Inside3 d printing_chuckalexander

Copyright © 2013 Solid Concepts Inc.
Industrial Scale
Additive Manufacturing
Technologies
Chuck Alexander
Product Manager
Solid Concepts Inc.

Source: Gartner 2012 Technology Hype Cycle
Gartner 2012 Technology Hype Cycle

Source: Gartner 2013 Technology Hype Cycle
Gartner 2013 Technology Hype Cycle

3D PRINTING/
ADDITIVE MANUFACTURING

Overview
Mission: To excel in rapid prototyping and manufacturing by
providing superior value through quality, delivery, and service.
Product
Development
(Prototype, Test, Refine)
Pre‐Production
(Sales, Market Introduction,
Mfg. Line Optimization)
Production
(Low Volume, Spares, Service,
Product Revision)

Technologies
PolyJet
Stereolithography (SLA)
Selective Laser Sintering (SLS)
Fused Deposition Modeling (FDM)
ZPrint 3D Color Prints
Direct Metal Laser Sintering (DMLS)
Additive
Manufacturing

PolyJet™
PolyJet is a high precision 3D
printing process with layers
as thin as 16 microns
(0.0006"). Suitable for
excellent appearance
models and patterns for
advanced urethane castings.
Applications: High resolution
concept models, low volume
over‐molded parts.

PolyJet Video
• Click to play video

PolyJet
PolyJet HD build (16μm
layers) offers finest
layer thickness
PolyJet Blue and SCI White
PolyJet offers fast delivery of highly
accurate models
SCI White material used to
create fine feature detail

PolyJet
Material Options
Material Build Envelope Resolution/Tolerances
PolyJet White
Opaque white, rigid, durable Objet Eden 260V
Objet Eden 500V
Recommended:
4" x 4" x 4“
(or larger flat objects)
Maximum:
19.3” x 15.4” x 7.9”
PolyJet (Fastest Build Speed)
30m (~.00118”) layer thickness by
42m  (~.00167”) X & Y axis
PolyJet HD (High Definition)
42m  (~.00167”) X & Y axis
Tolerance:
 .005” or  .001”/”, whichever is
greater
PolyJet Blue
Pale blue, rigid, durable
PolyJet Gray
Light gray, rigid, durable
Amber Clear
Clear (amber tint), rigid, durable
PolyJet Flex &
PolyJet Over‐Mold
Flexible black (Shore 27A‐95A) &
Flexible black over rigid PolyJet White
Objet Connex 500
Recommended:
4" x 4" x 4“
(or larger flat objects)
Maximum:
19.3” x 15.4” x 7.9”
PolyJet Flex & PolyJet Over‐Mold
42m  (~.00167”) X & Y axis
Tolerance:
 .005” or  .001”/”, whichever is
greater

SLA® (Stereolithography)
SLA (Stereolithography) provides
accurate concept models and
master patterns in record time.
Complete in‐house finishing
capability for production‐like
prototypes.
Applications: Concept models,
form/fit verification, master
patterns for cast urethanes,
investment casting patterns,
ID‐Light lightweight models.

SLA Video

Solid Concepts offers a wide variety of
photocure materials that were meticulously
selected to meet your project needs.
SLA has been a
material of
choice for many
wind tunnel
testing project.
Architectural
models are often
made with SLA
including this scale
mock‐up of San
Francisco for a new
Transbay Transit
Center & Tower.
Accura 60 is a
clear material
that can be
tinted such as
the red lens
seen here.

Finishing – Cosmetic Paint

• SLA master patterns were
used to create WALL‐E’s
body panels.
• This real robot was built for
tours, guest appearances,
and trade shows.

Lightweight Appearance Model – ID‐Light

Lightweight Appearance Model – ID-Light

Arts & Entertainment

QuickCast™ Investment Casting Patterns
Light Weight Patterns
• 10 ‐ 35% lighter (in general) than a
standard investment casting pattern
Pattern shown
• 0.0980 kg (left) vs. 0.1240 kg (right)
• 21% lighter
• Volume = 438 cm3
• 0.224 g/cc, 0.283 g/cc
• 19.98% of vol. occupied by sold mass
(left)
• 25.27% of vol. occupied by solid mass
(right)

QuickCast™
SC 1000
• Material engineered specifically
for investment casting
• Low water absorption
• High green strength
• Excellent face‐coat adhesion
• Higher yield

Large part expertise
QuickCast™
The 2011 PAC 12 football
trophy utilized both ID‐Light
and QuickCast investment
casting patterns.

