Published on March 12, 2014
PRESENTED BY DYLAN OLIVER
Today's 3D Printing and Additive Manufacturing Applications MD&M West Anaheim, CA // Tuesday, February 11, 2014
• 2008 – Company founded • 2011 – Headquarters relocated to Jack London Square Oakland, CA • 2013 – Oakland ofﬁce expansion • 2013 – New Production Center in Seattle, WA • 2013 – Inc. 500 Rank #369 Top 100 MFG Companies Rank #9 • 2013 – SF Business Times Rank #39
• Stratasys — PolyJet (InkJet) — Fused Deposition Modeling (FDM) — Solidscape • 3D Systems — Stereolithography (SLA) — Sintering Technologies — Z-Corp — Multi-Jet Modeling COMMERCIAL MANUFACTURERS • EOS — Sintering Technologies • Envisiontec — Digital Light Processing Technology (DLP) — 3D-Bioplotter
FDM Technology -Deposits real thermoplastic -Material cools & hardens during deposition process -9 diverse materials -Soluble or Breakaway support -Highly durable models PolyJet Technology -Jets liquid photopolymer -Cured by UV light -Breakaway support removed with Water Jet -Plus 130 Materials -Multiple materials in a single build Printing Head INDUSTRY LEADING TECHNOLOGIES
SLS/DMLS Technology - Fabrication Powder - Roller / Wiper - Build Cylinder - Piston - Powder Supply System - Scanner System SLA Technology - Moveable Table - Vat - Photopolymer - Scanner System INDUSTRY LEADING TECHNOLOGIES
Powder Binding Technology - Fabrication Powder - Roller / Wiper - Build Cylinder - Piston - Powder Supply System - Scanner System DLP Technology - Moveable Table - Vat - Photopolymer - Scanner System INDUSTRY LEADING TECHNOLOGIES Z-positioning unit Model at holding plate Polymerisation-basement with photopolymer DLP projection system
RIGID MATERIALS: POLYJET, FDM & SLARigid Materials: PolyJet, FDM and SLA
DESIGN CYCLES Typical Ideal
MINIMIZE COST OF CHANGE Source: Rosenberg, Boston University
FUSION by SHOCKATOO: WEARABLE ELECTRONIC • Smartband with built-in accelerator, microphone, microprocessor and Bluetooth 4.0 • Integrates the audio of music, visuals of concert lightshow and kinetic energy of dance • Final prototype needed to include the ﬂex, ﬁnish, and clarity to ensure proper light transmission, ﬁt, form and function of manufactured product • Prototype and testing iterations completed within two weeks
BEAM by SUITABLE TECHNOLOGIES: REMOTE PRESENCE DEVICE (RPD) • RPD with all-in-one monitor and audio system, charging dock, and interactive software for users to connect remotely • Audio system includes 6 microphone arrays to reduce background noise and cancel echoes • Needed to develop a specialized audio dampening component • Created 12 prototypes with complex geometries and quick turnaround • Cycle times 1-2 days, cost saving $35,000
TOOLING APPLICATIONS • Blow Molding • Fiber Layup • Injection Molding • Investment Casting • Jigs and Fixtures • Metal Hydroforming • Modular Fixtures • Molded Fiber • RTV Molding • Sand Casting • Spin Casting • Thermoforming
THE ZERO THEOREM • A sci-ﬁ movie directed by Terry Gilliam • Low volume production; more cost effective • Houses a Galaxy tablet • Custom app for buttons with conductive foam
KELLY MANUFACTURING • Line of aircraft instruments • Lead time for 500 units has been shortened to three days • Direct digital manufacturing reduces instrument part cost 5% and lead time 93% • FDM provided substantially better dimensional accuracy than the urethane casting process
PDS SOLUTIONS FOR MS INSTRUMENTS, INC.: MRI HOUSING • MRI device for lab animals • Low volume production requirement • Evaluated traditional manufacturing methods vs. 3D printing • 3D printing and ﬁnishing the PC models was quicker and less costly: eliminated tooling costs, allowed for printing inventory on demand, no re-tooling costs for design changes
CASE STUDY: 3D PRINTED EXOSKELETON
SURGICAL PLANNING Magnetic Resonance (MRI) Computed Tomography (CT Scan) UltraSound (US Scan)
• Flow of blood inside vessels is very hard to model on a computer • Why not print the design and test it in the real world? • Objet elastomeric materials closely imitates the mechanical properties of the blood vessels • Clear materials allow ﬂow visualization using particle imaging (PIV) CARDIOVASCULAR ANALYSIS
• Sterilization —Gamma Radiation, Ethylene Oxide, Steam Autoclave, Plasma, Chemical, etc. • Bead Blasting • Bonding and Gluing • Electroplating • Mass Finishing • Sanding and Painting • Sealing • Thermo • Vacuum Metalizing POST PROCESSING
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