Day 1: Which materials? Which processes? Sorting Through the Choices Materials Matter Selecting the Right Materials for Your Manufacturing Process and Application Day 1: Which materials? Which processes? Sorting Through the Choices

Which Manufacturing Process? Relative Cost Comparisons Business Factors Complexity Embedded systems 2

Cost per Unit 3

Cost per Complexity 4

High-level Considerations Purpose of Object Expectations Life-cycle Duty-cycle Physical factors Precision/tolerance Surface finish Color/transparency Specific material properties 5

AM Processes: Ink Jetting Very fine sprays of liquid polymers Fewer, proprietary materials (but growing quickly) 6

Jetting: Direct Write Systems Very fine sprays of liquid polymers Very small scale Few, proprietary liquid photopolymers Biological materials 7

Viscosity Extrusion “Print a building" Bio-plotters 8

VAT Photopolymerization a.k.a. stereolithography® Light hardens plastic resin Many materials, growing quickly 9

Binder Jetting Spray binders on powder material Often involves secondary infiltration/sintering Infiltrants to harden, strengthen parts Continuous colors Many powder materials Multiple materials & binders (e.g. HP Multi-jet Fusion) Combine materials and binders to make custom materials 10

Powder Bed Fusion a.k.a. SLS®, DMLS® Energy fuses particles in a powder bed Sintering/melting processes Polymers Metals Ceramics Composites 11

Directed Energy Deposition Laser deposition of metal powder materials Multiple, simultaneous materials Very scalable - often involves robotics Combine materials to make custom materials 12

Melt Extrusion Most common 3D printing process Melts & extrudes plastic filament Also known as “FDM”™ or “Rep-Rap” Many Materials Growing Every Day! 13

Sheet Lamination Paper (and sprayed glue) Ultrasonic consolidation of thin metal sheets Multiple metal materials Combine materials to make custom materials Embedded electronics 14

Materials for CNC Machining Nearly any material can be machined Compared to 3D printing Relative cost comparisons CNC Machining: much lower material cost for same material Many more materials for CNC CNC Machining: better material properties and behavior CNC Machining: easier to color parts CNC Machining often faster, including post-processing CNC Machining provides higher precision CNC Machining is more labor intensive but not necessarily faster 15

Common Material Types Woods Plastics Metals Custom/Composites Urethane Foams Other “Special” Materials 16

Most Common Material Classes Common Plastics Many! Metals Aluminum, Copper, Brass Magnesium Iron & steel alloys Stainless steels 17

Materials for Injection Molding Best for relatively high production volume Provides lowest cost per unit Many “common”-grade plastic resins Many “engineering”-grade plastic resins Fiber composites Specialty/custom plastics 18

Presentation by David Prawel Ph.D., June 28, 2016 Thank You. Questions? Presentation by David Prawel Ph.D., June 28, 2016 Founder & President, Longview Advisors Inc. Director, “Idea-2-Product” 3D Printing Laboratory (www.idea2product.net) Associate Director, Biomaterials Research & Engineering Laboratory, Colorado State University http://www.engr.colostate.edu/me/pages/research/researchlabs/BREL.html David.prawel@colostate.edu 19