ADVANCED RAW MATERIALS FOR ADDITIVE MANUFACTURING Octobre 2015 Nouveau matériau polymère flexible pour le procédé d impression 3D par frittage laser
WHO WE ARE ADVANC3D Materials is a privately owned and independent company. Material experts and polymer scientist, we develop and produce and distribute raw materials for 3D printing technologies ADVANC3D Materials also distributes SLS powders from major manufacturers OWN PRODUCTS ADVANC3D Materials GmbH info@advanc3dmaterials.com 2
DEFINITION OF SLS Selective laser sintering (SLS) is an additive manufacturing technique used for the low volume production of prototype models and functional components. Prototype Architecture Medical Aeronautic/Automotive ADVANC3D Materials GmbH info@advanc3dmaterials.com 3
PROCESS OF THE SLS SLS involves the use of a high power laser (ex: CO2 laser) to fuse small particles of plastic, metal, ceramic or glass powders into a mass that has a desired threedimensional-shape. The laser selectively fuses powdered material by scanning cross-sections generated from a 3-D digital description of the part (from a file or scan data) on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness, a new layer of material is applied on top, and the process is repeated until the part is completed. ADVANC3D Materials GmbH info@advanc3dmaterials.com 4
KEY PARAMETERS ON SLS PROCESS Particle Shape Particle size distribution Power flowability Optical behaviour Melting behaviour (melting point and enthalpy) Interfacial phenomena Crystallization behaviour Rheology of the melt Crystallization behaviour Shrinkage and warpage behaviour ADVANC3D Materials GmbH info@advanc3dmaterials.com 5
TECHNICAL REQUIREMENTS TO DEVELOP A FLEXIBLE MATERIAL FOR SLS PROCESS Thermal behavior (melting and crystallisation) Low viscosity for : a good coalescence of the molten particles a good interdiffusion of the macromolecular chains at interfaces Consolidation of the parts Low porosity ADVANC3D Materials GmbH info@advanc3dmaterials.com 6
TECHNICAL REQUIREMENTS TO DEVELOP A FLEXIBLE MATERIAL FOR SLS PROCESS Powder particles - size distribution X50 = 45-60 micron - Shape Excellent free-flow characteristics Homogeneous Powder bed -Good consolidation of the part - Decrease of the porosity - Dimensional stability ADVANC3D Materials GmbH info@advanc3dmaterials.com 7
ADSINT TPU NEW FLEXIBLE MATERIAL FOR SLS PROCESS Why TPU? A Chemistry allowing a lot of combinations tailoring of the properties isocyanate Aromatic Aliphatic Long polyol Ester Ether Carbonate Chain extender BDO HQEE PDO EHD ADVANC3D Materials GmbH info@advanc3dmaterials.com 8
ADSINT TPU NEW FLEXIBLE MATERIAL FOR SLS PROCESS Importance of selecting the isocyanate Aromatic Isocyanate TDI MDI PPDI NDI Temperature resistance Solvant resistance Mechanical and Dynamic properties Aliphatic Isocyanate IPDI HDI HMDI MXDI UV resistance High transparency Mechanical ADVANC3D Materials GmbH info@advanc3dmaterials.com 9
ADSINT TPU NEW FLEXIBLE MATERIAL FOR SLS PROCESS Importance of the choice of the long polyol Polypropylène glycol (PPG) Dynamic Poly tétraméthylène glycol (PTMEG) Mechanic HO O n O OH Poly adipate O HO O O O n O O O O OH Hydrolysis Polycaprolactone (PCL) Thermic Polycarbonate diol (PCDL) O O HO O O O n O OH ADVANC3D Materials GmbH info@advanc3dmaterials.com 10
ADSINT TPU NEW FLEXIBLE MATERIAL FOR SLS PROCESS Importance of the choice of the chain extender Butane diol, Hydroquinone (HQEE), Propane diol Classic High reactivity Thermic resistance Isosorbide Biobased Good reactivity Stifness increase Ethyl hexanediol Exotic low reactivity ADVANC3D Materials GmbH info@advanc3dmaterials.com 11
