2013-11-20 Plastics for Additive Manufacture, T Buesgen ... · Bayer MaterialScience Solutions Polyurethanes rigid foams Polycarbonates a applications Basic chemicals as product manufacture

Dr. Thomas BüsgenBayer MaterialScience AG

Plastics for Additive Manufacturing

20th November 2013, 3D Printing & Additive Manufacturing Industrial Applications Summit 2013, London

Sources: voxeljet, Materialise NV, Iris van Herpen

Bayer MaterialScienceProducts and Solutions

PolyurethanesRaw materials for rigid

and flexible foams

Polycarbonates Granules and sheets for a wide variety of applications

Basic chemicalsChlorine production as the backbone for product manufacture

One of the world's leading polymer producers

CoatingsRaw materials for coatings,

adhesives and specialties

High-performance materials for a changing world. Page 2 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London

20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG

Bayer MaterialScienceInnovations

Page 3

Research for tomorrow´s worldGlobal teams of inventors at Bayer MaterialScience develop new applications for materials and participate to design the future.

Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG

UV lamp

Photopolymer

Laser

Thermoplast

Plastics for Additive Manufacturing Material selection strongly depends on AM process

Liquid adhesive

Inkjetprint head

Stereolithography

Jetted Photopolymer

Binder Jetting

Selective Laser-Sintering

Fused Deposition Modeling

Low viscous polymer ink Very fine powders

Photo-curable resins Thermoplasts

Filaments

Page 4

Source: custompart.net


StereolithographyProcess:Highly focused UV laser traces out successive cross-sections in a vat of liquid photo-polymer�• Curing and solidification by laser�• Post-curing in UV oven Accura

PEAKAccura 60

VisiJetEX200

AccuraAmethyst

AccuraCeraMAX

0

20

40

60

80

100

0 50 100 150 200 250

Tens

ile s

treng

th (M

Pa)

Max. working temperature (°C)

Currently available for AM

Page 5



Jetted PhotopolymerProcess:Photo-Polymers (build + support material) �• Printed by inkjet head�• cured by UV lamp

UV lamp

Photo

polymer


Vero

Tango

VisiJet

0

20

40

60

80

100

0 50 100 150 200 250

Tens

ile s

treng

th (M

Pa)


Page 6



Binder jettingProcess:Powder bed consisting of polymer, ceramic or metallic particles, respectively �• Jetting of polymer binder�• Subsequent infiltration possible

Liquid adhesive

Inkjetprint head


PMMA

ZP 131

Steel infiltr. w/ bronze

0

20

40

60

80

100

0 50 100 150 200 250

InfiltrationTe

nsile

stre

ngth

(MP

a)


3D Systems (ZCorp)

voxeljet


Page 7 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG

Binder jettingProcess:Powder bed consisting of polymer, ceramic or metallic particles, respectively �• Jetting of polymer binder�• Subsequent infiltration possible

Liquid adhesive

Inkjetprint head


PMMA

ZP 131

Steel infiltr. w/ bronze

0

20

40

60

80

100

0 50 100 150 200 250

InfiltrationTe

nsile

stre

ngth

(MP

a)


3D Systems (ZCorp)

voxeljet

500


Page 8 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG

PEI

0

20

40

60

80

100

0 50 100 150 200 250

ABS

PC

PEI

PPSFPLA

0

20

40

60

80

100

0 50 100 150 200 250

Process:Filaments of thermoplasts �• 3 mm diameter�• build + support materials�• heated and applied as thin

fibers on a x-y-stage

Fused Deposition Modeling (FDM)Currently available for AM

Page 9


Tens

ile s

treng

th (M

Pa)


Polyphenyl-sulfone

Polyether-imid

Injection molded

Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG

Polyether-etherketone

PA11PS

PEEK

PP

0

20

40

60

80

100

0 50 100 150 200 250

PA11

PS

PEEK

PP

PA12

DuraFormFlex0

20

40

60

80

100

0 50 100 150 200 250

Selective Laser-Sintering (SLS)

