The rise of 3D printing has been compared to the beginning of the industrial era in how deeply it might impact our society. TechSoup, EESTEC and TechforTrade host Dr. Phil Reeves for a 3D printing hack day.

1. Session 2
ALM materials, processes
and economics
www.3d4d-challenge.org
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2. OBJECTIVES SESSION 2
1. To gain an appreciation of the different materials
that can be used by ALM processes for different
applications
2. To gain an understanding of different Additive Layer
Manufacturing technologies
3. To gain an understanding of the direct and indirect
costs of Additive Manufacturing
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3. The business cycle
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4. STEP 2 MATERIAL SELECTION
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5. STEP 2 MATERIAL ISSUES FOR CONSIDERATION
• What do I want my ALM part to DO!
– Mechanical strength (or not), density
– Thermal stability
– Thermal or electrical conductive (or
insulative)
– Corrosion resistant
– Water or moisture resistant or repellent
– Life cycle (how long is the application)
– Visual impact (colour / texture / tactility)
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6. MATERIALS ALM MATERIAL CHOICE
Organic materials Ceramic Polymeric Metallic
materials materials materials
Waxes Alumina ABS Aluminium
Cellular material Mullite Polyamide (nylon) Tool Steel
Zirconia PEEK Titanium
Silicon Carbide Composite loaded PA Inconel
Beta-Tri calcium Phosphate Thermosetting epoxies Cobalt Chrome
Ceramic (nano) loaded epoxies Copper
Silica (sand) PMMA Stainless steel
Plaster Polycarbonate Gold / platinum
Graphite Polyphenylsulfone Bronze
Aluminium loaded polyamide
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7. IMPLEMENTATION STEP 3 - RM PROCESS SELECTION
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8. STEP 3 CERAMIC PROCESSES
DIRECT
Adhesion of ceramic powder – Z-Corporation
INDIRECT
Ceramic loaded photopolymer – Ceram pilot, LAMP
Laser sintering of ceramic/polymer matrix - 3D systems
Cutting from sheet – CAMLEM
Extruded from paste – Freeze cast
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9. STEP 3 CERAMIC PROCESSES
DIRECT
Adhesion of ceramic powder – Z-Corporation
INDIRECT
Ceramic loaded photopolymer – Ceram pilot, LAMP
Laser sintering of ceramic/polymer matrix - 3D systems
Cutting from sheet – CAMLEM
Extruded from paste – Freeze cast
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10. STEP 3 Z-CORPORATION 3D PRINTING
• 3D Printing of a binder
into a bed of ceramic
powder
• Similar system used by
Therics for biocompatible
medical
• Similar process used by
ProMetal RTC for sand
casting cores
• Similar process used by
Monolite for architectural
parts
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11. (1) Images courtesy of Fabjectory www.fabjectory.com
(2) Images courtesy of www.figureprint.com
CERAMICS GIFTWARE AND TOYS
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12. STEP 3 POLYMERIC PROCESSES PROCESSES
POWDER
Selective laser sintering- EOS, 3D Systems
IR sintering – Sintermask, Lboro HSS, Desktop Factory
LIQUID
Laser curing of monomer – 3D Systems Stereolithography
DMD light during of monomer – Envisiontec Perfactory
Jetting of Photocurable monomer – Objet
Extrusion of a semi molten polymer – Stratasys FDM
SHEET
Chemical adhesion of sheet- 3D systems Invision-LD
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13. STEP 3 POLYMERIC PROCESSES PROCESSES
POWDER
Selective laser sintering- EOS, 3D Systems
IR sintering – Sintermask, Lboro HSS, Desktop Factory
LIQUID
Laser curing of monomer – 3D Systems Stereolithography
DMD light during of monomer – Envisiontec Perfactory
Jetting of Photocurable monomer – Objet
Extrusion of a semi molten polymer – Stratasys FDM
SHEET
Chemical adhesion of sheet- 3D systems Invision-LD
www.3d4d-challenge.org
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14. PROCESSES 3D SYSTEMS – SELECTIVE LASER SINTERING
• Powder material which
is selectively bonded
through localised
melting induced by
laser energy
• Multiple systems of
varying sizes and
configurations
• 20 year old technology
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15. Images courtesy of CRP Technologies www.crptechnology.com
RM APPLICATIONS 3D SYSTEMS – SLS with WINDFORM XT POWDER
250cc world championship motorcycle
Body components
Motorcycle seat
Mudguard & air intake
Mudguard
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16. CASE STUDIES Production parts - aerospace
Flame Retardant Material for FAA Requirements
Moving assemblies
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17. EXAMPLE Production parts – military aerospace
F18 – internal
ducting - 130 parts
to replace 1,250
Moving assemblies
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18. STEP 3 POLYMERIC PROCESSES PROCESSES
POWDER
Selective laser sintering- EOS, 3D Systems
IR sintering – Sintermask, Lboro HSS, Desktop Factory
LIQUID
Laser curing of monomer – 3D Systems Stereolithography
DMD light during of monomer – Envisiontec Perfactory
Jetting of Photocurable monomer – Objet
Extrusion of a semi molten polymer – Stratasys FDM
SHEET
Chemical adhesion of sheet- 3D systems Invision-LD
www.3d4d-challenge.org
www.econolyst.co.uk

