3D printing: disrupting the development and production phase in the product development cycles

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Automne 2016MEC6510A Fabrication avance en aronautique et microsystmes 31/10/20161

Laboratoire de mcanique multi-chellesLaboratory of multiscale mechanics

centre de recherche en plasturgie et compositesMarek BalazinskiDesign et fabrication B-450.11Tl. : (514) 340-4711 ext. [email protected]

Ilyass Tabiai

Daniel TherriaultSection mcanique applique A-103.3Tl: (514) 340-4711 ext. 4419www.polymtl.ca/[email protected]

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3D Printing in the industryPrototyping: Disrupting the design approach (Pratt & Whitney)Production: Shape and topological optimization (GE/Frustum)3D printing trainingSafety in the labFused Deposition ModelingStereolithography

31/10/20162PLan

31/10/201633D-PRINTING IN THE INDUSTRY

ManufacturingProductionPrototyping3D-printing disrupts the Development and Manufacturing cyclesManufacturing = ProductionDevelopment = Prototyping

Alcoa jet engine prototype

3D-printed compressors by P&W (PW1500G) for Bombardier C-serieshttp://fortune.com/2014/11/13/3-d-printing-jet-engines-alcoa/http://www.rapidreadytech.com/2015/04/printed-parts-will-be-used-in-jet-engines/

31/10/201643D Printing in the industry - PrototypingCase: Pratt and WhitneySource: M. Modafferi (Senior Director Research & Tech PW800 program) / F. Richard (Project Engineer in Research & Tech), CASI Quebec speakers from P&W Canada, 09/03/2016, Concordia University

10 iterations in 3 years before 3D-printingVS6 to 7 iterations / year nowPW800 family: Turbofan engine for regional and business jet marketFirst run: April 2012Still under development

WikipediaMakerbot Replicator 2Showing powerDesign decisions can be taken in days instead of weeks/months Reduced development hardware lead-timesAssembly tests, third party components assembly tests, wire and tubing clearance tests, at different stages of conception and designProduction readyPreparing production lines before having the parts

Prototyping = Mostly FDM, SLA, SLS

31/10/201653D Printing in the industry - ProductionYou only need what you needhttps://www.thingiverse.com

Before:Material-wise: massive cost improvements !Almost 100% free in the design process:Engineers and designers were not prepared for this but for shapes that can be manufactured using subtractive processesDozens ?Hundreds of manufacturing steps?

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31/10/201663D Printing in the industry - Production

Topological optimizationhttps://www.linkedin.com/pulse/re-design-frustum-3d-systems-direct-metal-printing-cuts-cornelusGE Aircraft challenge: reduce weight of a bracket while keeping it functional (2016)

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31/10/201673D Printing in the industry - ProductionRetrofittinghttps://www.wikipedia.comGE90 turbofan engine: Manufactured by GESince 1995For Boeing aircraftsThe world's largest and the most powerful jet enginehttp://insights.globalspec.com/article/840/3d-printed-parts-from-general-electric-set-for-retrofit-in-400-jet-engines

3D-printed housing for the T25 compressor inlet temperature sensorT25 sensor housing:First 3D-printed part certified by FAANo production line needed to repair old partsSpecific hardware updates

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31/10/201683D Printing in the industry - LIMITATIONSProduction:Currently weak to no (FE) modeling and process simulation capabiltiesProcess (set of parameters) is tuned for machine, part, material. In-situ non destructive inspection capabilities: large portion of batches destroyed for inspection purposesOnly 5 big machines manufacturersAbout 5 printable and usable metals

Source: M. Modafferi (Senior Director Research & Tech PW800 program) / F. Richard (Project Engineer in Research & Tech), CASI Quebec speakers from P&W Canada, 09/03/2016, Concordia UniversityDevelopment:Engineering tolerances must be adapted for the prototyping step, then re-designed for productionSafety concerns (particles? fumes?)Could be used for production in future if: better surface finish, better mechanical properties

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31/10/201693D Printing in the industryQuestions ?

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31/10/201610SAFETY IN THE LAB

FDMBeware of hot parts! (Nozzle/Bed)Beware of moving parts!Use spatula (and sharp tools) carefully, away from you

SLAAlways put your gloves onWork on protected surfacesUse spatula (and sharp tools) carefully, away from you

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31/10/201611PROJECTPrototyping technologies (FDM/SLA) to accomplish engineering projectUnderstand steps of 3D-printing process

Leverage 3D-printing advantages/disadvantages in design process

Manufacture original 3D-printed product which answers project specifics

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Main steps to 3D print: build a small castle*2016-10-3112MAIN STEPS

Idea:castle

Draw object in 3D(softwares: CATIA, ProEng)

Printing (adjust printing parameters)

Final product

Prepare file for printer (slicer)

*: CAD from Thingiverse / schematics: hotmess3d / printer: Makerbot Replicator

31/10/201613FUSED DEPOSITION MODELING

Schematics FDM printing headHotCoolT > Tg

A. Tsouknidas, Adv. Tribol., 2011, 2011, 746270.+

G-codeCNC machinehttp://www.hsmworks.com/docs/cncbook/en/

Schematics of CNC machineProcess(1) Heat melt polymer past its Tg, (2) extrusion, (3) layer-by-layer deposition.

Tg = glass transition temperature

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31/10/201614STEREOLITHOGRAPHYFormlabs.com

Printing of porous sphere by SLAAnimation of traveling laser light in SLA process*

Waheed, S., Cabot, J.M., Macdonald, N.P., Lewis, T., Guijt, R.M., Paull, B., Breadmore, M.C., 2016. 3D printed microfluidic devices: enablers and barriers. Lab Chip 16, 19932013

Rocking(peel)ProcessPolymerization activated by laser (UV)

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31/10/201615TODAYGeometrical limits of FDM or SLA 3D-printing process

FDMSLARecommended print settings

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31/10/201616THE PROJECTQuestions ?

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3D printing: disrupting the development and production phase in the product development cycles

Technology

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