Additive Manufacturing Technology

www.3trpd.co.uk

Additive Manufacturing Technology November 2012

Phil Kilburn DMLS Sales Manager

Agenda

• About 3T RPD Ltd

• Overview of Additive Manufacturing

• Manufacturing directly in metals

• Arcam - Electron Beam Melting

• EOS - Direct Metal Laser Sintering

• Applications

• Polymer Additive Manufacturing

• Started trading 1999

• Installed 2 x P700’s 2003

• DMLS Facility opened 2007

• Currently the largest commercial SLS

facility in UK, 3rd largest in Europe

• 2nd largest DMLS facility in UK

• Team

• 42 Permanent staff

About 3T RPD

Markets

Quality control

AS 9100 Rev. C

ISO 9001:2008

ISO 13485:2003

• 3T Quality

standards

Overview of Additive Manufacturing

• The process of creating 3D objects, layer by layer

• As opposed to subtractive manufacturing methods

Definition of Additive Manufacturing


Additive Manufacturing process


Additive Manufacturing

Process

Subtractive Manufacturing

Process



Parts are built up from a large number of very thin two-

dimensional cross sections (layers)

By convention the cross sectional layers are the X-Y plane

and the model is built up in the Z axis


X

Y

Z

Simple example

CAD model

Simple example

Layers built up

in Z axis

(accuracy)




Parts are built up from a large number of very thin two-

dimensional cross sections (layers)

By convention the cross sectional layers are the X-Y plane

and the model is built up in the Z axis

All processes used in layer manufacturing use STL files

(Standard Triangle Language) • This is the file format used in open systems

• Surface is represented by triangles

• X,Y,Z for each point on triangle and a vector to outside

• Tolerance of the original surface in relation to triangles is critical

0.01 Tolerance

2,400 triangles

0.001Tolerance

24,000 triangles

0.1 Tolerance

240 triangles


• Totally enclosed volume


• Totally enclosed volume (381514 triangles)

• All triangle are connected and face outwards


Overview of Additive Manufacturing Machines

Polymer based + Metal


Metal Based

Additive Manufacturing of Metal products

Arcam – Electron Beam Welding

Renishaw – Selective Laser Melting

Concept Laser – LaserCUSING® materials

EOS – Direct Metal Laser Sintering

A range of materials are currently available – but not on all machines

Stainless Steel

Cobalt Chrome

Titanium 6Al 4V

Inconel

Tool Steel

Aluminium

Gold

Silver

……

Overview of Additive Manufacturing - Metal

• A high energy beam is generated in the Electron Beam Gun

• The beam melts each layer of metal powder to the desired geometry

• Extremely fast beam translation with no moving parts

• Vacuum process eliminates impurities and yields excellent material

properties

• High build temperature gives form stability and low residual stress

• Low operating costs

Arcam – Electron Beam Welding

Overview of Additive Manufacturing - Arcam

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ARCAM EBM TECHNICAL DATA (Hot process)

• Build envelope 200 x 200 x 350 mm (W x D x H) or 300 x 200 mm (Ø x H)

• Build speed Up to 60 cm3/h

• Layer thickness 50 – 200µm

• Vacuum pressure <5 x 10–4 mBar

• Electron Beam power Up to 4000 W

• Electron Beam accuracy ±0.05 mm

• Electron Beam scan speed ~1000 m/s


• Materials available

– Ti6Al4V

– Ti6Al4V ELI

– Titanium Grade 2

– CoCrMo ASTM F75


• EOS M280

• Key characteristics

– Build volume: up to 250x250x300mm

– Up to 400W Yb fibre laser

– Spot size: 100µm

– Layer thickness: 20µm to 80µm

– Build speed Up to 32.4 cm3/h

• Surface finish

– As built: Ra~4-10µm

– After polishing: Ra~0.04-0.5µm

• Minimum wall thickness / feature size

– 0.04mm

• Accuracy

– +/- 0.2mm

Overview of Additive Manufacturing – DMLS

Definition: Direct Metal Laser Sintering

Melting and not sintering


Materials Available

• Maraging steel: 1.2709/M300

• Stainless steel: 15-5PH

• Stainless steel: 316L

• Cobalt Chrome: UNS R31538

• Nickel alloy: In718

• Titanium alloy: Ti6Al4V (Grade 5)

