Digital to Physical: 3D Printing for Diverse Sectors

Digital to Physical: ALM for Diverse Sectors

Dr Ben Wood, WMG, University of Warwick

b.m.wood@warwick.ac.uk

@benjaminmwood

Agenda

0845-0915 Registration, tea and coffee

0915-0930 Welcome and Introductions

0930-1100 Physical to Digital – Laser scanning and producing a CAD file

1100-1115 Refreshments Break

1115-1245 Digital to Physical – 3D printing and how to deal with ‘bad’ CAD

1245-1330 Lunch

1330-1500 Low Volume Manufacturing – The gap between prototype and product

1500-1600 Adding Functionality – Update on latest polymer technologies

1600 on 1 to 1s with the Polymer Innovation team – individual projects

What are we going to talk about?

Introductions

– Dr Alex Attridge

& Ercihan Kiraci

– Dr Greg Gibbons

– Dr Kylash Makenji

Introductions

• Name

• Company

• Why you’re here

• What you would most like to get from today

Physical to Digital

Scanning technologies and

creating useful data

Physical to Digital

• Contents

–Why go from physical to digital?

– Technologies for collecting data

• Laser Scanning

• X-Ray Computed Tomography (CT)

• Structured Light and Photogrammetry

– Laser scanning demo

–Case study examples

Why Physical to Digital?

• There are a number of reasons: – Measurement/CAD comparison

– Simulation/virtual testing

• CFD for fluid flow or aerodynamic modelling

• FEA for stress analysis

– Create tooling from a physical prototype

– Benchmarking competitor product

– Reverse engineer to surface model or CAD

Colour chart and measurements showing deviation from CAD

Creation of an FE mesh for a fatigue crack specimen to help understand the effect of the crack on performance of the part

Creation of a digital surface model from a 1/3 scale Le Manns Prototype class clay model, to enable a full-scale physical model to be machine cut for use as a plug for the bodywork mouldings

Internal benchmarking of an automotive switchgear mechanism, carried out as part of a “switch feel” customer clinic study

Reverse engineering to CAD of a suspension component from a classic rally car to improve strength and compatibility with modern suspension leg/damper technology

Collecting data

• Different technologies for capturing 3D surface geometry: – Laser scanning

– X-Ray CT scanning

– Structure light scanning (white/blue)

– Photogrammetry

• Different technologies for different applications

Laser scanning

• Typically utilises Class 2 red laser light

• Move laser “stripe” over the surface to be measured

• “Stripe” is actually made up of hundreds of points

• Point cloud of data collected – x, y, z, co-ordinates

• Post-processing required but easy to create mesh

Laser scanning

Point Cloud (XYZ)

Accuracy 10µm – System Accuracy approx 40µm

75 stripes/sec - 1000 points/sec data collection

Digital Calibration for every point captured

Multiple lasers

Line Scanner Cross Scanner

Laser scanning

Manual Measurement Arm (Faro, Nikon, Roma etc.)

Optical CMM

On-CMM laser scanning head

Laser scanning

• Good for collecting complex surface geometry

• Software can identify and characterise features

• CMM or portable systems

• Simple to use – quick results

• Data captured not perfect – line of sight issues

X-Ray CT scanning

• Uses X-ray technology to create a digital 3D model of the object scanned

• Similar concept to medical CT, but much higher powered and much more accurate

• Limit to size and density of object to be scanned

Projection Image at angle 1 deg.

Projection Image at angle 2 deg.

3D object reconstruction by back-projecting the projection images - Using reconstruction software

Reconstructed 3D model visualization as stack of images - Using visualization software

STL format export

DICOM Image series export

Point cloud data export

CT Scanning of an object to get Projection Images - Using XT 320 H Machine

X-ray source

Rotary table

Object with a cylindrical hole inside

Detector

Projection Image on screen

X-Ray CT scanning

• Excellent technology for internal inspection

• Typically good quality data generated

• Very large file sizes

• Struggles with big changes in density

Structured light

Traditionally white light More recently blue light Projects pattern on to surface Pattern is distorted and captured

Structured light

GOM Phase Vision

Breuckmann

Structured light

Often used to characterise panels, clay models, people(!) etc. Good for large surfaces Not so good for smaller objects Can take a while to set up

Photogrammetry

Digital SLR Approx 60 photographs

Cloud-based software 3D digital model

Hands-on Demo

• Laser Scanning

• Software

Down to the workshops!

