G.gibbons, wmg alm now and the future
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Additive Layer Manufacturing Next Generation Dr Greg Gibbons Head – ALM, WMG
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Transcript of G.gibbons, wmg alm now and the future
Additive Layer ManufacturingNext Generation
Dr Greg GibbonsHead – ALM, WMG
Stuff I might say…
• What is Additive Layer Manufacturing?
• Where is ALM technology now?
• Where is ALM being used?
• Where is ALM going?
– Plastic ALM
– Metals ALM
• How can I access the technology?
WHAT IS ALM?
What is ALM?
…it’s what the Daily Mailcalls: 3D Printing
What is ALM?
What is ALM?
WHERE IS ALM NOW?
WHERE IS ALM NOW?
Plastic ALM
Where is ALM now? - plastic• Printer market is differentiating into four markets:
Production
Professional
Personal
Prosumer
Where is ALM now? - plastic
• There are lots of prosumer printers installed..
Where is ALM now? - plastic
Where is ALM now? - plastic
WHERE IS ALM NOW?
Metallic ALM
Where is ALM now? - metal
• Two distinct classes of technology
– Powder bed
– Directed Energy Deposition
Where is ALM now? - metal
• Wide range of materials:– Ti alloy
– CP Ti
– Al20Si
– 316L stainless steel
– 17-4 PH steel
– Inconel 625, 718
– ….
• Full density and mechanical properties approachingwrought
Where is ALM now? - metal
WHERE IS ALM BEING USED?
• Prosthetic body parts!
Making? ….Useful things
Hayley Fraser’s new hand
Buttercup’s false leg
Artificial legs • Food!
• Houses– Chinese construction firm 3D
Print 10 houses in 24 hrs
– £2m and 12 years to design andmanufacture printer
– £3000 per home
– Layers of recycled concrete
– Environmentally friendly
Making? …. Large things!
• 3m Titanium part 3D Printed– Lightweight
– Efficient use of materials
– Installed on Comac C919 in 2014
– Flying by 2016
Making? …. Important things!
Making? …. Other things!
Clothing
Household Goods
Furniture
Fashion
Guitars
Cars
WHERE IS ALM GOING?
WHERE IS ALM GOING?
Plastic ALM
Where is ALM going? - plastic
• Four clear trends for plastic 3D Printing:
– Multiple materials, functional materials
– Faster processing
– Low cost ALM
– Cross-over ALM technology
Multiple materials, functional materials
• Inkjet printing technology
– Silver and carbon-based inks
– Print onto flexible substrates
• Generate simple, low voltage circuits– Conductive tracks
– Resistors
– Switches
– OLEDs
• Electroluminescence (EL)
– Low energy, low heat lighting
– Simple circuit
PEDOT-PSS transparent electrode
Zinc Sulphide Phosphor
Dielectric
Reflective (silver) rear electrode
Surface
+ve
-ve
LIGHT
Multiple materials, functional materials
• Low power batteries
Multiple materials, functional materials
• WMG Research – Hybrid ALM
– Hybridising inkjet printing with syringedeposition
– 2 x 512, 14pl nozzle heads, individuallyaddressed
– Low viscosity liquid inkjet printing
– Continuous flow for deposition of resinswith highly suspended solids
– SmartPump for deposition of higherviscosity resins and pastes at extremelyhigh resolution
Multiple materials, functional materials
• 4D Printing
– Printing active materials that have a response to external stimuli• Pressure, temperature, chemical, magnetic, electrical…
– Sensors, actuators, medical devices…• Artificial muscle
• Stents
• …
Multiple materials, functional materials
• High Speed Sintering (HSS)– Ink-jet printing of carbon ink onto
thermoplastic powder
– Melting of powder using infra-redwhere ink is patterned
– Possibility of 100x faster processing
Faster processing
• Research - Selective Laser Printing
– Laser printing of polymers
– High rate
– High resolution
– Multiple materials
Faster processing
Low cost ALM
• Reduced cost through lower cost systems
– Lost of small low cost systems
– All Fused Deposition Modelling (melted filament) based
Low cost ALM
• Reduced cost through lower cost systems
– Now emerging lots of other low cost technology
Cross-over ALM
• Emerging technologies that areutilising existing conventionaltechnology in a new way
• Arburg freeformer
– Modified plastic injectionmoulding
– 3 or 5 axis
– Utilises standard IM gradepolymers
• Based on well-established technology
• Existing, standard materials
WHERE IS ALM GOING?
Metal Fabrication
Where is ALM going? – metals
• Increasing capability
• Lower cost
• Hybrid CNC / ALM systems
Where is ALM going? - metals
• Increasing capability
– Faster build rates
– Larger build volumes
• Resulting in lower buildcost– DED significantly lower cost
than powder bed
– DED can have much higherbuild rates than powder bed
Where is ALM going? - metals
• Lower cost metal systems are emerging
MIT
– MIG welding based technology
– <$2,000
Where is ALM going? - metals
• Lower cost metal systems are emerging
MatterFab– Laser melting powder bed technology
– Uses low cost components and open source software
– ~$50k
Where is ALM going? - metals
• Biggest change is move to hybridised CNC and ALM
– ALM is used to clad metal
– CNC is used to finish machine the parts in-situ
– 100% finished parts off the machine
– Use to repair or augment existing parts or build new ones
• 3 suppliers present at the moment (Dec ‘14)
– Hybrid Manufacturing Technologies Ltd (micro SME)
– Optomec Inc (large enterprise)
– DMG Mori Seiki (large enterprise)
Where is ALM going? - metals
• Hybrid Manufacturing Technologies Ltd
– Fully retrofittable to any CNC or robotic platform
– Innovative docking of laser head using in standard tool changer
Where is ALM going? - metals
• Optomec LENS Print Engine
– Modular system• Deposition head
• Powder feeders
• Motion controller
• Process control
• Tool path software
– Retrofittable into selected CNC systems
Where is ALM going? - metals
• DMG Mori Seiki
– LaserTec 3D system
– 5-axis milling and laser cladding
WHERE IS ALM GOING?
Last but not least…..
• Moon bases– ESA with architects
– Robotic 3D Printers
– Use moon dust (Regolith)
Where is ALM going – to the moon!
HOW DO I ACCESS ALM TECH?
How do I access ALM tech?
• In-house acquisition of ALMtechnology vs using an externalbureau
• In-house costs– Machine– Maintenance– Materials– Labour– Overheads
• Cost may be higher in-house forplastic parts
– Bureaus can offer low cost throughhigh volume sales
• Beware of very low costprinters….may not live up toexpectations!
How do I access ALM tech?
• Access the technology through government fundedinitiatives such as the IIPSI
How do I access ALM tech?
• Need to investigate the use ofALM for a new product or in anew application or even a newALM technology?
• Work in collaboration with WMG– Innovate UK Innovation funding
• Smart Awards
• Feasibillity projects
• Collaborative R&D
• KTP
– H2020 EU funding
– UK Research Council Funding• EPSRC, MRC, ESRC, BBSRC
How do I access ALM tech?
• Need to investigate the use ofALM for a new product or in anew application or even a newALM technology?
• Work in collaboration with WMGstudents
– PhD or EngD studentships (3½ -4yr)
– Undergraduate projects (Oct-April)
– FT masters projects (Oct – August)
– WMG internships