19. PROCESSES 3D SYSTEMS - STEREOLITHOGRAPHY
• Photocurable liquid
monomer which cures
through exposure to a
UV Laser source
• Multiple systems of
varying sizes and
configurations
• 20 year old technology
www.3d4d-challenge.org
www.econolyst.co.uk

20. Images and video courtesy of Align www.invisalign.com
RM APPLICATIONS 3D SYSTESM STEREOLITHOGRAPHY
• Bespoke dental aligners
• SLA form tools
• Vacuum formed aligner
• 25+ SLA 7000’s
• Shallow vats
• Special formulation resin
• Millions of parts per annum
• $206-million T/O in 3-years
www.3d4d-challenge.org
www.econolyst.co.uk

21. STEP 3 POLYMERIC PROCESSES PROCESSES
POWDER
Selective laser sintering- EOS, 3D Systems
IR sintering – Sintermask, Lboro HSS, Desktop Factory
LIQUID
Laser curing of monomer – 3D Systems Stereolithography
DMD light during of monomer – Envisiontec Perfactory
Jetting of Photocurable monomer – Objet
Extrusion of a semi molten polymer – Stratasys FDM
SHEET
Chemical adhesion of sheet- 3D systems Invision-LD
www.3d4d-challenge.org
www.econolyst.co.uk

22. PROCESSES OBJET - POLYJET
• Photocurable liquid
monomer which is jetted
via a print head and cured
through exposure to a UV
light source
• Secondary water soluble
support material is also
jetted
• New System capable of
jetting multiple materials
and ‘mixing them’ to
produce variable Shore
Hardness
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23. • There are two kinds of Multi-material RP part
1. A part with two or more ‘different’ mechanical
properties (currently Durometer)
2. A part where two different materials are combined
to create a new ‘third material’
1. 2.
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24. • Multiple material RP is Unique to Objet
• Multiple material printing can only be achieved
using the Polyjet Matrix technology on the
Connex Family of printers
= +
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25. Images courtesy of Minerva Laboratories www.minervalabs.co.uk
RM APPLICATIONS OBJET – POLYJET
• Bespoke hearing aids
• Customised to patient
• Printed on mass
• 3 different colours
Business model adopted by
most other major in-ear
hearing aid manufacturers
Clear Rose Skin Tone
www.3d4d-challenge.org
www.econolyst.co.uk

26. STEP 5 POLYMERIC PROCESSES PROCESSES
POWDER
Selective laser sintering- EOS, 3D Systems
IR sintering – Sintermask, Lboro HSS, Desktop Factory
LIQUID
Laser curing of monomer – 3D Systems Stereolithography
DMD light during of monomer – Envisiontec Perfactory
Jetting of Photocurable monomer – Objet
Extrusion of a semi molten polymer – Stratasys FDM
SHEET
Chemical adhesion of sheet- 3D systems Invision-LD
www.3d4d-challenge.org
www.econolyst.co.uk

