1. Layered Manufacturing Technologies u Powder Solidification l 3D Printing (3DP) l Selective Laser Sintering (SLS) u Additive With Sacrificial Supports l Stereolithography (SLA) {= Liquid solidification} l Thermoplastic deposition ¡ Fused Deposition Modeling (FDM) ¡ Solid Object Printing w/ Multi-Jet Modeling (MJM) ¡ Solidscape’s ModelMaker {previously: Sanders} u “Subtractive” l Laminated Object Manufacturing (LOM)

2. Layered Solidification Processes Liquid-Based Approaches u Stereolithography (latest process needs almost no “supports”) Powder-Bed Based Approaches u 3D Printing (Z-Corporation) u Selective Laser Sintering

3. Stereolithography (SLA) u First commercial layered manufacturing technology (1988) u Photo-curable liquid resin u www.3dsystems.com www.3dsystems.com

4. Stereolithography (SLA) u UV laser beam solidifies the top layer of a photosensitive liquid. Build Stage UV Laser Beam Photopolymer

5. Stereolithography: Apparatus

6. Stereolithography Pre-process: u Orient part. u Choose slice thickness. u Slice parts and plan supports.

7. Stereolithography Process: u Position build platform (stage) just below liquid resin surface. u Smooth surface with re-coater blade. u Scan the outline of the current slice, loosely hatch part interior with laser. u Lower the build platform for next layer.

8. Stereolithography Post-process: u Raise part and drain out liquid. l (except liquid trapped by loose hatch) u Break off supports. u Rinse in isopropanol and water. u Dry with air hose. u Post-cure (strengthen) in UV oven.

9. Stereolithography Characteristics: u Slow process u Supports must be removed by hand u Lab environment necessary (gasses!) u Needs trained operator u Laser lasts 2000hrs, costs $20’000! u Little material choice, ($700 per gallon) u Parts can be brittle, fragile

10. Stereolithography Characteristics (cont.): u High accuracy l Layer thickness 0.001 - 0.006” l Minimum feature size 0.003 - 0.012” u Large build volume l Up to 20 x 20 x 23”

11. Powder-based Approaches Key Properties: u Needs no supports that must be removed! u Uniform bed of powder acts as support. u This powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part.

12. 3D Printing -- Principle u Selectively deposit binder droplets onto a bed of powder to form locally solid parts. Powder SpreadingPrinting Build Feeder Powder Head

13. 3D Printing: Some Key Players u Z Corporation: http://www.zcorp.com/ Plaster and starch powders for visualization models. u Soligen: http://www.zcorp.com/ Metal and ceramic powders for operational prototypes. u ProMetal: http://www.prometal-rt.com/ Metal sintering process for operational prototypes and art work.http://www.prometal-rt.com/ u Therics Inc.: http://www.therics.com/ Biopharmaceutical products, tissue engineering.

14. 3D Printing: Z Corporation The Z402 3D Printer l Speed: 1-2 vertical inches per hour l Build Volume: 8" x 10" x 8" l Thickness: 3 to 10 mils, selectable

15. 3D Printing: Z Corporation

16. u Digging out

17. Optional Curing: 30 min. @ 200ºF Keep some powder in place <-- Tray for transport

18. 3D Printing: Z Corporation Cleaning up in the de-powdering station

19. 3D Printing: Z Corporation The finished part u Zcorp, u 6" diam., u 6 hrs.

20. 120 Cell -- Close-up

21. Parallel Projection of the 4D 120-Cell u Zcorp, u 6" diam., u 6 hrs.

22. Morin Surface This is the half-way point of a sphere eversion (without causing creases or tears). 3D-Print 6 " diam. 5 hrs.

23. 3D Color Printing: Z Corporation The Z402C 3D Color Printer Differences compared to mono-color printer: l Color print head with: Cyan, Yellow, Magenta, Black, and Neutral. l Smaller build area. Specs: l Speed: 0.33 - 0.66 vertical inches per hour l Build Volume: 6" x 6" x 6" l Layer Thickness: 3 to 10 mils, selectable l Color depth: 80 mils below surface

24. 3D Color Printing: Z Corporation

25. Use compressed air to blow out central hollow space.

26. 3D Color Printing: Z Corporation Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors.

27. 3D Color Printing: Z Corporation “Lizard-Frame”: Final Infiltrated Part

28. Hypercube, Perspective Projections

29. Two Ways to Make a Hypercube 3D Color Print Assembly of flat FDM parts ==>

30. What Can Go Wrong ? -- Parts may brake before infiltration

31. What Else Can Go Wrong ? u Blocked glue lines u Crumbling parts

32. What Else Can Go Wrong ? u Some blocked glue lines u Uneven coloring  Art ?

33. Post-Processing for 3D-Printing Surface is porous, dusty.  Seal and strengthen the part: u Dip in wax: l Nice smooth finish l Needs separate waxing station u Infiltrate with “superglue”: l Tedious, dirty manual labor u Spray-paint with a sealant: l Polyurethane (yellowish, smelly) l Krylon (invisible)

34. Post-Processing for 3D-Printing u Spray-paint surface with Krylon

35. 3D Printing: Z Corporation An Informal Evaluation u Fast ! u Running expenses: moderate, (but overpriced powder) u Color print head and tubes need some care in maintenance. u Somewhat messy cleanup ! u Lot’s of dust everywhere...

36. Key Points: u Powder gets solidified with a laser. u Powder is kept just below melting point, heat from laser will fuse powder grains. u Un-fused powder acts as support, can easily be removed later. u Many different materials can be used when mixed with a suitable binder: nylon, metal, ceramics … Selective Laser Sintering (SLS)

37. SLS: Conceptual View

38. SLS Players 3D SYSTEMS u Representing the fourth generation of SLS® (selective laser sintering) technology, Vanguard™ and Vanguard™ HS (High Speed), are the first SLS® systems developed specifically for advanced manufacturing applications. u With the Vanguard system you can move directly from a CAD file to a durable, functional plastic or metal part or tool — in a fraction of the time required for traditional machining and tooling. http://www.3dsystems.com/products/sls/vanguard/index.asp

39. SLS from 3D SYSTEMS Use Vanguard or Vanguard HS system for: Plastic or metal parts, patterns & prototypes Complex metal tooling inserts Highly Durable Parts Parts with small features Short runs of plastic & metal parts Benefits: High part accuracy Fast build speed Unattended operation Uses plastic or metal materials Respond to customer demands Worldwide service and support

40. SLS: Laserform Parts

41. The Most Challenging SFF Part 3 rd -order 3D Hilbert Curve: u much weight u much length u no supports u only two tube- connections between the two halves.

42. Fabricated by ProMetal

43. ProMetal Process u A ‘green’ part is first formed, composed of stainless steel powder and a selectively applied binder. u This part is built bottom-up, layer-by-layer under direct computer control. u This green part is then sintered, the binder is drained out and replaced by liquid bronze. u ProMetal is a division of ‘The Ex One Company’, Irwin, PA.

44. The Objet PolyJet Process

45. u Pointer to the company: u http://www.2objet.com/ u See the movie... u http://www.youtube.com/watch?v=oMQWGBgNCtg http://www.youtube.com/watch?v=oMQWGBgNCtg

46. Which Process Should You Pick? Do you need a prototype (not just a model)?  SLS, FDM (for robustness, strength). Do you need a mold for a small batch?  SLA (for smooth, hard surface). Does part need multiple colors?  3D Color-Printing. Does part have convoluted internal spaces?  3D-Print, SLS, SLA (easy support removal).

47. Informal Process Ratings Matrix