Mutchler StratasysDirect V2 - Map Your Sho stratasys direct manufacturing additive metals eric mutchler 13 september identifying applications for 3d printings most coveted material

1 STRATASYS DIRECT MANUFACTURING

ADDITIVE METALS

ERIC MUTCHLER13 SEPTEMBER

IDENTIFYING APPLICATIONS FOR 3D PRINTINGS MOST COVETED MATERIAL


AGENDA

Section One – Identifying ApplicationsSection Two – Where's The BenefitSection Three – Designing For Additive MetalsSection Four – Build Set-UpSection Five – Controlling The ProcessSection Six – Summary


Stratasys is a global leader in 3D printing and additive manufacturing solutions.• Inventors of additive processes

Fused Deposition Modeling (FDM) and PolyJet

• 3,000+ employees across the globe

• Over 25 years of market leadership

• More than 110,000 systems sold (2014)

• $750M combined revenue (2014)

ABOUT STRATASYS


Stratasys Direct Manufacturing is one of the largest providers of additive and conventional manufacturing services.

• 7 U.S. manufacturing facilities

• 9 Manufacturing technologies

• 600+ employees

• Certifications: ISO 9001, AS9100

• ITAR registered

ABOUT STRATASYS DIRECT MANUFACTURING


PRODUCT MANAGER FOR LASER SINTERING

Eric Mutchler

6

Identifying Applications

7


9

10

Where's The Benefit


COOL FACTOR


COMPLEX STRUCTURES


MULTI-PART ASSEMBLIES


Eurostar‐E3000‐Copyright‐Airbus‐Defence‐and‐Space‐Ltd

WEIGHT REDUCTION


DESIGN VERIFICATION PRIOR TO CASTING

16

Designing for Additive Metals


• Extreme example of “burn”

“BURN”

• Supported area does not have “burn”

1.5in


TYPICAL BURN


• Are required• Made of the same build material

“SUPPORTS”


• Horizontal up to 30 degrees• 30 degree to 45 degree• 45 degree to 60 degree• 60 degree

SELF-SUPPORTING ANGLES


• Horizontal to 30 degrees always are supported• Aluminum can build at 30 degrees• All other materials require supports at 0-45 degrees

30 DEGREE


• 45-60 will have burn or roughness above typical• 60-Vertical will have typical overall appearance

45 and 60 DEGREE


• Full supports are required

HORIZONTAL SURFACES


• Arched tops can eliminate the need for supports

DESIGN FOR THE PROCESS


1‐5mm

0.05in ‐ 0.19in6‐9mm

0.20in ‐ 0.35in Over 9mm

0.36in

1-5 mm 6-9 mm Over 9 mm

0.05-0.19 in 0.20-0.35

in

HORIZONTAL HOLES


• Ways to create larger holes




• Application


TRAPPED SUPPORTS


• Not a flaw• Will repeat

THICKNESS TRANSITIONS


PLANE FORM DISTORTION


Build Set-Up


• Maximum round is 9.7 inches• Maximum square is 8.5 inches

START HERE…


• Max height is about eight inches• Layout optimized for best performance

PART POPULATION


• Orientate part• Attach solid supports• Fill with lattice support

TYPICAL BUILD SETUP


Controlling The Process


Customer-Manufacturer mutual understanding of application and the component demandsIdentify the anticipated AM benefit

• Part consolidation• lead time savings• cost or design integration tool

APPLICATION EVALUATION


• Identify risk regions including small features, thin walls, hover hangings, trapped volumes

• Redesign for the process or accept the known risk • Adjust part file in Solidworks/Magics to add solid support and encasements• Position part on build scene in Magics• Support file with various strategies of hatch supports

GEOMETRY EVALUATION

Supports Recommended

Supports Likely

Supports Required


Two Facilities: Austin TX and Belton TXSixteen Laser Based Metal Powder Bed Machines

• 9 (Austin)• 7 (Belton)

Eight Different Materials

MACHINE FLEET AND STRUCTURE


• Disseminate identical parameter sets across machines. • Any changes undergo a document process change request.• The parameters are rev controlled to ensure parts built today can be

built identically in the future.

COMMANDING THE FLEET


To prevent power disturbances, both DMLS sites have back-up power systems.

This helps maintain efficiencies and mitigate the risk of interrupted builds.

MAINTAINING POWER


Workbench - BuildIt / Powder Report

Digitally capture and mine powder composition

MATERIAL TRACEABILITY


Manufacturing Metrics

Work Order – Operation Sign OffJOB TRACKING


• Serial numbers designate machine, build, and location

• Allows for complete traceability all the way back to the raw material used/mixed

PART SERIALIZATION


Part Cutups

• Monitors quality from all machines

• Part specific quality check coupon cutups

• Geometry representative samples

• Metallographic reports

DESTRUCTIVE TESTING


Stress Relief

Plate‐Part Separation

Part Serialization

In‐process Inspection

HIP

SHT, PHT

Dimensional Inspection

RadiographicInspection

Performance Inspection

Stratasys Direct, In‐house

Powder Removal

This is the only Additive Step

Dimensional InspectionCMM, Faro, Surface Roughness

Radiographic InspectionX‐ray, CT scan

Performance InspectionHydrostatic Pressure, Air Effective Area

Heat Treating Vendor Radiographic Testing Vendor

Post Machining

Outsourced operations are executed by vetted strategic partners.

Cutup MetallographyDMLS

DMLS Delivered Parts are mostly Conventional


Summary


• Seek complex geometries• Consolidate parts• Modify existing geometries• Design for the process • Control the process• Document the process• Test to verify

SUMMARY


THANK YOU

Eric MutchlerProduct Manager LSStratasys Direct ManufacturingAustin [email protected]

Mutchler StratasysDirect V2 - Map Your Sho stratasys direct manufacturing additive metals eric mutchler 13 september identifying applications for 3d printings most coveted material

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