Material Options
SC 1000
Clear, water resistant, rigid,
durable
3D Systems Viper si2, SLA‐500 ,
iPro 8000
Max single piece part size:
25” x 29” x 21”
Standard Resolution:
0.007” Layer Thickness
Standard Tolerances:
 .015” or  .002”/”,
whichever is greater
‐ Or ‐
Premium Resolution:
Premium Tolerances:
 .015” or  .0015”/”,
SC 4500
White, highly accurate, excellent
sidewall characteristics
3D Systems SLA‐500
20” x 20” x 21”
SL 7545
White, good durability, slightly
flexible with good accuracy
3D Systems SLA‐7000
20” x 20” x 21”

Material Options
SL 7810
Very white, good surface finish
resembles ABS. Accurate parts with
exceptional elongation to break
and Izod Impact strength
3D Systems SLA‐5000, iPro 8000
25” x 29” x 21”
Premium Resolution:
Premium Tolerances:
 .015” or  .0015”/”,
whichever is greaterAccura 60 Clear
Clear, Polycarbonate‐like material,
durable tough plastic
SC 5500
Gray, accurate, durable
3D Systems Viper si2, iPro 9000
25” x 29” x 21”
HDSL Resolution:
 .010” or  .001”/”,

SLS® (Selective Laser Sintering)
SLS (selective laser sintering)
produces rugged Nylon 11
and Nylon 12 prototype and
production parts and is ideal
for Direct Digital
Manufacturing. Layer
additive, laser sintered nylon
powder.
Applications: Concept models,
prototypes, production parts.

SLS Video

Integrated SLS fuel tanks built without tooling.
Avionics & Automotive Fuel Tanks

Art & Architectural Models

Architectural Models

Automotive Applications
SLS Nylon 12 GF was used in this
underhood application to enhance
air flow in the Porsche 928 engine.
This SLS intake plenum
was used on a formula
style racecar during
competition.

Transportation – Electric Motorcycle

Aerospace Applications
SLS Nylon 12 GF was used to
create the gimbal seen below
This PEEK aerospace part
mixes hot engine air with
cold atmospheric air outside
the airframe, providing
regulated temperature.

Unmanned Aerial Vehicles

Material Options
Nylon 12 PA
White, general purpose,
rugged Nylon material
3D Systems Sinterstation HiQ HS,
EOS P 730
26” x 14” x 22”
 .015” or  .002”/”,
Nylon 12 GF
Aluminum filled Nylon
material, excellent surface
finish
Nylon 12 AF
Glass filled Nylon Material,
increased tensile modulus
3D Systems Sinterstation HiQ HS
12” x 10” x 17”

Material Options
NyTek™ 1200 CF
Carbon filled, superior
thermal properties
12” x 10” x 17”
 .015” or  .002”/”,
DuraForm HST
Fiber filled, high strength and
high temperature
PA 640 GSL
Lightweight, high stiffness and
high temperature

Material Options
NyTek™ 1100
White, high elongation,
aerospace applications
12” x 10” x 17”
 .020” or  .003”/”,
NyTek™ 1100 B
Black, high elongation,
FR‐106
Flame retardant nylon, FAR
25.853 rated
PEEK HP3
Flame retardant, FAR 25.853
and UL‐94 VO rated
EOS P800
25” x 13” x 12”

FDM (Fused Deposition Modeling)
FDM uses thermoplastic production
materials in a layer additive process.
FDM produces functional prototypes
and production parts.
Applications: Concept models, Direct
Digital Manufacturing, functional
prototypes, end‐use parts, visual
models, manufacturing tools,
engineering test models, low volume
production, high temperature parts.

FDM Video

End‐Use Parts
Short‐Run Production Parts
Jigs & Fixtures
Concept Models
Functional Prototypes

ULTEM 9085
ULTEM 9085 is a flame retardant
high performance thermoplastic
for DDM. It is ideal for the
transportation industry due to its
high strength‐to‐weight ratio and
its FST (flame, smoke, and
toxicity) rating.

Opportunity
Air Duct – Orbis Flying Hospital

Challenge

Process

As a result of engineering
approved by the DER and mfg.
audited by a DAR, an FAA
8130‐3 certification of
airworthiness ensured that the
duct made is ready to fly.
Results

Largest Integral Parts
FDM parts as large
as 36” x 24” x 36”
can be built in a
single build. Larger
parts can be built
in segments and
then assembled
together.

FDM® (Fused Deposition Modeling)
Material OptionsMaterial Build Envelope Resolution/Tolerances
ABS‐M30
Multiple colors and
applications
Fortus 400mc &
Fortus 900mc
production grade equipment
(from Stratasys)
400mc – 16” x 14” x 16”
900mc – 36” x 24” x 36”
(also 0.007” & 0.013” layer thickness)
 .010” or  .0015”/”,
ABS‐ESD7
Black, applications requiring
electro‐static‐dissapative
properties
PC‐ABS
Black, highest impact
resistance & good stiffness
PC‐ISO
White, good stiffness & HDT,
ISO cl VI cert.
ULTEM 9085
Tan, excellent HDT, Flame
retardant, FAR 25.853 &
UL‐94 VO rated

AM – How do you choose?
• Application
• Conceptual or Functional
• Part size & resolution (minimum
feature size)
• Material
• Accuracy
• Delivery
• Budget

Plastic Products Comparison

ZPrint is the easiest way to quickly turn 3D CAD data
into real colored parts. Parts are created with
powdered plaster composite material coupled with
a 4 color printing process. Color is printed directly
into the part. This type of color finish eliminates
the need for post‐processing paint.
Applications: Architectural Models, Avatars,
Presentation Models, Concept Evaluations,
Student Projects, Space Studies, Training Aids

Color is printed directly into the part utilizing a 4 color printing
process, allowing for 390,000 possible color combinations.

