manufacturing technology: additive vs subtractive manufacturing
PowerPoint Presentation Advanced Manufacturing Additive Manufacturing Week 4 – Primary Additive 3D printing processes History of AM Topography: 1890: J.E. Blanther suggested a layered method for making a mould for topographical relief maps (wax plates) Photosculpture: 1860: François Willème: 24 cameras around the object > an artisan carved a 1/24th cylindrical portion of the figure using a silhouette of each photograph (Bourell et al, 2009) 1951: O.J. Munz:proposeda system similar to stereolithography 1972: Pierre Alfred Ciraud: Thefirst successful AMprocess - apowder deposition methodwithanenergy beam 1970’s: Housholder (powder laser sintering), Kodama (photopolymers), Herbert (photopolymers) 1986: Charles (Chuck) Hull: obtained a patent for stereolitography (SL) and founded 3D Systems ( History of AM ) 1987: 3D Systems: SLA-1 (StereoLithography Aparatus 1) - first commercialised AM machine Good Morning America, TV Show, 1989 ( Ciraud )(Bourell et al, 2009; Drstvensek 2010) http://www.3ders.org/articles/20130226-how-far-3d-printing-has-come-since-good-morning-america-1989.html Rapid prototyping: Additive manufacturing of a design, often iterative, for form, fit, or functional testing, or combination thereof. Rapid tooling: the use of additive manufacturing or subtractive manufacturing methods (such as CNC milling) to make tools or tooling quickly, either directly, by making parts that serve as the actual tools or tooling components, such as mold inserts, or indirectly, by producing patterns that are, in turn, used in a secondary process to produce the actual tools. 3D printing: The fabrication of objects through the deposition of a material using a print head, nozzle, or another printer technology. Discussion: Term often used synonymously with additive manufacturing; in particular associated with machines that are low end in price and/or overall capability. (ASTM, http://www.astm.org/FULL_TEXT/F2792/HTML/F2792.htm) ( Terminology ) · Mock-ups, scale models · (Functional) prototypes · Tooling (moulds, patterns) · End-products http://static1.squarespace.com/static/509c281de4b0cd18c7335a ab/t/548e134ee4b023e5238feb68/1418597198577/ ( Additive manufacturing appl ications ) http://mastergraphics.com/imagingsolutions/wp- content/uploads/2013/12/Projet-x660.jpg https://image.architonic.com/img_pro2 -1/111/7752/Quin-chandelier-b.jpg + Minuses- (Chiu and Yu 2008; Czajkiewicz 2008, Manogharan 2015) ( Benefits or AM ) · ( + )Directly from 3D computer model · No tooling - mould is not required · No waste material (only support in some cases) · Complex shapes (a form in a form) · Faster design-to-part production · Small number of stages in a production process · Much cleaner workshops · Lower material consumption · Lower or no process engineering time · ( - )Just in time production, on-demand production Minuses · Relatively expensive (material, operation costs) · Limited materials · Limited size · For one or a small number of parts (Chiu and Yu 2008; Czajkiewicz 2008, Manogharan 2015) ( Additive manufacturing process 1 Conceptualisation and CAD 2 Conversion to STL 3 Transfer to AM machine and STL manipulation 4 Machine setup 5 Build 6 Removal and Cleanup 7 Post-process 8 Application ) Images: Project: Developing a Better Snowboard Binding Prepared by: Robert Leen Supervised by: Dr Paul Collins Assistance in the creation of the final prototype: Dr Clara Usma Alvarez Thesis prepared for: SEJ446: Engineering Project B SoE, SEBE Deakin University (Gibson et al, 2009) 1. Conceptualisation and CAD 3D model: · Created using 3D modelling · Created using 3D scanning · Combination of 3D modelling and 3D scanning CAD model (Solidworks 2014 modelling software) Sketch STL (.stl) is a file format for 3D model data used by machines to build physical parts; STL is the de facto standard interface for additive manufacturing systems. STL originated from the term stereolithography. (ASTM) It was created by 3D Systems. STL: · Is a polygonal (mesh) file · Describes the external closed surfaces of the original CAD model (no history) · Basis for calculation of the slices ( 2. Conversion to STL ) ( Connex3 (Objet 500) ) · Verification if the file is correct (normals, shells) · General part manipulation: · Part orientation (build height, specific location within the machine) · Multiple parts (same parts, different parts) · Scaling (mm, %) · Adding text (identification) ( 3. Transfer to AM machine and STL manipulation ) Build parameters: · Material constraints · Energy source · Layer thickness (time vs. accuracy) · Timings ( 4. Machine setup ) Superficial monitoring: · Material (enough material) · Energy(power outage) · Software (errors) ( 5. Build (Automated process) ) Once the AM machine has completed the build, the parts must be removed. Interaction with the machine: · Safety issues: temperatures lower than operating temperatures, no actively moving parts Interaction with the part: · May be fragile before post- processing ( 6. Removal and Cleanup ) · Careful, experienced manual manipulation · Time consuming Before parts are ready for use: · May be weak · May have supporting features that must be removed (cutting, melting) Symbolic image - http://d2rormqr1qwzpz.cloudfront.net /photos/2014/07/09/62427- cleaning.jpg ( 7. Post-process ) Surface finishing (visual, texture improvements): · Priming, gap filling (modelling filler / surfacer + sand paper) · Painting (car paint) Assembling together with other part or mechanical / electronic components ( 8. Application ) VIDEO: Deakin Designs - GripTight https://www.youtube.com/watch?v=cudZKafcQHc Classification of AM Adapted from Gibson et al, 2009 and Pham’s Layered Manufacturing classification Liquid Polymer 1D Channel SLA (3D Systems) 2x1D Channels Dual bean SLA (3D Systems) Array of 1D Channels2D Channels Polyjet (Object)DLP (EnvisionTEC), MicoTEC Discrete Particles Molten Material SLS (3D Systems), LST (EOS), LENS Phenix, SDM FDM, DODJET (Solidscape) LST (EOS)3D PrintingDPS ThermoJet Solid SheetsSolido PLT (KIRA) Overview over AM technologies https://www.additively.com/img/content/learn/process/3d-printing-technologies-overview-en.png StereoLithography (SL or SLA) A UV laser is curing a liquid photopolymer in a vat. The part is built by lowering the build platform into the vat. https://www.additively.com/en/learn-about/stereolithography VIDEO: Stereolithography (SLA) Technology https://www.youtube.com/watch?v=NM55ct5KwiI ( StereoLithography (SL or SLA) ) · Developed by 3D Systems · Requires support structures for overhangs (same material) · Very good accuracy and surface finish · Only photopolymers (not stable over time, have not well defined mechanical properties) https://www.stratasysdirect.com/wp- content/themes/stratasysdirect/img/tech_new/stereolithography/gal lery/stereolithography-sla-002.jpg http://2biy4djn37s2xoe622u8h9g1.wpengine.netdna-cdn.com/wp- content/plugins/wp-o-matic/cache/34f20_e-stage-2.jpg http://2biy4djn37s2xoe622u8h9g1.wpengine.netdna-cdn.com/wp- content/plugins/wp-o-matic/cache/b4243_e-stage-4.jpg Applications? http://d2n4wb9orp1vta.cloudfront.net/resources/images/cdn/cms/0808ct-rapid- part2c.jpg http://www.3ders.org/images/prox-950-v10-quickcast.jpg http://www.georgehart.com/cccg/Image82.jpg Fused Deposition Modelling (FDM) A plastic filament is melted and extruded through a nozzle. Parts are built by laying down