Course 6: Digital Factory Additive Manufacturing...Video : What is 3D printing? 3/80 Manufacturing...

Curriculum Development

of Master’s Degree Program in

Industrial Engineering for Thailand Sustainable Smart Industry

Course 6: Digital FactoryAdditive Manufacturing

Pisut Koomsap, AIT

Athakorn Kengpol, KMUTNB

Supapan Chaiprapat, PSU

What is an additive manufacturing and 3D printing?

Additive Manufacturing (AM) refers to a process by which digital 3D design data is used to build up a component in layers by depositing material.

2/80

Video : What is 3D printing?

3/80

Manufacturing for growth-the developing AM and 3D sectors

The use of AM for the production of parts for final products continues to grow. In ten yearsit has gone from almost nothing to 28.3% of the total product and services revenue from AMworldwide. Within AM for industry, there has been a greater increase in direct part production, asopposed to prototyping.

4/80

Manufacturing for growth-the developing AM and 3D sectors

In Industry 4.0 the use of the 3DP technology will be decisive for process efficiency andreducing complexity, allowing for rapid prototyping and highly decentralized production processes.

5/80

Additive Manufacturing in Industry 4.0

The Industry 4.0 offers cybernetic andphysical systems to cooperate profitablywith the goal of building intelligentfactories, redefining the role of humanbeings:

6/80


In industry 4.0 the use of the 3DP technology will be decisive for processefficiency and reducing complexity, allowing for rapid prototyping and highlydecentralized production processes

The product model could simply be off to the 'printing' site nearest to thecustomer, eliminating intermediate manufacturing steps, transportation andwarehousing.

7/80


Equipment

The manufacturing equipment will be characterized by the application of highlyautomated machine tools and robots.

8/80

The trend for the different value creation factors in Industry 4.0

Human

The numbers of workers will thus decrease. The remaining manufacturing jobswill contain more knowledge work as well as more short-term tasks. The workersincreasingly have to monitor the automated equipment.

9/80


Organization

The decentralized instances willautonomously consider local information forthe decision making. The decision itself willbe taken by the workers or by the equipmentusing methods from the field of artificialintelligence.

Process

AM and 3DP will be increasinglydeployed in value creation processes, sincethe costs of additive manufacturing havebeen rapidly dropping during the last yearsby simultaneously increasing in terms ofspeed and precision.

10/80


Product

The products will be manufactured in batch size one according to the individualrequirements of the customer. The physical product will be also combined with new servicesoffering functionality and access rather than product ownership to the customer as part ofnew business models.

11/80


- Increased design freedom versus conventional casting and machining

- Light weight structures, made possible either by the use of lattice design or by designingparts where material is only where it needs to be, without other constraints

- New functions, such as complex internal channels or several parts built in one

12/80


- Net shape process meaning less raw material consumption

- No tools needed, unlike other conventional metallurgy processes which require molds andmetal forming or removal tools

- Short production cycle time, the total cycle time including post processing usually amountsto a few days or weeks and it is usually much shorter than conventional metallurgyprocesses which often require production cycles of several months.

13/80


- Part size, in the case of powder bed technology, the part size is limited to powder bed size,such as 250x250x250 mm for standard powder bed systems.

- Production series, the AM processes are generally suitable for unitary or small series andis not relevant for mass production.

- Part design, in the case of powder bed technology, removable support structures areneeded when the overhang angle is below 45°.

14/80


- Material choice. Though many alloys are available, non-weldable metals cannot beprocessed by additive manufacturing and difficult-to-weld alloys require specific approaches.

- Material properties. Parts made by additive manufacturing tend to show anisotropy in the Zaxis.

- Besides. though densities of 99.9% can be reached, there can be some residual internalporosities.

15/80

Efficiency, creativity, accessibility-the advantages of AM

- Low-volume production, for appropriateproducts, AM replaces machine tooling.

- Lower-cost production, another benefit of AMover traditional machine tooling is the lowercost of manufacture.

