3D Printing

ATOA Scientific Technologies | Multiphysics CAE | Engineering Apps | 3D printing

ATOA: PUBLIC

3D PrintingMultiphysics CAE for The First Time Right

Dr Raj C Thiagarajan12 Aug 2015

Webinars

ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |2

ABSTRACT

• 3D Printing is projected as the next industrial revolution and it can potentially influence almost every aspect of ourdaily life in some way. The missing link or bottleneck in computer aided product development is prototyping orproduct manufacturing. New development in 3D printing such as digital material takes product development to newerheights. Functional 3D products with complex shapes for novel functionality can be manufactured right at yourdesktop. Self-replicating 3D printing machines can revolutionize the industrial manufacturing from linear to nonlineargrowth. For end customers, 3D printing technology enables complex, intricate design and high cost productionproducts, custom made.

• This webinar will start with an overview of 3D printing technology. The parametric CAD model design methodology inCOMSOL for 3D printing will be given. Material modelling for evaluating various materials such as polymers,composites, metals, ceramics and hybrid materials, suitable for 3D Printing will be detailed. Resistive, laser andinductive heating simulations for effective thermal processing will be highlighted. A wide range of 3D printed productsfrom molecular models to consumer products which are engineered using Multiphysics CAE will be showcased.

CAD CAE CAM of Product development, 3D Printing, Multiphysics CAE of 3D printing.


3D Printing

The fabrication of objects through the deposition

of a material using a print head - ASTM.

3D printing technology foundation comes from, more than two decades old Rapid

Prototyping, CNC, Robotics and Material Processing Technologies.

Current excitement is due to, technology maturity, open source electronics hardware,

crowdsourcing, digital fabrication, advancements in CAE, history free CAD, the maker’s

community, the availability of low cost printers, multi material technology, low cost laser,

the internet economy, all that propels 3D printing into an exciting future and possibility.

Faster Product Development, CUSTOM, Bottom up, Disruptive Business Model


Simulation based Product Development

Simulation based Computer Aided Product development for faster,Individual: Idea to Physical PrototypeIndustry: Concept to Market

Advantages of Virtual or simulation based product development is proven.Virtual Product Development : Concept - CAD - CAE - CAM

CAD: Digital 3D Design

CAE: Engineering Design and Analysis, Virtual Testing, product performance, Process design, life cycle evaluation.

CAM: Rapid Prototyping (RP), 3D Printing, Additive Manufacturing (AM), Direct Digital Manufacturing (DDM), Solid-Freeform Fabrication (SFF)


PRODUCT DEVELOPMENT CYCLE

● Product Development is long

Cycle process.

● Cost of Design changes increases

exponentially with product

development cycle.

● 80% of the product cost is

determined or committed at the

concept design stage


First Time Right Product Design

Design Change Cost in product development

•Cost of fixing = Stages X Times

•Cost of Design changes increases exponentially with

product development cycle.

•Multiphysics CAE + 3D printing for the first time

right product development


First Time Right Development Cycle

PREFERED CONCURRENT ROUTE for FIRST TIME RIGHT PRODUCT DEVELOPMENT


3D Printing : Conversion of Concept to Physical Product

CONCEPT

2D Sketches,

Drawing

CAD

3D Digital Model

iges, step

MESH

Triangular Tessellations

STL file

SLICE

2D layer by layer

Gcode

3D PRINT


3D Printing Technologies

Additive ManufacturingASTM F42 – Classification

1. Photopolymerisation: liquid photopolymer selectively cured by light activation

2. Material Jetting: droplets of build material are selectively deposited

3. Binder Jetting: a liquid bonding agent is selectively deposited to join powder materials

4. Material Extrusion: material is selectively dispensed through a nozzle

5. Powder Bed Fusion: thermal energy selectively fuses regions of a powder bed

6. Sheet Lamination: sheets of material are bonded to form an object

7. Directed Energy Deposition: focused thermal energy is used to fuse materials by

melting as they are being deposited


3D Printing Material and Methods

Materials● Solid Thermoplastics● Liquid photopolymers● Polymer,metal, ceramic powders

Methods● FD (Fused Deposition Modelling)● SL (Stereolithography Apparatus)● LS (Selective Laser Sintering)


3D Printing and Multiphysics CAE

Material ProductProcess andSystem

Trial and Error

vs

Physics based

modelling

For the first time right


FD (Fused Deposition Modelling)

A material extrusion process used to make thermoplastic parts through heated extrusion and deposition of materials layer by layer –ASTM

•Thermoplastic filament

•XY motion extruder, heater head

•Z motion support bed.

