Additive Manufacturing with Metals
Additive Manufacturing with Metals Society of Manufacturing Engineers Greater Charleston Chapter 430
Trends in Additive Manufacturing (AM)
Capabilities of AM Technology For Metals
Design For Additive Manufacturing (DFAM)
Additive Manufacturing with Metals 2
Trends in Additive Manufacturing
Additive Manufacturing with Metals 3
“3D printing and 3D imaging are causing design and manufacturing professionals to rethink their approach to new product development.” - Terry Wohlers
Additive Manufacturing – the 3rd Industrial Revolution 4
AM can change the way we do Business 5
Metal Printing Introduced With DMLS
DMD
AM Timeline 6
Worldwide sales of 3D printing machines for metal parts were up 45% in the 3rd quarter compared to the same period last year.
“The trend of using 3D printing for finished goods, direct part production is most evident in the metal side of the industry” Chris Conery, CONTEXT
The aerospace, automotive and medical markets are the leading industries for metal 3D printing
Metal is King in AM 7
Who uses metal printing?
Players – big players 8
Make what could not be made before 9
Make what you can imagine 10
Make things that could not be made before Mimics nature, much like nature builds cell by cell Empowers mass customization
◦ mass produced, identical products obsolete
Similar properties to traditionally manufactured parts
Complex cellular castings - VT
Capabilities of Metal AM 11
Metal Printing Technologies
Direct Metal Laser Sintering Electron Beam Melting Laser Metal Fusion Laser Metal Deposition Binder Jetting
Additive Manufacturing with Metals 12
Powdered metal layers sintered with laser Materials ◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦
17- PHSS 15-5 PHSS 316L Aluminum Hastelloy X Inconel 625 Inconel 718 Cobalt Chrome Ti 6AI-4V Maraging Steel MS1
Laser Sintering DMLS 13
Aerospace - Aircraft Engines & Development Repair Applications Oil & Gas industry Missiles & Propulsion Orthopedics & Spine Rig Testing Injection MoldTool Inserts Medical Implants & Instrumentation
Laser Sintering DMLS 14
Powdered metal melted with laser Denser parts than DMLS Materials
◦ Steels, high strength steels ◦ Alloys based on Ni, Co, Al, Cu or Ti
Laser Metal Fusion (LMF/SLM) 15
Powdered metal layers melted with electron beam Denser parts than DMLS Layer Thickness 0.0024” Mainly used in Aerospace Production Hardware Prototypes
Material – Ti 64
Electron Beam Melting 16
Metal powder injected into laser beam
Materials ◦ Steels ◦ Metallic glasses ◦ Alloys based on Ni, Co, Al, Cu or Ti
Laser Metal Deposition (LMD) 17
5 axis versatility Component repair Mold / tooling repair Cladding
Lasertec + DMG Mori ◦ Additive and subtractive
Laser Metal Deposition (LMD) 18
Similar to Color Jet printing with layers of powdered metal ◦ Developed at MIT
Self supporting No in-process heat Part is sintered in a post process furnace May be infiltrated with melted metal (e.g. bronze)
Binder Jetting 19
Fiber laser creates very short pulses of high energy laser light (quadrillionth of a second) Unprecedented resolution and accuracy (sub-micron) High melting temps (3000 C) Less heat affected zone Microcavities possible
◦ Bio-sensing ◦ Optoelectronics ◦ Quantum data storage
Materials
◦ tungsten and pure iron in R&D
Future - Femtosecond Laser Melting 20
Design for AM
Design for AM (DFAM) - Maximize product performance through the synthesis of shapes, sizes, structures, and material David Rosen, Georgia Tech
Complexity is Free
Additive Manufacturing with Metals 21
Usage of complex geometry in achieving design goals, with no time or cost penalties compared to simple geometry;
Designers can avoid most manufacturing process constraints
Usage of customized geometry direct to production from 3D data
Consolidate parts, integrate features into more complex parts and avoid assembly issues
Direct fabrication from digital data allows low production volumes to be economical
AM Design Principles 22
Shape complexity: ◦ ◦ ◦ ◦
Build virtually any shape Lot sizes of one Customized geometries Shape optimization is enabled without hard tooling
Material complexity:
◦ Material processed one layer at a time ◦ Manufacture parts with complex material compositions property gradients
Hierarchical complexity:
◦ Multi-scale of features, sub-features
Functional complexity:
◦ Functional devices can be fabricated directly by embedded components and kinematic joints
AM Capabilities 23
Design for functionality
◦ Topology optimization - If a part’s function can be defined, it can be optimized
Cellular structure utilization
◦ Foams, honeycombs, lattice ◦ Energy absorption and insulation ◦ Strength/weight optimization
Redesign kinematic mechanisms as compliant mechanisms
◦ Bending structural elements causes desired output behavior
AM Design Strategy 24
Design for additive manufacturing by creating optimized structures Structures can be created that cannot be manufactured using traditional methods ApplicationsAerospace, automotive, medical, architectural