Page 10

Process:Powder of thermoplastic polymer �• ~ 100 µm particles�• pre-heated just below Tmelt

�• laser-sintered layer-by-layer

Biobased material



Laser

Thermoplast

Tens

ile s

treng

th (M

Pa)



Polyether-etherketone

PA11PS

PEEK

PP

0

20

40

60

80

100

0 50 100 150 200 250

PA11

PS

PEEK

PP

PA12

DuraFormFlex0

20

40

60

80

100

0 50 100 150 200 250

Selective Laser-Sintering (SLS)

Page 11

Process:Powder of thermoplastic polymer �• ~ 100 µm particles�• pre-heated just below Tmelt

�• laser-sintered layer-by-layer

Biobased material

PA11PEEK

EOS Stainless

steel

EOS Cobalt

Chrome

0

200

400

600

800

1000

1200

1400

0 250 500 750 1000 1250Max. working temperature (°C)


Laser

Thermoplast

Tens

ile s

treng

th (M

Pa)



Cost ComparisonMaterials for AM vs. conventional

SLA Photopolymer resins ~ 175 to 225 $/kg

PolyJet photopolymers ~ 100 to 300 $/kg

SLS powders (PA12) ~ 85 to 100 $/kg

FDM personal 3D printers ~ 15 to 50 $/kg

FDM professional (ABS, PC) ~ 250 $/kg

FDM (PEEK, PEI) > 500 $/kg ABS ~ 2 $/kg

PC ~ 3 $/kg

PA6 ~ 3 $/kg

PA11 7 �– 13 $/kg

PEI 15 �– 20 $/kg

PEEK 34 �– 68 $/kg

Sources:Wohler�’s Report 2013, plasticker.de

Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AGPage 12

Summary Material Selection for AM�• All additive manufacturing processes

require specific material classes

�• Final material properties very dependent on used AM technology

�• Usually anisotropic material properties due to layered building

�• Additive Manufactured parts do not match properties of injection molded ones, yet

Today main application in rapid prototyping, visual aids, art,�…

Need for: larger choice in polymer material and properties (e.g. elastic)Scalable processes and competitive prizes

Sources: 3D Systems, voxeljet

Page 13 Plastics for Additive Manufacturing �• 3D Printing & Additive Manufacturing Industrial Applications Summit �• London 20th Nov. 2013 �• Thomas Büsgen �• Bayer MaterialScience AG

New Developments:3D printing from polymer pellets

Arburg presents Freeformer

�• Combination of injection molding and FDM technology

�• Uses any kind of thermoplastic pellets (no filament)

�• Printing of several materials

�• No support material by 5 axis building


Sources: Arburg.com

New Developments:First Fully-functional Flexible Material in 3D Printing

�• Basis: Thermoplastic Polyurethane (Desmopan®, Bayer MaterialScience)

�• Milled into fine powder of ~100 µm (Desmosint® TPU 92A-1, Lehmann&Voss)

�• Selective Laser-Sintering

Unique properties for AM material:Durable elasticity

High tear resistance

High resistance to dynamic loading

High abrasive resistance

Snappy response

Good temperature range (-20 to 80 °C)

Elongation at break >350 %Sources: Lehmann&Voss, Materialise NV, Iris van Herpen


Thomas BüsgenSenior project leader 3D digital printing New Applications EMEABMS-CAS-INN-NAEMEA51368 Leverkusen, Building Q 1+49 214 30 48654 [email protected]

Thank you

3D-Printed Bayer crossSize: 4 cm in diameter, 1.5 mm in height


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2013-11-20 Plastics for Additive Manufacture, T Buesgen ... · Bayer MaterialScience Solutions Polyurethanes rigid foams Polycarbonates a applications Basic chemicals as product manufacture