1PADT CONFIDENTIAL
Answers to your Questions
on Metal 3D Printing
February 2016
Dhruv Bhate, Ph.D.Senior Technologist, PADT Inc.
Rey ChuPrincipal, PADT Inc.
Email: [email protected]
Concept Laser Metal 3D Printing at NASA Marshall
2PADT CONFIDENTIAL
• 50 min talk, 10 minutes open Q&A
• Submit questions or issues through chat window (bottom left) at any time– Select “Send to Presenters”
• Submit question via email after the webinar to [email protected]
Webinar Logistics
3PADT CONFIDENTIAL
Dhruv Bhate
• Senior Technologist at PADT, Inc.
• Ph.D. in Mechanical Engineering (Purdue, 2008), M.S. in Mechanical Engineering (CU Boulder, 2003)
• 7 years experience in laser-based manufacturing in the semiconductor industry
• Currently focused on 3D printing of high performance polymers and metals at PADT
Speaker Bios
Rey Chu
• Co-Founder of PADT, Inc. and Principal, Manufacturing Technologies
• Over 25 years experience in additive manufacturing / 3D printing processes, involved with process and application development since the early 1990s
• Frequent speaker at additive manufacturing seminars and conferences
4PADT CONFIDENTIAL
Objectives of this Webinar
1. Introduce PADT and Concept Laser
2. Describe metal 3D printing technology by answering the questions we most often get about it
3. Provide a gateway to assessing if and how metal 3D printing can benefit you and your company
5PADT CONFIDENTIAL
• Introductory:– Who are PADT and Concept Laser?
– How does laser-based metal 3D printing work?
– Are there other ways to 3D print in metal and how do they compare?
• Technical:– What are the different process steps involved?
– How “good” are 3D printed metal parts?
• Strategic:– What materials and machines do you offer?
– Who uses this technology today?
– What is the value proposition of metal 3D printing for me?
– What can I do after this webinar?
Outline of Questions
6PADT CONFIDENTIAL
Who are PADT and
Concept Laser?
7PADT CONFIDENTIAL
PADT: What We Do
ManufacturingProduct
Development
Simulation
Sales Services Training ConsultingR&D
8PADT CONFIDENTIAL
PADT by the Numbers
• Founded in 1994, 21 years in business
• 82 employees
– 19 years average experience, 4 PhDs & 13 Masters degrees
• R&D labs with $2M in equipment
• Over 1700 Customers served
– Over 100000 Prototypes & Functional Parts Delivered
• 3D Printing since 1994
– Over 350 product development projects completed
– Over 7200 numerical simulation models run
• Over 7600 Support Cleaning Apparatus (SCA) Systems Sold
• Stratasys Platinum Partner 2015 – Highest commercial reseller award
• ANSYS Channel Partner
• 13 Small Business Innovation & Research (SBIR) awards since 1999
9PADT CONFIDENTIAL
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
10PADT CONFIDENTIAL
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)
Supporting AM Capstone Project for 6 Engineering Seniors
AZ Bio Fast Lane Award 2011 (PADT Medical)
13 awards, Commercialization Index of 90, Small Business Innovation Research (SBIR)
www.concept-laser.de11 | Concept Laser GmbH
About - Concept Laser
Concept Laser is the global leader in the design and manufacture of powderbed-based laser metal additive manufacturing systems.
www.concept-laser.de12 | Concept Laser GmbH
About - Concept Laser - Background
· 1997 – Development of Laser Melting Technology
· 1999 – First patent for stochastic exposure
· 2000 - Concept Laser GmbH established
· 2002 – First machine delivery for metal 3D Printing
· 2003 – Sales, Marketing and Service structureimplemented
· 2012 - Concept Laser, Ningbo (China) established
· 2014 - Concept Laser Inc., Dallas (USA) established
13PADT CONFIDENTIAL
Concept Laser and PADT
• PADT exclusive reseller for Concept Laser Inc. in AZ, NM, CO, UT and CA
• PADT offices in all 5 states,
HQ in AZ with metal machine
and benchmark capability
• Strong partnership between the two companies built on relationships extending back over two decades
• Partnership based on each company’s technical strengths
14PADT CONFIDENTIAL
How does Metal 3D
Printing Work?
15PADT CONFIDENTIAL
Laser
Inert gas
Coating
Powder
Metal 3D Printing Working PrinciplePowder Bed Laser Fusion (LaserCusing®)
Video (dual laser)
16PADT CONFIDENTIAL
Process Physics
Wayne King et al. (LLNL), 2015
Wayne King et al. (LLNL), 2015
https://str.llnl.gov/january-2015/king
Gockel et al., 2014
17PADT CONFIDENTIAL
Are there other ways to
3D print metal and how
do they compare?
