ExOne Direct Material Printing - Binder Jetting Technology

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Asia | The Americas | Europe Direct Material Printing 1

Transcript of ExOne Direct Material Printing - Binder Jetting Technology

Asia | The Americas | Europe

Direct Material Printing

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• ExOne is a leading additive manufacturing company dedicated to the manufacturing sector.

• ExOne is a global supplier of 3D printing systems and offers design and manufacturing services of 3D printed products.

• ExOne systems are able to print in a variety of materials with the largest available build sizes.

• ExOne has Production Service Centers (PSC) throughout the United States, Europe, and Japan.

• ExOne Global Headquarters is located in North Huntingdon, Pennsylvania

Company Overview

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ExOne Global Facility Locations

ExOne

North America

WEST

ExOne

North America

MID-WEST

ExOne

North America

MID-ATLANTIC

ExOne

North America

SOUTH

ExOne

BRAZIL

ExOne GmbH

GERMANY

ExOne

CHINA

ExOne KK

JAPAN ExOne

ITALY Srl

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Classification Technology Description Materials Developers

Binder Jetting 3D Printing Ink-Jetting

Creates objects by depositing a binding agent to join powdered material

Metal, Polymer, Ceramic, Other

ExOne (US) VoxelJet (Germany) 3D Systems (US)

Direct Energy Deposition

Direct Metal Deposition Laser Deposition Laser Consolidation Electron Beam Direct Melting

Builds parts by using focused thermal energy to fuse materials as they are deposited on a substrate

Metal: powder and wire

DM3D (US) NRC-IMI (Canada) Irepa Laser (France) Trumpf (Germany) Sciaky (US)

Material Extrusion Fused Deposition Modeling

Creates objects by dispensing material through a nozzle to build layers

Polymer Statasys(US) Delta Micro Factory (China) 3d Systems (US)

Material Jetting

Polyjet Ink-jetting Thermojet

Builds parts by depositing small droplets of build material, which are then cured by exposure to light

Metal, Photopolymer, Wax

Stratasys (US) LUXeXcel (Netherlands) 3D Systems (US)

Powder Bed Fusion Direct Metal Laser Sintering Selective Laser Melting Electron Beam Melting Selective Laser Sintering

Creates objects by using thermal energy to fuse regions of a powder bed.

Metal, Polymer, Ceramic

EOS (Germany) Renishaw (UK) Phenix Sytems (France) Matsuura (Japan) ARCAM (Sweden) 3D Systems (US)

Sheet Lamination Ultrasonic Consolidation Laminated Object Manufacture

Build parts by trimming sheets of material and binding them together in layers.

Hybrids, Metallic, Ceramic

Fabrasonic (US) CAM-LEM (US)

VAT Photopolymerization

Stereolithography Digital Light Processing

Build parts by using light to selectively cure layers of material in a vat of photopolymer.

Photopolymer, Ceramic

3d Systems (US) Envision TEC (Germany) DWS Sri (Italy) Lithoz (Austria)

Additive manufacturing processes, adapted from ASTM, 2012

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Binder Jetting Process

Binder jetting A printhead selectively dispenses binder on a thin layer of powder. Powder layers can be spread by a counter-rotating roller from a supply chamber to the build chamber, or the powder can be spread by a recoater. After the part is completed, the build chamber is removed to a curing oven, after which the part is depowdered and prepared for sintering or infiltration.

Advantages Economics are great. Well suited for large parts. All kinds of powders can be used. Support structures are not needed.

Disadvantages Surface finishes are generally ~400 microinch. Post-processing such as sintering is necessary for processing metals, ceramics, and other materials.

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Binder Jetting Process

Droplet Interaction with Powder Analogous to inkjet paper printer:

(Binder ≡ Ink Powder Layer ≡ Paper) Exception: Binder must penetrate to bond

with previous layer

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3DP is Basic Powder Metallurgy

Bonded

Partially Sintered

Infiltrated

Highly Sintered

Powder metallurgy is the process of blending fine powdered materials, pressing them into a desired shape or form (compacting {printing}), and then heating the compressed material in a controlled atmosphere to bond the material (sintering). The powder metallurgy process generally consists of four basic steps: powder manufacture, powder blending, compacting, and sintering. (Wikipedia)

Product Forms

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Advantages of ExOne’s Process

