From Rapid Prototyping to Quick-Turn Production Day 1: Review of Industrial Additive Manufacturing Options

Course Content Intent Focus What’s available Design considerations Production processes Focus Industrial-grade AM Concept  low-volume production Photo courtesy of 3T RPD 2

Terminology Umbrella terms Application terms Technology 3D printing = additive manufacturing Application terms Rapid prototyping Direct <digital> manufacturing Technology SL = SLA DMLS = SLM = LM 3

Selection Many options Define Better, faster, cheaper Each with pro/con Define Application Requirements for success Better, faster, cheaper Pick any two 4

AM Options Dozens of technologies Good news/bad news Hundreds of models Good news/bad news Wide selection Can be confusing Machine | material pairings 5

AM Characterization Advantages Limitations Speed Low startup cost Design freedom Automated build Many material classes Unique Limitations Throughput High piece-part price Freedom constrained Manual post Few material options Unique 6

AM Classes Vat photopolymerization Material jetting Binder jetting Material extrusion Powder bed fusion Sheet lamination Directed energy deposition 7

AM Classes – Vat Photopolymerization Stereolithography (SL) Advantages Resolution Finish Speed Limitations Somewhat functional Light/moisture sensitive Digital Light Processing (DLP) Advantages Resolution Finish Speed Limitations Somewhat functional Light/moisture sensitive Small parts **** advantages/limitations are intentionally the same; through words will illustrate the “sublte” differences between them 8

AM Classes – Material Jetting PolyJet/MultiJet Printing (MJP) Advantages Resolution Finish Speed Multi-material Limitations Somewhat functional Light/moisture sensitive **** advantages/limitations are intentionally the same as previous; through words will illustrate the “subtle” differences between them 9

AM Classes – Binder Jetting ColorJet Printing (CJP) Advantages Speed Multi-color Low-cost materials Limitations Resolution Finish Strength Digital Part Materialization (DPM) Advantages Speed Sand/metals Low-cost materials Limitations Resolution Finish **** advantages/limitations are intentionally the same as previous; through words will illustrate the “subtle” differences between them 10

AM Classes – Material Extrusion Fused Deposition Modeling (FDM) Advantages Functional materials Soluble supports Straightforward ops Limitations Material selection Speed Surface finish 11

AM Classes – Powder Bed Fusion Laser Sintering (LS) Advantages Functional materials Production rates Limitations Material selection Accuracy Surface finish Direct Metal Laser Sintering (DMLS) Advantages Functional materials Good properties Limitations Cost Throughput Secondary ops 12

AM Classes – Sheet Lamination Selective Deposition Lamination (SDL) Advantages Material cost Full-color option Limitations Material selection/properties Speed 13

AM Classes – Directed Energy Deposition Laser Engineered Net Shaping (LENS) Advantages Materials Speed Limitations Repair work focus Geometry limits Electron Beam Additive Manufacturing (EBAM) Advantages Materials Speed Limitations Gross net shape 14

AM Future More technology Impact Incremental Innovative Better performance Improved quality More applications Increased risk of obsolescence 15

Insource Vs. Outsource Business decision If insource, keep suppliers Cost Time Control If insource, keep suppliers Over capacity Desired materials Desired technologies INSOURCE OUTSOURCE 16

Summary Many options Selection requires insight With distinct pro/con Selection requires insight Understand advantage/limitation Define key success criteria Specify application Define criteria Part by part 17

Join Us for Day 2 Design Considerations for Manufacturability A look at materials and DFM For process selection 18

Questions Please post your questions in the live online chat and I will answer them there! Todd Grimm T. A. Grimm & Associates (859) 331-5340 Todd.Grimm@tagrimm.com 19

About Proto Labs Proto Labs is a leading technology-enabled, quick-turn manufacturer of custom prototypes and low-volume production parts. Proto Labs’ proprietary software translates 3D CAD models into instructions for rapid manufacturing processes that include injection molding, CNC machining and 3D printing. 20

About Proto Labs cont. Automated, online quoting system analyzes the CAD model, proposes revisions to improve manufacturability, and provides a quote within 1-3 hours.   Rapid Injection molding is used for custom prototypes, bridge tooling and low-volume production runs of 25 to 10,000+ plastic, metal, and liquid silicone rubber parts. Parts are made in 1-15 days. Three-axis milling and CNC turning is used for engineering-grade plastic and metal parts in quantities of 1 to 200+. Parts are made in 1-3 days. 3D printing is used for plastic and metal parts with complex geometries in quantities of 1 to 50+. Parts are made in 1-7 days. 21