The Additive Manufacturing Gold Rush. Dream or Reality?
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1 The Additive Manufacturing Gold Rush Dream or Reality?
2 Where s the Rush? Source: Gartner (July 2014)
3 The Additive Manufacturing Gold Rush Tools of the Trade
4 Additive Manufacturing (AM) Basics CAD Solid 3D Computer Model STL Data Conversion of solid computer model to triangulation data Slice Data STL Data is sliced into thin 2D cross-sections 3DP Machine Part or Mold is made one 2D cross section at a time by additive manufacturing processes Part/ Mold Part or Mold is removed from machines and hand finished Customer Part or Mold is delivered to the Customer or Foundry
5 Standardized AM Categories Binder Jetting Directed Energy Deposition Material Extrusion Material Jetting Powder Bed Fusion Sheet Lamination Vat Photopolymerization
6 Standardized AM Categories
7 Binder Jetting Image Source ExOne ( Copyright 2012 ExOne Copyright 2012 ExOne Image Source Ford Motor Company Process: Liquid bonding agent is selectively deposited to join powder materials Technologies: Varies by binding material Materials: Plastic, Ceramic, Metal, Sand, PMMA
8 Directed Energy Deposition Process: Focused thermal energy melts material as it is deposited Technologies: LENS, EBF, DMD Materials: Metals (wire or powder)
9 Material Extrusion Process: Material is selectively dispensed through a nozzle Technologies: FDM, FFF Materials: ABS, Polycarbonate, PLA, Nylon, Ultem
10 Material Jetting Process: Droplets of build material are selectively deposited Technologies: CS, DOD Materials: Wax, Photopolymers
11 Powder Bed Fusion Process: Thermal energy selectively fuses regions of a powder bed Technologies: SLS, DMLS, EBM, SHS, SLM Materials: Powdered Metals, Polymers, Composites, and Ceramics
12 Sheet Lamination Process: Sheets of material are bonded to form an object Technologies: UAM, LOM Materials: Foil of Metal, Plastic or Paper
13 Vat Photo Polymerization Image Source Ford Motor Company Image Source Solid Concepts ( Image Source Ford Motor Company Process: Liquid photopolymers selectively cured by light polymerization Technologies: SLA, CLIP, DLP Materials: UV-Curable Photopolymers
14 And More Hybrid technologies DMG Mori Sieki MC Machinery Optimec (add-on) AMBIT (add-on)
15 And Bigger
16 The Additive Manufacturing Gold Rush Finding Gold
17 Prototype Visualization Flow Testing Performance Testing Verification of design intent / fit / form Optimization of assembly sequence / methods Functional Prototypes 17
18 Indirect Manufacturing Tooling, Fixtures, Gauges 18
19 Direct Manufacturing Light Weighting Tungsten Light Weighting / Thermal Management Complex Geometry Heat Exchanger 19 Fuel Nozzle
20 Complex Structures
21 Medical Affordable Customization
22 Fashion
23 Food
24 Manufacturing Multi-Material Surface Treatment Embedding Repairs 24
25 In Situ Manufacturing
26 The Additive Manufacturing Gold Rush The Hard Reality
27 Additive Manufacturing (AM) Basics CAD Solid 3D Computer Model CAD Capabilities STL Data Slice Data Conversion of solid computer model to triangulation data STL Data is sliced into thin 2D cross-sections Interoperable Standard 3DP Machine Part or Mold is made one 2D cross section at a time by additive manufacturing processes Capital Expenditure Part/ Mold Customer Part or Mold is removed from machines and hand finished Part or Mold is delivered to the Customer or Foundry Post Processing
28 It s Always Better In The Demo
29 The Bin of Broken Dreams
30 Just Add Powder
31 Where Is The Gold?
32 Where Is The Gold?
33 Standards Material And Process The Wild Wild West
34 Need For Standardization Parameters Interoperability Process Predictable Results Materials Freedom of Choice Users OEMs
35 Need For Standardization Quality control Repeatability Parameters, Materials, Process
36 Standards File Format ASTM F42 ISO TC 261 STL file format AMF file format Multiple Materials Graded Materials Microstructure
37 Standards
38 The Additive Manufacturing Gold Rush The Good, The Bad and The Ugly
39 Intellectual Property The Good
40 Intellectual Property The Good
41 Intellectual Property The Bad Remember Napster? What if you could make an exact copy of any object?
42 Intellectual Property - The Ugly
43 The Additive Manufacturing Gold Rush Dream or Reality?
44 The California Gold Rush The Dream and the Legacy
45 The AM Gold Rush Variety of technologies Continuous Innovation Significant Investment
46 The AM Gold Rush Traditional manufacturing will not disappear Evolution more than Revolution New applications discovered every day IP challenges Standards
47 The AM Gold Rush New Business Opportunities and Models Consolidation Cross-Pollination Still many Dreams to be brought to reality
48
1.8.3 Haptic-Based CAD 1.9 About this Book 1.10 Exercises References Development of Additive Manufacturing Technology
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