Digital to Physical

Additive Layer Manufacturing

Digital to Physical

• Contents –Data generation for ALM

• Data sources and examples

• Data repair

– System setup – an overview

– System set-up - practical hands-on)

–ALM – ‘the real deal’

DATA GENERATION

05/12/2012 30

Data Generation

• All systems use a ‘.STL’ file: – Surface triangulated mesh file representing the

surface of a component

• STL files can be generated from – Directly from export of 3D CAD – Surface scan data – Volumetric (e.g CT data)

• Data from any of these methods may require pre-processing to be useable in ALM

STL files from CAD

• Use ‘export ‘or ‘save as’ function to create STL

STL files from surface scan • Scan of iPhone 4 case:

STL from CT/MRI scan

Errors in STL files • Some STL files can be very poor quality

• Particularly from scan or CT…

…but can be poor CAD:

– Missing surfaces

– Gaps

– Intersecting surfaces

– Inverted triangle

normals

Errors in STL files

• Most ALM systems will not tolerate this and will require a ‘perfect’ STL file

– One single continuous surface

– All surface normals are correct

• Software is available to fix errors relatively easily

05/12/2012

SYSTEM SETUP – AN OVERVIEW

System Setup – Overview • STL file is the starting point for

any ALM system

• STL may contain colour information (color STL)

– Currently only ZCorp systems

– Mcor about to release colour system based on bonded paper sheets (Iris)

• VRML colour files are also accepted in ZCorp systems

System Setup – Overview • All system have proprietary software,

e.g: – Insight (Stratsys – FDM) – Objet Studio (Objet - MJM) – Zprint (ZCorp – 3D Printing)

• Functions available: – Operators on model

• E.g. rescale, rotate, translate, copy

– Support generation – Selection of build parameters

• Usually defaults, but can ‘play’ on some systems

– Obtain time, material usage information • Useful for quoting purposes

System Setup – Overview • Some systems require a support

structure to be generated

• This is always necessary for non-powder bed based systems

• Support acts as a surface to accept the next layer

• The system interface software generates this automatically

• Some control on the type of support is allowed, usually to minimise material usage – Density – Shape

System Setup – Overview • Additional functionality is available with the ‘new’ multi-

material printers, giving the ability to: – insert an assembly and define the type of material of each part in the

assembly

– overcoat with materials

– choose glossy or matte surface finish

ADDITIVE MANUFACTURING– THE REAL DEAL

Additive manufacturing– the real deal

• Materials

• Accuracy

• Resolution

• Sizes

• Time

• Costs

• ‘non added value’ activity

Polymers • Most common thermoplastics are:

– SLS (PA, PS)

– FDM (ABS, PLA, PC, PEEK)

• Most common thermosets are: – Acrylic (MJM)

– Epoxy (SLA)

– Wax-like (for investment casting)

• The HDT of FDM materials is equal to the IM grade

• The HDT of other polymers is usually lower than 500C

• High temperature polymers are available – PEEK (SLS)

– PPSF, ULTEM (MJM)

• Transparency is available but not for FDM and SLS – Translucency is available for FDM (ABSi - Methyl methacrylate-acrylonitrile-butadiene-

stryrene copolymer)

• Fire retardancy is available (most systems)

• Biocompatibility is available (non-implantable) for most systems

Metals

• Most metals processed using SLS

• Wide range of commercial materials

– Ti, Ti alloys, stainless steel, Inconels, CoCr, Maraging steel, tool steel, aluminium…

• Now systems processing Ag, Au, Pt (EOS-Cookson Metals tie-up)

• Mechanical properties usually approach or match those of wrought materials

Accuracy, Resolution

• Resolution and accuracy are not the same!

