3D Printing, Additive Manufacturing, and Solid Freeform - - PowerPoint PPT Presentation

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3D Printing, Additive Manufacturing, and Solid Freeform - - PowerPoint PPT Presentation

Aug 11, 2023 300 likes •744 views

NSF Additive Manufacturing Workshop 3D Printing, Additive Manufacturing, and Solid Freeform Fabrication: The Technologies of the Past, Present and Future Joseph J Beaman Department of Mechanical Engineering The University of Texas

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Department of Mechanical Engineering The University of Texas at Austin

NSF Additive Manufacturing Workshop

3D Printing, Additive Manufacturing, and Solid Freeform Fabrication: The Technologies of the Past, Present and Future

Joseph J Beaman Department of Mechanical Engineering The University of Texas

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Department of Mechanical Engineering The University of Texas at Austin

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Department of Mechanical Engineering The University of Texas at Austin

Solid Freeform Fabrication

Fabrication of complex freeform solid objects directly from a computer model of an object without part-specific tooling or human intervention.

Art to Part

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Department of Mechanical Engineering The University of Texas at Austin

Voxel Manufacturing - 1985

Layered Manufacturing

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Department of Mechanical Engineering The University of Texas at Austin

Strength Accuracy 3D Printing – Concept Models Prototypes Machining Forms Patterns Manufacturing SFF Markets

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Department of Mechanical Engineering The University of Texas at Austin

Market Segments & Barriers

  • Concept Models
  • Cost
  • Some performance
  • Machining Forms
  • Cost & competition
  • Patterns
  • Accuracy
  • Surface Finish
  • Rapid Prototyping
  • Materials
  • Manufacturing
  • Materials
  • Process Control
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Department of Mechanical Engineering The University of Texas at Austin

Innovations in materials and processes are transforming rapid prototyping to rapid manufacturing

  • Manufacturing near the point of use - enables rapid deployment
  • “On demand” manufacturing - reduces inventories and wait times
  • Replacement of metals with lightweight materials - enables new applications

Additive manufacturing “makes it as cheap to create single items as it is to produce thousands... It may have as profound an impact on the world as the coming of the factory did.”

‘The Manufacturing Technology That Will Change the World’

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Department of Mechanical Engineering The University of Texas at Austin

History

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Department of Mechanical Engineering The University of Texas at Austin

Prehistory - Layered Additive Structures have

been around for awhile

The oldest pyramid known is the Step Pyramid of King Zoser at Saqqara. It was built during the Third Dynasty (ca. 2800 B.C.)

Dave Rosen

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Department of Mechanical Engineering The University of Texas at Austin

Kodama Herbert Housholder

Early Parts

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Department of Mechanical Engineering The University of Texas at Austin

Françoise Willème’s Photosculpturing studio Paris about 1870 Admiral Farragut sits, late 1860’s, for photosculpture

The Past

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UT Historical AM Contributions

UT Develops 1st SLS Machine (Deckard & Beaman) UT Commercializes to DTM First Commercial SLS Parts Sold 1988 Ti SuperAlloy SLS Parts SiC Laser Sintered Parts (indirect) Custom Nylon Ankle‐Foot Orthotics Flame Retardant Nanocomposites SLS Characterization 2nd Generation High Temperature Polymer SLS Testbed Silicon Infiltrated Silicon Carbide Fuel Reformer 1987 1989 First SLS Machine Sold 1992 1998 2013 2011 2002 2010 2007 BAMBI

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Department of Mechanical Engineering The University of Texas at Austin

Processes

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Department of Mechanical Engineering The University of Texas at Austin

Selective Laser Sintering

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Department of Mechanical Engineering The University of Texas at Austin

Selective Laser Sintering (SLS)

Technology: Laser fused powders Introduced: 1992

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Department of Mechanical Engineering The University of Texas at Austin

Stereolithography

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Department of Mechanical Engineering The University of Texas at Austin

Stereolithography (SLA)

