The Future of Materials, Design and Technology for Additive Manufacturing: Meeting the Challenges at the State University of New York and Opportunities

for Collaboration

Gary Halada

Department of Materials Science and Engineering

Stony Brook University, New York

gary.halada@stonybrook.edu

The SUNY Network of Excellence in Materials and Advanced Manufacturing:

Digital and Additive Manufacturing

This initiative takes advantage of SUNY’s and SUNY partners’ technical expertise and extensive infrastructure, including:

• The Center for Digital Additive Manufacturing (DAM) at the University at Buffalo ‐SUNY

• Binghamton’s Laboratory for Advanced Manufacturing Processes and Sensing (LAMPS)

• The Hudson Valley Advanced Manufacturing Center at SUNY– New Paltz • Stony Brook’s Materials Research Centers in polymers and thermal spray

technology • Brookhaven National Laboratory’s National Synchrotron Light Source II and the

Center for Functional Nanomaterials • The Long Island Forum for Technology’s Composites Prototyping Center • Buffalo Manufacturing Works – EWI • Additive manufacturing resources, expertise and facilities across the State

University of New York

(courtesy of Santokh Badesha, Xerox)

6 Thanks to Hod Lipson, Cornell

Primary additive manufacturing technologies

• Extrusion – primarily for thermoplastic polymers, clays and soft materials which can be processed (i.e. baked) post-deposition, some composites

• Binder jet printing

– With or without subsequent polymerization

• Photopolymerization

• Aerosol jet direct writing

• Directed energy methods – high quality prints for metals and some ceramics

– Powder bed fusion or melting

– Direct metal laser sintering (DMLS); selective laser melting (SLM)

– Laser engineered net shaping (LENS)

– Electron beam methods

• Other methods (sheet lamination, for example)

• Hybrid methods (e.g. a LENS head added to a CNC machine)

All have advantages/disadvantages based on materials which can be used and their cost; speed; resolution; extent of post-deposition processing or need for removal of support structures; durability of prints; robustness of equipment; level of training required

New Horizons in Digital and Additive Manufacturing March 16-17, 2015 Marriott Hotel, University at Buffalo -- SUNY

SBU FSC

BU

UB

NP

Primary campuses involved in additive manufacturing research, education and applications

SUNY Expertise and NYS needs • Key expertise

– Process modeling (UB, BU) – Design optimization for AM (UB, SBU) – Embedded systems (BU) – Embedded sensors (UB, BU) – Biomaterials (BU, SBU) – Nanocomposites (SUNY Polytech, SBU) – ‘Green’ polymers and composites (SUNY ESF, SBU) – Polymers (SBU, SUNY ESF) – Mechanical properties/manufacturing (SBU, Farmingdale, New Paltz) – Metals and metallurgy (SBU, FSC)

• Industrial needs – Better understanding of how AM can enable new products, improve processes,

save money, time and energy, etc. – Integration into current industrial commercial production systems – Qualification – requires testing and optimization of material properties for

manufacturability, functionality, robustness, performance – Workforce development – training – Needs of artisanal users versus needs of industry

How do we “bridge the gap”?

Characterization: SUNY Polytech, UB, BU, SBU, BNL Education and training: All

Industrial collaboration Commercialization of technology Development of training programs Dissemination of information Teaming for federal grants

Highlighted research, expertise and capabilities at SUNY campuses

Stony Brook University: Materials and Additive Manufacturing

• Research programs in Departments of Materials Science and Engineering and Mechanical Engineering

• Additive Manufacturing Materials Design Institute: Surface and interface analysis, Polymeric and composite

materials for FDM, Development of nanostructured powders for metal printing via laser sintering

• Center for Thermal Spray Research (MRSEC)

• Garcia Center for Polymers at Engineered Interfaces (MRSEC)

• CMADO: Mechanical testing and modeling for soft robotics, 3D printing

• Thermal-Laser Laboratory, Department of Mechanical Engineering

• Industrial outreach

• Sinterstation, FDM systems, Stratasis Objet260

• Materials testing and characterization

• Mechanical testing

• Composites Prototyping Laboratory (LIFT)

• Interdisciplinary Education and STEM outreach

• Multidisciplinary “Innovation Laboratory”

• Advanced Manufacturing Laboratory (Mech Eng program)

• Additive Manufacturing Materials Teaching Laboratory (Engineering Science, MSE major programs,

Manufacturing Engineering and Nanotechnology minors)

• Close interaction and continuous collaboration with Brookhaven National Laboratory

• National Synchrotron Light Source II

• Center for Functional Nanomaterials

Advanced Manufacturing Laboratory

Innovation Laboratory

SBU Education and training facilities

Additive Manufacturing Materials Teaching Laboratory (Dept. of Materials Science and Engineering)

