1. Additive Manufacturing Seminar
This is NOT a sales seminar!!!
My purpose here is to share information and educate

2. Introduction What is the term Additive Manufacturing mean?
Additive Vs. Subtractive Manufacturing
In subtractive we start with stock and remove material to get the net shape (traditional machining)
In additive we start with nothing and add material to get the net shape
Our RP goal is to get the best quality parts, in the shortest possible time, at the lowest possible cost.

3. Rapid Prototyping (RP)
Introduction of RP – Additive Process
Generate a prototype part by Layering Manufacturing Technology - composite material layer by layer
Build in one step - directly from model to manufacturing

4. From Concept to full Production

5. Rapid Prototyping - definition
(RP) is defined as a group of techniques used to quickly fabricate a model of a part or assembly using three-dimensional computer aided design (CAD) data.
Rapid Prototyping ,also referred to as solid free-form manufacturing, computer automated manufacturing, and layered manufacturing.
RP has obvious use as a vehicle for visualization.

6. Prototypes

7. Evolution of Rapid Prototyping
3D objects were used to demo model since early history
Mud, wood, clay and paper was used to create mockups
With the industrial revolution machine tools were used to create scaled models
The digital era brought a leap step to advanced layer additive prototyping and manufacturing
Prototypes are made from solidified liquid, powder, sheets and jetting materials
Advanced materials are leading into the future of rapid manufacturing techniques and technology

8. Evolution of Rapid prototyping
Industry started in the mid 80’s
Around 30,000 products sold world wide.
Great achievements in machine performance and model quality.
Fairly expensive technologies introduced up to date.
Every technology has it’s pros and cons.

9. The fathers of Rapid Prototyping
In the early 1980’s Charles Hall developed the liquid polymerization based Stereolithograpy apparatus (SLA)
Granted the original patent
Considered to be “ the founder” of RP
In the late 1987, Carl Deckard developed the powder based Selective Layer Sintering process (SLS)

14. Technology and operation concept
Liquid resin solidification – Stereolithography
Powder solidification – Sintering
Polymer jetting
Fused deposition
Laminated objects

15. Stereolithography Stereo – three dimensions Lithography – printing
Started with acrylic resins in the early 1980’s
Epoxy resins are more common now
Very good accuracy
$$$, Brittle (originally)
UV Laser cure
Relatively slow speed
Newer resins with improved properties

21. Supports structure

22. Stereolithography apparatus - SLA

23. UV Laser Depth of penetration
Bullet shape cure into resin, energy exposure determine the depth and width of cure pattern
Laser
Laser

24. UV laser cure into the resin
Bullet shape laser beam cure penetration into resin Dp Ec

25. Laser cure on Epoxy resin

26. Building on angle to min. supports

27. SLA 5000 machine

29. resins can get color by exposure

30. Medical model visualization aid

31. Click

32. Click

35. Assembly part evaluation - SLA

36. SLA parts can be metal plated

37. Selective laser sintering -SLS
Developed in late 1980’s
Powder base
$$$ good accuracy
No need for supports – powder is self supporting
Shrink and curl challenge
Can do short run Rapid Manufacturing without tooling
Range of materials nylon to sintered metallic powders

38. Selective Laser Sintering - SLS

39. SLS

40. Click

41. SLS Nylon parts

42. Complex assembly – SLS model

43. Click

44. Click

45. SLS Materials (partial list)

46. Fused Deposition Modeling- FDM
Developed by S. Scott Crump in the late 1980s
Commercialized in early 1990s
Principle of laying down molten material in layers
Nozzle is heated to melt the thermoplastics material
The print head moves on X-Y Axis to draw the layer
The platform drops down on Z for each layer
Separate dissolvable support material
Several material and color options

47. FDM

48. Click

49. Click

50. Click

51. Powder Liquid Binding
inkjet-like printing head moves across a bed of powder
selectively depositing a liquid binding material
A fresh layer of powder is added on top of the model
can print parts in full color by the binding liquid
unbound powder is removed
limited application in high accuracy
Post cure by glue infilteration
parts are fragile and brittle even after post processing
The OEM of this Technology is Z-Corporation.