ADSINT TPU NEW FLEXIBLE MATERIAL FOR SLS PROCESS Importance of the stoechiometry Polyol ISO Chain extender Control of the hard segment content Elasticity, Hardness ADVANC3D Materials GmbH info@advanc3dmaterials.com 12
ADSINT TPU THERMAL BEHAVIOR AND TEMPERATURE WINDOW FOR SLS Wide melting region and low melting enthalpy SLS window > 25 C will be improved with the next generation of ADSINT TPU ADVANC3D Materials GmbH info@advanc3dmaterials.com 13
ADSINT TPU POWDER PARTICLES SHAPE AND SIZE DISTRIBUTION ADSINT TPU is obtained by grinding Particle size distribution Measurement Method Metric Value Average particle size (X50), volume/number ISO 13320 58 µm / 8 µm Average particle size (X90), volume/number ISO 13320 105 µm / 21 µm PSD max (99%) Air Jet Sieve 90 µm Powder packed density 23 C ISO 1068-1975 0,50 ± 0,05g/cm3 No impact on the homogeneity of the powder bed on the flowability of the powder (flow time = 40 s vs. 60 for Duraform PA, Norma ISO R 60) ADVANC3D Materials GmbH info@advanc3dmaterials.com 14
ADSINT TPU SLS PROCESSING PARAMETERS Processing parameters Recommendations Layer thickness : 100-150µm. Laser power : minimum 20 W (for a laser speed of 2.5 m/s and a layer thickness of 100 µm). The bed temperature should not exceed 135 C to avoid sticking. The feed temperature should not exceed 115 C to avoid low quality bed powder. ADVANC3D Materials GmbH info@advanc3dmaterials.com 15
ADSINT TPU MECHANICAL PROPERTIES Measurement Method & Conditions Metric Value Tensile strength at break ISO 527-2:93-1B (X direction) 8 MPa Elongation at break ISO 527-2:93-1B (X direction) 250 % Flexural modulus ISO 178 (23 C) 10 MPa Short Hardness A ISO 868 (20 C) 88-92 ADVANC3D Materials GmbH info@advanc3dmaterials.com 16
ADSINT TPU FOR SLS Benefits Flexible with high mechanical properties Low refresh rate (<25%) Lower energy for processing Excellent colour stability Very good finition Variation Natural Black GB30 (High stiffness, low cost) ADVANC3D Materials GmbH info@advanc3dmaterials.com 17
OVERVIEW ON ADSINT PREMIUM FOR SLS ADVANC3D Materials GmbH info@advanc3dmaterials.com 18
OVERVIEW ON ADSINT PREMIUM FOR SLS POWDERS FOR THE SLS PROCESS AdSint Premium Made in Europe. Broad product range and technical support to answer all your questions. Machine parameters given as well as one site technical support. Materials: PA11 natural or black (with USPVI approval) PA12, PA12 black, PA12GB30, PA12GB40 PP More to come in 2016... ADVANC3D Materials GmbH info@advanc3dmaterials.com 19
ADSINT PA12 PA12 powder for SLS Applications Benefits Low refresh rate (<25%) Excellent colour stability Incomparable smooth finish (no post-treatment) Applications Variations Consumer goods Functional prototypes Lifestyle products Industry Production series Black GB30 (High stiffness, low cost) GB40 (Higher stiffness, lower cost) ADVANC3D Materials GmbH info@advanc3dmaterials.com 20
ADSINT PA11 PA11 powder for SLS Applications Benefits Higher mechanical properties Low refresh rate (<25%) Excellent colour stability Extra white Applications Medical (with USPVI approval) Consumer goods Functional prototypes Lifestyle products Industry Production series Variations Natural Black (mass colored) ADVANC3D Materials GmbH info@advanc3dmaterials.com 21
ADSINT PP PP powder for SLS Applications Benefits Low refresh rate (<15%) Excellent colour stability Extra white Applications Consumer goods Functional prototypes Lifestyle products Industry Production series Variations Natural Black ADVANC3D Materials GmbH info@advanc3dmaterials.com 22
