N A V I G A T I N G T H E D I G I T A L T H R E A D
U n d e r s t a n d i n g A d d i t i v e M a n u f a c t u r i n g f o r I n d u s t r i a l A p p l i c a t i o n s
Presented by:
David K. Leigh
Senior Vice President of Engineering
Stratasys Direct Manufacturing
O V E R V I E W :
A . M . S E R V I C E S N E T W O R K
• Stratasys’ advanced manufacturing servicesbusiness unit is the largest provider of additive manufacturing
– 9 U.S. Manufacturing Facilities – 150,000 Ft2 Production Space – 12 Primary Technologies – 600+ Employees
– ITAR Registered
• ISO 9001
Valencia (2), Poway, Tucson, Phoenix, Austin, Eden Prairie, Belton & Troy
• AS 9100
Valencia, Austin, Eden Prairie, & Belton
• 275+ Industrial AM Systems
• 1,600 unique part numbers
• Over 35K end-use part details and assemblies manufactured in 2014
O V E R V I E W :
L E A R N I N G O B J E C T I V E S
•
Introductory assessment of processes capable of direct part
production
•
What applications each technology is best suited for
•
How to integrate additive capabilities into production
•
Managing design specifications and tolerance requirements for
Laser Sintering
•
Review of real-world applications using A.M. technologies
•
Capabilities & limitations of CAD systems
H I G H P E R F O R M A N C E
A D D I T I V E P R O C E S S E S F O R
D I R E C T P A R T P R O D U C T I O N
P R O D U C T I O N T E C H N O L O G I E S
Selective Laser Sintering
Direct Metal Laser Sintering
Fused Deposition Modeling
CNC Machining
Cast Urethanes
SLS
DMLS
FDM
CNC
CAST
R A N G E O F 3 D P R I N T I N G S Y S T E M S
Consumer-Grade Industrial Mfg. Systems
Novel Widgets To Concept Models Functional Prototypes To End-Use Hardware Few AM processes currently
vetted and approved for flight hardware production
S E L E C T I V E L A S E R S I N T E R I N G
Uses a CO2 laser to fuse thermoplastic powders layer-by-layer to produce
highly complex geometries from sliced CAD data
• Batching/Nesting
• Excellent mechanicals and durability
• Lightweight, thin-walled parts
• High strength-to-weight ratio
• Does not require build supports
• Nylon 11s and 12s
• Filled and unfilled materials
• Chemically resistant and flame retardant options available
M A T E R I A L S A N D P L A T F O R M S
• Materials: – FR Nylon 11 – Nylon 11 – FR Nylon 12 – Nylon 12– Carbon Fiber Filled Nylon 11 & 12
– Glass Filled Nylon 12
– Carbon Fiber & Glass Filled Nylon 11
– PEEK & PEKK
• .004” - .006” layers • Max. Build Envelope:
– 15”L x 13”W x 18”H (standard platform)
A E R O S P A C E A P P L I C A T I O N S
Additive Manufacturing is opening up design possibilities for ducting applications, including production of lightweight integrated structures that enable part consolidation.
D I R E C T M E T A L L A S E R S I N T E R I N G
• A layer-additive process thatproduces rugged metal prototype and production parts.
• Supports required due to high energy process
• Ideal for geometries that can’t be CNC machined, light-weight designs, and part consolidation
• Applications: small functional parts, complex geometries, end-use
M A T E R I A L S & P L A T F O R M S
• Materials: • Stainless Steel • Cobalt Chrome • Inconel 625,718 • Aluminum• Titanium (coming soon) • 20-micron to 40-micron layers • Optimal Build Size:
– Up to 4” x 4” x 4”
• Max. Build Envelope:
F I N I S H I N G & P O S T T R E A T M E N T S
Secondary operations can be applied to DMLS parts to meet your specifications.
• Options Include: – Micro Shot-Peened – Brushed – Hand Polished – CNC Machined – Tumbled
•
Post Treatments:
– Heat treating – Stress relief– Hot Isostatic Pressing
– Aging
Supports Removed –
standard Machine Finish
Al Oxide Blast Shot Peened
F U S E D D E P O S I T I O N M O D E L I N G
Thermoplastic filament is heated to a semi-liquid state and extruded across computer-controlled tool paths to build parts layer-upon-layer.
• Produces prototypes as well as end-use parts.
