Additive Manufacturing - WordPress.com...layered on top of one another and the shape of the layer is cut out. • The most common sheet-stacking process is Laminated Object Manufacturing

Additive Manufacturing

An Introduction

Presented By:Product Realization

Contents

1. An Introduction to Additive Manufacturing

2. The Technology of Additive Manufacturing

3. The Economics of Additive Manufacturing

4. The Future of Additive Manufacturing

5. Additive Manufacturing and You !

6. Q&A

Notes

Ground Rules

1. Thou Shall not be driven to sleep !

2. Introductory

3. Crowd-Sourcing

1. Introduction

3

Introduction: Futuristic, Disruptive Technologies

4

Technology Research

Technical Professional Association

Newspaper Consulting Firm Defense Research

GartnerThe Top 10 Strategic

Technology Trends for 2014

IEEETop 10 Technology trends

for 2014

Huffington Post10 of the Biggest Trends in

Technology For 2014

McKinsey12 Disruptive Technologies

Rand CorporationFuture Technology Landscapes: Insights,

analysis and implications for defence

https://www.gartner.com/doc/2667526/top--strategic-technology-trends

http://www.computer.org/portal/web/membership/Top-10-Tech-Trends-in-2014

http://www.huffingtonpost.com/damon-m-banks/10-of-the-biggest-trends-_b_4725708.html

http://www.mckinsey.com/insights/business_technology/disruptive_technologies

http://www.rand.org/pubs/research_briefs/RB9754.html

Mobile Device diversity and management

The Mobile Cloud Data Privacy Mobile Internet Additive Manufacturing

Mobile apps and applications The Web-of-Things The Web of Things Automation of knowledge work Advanced Materials

The internet of everything Extreme Data Ultra HD 4K Will Spread to Television and Phones

The internet of things Cybersecurity

Hybrid cloud and IT as service broker

3D Printing No-Touch Interfaces Cloud Technology Small scale energy storage

Cloud/client architecture Online Learning 3-D Printing Advanced Robotics Synthetic environments

The era of personal cloud Mobile Networks Wearable Technology Autonomous and near autonomous vehicles

Software defined anything Social Networks vs. Privacy Large Cloud Services Next generation genomics

Web scale IT Plugged-in Healthcare Personal Cloud Services Energy storage

Smart Machines Plugged-in Government Online Video Streaming 3D Printing

3D Printing Scientific Cloud Analysis Social Networks That Are IT Policy Friendly

Advanced Materials

Advanced Oil and gas exploration and recovery

Renewable energy

Introduction: The Fundamentals

5

• Layer by Layer Manufacturing.

• X Subtractive Manufacturing

• Different processes based on state of material:

• Solid based: Fused Deposition Modeling, Laminated Object Manufacturing.

• Liquid based: Stereolithography, Photo Polymerization, inkjet Printing.

• Powder based: Selective Laser sintering, Direct Metal laser sintering.

• Different processes based on type of material:

• Plastic based: Stereolithography, Selective laser sintering, Fused Deposition modeling.

• Metal based: Selective laser melting, Electron Beam Melting, Direct Metal

laser sintering, Laminated Object Manufacturing.

• Video:

6

Introduction: A Brief History

1980s

The Birth of 3D PrintingCharles Hull, invents Stereo lithography (SLA) which enables a tangible object to be created from 3D Data. It is used to test a design before investing in a larger manufacturing program.

1990s

Building parts, layer by layerThe first SLA machine is produced by 3D Systems, co-founded by Chuck Hull. The machine’s process involves a UV laser solidifying photopolymer, a liquid with the viscosity and color of honey that makes 3D parts, layer by layer. Though imperfect, the machine proves that highly complex parts can be made overnight.

Advances in medicine with engineered organsThe first lab grown, organ; young children undergo urinary bladder augmentation using a 3D synthetic scaffold coated with their own cells. This was a Wake Forest Institute of Regenerative Medicine.

2000s

3D Printer KidneyA miniature functional kidney, that is able to filter blood and produce diluted urine at the Wake Forest. Efforts on to start printing organs and tissues. 3D Printing is Open-sourced !

RepRap, an open source initiative to democratize manufacturing. Mass Customization in Manufacturing

The first SLS machine for on-demand manufacturing of industrial parts and prostheses. Objet creates a multi-material printing machine The First Self Replicating Printer

RepRap releases Darwin, which is able to print most of its components by itself !The era of DIYShapeways launches a Private Beta for a new co-creation service allowing artists, architects and designers to make their 3D Designs as physical objectsProsthetics advancesComplete, working 3-D prosthetic legs, with all parts: knee, foot, socket etc printed in the same structure without any assembly. Creates Bespoke , a manufacturer of prosthetic devices.