27. PROCESSES STRATASYS – FUSED DESPOSITION MODELLING (FDM)
• Thermoplastic is
extruded from a nozzle
and deposited onto a
build platform
• Multiple systems of
varying sizes and
configurations
• Range of REAL engineering thermoplastics
www.3d4d-challenge.org
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28. RM APPLICATIONS STRATASYS – FDM
Structural components Press tool
Electronics housing Robot gripper
This is just the same technology as MakerBot – but industrial
www.3d4d-challenge.org
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29. STEP 5 METALLIC PROCESSES
DIRECT (bed)
Cut from sheet material - Solidica ultrasonic compaction
Consolidation of powder with laser – Concept Laser, Phenix, MTT, EOS
Consolidation of powder with electron beam - Arcam EBM
DIRECT (feed)
Jetting of powder into laser beam – Optomec, Trumpf, Accufusion
INDIRECT
Consolidation of powder with laser - 3D systems Laser form
Jetting of binder into powder bed – ProMetal, F-Cubic
www.3d4d-challenge.org
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30. STEP 4 METALLIC PROCESSES
DIRECT (bed)
Cut from sheet material - Solidica ultrasonic compaction
Consolidation of powder with laser – MTT, Concept Laser, Phenix, EOS
Consolidation of powder with electron beam - Arcam EBM
DIRECT (feed)
Jetting of powder into laser beam – Optomec, Trumpf, Laser Consolidation
INDIRECT
Consolidation of powder with laser - 3D systems Laser form
Jetting of binder into powder bed – ProMetal, F-Cubic
www.3d4d-challenge.org
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31. METALLIC MTT – SELECTIVE LASER MELTING (SLM) Realizer
• Powder bed consolidated
by a laser
• Old systems - Inert
atmosphere and air ‘knife’
designed for reactive
materials such as titanium
• New systems – Vacuum
chamber build area
• Also sold outside EU by
3D Systems as
Sinterstation Pro SLM
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32. PARTS MTT – SELECTIVE LASER MELTING (SLM) Realizer
Titanium Al6V4 Stainless Steel
Cobalt Chrome Aluminium
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33. STEP 3 METALLIC PROCESSES
DIRECT (bed)
Cut from sheet material - Solidica ultrasonic compaction
Consolidation of powder with laser – MTT, EOS, Concept Laser, Phenix
Consolidation of powder with electron beam - Arcam EBM
DIRECT (feed)
Jetting of powder into laser beam – Trumpf, Optomec, Laser Consolidation
INDIRECT
Consolidation of powder with laser - 3D systems Laser form
Jetting of binder into powder bed – ProMetal, F-Cubic
www.3d4d-challenge.org
www.econolyst.co.uk

34. METALLIC TRUMPF – DIRECT METAL DEPOSITION (DMD)
• Powder blown into the beam of a
moving laser
• Good for depositing material onto
a substrate
• Excellent microstructure
• Limited geometric freedom
• Large foot-print, but slow
• Multiple materials and
combinations
• Limited accuracy and resolution
(Near NETT shaped)
www.3d4d-challenge.org
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35. Images courtesy of Trumpf www.trumpf.com
PARTS TRUMPF – DIRECT METAL DEPOSITION (DMD)
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36. STEP - 4 STEP 4 – PROCESS CAPABILITIES & CONSTRAINTS
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37. STEP - 4 STEP 4 – PROCESS CAPABILITIES & CONSTRAINTS
Does the component geometry fit on the machine (X,Y,Z)
Laser Cusing
Does the technology have the accuracy to manufacture
the geometry you desire
Does the layer deposition configuration allow for the
Arcam EBM manufacture of the geometry you desire (powder bed vs.
powder feed)
Innoshape DMD Does the technology build in layers thin enough to
provide an acceptable part resolution
Does the layer thickness provide an acceptable surface
Trumpf DMD
finish and tactility
EOS DMLS
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38. STEP - 4 STEP 4 – PROCESS CAPABILITIES & CONSTRAINTS
What geometric variation do I get between builds on this
technology
EnvisionTEC
Does part position on the machine bed effect geometric
tolerances
Stratasys FDM
Does part position or orientation effect mechanical
properties
Objet Polyjet
Will system variables such as chamber temperature,
laser power or calibration of optics effect my final part
Will the material-process interface effect the final part,
Invision LD
such as the age of the material or the amount of recycled
material in the system
3D Systems SLS
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39. STEP - 5 STEP 5 PROCESS COST
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40. STEP - 5 UNDERSTANDING COST (comparison between suppliers)
Machine
depreciation is
a function of
build time
Cost
Build time is a
function of part Machine
geometry & depreciation
material
($) Variable
Operational
Material usage Overheads Fixed
is a function of
Labour
geometry
Material
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41. STEP - 5 COST vs. QUALITY
• Part orientation
– Orientation to save on cost could create
stair-stepping
– Orientation could increase errors in the
Z-axis
• Chosen Layer thickness and number
of layers
– Thinner layers will give a better surface
and resolution
– More layers will increase cost
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www.econolyst.co.uk

