Designing for the dmls process oct2015
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Designing for the dmls process oct2015
- 1. DESIGNING FOR THE DMLS PROCESS JONATHAN BISSMEYER Senior Quality Engineer
- 2. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING ABOUT PROTO LABS
- 3. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING OUR EQUIPMENT Concept Laser M2 and Mlab machines
- 4. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING DESIGNING FOR DMLS Not a replacement for traditional machining, casting, sheet metal fabrication or metal injection molding (MIM)
- 5. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING Reduction of components Reduction of weight Quicker assembly times Reduction of cost Complexity DESIGN GOALS FOR DMLS
- 6. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING Complex geometries DESIGN GOALS FOR DMLS
- 7. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING Urban utility bike, EVO Allows riders to easily attach and detach different components CASE STUDY: HUGE DESIGN
- 8. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING DMLS was used to create the lugs, crankset shell and fork crown CASE STUDY: HUGE DESIGN
- 10. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING SMALL FEATURE RESOLUTION Minimum feature size: 0.150 mm (0.006 in.) Mesh structures
- 11. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING THIN WALLS (<1 mm/0.040 in.) Rule of thumb: 40 : 1 height : wall thickness
- 12. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING SURFACE ROUGHNESS Material Build parameters Part orientation
- 13. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING SURFACE ROUGHNESS Machine Material Vertical Sidewall (Ra) Angled Upfacing Surface (45°) (Ra) Upfacing Surface (Ra) Angled Downfacing Surface (45°) (Ra) Concept Laser M2 (250 mm) Stainless Steel (316L) 195 225 395 565 Titanium (Ti64 ELI) 215 250 305 335 Aluminum (AlSi10Mg) 250 295 415 435 Inconel 718 350 405 610 960 Concept Laser Mlab (90 mm) Stainless Steel (316L) 135 170 355 275 Stainless Steel (17-4 PH) 155 185 440 420 Cobalt Chrome 255 135 325 340
- 14. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING SUPPORTS Connect the part to the platform Hold features in place Prevent warping Photo courtesy Concept Laser
- 15. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING SUPPORT removal process Can be intensive and may require machining, EDM Design tip: Design parts that will require minimal supports. This will also improve part quality Photo courtesy Concept Laser
- 17. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING INTERNAL FEATURES Support and powder removal access Design tip: Lattice structures can be used internally to reduce weight and provide support Channels, overhangs, self-supporting angles, bridge dimensions
- 18. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING SELF-SUPPORTING ANGLES CAD 50 degrees 45 degrees 40 degrees 35 degrees 30 degrees 25 degrees 20 degrees
- 19. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING OVERHANGS If the next layer is larger than the previous layer, it will create an overhang DMLS has a small allowance for unsupported overhangs (0.5 mm/0.020 in.)
- 20. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING CHANNELS AND HOLES Channels and holes are self-supporting features Great for conformal cooling applications
- 21. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING CHANNELS AND HOLES As the diameter increases, the overhangs increase 8mm (.31”) 6mm (.24”) 5mm (.2”) 15mm (.6”) 12mm (.47”)
- 22. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING BRIDGES 1mm 2mm 3mm 4mm 5mm Minimum allowable unsupported bridge distance is small (~2 mm/0.080 in.)
- 23. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING INTERNAL STRESSES | WARPAGE Changes in cross- sectional areas can lead to warpage Large flat surfaces can bend build plates and shear bolts Design tip: Design in additional material to gradually transition into larger cross-sections
- 24. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING DESIGN EXAMPLE: REV 1 Three-component assembly Supports!
- 25. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING DESIGN EXAMPLE: REV 2 Reduction of components/assembly time/weight … BUT…
- 26. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING DESIGN EXAMPLE: REV 3 Best surface finish, small warpage potential Self-supporting features eliminate need for most supports
- 27. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING PROTOTYPING OR PRODUCTION DMLS can be a production method for complex geometries DMLS is also a low-cost, quick-turn method for prototyping components using actual end-use materials OPTIMIZE DESIGN HIGHER VOLUME
- 28. ADDITIVE MANUFACTURING | CNC MACHINING | INJECTION MOLDING CASE STUDY TRANSITION TO CONVENTIONAL MFG Total Cost (Tooling + Parts) DMLS MIM Part Quantity Cost 0 100 200 300 400 Breakeven point
- 29. CONCLUSION DMLS opens up new design options, but it will not replace conventional manufacturing methods Understanding constraints will maximize benefits of DMLS for part design QUESTIONS?
Notes de l'éditeur
- Proto Labs founded in 1999 Acquired Fineline in 2014, located in Raleigh, North Carolina. Specialize in additive technologies: SL, SLS and DMLS
- Direct metal laser sintering (DMLS) is an additive technology that opens up new design freedoms not possible with conventional manufacturing methods DMLS is not a replacement for traditional machining, casting, sheet metal fabrication or metal injection molding (MIM), but another tool for designers to utilize.
- DMLS has some limitations, but by anticipating these, designers can take full advantage of the technology
- Although small features can be resolved, they are not always feasible Warpage can come into play on thin walls as they grow in height At a certain height, free standing thin features will fail
- Surface roughness varies based on material, build parameters and part orientation Possible to customize parameters for best surface roughness, but will sacrifice material properties Surface roughness can be eliminated with post processing, but all areas may not be accessible
- Parts have received our standard finish: bead blasting and shot peening
- DMLS parts require supports to connect part to platform and hold features in place Supports prevent part from warping during rapid melting and cooling process
- Support removal process can be intensive. May require machining, EDM Design tip: Design parts that will require minimal supports! This will also improve part quality
- A huge benefit of DMLS is the ability to create complex internal features Channels, overhangs, self supporting angles and bridge dimensions must all be taken into consideration when designing areas that may be hard to access If an internal feature requires supports, but allows no access, the supports remain inside, and the geometry may not function as intended Accessibility for powder removal should also be taken into consideration Design tip: Lattice structures can be used internally to reduce weight and provide support
- 316L, 30 micron layers
- DMLS is a layer-by-layer process If the next layer is larger than the previous layer, it will create an overhang Unlike other additive processes, DMLS has a small allowance for unsupported overhangs (0.5 mm/0.020 in.) If left unsupported, large overhangs may lead to build crash
- As the hole diameter increases, the overhangs increase near the closing of the hole Unsupported holes larger than 8 mm (0.31 in.) diameter will suffer downfacing distortion/curl, and potentially create other build issues Design tip: Use diamond or teardrop shapes for larger diameter channels
- A bridge is any flat downfacing surface that is supported by two or more features Minimum allowable unsupported bridge distance is small (~2 mm/0.080 in.)
- Changes in cross-sectional area can lead to warpage between features Large flat surfaces can bend build plates and shear bolts Design tip: Design in additional material to gradually transition into larger cross-sections
- Reduction of components/assembly time/weight … BUT…supports interfere with function and add build time ($$$). Surface roughness will suffer, potential warpage issues
- Best surface finish, small warpage potential Self-supporting features eliminate need for most supports
- Once the design has been optimized using DMLS, it can be transitioned to a higher volume conventional manufacturing process Throughput gains (more parts in less time) Cost reduction
- Initial design concept proven using DMLS Throughput limited to 80 parts per week Transitioned to MIM to achieve scale of thousands of parts per week Lower overall cost, including MIM tooling