• Accuracy and resolution are complex and are highly dependent on system and component size, and on quality of calibration

05/12/2012

Accuracy Resolution

x y z x y z

SLS metal

30 30 20 100 100 20

SLS polymer

100 100 100 50 50 50

MJM 20 20 16 40 40 16

3DP 250 250 89 100 100 89

• Polymers – Wide range of size capabilities (50mm-3m+)

– Small bed sizes often have higher resolution

– Large bed sizes often have faster build rates

• Metals – Most metals systems have beds

<300x300x300mm

– Soon to be released have 500x500x300mm

• Time is very difficult to assess from an STL file since:

• Time is dependent upon:

– Part volume

– Part dimensions

– Part orientation

– Material used (even in the same process)

– Level of finishing required

– How much you want to pay (premium for queue jumping)

Costs (using a bureau)

• Not easy to assess just from an STL file since:

• Cost is very much dependent upon: – Volume of the component (amount of material)

– Part dimensions

– Cost of the material

– Amount of support material

– Resolution required (number of slices)

– Orientation required (taller the dearer)

– Number of parts required (often cheaper per part to have multiples – especially for SLS)

– Level of finish required

Costs (in-house)

• If you have system in-house, need to consider: – Maintenance costs – Material costs (including scrap, waste) – Consumables costs – Infrastructural costs – Labour costs (set-up and clean-down)

• Costs can vary widely depending on the system – System - £500-£1m+ – Maintenance – £100 – £30k PA – Material - £1 - £600 /kg – Infrastructural - £0 - £100k + – Labour - £5 - £200 per part

Low Cost Systems • Recent huge rise in ultra-

low cost systems – Makerbot, BFB, Cubify …

• Based on FDM technology

• £500 - £2,500

• Material costs ~£20/kg

• No dedicated computer

• No training

• Simple post-processing

Low Volume Manufacturing: Bridging the Gap

Dr Ben Wood & Dr Kylash Makenji

Outline

• Identifying the problem

– How to go from prototype to production?

• Direct manufacturing methods

• Rapid Tooling

– Indirect

– Direct

• Live demo of direct tooling

CNC Machining

The Problem

Tooling Cost

Number of Parts

10,000 100,000 1 1,000,000+ 1000 100

Injection Moulding

Compression Moulding

Rotational Moulding

Low Volume Manufacturing

What is Rapid Tooling?

• Early definition of Rapid Tooling:

“a process that allows a tool for injection moulding and die casting operations to be manufactured quickly and efficiently so the resultant part will be representative of the production material.” - Karl Denton 1996

• With Rapid Tooling now covering a wider range of

applications, this has generalised to:

“a range of processes aimed at reducing both the cost and time for

the manufacture of tooling.”

Classification of Rapid Tooling

• Indirect

– Use of a Rapid Prototype (RP) pattern to manufacture a tool in a secondary operation

• Direct

– Directly produce the tool using a layer-additive process

Indirect Rapid Tooling

• Cast tooling

– Cast resin tooling

– Cast metal tooling

– Cast ceramic tooling

• Metal spray tooling

– Kirksite thermal spray tooling

– Rapid Solidification Process tooling

– Sprayform tooling

• Indirect laser sintered tooling

– 3D LaserForm process

• 3D Printed tooling

– Extrude Hone Prometal

Cast Resin Tooling

• Obtained by two primary methods: – Room temperature vulcanised silicone

– Rigid resin tooling

• Room temperature vulcanised silicone – Silicone rubber tools for vacuum casting of

(generally) polyurethane parts

– RP model employed as master pattern

– Multistage process

– Resin parts vacuum cast or injected into tool

– Expensive materials

– Low volume (~30 parts) / extremely rapid (1-2 days)

Cast Resin Tooling

• Obtained by two primary methods: – Room temperature vulcanised silicone

– Rigid resin tooling

• Rigid resin tooling – Aluminium filled epoxy resin tools used for

injection / blow moulding

– As for RTV silicone, RP model used as master pattern

– Multistage process

– Difficult and slow to mould parts

– Volumes up to ~500 / very rapid (3-5 days)

Direct Rapid Tooling

• Direct metallic tooling

– Direct laser melted metallic tooling • EOSint M DirectTool

• MCP Selective Laser Melting (SLM)

• Direct polymeric tooling

– 3D Printed mould inserts • Object Connex 260 • Fortus FDM

Laser Melted Metallic Tooling

• DirectTool – Latest system EOSINT M270

– Process:

• Direct laser melting of metal powder

• Ability to polish to mirror finish

– Materials:

• DSH20 (tool steel)

• DS20 / 50 (20mm and 50mm steel)

• DM20 / 50 (20mm and 50mm bronze)

– Very hard tooling possible (42HRc)