layer-by-layer. https://www.additively.com/img/content/learn/process/additive-manufacturing-fused-deposition-modeling-en.png VIDEO: Fused Deposition Modeling (FDM) Process - 3D Printer https://www.youtube.com/watch?v=b-J9nJtbc6M ( Fused Deposition Modelling (FDM) ) · Developed by Stratasys · Requires support structures for overhangs (same - break-away / different – soluble material) · Fully functional parts in standard plastics (ABS, PC) · ( https://makearchitecture.files.wordpress.com/2010/03/photo-10.jpg )Parts with good mechanical properties, durable over time · ( https://solidoodletips.files.wordpress.com/2012/07/p 1160292.jpg )Surface has a step-structure and fine details cannot be realised http://1.bp.blogspot.com/- jOHle_CYriY/UZxxfrkSmKI/AAAAAAAABDc/ 2YJCbXsk3vk/s1600/IMG_0708-owl.JPG Applications? http://reprap.org/mediawiki/images/thumb/d/dc/Prusa_Diamond_yellow.JPG/300px-Prusa_Diamond_yellow.JPG Fused Deposition Modelling (FDM) Laser Sintering (LS) (Selective Laser Sintering, SLS) A thin layer of plastic powder is selectively melted by a laser. The parts are built up layer by layer in the powder bed. https://www.additively.com/img/content/learn/process/additive-manufacturing-laser-sintering-en.png VIDEO: How sls 3d printing works https://www.youtube.com/watch?v=0sLcobtfHFY ( Laser Sintering (LS) ) · Developed by DTM (later 3D Systems) · No support required (powder!) · Parts in standard plastics (PA) with good mechanical properties · Parts do not have exactly the same properties as injection moulded parts · Rough surface finish https://gigaom.com/wp-content/uploads/sites/1/2014/04/screen-shot-2014- 04-24-at-5-17-17-pm-804x532.png http://s3.amazonaws.com/cideas- assets/images/processes_SLS/sidebar/ProcessSLSplaneart.jpg https://i.materialise.com/blog/wp-content/uploads/2015/12/laser-sintering-3d- printer.jpg Applications? https://s-media-cache-ak0.pinimg.com/736x/85/a5/57/85a5578870bdf6162f49133fda013b3d.jpg http://assets.nydailynews.com/polopoly_fs/1.1 281915.1362673225!/img/httpImage/image.jp g_gen/derivatives/article_750/3d-printing.jpg Laser Melting (LM) (Direct Metal Laser Sintering, DMLS) A thin layer of metal powder is selectively melted by a laser (or multiple lasers). The parts are built up layer by layer in the powder bed. https://www.additively.com/img/content/learn/process/additive-manufacturing-laser-melting-en.png VIDEO: Direct Metal Laser Sintering (DMLS) Technology https://www.youtube.com/watch?v=bgQvqVq-SQU ( http://www.harbec.com/wp- content/uploads/2014/08/img_3141 660x445.jpg http://www.objective3d.com.au/wp-content/uploads/2016/ 04/556.png ) Laser Melting (LM) · DMLS developed by EOS · Requires support structures (anchor parts and overhanging structures). This enables the heat transfer away where the laser is melting the powder. · Parts in standard metals with high density - above 99% (can be further processed as any welding part) · Good mechanical properties (comparable to traditional production technologies) · Slow and expensive · Tolerances and surface finishes are limited (can be improved in post-processing) Applications? ( Laser Melting (LM) ) http://www.industrial-lasers.com/content/dam/ils/online- articles/2016/03/slm_1.jpg http://d2n4wb9orp1vta.cloudfront.net/resources/ images//cdn/cms/Golf_Tool_Insert--resized.jpg http://www.makepartsfast.com/wp-content/uploads/2012/03/GPI-prototype-3D- printing-parts-7.jpg http://serkov.su/blog/wp-content/uploads/2014/10/Medical-Modeling.jpg Electron Beam Melting (EBM) A thin layer of metal powder is selectively melted by an electron beam. The parts are built up layer by layer the in the powder bed. https://www.additively.com/img/content/learn/process/additive-manufacturing-electron-beam-melting-en.png VIDEO: Direct Manufacturing: ARCAM https://www.youtube.com/watch?v=M_qSnjKN7f8 ( http://d2n4wb9orp1vta.cloudfront.net/resources/i mages/cdn/cms/AM1112_Military_Image2.jpg ) · Developed by Arcam · Limited number of standard metals with high density (above 99%): Cobalt-chromium alloys, Nickel-based alloys, Titanium · Parts with good mechanical properties (comparable to traditional production technologies) · Slow and expensive process · EBM produces less thermal stress in parts and therefore requires less support structure than LM · Not so good surface finishes as LM (more post-processing – better tolerances) http://www.arcam.com/wp-content/uploads/Arcam_EBM_System_A2X.jpg ( Electron Beam Melting (EBM) ) Applications? Electron Beam Melting (EBM) http://www.arcam.com/wp-content/uploads/Acetabular_cup_with_SEM- e1359107753132-560x394.jpg http://www.ipmd.net/assets/userfiles/ipmd/images/NEWS/March_2013/arcam_skull.gif http://www.arcam.com/wp-content/uploads/hydraulic-manufold.jpg http://www.arcam.com/wp- content/uploads/Turbine_blade_for_aero _engine-e1359966492148-288x416.jpg Binder Jetting (BJ) (3D printing, 3DP) Inkjet print heads apply a liquid bonding agent onto thin layers of powder. By gluing the particles together, the part is built up layer by layer. https://www.additively.com/img/content/learn/process/additive-manufacturing-binder-jetting-en.png VIDEO: D2W Multi-Colour 3D Printer in Action https://player.vimeo.com/video/105006874 ( https://player.vimeo.com/video/105006874 ) · 3DP developed by Z Corporation · No support required (powder!) · Almost any material that is available in powder form (plaster, sand, plastic, metal, sugar) · Fast and cheap · Parts in full colour are possible · ( https:// www.digits2widgets.com/3d- printing/multi-colour-3d-printing/ ) ( https:// www.digits2widgets.com/wp- content/uploads/2015/04/Processing- Multi-Colour-3-of-5.jpg ) ( https:// www.digits2widgets.com/wp- content/uploads/2015/04/Processing -Multi-Colour-4-of-5.jpg )Parts directly from the machine are fragile ( Binder Jetting (BJ) ) Applications? Binder Jetting (BJ) http://www.3dz.it/wordpress/wp- content/uploads/2016/03/copertina_corvalli s_stampanti3D_italia_3dsystems_artec_to pografia.jpg http://tallerdesoluciones.blogs.inti.gob.a r/files/2014/01/projet260C.jpg ( http://www.wired.com/wp- content/uploads/2015/02/DOOB3.jpg ) http://mastergraphics.co m/imagingsolutions/wp- content/uploads/2013/12 /Projet-x660.jpg Photopolymer Jetting (PJ) (Polyjet/ Multijet modeling) Inkjet print heads are used to jet liquid photopolymers onto a build platform. The material is immediately cured by UV lamps and solidified which allows to build layers on top of each other. https://www.additively.com/img/content/learn/process/additive-manufacturing-photopolymer-jetting-en.png VIDEO: PolyJet Technology https://www.youtube.com/watch?v=Som3CddHfZE ( Photopolymer Jetting (PJ) ) · Polyjet developed by Objet · Multi-material and multi- colour parts: several materials can be jetted at the same time (different shore hardness, translucency) · UV-active photopolymers (parts are not durable over time, limited mechanical properties) · Good accuracy and surface finishes https://i.ytimg.com/vi/D4Yq3glEyec/maxresdefault.jpg http://www.formakers.eu/media/85.228.1331364706.22.jpg Applications? http://www.smg3d.co.uk/images/3d-printed-car-fob_large.jpg Photopolymer Jetting (PJ) http://cdn.shopify.com/s/files/1/0180/7671/products/Me dicalApplicationLR_2_1024x1024.jpg?v=1348918917 http://www.gxsc.com/images/news/bordered_screwdriver.jpg Material Jetting (MJ) (Drop on Demand - DOD, Thermojet) Inkjet print heads are used to jet melted wax materials onto a build platform. The material cools and solidifies which allows to