DIY Kits in the marketMakerBot , an open-source hardware company for 3-D printers starts selling DIY kits that allow buyers to make their own printers and products.Blood Vessels !A 3-D bioprinter is used to print the first blood vessels.

2010s

World’s First !Robotic aircraft: Seven days, €5,000, elliptical wingsCar: TEDxWinnipeg, . 200 mpg in highway. $10,000~$50,000Gold and Silver !: Materialise

The Big ElephantGE: World’s first large dedicated additive manufacturing plant in Alabama , $200M Plant in Pune.

Aerospace Innovation Pratt and Whitney Additive Manufacturing Innovation Center at the University of Connecticut

3D Printer Prosthetic Jaw Layerwise machine for a lower jaw, implanted into a 83 year old woman suffering from chronic bone infection. Research for growth of new bone tissue.

Period of Growth and consolidation 3D Systems makes 50 acquisitions in three years !Stratasys merges with Objet, buys MakerBot, Solid Concepts and Harvest Technologies

1984

1992

1999

2002

2005

2006

2008

2009

2011

2012

2013

2014

7

2. Technology: Solid Based Processes• Solid-based processes use a variety of solid, non-powder, materials and each process differs in how it

builds the layers of a part.

• Most solid-based processes use sheet-stacking methods, in which very thin sheets of material are layered on top of one another and the shape of the layer is cut out.

• The most common sheet-stacking process is Laminated Object Manufacturing (LOM), which uses thin sheets of paper, but other processes make use of polymer or metal sheets.

• Other solid-based processes use solid strands of polymer, not sheets, such as Fused Deposition Modeling (FDM) which extrudes and deposits the polymer into layers.

8

Fused Deposition Modeling• Fused deposition modeling (FDM) is an additive manufacturing

process in which a thin filament of plastic feeds a machine • A print head melts it and extrude it in a thickness typically of 0.25 mm

Laminated Object Manufacturing• Laminated Object Manufacturing (LOM) is a process that combines

additive and subtractive techniques to build a part layer by layer. • In this process the materials come in sheet form. • The layers are bonded together by pressure and heat application and

using a thermal adhesive coating.• A carbon dioxide laser cuts the material to the shape of each layer

given the information of the 3D model from the CAD and STL file.

2. Technology: Solid Based Processes

2. Technology: Liquid Based Processes

9

• These additive technologies typically use photocurable polymer resins and cure selected portions of the resin to form each part layer.

• Ex: Stereolithography (SLA), Jetted Photopolymer , Ink Jet Printing, which may use a single jet or multiple jets.

Jetted Photopolymer• Jetted photopolymer is an additive process that combines the techniques used in

Inkjet Printing and Stereolithography. • The method of building each layer is similar to Inkjet Printing, in that it uses an array

of inkjet print heads to deposit tiny drops of build material and support material to form each layer of a part.

• However, as in Stereolithography, the build material is a liquid acrylate-based photopolymer that is cured by a UV lamp after each layer is deposited.

2. Technology: Liquid Based Processes

10

Stereolithography• This process consists of curing or solidification of a photosensitive polymer when an

ultraviolet laser makes contact with the resin. • The thickness of each layer as well as the resolution depends on the equipment used. • A platform is built to anchor the piece and supporting the overhanging structures. • Then the UV laser is applied to the resin solidifying specific locations of each layer.

Inkjet Printing• The additive fabrication technique of inkjet printing is based on the 2D printer

technique of using a jet to deposit tiny drops of ink onto paper. • In the additive process, the ink is replaced with thermoplastic and wax materials,

which are held in a melted state. • When printed, liquid drops of these materials instantly cool and solidify to form a

layer of the part.

11

• In powder-based processes, such as Selective Laser Sintering (SLS), a selected portion of powdered material is melted or sintered to form each part layer.

• The use of powdered material enables parts to be fabricated using polymers, metals, or ceramics.

• Other powder-based processes include Direct Metal Laser Sintering (DMLS) and Three Dimensional Printing (3DP).