Optimized structures 25
Being forced to design in a sketch-based fashion, which is essentially 2D, limits solutions to traditional fabrication methods Example of piston design optimized for AM (23% lighter)
Better performance 26
DMLS/SLS printed IM tools May cost 2X machined tools Ability to optimize cooling channels in tool cores, avoiding complex tooling tricks Can reduce cycle times by 60%, scrap rates cut from 50% to 0% (Laser Bearbeitungs Center, DE)
Tooling
EOS Suggestions for determining cooling channel diameter and spacing
27
Examples of AM with Metal
Additive Manufacturing with Metals 28
"3D printing opens up a whole new way of thinking about the design of components, where printed parts allow for higher complexity and more complex features that allow significant weight savings or enhanced flowability for cooling within the component." Gary Cosmer, CEO, MTI
MTI – one-off oil pump pulley for racecar in 3 days
Titanium part, traditionally machined from billet into 3 parts, e-beam welded. 25% failure rate mainly due to imbalance (must spin at 10,000 rpm) Designed for AM – 1 part, perfectly balanced
◦ Requires skim machining of surface
EFC Systems - Painting Bell 31
GE Aircraft ◦ ◦ ◦ ◦ ◦
Reduced weight of engine bracket by 70% Utilized Topology optimization (Inspire) Material is Titanium Estimated to save ~$10 million 3D Systems ProX™ DMP 320
Example 2 – aircraft engine bracket 32
Indirect Metal
Additive Manufacturing with Metals 33
Custom Turbines for Hydro Electric Power Plants by Tushino Power Tools
Customization: water pressure, drop height and flow rate 3D printing enables customization Speeds up production times Easier handling, reduced weight
20% Efficiency Increase in Turbines
FDM for sheet metal forming Reduced lead times for tooling Design flexibility Natural porosity and lubricity (ULTEM and PC) Repeatable tool forms, updates are simple, cheap Lighter weight – human factors
Tooling 35
SME ◦ Additive Manufacturing Certificate Program
ASTM
◦ Proposed guide to create design rules for AM in Nov 2015
America Makes
◦ A community for developing AM standards, tools, education and research
AMSE
◦ AM group, AM3D conference
RAPID 3D technology event ◦ May 2016
Standards and Education 36
We can produce parts with most AM processes 3D printer sales and service through SOS 20+ service bureaus in network (including Quickparts and Stratasys Direct) Engineering prototypes, end use parts, visual models Quick turn quotes and delivery Guaranteed best quote for equivalent service Personal attention
Reify Services
Thank You
Questions? 38
Trends in Additive Manufacturing (AM)
Capabilities of AM Technology For Metals
Design For Additive Manufacturing (DFAM)
Additive Manufacturing with Metals 2
Trends in Additive Manufacturing
Additive Manufacturing with Metals 3
“3D printing and 3D imaging are causing design and manufacturing professionals to rethink their approach to new product development.” - Terry Wohlers
Additive Manufacturing – the 3rd Industrial Revolution 4
AM can change the way we do Business 5
Metal Printing Introduced With DMLS
DMD
AM Timeline 6
Worldwide sales of 3D printing machines for metal parts were up 45% in the 3rd quarter compared to the same period last year.
“The trend of using 3D printing for finished goods, direct part production is most evident in the metal side of the industry” Chris Conery, CONTEXT
The aerospace, automotive and medical markets are the leading industries for metal 3D printing
Metal is King in AM 7
Who uses metal printing?
Players – big players 8
Make what could not be made before 9
Make what you can imagine 10
Make things that could not be made before Mimics nature, much like nature builds cell by cell Empowers mass customization
◦ mass produced, identical products obsolete
Similar properties to traditionally manufactured parts
Complex cellular castings - VT
Capabilities of Metal AM 11
Metal Printing Technologies
Direct Metal Laser Sintering Electron Beam Melting Laser Metal Fusion Laser Metal Deposition Binder Jetting
Additive Manufacturing with Metals 12
Powdered metal layers sintered with laser Materials ◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦ ◦
17- PHSS 15-5 PHSS 316L Aluminum Hastelloy X Inconel 625 Inconel 718 Cobalt Chrome Ti 6AI-4V Maraging Steel MS1
Laser Sintering DMLS 13
Aerospace - Aircraft Engines & Development Repair Applications Oil & Gas industry Missiles & Propulsion Orthopedics & Spine Rig Testing Injection MoldTool Inserts Medical Implants & Instrumentation
Laser Sintering DMLS 14
Powdered metal melted with laser Denser parts than DMLS Materials
◦ Steels, high strength steels ◦ Alloys based on Ni, Co, Al, Cu or Ti
Laser Metal Fusion (LMF/SLM) 15
Powdered metal layers melted with electron beam Denser parts than DMLS Layer Thickness 0.0024” Mainly used in Aerospace Production Hardware Prototypes
Material – Ti 64
Electron Beam Melting 16
Metal powder injected into laser beam
Materials ◦ Steels ◦ Metallic glasses ◦ Alloys based on Ni, Co, Al, Cu or Ti
