3D Printing Seminar

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Staff Exchange EEN Sabanci University Netherlands Chambre of Commerce

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Program 7th July (Sabanc University)

Touring the university

Presentation: Innovation scan and Syntens methodology

Lunch

Visit to Technopark Istanbul

Presentation: 3D printing and 3D scanning technologies for desing and small scale manufacturing

15' intro of EEN / Dutch ecosystem maybe?

30' presentation

30' Q&A

Back to city via shuttle

8th July (Sabanc University)

Workshop: How to assess the innovation potential of an SME / developing an action plan (sharing the Syntens experience)

Lunch

Visit to +90 / Rapid prototyping company

Back to city via shuttle

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Shaping without restrictions: New opportunities with Additive

Manufacturing

Alain Dirven

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Rapid Manufacturing

e-Manufacturing

Solid Freeform Fabrication

Layered Manufacturing

3D Printing

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Rapid Prototyping:

Manufacturing of physical prototypes direct from 3D CAD data by adding material

Rapid Manufacturing:

Manufacturing of functional (end)products & parts

Rapid Tooling:

Manufacturing of molds, dies & tools

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Direct Manufacturing

Design = digitally 3D fixed

Object is made by addition of material

Fast production by reduction of processteps

Complex geometric objects possible

Low volumes

No mold or tool is required (reduction of investment & time)

Design for Function, not for Manufacturing

Makes impossible shapes possible!

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New concepts?

(Wat is dit?)

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Anything you shape in 3D . . .

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. . . can be made!

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Unlimited freedom of design!

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No restrictions anymore!

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Why so interesting?

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Title of the presentation | Date | # 3D CAD Modelling 3D Scanning

MRI or CT Scanning

Slicing

Manufacturing of Part

Post Processing

RP Interface (STL)

(Build supports)

Part Completed

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Which applications?

1. Rapid Prototyping: Models & Prototypes

2. Rapid Manufacturing: Products

3. Rapid Tooling: Tools & Dies

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New services

Validation 3D CAD-file;

Functional testmodels

Aesthetics

Ergonomy

Assembly, fitting & form, handling

Windtunnel, air & waterflow

To provide customer small series (n= 1-100) without necessarity to invest in mold;

For early deliveries before released mold or tool;

Manufacturing of master (=indirect).

1. Prototyping

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New product opportunities

Integrating multiple functionality into one complex part;

Custom made product;

Developing new specific part without necessarity to invest in mold;

Less manufacturing steps, fast delivery and less risk on delay;

Manufacturing of master (=indirect f.e. casting)

2. Products

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Productexample

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New tool opportunities

Direct production of complex parts, no milling or grinding restrictions (Bridge tooling);

Integration of several separate parts into one integrated design;

Optimized shapes and dimensions, complex cooling channels;

Addition of high wear resistant surfaces;

3. Rapid Toolmaking

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Powder systems

Liquid/paste systems

Deposition systems

Laser Cutting

Laser Sintering

Laser Curing

Binder jetting

Thermoplastic jetting

Photopolymer jetting

Layered systems

Laser Melting

Rapid Manufacturing Familiy Tree

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Powder systems

Liquid/paste systems

Deposition systems

Laser Cutting

Laser Sintering

Laser Curing

Binder jetting

Thermoplastic jetting

Photopolymer jetting

LOM

3D Printing

FDM

SLA

Layered systems

SLS

Laser Melting

Rapid Manufacturing Familiy Tree

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LOM: Laser Object Manufacturing

Proces: Cutting and bonding of coated paper layers

Materials: Layers of impregnated paper

No supports required

LOM Laser Cutting

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SLA: Stereo Lithography

Proces: Curing of UV epoxyresin

Materials: UV curable epoxy resins

Laser Curing SLA

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SLA: Stereo Lithography

Proces: Curing of UV epoxyresin

Materials: UV curable epoxy resins

Laser Curing SLA

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Micro-stereolithography

Laser Curing SLA

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SLS: Selective Laser Sintering

Proces: Bonding of powder by heat

Materials: Powders of plastics or coated metal

SLS Laser Sintering:

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DMLS: Direct Metal Laser Sintering

Proces: Bonding by sintering of metalpowder in a powderbed.