PRODUCTS: ADSINT CUSTOM Available from July 2015 POWDERS FOR THE SLS PROCESS AdSint Custom You need a tailor-made product? Our team of plastic engineer has the answer. All kinds of materials, special effect, special properties, flame retardant, magnetic, high density, own color challenge us! Available for orders from 400 kg. We develop a product for you and make it work on your SLS printer! ADVANC3D Materials GmbH info@advanc3dmaterials.com 23
DISTRIBUTION PRODUCTS Benefits Incomparable smooth finish (no post-treatment) Low refresh rate (<25%) Excellent colour stability Applications Consumer goods Functional prototypes Lifestyle products Industry Production series Variations Natural Grade Coathylene Sint Polymer Particle size X50 (μm) Sint PS Polystyrene 45-60 Sint PP Polypropylene 50-70 Sint PP Flex* Copo-PP 50-70 * Under development ADVANC3D Materials GmbH info@advanc3dmaterials.com 24
OVERVIEW ON ADWIRES FOR FDM ADVANC3D Materials GmbH info@advanc3dmaterials.com 25
OVERVIEW ON ADWIRES FOR FDM Advanc3D Materials worked on the materials key properties, as much mechanical and thermal as printability and user friendliness, to provided the most adapted products: Tensile strength Elongation at break Impact resistance Melt viscosity Crystallization speed Filler rate (eg Wood or Bronze) Time of solubility (eg PVA) Surface finish Material stability Feature detail accuracy Needs of support Easy of feed into printer Spool manipulation and design Adhesion issues We also developed materials focused on recyclable, biobased or local feedstock (in UE) ADVANC3D Materials GmbH info@advanc3dmaterials.com 26
OWN PRODUCTS: ADWIRE BASIC FILAMENT FOR THE FDM PROCESS Available from September 2015 Basic filament assortment for the best price-performance ratio. Technical support to answer all your questions. Materials: PLA ADVANC3D Materials GmbH info@advanc3dmaterials.com 27
OWN PRODUCTS: ADWIRE PREMIUM FILAMENT FOR THE FDM PROCESS Available now! High quality filament for the best printing results Technical support to answer all your questions. Materials: PLA & ABS ADVANC3D Materials GmbH info@advanc3dmaterials.com 28
OWN PRODUCTS: ADWIRE PREMIUM Coming Soon FILAMENT FOR THE FDM PROCESS Coming soon High quality filament for the best printing results. Soon available as an imitation of real materials and special characteristics. Technical support to answer all your questions. Applications: Wood: Real wood looking filament for furniture, toys... Bronze: Metal appearance and strong resistance. PETG: Good toughness, transparency, little shrinkage, Cleaning: To clean the printer s extruder between different filaments TPU: Soft touch, adjustable flexibility Nylon: Best mechanical properties for the best printer! ADVANC3D Materials GmbH info@advanc3dmaterials.com 29
OWN PRODUCTS: ADWIRE CUSTOM FILAMENT FOR THE FDM PROCESS On demand custom high quality filament that will meet your highest needs, tell us what you need and we will make it happen! Technical support to answer all your questions. Applications: Any color Any property: conductivity, flame retardancy, antistatism,... Any texture After effects such as shiny filament! Any smell ADVANC3D Materials GmbH info@advanc3dmaterials.com 30
OWN PRODUCTS: ADWIRE CUSTOM FILAMENT FOR THE FDM PROCESS On demand custom high quality filament that will meet your highest needs, tell us what you need and we will make it happen! Technical support to answer all your questions. Applications: Any color Any property: conductivity, flame retardancy, antistatism,... Any texture After effects such as shiny filament! Any smell ADVANC3D Materials GmbH info@advanc3dmaterials.com 31