Makerbot Replicator and Replicator 2X -- with 1.75 and 3 mm extruders (teaming with local company producing 3 mm filaments) Two Hyrel system 30 printers -- plasticene, PLA, ABS, Nylon Charpy impact tester, Instron tensile testing, corrosion testing NDE equipment: -- Rebound hardness tester -- Ultrasonic flaw detection -- Eddy current system -- Optical microscopy Available testing in other labs includes FTIR, Raman spectroscopy, X-ray photoelectron spectroscopy, SEM/EDAX

SBU laboratories developing and testing new composite materials, nanocomposites, and composite coatings

The Center for Thermal Spray Research (CTSR) at Stony Brook University was established in 1996 through the NSF Materials Research Science and Engineering Centers program. Thermal spray technology continues to grow and services a broad industrial community; coatings are ubiquitous in gas turbine engines (propulsion and energy), automotive, pulp/paper and infrastructure maintenance. Emerging applications include coatings for orthopedic and dental implants, solid oxide fuel cells, and functional sensors for harsh environments.

The Garcia Center for Polymers at Engineered Interfaces (M. Rafailovich, J. Sokolov, D. Gersappe) is a collaboration of academic, industrial, and government laboratories. The goal of the MRSEC is to combine the instrumentation and expertise of the participating institutions into a coordinated research program on polymers interface science. The principal focus areas include thin films, coatings, nanostructured materials, and composites.

Properties of polymer blends

Self-extinguishing nanocomposites

Research on materials for additive manufacturing and prototyping, taking advantage of key strengths -- Processing-properties-performance testing for printed metallic components (collaboration with Youngstown State University), and polymeric components (collaboration with SUNY New Paltz and the University at Buffalo) -- Printing of piezoresistive composites (collaboration with University at Buffalo and Buffalo Manufacturing Works) -- Nanocomposite development for materials extrusion printing -- Optimizing material and post processing methods for biomedical applications (tissue scaffolding, anti-microbial, dental, etc.) -- Studies of energy and cost efficiency for additive manufacturing -- Collaborate with NoE MAM focus areas in biomaterials, flexible electronics, green composites, etc.

Additive Manufacturing Materials Design Institute -- G. Halada, J. Trelewicz, M. Rafailovich

Collaboration with UB (R. Rai) on 3D printed conformal sensors

High energy ball milling and laser sintering of nanocrystalline powders for additive manufacturing (Trelewicz, Halada)

AMMDI Current research projects

• Development of feedstock (PLA, ABS, PC + inorganic, organic components) to enhance utility and generate new applications.

• Enhancing the growth of stem cells on FDM deposited PLA biocompatible substrates

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Bi ndi ng E nergy (eV)

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C1s photoelectron spectra from as printed PLA and following acetone treatment

Changes in carbonyl region representing potential sorption sites for nanoparticle synthesis

Surface and interface analysis of materials for additive manufacturing (Halada, BNL)

Design of printable materials for biomedical applications (Rafailovich, Halada)

Printable Catalytic Metallic Nanoparticles (patent pending – Halada, commercial partner)

Design of printable metal-organic materials and structures to support oxygen reduction reaction (ORR)

50 µm

3D Printed (Selective Laser Sintered) 316 Stainless Steel -- G. Halada, J. Trelewicz (Stony Brook University); G. Manogharan (Youngstown State University)

Optical micrograph (above) showing sintered powder (30 micron); SEM of etched surface (left) shows potentially metastable microcrystalline structure

Potentiodynamic scans in 0.1 M HCl (cold rolled standard 316 above, sintered below)

• Studies of SLS printed 316 stainless steel rods indicates reduced corrosion resistance and microcrystalline structure • New tests have begun to show submicron structure, as well as possible elemental enrichment at grain boundaries;

nanoindentation tests being used to study effect of structure on mechanical properties • Current studies underway to identify impact of laser printing speed and other factors

Studies indicate critical need to apply nanocharacterization tools for imaging and chemical analysis to optimize the processing-structure-properties-performance relationship for AM

The Additive Manufacturing Prototyping and

Applications Center (AMPAC) Proposed (New York State Economic Development)

• A distributed center which leverages leading expertise and state-of-the-art analytical and manufacturing equipment at Stony Brook University and at the Composites Prototyping Center (LIFT), including: – Makerbot Innovation Center, focused on biomedical applications,

education and training – A multi-material printer which can incorporate fiberglass and Kevlar

fibers into nylon structures for prototyping and manufacturing of strong, flexible structures

– A design laboratory, supported by current expertise in the Department of Mechanical Engineering, focusing on exploring novel structures and multi-material systems

– Collaboration with new binder jet printing facility in SBU Dental School, with the New York State Center for Advanced Technology in Sensor Systems and Diagnostic Tools at SBU and their programs in flexible, integrated electronics and prototyping, and with the Advanced Energy Center (to support future industrial outreach and interactions.