• Very strong and functional
• High strength-to-weight ratio
• Chemically resistant & flame-retardant options available
• Large build volume (36” x 24” x 36”)
M A T E R I A L S
• ABS
– Great durability with a wide variety of color choices
• ABS-ESD7
– The benefits of ABS with added static dissipative properties
• ABS-M30
– Stronger than standard ABS with a variety of color options
• ABSi
– Solid and semi-translucent colors with better impact strength than ABS
• ASA
– UV resistance for outdoor commercial and infrastructure end-use parts
M A T E R I A L S
• PC
– Excellent durability and tensile strength
• PC-ABS
– Blend with the highest impact resistance of any polycarbonate
• PC-ISO
– ISO 10993 certified, USP Class VI,
Classification 1 for medical applications
• FDM Nylon 12
– Excellent fatigue and chemical
resistance, one of the most popular plastics used in engineering
• PPSF
– Best heat and chemical resistance of any thermoplastic
• ULTEM 9085
– Certified to withstand flame, smoke, and toxicity (FST)
U L T E M 9 0 8 5
ULTEM 9085 is a flame
retardant high performance thermoplastic for DDM. It is ideal for the aerospace and transportation industries due to its high strength-to-weight ratio and its FST rating.
C A S T U R E T H A N E
Liquid silicone rubber is poured around a master pattern. The resulting mold is pulled from the pattern and cured, then subsequently used to cast urethane
parts.
• SLA or CNC master pattern
• EMI, RFI shielding
• Cast in color and texture
• Complex over-molding
• Short-run or low volume mfg
• Bridge production
• Composite casting options
– Fiberglass
– Graphite
F I N I S H I N G
Hand Finishing/Sanding Cosmetic Prime and Paint
EMI & RFI Shielding
Textures & Mold-Tech® Finishes Hardware (inserts, helicoils, etc.)
Assembly Vapor Polish
ECS Ducting for Bell Helicopter
Harvest Technologies produces complex parts for the Environmental Control System (ECS) of multiple Bell helicopters
DMLS Fuel Nozzle in GE LEAP Engine
GE is replacing their previous fuel nozzle (which required 20 small parts to be welded together) with a 3D printed cobalt chrome nozzle. They expect to implement this nozzle in 2015-16, and produce 25K nozzles annually.
Metal Plated SLS and Cast Urethane Parts for Emirates
Emirates utilized metal plated FR-106 SLS parts for the table lamps in their Super First Class cabin on the A380. They also chose cast urethane parts for the flower vases.
A S S E S S I N G W H E R E
A D D I T I V E M A N U F A C T U R I N G
M A K E S S E N S E
M F G T E C H N O L O G Y I N P R O D U C T
D E V E L O P M E N T C Y C L E
F R E E D O M O F A D D I T I V E
M A N U F A C T U R I N G
• Tool-less (no molds, MUD bases, fixturing, cutters, etc.)
• Geometries designed for maximum functionality vs. tooling constraints
• No worries about undercuts, overhangs, gating, venting, etc.
• No need for draft angles, radii, fillets
• Creative contours, internal features, ribbing/stiffening
• Innovative weight savings capabilities (shelling, lattice work, honeycomb, supports)
• Part consolidation
P A R T C O N S O L I D A T I O N
Traditional Manufacture:
16 piece assembly
Additive (LS) Manufacture:
L I M I T A T I O N S O F
A D D I T I V E M A N U F A C T U R I N G
• Cost of machines & raw materials
• Limited recyclability of used material
• Build anomalies and associated scrap rate
• As-built tolerance lesser than tooled processes
• Necessary post processing for dimensional tolerance & cosmetics
• Anisotropy due to building in layers
• Feature detail and aesthetic qualities
E C O N O M I C S
( H O W A N D W H E R E T O S A V E )
• Low to mid volume production with no set up
• Virtual inventory, On demand mfg
• Batching & nesting (LS especially)
• Rev’ing designs without tooling modifications
• Effects of “splitting pie” between multiple vendors
– Customer costs: NREs qualifying & maintaining suppliers
– Fixed cost barriers & thresholds for suppliers
R E V I E W :
C O M M O N R E A S O N S T O C H O O S E A . M .
• Weight savings
• Part consolidation
• Cost savings for low quantities
• One-offs and spares
• Parts undergoing several revisions or customization
• Faster time to market
• Ease of use/installation
Weight savings and part consolidation result in immediate cost savings to you, the manufacturer, and potential continued cost savings for the end-user over the life
M A N A G I N G D E S I G N S P E C S
A N D T O L E R A N C E S I N
F A C T O R S A F F E C T I N G
D I M E N S I O N A L C O N T R O L
•
Part Strength Requirements
•
Global Scaling
•
Laser Beam Characteristics
P A R T S T R E N G T H :
A B A S I C R E L A T I O N S H I P
MECHANICAL STRENGTH
↑
P A R T S T R E N G T H
•
It is easy to build weak parts in LS
•
Flight parts require strength validation
•
Tensile bars are fabricated next to parts
–
Ultimate Tensile Strength (UTS)
–
Elongation at Fracture (EAF)
–
Individual Tensile Modulus (ITM)
P A R T S T R E N G T H :
M A T I N G L S P A R T S
Outer surfaces typically grow .005” (orange)
• Line to line CAD model results in interference • Negative features close
