Smart Parts:

Additive Manufacturing for Integrated Electro-mechanical Devices

FDM Technology

Who is Stratasys?

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Inkjet Technology

Today’s Event

Host

Kim Killoran Stratasys, Inc.

Presenters

Jeff DeGrange Vice President of Direct Digital Manufacturing

Bill Macy Application Development Lead

Smart Parts/Smart Tools

Additive manufacturing (AM)

• Integrated electro-mechanical devices

• Printed structures & printed electronics

Will cover:

• Process

• Applications

• Advantages

• Considerations

• Future

Overview

Marrying two AM technologies

• Fused Deposition Modeling (FDM)

• Aerosol Jet

Fully printed hybrid structures

• Game changer

• Streamline production

Joint development project

• UAV wing

• Research & feasibility

• In-situ, single process

Industries & Applications

Aerospace

Automotive

Consumer electronics

Medical

• Devices

• Appliances

Advantages

Revolutionary

• Weight balanced

• Reduced part count

• Fewer failure modes

•AM benefits

• Complex structures with more functionality

• Less waste

• Fewer process steps

• Accelerate manufacturing

• Flexibility

• Cost reduction

Process

Fused Deposition Modeling (FDM)

• Thermoplastic materials

Process

Fused Deposition Modeling (FDM)

• Thermoplastic materials

Process

Fused Deposition Modeling (FDM)

• Thermoplastic materials

Process CAD File Completed Part Manufacture

Process

Aerosol Jet

• Atomized & collimated

• High-velocity stream

Process

Aerosol Jet

• Atomized & collimated

• High-velocity stream

Process

Aerosol Jet

• “Inks” that can be aerosolized

• Nano-particle suspensions

• Metal complexes

• Carbon nanotubes

• Organic conductors

• Dielectrics

• Adhesives

• Sensor materials

UAV Wing

FDM material

• ULTEM* 9085

• High HDT and Tg

• Mechanical strength

•Aerosol Jet materials

• Nano-particle silver ink (Cabot CSD-23)

• UV-curable dielectric (Sun Chemicals 97B)

Process

• Part

• Electronics Design

• FDM structure Build – FDM

• Sand

• Soda blast Surface Prep

• FDM-built fixtures Fixture

• Self-leveling compound, printed Surface Prep

• Conductive ink Print – Aero. Jet

• Oven processing Sinter Ink

• Global seal coat

• Localize printed coating Overcoat

Printed Electronics

Sensors/Devices

• Resistance temperature

detectors (RTD)

• Resistive heating elements

• Antennas

• Strain gauges

• Chemical sensors

•Electronic components

• Resistors

• Capacitors

• Inductors

• Surface mount connections

•Circuits

• Power

• Signal

• Ground planes

• RF strip lines

UAV Printed Electronics

Sensors/devices

• Antenna

• Strain gauge

•Circuits

• Power

• Signal

Results

Signal circuit

• LED: printed traces/connections

• 100 x 20 μm

•Power circuit

• 1,000 x 60 μm

• Powered 20 V, 0.5 amp motor

Details

< 30 minutes

CTE mismatch

cracks

Results

Antenna

• Large surface area with 0.40 mm gaps

• > 1 hour

• Transmitted real-time video feed

•Strain gauge

• 100 μm

• Fine conductive traces

• Could not bridge surface defects

Advantages

•New design strategies

• Electro-mechanical design at digital level

•Flexibility

• Design optimization

• Design change

•Cost reduction

• Smaller BOM; fewer processes

• Eliminate tooling and labor

Cycle time reduction

• Product development and manufacturing

Demonstrator

•13.5-inch wing

• FDM – 6 hours

• Aerosol Jet – 1 hour

•Functional

• Motors (propeller)

• LED signal lights

• Slot antenna

• Integrated contacts

R&D

•Considerations

• Surface finish

• Surface energy

• CTE mismatch

• High-temp structure (secondary sintering)

• Shift electronic design approach

Future work

• Design rules

• Interface requirements

• Performance expectations

• Supportability methods

Future

•Technology integration

• In-situ process

•Expand applications and industries

•Revolutionize products

• Biomimicry, organic shapes

• Bone | FDM

• Nervous system | Aerosol Jet

• “We have the technology. We can make him

better...stronger...faster”

More Information

www.stratasys.com/webinar_smartparts

• Download webinar slides

• View webinar on demand

Applications

• Optomec: Ken Vartanian - kvartanian@optomec.com

• Stratasys: DDM Group - ddm@stratasys.com

Questions?

More information:

www.stratasys.com/webinar_smartparts