Materials: Powders of metals.

DMLS Laser Sintering:

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DMLM: Direct Metal Laser Melting

Proces: Melting of metal powder

Materials: Fully dense

Laser Melting: DMLM

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Laser Cusing

(Concept Laser)

Proces: Melting of added metal powder

Materials: Titan-, Nikkel-, Kobalt- en Steelalloys

High small ribs possible

Materialproperties equal or better

No material porosity

Combinatiion of different metals (Functionally Gradient Materials)

Laser Cusing Laser Melting:

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DSPC: Direct Shell Production Casting:

Proces: Binder is deposited to bond a bed of ceramic powder in layerwise cross sections.

Materials: Binding resin

Binder Jetting DSPC 3D Printing

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3D Printing

Proces: A liquid adhesive compound is deposited by a multi-channel jetting head onto the top layer of a bed of powder object material.

Materials: Wax, Binder

3D Printing Binder Jetting

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FDM: Fused Deposit Modelling

Proces: Addition of molten filament

Materials: ABS, Butyl styrene, PLA

Thermoplastic Jetting FDM

Example of direct digital manufacturing of parts

for end us. With FDM, BMW built this hand-held

assembly tool used in manufacturing cars.

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Objet

Proces: Addition of UV cureable photopolymer

Suppliers: Objet

Photopolymer Jetting Objet

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Color models

Pro

toty

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g A

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Prototyping: Scale models

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Prototyping: SLA indirect

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Operating tools

App

licati

ons:

Tools

Chirurgy: Tools

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Operating tools Chirurgy: Tools

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licati

ons:

Tools

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Protheses & Inplants

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ons

Medical products

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Chirurgical models

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ical A

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Health: Hearing aids

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Interior: Lamps

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ons: Pro

ducts

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pplicati

ons: Pro

ducts

Additional features

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Additional features

Applicati

ons: Pro

ducts

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Example of direct digital manufacturing of parts for end

us. With FDM, BMW built this hand-held assembly tool

used in manufacturing cars.

Industry: Tools

Applicati

ons

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Machine construction: Tools

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ons

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Industry: Tools

Robotgrippers met gentegreerde luchtkanalen voor zuigcups

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Luchtafvoerkanaal koelunit

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ons

Industry: Tools

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Afzuigkop voor Bosch schuurmachine

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ons

Industry: Tools

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Industry: Ceramic parts

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Moldmaking: SLA inserts

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ons

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Industry: Special parts

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ons

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Werkzeugbau

Hofmann

LaserCusing

(Germany)

JB Ventures

(Netherlands) Applicati

ons

Industry: Moldmaking

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Industry: Moldmaking

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ons

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Industry: Machine parts

Carat Duchatelet Deursloten voor gepantserde voertuigen

(vooraan huidige sloten, achter de vernieuwde versie

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ons

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4. 3D Scanning

Reproduction or copying;

Scaling;

Orthopedic products (f.e. protheses)

Manufacturing of master (=indirect).

Reverse Engineering

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ons

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3D Scanning: Arts

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3D Scanning: Arts

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Surfacequality (stepping, sintering) needs extra processteps;

Hardness of material;

Strong competing developments in HSM, Aluminium Alloys;

Large mouldparts expensive, longer leadtime;

Mouldmaker unknown with addition of material & properties;

Better quality but expensive protoparts competing with high moldinvestment;

Disadvantages/threads

Tre

nds

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Serial volume

Functionality

Tre

nds

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rends

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15 metal alloys!

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nds

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General

Cheaper machines, increasing low-end machines;

Faster, more accurate & reproducible;

Hybrid techn.: Sintering / Contour milling

FDM based machines are growing fast;

Increase of range of materials: Ti, H13, Stainless Steel, CrCu, WC-Co, Ceramics

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Questions?