 Technology: Curable

Liquid Resin

 Introduced: 1988  Major Vendor: 3D

Systems

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Department of Mechanical Engineering The University of Texas at Austin

Fused Deposition Modeling

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Department of Mechanical Engineering The University of Texas at Austin

Fused Deposition Modeling (FDM)

 Technology: Filament

Extrusion

 Introduced: 1991  Major Vendor:

Stratasys

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Department of Mechanical Engineering The University of Texas at Austin

Ink Jet Systems

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Department of Mechanical Engineering The University of Texas at Austin

Ink Jet Systems

 Technology: Ink jet

deposition

 Introduced: 1994  Major Vendors:

Solidscape, Sanders Prototyping, 3D Systems

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Department of Mechanical Engineering The University of Texas at Austin

3D Printing

  • Technology:

Selective deposition

  • f binders into

powder

  • Introduced: 1996
  • Major Vendor: Zcorp
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Department of Mechanical Engineering The University of Texas at Austin

Additive Manufacturing

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Department of Mechanical Engineering The University of Texas at Austin

Cost versus Production Volume

Loughborough Univeristy 2000

31x45x36

5 10 15 20 25 30 2000 4000 6000 8000 10000 12000 14000 16000 18000 200

Production volume Cost per part (Euros)

Injection Moulding Laser Sintering (EOSP 360) Stereolithography (SLA 7000) Fused Deposition Modelling (FDM 2000)

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Department of Mechanical Engineering The University of Texas at Austin

Direct Manufacture

(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 Part Count = 1 Courtesy of 3D Systems / Boeing

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Department of Mechanical Engineering The University of Texas at Austin

Barriers to Additive Manufacturing

  • Surface finish
  • Production speed
  • Cost
  • Machines
  • Materials
  • Variation from part to part
  • Inadequate process control
  • Materials availability
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Department of Mechanical Engineering The University of Texas at Austin

Direct Metals

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: EOS (Laser Sintering)

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: SLS Titanium

SLS processed AIM-9 Sidewinder missile guidance section housing (90% scale)

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: AeroMet

As built part Finished part Process schematic Actual machine

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: POM

Process schematic

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: Optomec

Actual Machine Process schematic Wind tunnel prototype Hip replacement implant

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: Solidica (Ultrasonic consolidation)

Process schematic Tooling for injection molding

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Department of Mechanical Engineering The University of Texas at Austin

Metal Components: ARCAM (e-beam sintering)

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Department of Mechanical Engineering The University of Texas at Austin

  • The Future
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Department of Mechanical Engineering The University of Texas at Austin

Multiple Materials

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Department of Mechanical Engineering The University of Texas at Austin

M2SFF

Graded Tungsten Carbide / Cobalt

Potential performance enhancement with use of FGM.

Possess greater amounts of tungsten carbide near working surfaces to provide greater erosion resistance. .

Possess greater amounts

  • f cobalt in regions of

expected fracture to increase ductility.

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Department of Mechanical Engineering The University of Texas at Austin

A New ManufacturingArchetype

  • Traditional Manufacturing:
  • Regional Push-Button Manufacturing
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Department of Mechanical Engineering The University of Texas at Austin

Changing the Landscape of Design and Invention

  • Elimination of Constraints:
  • Rather than
  • DFM Design for Manufacturing
  • Invert the process to
  • MFD Manufacture for Design
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Department of Mechanical Engineering The University of Texas at Austin

Application Sectors

Spectrum emphasizes strategic needs. Military Rehabilitation Assistive Technologies Consumer Products

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Department of Mechanical Engineering The University of Texas at Austin

Complex Engineered System 3D-Fax - Demonstrated in 1992

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Department of Mechanical Engineering The University of Texas at Austin

We have seen this before

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Department of Mechanical Engineering The University of Texas at Austin

Conclusion

  • Additive Manufacturing is an exciting and emerging

field

  • Special thanks to NSF, ONR, DARPA