18PADT CONFIDENTIAL
Electron Beam Melting
Metal 3D Printing Technologies
Powder Bed Fusion Directed Energy Deposition
Powder Bed Binder Jetting
http://www.sciaky.com/
http://www.optomec.com/
Laser based fusion (LaserCusing®, SLM, DMLM)
http://www.me.vt.edu/dreams/binder-jetting/
19PADT CONFIDENTIAL
Comparison of Metal AM Technologies
Laser Powder Bed Fusion Electron Beam Powder
Bed FusionDeposition Binder Jetting
� High build temperature provides good shape stability and low residual stress in the part requiring fewer or no supports
� Surface morphology well suited for bone integration
� Good mechanical properties
� Reduced material choices (Ti, CoCr)
� Higher capital cost� Poor surface roughness
� Very high deposition rates and very large structures
� Lower material costs especially with wire
� No need for recycling powders, higher material usage efficiency
� Functionally graded materials
� Large material options
� Poor detail and resolution compared to laser melting
� Poor surface roughness compared with laser melting
� Good mechanical properties and high densities
� Large build volumes� Large material options
� Need for support structures requires expert design and setup for print
� Stress relief and support removal post processing steps
� No support structures needed
� Faster and more affordable to print than powder bed fusion
� Large material options
� Limited mechanical properties compared to powder bed fusion techniques
Versatile, Strong
Properties Very Large Parts
Complex Designs in
Titanium, Strong
PropertiesFast, Affordable
20PADT CONFIDENTIAL
What are the
different process
steps involved?
21PADT CONFIDENTIAL
Concept Laser LaserCusing Process
https://www.youtube.com/watch?v=Ar2LmOpm8W0
22PADT CONFIDENTIAL
Post-Processing for a Finished Part
www.protolabs.com
Excavation
Parts fused to build
platform by supports
Heat Treatment
• Stress relief• Void minimization• Microstructure optimization
Ti6Al4V
Unoptimized
Vacuum furnace
Support Removal
Bandsaw
Wire EDM
Shot peening
Finishing
Tumbling &
Polishing
Other Processes:
• Electrochemical polishing• Abrasive Flow Machining
(Extrude Hone) for internal surfaces
http://www.sjf.tuke.sk/transferinovacii/pages/archiv/transfer/21-2011/pdf/143-148.pdf
23PADT CONFIDENTIAL
Ancillary Requirements for Operating Machines
Vacuuming & Disposal
Milling Bead Blasting Demagnitization
PPE & Class D Fire Extinguisher
Data Preparation Software Build Plate Preparation
Inert Gas (N2/Ar)
Sieving
Magics
24PADT CONFIDENTIAL
How “good” are 3D
printed metal parts?
25PADT CONFIDENTIAL
Solidification Structure: Macrostructure
• Dimensional resolution and tolerances
• Surface Roughness (Rz)
EPMA
Layer Thickness Min. Feature Size
20 µm (0.0008”) 150 µm (0.006”)
30 µm (0.0012”) 380 µm (0.015”)
Beam spot size = 50um
Layer Thickness (varies)
Tolerances: “Typically, tolerances of ±0.003 in. (76µm), plus an additional 0.001
in./in. (0.001mm/mm), are expected and achieved on well-designed parts”
- Real-world experience from ProtoLabs Yasa et al. (2014)
26PADT CONFIDENTIAL
Solidification Structure: Microstructure
• Density
EPMA
- Densities of 99.7-99.9% demonstrated for Ti6Al4V, further improvements possible with HIP
Ti6Al4V
Ti6Al4V
Kruth et al, ISEM XVI
• Grains and Phases
- Fine grains due to rapid solidification
Top
Side
27PADT CONFIDENTIAL
Mechanical Properties
EPMA (from Fraunhofer IFAM)
3D
Pri
ntin
g +
HT
3D
Pri
ntin
g +
HT
3D
Pri
ntin
g +
HT
3D
Pri
ntin
g +
HT
Fo
rge
d
Fo
rge
d
Fo
rge
d
PM
+H
IP
PM
+H
IP
PM
+H
IP
28PADT CONFIDENTIAL
Industry-specific Applicability
Mantel, 2011, Stellenbosch University, South Africa, http://hdl.handle.net/10019.1/18142
29PADT CONFIDENTIAL
Real Time Quality Management (QM)
30PADT CONFIDENTIAL
Aerospace and Medical Certification
Aerospace
• FAA and FDA approving each product on a case-by-case basis.
• FDA additional concerns of device cleanliness, biocompatibility and removal of processing materials.
• Ongoing efforts along with ASTM and ISO to establish 3D printing certifications
Medical
Sensor Housing: First metal 3D printed engine part, FAA approved April 2015
Spinal Implant: Titanium alloy, approved by FDA July 2015
Hip Implant: Titanium alloy, approved by FDA in 2011
31PADT CONFIDENTIAL
What Materials and
Machines do you offer?