•Sensor, control, interface system

Polymer wire

X-Y movement

Extruder

Heater

Object

Build platform

Z movement

Schematic Illustration of FD 3D printer


FD Physics

Thermomechanical + Phase change + Flow process

Pressure Flow (Poiseuille Flow)dP= 2 η L Q / π d4

Viscoelastic Material behaviour,

Power law, Carreau - Yasuda, ..

Print Resolution = f(d, L, T, P, η), Extruder, Process and Material Parameters

d

D

alfa

M

F

Solidification

P - Plunger

Melting

Polymer

liquid

dP

L

Die Swell

Solid polymer wire


FD : Multiphysics CAE

Viscoelastic material modelling, Process flow, Part warpage and residual stress, Part performance

Extrusion die DesignEffect of die angle on exit pressure and velocity

Process optimizationEffect of pressure on shear rate of a

viscoelastic material


SL (Stereolithography)

a vat photopolymerization process used to produce parts from photopolymer materials in a liquid state using one or more lasers to selectively cure to a predetermined thickness and harden the material into shape layer upon layer -ASTM

Photopolymer

Laser source and mirror control

Z motion support bed.

Sensor, control, interface system

Mirror

Laser beam

Laser Source

Platform

Z move

Photosensitive Resin

Part


SL Physics

Laser Radiation exposureSize, time and intensity

PhotoinitiationPhotopolymerisation

MonomerOligomerPhotoinitiator

+ UV Radiation = Cure Reaction

Heat transfer

SL performance f(Resolution, Speed, Temp, degree of cure)

A Gaussian laser and a resin obeying Beer’s Law.

E, exposure at y, z, PL , laser power, w0 beam

radius, Vs scanning speed, Dp , Penetration depth

hν

Photoinitiator Oligomer Monomer


SL : Multiphysics CAE

Photopolymerisation chemical reaction modelling

Laser Optics Ray tracing

Laser Radiation heating process modelling.Scanning of the laserLaser radiation heating

Conduction, convection and Radiation heat transferCoupled to Photopolymerisation chemical reaction for the degree of cure.


LS (Laser Sintering)

A powder bed fusion process used to produce objects from powdered materials using one or more lasers to selectively fuse or melt the particles at the surface, layer by layer, in an enclosed chamber.

LS – Selective Laser Sintering / Melting (SLS/SLM)

Sinters Fuses or melts powdered material (polymer, metal, or ceramic)

laser or electron beam.

Mirror

Powder

Roller

Laser

Source

Build

Platform

Z move

Powder

Bed

Laser beam

Part

Powder

Stock


LS Physics

Granular/ powder material sintering, fusion or melting

Laser heatingHeat transferPhase change Coalescence

Frenkel’s relation, t~ηD / σSolidification, Densification

Solidified Layers

Sintered Layers

Laser Beam

Melting and Coalescence

Powder layer

Scan Direction

D


LS : Multiphysics CAE

Laser Heating

Granular material fusion: Coalescence of viscous particles due to Surface forces,.. Two phase level set method

Phase transition by a moving boundary interface according to the Stefan problem as a function of process parameter gradients


3D Printing and Multiphysics CAE

Product Design

Process modellingOverhang and supportWarpage and ShrinkageResidual stress

Part performance for First Time Right


3D Printed Part Performance

Additive manufactured Materials Property predictionMicrostructure is starting point for part performance Schematics of Microstructure and sample micromechanics results.

FDTransverse isotropic X, ZLower transverse properties

SLTransverse isotropy, X, YProperties are inherited from the photopolymer

LSisotropic, X ,Y, ZProperty reduction due to porosity

X

Z

Y


Molecular to CAD to 3D Prototypes

Molecular model with atomic level properties.

Conversion of atom data into solid model

CAD model to STL file and 3D printing.

Molecular structure inspired ultra lightweight macro materials and structures.


Future of 3D Printing

Multi materialPolymer, Metal, Ceramic, Natural, Bio… all in one

Multi functional Material (engineering) + Electronics (semiconductor)

Industrial scale 3D printing MachinesHeavy Industrial Machines, Residential home, Infrastructure

InnovationsNanomaterials, 4D printing, Self assembling systems,...

will enable breakthroughs in 3D printing


CAD CAE CAM of 3D Printing@ 3d.atoa.com

This webinar is from

atoa.com

3D Printing

Design

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