• No extra charge for part complexity

• Offers endless patterns and part geometry

• No support structures needed

• Requires no build plate to begin on

• Easy optimization of traditional

• No tool paths required

• Multiple different parts can be built in a single print bed

• Parts can be modified on the CAD file in seconds, and reprinted without complicated tooling changes

• Use of industrial graded materials

• Large build envelopes

• High print speed

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Direct Metal PSC (North Huntingdon, PA)

• ISO 9001: 2008 CERTIFIED

• Reverse design engineering (modeling or scanning)

• Prototypes services

• Optimization for additive manufacturing

• Finishing in-house

• Low volume production contract services

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Industries Served

AUTOMOTIVE AEROSPACE

ENERGY HEAVY EQUIPMENT AND

MACHINERY

GENERAL CONSUMER FILTRATION AND MINING

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General Products

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Functional Working Parts

• Print functional working prototypes or production run

quantities for real life applications

• Possible post processes but not limited to the following:

Machine: 420SS - typically has a tensile strength range of 60-

75 ksi conventionally machining may require slower

speed and feed rates

316SS – can be traditionally machined

Finish: Mass finishing with polishing media

Grind, Sand, Polish

Coat: Clear Coating, plating, powder coat, paint

Weld: Silicone Bronze rod and TIG weld

Silver Solder (Harris Products 45N, stay below 700⁰ C)

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Multiple Part Consolidation

• 27 traditional individual components

reduced to a single piece

• Reduction of documentation and time

• Delivered in weeks not months

• On-the-fly changes are possible

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Optimization

Traditionally Manufactured Part

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Part Information

Optimized for 3D Printing – Pass 1

Optimized for 3D Printing – Pass 2

Name: Nacelle Bracket Application: Aerospace Prototype Printed Material: 420 Stainless Steel and Bronze

Weight = 7.8 lbs.

Weight = 2.8 lbs.

Weight = 1.4 lbs.

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Certified Materials (PSC Offerings)

316 Stainless Steel Infiltrated with Bronze

30 or 60 micron

420 Stainless Steel Infiltrated with Bronze

30 or 60 micron

Inconel 625 (Highly Sintered)

30 Micron

Iron Infiltrated with Bronze

30 micron

Bonded Tungsten Soda Lime Glass

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Printable Materials

17-4 316

Inconel 718

Cobalt Chrome Iron Chrome Aluminum Tungsten Carbide

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420 Stainless Steel Infiltrated with Bronze

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316 Stainless Steel Infiltrated with Bronze

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Iron infiltrated with Bronze

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Inconel 625

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Inconel 625 (Highly Sintered)

AS SINTERED PARTS

POST PROCCESSED

* Engine Turbine Blade used

for demonstration piece only *

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Surface Finishes

Line of Sight Operation

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Available Finishes

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Case Studies

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Case Studies

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Process Steps

Print Directly from CAD Depowder

Heat Treatment Final Product

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Direct Material Machines

Production

&

Prototyping

Prototyping

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Production

Research

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Education

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Innovent

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M-Flex

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Print Platform

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Tested and Certified

• Mechanical Testing

– Tensile strength & modulus – Compressive strength & modulus – Flexural strength & modulus – Fatigue & fracture toughness – Impact strength (Charpy & Izod)

• Metallography & Microscopy

– Specimen Preparation • Mounting, grinding, polishing equipment

– Microscopy • Inverted Light Microscope • Scanning Electron Microscope (SEM) • Image Analysis Software

• Hardness

• Density

– Archimedes, Helium Pycnometry, Bulk • Coefficient of Thermal Expansion (CTE)

SEM Machine

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Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.

ExOne The Americas

MID-ATLANTIC

127 Industry Boulevard North Huntingdon, PA 15642 USA +1 877 773 9663 MIDWEST

2341 Alger Drive Troy, MI 48083 USA +1 248 740 1580 SOUTH

7409 Railhead Lane Houston, TX 77086 USA +1 281 931 0011

ExOne Europe

ExOne GmbH

Daimlerstrasse 22 86368 Gersthofen Germany +49 821 65063-0 ExOne Italy SRL

Via Galileo Galilei 68 Località La Pigna 25015 Desenzano del Garda Brescia, Italy ExOne Asia

161-5 Haneo Odawara-shi, Kanagawa Japan 256-0804 +81 465 44 1303

exone.com +1 877 773 9663

SOUTHWEST 3905 N. Pecos Rd N. Las Vegas, NV 89115 +1 702 487 3977

NORTHWEST 1307 W. Valley Highway N. Auburn, WA 98001 +1 253 394 0357