Embed Size (px)
Citation preview
1PADT 2016, All Rights Reserved
Introduction to Additive
Manufacturing (AM)
July 2016
Dhruv Bhate, Ph.D.Senior Technologist, PADT Inc.
Email: [email protected]
2PADT 2016, All Rights Reserved
Outline
• Introduction to AM @ PADT
• AM Processes & Materials
• Key Drivers for AM
• Learn More & Get Involved
3PADT 2016, All Rights Reserved
INTRODUCTION TO
ADDITIVE MANUFACTURING AT PADT
4PADT 2016, All Rights Reserved
PADT: What We Do
ManufacturingProduct
Development
Simulation
Sales Services Training ConsultingR&D
5PADT 2016, All Rights Reserved
PADT by the Numbers• Founded in 1994, 22 years in business
• 85 employees
– 19 years average experience, 4 PhDs & 13 Masters degrees
• R&D labs with $2M in equipment
• Over 1,700 Customers served
– Over 100,000 Prototypes & Functional Parts Delivered
– Over 350 product development projects completed
– Over 7,200 numerical simulation models run
• Over 9,900 Support Cleaning Apparatus (SCA) Systems Sold
• Strong Partnerships:
– Stratasys Platinum Partner 2015
– Concept Laser Consultative Partner
– ANSYS Channel Partner
• 13 Small Business Innovation & Research (SBIR) awards since 1999
Tempe, AZ Phoenix, AZ
Torrance, CA Littleton, CO
Albuquerque, NM Murray, UT
6PADT 2016, All Rights Reserved
PADT Capabilities: Additive ManufacturingFused Deposition Modeling
(Fortus 450, 400, 250)
Stereolithography (SLA)
Selective Laser Sintering
Selective Laser Melting (Concept Laser MLab Cusing R)
Arriving Summer 2016
Material Jetting (Polyjet)
7PADT 2016, All Rights Reserved
PADT Additive Manufacturing (AM) Technology Timeline
20152010200520001995
Stereo
lithography
1994*
SLA 250
Selective Laser
Melting (Metal)
MLab Cusing R
Selective Laser
Sintering
Material Jetting
(Polyjet)
1999
Sinterstation 2000 plusHiQ Thermal
Sensing Upgrade
2005
Multi-zone
Heating Upgrade
2012
Viper Si2
2006
ProJet 6000
2011
Connex 500
2009
Objet 500
2014
2015
Fused Deposition
Modeling
FDM 2000
1995*
Prodigy
2000*
Dimension
2002
Fortus 400 Fortus 450
2009
*retired
8PADT 2016, All Rights Reserved
PADT Capabilities: AM Post-Processing & FinishingFDM Support Cleaning Apparatus
(Designed, developed and sold by PADT)Gas vac Blue M Oven
Finishing (Support removal, painting, polishing)
Powerblast (High
Pressure Water Cleaner)
9PADT 2016, All Rights Reserved
PADT Capabilities: Rapid & Advanced Manufacturing
NC Milling & Lathe Injection Molding (at partner site)
Chemical Hood & WorkspaceCustomized Testing Lab
10PADT 2016, All Rights Reserved
PADT Capabilities: Reverse Engineering & Inspection3D Scanning (Steinbichler) Cross-sectional Scannning (CGI)
Reverse Engineering Software
(GeoMagic Design X)
File Formats (Including Inspection Results)
3D Scanning (Geomagic Capture)
11PADT 2016, All Rights Reserved
PADT Capabilities: DesignSolidWorks Pro/Engineer
Topology Optimization (ANSYS GTAM) ANSYS SpaceClaim
12PADT 2016, All Rights Reserved
PADT Capabilities: SimulationStructural (Statics & Dynamics) Transient Dynamics Multiphysics
Simulation Tool Customization, Process
Automation
High Performance Computing for Simulation
13PADT 2016, All Rights Reserved
AdditiveManufacturing
Design & Simulation
Characterization & Theory
PADT R&D Focus Area