Laser Metal Deposition (LMD) 17
5 axis versatility Component repair Mold / tooling repair Cladding
Lasertec + DMG Mori ◦ Additive and subtractive
Laser Metal Deposition (LMD) 18
Similar to Color Jet printing with layers of powdered metal ◦ Developed at MIT
Self supporting No in-process heat Part is sintered in a post process furnace May be infiltrated with melted metal (e.g. bronze)
Binder Jetting 19
Fiber laser creates very short pulses of high energy laser light (quadrillionth of a second) Unprecedented resolution and accuracy (sub-micron) High melting temps (3000 C) Less heat affected zone Microcavities possible
◦ Bio-sensing ◦ Optoelectronics ◦ Quantum data storage
Materials
◦ tungsten and pure iron in R&D
Future - Femtosecond Laser Melting 20
Design for AM
Design for AM (DFAM) - Maximize product performance through the synthesis of shapes, sizes, structures, and material David Rosen, Georgia Tech
Complexity is Free
Additive Manufacturing with Metals 21
Usage of complex geometry in achieving design goals, with no time or cost penalties compared to simple geometry;
Designers can avoid most manufacturing process constraints
Usage of customized geometry direct to production from 3D data
Consolidate parts, integrate features into more complex parts and avoid assembly issues
Direct fabrication from digital data allows low production volumes to be economical
AM Design Principles 22
Shape complexity: ◦ ◦ ◦ ◦
Build virtually any shape Lot sizes of one Customized geometries Shape optimization is enabled without hard tooling
Material complexity:
◦ Material processed one layer at a time ◦ Manufacture parts with complex material compositions property gradients
Hierarchical complexity:
◦ Multi-scale of features, sub-features
Functional complexity:
◦ Functional devices can be fabricated directly by embedded components and kinematic joints
AM Capabilities 23
Design for functionality
◦ Topology optimization - If a part’s function can be defined, it can be optimized
Cellular structure utilization
◦ Foams, honeycombs, lattice ◦ Energy absorption and insulation ◦ Strength/weight optimization
Redesign kinematic mechanisms as compliant mechanisms
◦ Bending structural elements causes desired output behavior
AM Design Strategy 24
Design for additive manufacturing by creating optimized structures Structures can be created that cannot be manufactured using traditional methods ApplicationsAerospace, automotive, medical, architectural
Optimized structures 25
Being forced to design in a sketch-based fashion, which is essentially 2D, limits solutions to traditional fabrication methods Example of piston design optimized for AM (23% lighter)
Better performance 26
DMLS/SLS printed IM tools May cost 2X machined tools Ability to optimize cooling channels in tool cores, avoiding complex tooling tricks Can reduce cycle times by 60%, scrap rates cut from 50% to 0% (Laser Bearbeitungs Center, DE)
Tooling
EOS Suggestions for determining cooling channel diameter and spacing
27
Examples of AM with Metal
Additive Manufacturing with Metals 28
"3D printing opens up a whole new way of thinking about the design of components, where printed parts allow for higher complexity and more complex features that allow significant weight savings or enhanced flowability for cooling within the component." Gary Cosmer, CEO, MTI
MTI – one-off oil pump pulley for racecar in 3 days
Titanium part, traditionally machined from billet into 3 parts, e-beam welded. 25% failure rate mainly due to imbalance (must spin at 10,000 rpm) Designed for AM – 1 part, perfectly balanced
◦ Requires skim machining of surface
EFC Systems - Painting Bell 31
GE Aircraft ◦ ◦ ◦ ◦ ◦
Reduced weight of engine bracket by 70% Utilized Topology optimization (Inspire) Material is Titanium Estimated to save ~$10 million 3D Systems ProX™ DMP 320
Example 2 – aircraft engine bracket 32
Indirect Metal
Additive Manufacturing with Metals 33
Custom Turbines for Hydro Electric Power Plants by Tushino Power Tools
Customization: water pressure, drop height and flow rate 3D printing enables customization Speeds up production times Easier handling, reduced weight
20% Efficiency Increase in Turbines
FDM for sheet metal forming Reduced lead times for tooling Design flexibility Natural porosity and lubricity (ULTEM and PC) Repeatable tool forms, updates are simple, cheap Lighter weight – human factors
Tooling 35
SME ◦ Additive Manufacturing Certificate Program
ASTM
◦ Proposed guide to create design rules for AM in Nov 2015
America Makes
◦ A community for developing AM standards, tools, education and research
AMSE
◦ AM group, AM3D conference
RAPID 3D technology event ◦ May 2016
Standards and Education 36
We can produce parts with most AM processes 3D printer sales and service through SOS 20+ service bureaus in network (including Quickparts and Stratasys Direct) Engineering prototypes, end use parts, visual models Quick turn quotes and delivery Guaranteed best quote for equivalent service Personal attention
Reify Services
Thank You
Questions? 38
