3D Printing Applications in Industry and Home

FRC+ Project Riihimäki April 15, 2014 3D Printing Applications in Industry and Home Jukka Tuomi Aalto University Finnish Rapid Prototyping Association FIRPA 1 Jukka Tuomi, Aalto-yliopisto

2 Jukka Tuomi, Aalto-yliopisto

3D Printing - Hype 4 Jukka Tuomi, Aalto-yliopisto

Stock Market 5 Jukka Tuomi, Aalto-yliopisto

Additive Manufacturing 3D Printing = Additive Manufacturing = - Rapid Prototyping, RP - 3D Printing - Rapid Manufacturing, RM - Free Form Fabrication, FFF - Additive Manufacturing, AM (ASTM ja ISO standardit) Material removal processes Stone age (40 000 eaa)*- - - - - - - Material forming processes - - - - - Copper age (5 000 eaa)** -- - Material additive processes 1988 - - *) Aurignasin kulttuuri **) Sulatettu kupari, taottu aiemmin 6 Jukka Tuomi, Aalto-yliopisto

3D Printing Materiaalia lisäävä valmistus, 3D-tulostus, Additive Manufacturing, AM (Rapid Prototyping, RP tai Rapid Prototyping and Manufacturing, RP&M) on yhteinen nimitys ryhmälle valmistustekniikoita, joilla fyysinen kappale valmistetaan suoraan numeerisen määrittelyn (3D-CAD) pohjalta nopeasti, täysin automaattisesti, geometrisilta rajoituksiltaan vapaassa prosessissa. ASTM International F42 committee on Additive Manufacturing Technologies: Additive Manufacturing (AM) is the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. a) b) 7 Jukka Tuomi, Aalto-yliopisto

3D Printing Process1/2 3D-CAD - Ideas - Pro/E - Catia - SolidWorks -.stl file RP&M - SLA - SLS - DMLS - LOM - FDM -.stl file Layer-by-layer manufacturing Physical part 8 Jukka Tuomi, Aalto-yliopisto

3D Printing Process 2/2 3D Model 3D Printing Physical part 9 Jukka Tuomi, Aalto-yliopisto

Examples 1/2 10 Jukka Tuomi, Aalto-yliopisto

Examples 2/2 11 Jukka Tuomi, Aalto-yliopisto

High-End Products 12 Jukka Tuomi, Aalto-yliopisto

Why? 1990 - Rapid Prototypig 1995 - Rapid Tooling 2000 - Rapid Manufacturing 2010-2000 SuperMachines Time to market Faster Ramp-up Agile manufacturing and customization High-end products, production and logistics 13 Jukka Tuomi, Aalto-yliopisto

Application Oriented Classification Prototypes Components Tools 14 Jukka Tuomi, Aalto-yliopisto

Airbus: AM manufactured future airplane 60 % cheaper 30 % lighter Titanium parts 1:25 ratio in buy to fly 1:25 ratio in CO2 emissions Innovation potential 3 % of all patents by a team of 9 AM experts in 2008 (0.02 % of total staff of 57 000) GE Aviation: 50% engine weight reduction 15 Jukka Tuomi, Aalto-yliopisto

AM General Issues - Manufacturing constraints - Features regardless of their position in the part - Minimization of number of parts - consolidation - Elimination of fasteners - Maximization of product performance - Complex geometries - Customized geometry - To ignore all of the constraints imposed by conventional manufacturing processes 16 Jukka Tuomi, Aalto-yliopisto

ASTM-Approved AM Process Terms Vat Photopolymerization Powder Bed Fusion Material Extrusion Material Jetting Binder Jetting Sheet Lamination Directed Energy Deposition 17 Jukka Tuomi, Aalto-yliopisto

Laser Sintering (Powder Bed Fusion) 18 Jukka Tuomi, Aalto-yliopisto

DMLS Equipment 19 Jukka Tuomi, Aalto-yliopisto

One Layer 20 Jukka Tuomi, Aalto-yliopisto

Laser Melting Powder 21 Jukka Tuomi, Aalto-yliopisto

The Process 22 Jukka Tuomi, Aalto-yliopisto

220 Parts Ready for Post Processing 23 Jukka Tuomi, Aalto-yliopisto

Design for function 27 Jukka Tuomi, Aalto-yliopisto

AM Unique Capabilities 1/2 1 Shape complexiti - part complexity is virtually unlimited - custom-designed geometries 2 Hierarchical complexity - nano-scale - micro-scale - mesostructures (0.1-10 mm) - part-scale - Foams, honeycombs, lattice structures (p) - Put material only where it is needed - High strength low mass - Energy absorption - Thermal and acoustic insulation - Stochastic processes designed cellular materials 28 Jukka Tuomi, Aalto-yliopisto

Weight Optimization 29 Jukka Tuomi, Aalto-yliopisto

AM Unique Capabilities 2/2 3 Functional complexity - kinematic joints - inserts 4 Material complexity - different material properties in different regions - LENS and DMD - Objet 30 Jukka Tuomi, Aalto-yliopisto

Fashion 31 Jukka Tuomi, Aalto-yliopisto

Furniture 32 Jukka Tuomi, Aalto-yliopisto

Additive Manufacturing Networks Customers Company networks - Design - Manufacturing - Logistics How do the customers behave? How do we express the products for the customers? What means customisation in here? 33 Jukka Tuomi, Aalto-yliopisto

Trends 1/2 Component manufacturing 3D Printing Technical prototypes Now Future 34 Jukka Tuomi, Aalto-yliopisto

Trends 2/2 DIY Do It Yourself Metals End product manufacturing AM Standards New design systems - Tinkercad - 3DVIA - 123D - 35 Jukka Tuomi, Aalto-yliopisto

Truth? EADS produces world s first bike using revolutionary ALM technology (Airbike). Soon spare parts for human beings will be printed. Gun has been printed. Soon food will be printed. 3D-printing will become general in homes. Etc. 36 Jukka Tuomi, Aalto-yliopisto

Thank you! Jukka Tuomi jukka.tuomi@aalto.fi 0500-713420 37 Jukka Tuomi, Aalto-yliopisto