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.
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |3
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |4
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)
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |5
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |6
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |7
First Time Right Development Cycle
PREFERED CONCURRENT ROUTE for FIRST TIME RIGHT PRODUCT DEVELOPMENT
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |8
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |9
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |10
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)
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |11
3D Printing and Multiphysics CAE
Material ProductProcess andSystem
Trial and Error
vs
Physics based
modelling
For the first time right
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |12
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |13
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |14
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |15
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |16
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
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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.
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |18
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
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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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |20
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |21
3D Printing and Multiphysics CAE
Product Design
Process modellingOverhang and supportWarpage and ShrinkageResidual stress
Part performance for First Time Right
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |22
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
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |23
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.
ATOA Scientific Technologies | ATOA: Public| atoa.com | COMSOL Webinar | 3D Printing |12 Aug 2015 |24
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
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CAD CAE CAM of 3D Printing@ 3d.atoa.com
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