– Very high accuracy (~50mm) / 20mm layers

– Conformal cooling channels

• Many similar processes, 2 most employed are: – DirectTool – EOS GmbH – Selective Laser Melting (SLM) – MCP Inc

Laser Melted Metallic Tooling

• Selective Laser Melting – Latest system „Realizer‟

– Process:

• Direct laser melting of metal powder

• Ability to polish to mirror finish

– Materials: • Any metallic powders 10-30mm

• Stainless steel most common

– Very high accuracy (~50mm) / 50mm layers

– Conformal cooling channels

• Many similar processes, two most commonly employed are: – DirectTool – EOS GmbH – Selective Laser Melting (SLM) – MCP Inc

3D Printed Polymer Inserts

• Manufacture a tool insert by ALM

– Accurate

– Good surface finish

– Very rapid (30 mins-2 hours)

3D Printed Polymer Inserts

• Ready for mass production

– Injection mould tooling

– Lower cost ‘pocket’ tool

– Can be used with wide range of inserts

• Easy, quick and inexpensive to make changes

INJECTION MOULDING TOOL INSERTS

Hands - On

Polymers

Material Compatibility

Process Comparison

Process Capital

Equipment Cost

Production Rate Tooling Cost Part Volumes

Compression Moulding

Low Slow Low 100 – 1 mill

Vacuum Forming Medium Medium Medium 10,000 – 1 mill

Injection Moulding High Fast High 10,000 – 100 mill

Extrusion Medium Fast Low – Medium Med - High

Blow Moulding Medium Medium Medium 1,000 – 100 mill

Rotational Moulding

Medium Slow Medium 100 – 1 mill

Summary

• Many potential manufacturing routes for low volume

– Right choice depends on part and material

• ALM can be used for much more than prototyping

– Key to most rapid tooling methods

Adding Functionality

IIPSI Capabilities and State of the Art

Outline

• Shape memory polymers

– Active disassembly

• Printed and plastic electronics

– Conductive polymers

– Low cost applications

– Integration

• What would you like to see?

Shape Memory Polymers

• Can be ‘programmed’ to change shape when given a trigger

• High material cost = niche applications

Mould part

Force into temporary

shape Cool

Restrain

Set temporary

shape Heat

Return to original shape

SMP Research Focus

Medical

Aerospace/defence – morphing wings Outer Space – Zero Gravity

SMPs for SMEs!

• ‘Active’ disassembly

– Ideal for automotive, consumer electronics

• Automatically release at end of life

– Materials separation, recycling

• Low complexity

– Maximise added value

PLASTIC AND PRINTED ELECTRONICS

Conductive Polymers

• Actual conductive polymers not common

– Difficult to process, not like plastics

– Normally dissolved in solvent

• Applications in PV and EL/OLED

– Useful as part of a printed or plastic electronic component

Plastic and Printed Electronics

• Growth area

– Funding opportunities

• Costs reducing

– Expensive materials vs volume production

• Key applications

– Display technology

– ‘Smart’ Packaging

– IoT

• Electroluminescence (EL)

– Low energy, low heat lighting

– Simple circuit

PEDOT-PSS transparent electrode

Zinc Sulphide Phosphor

Dielectric

Reflective (silver) rear electrode

Surface

Plastic Electronics

EL Applications

Low Cost Plastic Electronics

Airbrush Method

Screen Printing Type Method

Direct In-Mould Layer Application

Post Mould Layer Application

• Bespoke system hybridising MJM with syringe deposition – 2 x 512, 14pl nozzle heads,

individually addressed

– High viscosity liquid dispensing

– Continuous flow for deposition of resins with highly suspended solids

– SmartPump for deposition of higher viscosity resins and pastes at extremely high resolution

Hybrid 3D Printing

• Integrated manufacture

– Functional components

– Electronic circuits

• Facilitates adding of functionality and connectivity

– Eg interactive books

– Internet of Things (IoT)

Summary

• Complex circuits require expensive kit and specialist knowledge

• Market is growing, costs coming down – Printing technology, roll-to-roll

• Simple circuits achievable with low capital – Layer-by-layer deposition of materials

• Future is in integration – IoT – https://www.youtube.com/watch?v=zG2dvxSKEGU

– https://www.youtube.com/watch?v=Kgw51_PtDSs

OVER TO YOU! What would you like to see in the IIPSI?

Digital to Physical: 3D Printing for Diverse Sectors

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