Introduction to 3D Printing and Related Careers

Introduction to

3D Printing and

Related Careers

by James C. (Jim) Bach Multi-Discipline Engineer

28-OCT-2019

28-OCT-2019 2 Jim Bach

Introduction to 3D Printing Inter-Related Questions Posed by Class

–What Types Of Jobs Are Out There? –What Careers/Majors Are Related To 3D Printing? –How Is It Used On The Work Force? –How Can This Be Used As A Skill?

Answers: –Mechanical Engineer oUses 3D-printed parts during initial product development Show-and-Tell during ‘Customer Meetings’ Verify ‘fit up’ of components (i.e. will the parts assemble?) Lab experiments (ex: test fixtures, forming jigs, drill templates)

oSometimes uses 3D-printed parts for “1st samples” to customer

–Manufacturing Engineer oAssembly-line Fixtures oTest Stands oCustom ‘Tools’ (jigs) oSmall-scale mock-up of an assembly line (floor planning)


Introduction to 3D Printing Answer (cont.):

–Chemist oModels to depict/illustrate a chemical composition oCustom lab-wear equipment Ex: fixtures for holding beakers, tubing, etc.

–Physicist oModels to depict/illustrate a physical relationship between objects oComponents for performing lab experiments Ex: fixtures for holding optical elements

–Bio-Engineering oProsthetics (limb replacements) Ex: hands, arms, legs, feet

oOrthopedics (joint replacements) Ex: hips, knees

oSurgery (organ stand-ins for practicing operations) Ex: hearts, lungs, livers, kidneys, ribs


Introduction to 3D Printing Answer (cont.):

–Sports Safety/Medicine oDesigning/testing concepts for safety equipment for players Ex: Helmets, mouth guards, shin guards

oDesigning post-injury aids Ex: crutches, leg braces, removable casts

–Architectural Engineer oDemonstration of planned structures to clients Ex: houses, office buildings

–Civil Engineer oDemonstration of planned structures to clients Ex: bridges, highways, sea ports, parks

–Librarian oSome local libraries offer “3D Design and Printing” facilities CAD workstations where citizens can design their parts o Usually this is offered as a free service to library card holders

3D Printers where staffers can print the citizen’s part o Usually there is a modest charge to cover the material cost


Introduction to 3D Printing How Did You Learn 3D Printing?

•I was working as a “multi-disciplined” engineer within the “Advanced Systems” group for a cooking appliance manufacturer –Multi-Disciplined meaning needing to work as: oElectronics Engineer: Designing electronic circuits oSoftware Engineer: Writing lab-test/data-analysis software oMechanical Engineer: Designing structural elements (3D CAD) oThermal Engineer: Dealing with temperatures involved w/ cooking oPatent Researcher: Reading/writing patents related to our field

–Job was open-ended “How can we use sensors to improve the cooking experience for the consumer?” oNeeded to perform lab experiments to test proposed concepts oNeeded to create proof-of-concept demos for management

–While designing things, creating demos, and performing lab experiments I made extensive use of 3D-printed parts oLuckily the company had a “printer farm” with a wide variety of

printers (SLA, SLS, FDM, PolyJet) and materials to choose from


Introduction to 3D Printing How Did You Learn 3D Printing? (cont.)

•I was eventually put onto a “New Product Development” project for electric cooktops, specifically to design the ‘optics’ for the User Interface (UI). –Although the 3D CAD software had “Photo Rendering” capability (to preview how the UI should appear), the components still had to be prototyped and tested to verify that things looked as good in real life as in the renderings. o3D-printing the various optical elements allowed for numerous

design iterations in a short period of time There were numerous design tweaks that were made once real

world parts were tested (i.e. ‘lit up’ in the lab) o Often the 3D models (material properties) were adjusted until the renderings

resembled the reality

oMajor design elements that were 3D-printed for optical testing:


Introduction to 3D Printing Examples of 3D-printed parts

•“Light Guide” for cooktop user interface (UI) optics –Initial prototyping was performed w/ 3D-printed parts –Production parts were Injection Molded

•“Assembly Fixture” for production of cooktop UI –Used to mate “Diffuser Film” with “Printed Circuit Board” –All parts (other than fan, screws, magnets) were 3D-printed

SLS Injection

Molded

PolyJet


Introduction to 3D Printing Examples of 3D-printed parts

•“Test Fixture” for production of cooktop UI –All parts (other than electrical contacts) were 3D-printed

•“Air-Flow Straightener Nozzle” for sensor test stand –Needed to produce laminar (even) air flow across sensors Before 3D-printed Nozzle After

PolyJet

FDM w/ Dissolvable Supports


Introduction to 3D Printing Have You Used 3D-printing In Your Personal Life?