42. STEP - 5 UNDERSTANDING OPERATIONAL OVERHEAD COSTS
Cost
Operational Machine
overheads are a ($) depreciation
function of the Variable
processes Operational
Overheads Fixed
Labour
Material
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43. STEP - 5 UNDERSTANDING OPERATIONAL OVERHEAD COSTS
• Does the process require a shielding gas
• Does the process require special
filtration
• Does the process require a sacrificial
plate to build the parts onto
• Do the parts require machining to
remove them from the build plate
• Does the process need to operate in a
controlled or conditioned environment
• Does the process need water cooling or
compressed air
• Will parts require post process machining
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44. STEP - 5 UNDERSTANDING MATERIAL COSTS
Cost
Machine
depreciation
($) Variable
Operational
Material usage Overheads Fixed
is a function of
Labour
geometry
Material
www.3d4d-challenge.org
www.econolyst.co.uk

45. STEP - 5 UNDERSTANDING MATERIAL COSTS
• How much material is required to
consolidate the geometry (cost per kg)
• How much material will be required to
generate the support structures
(orientation dependent)
• How much material will be lost during
the build cycle and clean-up (trapped
voids, re-entrant features)
• Can all un-processed material be
recycled (Polymers 50% metallics
97%)
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46. STEP 6 COST BENEFIT ANALYSIS
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47. STEP 6 COST BENEFIT ANALYSIS
• Supply chain savings
• First to market advantage
• Lead time compression
• Environmental / sustainability benefits
• Logistical costs
• Transaction costs
• Life cycle costs
• End of life
• Skills
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48. CASE STUDY LIFE CYCLE COSTS
• Supply chain savings
• First to market advantage
• Lead time compression
• Environmental savings
• Logistical costs
• Transaction costs
• Life cycle costs
• Skills
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49. All image courtesy of 3D Systems and The Boeing Company www.3dsystems.com www.boeing.com
CASE STUDY LIFE CYCLE COSTS
(A) Conventional Duct fabricated from
Vac Formed plastic
Part Count = 16 (plus glue)
(B) Component modified and
consolidated for fabrication via
Additive Rapid Direct Manufacture
Part Count = 1
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50. All image courtesy of 3D Systems and The Boeing Company www.3dsystems.com www.boeing.com
CASE STUDY LIFE CYCLE COSTS
äService Checks reduced from 7 to 1
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51. SUMMARY SUMMARY
1. The ‘REAL’ business benefits of using AM are in its
application as an ‘ENABLING’ technology, rather
than as a ‘DISRUPTIVE’ technology.
2. aM is suited to new business models and new ways
of working (distributes manufacture, home
manufacture, co-creation, remanufacturing)
3. There are a vast array of ALM processes with many
applications
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52. OBJECTIVES SESSION 2
1. You should now have an appreciation of the
different materials that can be used by ALM
processes for RM applications
2. You should now have an understanding of different
Additive Layer Manufacturing technologies
3. You should now have an understanding of the
direct and indirect costs of Additive Manufacturing
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www.econolyst.co.uk

53. THE 3D FOR DEVELOPMENT CHALLENGE
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54. QUESTIONS SESSION 2
Any Questions
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