• Aluminium alloy: AlSi10Mg


• Fine grain structure and dense material

X-section

Optical

micrograph

SEM

micrograph

SEM

micrograph Optical

micrograph

Microstructure of Metal materials

• Fine grain structure in Ti6Al4V

X-section

Optical

micrograph

Fully dense

α/α'-β structure


• Fine grain structure and dense material

– Microstructure of heat treated IN718


Overview of Additive Manufacturing - DMLS

General comments about DMLS materials

• Full melting process = ~100% density

• Properties of as-built DMLS parts: close to or better than cast

• Final properties dependent on heat treatment

• Can be processed like any other conventionally produced

alloys

• Can be used for prototyping applications as well as

manufacturing applications

Overview of Additive Manufacturing - DMLS

Basic principles of DMLS

• Powder is not self supporting

• Parts have to be attached to the platform

• Post-finishing needed

Basic principles of DMLS

15-5PH

Demonstration part: build angle effect

In718

Demonstration part: build angle effect

• Process

– Orientate part

– Add finishing stock (+0.1- 0.5mm)

– Automatic creation of support structure in Magics

Support structure

• OK for prototyping work but not for manufacturing

Support structure

• Bike pedal

Support structure

• Stator Ring

– Material: Cobalt chrome

– Dimensions: dia160mm x H60mm

– Layer thickness: 40micron

– Build time: 40h

– Finishing (including polishing): 50h

– Polishing: First Surface (Micro

Machining Process)

• Cost: ~£4500

Aerospace application

• Fuel Injector

– Material: Inconel 718

– Designed for DMLS, 8 parts in 1



– Build time: (2off) 50hrs

– Finishing: 3h

• Cost: ~£3500 (each)


• Swirler

– Material: Cobalt Chrome



– Build time: 90h (45 parts)

– Finishing (including polishing):

30h


Cost: ~£300 (unit cost for 45 parts)

Current Optimised (by Within)

(Build time) + (machining time)

316L 30h + 3h 14h + 1h

Weight 100% 30%

Fully-Automatic Design – Within Enhance

Savings Project – Seat Belt Weight Reduction

• Commercial aircraft can have anything up to 850 seat belt buckles

• Traditionally constructed, airline seat belt buckles weigh between

– 155g (Steel)

– 120g (Aluminium).

• Manufactured in Titanium using additive manufacturing, weight is

reduced to 68g without compromising strength

Savings Project – Seat Belt Weight Reduction

Several processes are readily available in the UK

Stereolithography – SLA

Fused Deposition Modelling – FDM

3D Printing – Z Corp

Selective Laser Sintering – SLS

A range of materials are currently available – but not on all machines

Epoxy based materials

Nylon

ABS

Wax

Polystyrene


Polymer Based






Polymer based

http://www.thinglab.co.uk/images/product_rapid_zcorp_zprinter_650_4.jpg

http://www.thinglab.co.uk/images/product_rapid_zcorp_zprinter_650_6.jpg






Polymer based





Selective Laser Sintering – SLS


Polymer based

Nylon 11

Plastic AM Materials

* Standard at 3T

Nylon 12 (Polyamide PA2200) *

Glass Filled Nylon 12 (Polyamide PA3200) *

Alumide (Aluminium Fleck/Nylon 12)

Polystyrene (PrimeCast 101)

Carbon Filled

Flexible

Flame Retardant

PEK

Minimum wall thickness

Wall thicknesses > 1mm

Accuracy

Typical accuracy to be within:

Dimensions <100mm +/- 0.3mm

Dimensions >100mm +/- 0.3%

Designing for Plastic AM

Build chamber – fully packed build – material is self supporting


Polymer Based

Polymer Based applications

Models created from CT and MRI data

Source - Econolyst


Integration of several parts into a single component


Living hinges and assemblies built in one


Secondary finishing

Brass inserts for small diameter

threads

Larger pars welded together

Finishing for Plastic AM

Special Finishes

Plating


Effects of adding 100 micron nickel layer to SLS Pa bars

0

20

40

60

80

0 5 10 15 20

Strain %

Str

ess M

Pa 1 Pa Control

2 Pa Control

3 100micron Ni

3 100micron Ni


Permanent Surface Colouring


Painting


Special Finishes

Vacuum Metallised

• P 800 EOSINT

– 4 machines only

• Process controls still

being investigated

• Variation in

– Mechanical properties

– Colour

– Shrinkage

PEK Plastic AM

http://www.eos.info/javasc

A. ANALYSIS OF SINTERED PEK parts (x, y and z) Conclusions

•Ultimate Tensile strength in Z direction is 50% of that in X and Y

•Colour variation is a surface property

•Darker colours are produced closer to the centre and bottom of the build chamber

•There is no observed link between colour and tensile strength

•There is more variation in shrinkage in Z direction than in X and Y

•In Z direction pale samples show less shrinkage

Open Coil Surface Support Development.

30% open to Helium in XYZ

Yield Stress at ~600MPa

0.5mm thick sheet.

Hole Dia. ~ 0.12mm

3D printed Ti End Spacers

THANK YOU

Phil Kilburn

Email: [email protected]

Tel: +44 7919 924838 / +44 635 580284

mailto:[email protected]

Additive Manufacturing Technology

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