•Home Project: –“Door Stop” for sliding “Barn Doors” oThe doors would roll past ‘center’ and come-out of lower track oThis prevents the doors from passing ‘center’

•Car Project: –Cup Holder Inserts oCup holders in my new Subaru are too large for most cups/mugs Cups/mugs tend to rock back/forth during start/stop motion

oThis prevents ‘normal’ sized cups/mugs from tipping/spilling Designed specifically to hold: o Starbucks coffee cups o Soda cans o Juice bottles

All parts FDM-printed in ABS Performed by local library “3D Printer Lab”


Introduction to 3D Printing 3D Printing In General

•Part is formed layer-by-layer (many ‘slices’) –Model Creation software exports typically to “STL” format oSTL = Stereo Lithography Also referred to as: o "Standard Triangle Language“ o "Standard Tessellation Language"

–3D Printer software converts this into the “slices” (layers) needed to actually print the part

•Layer N material bonds to layer N-1 (previous layer)

Original Model STL File Sliced-Up Model


Introduction to 3D Printing Types of 3D Printing

•Heat Formed: –FDM: Fused Deposition Modeling Most common for ‘hobbyist’

oMelted material extruded (pumped-out of a nozzle) onto part Typically some sort of plastic as a thread on a spool

oBonds-to previously printed layer as it cools (turns hard)

–SLS: Selective Laser Sintering (Sintering = Melting, Fusing) oPowdered material sintered (melted) together by laser Typically some sort of powdered plastic (but can be metal)

oBonds-to previously printed layer as it cools (turns hard)

•UV-Cured: –STL: Stereo-Lithography oUV Laser “Draws” the layers of the part within a vat of liquid Typically a thick, gooey liquid polymer (will ‘cure’ as a plastic)

oBonds to previously printed layer as UV laser cures it (turns hard)

–PolyJet: oLiquid material extruded (pumped-out of a nozzle) onto part Typically a thick, gooey liquid polymer (will ‘cure’ as a plastic)

oBonds-to previously printed layer as UV light cures it (turns hard) UV light typically trails-behind the ‘print head’ (nozzle)


Introduction to 3D Printing Pros/Cons of 3D Printing Methods

•Heat Formed: –FDM: Fused Deposition Modeling Most common for ‘hobbyists’

oPros: Machines and materials are very inexpensive (hobbyists can afford)

The printed parts are easily machined (e.g. tapped holes) Many material types/colors are available (PC, ABS, etc.) Can buy printers that use ‘dissolvable’ support material

oCons: Inexpensive machines need to print ‘break-off supports’ on part o Can affect surface finish of part and/or limit geometries that can be printed

Printed parts can be brittle, especially if thin and long o Need to pre-plan your ‘build direction’ carefully

–SLS: Selective Laser Sintering (Sintering = Melting, Fusing) oPros: Printed parts are strong and uniform; can print metals The printed parts are easily machined (e.g. tapped holes) No need for ‘support material’

oCons: Machines and materials are very expensive The “dust” (fine powder) material is dangerous to inhale o Metal printers require rooms w/ sealed ventilation; operator wears respirator mask


Introduction to 3D Printing Pros/Cons of 3D Printing Methods

•UV-Cured: –STL: Stereo-Lithography oPros: Printed parts are strong and uniform The printed parts are easily machined (e.g. tapped holes) Materials capable of handling high temperatures are available Can print ‘clear’ parts (some machines can make ‘optically clear’)

oCons: Machines and materials are very expensive Handling the liquid material is messy Parts often requires UV Curing after removed from printer

–PolyJet: oPros: Many material colors are available, including o Translucent (nearly-clear) o Rubber-like (Some printers can mix the ‘rubber’ w/ ‘hard’ material to obtain any stiffness desired)

oCons: Machines and materials tend to be expensive Materials tend to be soft and parts warp at high temperatures The printed parts tend to be brittle (can crack when tapping holes)


Introduction to 3D Printing

END OF PRESENTATION

Introduction to 3D Printing and Related Careers

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