3D Printing Yesterday! Today! · PDF fileShane Rolton Wysiwyg3d.com.au ProZ3d.com.au 3D...

Shane Rolton Wysiwyg3d.com.au

ProZ3d.com.au

Shane Rolton Wysiwyg 3D and ProZ 3D

Shane Rolton (BE Mech)

3D Printing

Yesterday! Today!

Tomorrow??????????????????????


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Background

Presenter

• A Cadet Engineer with Hawker De Havialland ‘92

• 1999 Engineering Manager New Dawn Design

• Founded Wysiwyg 3D – 2003. 3D Scanning services provider

• Formed ProZ 3D - 2012, a collaboration of 3 industry leading companies – Wysiwyg 3D, Qubic, and CNC Engineering. 3D Printing Solutions provider!

• Backgound in Manufacturing, CAD, toolmaking, machining, 3D scanning and metrology, and 3D printing.

• We can do it Attitude!


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3D Printing – Additive Manufacturing History

3D Systems (3DS), Stratsys – Main Players!

• 3DS invented 3D printing with its Stereolithography (SLA) printer and was the first to commercialize it in 1989.

• Scott Crump invented FDM (Fused Deposition Modelling) in 1991 – Now Stratasys • 3DS invented Selective Laser Sintering (SLS) printing and was the first to

commercialize it in 1992. • 3DS invented the ColorJet Printing (CJP) class of 3D printers and was the first to

commercialize 3D powder-based systems in 1994. • 3DS invented MultiJet Printing (MJP) printers and was the first to commercialize it

in 1996.

• 3D printing has been used in Australia since mid 1990’s!


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3D Printing – Additive Manufacturing What is it?

Back to the Basics

It is the construction of a 3 dimensional object by depositing material layer by layer controlled by a computer, defined by

CAD!

Compared with CNC machining – the removal of material layer by layer, controlled by a computer, defined by CAD!

How? What Processes are involved?

Ink jet, gluing, melting, welding, chemical fusion, curing, spraying!


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The Range?

Lower price points Higher Performance

3D Printers for Every Need


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SLA® (Stereolithography)


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SLA Technology Overview


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SLA Is Used for the Broadest Range Of Applications

Ceramic

Clear Durable Ceramic

Casting

Ceramic Bio-Compatible

Durable Optically Clear

Tough

High-Temp


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SLA Delivers Accuracy

Difference form nominal in microns

0

5

10

15

20

25

30

35

-100 -80 -60 -40 -20 0 20 40 60 80 100

Frequency

3 Sigma

Accuracy +/- 45 μm

Standard Deviation < 15 microns


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0.25 mm

Accuracy and Precision


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SLA Delivers Fine Features

0.125 mm walls, holes and features


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Print Large Parts, Accurate from End-to-End

up to 1500 x 750 x 550 mm

12

while still preserving minute detail, high accuracy and repeatability


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3D Systems SLA Printers

ProJet 6000 ProJet 7000 iPro 8000 ProX 950

Maximum Build volume

10 x 10 x 10 in

(250 x 250 x 250 mm)

15 x 15 x 10 in

(380 x 380 x 250 mm)

26 x 30 x 22 in

(650 x 750 x 550 mm)

59 x 30 x 22 in

(1500 x 750 x 550 mm)

Accuracy

0.001-0.002 inch (0.025-0.05 mm) per inch of part

dimension


dimension


dimension


dimension Maximum Resolution

0.075 mm, 0.050 mm layers





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SLA Materials


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ProX™ 500

SLS® 3D Printer


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How it works – SLS Selective Laser Sintering


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ProX 500

Economically manufacture injection molding-grade plastic parts for demanding end-use applications


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SLS and Additive Transforms Manufacturing

Consolidate parts, reduce labor and eliminate tooling

Traditional manufacturing:

• 15 parts

• 5 SKU’s

• 3 custom tools

• 10 assembly checks


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SLS and Additive Transforms Manufacturing

Consolidate parts, reduce labor and eliminate tooling

SLS additive manufacturing:

• 1 part

• 1 SKU

• 0 custom tools

• 1 assembly check


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SLS Transforms Design and Manufacturing

No Tooling + Complete Design Freedom And Optimized parts!


