The largest trusted community of design engineering professionals Sponsored by: Rapid Prototyping Advances with Inkjet-Based 3D Printing Day 1: Comparison of Inkjet-Based vs Other 3DP Methods Lecturer: Mychal Anderson, Applications Engineer Stratasys Direct Manufacturing

The largest trusted community of design engineering professionals Sponsored by:  Previously Solid Concepts, RedEye and Harvest Technologies 8 U.S. manufacturing facilities 12 primary technologies 600+ employees Certifications: ISO 9001, AS9100 ITAR registered Stratasys Direct Manufacturing Stratasys Direct Manufacturing is one of the largest providers of additive and conventional manufacturing solutions: 2

The largest trusted community of design engineering professionals Sponsored by: Stratasys Direct Manufacturing 3

The largest trusted community of design engineering professionals Sponsored by: How it Works Photocurable resin Very fine layer lines/ resolution ” resolution on Z axis Minimum feature size is around 0.012” 0.060” minimum thickness for some designs/ materials Inkjet-Based 3D Printing Model Material Instant UV Curing Support Material Printing Head 4

The largest trusted community of design engineering professionals Sponsored by: Additive Manufacturing Technologies  End-Use Part Production  Material deposition (Fused Deposition Modeling)  Laser Sintering  Metal Powder Bed Fusion (DMLS, EBM) 5

The largest trusted community of design engineering professionals Sponsored by:  FDM utilizes heated thermoplastic filaments in a semi- liquid state and extrudes those filaments in computer determined designs one layer at a time.  FDM has one of the larger build platforms or any 3D print technology at 36” x 24” x 36” Fused Deposition Modeling (FDM) 6

The largest trusted community of design engineering professionals Sponsored by:  Powdered nylon compositions – filled or unfilled – are heated and fused together layer by layer to create lightweight, durable designs. Laser Sintering (LS) 7

The largest trusted community of design engineering professionals Sponsored by:  Metal and metal alloys in powder form are sintered – heated and fused – together in a process akin to a very fine, precise welding to create durable, highly complex fully dense metal parts which would be impossible to achieve through conventional manufacturing. Metal Powder Bed Fusion Direct Metal Laser Sintering (DMLS) 8

The largest trusted community of design engineering professionals Sponsored by:  Intricate, accurate parts  Digital materials with customized properties  High resolution master patterns and concept models Inkjet-Based Applications 9

The largest trusted community of design engineering professionals Sponsored by: Inkjet-Based vs. Vat Photopolymerization Vat Photopolymerization  Ideal for investment cast patterns (alternative to wax models)  Large models Inkjet-based Printing  Elastomeric and rigid materials  Simulate rubber  Articulate soft-touch or flexible materials  Small models 10

The largest trusted community of design engineering professionals Sponsored by: Inkjet-Based vs. Vat Photopolymerization: Mechanical Properties 11

The largest trusted community of design engineering professionals Sponsored by: Inkjet-based vs Vat Photopolymerization: Materials Left bar = Experimental values Right bar = Datasheet values NOTE: Greenfire parts require a thickness of at least 0.060” to achieve full mechanical properties 12

The largest trusted community of design engineering professionals Sponsored by: InkJet vs. Vat Photopolymerization: Materials Left bar = Experimental values Right bar = Datasheet values NOTE: Greenfire parts require a thickness of at least 0.060” to achieve full mechanical properties 13

The largest trusted community of design engineering professionals Sponsored by: InkJet vs. Vat Photopolymerization: Materials Left bar = Experimental values Right bar = Datasheet values NOTE: Greenfire parts require a thickness of at least 0.060” to achieve full mechanical properties The flexural strength represents the highest stress experienced within the material at its moment of rupture 14

The largest trusted community of design engineering professionals Sponsored by: Inkjet-Based vs. Vat Photopolymerization: Surface Details 15

The largest trusted community of design engineering professionals Sponsored by: Inkjet vs. Vat Photopolymerization: Surface Details Demon Head 80MB File 4” x 3.7” x 2” Vat Photopolymerization Model Somos NeXt Layer Thickness = 0.005” InkJet-Based Printing Model VeroBlue Layer Thickness = ” (PolyJet-HD) 16

The largest trusted community of design engineering professionals Sponsored by: Inkjet-Based vs Vat Photopolymerization: Surface Details Vat Photopolymerization Layer Thickness = 0.005” Inkjet-Based Printing Layer Thickness = ” 17

The largest trusted community of design engineering professionals Sponsored by: Inkjet vs. Vat Photopolymerization: Surface Details Inkjet-Based Printing Detail Layer Thickness = ” Vat Photopolymerization Detail Layer Thickness = Sidewall Detail 18

The largest trusted community of design engineering professionals Sponsored by: Inkjet-Based Applications 19

The largest trusted community of design engineering professionals Sponsored by: Challenge: Doctors required patient skull models to better prepare for procedures Solution: PolyJet’s fine layers build extremely accurate models with smooth surfaces Results: Surgeons have in-depth knowledge of patient’s skull structure prior to performing operation National University Hospital (NUH) 20

The largest trusted community of design engineering professionals Sponsored by:  Challenge: SF Opera House sought to recreate their iconic chandelier as a collectible item available in their gift shop.  Solution: Inkjet-Based printing with PolyJet High Definition (HD) resulted in ideal, highly detailed and accurate renderings of the chandelier design. Jersey McDermott, craftsperson with San Francisco Opera Costume Shop, used the PolyJet HD prints as master patterns to create detailed cufflinks and necklaces.  Results: Stunning portrayals of the iconic San Francisco Opera Chandelier which guests can take home with them and cherish. San Francisco Opera Chandelier 21

The largest trusted community of design engineering professionals Sponsored by: Thank You Day 2: Achieving Greater Inkjet-Based 3DP Details, Surface Quality & Finishes with the Newer Materials 22