- Responsive production, AM offers faster leadtimes than traditional manufacturing methods.

16/80

Efficiency, creativity, accessibility-the advantages of AM

- Shorter supply chains. AM has the capacityto shorten the manufacturing supply chain.

- Democratization of production.

- Optimized design. The capacity of AM toallow the “fundamental rethinking andredesign of products” can result in bettercomponents,

17/80

The road ahead-challenges and opportunities for AM

- Materials - Software

- Data management - Sustainability

- Affordability - Speed

- Reliability - Intellectual property

- Standards - Business funding

- Education

18/80

Forging a future for AM

- Media attention, in February 2011, The Economist published an article, ‘The printed world8,’ which 3T RPD chief Executive officer Ian Halliday described as, “a tipping point for themedia that has since produced global awareness of AM – which is no longer just forgeeks”.

- Stimulating R&D through competitions. In December 2012, The TSB and researchcouncils launched a competition 9 which will fund 18 innovative 3D printing research anddevelopment projects with £8.4 million in UK government funding.

19/80

Forging a future for AM

- Creating clusters. Creating AM business clusters could create opportunities for cross-pollination of ideas between companies, accelerating innovation.

- Finding mavericks. Peter Marsh believes AM would benefit from attracting maverickfigures in the mold of entrepreneur James Dyson and designer Thomas Heatherwick.

20/80

Building a framework

Defining the sector. Defining thedifferences between 3D printing and AM tocreate clearer market segmentation could helpthe AM and 3D printing sector attract publicand private investment.

21/80

Industrialization of 3DP Technology

AM technology is gradually becoming the core technology and there is a growingconsensus that 3DP technologies will be one of the next major technological revolutions.The fig. shows the 3DP procedure future Industry 4.0.

22/80

Seven Additive Manufacturing Method

23/80

Vat photopolymerization

It differs from many additive manufacturingprocesses in that it begins with the use of aliquid rather than a powder or a filament.Additive printing techniques vary althoughthey all use photopolymer resins often tough,transparent and castable materials.

24/80

Video : Vat photopolymerization

25/80

Material Jetting

It is an additive manufacturingprocess that uses drop-on-demand (DOD)technology. Like a 2D inkjet printer, tinynozzles dispense tiny droplets of a waxyphotopolymer, layer by layer. UV light curesand hardens the droplets before the next layeris created.

26/80

Video : Material Jetting

27/80

Material Extrusion

Fused deposition modeling (FDM) isperhaps the most well-known additivemanufacturing process. When the generalpublic hears “3D printing,” this is the processthey often think of. A thermoplastic filament isextruded through a heated nozzle and ontothe build platform.

28/80

Video : Material Extrusion

29/80

Binder Jetting

It is similar to material jetting,although it employs powdered material and abinding agent. Nozzles on these 3D printersdeposit tiny droplets of a binder on anultrafine layer of powdered metal, ceramic orglass.

30/80

Video : Binder Jetting

31/80

Sheet lamination

Sheet lamination is an additivemanufacturing process in which ultra-thinlayers of solid material are bonded byalternating layers of adhesive. It is possible touse a variety of materials in this additiveprocess called laminated objectmanufacturing.

32/80

Video : Sheet lamination

33/80

Powder Bed Fusion

It is a process common to a variety of popular additive printing techniques direct metallaser melting, electron beam melting, directed metal laser sintering, selective laser melting,selective laser or heat sintering.

34/80

Video : Powder Bed Fusion

35/80

Directed Energy Deposition

Directed energy deposition, (alsocalled direct metal deposition or metaldeposition), utilizes highly focused thermalenergy delivered via laser, electron beam orplasma arc to melt and fuse material jettedinto the heated chamber from eitherpowdered metal or wire filament.

36/80

Directed Energy Deposition

37/80

Stereolithography (SLA) : Components

The technology and the term were created in 1986by Chuck Hull, founder of 3D printing company 3DSystems. According to him, SLA is a method ofcreating 3D objects by successively “printing”layers, by which he meant a photosensitivematerial.

