Advances in Additive Manufacturing

• Track F: SESSION II 3:45pm - 5:00pm

• Dr. Gary Halada, Stony Brook University

• Dr. Daniel Slep, ChemCubed

• Dr. Hod Lipson, Columbia University

• Dr. Ronald Aman, Rochester Institute of Technology

Moving Additive Manufacturing Forward: Materials and Energy

Challenges

Gary Halada Department of Materials Science and Engineering Director, Additive Manufacturing Prototyping and

Applications Center (AMPAC) Stony Brook University

http://www.tumotech.com/2014/11/10/disconnect-between-expectations-and-reality-catching-up-with-q3-of-the-3d-printing-industry/

What are the barriers to use of additive manufacturing (3D printing)?

Wrought 316L

SLS 316L

Potentiodynamic scans in deaerated 0.1M HCl

Trelewicz, J. R., Halada, G. P., Donaldson, O. K., & Manogharan, G. (2016). Microstructure and Corrosion Resistance of Laser Additively Manufactured 316L Stainless Steel. JOM, 68(3), 850-859.

Questions

• What are the major energy and cost factors for additive versus traditional manufacturing processes?

• How does the potential for new materials with novel functionality and properties impact the energy and economic driving factors for additive manufacturing?

• How do new technologies and new applications impact this picture?

Problems in comparing technologies

• Additive has certain disadvantages (speed/resolution/size trade-offs, limitations in material selection, post-processing to improve material properties)

• But also advantages (customization, small runs possible, rapid concept to reality and re-design, innovative design possible)

• How do you put a dollar value on innovation in design?

“Embodied energy”

• Usually defined as the materials processing energy + manufacturing processing energy

• In manufacturing, embodied energy of raw (source) materials is often more important than the energy requirements to process/manufacture the materials into the final product.

• Also can use Bill of Materials (BOM), Life Cycle Analysis, other measures of energy in a manufactured product

http://web.mit.edu/ebm/www/Publications/9_Paper.pdf “A Tool to Estimate Materials and Manufacturing Energy for a product”, N. Duque Ciceri, T.G. Gutowski and M. Garetti

Also Need to account for location of manufacture and use, does not take into accnunt LCA, etc.

Embodied energy in manufactured products

A method used to estimate Energy Consumption Rate for additive manufacturing: (as per Y. Luo, et al., Environmental Performance Analysis of Solid

Freeform Fabrication Processes, Proceedings of the 1999 IEEE International Symposium on Electronics and the Environment, 1999. ISEE -1999.

ECR (kWh/kg) = power rate/process productivity

Power rate = how much power is used (kW)

Process productivity = kg/h of material produced

In terms of a single layer, process productivity is proportional to scanning speed x width of single pass x layer thickness x material density (corrected via a ‘process overhead coefficient’ which is 0.7 for stereo lithography, 0.6 for laser sintering, 0.9 for fused deposition).

So, we can reduce the consumption rate by somehow increasing speed of formation of layers, or by reducing overall power consumption.

A Comparison of Energy Consumption in Bulk Forming, Subtractive, and Additive Processes: Review and Case Study, Hae-Sung Yoon, Jang-Yeob Lee, Hyung-Soo Kim, Min-Soo Kim , Eun-Seob Kim , Yong-

Jun Shin , Won-Shik Chu , and Sung-Hoon Ahn, INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY Vol. 1, No. 3, pp. 261-279 JULY 2014

So, if specific energy consumption and scaling factors do not look especially competitive (at this time), are there potential energy savings?

Role of envelope utilization (using as much of the build space as possible)

However, as build space increases, costs increase fairly rapidly.

Amount of infill versus mechanical properties – and its impact on cost

Other cost and energy savings of AM

• Reduction of waste (Overproduction, transportation (as a source of risk), rework/defects, over-processing, unnecessary motion, inventory, waiting (workers, equipment)

• Consumers proximity to production

• Supply chain issues Factors which make AM competitive – but the potential value of some factors is very difficult to estimate……

“Embodied Innovation”

• Perhaps a more important comparison – can make new things with game-changing capabilities

• Additive manufacturing leads to process innovation (sometimes seen as disruptive to jobs)

• Additive manufacturing may more importantly be a path to product innovation (usually seen as job-creating)

• Product innovation has potential for large impacts on energy production, transmission, storage, use and sustainability.

• “You can’t get there from here.” – not true

https://www1.eere.energy.gov “Unlocking the potential of additive manufacturing in the fuel cells industry” Blake marshall, Bradley Wright, Benjamin Lunt

The Role of Material Innovations

• Recyclability/re-use decreases embodied energy

• New functional materials can reduce complexity, and hence energy costs

• Multi-materials/integrated parts manufacturing reduces assembly and labor

• Reducing the embodied energy in source materials

Future perspectives on sustainable tribology I. Tzanakis, M. Hadfielda, B. Thomas, S.M. Noya, I. Henshawc, S. Austend, Renewable and Sustainable Energy Reviews 16 (2012) 4126–4140

Silver catalyst printed on 304 stainless steel, cyclic polarization (100 redox cycles) in 0.1 M NaOH (pH 12)

New application with functional materials: Printing of catalytic materials

Cyclic voltammetry showing reversibility of redox reaction. -- valuable for the ORR in alkaline fuel cells, etc.

ChemCubed and G. Halada (SBU): Provisional Application : Printable Catalytic Metallic Nanoparticles (Docket 788-267 PRO)

Ag oxidation

Oxygen reduction reaction (ORR)

Conclusions and questions

• If energy, cost, time, etc. are at least reasonable, the other advantages become the driving factors.

• How do we improve current technologies?

• How do we develop new technologies and new materials?

• How does this impact the market for use and applications of 3D printing, including the tremendous potential for innovation in design? The true advantage to additive

manufacturing may be in how it impacts the way we think about design.