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SLS – Patient Specific Instrumentation (Mass

Customization)

• Implant instrumentation – Reduced sterilization and inventory costs

– Disposable system delivered in a single pre-sterilized box

– Minimal instrumentation required

– Reduced Operating Room and Surgeon time

– Better Fit, minimally invasive, faster recovery


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SLS – Mass Customized Industrial Design

23


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SLS – Functional Prototypes

SLS parts can mimic injection molded plastic performance

Production SLS Printed

Performance sensor data almost identical


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ProX 500 Benefits – High Speed &Throughput

baby car seat and recliner

34 hours build time

240 Mobile printer covers

80 hours build time

24 bridges for Car for handicaped people

52 hours build time


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ProX 500 Benefits – Breakthrough Plastic Material

Produces smoother surfaces and injection molding-like part quality, with resolution and edge definition that surpasses existing alternatives

New high performance plastic material: DuraForm® ProX


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ProX 500 Benefits – Functional Performance

Strong, flexible material

• Highly elastic

• Enables living hinges

• Easy fit


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ProX 500 Tech Specs

Build size 381 x 330 x 457 mm (15 x 13 x 18 in)

Powder layout Variable Speed Counter Rotating Roller

Layer thickness 0.08 – 0.15 mm

Imaging system ProScan DX Digital High Speed

Scanning speed Fill - 12.7 m/s (500 in/s) Outline- 5 m/s (200 in/s)

Volume build rate 2 L/hr


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ProX™ 100, 200 and 300 EOS, and MTL plus others

Fully functional METAL parts in hours

Not Just for Printing GUNS!!!!!!!


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ProX Direct Metal Printing Movie


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ProX 100, 200, 300 Direct Metal Production Printers

High density, metal printed parts from a large choice of materials with the highest detail and precision


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Large choice in standard metal alloys and ceramics

• 9 alloys available directly from 3D Systems

• CoCr- Cobalt Chrome

• 17-4PH Stainless Steel

• 1.2709 Maraging Steel

• AlSi12 Aluminium Alloy

• Ti6Al4V Titanium Alloy

• Inconel 718

• Hastelloy X

• 316 L stainless Alloy

• Inconel 625

• Additional metals, ceramics, and precious metals can also be printed on ProX DMP

Inconel 718 AI2O3

AlSi12 Pure Cu Pure Cu

AlSi12


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Unmatched design and manufacturing freedom Manufacture the Un-manufacturable!!!!


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High density parts

Density> 99% of theoretical part


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Highest accuracy, best detail resolution

150 micron wall thickness


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Smallest Parts – detail resolution

2mm gear with 20 teeth

C- clamp holding 16 thou wire


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Excellent Tolerances & Repeatability

Repeatability

~20 microns in all 3 axes


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Aerospace

Jet Engine Fuel Nozzles


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Dental

Dental partials manufacturing

in CoCr


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Jewelry


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Tooling

Blow Mold with conforming holes


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Patient Specific Implants and Devices

Custom acetabular cup

for hip replacement surgery


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ProX™ 100, 200 and 300 Direct Metal Printers

ProX 100 ProX 200 ProX 300

Build volume 3.94 x 3.94 x 3.15 in

(100 x 100 x 80 mm)

5.51 x 5.51 x 3.94 in

(140 x 140 x 100 mm)

9.84 x 9.84 x 11.81 in

(250 x 250 x 300 mm)

Laser power 50W 300W 500W

Loading Manual Semiautomatic Automatic

Recycling System Optional external system (PX BOX)

Optional external system (PX BOX)

Automatic

Dental version available Dental version available


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ProJet® 5500X

Variable Engineered Composite 3D Printer


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ProJet 5500X Intro Movie


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Multiple engineered composite materials

Rigid, ABS-like white plastic

Rubber-like black tires

Moderately flexible front wing


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Multi-material benefits


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Composite material choices

The 5500X mixes materials on the fly, so you can choose virtually any number of combinations to get the properties you want

Flexible Rigid

Black White Clear


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Accurate parts


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Easy post-processing

Supports are printed in wax

No special water hookups needed

Wax simply melts away


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New VisiJet® Composite Materials

• VisiJet® CR-WT Rigid White ABS-like Material

– Durable

– Rigid

– High temperature resistance


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• VisiJet® CF-BK Black Rubber-like Material

– Rubber-like look and feel

– Extreme flexibility

– Absorbs shocks and impacts to enhance durability


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• VisiJet® CR-CL Clear Polycarbonate-like Material

– See-thru clarity when polished

– Simulates polycarbonate or glass

– Functional durability resists scratching


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ProJet 5500X tech specs

Build size 550 x 393 x 300 mm (21.6 x 15.5 x 11.8 in.)

Selectable print modes

HD Mode: 32µ layer thickness 375 x 375 DPI resolution

UHD Mode: 29µ layer thickness 750 x 750 DPI resolution

Print resolution Prints extreme fine features down to 0.01” (0.25mm)

Warranty 5-year print-head warranty

Printer dimensions 1700 x 900 x 1650 mm (67 x 35.4 x 65 in.)


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ProJet® 5000

Large Plastic 3D Printer


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How it works – MJP MultiJet Printing And Polyjet. Both Brands have these!


