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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
pin
g A
pp
licati
ons
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Prototyping: Scale models
Pro
toty
pin
g A
pp
licati
ons
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Prototyping: SLA indirect
Pro
toty
pin
g A
pp
licati
ons
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Operating tools
App
licati
ons:
Tools
Chirurgy: Tools
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Operating tools Chirurgy: Tools
App
licati
ons:
Tools
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Protheses & Inplants
Applicati
ons
Medical products
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Chirurgical models
Med
ical A
pp
licati
ons
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Health: Hearing aids
Med
ical A
pp
licati
ons
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Interior: Lamps
Applicati
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
Applicati
ons
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Industry: Tools
Robotgrippers met gentegreerde luchtkanalen voor zuigcups
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Luchtafvoerkanaal koelunit
Applicati
ons
Industry: Tools
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Afzuigkop voor Bosch schuurmachine
Applicati
ons
Industry: Tools
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pplicati
ons
Industry: Ceramic parts
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Moldmaking: SLA inserts
Applicati
ons
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Industry: Special parts
Applicati
ons
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Werkzeugbau
Hofmann
LaserCusing
(Germany)
JB Ventures
(Netherlands) Applicati
ons
Industry: Moldmaking
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Industry: Moldmaking
Applicati
ons
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Industry: Machine parts
Carat Duchatelet Deursloten voor gepantserde voertuigen
(vooraan huidige sloten, achter de vernieuwde versie
Applicati
ons
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4. 3D Scanning
Reproduction or copying;
Scaling;
Orthopedic products (f.e. protheses)
Manufacturing of master (=indirect).
Reverse Engineering
Applicati
ons
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pplicati
ons
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!
Tre
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?