3D Printing/ Process Parameters

DesignDept. of Mechanical Engineering
June, 2016
60 % volume Topology optimization
Design, Material & Process Parameters
1. In the design process; 2. In the printing process.
• For 3D printing, redesign to save more material.
Slide 5
The 3D in the 3D printing is 2D by 1D...
courtesy of APWorks, 2016
InkJet, ...
traditional production process...
Need to Optimize PROCESS PARAMETERS
• However, 3D in the 3D printing is
achieved by 2D multiplied by 1D.
Items
Items
Slide 7
• Speed • Slow
• Cost • Medium
ref: Optimization of fused deposition modeling process parameters, 2015, Advances in Manufacturing
Cause and Effect Diagram
Layer thickness
x
y
z
Influences of Print Speed and
Layer Thickness on
Coalescence in FDM
mm/sec mm/sec
co a
le sc
en ce
co a
le sc
en ce
thermal energy of the semi-
molten materials.
C o
a le
sc en
MECHANICAL PROPERTIES OF FUSED DEPOSITION MODELING
PARTS MANUFACTURED WITH ULTEM*9085, ANTEC 2011, Boston
FLAT
UPRIGHT
ON-EDGE
• Structural components
Maximum build size 700 mm x 380 mm x 560 mm
Speed Medium
Cost Medium
metals (steel, titanium, tungsten),
ceramics (silicon carbide) and
Metal Technology Co. 3D Systems
•A focused laser beam is used to fuse/sinter powder particles in a
small volume within the layer.
KEY PARAMETERS (Laser Source)
Laser Parameters Laser Power / Laser Energy
Spot Size
Scanning Speed
Scanning Mode
Interval Time
Exposure Time
Exposure Time, length of time
when laser spots in one point
Point Distance, distance
between laser spots
SLS process parameters: Laser Power, Scanning speed, Exposure Time, Point Distance, etc
A. Stwora, G. Skrabalak, Influence of selected parameters of Selective Laser Sintering process on properties of
sintered materials, Journal of Achievements in Materials and Manufacturing Engineering 61/2 (2013) 375-380.
C o
m p
re ss
iv e
S tr
en g
• Multi-scale approach to select
Optimization of process parameters: raster angles and gaps; laser power, scanning
speed, exposure time, point distance, etc
• Measurement of mechanical attributes
for various process parameters
• Need to perform Topology
optimization considering material
anisotropy, layer direction
Need to develop Models for predicting the KPI in terms of Process Parameters
• Fiber reinforced composites
Tools 2-4Tools 2-3
Items
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DetectionXSeverity OccurrenceX = RPN (Risk Priority Number)
ItemsItemsQuality of Product
Slide 16
chopped carbon fiber is
placed layer by layer.