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Large Parts and Lots of Parts!

57


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Fine Detail Resolution

Features down to 0.01 inches (0.25mm)

No stair-stepping on curved sidewalls

Micro-fine features; razor-sharp definition


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ProJet 5000 – VisiJet® M5 Material Options

• Select the material that works in your application

• Choice of clear, high elongation plastic; high-strength, PP-like plastic or rigid, white plastic with high temperature resistance


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New VisiJet M5 Black Plastic Material

• High strength

• PP-like high flex

• Beautiful, jet-black color

• Great for

– Large panels & housings

– Snap fits & assemblies

– Tire models

– Prototypes

– End use parts


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Property VisiJet M5 Black Typical Polypropylene

Tensile Strength, MPa 32.8 33

Tensile Modulus, MPa 1555 1344

Elongation, % 15.4 12-23

VisiJet M5 Black: Mechanical Performance

• High detail on both large and small parts

• Highly requested jet-black color

• Functional parts for extended use and testing


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Property VisiJet M5-X Typical ABS

Tensile Strength, MPa 39.4 41-60

Tensile Modulus, MPa 1924.6 2275-2500

Elongation, % 7.8 5-25

VisiJet M5 X: Mechanical Performance

• High Modulus material, stiff feel

• Brilliant white finish

• Large flat panels and other geometries requiring stiff properties


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ProJet® 4500

Full Color Plastic 3D Printer


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ProJet 4500 Intro Movie


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ProJet 4500

Combine the power of vibrant full color with durable plastic parts.


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The benefits of color combined with strength

Which communicates your idea better?


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High-Quality Full-Color Printing

Life-like. Photo-quality. In Three Dimensions.

Enhance communication and design Improve marketing Impress customers


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Applications

Customized end-use products


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Applications

Durable concept models


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Applications

Functional prototypes


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Applications

Medical models


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Applications

Digital 3D art


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Key features

Almost 1,000,000

brilliant colors

Relative size to model

Amazing small feature detail


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Materials

Revolutionary VisiJet® C4 Spectrum™ materials bring full-color capability to plastic parts.


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ProJet 4500 tech specs

Build size 8” x 9.5” x 8” (203 x 241 x 203 mm)

Color Continuous-Tone CMY

Print resolution 600 x 600 dpi

Layer thickness .004 ” (.102 mm)

Build speed Up to ½ in/hour (12mm/hr)


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VisiJet C4 Spectrum material specs

Tensile Strength 24.8 MPa

Tensile Modulus 1600 MPa

Elongation at Break 3.6%

Flexural Strength 36.5 MPa

Flexural Modulus 1125 MPa

Hardness Shore D 79

Heat Distortion Temperature

57 °C


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ProJet® 3500 series for Plastic Parts

Precise, User-friendly and Flexible 3D Printing


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VisiJet® M3 X

• White, injection molded plastic look and feel

• ABS-like performance

VisiJet® M3 Black

• Black, injection molded plastic look and feel

• High strength and flexibility plastic

VisiJet® M3 Crystal

• Transluscent

• Tough polypro/ABS- like performance

• Class VI Certified for medical applications

VisiJet® M3 Proplast

• Translucent White

• Durable plastic performance

VisiJet® M3 Navy

• Blue


VisiJet® M3 Techplast

• Gray


VisiJet® M3 Procast

• Dark blue for improved surface inspection

• Castable plastic

High Performance Materials For More Applications

Advanced Performance


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Optimized Capacity

• Stack & nest parts to use entire build volume

– Take advantage of longer free periods

– Gain additional thru-put without sacrificing build time

– Maximize utilization of the available build volume

Why print in only 2-dimensions when it’s a 3D printer?


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… with Micro-fine Detail Resolution

• Features down to 0.01 inches (0.25 mm) • No geometry limitations


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Accuracy & Precision

• Tolerances down to +/- 0.001-0.002 inches per inch (+/-0.025-0.05 mm per 2.54 mm)

0

10

20

30

40

-40 -30 -20 -10 0 10 20 30 40

Fre

qu

en

cy

Difference from nominal in microns


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Build More Parts, Faster

• Fast print speed with the wide-pass print head design

• Combine multiple parts in single build to optimize the build

• High volume capacity meets peak production demand


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Automated Process – from File to Ready-to-Use Part

• Fast and easy support removal – Wax supports simply dissolve with no support scars

– Hands-free process saves time and labor

– No geometry limitations

– Fine delicate features preserved


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ProJet® 3500 Dental CAD/CAM 3D Printers

Precise, User-friendly and Flexible Dental 3D Printing


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Print Beautiful Parts…

• No stair-stepping on curved sidewalls

• Exceptionally Smooth Surfaces


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… with Micro-fine Detail Resolution

