1PADT 2016, All Rights Reserved

Introduction to Additive

Manufacturing (AM)

July 2016

Dhruv Bhate, Ph.D.Senior Technologist, PADT Inc.

Email: dhruv.bhate@padtinc.com

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 dhruv.bhate@padtinc.com to

learn more

36PADT 2016, All Rights Reserved

Thank You!