Direct Digital Manufacturing with Additive Fabrication Technologies

May 7, 2013

Professional Systems

Materials is what makes the difference!

Traditional Tooling Alternatives • Metal Fabrication Tooling

Stretch Forming

Hydro Forming

• Weight savings over solid metal tooling

• Self-lubricating polymers

• Large Tools

• 2.3m Long Hydro Form Tool

• PC Material

• Methods to join parts proven

Large Tool

Optimized Tool

100+ Cycles100+ Cycles

Original Tool

Traditional Tooling Alternatives • Metal Fabrication Tooling

End Use Parts – Renewable Energy

Sandwich composites for wind turbine components• Strength to weight ratio critical• Cores increase stiffness and bending strength

Commercial-grade thermoplastic Fortus generated cores • Withstand lay-up and curing process +250°F / 50

psi• Support lay-up and curing without tooling• Composite parts up to 30% lighter

Result in process improvements for composite parts • Design flexibility: closed internal passages• Make changes or custom parts faster

First article produced in 6 days• Reduces leadtime by 67%• Reduces costs by 52%

Sandwich Composite Production Cost Cut 52%

12 days(67%)

$14,000(52%)

Savings

6 days$13,000Direct DigitalManufacturing

18 days$27,000Conventional fabricating

TimeCostMethod

Printed ElectronicsAerosol Jet

Durable, Stable Parts

Functional door handles

Replacement Bumpers

Hollow Part Molds

Multi-piece cores

Multi-piece post bonded components

FDM soluble cores

Manufacturing

Urbee

Urbee is a two-passenger hybrid car designed to be incredibly fuel efficient, easy to repair, safe to drive, and inexpensive to own.

End-Use PartsCurrent Commercial Applications

• ECS Ducts

• Avionics Racks

• In-Flight Entertainment

• Window Reveals

End Use Parts – Light Aircraft

Picture courtesy of RapidPSI

Aerospace – Interior applications

ULTEM 9085 Flame, Smoke, & Toxicity ratedEnables commercial aerospace interior applications

End-Use PartsFuture Commercial Applications

Customized…

• Air vent & light fixtures

• Cabin interiors

• Seating

• Panels

• Storage

• Cockpit & gauge clusters

End-Use PartsCurrent Military/Defense Applications

• Optimized wing sections

• UAV’s

• Wind Tunnel Models

• Camera Gimbals

• ECS Ducts

On Demand Additive Manufacturing of a Basic Surgical Kit DARPA Service Chiefs Fellowship Program

Printed Basic Surgical KitUprint in mock field location connected to generator power

Soldier wearing “Cut Suit” Simulated laparotomy surgery using FDM surgical tools

Design

Iris van Herpen, Fashion Designer

The ability to vary softness and elasticity inspired us to design a

“second skin” for the body acting as armor-in-motion; in

this way we were able to design not only the garment’s form but

also its motion.

Emma’s Arms

NemoursA Children’s Health System

Emma’s Story

3D printed “exoskeleton” lets a little girl lift her arms

and play.

THANK YOU!

Brian Sabartbrian.sabart@stratasys.com