• Features down to 0.01 inches (0.25 mm) • No geometry limitations


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Consistently Sharp Edges and Corners

• Clean, straight edge definition

• Exceptional small hole definition


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Accuracy & Precision

• Tolerances down to +/- 0.001-0.002 inches per inch (+/-0.025-0.05 mm per 2.54 mm)

0

10

20

30

40

-40 -30 -20 -10 0 10 20 30 40

Fre

qu

en

cy

Difference from nominal in microns


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VisiJet® M3 Dentcast

• Wax-up castable and pressable material

• Dark green

VisiJet® M3 Pearlstone

• Dental models

• Solid stone appearance

VisiJet® M3 Stoneplast

• Dental models

• Transparent, clear or stone finish, dyeable

• Class VI Certified for medical applications

High Performance Specialty Materials

Engineered Performance


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ProJet 3500 series for Plastic Parts - Summary

• Quickly print superior quality dental wax-ups and models

• High resolution with sharp edges, crisp details and smooth surfaces

• Intuitive and easy-to-use in your office or remotely

• High productivity digital dental workflow


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ProJet® x60 Series

Fast, Affordable Full Color 3D Printing


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ProJet x60 Series


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Communicate with Color

COLOR


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+90% of colors in

Adobe® Photoshop possible

High Resolution


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Words

Picture

Model

5 Prong

10 Amp

Plug

A picture may be worth a thousand words, but how much money is a full

color 3D model worth?


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ProJet® 1200

High Precision, Low Cost Professional 3D Printer


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ProJet 1200

Small, precise parts and casting patterns with micro-SLA quality at a breakthrough price


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ProJet 1200 Intro Movies

Dental Jewelry

Click videos to play


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Tough plastic that’s castable

Use prints directly as casting patterns

Crown

Sprue

Mold

Cement

99.99% ash free burnout


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Prosthodontic 3D printing

Full anatomy pressed crowns


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Revolutionizing digital jewelry production

A 3D printer right on your workbench

Print casting-ready rings in under 2 hours for less than $1


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Virtually any small cast metal part


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Built-in post processing

Built in UV curing chamber


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How it works – micro-SLA®

Build Platform

Build Cartridge

Mirror Imager

Resin is in the bottom of the build cartridge and the build platform is lowered. Resin is cured by imager through the window on the print cartridge and onto the build platform


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How it works – micro-SLA

Part

Imager

Repeat the process one 30 micron layer at a time until part the precise part is finished


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FDM – Type – Stratsys professional plus 100’s of toy versions!

Fused Deposition Modelling – Heated Extruder

• This is where the consumer market is at!

• Developed 1991 and used in commercial machines, it was the release of this patent that started the home 3D printing trend!

• $500 to $300,00 plus!

• All work the same, but you get what you pay for!


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FDM – Type – How they work!


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The Today!

If we compare 3D printing to 2d printing, I feel we are currently somewhere between the 9 pin dot matrix and the 24 pin dot matrix paper printers of the early 1990’s!

A time when consumers have cool desktop machines that do a job, but for high quality we still have to use service providers!


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The Future!!! ???????

Lets rewind 150 - 200 years!

• Bespoke manufacturing – Craftsman, 1 offs, made to order, slow, expensive, Fully Customized.

Rewind to 1910! Henry Ford (Even today this is mainstream)

• Production line approach, “you can have any colour you like as long as it’s Black” – mass production has begun. Manufacture 1000’s of the same items to reduce the cost. Tooling costs are huge, high volumes required. Little choice, very little customization!


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Future – Mass Customization!

• You can have any combination of colours, shape, materials all made to order but at mass production prices! Ie Hearing Aids

• Additive in Metal and then finishing! Ie print with material on and grind, or edm. Why not Print the electrode, polish and use in a undersized printed cavity!

• Especially difficult to machine materials!

• Challenges ahead – Material validation? Process validation?

– CT, Xray, Simulations, build orientation, material selection, IP, Legals (Police and the Gun Thing),


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Future – Mass Customization!

• Medical – cells in a matrix of protein! Uni Wollongong!

• Deployable machines to oceans, deserts and space?!

• Cheaper, higher quality in the home (just like colour laser printers)

• Complexity comes for FREE!

• Design for Manufacture – Different constraints!

• What if you combined a standalone 3D printer and a production line? Henry Ford’s 3D Printer of the Future!?


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The Possible Future!!!!!!


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Questions?????

THANKYOU!

Shane Rolton [email protected]

www.wysiwyg3d.com.au www.proz3d.com.au

mailto:[email protected]

http://www.wysiwyg3d.com.au/

http://www.proz3d.com.au/

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