Collaborations to Support Center Development

Research collaborations

Partner in AMPAC, collaborations in education, outreach

Developing university-industry partnerships in additive manufacturing

Partner in university collaborative research; outreach to industry

AM labs, polymer, metal printers, sensor and control R&D

Nanomaterials

‘Green’ materials

Innovation lab, Hudson Valley Advanced Manufact. Cntr.

Institute for Research and Technology Transfer

Community Colleges Training and outreach

Departmental research programs: • Materials

(multimaterial, functionalization, surface and interface)

• Mechanical (design optimization, testing)

• Biomedical • Chemistry

CAT (flexible electronics) Innovation Lab (education and design) Medical (dental, bioprinting) AMPAC Rapid prototyping (industry outreach) Advanced Energy Center

Department of Mechanical Engineering: Computational Modeling Analysis and Design Optimization (CMADO Lab): Develop functionally graded cellular architectures tailored for energy absorption and impact mitigation Material is designed to exhibit constant plateau stress, large densification strain, smooth transition from elastic to plastic regions, controllable failure modes, and minimal spring back effect.

2D

3D

Examples of printed specimens Investigate the Large strain behavior, localization, instabilities, shear bands

Computational and experimental tools are used to investigate the large strain behavior

* 2 * 2 *

1111 1111 2222 2222 1122 11220.5*(C C ) 0.5*(C C ) 5*(C C )H H HJ

Integrated Computational Design & Additive Manufacturing of High-performance Metastructures

Example 1: Single-Material Metastructure

Integrated Computational Design & Additive Manufacturing of High-performance Metastructures

Example 2: Multimaterial Metastructure

Poisson’s Ratio = -0.5

Hard material:

E = 1, VR = 45%

Soft material:

E=0.2, VR=15%

Brookhaven National Laboratory: Close collaborations and research partnerships with Stony Brook University

Best-in-class brightness & flux from far infrared to hard x-rays

•Storage Ring (~ ½ mile in circumference)

•Began in 2014/2015

National Synchrotron Light Source II

Highly optimized x-ray synchrotron delivering: • extremely high brightness and flux • exceptional beam stability • advanced instruments, optics, and detectors

Providing best-in-class capabilities for: • imaging systems with nanoscale resolution • determining chemical reactivity in-situ in real time

Enabling studies of: • interfaces and nanostructures • electronic excitations and chemical reactivity • in-situ chemical, magnetic, and biological imaging • materials synthesis, catalytic reactions,

superconductors, and magnets at extremes of temperature, pressure, and magnetic field

Resulting in scientific advances in: • clean, renewable, and affordable energy • molecular electronics • high temperature superconductors • structure-based drug design

NSLS-II: A Powerful New Photon Microscope

New Science

Nanoscience

Life Science

Nanocatalysis

New Capabilities

Nanoprobes

Diffraction Imaging

Coherent Dynamics

NSLS-II Experimental Tools Beamlines

Sub-meV nano-ARPES LEEM/PEEM

Sr2CuO3

Electron Spectro-Microscopy (ESM)

Soft Matter Interfaces (SMI)

Soft Inelastic X-ray Scattering (SIX) Inner Shell Spectroscopy (ISS)

In-Situ & Resonant X-Ray Studies (ISR)

Full-field X-ray Imaging (FXI)

Advancing photoemission to characterize electronic structure of functional materials w/ high spatial resolution

semiconductor failures CaCO3 drilling

High speed TXM w/ 30 nm resolution

Real-time 3D imaging of natural and man-made

materials in working environments

Time resolved XAS with high E-resolution and at ultra-dilute concentrations

In-situ, time-resolved, element specific studies of nanocatalysts, mettalloenzymes, environmental contaminants, batteries, and fuel

cells

Integrated materials physics studies

Powerful capabilities for in-situ, real-time growth, atomic structure of

surface and interfaces, magnetic/orbital scattering, domain

imaging, high magnetic fields

Elementary excitations (magnons, phonons and orbitons) in nanoscale

samples (100 nm)3 w/ applications to superconductivity, nanocatalysts, energy

storage materials

World-leading soft x-ray energy resolution

Understanding self-assembly of nanomaterials in order to create new hierarchical materials with

tailored functionality

In-situ real-time studies of solid/liquid/vapor interfaces

of complex materials

The Center for Functional Nanomaterials (CFN) explores the unique properties of materials and processes at the nanoscale. The CFN is a user-oriented research center whose mission is to be an open facility for the nanoscience research community and advance the science of nanomaterials that address the nation's energy challenges.

