1. Day 1: Additive Manufacturing
Leveraging Advances in Computer-Aided Design Tools in 3D Printing
Day 1: Additive Manufacturing

2. Day 1 Additive Manufacturing
Overview
AM Methods
Materials
Benefits of AM in Tooling
Creating tools with AM
Short runs
Tool cost offset
Fixtures and jigs
Verifying tools
Prototyping before cutting

3. Day 2: CAD Tools and Design
3D Design Software
CAD
VFX
Solid Models
Mesh Models
Algorithm based tools
SW to design geometry
Can makes shapes only with additive manufacturing

4. Day 3: Case Studies Wearables & Jewelry Aerospace & Automotive
Jewelry fashion
Tbd
Wax casting
Ask rob
High tech
Ear buds—nt infinitely customizable
Eyeglass ware
Shoes
TPU
Aerospace & Automotive
Investment casting section
Nylon
Ask ssys
Bmw ssys
Ask jim Orrock
Biomedical
Invisalign
MRI data to AM
jeffrey
New Structures only available by AM
Bike
Housing……..
Look for exampless

5. Overview
3D printing is here to stay in applications from wearables to aerospace with many entry points
Overview of 3D printing methods and materials
Q&A

6. 3D Printing
Additive manufacturing method that is rapid and personalized
Simple — 3D model to digital file to printing
“Adds” materials where necessary
Allows for rapid changes
No tooling or molds
Digital
Capability for small batch design
Can be personalized to specific anatomy or architecture

7. 3D Printing Methods Methods Fused deposition modeling Ink jet
Powder bed
Metal sintering
Liquid polymer crosslinking or binding
Laser direct write and projection imaging
Liquid resin
Laser direct write
Projection imaging (DLP)
Laminated Object Manufacturing
Electron beam fabrication
All have a common characteristic of taking a 3D model file (OBJ), “slicing it” and importing that STL, 3MF or AMF file to the printer

8. Software CAD tools Freeform modeling tools Sculpting tools
Slicers and 3D printing hosts
Cross-platform
Platform-dependent tools
Future SW to handle 3D images from cameras

9. Fused Deposition Modeling
Discovered and patented by Scott Crump and colleagues at Stratasys
Most common type of personal use 3D printer and well sought-out technique for commercial applications
Printer liquefies plastic and puts it down layer-by-layer
200 μm layer resolution
Each layer “fuses” to the last layer due to the properties of the polymer during its melt phase
Works with a variety of polymers
PLA most common in home printers
Higher strength polymers common in commercial printers
Can also be used with composite materials

10. Ink Jet Layer by layer fluid deposition Fluids can be particle-laden
100 μm layer resolution with high accuracy
Capable of printing complex geometries
Capable of printing multi-materials in single build

11. Stereolithography (SLA)
UV laser light projection into photopolymer
Object built layer by layer
50 μm layer height (higher resolution)

12. Selective Laser Sintering
Generates complex 3D parts
Solidifies powder material layer-by-layer
Capable of working with many materials like polymers, metals and ceramics
Solidification occurs by fusing or sintering material by a laser beam
Requires high energy laser

13. Electron Beam Melting Use of CAD file import Layer by layer process
High resolution
Uses metal powder, vacuum chamber and narrow electron beam
Melt quality can yield high strength properties of the material
Vacuum environment eliminates impurities (oxides and nitrides)
Handles very complex geometries

14. Powder Liquid 3D Printing
Initial invention by Michael Cima, and Emanuel Sachs (1993)
Licensed by Z Corp (now owned by DDD)
Powders and binders on bed printer
Build rate of about 25 mm/hour
Works with a variety of materials
Ceramics
Metals
Plastics

15. The Future of 3D Printing: Materials
Large gains have been made in materials for both 2D and 3D printing
Materials for FDM, inkjet and resin printing
Requires collaboration between academic institutions, 3D printer manufacturers and materials suppliers
2D printing materials are being moved to 3D printing for drop on demand printing:
Nanoparticles, CNTs, quantum dots
Shape memory polymers
Scaffolding materials
Mesoporous materials
Sacrificial materials

16. Question #1
What features are necessary in the next generation of 3D printers?
(answer the question in chat)

17. The Future of 3D Printing: The Need for Speed
Carbon 3D, founded by Joseph DeSimone and his lab members
Liquid resin photopolymerization process with much faster print times
Can it move into medical printing?
Can this process be used for functional materials?
Time of printing reportedly beat by:
Chinese lab
Prodways

18. Jigs and Fixtures
Custom tools can be created, tested, and deployed quicker at a lower cost.
Jigs and fixtures can be 3D printed on the factory floor and implemented within hours of a design change.
Assembly fixtures at MakerBot

19. Question #2
Other than rapid prototypes, what applications of 3D printing are common for engineering and manufacturing?
(answer the question in chat)

20. Conclusions
Imaging may become key component of the success of 3D printing adoption for truly tailored anatomies and architectures
“the perfect fit”
The requirement for motion control accuracy to be below or at the resolution of 40 µm will remain cost-prohibitive and delay mass entry into market
Not having a well-developed supply chain for functional materials will delay research and development causing further delays in commercialization
Cost of ownership will continue to manage entry into field and limit return on investment
AM has a sweet spot for fixturing in industrial manufacturing operations