In 1992, 3D Systems created the world’s first SLAapparatus, which made it possible to fabricatecomplex parts, layer by layer, in a fraction of thetime it would normally take. SLA was the first entryinto the rapid prototyping field during the 1980sand has continued to advance itself into a widelyused technology.

38/80

Stereolithography (SLA) : Components

Every standard SLA 3D printer is generallycomposed of four primary sections:

- A tank filled with the liquid photopolymer: The liquidresin is usually a clear and liquid plastic.

- A perforated platform immersed in a tank: Theplatform is lowered into the tank and can move upand down according to the printing process.

- A high-powered, ultraviolet laser

- A computer interface, which manages both theplatform and the laser movements

39/80

Stereolithography (SLA) : Software

As is the case for many additive manufacturing processes, the first step consists of designing a 3Dmodel through CAD software. The resulting CAD files are digitalized representations of the desiredobject.

If they are not automatically generated as such, the CAD files must be converted into STL files.Standard tessellation language (STL), or “standard triangle language”, is a file format native to thestereolithographic software created by the Abert Consulting Group specifically for 3D Systems backin 1987. STL files describe the surface geometry of the 3D object, neglecting other common CADmodel attributes, such as color and texture.

The pre-printer step is to feed an STL file into a 3D slicer software, such as Cura. Such platforms areresponsible for generating G-code, the native language of 3D printers.

40/80

Stereolithography (SLA) : SLA 3D Printing

When the process starts, the laser “draws” the first layer of the print into the photosensitive resin.Wherever the laser hits, the liquid solidifies. The laser is directed to the appropriate coordinates by acomputer-controlled mirror.

41/80


At this point, it’s worth mentioning that most desktop SLA printers work upside-down. That is, thelaser is pointed up to the build platform, which starts low and is incrementally raised.

42/80


After the first layer, the platform is raised according to the layer thickness (typically about 0.1 mm)and the additional resin is allowed to flow below the already-printed portion. The laser then solidifiesthe next cross-section, and the process is repeated until the whole part is complete. The resin that isnot touched by the laser remains in the vat and can be reused.

43/80


Post-Processing

After finishing the material polymerization, the platformrises out of the tank and the excess resin is drained. Atthe end of the process, the model is removed from theplatform, washed of excess resin, and then placed in aUV oven for final curing. Post-print curing enablesobjects to reach the highest possible strength andbecome more stable.

44/80

Stereolithography (SLA) : Video

45/80

Stereolithography (SLA)

Pros

SLA is one of the most precise 3D printing techniques on the market.

Prototypes can be created with extremely high quality, with finely detailed features (thinwalls, sharp corners, etc…) and complex geometrical shapes. Layer thicknesses can bemade as low as 25 μm, with minimum feature sizes between 50 and 250 μm.

SLA provides the tightest dimensional tolerances of any rapid prototyping or additivemanufacturing technology: +/- 0.005″ (0.127 mm) for the first inch, and an additional0.002″ for each additional inch.

Print surfaces are smooth.

Build volumes can be as high as 50 x 50 x 60 cm³ without sacrificing precision.

46/80

Stereolithography (SLA)

Cons

Printing tends to take a long time.

Steep slopes and overhangs require support structures during the building process. Suchparts may potentially collapse during printing or curing phases.

Resins are comparatively fragile and therefore not suitable for functional prototypes ormechanical testing.

SLA offers limited material and color choice, usually offering black, white, grey and clearmaterial. Resins are oftentimes proprietary and therefore cannot be easily exchangedbetween printers from different brands.

SLA printing costs are comparatively high (e.g. machine, materials, lab environment).

47/80

Selective Laser Sintering (SLS)

Another laser-based additive manufacturingtechnology is selective laser sintering (SLS). Thistechnology, however, creates a model from drymedia instead of liquid.