•Thin film nanofabrication and processing capabilities within a 5,000 sq. ft. Class 100/1000 cleanroom facility •Synthesis of organic and inorganic nanomaterials with specified functionality •Time resolved absorption and emission spectroscopy •Atomic resolution imaging with scanning transmission (STEM), transmission (TEM), and scanning tunneling (STM) electron microscopy •Theory and diverse software packages for quantum chemistry and materials property calculations.

Energy -- Materials (nano) -- Surface reactivity

Environment --Remediation --Resources

Medicine and health -- Devices, implants -- Theraputics, drugs

Education

Advanced manufacturing

-- Electronics -- Free form

XPS, Auger, SIMS FTIR, Raman SEM, TEM, STM, SPM, AFM

DFT, MD

RBS, EDS, XRF synchrotron X-ray techniques

Value of complementary spectroscopic/imaging/modeling techniques to understand materials processing/structure/properties/performance:

microscopy

Surface sensitive (~10 nm)

Chemistry in near-surface and bulk

Images/text courtesy of Dan Freedman

Public/Private Capital Funding/Partnerships •$250,000 from Ulster County businessman Sean Eldridge of Hudson River Ventures. (May, 2013) •$250,000 matching grant from Central Hudson. •$1M in NYS funding through the Consolidated Funding Application (Fall, 2013) •$850,000 from NYS for 3D Printing Lab (Fall, 2014) •$10 million from SUNY2020 for Engineering Hub (Fall, 2014) •Collaborations with MakerBot/Stratasys and 3D Systems

Mission: be an educational and technological leader in 3D design and printing in the Hudson Valley. The Center works with businesses and individuals to supply 3D printing and design services Educate business about the different 3D printing technologies and how they can be used. Help support the growth of new businesses using the technology available through the Center and STARTUP NY Started 2014, 8 interns and over 50 clients to date

HVAMC Equipment Goal: cover as many 3D printing applications as possible - Print in multiple different polymers (FDM, polyjet) - Print in full color (powder/inkjet or polyjet) - Print in very high resolution and good surface finish (SLS, SLA or polyjet) - Print in metal (powder/inkjet or SLS)

Stratasys Dimension 1200ES 3D Systems Projet 660 Stratasys Fortus 400mc 25 MakerBot Replicator 2 5 MakerBot Replicator 2X MakerBot Z18

Stratasys FDM Printers – ABS/PC, Polycarbonate, ABSi (translucent), Nylon 12, ULTEM and other materials - Uses a soluble support system - Very easy to use and makes very robust parts. - Good resolution and precision 3DS Projet 660 – Full color printer that uses a gypsum-like material - Better resolution that FDM, but parts aren’t as functional MakerBots – Useful for multimaterial and mini “production runs” - Filament cost is 1/5 of Stratasys machines

SUNY New Paltz Engineering Innovation Hub : Supported by $10 million SUNY2020 Challenge Grant New Mechanical Engineering program (as of 2014)

Institute for Research and Technology Transfer Conduct research and development of new technologies that can lead to the development of

commercial products that will contribute to the enhancement of job opportunities and the prosperity of the region

Transfer technology to bridge the gap between newly developed technologies in laboratories and industrial commercialization

Offer the industrial community outsourcing opportunities and access to systems at the cutting edge of technology to reduce manufacturing cycle time and assist in bringing products to the market faster than the competition

Provide specialized training, courses and workshops to sharpen the skills of our students with practical technical knowledge in CAD/CAM/CAE; CNC, Robotics, Quality Control and Quality Management

Provide academic and industrial communities with access to advanced technology and prominent faculties who are experts in their fields

Metal-based Systems EOS M290 Direct Metal Laser Sintering (DMLS) (One of total three in the country, and only research university) Capability to process Cobalt Chrome, Titanium, Aluminum, Aluminum Alloys, Stainless Steel, Maraging Steel, and Inconel Includes onboard camera. Full environmental protection and processing suite.

Nonmetal Systems (Professional Quality)

Stratasys Objet30 Pro Photopolymer Jetting Photopolymer (Plastics)

3D Systems Binder Jetting

(3DP) For Nylon

Stratasys UPrint SE+ Fused Deposition Modeling For ABS Plastic

Roland ARM-10 Stereolithography (DLP) For Photopolymers

Optomec Aerosol Jet Nano inks and conformal electronics

Certify-as-you Build Quality Assurance in Additive Manufacturing.