2. Technology: Powder Based Processes

12

Selective Laser Sintering• This is a three-dimensional printing process in which a powder is sintered or fuses

by the application of a carbon dioxide laser beam.• The chamber is heated to almost the melting point of the material. The laser fused

the powder at a specific location for each layer specified by the design. • The particles lie loosely in a bed, which is controlled by a piston, that is lowered the

same amount of the layer thickness each time a layer is finished.

Direct metal laser sintering• The DMLS machine uses a high-powered 200 watt Yb-fiber optic laser. • Inside the build chamber area, there is a material dispensing platform and a

build platform along with a recoater blade used to move new powder over the build platform.

• The technology fuses metal powder into a solid part by melting it locally using the focused laser beam.

2. Technology: Powder Based Processes

3D Printing 3DP is a process in which water-based liquid binder is supplied in a jet onto a starch-based powder to print the data from a CAD drawing.The powder particles lie in a powder bed and they are glued together when the

binder is jetted.This process is called 3DP because of the similarity with the inkjet printing

process that is used for two-dimensional printing in paper.

Classification Material

Ae

rosp

ac

e (

air

fra

me

)

Ae

rosp

ac

e (

en

gin

es)

Ae

rosp

ac

e (

ca

bin

)

Au

tom

oti

ve

(R

oa

d)

Au

tom

oti

ve

(S

po

rt)

Me

dic

al

(Ort

ho

pa

ed

ic)

Me

dic

al

(Pro

sth

eti

c)

Me

dic

al

(De

nta

l im

pla

nts

)

Me

dic

al

(su

rgic

al

gu

ide

s)

Me

dic

al

(He

ari

ng

aid

s)

En

erg

y (

ge

ne

rati

on

)

En

erg

y (

sto

rag

e)

Cre

ati

ve

in

du

stry

(a

rtif

ac

ts)

Co

nsu

me

r g

oo

ds

(je

we

lle

ry)

Co

nsu

me

r g

oo

ds

(to

ys

an

d g

am

es)

Co

nsu

me

r g

oo

ds

(ho

me

/fa

shio

n)

De

fen

ce

(w

ea

po

ns)

De

fen

se (

PP

E,

arm

ou

rs)

De

fen

se (

log

isti

cs

& s

up

po

rt)

Ele

ctr

on

ics

(pa

ck

ag

ing

)

Ele

ctr

on

ics

(se

nsi

ng

)

Pro

oty

pin

g

To

oli

ng

Metal Y Y Y Y Y Y N Y N N Y Y Y Y N N Y Y Y N Y Y Y

Polymer N N Y Y Y Y Y N Y Y N Y Y Y Y Y N Y Y Y Y Y Y

Ceramic N Y N N N Y N Y N N N Y Y N N N N Y N N Y Y Y

Metal(powder feed) Y Y N Y Y N N N N N Y N N N N N N Y Y N N Y Y

Metal (wire feed) Y N N N N N N N N N Y N N N N N N Y Y N N Y Y

Photopolymer N N N N Y N Y N N Y N Y N Y N Y N Y N Y Y Y Y

Wax N N N N N N N N N N N N N N N N N N N N N Y Y

Metal N N N Y Y N N Y N N N Y Y Y N N N N N N Y Y Y

Polymer N N Y Y N Y Y N Y N N Y Y N N N N N N Y N Y N

Ceramic N Y N N Y Y N Y N N N Y Y N Y N N N N N Y Y Y

Material Extrusion Polymer N N Y Y N Y Y N Y N N N Y N N N N N Y Y Y Y Y

Vat

PhotolpolymerizationPhotopolymer N N N N N N Y N Y Y N N Y Y N Y N N N Y Y Y Y

Hybrids Y Y Y N Y N Y N N Y N Y N N N N N Y N Y Y Y N

Metallic Y Y Y N Y N N N N N Y Y N N N N Y N N Y N Y Y

Ceramic N Y N N N Y N Y N N N Y N N N N N N N N N Y N

Shee Lamination

Binder Jetting

Material jetting

Directed Energy

Deposition

Powder Bed Fusion

2. Technology: Mapping with Industry

Source: UK Additive Manufacturing, Special Interest Group , Sep 201213

14

2. Technology: Mapping with Companies

Source: UK Additive Manufacturing, Special Interest Group , Sep 2012

Additive technologies Base materials

Selective laser sintering (SLS)Thermoplastics, metal powders, ceramic powders

Direct Metal laser sintering (DMLS) Almost any metal alloy

Fused deposition Modelling (FDM)Thermoplastics, eutectic metals

Stereolithography (SLA) Photopolymer

Digital Light Processing (DLP) Liquid resin

Fused Filament Fabrication (FFF) PLA, ABS

Melted and Extrusion Modelling (MEM) Metal wire, plastic filament

Laminated object manufacturing (LOM) Paper, metal foil, plastic film

Electron beam melting (EBM) Titanium alloys

Selective heat sintering (SHS) Thermoplastic powder

Powder bed and inkjet head 3D printing, Plaster-based 3D printing (PP)

