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Drs. Ing. R. Abdoel (Ricardo) Powered by Centre of Expertise
High Tech Systems & Materials
Future Outlook
• From Lab to Fab
• It’s here to stay!
• Versatility - impact on all sectors
• Addition not replacement
• Global Design Local Manufacturing
• Education – Tech. Knowledge – Process Control – (advanced)
Material Science
• Capital Intensity - Intellectual Property
• 3D Design Mindset – Design for Function
• Strong collaboration throughout the whole value chain
• More, better and user-friendly software
• Economies of Scale – Scale the Economy
Gartner Hype Cycle
(IDtechEx, 2014)
(Gartner, 2014)
Technologies
Applications
Materials??
(Rogers, 1995)
Diffusion of Innovation (DOI)
Additive Manufacturing
Creative Industry (art & design)
Agro / Food Industry
Bio-Medical / Dental Industry
Automotive Industry
Fashion Industry
Aerospace Industry
4 kg 1 kg
55%
3D printers (consumers, personal)
Quality ~ Size | Speed | Resolution | Tolerance | Material | Design | AM Process
Price ~ €250 to €3000
3D printers (industry, production)
Price
€250.000
to
€1.4 mlj.
Quality ~ Size | Speed | Resolution | Tolerance | Material | Design | AM Process
3DP = materialDESIGN
Design versus Material
Toon Roels, Materialise
Z-direction through design Ferrie van Hattum, Saxion
Dril a hole (subtractive) Built a hole (additive)
Mindset Think and Design in 3D
Design Freedom (3D 4D)
Design for Function
Design Rules / Guidelines
Design Rules / Guidelines
Manifolds and Channels Molds / Casts
Design Product and Support
Unsupported
overhang Orphan
part Upward
Slope
The most suitable build direction? Topology optimization Organic
3D Printing: the process + variations
Idea CAD Slice PreProc Print PostProc T&M Product
Range of
Materials Print
Technology
Design
Accuracy
Cost
Material Selection and Dependencies
Function
Process
Shape Material
Structure
Properties
Performance
Processing
Interaction of Function and Material
(Granta Design) • Mechanical
• Thermal
• Electrical
• ……..
Material Scientists Designer/Engineer
Topology Optimization
(Altair)
(EADS)
“design flexibility, low material waste and
low cost of producing parts from hard
materials that are otherwise difficult to
machine”
The optimized design retained the
same characteristics in terms of
stiffness and bolt loading, while
reducing the stresses on the part
Material content within the model?!
• SLS (Selective Laser Sintering)
• SLM (Selective Laser Melting
• EBM (Electron Beam Melting)
• FDM (Fused Decomposition Modelling)
• WAAM (Wire and Arc AM)
• SLA (Stereo Lithography Apparatus)
• DLP (Digital Light Processing)
• SHS (Selective Heat Sintering)
• LOM (Laminated Object Manufacture)
• DMLS (Direct Metal Laser Sintering)
• ….
AM Process Technologies
Materials for 3D Printing (multi, mix)
(imaterialise)
• Material Selection Process
• Raw Materials Particle Size Distribution
• Temperature influence (before, during, after)
• Print Process/Technology
• Multi material (mix, blended), CerMets
• Machine and Material Flexibility/Process-ability
• Topology optimization
• Limitations of current manufacturing methods
• Changing materials “on the fly”
Variables (>400) on 3D part quality and performance
Developments in (advanced) materials
• Total AM material consumption from 900 t to 9,000 t by 2023
• Creation of Metal Powder Complex proces Expensive
• Powder with high purity and narrow distribution
• Hard to get from large providers (small orders)
• Usually sold by AM system providers (vendor lock-in)
• Flexible materials, Bio-Degradable
• Multi-material, Multi-Color, Part fabrication
• Embedded Components
ExOne Inconel alloy 625 nickel-based alloy
Examples:
Inconel 718® has been introduced as a qualified material for use in
Arcam’s EBM systems specifically for the Arcam A2X platform.
Combining Materials
By combining the two materials, their strengths have been joined and their
weaknesses hidden.
Hybrid CNT/IGZO circuits on a
polyimide film laminated on a
polydimethylsiloxane (PDMS)
substrate
Applications:
Organic Light Emitting Diodes
(OLEDs), digital circuits, radio
frequency identification (RFID)
tags, sensors, wearable electronics,
and flash memory devices. Even
heads-up displays on vehicle
dashboards could soon be a reality.
MATERIALS
AMT = Multidisciplinary Approach
“we’ve only seen the tip of the iceberg!” -Terry Wholers -
MANUFACTURING
SUSTAINABILITY DESIGN
EDUCATION SOFTWARE
SUPPLY CHAIN PRODUCTION
BUSINESS
TEST & MEASUREMENT ENGINEERING
RESEARCH PROCESS
X-Factor
Education
(DigiNova,2014)
(AM Platform, 2013)
(Berenschot, 2013)
Y-Factor
(Inter)national Collaborative Effort
Machine
Materials
Process
Z-Factor
Government Education
Industry
Fontys Objexlab
Fontys Objexlab Business Model
Internships, Graduation,
Promotion, Entrepreneurship
Teachers,
Professors,
Students,
Trainees,
Companies
EDUCATION:
Bachelors
Courses
Workshops
Training
VO, MBO, HBO, HBO+
PROJECTS:
Prototyping
Design & Engineering
Low Volume production
SME, OEM, partners
DEMO CENTER:
Promotion
Facility Sharing
Demo machines/processes
Industry
APPLIED RESEARCH:
Design Rules, Guidelines
Thermal Engineering
Test & Measurement
Parameter Research
Product Properties
Material Properties
SME, OEM en P in E
AM-Academy (www.am-academy.nl)
AM basics &
businesses
• “not for profit”
• Introduction AM and application areas;
• AM Technologies;
• AM Machine Operations;
• Design Rules, guidelines for AM;
• Design of Experiments AM Machine Parameters;
• Lean Manufacturing and Supply Chain with AM;
• Thermal Engineering challenges with AM Machines and Production;
• Test and Measurement (destructive / non-destructive);
• Material properties of AM products;
• 3D scanning (reverse engineering);
• Workshops
• Seminars and conferences
Design &
Engineering Materials &
Processes Additive
Manufacturing
Post Processing
& Testing
Founding Partners:
AM Challenges
• Awareness
• Accuracy of products conform specifications
• Repeatability and production speed
• Materials properties (consumable, product)
• New materials and Multi Materials (customized chemistries)
• Particle Size Distribution
• Price of materials Vendor Lock-In
• Thermal problems during printing and post processing
• Dimensional stability and shape retention
• Process Control, monitoring, tracking/tracing, in-process inspection
• Standardization (NEN, ISO, ASTM, SCC, BNQ)
• Safety (powder, fumes, resin but also machine)
• Design in 3D and Topology Optimization
• Education and Research
Invitation Collaboration Opportunities
• Factories of the Future
• Applied Research
• Educational programs
• Entrepreneurship
R. A. Abdoel (Ricardo), MSc., BEng. Rachelsmolen 1 5612 MA Eindhoven Gebouw R1, 0.196
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High Tech Systems and Materials
@ricardoabdoel | @OBJEXLAB
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www.objexlab.com
+31 (0) 613440585
FONTYS OBJEXLAB
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