Download - 2013 03-12-masterclass-biomedical-applications-of-am sirris-trends

Additive Manufacturing – Market, Trends and Future

Thierry Dormal

Motor vehicles 20%

Aerospace 12%

Industrial/business machines 11%

Consumer products/electronics

20%

Medical/dental 15%

Academic institutions 8%

Military 6%

Architectural 3%

Other: 5%

AM business - World repartition

Source : Wohlers 2011

2

Sirris 29 %

Sirris 22 %

Organized by SIRRIS the 12th of March 2013 Masterclass: Biomedical applications of Additive Manufacturing

3

Trends for AM & 3DPrinting

• Aerospace : large interest to evaluate AM technologies and start

standardisation & certification (Airbus, ESA,..) • Mega scale free-form of buildings: D-shape (granular sands) • 3D printing of nanostructures • 3D bio-printing (organs & tissues) • Conductive materials incorporated into layered composites

radar absorbing materials

• Cost of 3D printers down to 500 € but also up to > 1 M€ • Large companies coming on the AM market: HP with FDM, Fujifilm with Dimatix (DMP) for solar cells,…


4

Low cost 3D printers • > 120 3D printers available • Mostly based on FDM, FFF

• From 400 to 1000 €


5

Low cost 3D printers • > 120 3D printers available • Mostly based on FDM, FFF

• From 1000 to 2000 €


6

Low cost 3D printers • > 120 3D printers available • Mostly based on FDM, SLA, DLP

• 2000 – 7000 €


7

Large systems : Voxeljet: up to 4 meters.


VX4000

Voxeljet: Sand & plastic. 600 dpi. 26560 DOD jets. 67 h. for 1000mm (15 mm/h)


10

The future of Additive Manufacturing

• Three different ways of using AM technologies

• Prototyping for visual models or functional parts

• Direct production of parts (light redesign, only validation)

• Direct production of parts redesigned for AM

(no way back to conventional production)


11

Additive Manufacturing Limitations

• Geometrical limitations: • Wall thickness: 0.3 mm – 1.5 mm • Length of internal channels (powder removal) • Max. size: 100 mm 4000 mm.

• Anisotropy (axe Z) for some mechanical properties • Surface quality (layer thickness, orientation) • Support structures for 3D building with some AM techniques.

(generation, building, removal)

• Some understanding of the AM processes are required for

• The designer (dimensioning, resolution, wall thickness)

• The manufacturer (part orientation, support generation, shrinkage factor, warping)


12

Geometrical Complexity (Polymers)

• No tool required for series production: • No draft angle required for demouldability • No mould filling problems

Freedom of Creation Hettich: Rotolavit Blood centrifuge (< 1.000 units / year) 30 % less expensive than with injection moulding 32 components 3 components (2 with LS, 1 with IM) Manufacturing on demand (customization)


13

Geometrical Complexity (metal)

• No tool required for series production: • No draft angle required for demouldability • Internal walls and details

Wim Delvoye / 3DP metal SIRRIS Steel part (Concept Laser)


14

Less components - Assembly reduction

• Redesign of a laser collimator for space app.: • 13 components 2 components • Cooling system and geometry optimization


15

Integration of functions

• Integration of snap fits, hinges,...

EBM - Oak Ridge National Lab

EOS

Materialise MGX


16

Integration of functions

• The design of a complex part with several local functions (spring effect, damping effect) usually requires the assembly of components in different materials.

• With AM, this is possible in one step with bi-material process like the Connex machine (Objet)

Connex (Objet)


17

Lightweight parts – Lattices structures

• Weight reduction using lattices structures with minimal strength reduction • Local variation of lattice types

graded porosity • Shock damping, vibration reduction • Biomedical implants: bone regeneration


18

Lightweight parts - Topology optimization

• Automated design based on the applied constraints (Topol) • Same mechanical properties

SIRRIS redesign (Compolight)


Free space definition

Efforts repartition

STL file

Smoothing or redesign based on the STL geometry

Flying Cam example (Compolight project)

Stress verification

Lightweight parts - Topology optimization


20

Customization – unique parts & short series

• Unique parts for art, aerospace, biomedical applications

• Mass customization: variants for each

country

Hearing aids


21


• Olaf Diegel (Massey University)

Design: presets or user defined No AM for head, neck & frets


22


Aline Salmon 3DP metal (Sirris)

Sac féminin haut de gamme YAMM (200 parts) Anne Valérie Bribosia 3DP metal (Sirris)


23

3D surface texturing

• Library of texturing types available for the designer • Stone, wood, marble, leather, … • Visual effect as well as adherence & special grip


24

4 injection moulds produced with & without conformal cooling channels

Conformal cooling channels - Hipermoulding project

∅4 mm

Drastic reduction of the cycle time (up to 35%) Enhancement of part quality Enhancement of tool lifetime Profitability up to 200.000 euros/year (prod. 6 Mparts)


25

Catamaran (Hydrauvision) – Compolight project

Hydraulic units with complex internal channels Reduction of the weight and size of the original part 3DP Prometal (Sirris)


26

Functionaly Graded Materials

Example with Ti alloys (source OPTOMEC): 3 different Ti alloys with 3

specific functions: impact resistance, fatigue and creep


• AM : huge design freedom • Some limitations / guidelines need to be known • AM should be considered from the product conception phase • An efficient design for AM allows to use these products as end

products rather than prototypes

• AM maturity: large range of cost, performance & applications


28

Additive Manufacturing

Thanks

Contact: Thierry Dormal [email protected]