With SLS, the media, generally plastic or nylon, isplaced inside a forming chamber, again containing amovable surface. The media is a particle with atexture somewhere between granulated sugar andflour. The chamber temperature is then raised to justbelow the melting point for the selected media.

48/80


A mirror-directed laser beam draws a profile of thedesired model into the warm media. The energypushes the media’s surface temperature just aboveits melting point, causing the particles to fusetogether or sinter.

The surface then drops a fraction of a millimeter anda wiper sweeps a fresh, level layer of media acrossthe work field. The process repeats again and again,creating a model in much the same manner as most3D printing processes.

Variations of SLS include direct metal laser sintering(DMLS) or selective laser melting (SLM), which applya similar technique to metals.

49/80

Selective Laser Sintering (SLS) : Components

50/80


Pros

A distinct advantage of SLS printing over FDM and SLA is that it can produce parts with much higher strengths. Additionally, the SLS process requires no supports, as the level of the unsinteredmedia rises with that of the sintered product, acting as support material for the model being manufactured. This means complex structures are generally much easier to produce with SLS.

Once sintering is complete, most SLS models require only a gentle post-process media blast, similar to sandblasting, to sweep away any remaining unsintered particles.

51/80


Cons

SLS is not without its downsides. The main drawback is accessibility. Because the technology requires a high-power laser, SLS machines are both expensive and unsafe to operate in anything less than a workshop type of space.

Furthermore, as the process involves particles that are only surface liquefied, finished projects tend to exhibit rough, grainy surfaces. This can be mitigated through the post-print blast cleaning process, but SLS alone will never produce a smooth, shiny surface.

52/80

Selective Laser Sintering (SLS) : Video

53/80

Selective Laser Melting (SLM)

Selective laser melting, or SLM, is a type of metal additive manufacturing or 3D printing.Often, the terms SLM and direct metal laser sintering (DMLS) are used interchangeably.However, the two technologies differ slightly, in that SLM melts pure metals while DMLSfuses metal alloys.

SLM is one of the most exciting 3D printing technologies available today and is utilizedboth for rapid prototyping and mass production. The range of metal alloys available isfairly extensive. The end result has properties equivalent to those manufactured viatraditional manufacturing processes.

54/80


SLM is very similar to SLS, and both processes are covered under the powder bed fusion umbrella. The majordifference is the type of feedstock or powder it uses. While SLS uses mainly nylon (PA) polymer materials, SLMis specifically for metals.

Nevertheless, the basic process is the same. As demonstrated in the image below, the laser sinters the powdertogether, layer-by-layer, until the model is complete.

55/80


However, there is one big difference betweenSLM and SLS. Due to the constraints of theSLM process and the weight of the material,SLM requires support structures to be addedto any overhanging features. This differs fromSLS, where the surrounding powder materialcan provide enough support, allowingfreeform shapes and features to be realized.

56/80


Pros

Large range of metals available

Ability to realize complex shapes or internal features(which would be incredibly difficult or expensive toachieve via traditional manufacturing)

Reduced lead times, due to no need for tooling

Part consolidation, allowing the production of multipleparts at the same time

57/80


Cons

Expensive, especially if parts aren’t optimized or designed for the process

Specialized design and manufacturing skills and knowledge needed

Limited currently to relatively small parts

Rough surface finish

Lots of post-processing required

58/80

Selective Laser Melting (SLM) : Video

59/80

Case Study

4.1 Aerospace

4.1.1 borescope bosses for A320neogeared Turbofan engine

Additive process used: Laser Beam Melting

The bosses are made by selective lasermelting (SLM) on an EOS machine.

60/80

Case Study

4.1 Aerospace

4.1.2 Support to satellite antenna


Part made by EBM with optimized designthanks to topology optimization

61/80

Case Study

4.1 Aerospace

4.1.3 RSC emission Rake


The water cooled emission rake is placedinto the exhaust duct of a high pressurecombustion facility. It is used to samplehot exhaust gases using 6 sampling tubesand supplies the gas to an analyzing system.