32PADT CONFIDENTIAL
Non-Reactive Metals Reactive Metals
http://www.conceptlaserinc.com/materials/
Materials
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
33PADT CONFIDENTIAL
Machines OfferedB
uil
d
Vo
lum
eC
ost
*M
ate
rials
Xline 2000R
31.5” x 16” x 20”
Reactive & Non-Reactive
$2.1-2.3 M
M2 Cusing
10” x 10” x 11”
Reactive & Non-Reactive
Single Laser: $ 650-750 KDual Laser: $750-950 K
M1 Cusing
10” x 10” x 10”
Non-Reactive only
$ 450-600 K
Mlab Cusing R
3.5” x 3.5” x 3”
Reactive & Non-Reactive
$ 235 K
Mlab Cusing
3.5” x 3.5” x 3”
Non-Reactive only
$ 200 K
*Prices are approximate, shipping costs not included
34PADT CONFIDENTIAL
Who uses these
machines today?
35PADT CONFIDENTIAL
Application Sectors
Aerospace Automotive Tooling
Medical Dental Jewelry
36PADT CONFIDENTIAL
Case Studies
Drills with improved cooling flow
Mapal Inc.http://www.etmm-online.com/additive_technology/articles/511008/
Fuel system assembly (10 parts reduced to 1 with 70% cost, and
42% weight reduction)
Airbushttps://youtu.be/Cy3V3KR1LWc
Dental crowns and implants
Laser Add Center, GmBHhttp://www.laser-add-center.de/application/dental.html
37PADT CONFIDENTIAL
What is the Value
Proposition of Metal
3D Printing for me?
38PADT CONFIDENTIAL
The Metal 3D Printing Value PropositionDriver 1: Functional Prototypes in Product Development
Flypcap
39PADT CONFIDENTIAL
The Metal 3D Printing Value PropositionDriver 2: Design Opportunity
Internal Features
Assembly Consolidation
Strength-Weight Optimization
Bio-Inspired
Concept Laser
Airbus
Boeing
GE
40PADT CONFIDENTIAL
The Metal 3D Printing Value PropositionDriver 3: Supply Simplification
2011 Committee on Examination of the U.S. Air Force's Aircraft Sustainment Needs…
Airbus
41PADT CONFIDENTIAL
The Metal 3D Printing Value PropositionDriver 4: Low Volume, High Mix Manufacturing
Mass Customization
High Volume Manufacturing
Low Volume, High Mix
42PADT CONFIDENTIAL
The Metal 3D Printing Value PropositionDriver 5: New Applications & Research
http://www.fastcoexist.comWyss Institute, Harvard U
Applications! Fundamental Research
http://3dprinting.com/bio-printing/
http://www.3dprinterworld.comDeLoitte Genesis
& Simulation
Concept Laser is open source
powder and SW architecture
43PADT CONFIDENTIAL
Metal 3D Printing Trends
Worldwide Metal Systems Sales (2015)
Percentage of AM Revenue from Functional Parts
Forecast metal AM costs [EUR/cm3]
2013 costs = approx. $55 per cu. inch.
44PADT CONFIDENTIAL
What now?
45PADT CONFIDENTIAL
Contact Us to Assess if Metal 3D Printing is Right For You!
Send an email to: [email protected] fill out survey at end of webinar to have us contact you
PADT – your partner in Metal 3D printing
Initiate a conversation about:
• Industry- and Application specific Landscape• Challenges & Opportunities• Total Cost of Ownership, Unit Cost• Concerns about changing to Metal 3D Printing
46PADT CONFIDENTIAL
• Company Pages:
– PADT: www.padtinc.com
• Follow our AM Blog: http://www.padtinc.com/blog/additive-manufacturing
– Concept Laser (US): http://www.conceptlaserinc.com/
• Papers & Reports:– European Powder Metallurgy Association (EPMA) Brochure: “Introduction to Additive
Manufacturing”: http://www.epma.com/am
– Wohlers Report (annual, fee): http://wohlersassociates.com/
– Review Paper (free access): “Metal Additive Manufacturing: A Review”: http://link.springer.com/article/10.1007/s11665-014-0958-z#/page-1
• 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
• Metal Additive Manufacturing Magazine (free digital editions): http://www.metal-am.com/
Learn More
47PADT CONFIDENTIAL
Thank You!
Dhruv Bhate, Ph.D.Senior Technologist, PADT Inc.
Rey ChuPrincipal, PADT Inc.
PADT HEADQUARTERS
at the ASU Research Park7755 S. Research Dr.Suite 110Tempe, AZ 85284480-813-4884 Office480-813-4807 Fax
Contact Us to Assess if Metal 3D Printing is Right For You!
Send an email to: [email protected] fill out survey at end of webinar to have us contact you
Top Related