon 12 Excellent fatigue and chemical resistance, one of the most popular plastics used in engineering PPSF Best heat and chemical resistance of any thermoplastic ULTEM 9085 Certified to withstand flame, smoke, and toxicity (FST)

17 U LT E M ULTEM 9085 is a flame retardant high performance thermoplastic for DDM. It is ideal for the aerospace and transportation industries due to its high strength-to-weight ratio and its FST rating.

18 C A S T U R E T H A N E Liquid silicone rubber is poured around a master pattern. The resulting mold is pulled from the pattern and cured, then subsequently used to cast urethane parts. SLA or CNC master pattern EMI, RFI shielding Cast in color and texture Complex over-molding Short-run or low volume mfg Bridge production Composite casting options Fiberglass Graphite kevlar

19 F I N I S H I N G Hand Finishing/Sanding Cosmetic Prime and Paint EMI & RFI Shielding Textures & Mold-Tech Finishes Hardware (inserts, helicoils, etc.) Assembly Vapor Polish Hand Polish (Metals)

20 M A N U F A C T U R I N G C A S E S T U D I E S ECS Ducting for Bell Helicopter Harvest Technologies produces complex parts for the Environmental Control System (ECS) of multiple Bell helicopters

21 M A N U F A C T U R I N G C A S E S T U D I E S DMLS Fuel Nozzle in GE LEAP Engine GE is replacing their previous fuel nozzle (which required 20 small parts to be welded together) with a 3D printed cobalt chrome nozzle. They expect to implement this nozzle in , and produce 25K nozzles annually.

22 M A N U F A C T U R I N G C A S E S T U D I E S Metal Plated SLS and Cast Urethane Parts for Emirates Emirates utilized metal plated FR-106 SLS parts for the table lamps in their Super First Class cabin on the A380. They also chose cast urethane parts for the flower vases.

23 A S S E S S I N G W H E R E A D D I T I V E M A N U FA C T U R I N G M A K E S S E N S E

24 M F G T E C H N O L O G Y I N P R O D U C T D E V E L O P M E N T C Y C L E

25 F R E E D O M O F A D D I T I V E M A N U F A C T U R I N G Tool-less (no molds, MUD bases, fixturing, cutters, etc.) Geometries designed for maximum functionality vs. tooling constraints No worries about undercuts, overhangs, gating, venting, etc. No need for draft angles, radii, fillets Creative contours, internal features, ribbing/stiffening Innovative weight savings capabilities (shelling, lattice work, honeycomb, supports) Part consolidation Green mfg with less waste (no milling away of excess material)

26 PA R T C O N S O L I D AT I O N Additive (LS) Manufacture: One Contiguous Traditional Manufacture: 16 piece assembly

27 L I M I TAT I O N S O F A D D I T I V E M A N U F A C T U R I N G Cost of machines & raw materials Limited recyclability of used material Build anomalies and associated scrap rate As-built tolerance lesser than tooled processes Necessary post processing for dimensional tolerance & cosmetics Anisotropy due to building in layers Feature detail and aesthetic qualities Limited economies of scale

28 E C O N O M I C S ( H O W A N D W H E R E T O S AV E ) Low to mid volume production with no set up Virtual inventory, On demand mfg Batching & nesting (LS especially) Rev ing designs without tooling modifications Effects of splitting pie between multiple vendors Customer costs: NREs qualifying & maintaining suppliers Fixed cost barriers & thresholds for suppliers

29 R E V I E W : C O M M O N R E A S O N S T O C H O O S E A. M. Weight savings Part consolidation Cost savings for low quantities One-offs and spares Parts undergoing several revisions or customization Faster time to market Ease of use/installation Weight savings and part consolidation result in immediate cost savings to you, the manufacturer, and potential continued cost savings for the end-user over the life of the product

30 M A N A G I N G D E S I G N S P E C S A N D T O L E R A N C E S I N L A S E R S I N T E R I N G

31 F A C T O R S A F F E C T I N G D I M E N S I O N A L C O N T R O L Part Strength Requirements Global Scaling Laser Beam Characteristics Part Bed Thermal Control

32 PA R T S T R E N G T H : A B A S I C R E L AT I O N S H I P MECHANICAL STRENGTH DIMENSIONAL ACCURACY

33 PA R T S T R E N G T H It is easy to build weak parts in LS Flight parts require strength validation Tensile bars are fabricated next to parts Ultimate Tensile Strength (UTS) Elongation at Fracture (EAF) Individual Tensile Modulus (ITM) Offset Yield Strength (OSY)

34 PA R T S T R E N G T H

35 PA R T S T R E N G T H : M AT I N G L S PA R T S Outer surfaces typically grow.005 (orange) Line to line CAD model results in interference Negative features close Positive features grow

36 G L O B A L S C A L I N G Compensates for part shrinkage Compensates for mechanical constants Global scaling error is cumulative.5% error on dimension % error on dimension % of dimension is more representative of the process than hard tolerance callout

37 L S D I M E N S I O N A L D E S I G N G U I D E L I N E S Allow point load application of force for profile conformity. Fitment between parts should allow for positive features to grow and negative features to shrink

38 L A S E R B E A M C H A R A C T E R I S T I C S Most Noticeable Characteristics Laser Beam Diameter (.018 ) Beam offsets Laser On/Off Response More significant with smaller dimensions

39 L A S E R B E A M C H A R A C T E R I S T I C S

40 PA R T B E D T H E R M A L C O N T R O L

41 L S D I M E N S I O N A L D E S I G N G U I D E L I N E S

42 Q U E S T I O N S? Thank You David K. Leigh Senior Vice President of Engineering Stratasys Direct Manufacturing David.Leigh@stratasysdirect.com