62/80

Case Study

4.1 Aerospace

4.1.4 Repair of worn lips on a labyrinth seal

Additive process used: Laser Metal Deposition

This engine’s part is turning at 30000 RPM. After10000 hours of flight, the different lips of partsare worn and do not guarantee the efficiency ofthe seal. With the LMD process, it was possibleto rebuild the different worn lips.

63/80

Case Study

4.2 Energy

4.2.1 burner repair


Customized EOSINT M 280 machine for precise,cost-effective, and faster repair of worn burnertips of gas turbines exposed to extremetemperatures.

64/80

Case Study

4.2 Energy

4.2.2 vacuum permeator


Part of a bigger system to demonstrate thepossibility of tritium recovery in fusion reactors.Its manufacturing entailed various challenges:component dimensions, geometric changesalong its section, metallurgical, file handling.

65/80

Case Study

4.3 Medical

4.3.1 Removable partial Denture (RPD) framework


The part is a metal framework for a removable partialdenture (RPD). When fully assembled, the RPD is adenture for a partially edentulous dental patient. 3Ddata retrieved directly from the patient’s mouth.

66/80

Case Study

4.3 Medical

4.3.2 Hearing aid


67/80

Case Study

4.3 Medical

4.3.3 Cranial implant


Development and manufacture of a customized andprecision-fi implant with high permeability for liquidsand perfect heat dissipation on an EOSINT M 280machine

68/80

Case Study

4.3 Medical

4.3.4 Cleanable filter Disc


Traditional methods of creating filters often result ingaps between the securing steel ring and the mesh,as well as the weft and warp strands of the wovenwire. Known as ‘bugtraps’, these can quickly gatherbacteria and dirt.

69/80

Case Study

4.4 Industry

4.4.1 pressure sensor house

Additive process used: Precision inkjet onpowder bed

70/80

Case Study

4.4 Industry

4.4.3 Tooling insert


Inserts with conformal cooling channels toproduce arm-rests for cars, built on EOSINT M270 machine. Optimize the cooling process toreduce the production cycle period, improvecomponent quality and increase maintenanceintervals.

71/80

Case Study

4.4 Industry

4.4.4 Conformal cooling channel inmold/nozzle

Additive process used: Laser Beam MeltingComplicated cooling channel can be installedinside of parts by AM with 3D design data.

72/80

Case Study

4.5 Automotive and Car Racing

4.5.1 prototype of heat exchanger


New design with self-supporting integratedcooling fins on outside surfaces and turbulatorsinside cooling tubes to disrupt the flow of thecooled fluid.

73/80

Case Study

4.5 Automotive and Car Racing

4.5.2 Roll Hoop

Additive process used: Electron Beam Melting

The impact structure used to protect the driverin the event of roll over incident is traditionallymade by investment casting. AM has theadvantage of being able to produce thesecomplex designs with a very short lead time.

74/80

Case Study

4.6 Consumer goods

4.6.1 Platinum hollow charms


Platinum has always been difficult to use withcasting. With SLM technique it’s possible tomatch its fashion effect with the maximumfreedom of shape, also preserving light weightsto let it be it affordable.

75/80

Case Study

4.6 Consumer goods

4.6.2 Rygo sculpture

Additive process used: Precision inkjet onpowder bed

Bathsheba Grossman is an artist recognizedfor her 3d printed art and sculptures. Not manyof her complex designs can be produced in anyother way than additive manufacturing.

76/80

Video : Examples and applications of 3D printing

77/80


78/80


79/80

Video : 4D Printing is the Future of Design

80/80

Course 6: Digital Factory Additive Manufacturing...Video : What is 3D printing? 3/80 Manufacturing...

Documents

Transcript of Course 6: Digital Factory Additive Manufacturing...Video : What is 3D printing? 3/80 Manufacturing...