52. Click

53. Click

54. Click

55. Click

56. Multijet; PolyJet Modeling
wax-like thermopolymer plastic models
Printing head with multiple spray nozzles (jets)
These jetting heads spray tiny droplets of melted material
When cooled it hardens on impact to form the solid object
Some printers use UV cure process
Accuracy depends on printer head resolution DPI
Good for investment casting patterns

57. MJM – Thermojet printer

58. MJM

60. MJM; PJM Printers

61. MJM
Click

62. Click

63. Click

64. Object’s MJM printer
Click

65. Click

66. Rapid prototyping categories
Hi End: Above $100K
Mid Range: $40K – $80K
Low End: Below $20K

67. Competitive analysis

68. RP Users

69. Mechanical Properties for RP
Strength
Elongation / at brake / Elastomer
Modulus
Toughness
Heat deflection temperature
Izod notched brake
Hardness
Clarity

70. Mechanical Properties

71. Mechanical Properties

73. RP Sequence CAD solid (surface) model ‘.STL’ file Slicing the file
“water tight” model
Tolerance
‘.STL’ file
Tessellation and file size
Slicing the file
Final build data
Building (3D printing) the part
Supports removal
Post processing

74. CAD Solid Model
Solid model or closed surface model required

75. CAD to STL
To produce a model from CAD data, export 3D CAD model as a STL file.
The parameters used to generate this file will directly influence the quality of the model.
STL is the standard file type used by all Rapid Prototyping systems.
A STL is a triangulated approximation representation of a 3D CAD surfaced model.
You cannot build the model any better or smoother than the STL. So if the STL is coarse and faceted, that's what you will see in the model.

76. .STL File Software generates a tessellated object description
File consists of the X, Y, Z coordinates of the three vertices of each surface triangle, with an index to describe the orientation of the surface normal

77. .stl – right hand rule - Normals

78. stl with normal vectors

79. Click for the movie

80. .stl

82. From Art to STL Physical parts can be scanned and output to STL format
triangle count of 20,024,
file size of 1,001,284 bytes

84. Watertight STL??

85. “Bad” STL

86. “bad” vs. “good” STL

87. Slicing STL file
STL
Raw Slice
Slice
Layer data
3D part

88. Slicing the model –contour line

89. Sliced contour

90. Slicing STL data (.sli)

94. Rapid Prototyping Applications
Design evaluation
Physically holding a part vs. viewing it on screen
Function verification and tests
Form; Fit; Function -- (FFF)
Assemblies; wind tunnel; medical; marketing evaluation
Master patterns
Casting; investment casting; soft tooling
Advance to production process
Jigs; prototype to metal

95. RP in the Development Cycle
Product design
Increase part complexity and diversity with little effect on lead time and cost
Minimise time-consuming discussion and evaluations of manufacturing possibilities
Tool design and manufacturing
Minimise design, manufacturing and verification of tooling
Reduce parts count and eliminate tool wear

96. RP in Product Development Cycle
Product design
Increase part complexity and diversity with little effect on lead time and cost
Minimise time-consuming discussion and evaluations of manufacturing possibilities
Tool design and manufacturing
Minimise design, manufacturing and verification of tooling
Reduce parts count and eliminate tool wear

97. RP in Product Development Cycle
Assembly and test
Reduce labour content of manufacturing (e.g. machining, casting, inspection and assembly, etc.)
Reduce material costs (e.g. handling, waste, transportation, spare and inventory, etc.)
Function testing
Avoid design misinterpretations mistakes , i.e. what you design is what get)

98. From Prototyping to Tooling
Rapid tooling
Making the tool from the prototype master
Save time and money
Soft tooling
From 3 to 25 parts per tool
Tools made out of Silicon Rubber (soft)
plastic Polyurethane parts
Range of mechanical properties and colors
Wax parts for further Investment Casting

99. Silicone RTV tool

100. Saving time = Saving money

101. RTV – Room Temperature Vulcanization Casting

102. From Prototyping to Tooling
Bridge tooling
intermediary between Soft Tooling and Hard Tooling
From hundreds to few thousands of parts
back up materials like Epoxy Resin around the master
Metal powder interfiled tools
Keltool
Production tooling (NOT BY RP)
Steel or aluminum machined tools
For injection molding machines
Millions of parts from each tool

103. Silicone tool casting

104. Composite Tooling (Epoxy Tooling)
molds are reasonably fast in comparison to machined molds
relatively inexpensive way to create prototype and production tooling.
much higher compression strength and heat resistance
Good when production material is required
Master pattern is by RP

106. Bridge tooling (epoxy) and (wax)Part

107. Rapid Tooling

108. 3D Keltool Moderate to high volume metal tool
RP pattern from which a rubber mold is created
The rubber mold is used to cast a steel powder and polymer binder mixture – “green part”
Copper infiltrated resulting in a tool with about 70% steel and 30% copper content
Advantageous for small, complex molds that would require much time to make with CNC or EDM techniques.

109. 3D Keltool

110. 3D Keltool process

111. Production (traditional) tooling
CORE CAVITY

112. Tool Cycle time – Tool Temperature

114. Thank you