Plaster

Source: AIM practice, Infotech, Secondary research incl. Wikipedia

2. Technology: Materials

15

16

2. Technology: Comparing different technologies

Source: CustomPartNet

17

0

1

2

3

4

SLA

SLS

FDM

3DP

SLA, 1.99

SLS, 2.68FDM, 2.44

3DP, 1.74

Overall: Equal Weightage

2. Technology: Comparing different technologies

18

3. Economics: Market Size

1.7 2.2 2.6 3.2 3.74.3

5.15.9

6.6

2011 2012 2013 2014 2015 2016 2017 2018 2019

Other2%

Visual aids10%

Presentation models

8%

Functional models

18%

Fit and assembly12%

Patterns for prototype tooling

12%Patterns for

metal casting9%

Tooling components

3%

Direct part production

19%

Education/ research

7%

AM Usage- Current

Other5%

Auto20%

Aerospace12%

Industrial11%

Consumer products

20%

Medical 15%

Academics8%

Government/ Military

6%

Architecture3%

AM Industry Split- Current

No In $ BillionsAdditive Manufacturing Growth Rate

Aerospace

Medical, tooling

Dental, Prototyping

3. Economics: Attractiveness

19

High Complex/ Low volume- Produce Parts which are difficult to manufacture

Removing the Manufacturability in Design !

Let your products do more, and better !

Customization to the extremes

Sustainability

New Paradigms in Supply Chain

Reduce time to market

3. Economics: Business drivers

20

1.Economic low volume production • Reduces the need for tooling (moulds / cutters) • Reduced capital investment & inventory • Simplifies supply chains & reduced lead times

2.Increased geometric freedom • Re-entrant features • Variable wall thicknesses • Complex honey combs • Non-linear holes • Filigree structures • Organic / genetic structures

3.Increased part functionality • Replacing surface coatings & textures • Modifying physical behaviour by designing ‘mechanical properties’ • Embedding secondary materials (optical / electrical) • Grading multiple materials in a single part

3. Economics: Business drivers

21

4.Product personalisation • Medical devices • Consumer goods • Artefacts • Online design tools • Co-creation

5.Improvised environmental sustainability • Reduced raw material consumption • Efficient supply chains • Optimised product efficiency • Lighter weights components • Reduced lifecycle burden

6.New supply chains and retail models • Distributed manufacture • Manufacture at the point of consumption • Demand pull business models • Stockless supply chains • Chainless supply chains (home manufacture)

22

3. Economics: Benefits and Challenges

3. Economics: Part Redesign of an Aerospace landing gear

23

1. Major support component2. Hinge3. Wheel truck4. Shock absorber5. Actuator

• Overall dimensions: 70x210x70 (WxLxH in mm)• AlSi10Mg• Main landing gear of an aircraft: Piaggio Aero

AM Design Rules• Use AM capabilities• Rethink assembly towards freeform design and reduce

part count by integrating functions• Reduce raw materials and hence energy but do not

compromise on weight• Use freeform designs and use undercuts and hollow

structures• Design optimal shape of the part as per its

functionality.

Constraints• Positions of holes for the connection with the actuator• Side portions of the major support: fitment with the

coupling elements. • End feature of the truck linked with wheel hub• Hinge axis position to preserve kinematics

Changes• Integrated hinge is produced, lock requirements and

assembly requirements are removed• Cross sections of the major support component are

reduced to decrease weight• Surfaces are blended smoothly: uniform weight

distribution• Material in the central section is partially eliminated• Holes are produced directly by AM , process tolerance

is better at 0.2% of the nominal dimension

(a) Cross section of the major support(b) Top view(c ) Unchanged surfaces are highlighted in orange

3. Economics: Aerospace Trends

24

Boeing• Used in both military and commercial aircraft.