Prahalad K. Rao, PhD. Assistant Professor Systems Science and Industrial Engineering (SSIE), Binghamton University, The State University of New York.

Analytical and Diagnostics Laboratory

The Analytical and Diagnostics Laboratory (ADL) is equipped with full array of state of the art instruments for various characterization and analytical tasks of R&D and industrial application. Some of them are listed below: Microscopy and analysis: Optical microscopes, scanning microscope (SEM),

transmission electron microscope (TEM), and dual beam focus ion beam (FIB). Surface analytical instruments: X-ray photo emission spectroscopy (XPS) with

small spot analysis capability and ultra violet photo electron spectroscopy (UPS) with depth profiling capability.

Crystal structure and small particle characterization: X-ray diffraction, small angle X-ray scattering (SAXS), laser particle size analyzer, powder surface area measurement tool.

Thermal analysis and mechanical testing: DSC, TGA-MS, TMA, and DMA. Non-destructive testing: Scanning acoustic microscope (SAM), High resolution X-

ray imaging system, and infrared microscope. Thin film deposition tool: Laser deposition for metals, insulations and

semiconductors. Machine shop. Fees to outside users range from around 50 to 350 dollars per hour

Center for Digital Additive Manufacturing (DAM)

Goals/Challenges for Additive Manufacturing? Increasing manufacturing speed, reducing post-processing and improving surface quality,

develop low cost material , multi-material additive manufacturing, self sensing/control component manufacturing, computational analysis/design of components.

What is Additive Manufacturing? Additive manufacturing creates components directly from a computer model, adding material only where needed, which means unlimited design flexibility, decreased energy consumption, reduced

waste, and reduced time to market.

WNY Industry

The University at Buffalo, through the resources of DAM, along with the expertise of UB faculty in the School of

Engineering and Applied Sciences (SEAS), is in a unique position to help small to medium size businesses in

WNY in the area of additive manufacturing. DAM will help small to medium size businesses in WNY to

incorporate advanced additive manufacturing and design modeling/simulation techniques directly in their

workflows. In doing so, this new capability will help them: (1) improve their product line, (2) decrease the time to

market for new product development, (3) improve their productivity, and (4) increase their overall

competitiveness.

Innovative Additive Manufacturing

Technologies and Computational

Methods for Next Generation Products

STEM and Higher Education

DAM center will be introducing the next generation of engineers to the next generation of manufacturing by

working with student teams from regional high schools to create prototypes, components, and working systems

to support entries in competitions like FI RST Robotics. In addition, DAM will educate next generation

undergraduate and graduate students in the area of advanced additive manufacturing that will create the trained

workforce which can seamlessly transition to WNY industries. The faculty stakeholders of the DAM will

through their research create a vibrant center of activity in training the next generation of manufacturing

leaders.

Additive Manufacturing Research and Development

C-CAM will pursue novel research focused on advancing manufacturing by leveraging:

• Metal functional component 3D printing,

• Multi-scale modeling and simulation-based integrated design and manufacturing of 3D printed parts and

assemblies,

• Integrated sensing, testing, and control technologies for next generation 3D printed parts and machines.

• Design and Optimization of 3D printing technologies for next generation biomedical, aerospace and low

volume customized products.

Complimentary Resources at UB

The center will germinate expertise in Additive Manufacturing and leverage recent and longstanding UB investments in high-end computing and data

services, material sciences, material informatics, mechanics of materials and computational data sciences and engineering, CCR, Jacobs Institute, Material

Characterization Center

Center for Digital Additive Manufacturing (DAM)

Sample Digital Additive Manufacturing (DAM) Research Projects

Stereolithography 3D Printing of Human Organ on a Chip (Chi Zhou)

Conformal 3D Printed Sensors (Rahul Rai)

(a) (b)

(c)

(a) (b) (c)

(d)

Digital Additive Manufacturing (DAM) Facilities

Associated Faculty:

Rahul Rai, Mechanical and Aerospace Engineering

Chi Zhou, Industrial and Systems Engineering

Tarunraj Singh, Mechanical and Aerospace Engineering

Sonjoy Das, Mechanical and Aerospace Engineering

Olga Woodo, Mechanical and Aerospace Engineering

Gary Dargush, Mechanical and Aerospace Engineering

Dedicated space in Bonner Hall, UB

Feedback Control of the Additive Manufacturing Process (Tarunraj Singh)

• Robust Control

• Multi sensor data fusion

• Sensitivity Analysis

Controller

Industrial collaboration Commercialization of technology Development of training programs Dissemination of information Teaming for federal grants