Colors define the
aerodynamic pressures
on the fuselage

Material Options
Material Build Envelope
ZPrint
with ZP 150‐Z Bond Material
ZP650 3D color print system
Maximum:
10” x 15” x 8”

Finishing
Menehune Hale
ID‐Light/ SLA (Stereolithograph) – process uniquely offered by Solid Concepts

• Hand Finishing/Sanding
• Cosmetic Paint
• Non‐cosmetic Paint
• EMI & RFI Shielding
• Textures & Mold‐Tech® Finishes with
Cast‐in Capabilities
• Hardware (inserts, helicoils, etc.)
• Assemblies
• Vapor Polish
Finishing
Green ABS Machine Finish vs Hand Finished with Cosmetic Green Top Coat

Finishing
Bulwark Football Helmet
SLS (Selective Laser Sintering) | Hand Finished with Cosmetic Top Coat

DMLS (Direct Metal Laser Sintering)
DMLS (Direct Metal Laser Sintering) produces rugged
metal prototype and production parts. Layer
additive, sintered metal and alloy powdered
materials.
Applications: Small functional parts, detailed
prototypes, production parts.

DMLS Video

DMLS is ideal for geometries
that can’t be CNC machined.
Cobalt Chrome MP1 is
biocompatible and often used
for surgical assist products.
DMLS uses metal and alloy
materials to rapidly produce
production parts.

Thin‐walled Turbine Combustion Chamber – Inconel 718

Integrated Pressure Taps Stainless Pitot Tubes

Integrated Cooling Channels for Injection Mold Tooling Insert

NASS Spinall Implant – Ti6Al4V

Material Options
Stainless Steel 17‐4 PH
White, high elongation,
EOS M270 & M280
9” x 9” x 7”
Optimal max part size:
4” x 4” x 4”
20 – 40 micron Layer Thickness
 .005” or  .002”/”,
Inconel 625 & 718
Black, high elongation,
Colbalt Cromium CoCr
Specialty material
Titanium Ti6Al4V
Specialty material

QuantumCast™ Cast Urethanes
QuantumCast cast urethanes
(proprietary advanced casting
technology and advanced formula
polymers) produce strong pre‐
production and short‐run production
components.
Applications: Pre‐sales, trade shows,
clinical trials, UL/CSA certification,
production parts, alpha & beta builds,
engineering verification, large part
manufacturing, early revenue
generation, assembly & quality
inspection.

QuantumCastTM Video

Transitioning to Cast Urethanes
Foreground – SLA (Stereolithography) Master Pattern
Background‐ Cast Urethane with cast in texture and cast in color

Cast Urethanes ‐ Time to Market
Star Trac | California
Cast Urethane Short Run | Bridge to Production

Cast Urethanes – “Creatures”
Dena’ina Civic Center | Alaska | Artist: Ralph Helmick
Cast Urethane Short Run for 100’s of “creatures” without tooling

Unmanned Submarine
University of Colorado/ National Geographic
Multiple Technologies: FDM, Cast Urethanes, SLS

Unmanned Aerial Vehicles
Area‐I | Georgia
Multiple Technologies: SLS, FDM and CNC, Composites, for fuel tank, ailerons, control surfaces, mounting plates, more…

Aerospace
DRS Technologies | Electronics Cooling Duct Designed for Additive Manufacturing
SLS (Selective Laser Sintering)

Prosthetics
Direct Dimensions Inc. | Maryland
PolyJet Master Pattern for Customer Molding Process

QuickCast Investment Casting Patterns
Knee Replacement Patterns Created for Individuals – Example of Mass Customization
SLA (Stereolithography) QuickCast Investment Casting Patterns

DMLS – Direct Metal Laser Sintering
Dental Copings and Bridges Manufacturing
Images & application courtesy of EOS

Motorsports
Within Technologies | www.within‐labs.com | United Kingdom
DMLS (Direct Metal Laser Sintering) | Titanium Hood Scoop for Formula 1 Racing

Micro Cooler
Microchip level temperature control design requires no supports during Additive Manufacturing build process

Heat Exchanger
Enhance Software | DMLS

Osseointegration
Encouraging ingrowth of bone into an implant

Liquid Lattice
Carrying load while minimizing weight

The Future of AM/3DP Looks Bright
• Opportunities for Market Growth
– 3D capture software
– Process control
– Materials
– Finishes
– Lower cost of ownership

Resources
• Websites
www.SolidConcepts.com (full service)
www.ZoomRP.com (self service)
• Technology Videos
http://youtube.solidconcepts
• Chuck Alexander
chuck.alexander@solidconcepts.com
(661) 295‐4482
• Thank you to:
Within Labs: http://www.within‐lab.com/
EOS: www.eos.info

Inside3 d printing_chuckalexander

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