• Materials: Polymers; Technology: Laser sintering, Fused Deposition modeling; Equipment: EOS, Stratasys

• Applications

1. Higher Temperature Subsystem Zones : Exhaust Ducting, electrical shrouds(NEED –Higher Temperature Polymer Development)

2. Higher Temperature Tooling: Composite Fabrication(NEED –Higher Temperature Polymer Development)

3. Secondary Structure: (NEED –Higher Modulus, % of Elongation, and Ultimate Tensile Strength Material)

4. Cabin Interior Paneling, Wire Bundle Clips, Airflow Diverters(NEED -Flame Retardant Polymer Certification

GE• Acquired Morris Technologies in 2012, signed a bond with Sigma Technologies. Plans to secure the AM Supply Chain

• Materials: Every single material(plastic and metal), every single machine

• Mainly used to make jet engine parts but using for other sectors as well like healthcare.

• Plan to advance the use of AM made jet engine parts by 25% and will produce more than 10,000 additive manufactured components by 2020

• Used this Technology in the LEAP jet engine for 16 3D Printed fuel nozzles

Pratt & Whitney

• Flight testing of components for the Pure Power PW1500G and PW1200G

• Materials:Metallic; Technology: Laser sintering, Electron beam machining; Equipment: EBM, not known

• Applications

1. Prototypes

2. Tubes in the manifold

Machine Product/ Service Materials(s) Technology Client/ Partner Uniqueness News/ Trends Source

3D Systems Surgical DevicesCastForm &

DuraForm

Selective laser

sintering

FHC- Medical

equipment maker

Quick turnaround time

of 72 hours.

Training and tech

support by 3D

Systems themselves

http://www.3dsystems.com/sites/www.3

dsystems.com/files/3DS-FHC-case-

study.pdf

3T RPD

Implants- facial Titanium-

Ti6Al4V

Direct metal laser

sintering- EOS

Queen’s Medical

Centre, Nottingham

DMLS- more

consistent end

product, less post

production

processing

http://www.3trpd.co.uk/portfolio/titaniu

m-mandibular-implant-for-qmc-

patient/gallery/medical-case-studies/

Surgical instrument

mfg. – spinal disc

implant

Titanium-

Ti6Al4V

Direct metal laser

sintering- EOS

Ranier Technology,

Medical device dev.

Reduction in number of

assemblies & hence

easy to clean

instruments

Post processing-

Micro maching

process

http://www.3trpd.co.uk/portfolio/ranier-

technology-ltd-titanium-is-ideal-

solution/gallery/medical-case-studies/

Arcam

Standard and

custom implants,

trabecular

structures

Ti6Al4V, titanium

grade 2, cobalt-

chrome ASTM

F75

Electron beam

melting

Medical device

contract

manufacturer

Arcam has over 25

patents for its EBM

technology

http://www.arcam.com/solutions/orthop

edic-implants/

EOS

Orthopaedics-

Stereotactic

platforms

PA 2201

polyamide

powder

DMLSFHC- Medical

Equipment maker

Machines are smaller,

lighter and more

accurate

Morris Technologies,

now a part of GE uses

this extensively

http://www.eos.info/press/customer_cas

e_studies/climbing_shoe

Materialise

tracheal splint polycaprolactoneUniversity of

Michigan

Emergency clearance

from the FDA3-D Printing

http://www.materialise.com/cases/baby-

s-life-saved-with-groundbreaking-3d-

printed-device

Surgery planning

and guide servicesNot relevant

Doctors, guitar

player ( for the

elbow bone)

Surgery time reduced

from 3 hours to 45

mins.

http://www.materialise.com/cases/strikin

g-the-right-note-with-a-well-planned-

radius-reconstruction

Medical

Modeling Inc

Virtual surgical

planning,

engineered porous

geometries

Not relevant

Stereolithography,

electron beam

melting

http://www.medicalmodeling.com/

25

3. Economics: Medical Trends

AssessmentDesign &

engineering

Material and process

selection

Prototyping & process

optimization

Parts Production

Post Processing

Supply & Distribution

3. Economics: Capabilities and Ecosystem

Research

Manufacturability assessment

Prototyping, optimization and testing

Parts production and post processing

Logistics

- DF(AM)EA- Intelligent

automation- Part Libraries-

Domain specific

- Digital thread-data driven simulation and modeling

- Reverse engineering

- Process capability database

- Materials database

- Small batch manufacturing

- Process planning specific to part, geometry, material and equipment

- - Model based- - Open

Architecture- - Sensor

feedback - - Automation

- Finishing-machining, heat treatment, coating.