We seek to address complex problems in Additive Manufacturing that benefit from a combination of experimental, theoretical and numerical approaches
2
22
3
*
1
)cot5.14.2(1
1
sinsin
cos
l
t
l
hl
tEE
s
s
14PADT 2016, All Rights Reserved
PADT Recognition & Outreach
Voting member, ASTM Standards
F42 on Additive Manufacturing
Additive Manufacturing
Users Group 2012 DINO
Award (Brad Palumbo)
Supporting startups at the
Center for Entrepreneurial
Innovation (CEI)
America Makes Silver
Member
Highest partner status
for commercial resellers
2011 Governor's
Celebration of Innovation
Pioneering Award
2011 Spirit of Enterprise Award
(Entrepreneurial Leadership)
AZ Bio Fast Lane Award 2011
(PADT Medical)
13 awards, Commercialization
Index of 90, Small Business
Innovation Research (SBIR)
Research Awards
Grant awarded July 2016
for research on AM lattice
modeling (18 months)
15PADT 2016, All Rights Reserved
INTRODUCTION TO
ADDITIVE MANUFACTURING
16PADT 2016, All Rights Reserved
Additive vs Conventional (Subtractive) Manufacturing
Conventional Manufacturing
3D Printing (Additive Manufacturing)
http://www.dainikdisha.com/
17PADT 2016, All Rights Reserved
Additive Concept
Raw MaterialProcess
Technology Product
18PADT 2016, All Rights Reserved
Classification of Additive Manufacturing Processes
Raw Material
Liq
uid
Fila
me
nt /
Wire
Sheet
Process Technology
Laser Polymerization Material Jetting
Fused Deposition Wire + Electron Beam
Light Projection
Polymerization
Ultrasonic bonding
Po
wd
er
Laser Fusion/Sintering Electron Beam Melting Binder Jetting Powder + Laser
Laser Lamination
19PADT 2016, All Rights Reserved
Materials (Polymers)
Thermoplastics (FDM) Photopolymers (Polyjet)
20PADT 2016, All Rights Reserved
Non-Reactive Metal Alloys Reactive Metal Alloys
http://www.conceptlaserinc.com/materials/
Materials (Laser-based for Metals)
316L Stainless Steel 30Al/31Al Aluminum Alloy Ti6Al4V Titanium Alloy
Commercially Pure Titanium
Maraging Hot-Work Steel
Bronze Alloy
Stainless Hot-Work Steel
17-4 PH Stainless Steel Inconel 718 Inconel 625
Biocompatible CoCrW Alloy
Biocompatible Ti6Al4V Alloy
21PADT 2016, All Rights Reserved
Additive Manufacturing Trends
Worldwide AM Revenue
(USD, Millions)
Services
Products
Percentage of AM Revenue from Functional Parts
AM System Installations by Sector
22PADT 2016, All Rights Reserved
ADDITIVE MANUFACTURING
DRIVERS
23PADT 2016, All Rights Reserved
Rapid Prototyping and Tooling
Design Freedom
Lead Time Reduction
Manufacturing Cost Reduction
New Applications
Top 5 AM Drivers
1
2
3
4
5
Rolls Royce Trent XWB
24PADT 2016, All Rights Reserved
Rapid Prototyping1
Wind Tunnel Models (Lockheed Martin Corp.)
Display Models (Lockheed Martin Corp.)
Mock-Ups & Fit Tests (Lockheed Martin Corp.)
Low-cost, rapid manufacturing of one of a kind
parts allows for faster product development cycles
• 50-90% cost reductions
• 80-95% lead time reductions
25PADT 2016, All Rights Reserved
Rapid Tooling1
Organic Innovation, operators and engineers
design and print tooling and improvements at low
cost and fast turnaround time and see the results of
their ideas
C-130 Microvane Tooling (Lockheed Martin Corp.)
Drill Jigs (Lockheed Martin Corp.)
Layup Tool (Lockheed Martin Corp.)
