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

2. 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

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

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

5. 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

6. 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

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

8. 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

9. 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

10. 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

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

12. 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

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

14. 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

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

16. 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

17. 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

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

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

20. 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

21. 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 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