- Inspection-geometry, material properties

- - Customer based distribution centers

- - Packaging processes

1. Integrative Education, training and workforce development

2. Sustainability: People, profit, planets

26

4: The Future:- Trends

27

2003 2008 2013 2018 2023

IP Protection

Material Cost

Hardware Cost

Laser Power/ Scan Speed

Print heads/ capacity

Productivity (kg/h)

???

4. The Future: Patents ???

28

No

Patent No

Date of Expiry

Description CurrentAssignment

Remarks

1 5,569,349October29,2013

“Thermal Stereolithography” discloses an apparatus of and method for providing 3D objects through the principles of stereolithography using flowable materials.

Unavailable(previously Almquist)

Stratasys

2 5,587,913December 14, 2013

“Method Employing Sequential Two-Dimensional Geometry for Producing Shells for Fabrication by a Rapid Prototyping System” discloses a method for producing 3D objects using a computer-generated specification of a solid object to interleave the planning and building phases of production on a slice-by-slice basis.

Unavailable(previously Statasys)

Stratasys

3 5,597,589January28, 2014

“Apparatus for Producing Parts by Selective Sintering” discloses an apparatus for producing a 3D object from powder.

Unavailable (Previously DTMCorporation )

3D Systems

4 5.609,812March 11, 2014

“Method of Making a Three-Dimensional Object by Stereolithography” discloses a method of producing a 3D object from a medium that is solidifiable upon exposure to synergistic stimulation

Unavailable (Previously 3D Systems)

3D Systems

5 5,503,785June 2, 2014

“Process of Support Removal for Fused Deposition Modeling” discloses a process for producing 3D objects having overhanging portions freely suspending in space.

Unavailable (Previously Stratasys)

Stratasys

29

Short Term (0~2 years) Medium Term (2~5 years) Long term (5~ years)

Knowledge based design combined with structural

optimization

Integrated structural and material design

optimization

Shared database of material properties, factoring production and

end use

Clear specifications for materials

and processes

Processes and techniques to improve mechanical properties of

functional parts

Bio-mimicry: Structures based upon biological examples

4: The Future:- Design Trends

29

30

Short Term (0~2 years) Medium Term (2~5 years) Long term (5~ years)

Validate products: structure, property, process

Work with OEM for incorporating sensors in

machines

Map process parameter effect on surface finish

Physics based modeling: co-relate defects to resulting properties

Co-development of hybrid processes (electron beam &

laser)

Methods for working the material during deposition

Integration of sensor data into process control algorithms

Alloys designed for specific applications

4: The Future:- Technology Trends

31

Short Term (0~2 years) Medium Term (2~5 years) Long term (5~ years)

Industry standards for selected processes

Advanced in-process monitoring and control

Compare, understand variability and control machine-machine

output

Industry standards for processes and alloys, domain specific (aerospace and

medical)

Material property databases for alloys (Ti, Al and Ni based) and

plastics

Alternatives to conventional qualification methods, validated models, part similarities

4: The Future:- Qualification & Certification Trends

32

Short Term (0~2 years) Medium Term (2~5 years) Long term (5~ years)

Rigorous equipment study and comparison

Establishment of test programs

Improve machine capability in terms of surface finish

and dimensional accuracy

Standard Qualification and certification of specific families

Versatile machines: Multiple processes/ geometries, larger sizes and use wire

or powder

Improved mechanical properties: Density, fatigue, strength

4: The Future:- Equipment Trends

Technical• Speed and Material Throughput

• Envelope size, accuracy, finish, resolution, detail

• CAD Design Software

• Materials

• Qualification and Certification

33

4: The Future:- Challenges

Not Quite Technical !• Monopoly

• Education

• Economies of Scale

• Regulation and Security !

34

The factory of the future will have only two employees, a man and a dog. The man will be there to feed the dog. The dog will be there to keep the man from touching the equipment.

Warren G Bennis

Notes

35

Process Control

36

Quality Considerations

37

Effect of :

1. Design: Orientation, Supports

2. Build: Direction, angle

3. Bed Temperature

4. Layer Thickness

5. Scan: Spacing, speed and length,

6. Powder Characteristics:

7. Laser parameters: power, density, pulse duration, pulse frequency

Effect on :

1. Mechanical properties: Ultimate tensile strength, yield strength, Toughness (Impact)

2. Density

3. Surface quality

4. Microstructure

5. Residual Stresses

Mechanical Properties

38