26PADT 2016, All Rights Reserved
Design FreedomInternal Features2
Fuel Nozzle (GE
Aviation)
Space Launch Fuel Nozzle
(NASA Marshall)
Layer-by-layer manufacturing process allows
for more complex geometries – design with
(almost) no constraints!
UAV Wing (Aurora Flight Sciences)
27PADT 2016, All Rights Reserved
Design FreedomStrength-Weight Optimization2
Topology optimization allows for reducing the
material requirements for any desired objective
(stiffness, strength, extension etc.) – AM enables
manufacturing of these designs!
Bracket with 30% weight reduction (Airbus)
Topology Optimization (ANSYS)
Seat-belt buckle - 55% weight reduction, estd. 72.5kg on
Airbus 380 (EOS)
Bracket (Honeywell)
Exhaust Sensor (RSC Engg.)
28PADT 2016, All Rights Reserved
Design FreedomParts Consolidation2
Airbus Fuel Assembly (10 parts to 1)Sensor Housing, GE (20 parts to 1)
Parts previously designed for manufacturing and
subsequent assembly can now be printed in a
consolidated manner to eliminate assembly costs
(labor and parts)
Satellite Waveguide, Renishaw
(77 parts to 1)
133 g 53 g
29PADT 2016, All Rights Reserved
Lead Time ReductionEliminate Supplier Sourcing3
2011 Committee on Examination of the U.S. Air Force's Aircraft Sustainment Needs…
Deloitte University Press
US NavyRaytheon
Additive Manufacturing enables point-of-use
manufacturing!
30PADT 2016, All Rights Reserved
Replacement parts for a 30-year old
component within a week (Airbus)
Lead Time ReductionAccelerate Development, Replacement & Repair3
Turbine blade repair (DM3D, MT Additive)
Super Draco Thruster: concept to hot
firing in 100 days (Space X)
31PADT 2016, All Rights Reserved
Manufacturing Cost Reduction4
Mass Customization
High Volume Manufacturing
Low Volume, High Mix
32PADT 2016, All Rights Reserved
New Applications5
3D Printed Electronics (PEN, Inc.)
http://3dprintingindustry.com
Armor & Exoskeleton
Space Construction (ESA)
On-Orbit Manufacturing (Tethers Unlimited)
Bioprinting
33PADT 2016, All Rights Reserved
LEARN MORE & GET INVOLVED
34PADT 2016, All Rights Reserved
Learn More
• Online Courses:
– “3D Opportunity: Additive Manufacturing for Business Leaders”: https://novoed.com/3d-
opportunity
– “Bioprinting: 3D Printing Body Parts”: https://www.futurelearn.com/courses/bioprinting
• Reading:
– European Powder Metallurgy Association (EPMA) Brochure: “Introduction to Additive
Manufacturing”: http://www.epma.com/am
– Wohlers Report (annual, fee): http://wohlersassociates.com/
– Metal Additive Manufacturing Magazine (free digital editions): http://www.metal-
am.com/
• Conferences:
– AMUG: http://www.additivemanufacturingusersgroup.com/events.htm
– RAPID: www.rapid3devent.com
– SFF Symposium: http://sffsymposium.engr.utexas.edu
– formnext: https://www.mesago.de/en/formnext/The_conference/Welcome/index.htm
• America Makes Membership: www.americamakes.us
– Online, Living Textbook expected in 2017 (PADT leading effort)
35PADT 2016, All Rights Reserved
Arizona Additive Manufacturing Committee (AZ Tech Council)
Started June 2016, with goals:
Promote AM and educate potential
users
Act as a forum to influence local
regulation
Inform progress of national
certification and standards
organizations
Serve as a rallying point for
collaboration
- 53 individuals representing 34 entities
in AZ (and growing)
- Next meeting is at PADT (Monday,
August 15, 4-5:30pm)
- Contact [email protected] to
learn more
36PADT 2016, All Rights Reserved
Thank You!
