2013 03 12 Masterclass Biomedical Applications of Amsirrisaddtechnic 130313103718 Phpapp01 PDF

Masterclass:
Biomedical applications of
Additive Manufacturing
Part 03 : Technical aspects
Magnien Julien
Context sensitization
Additive Manufacturing principle
Description of the different AM technologies
Technologies comparison
Well suited applications cases
Conclusions
Masterclass: Biomedical applications of Additive Manufacturing
Organized by SIRRIS the 12th of March 2013
The traditional ways to manufacture parts are :

Machining : remove material from a bloc larger than the part itself. This is
a subtractive way.
Injection/molding : build a mold and place a melted material inside

which will solidify.
MACHINING
o
o
o
o
Very high precision

Long time and higher price
needed if complex part
Need to replace tool when worn
Geometrical restriction due to
tool access
A lot of waste material
Sometimes several steps to have
the final part
Single material parts
INJECTION / MOLDING
o
o
o
o
High production rate

1 mold = 1 part model
Long test period to find good
parameters
Complex fluid dynamic
(shrinkage, solidification rate,)
An error at the early beginning
have a very expensive impact
Strong geometrical limitations
Single material parts
AM try to solution these problems since 1990 :
Only the required material is used.

To increase the geometrical complexity, a layer-by-layer building fashion
is chosen.
No tools are used.
The complexity doesnt increase the cost.
Very different parts (size, complexity,... even color !) can be built together
in a same job, and even be added during processing.
Some technologies allow multi-materials parts in one shot.
Functionalities can be added (hinges, spring, gears,)
The delay is usually a week, compared to several months with the
traditional ways
Customization can be used at its highest level
Weight reduction is far more easy than before (lattice)
Texturing, conformal cooling, internal cavities,
- Is it just perfect ? Almost :
Part size limitation : 250 x 250 x 300 mm as mean vol (max 2000 mm).
Minimum wall thickness : 0,3 -> 1,5 mm
Surface quality : Ra ~10 20 m
Anisotropy of mechanical properties due to layer-by-layer
The raw material (usually powder) is surrounding the part after the
process. Inside and outside So It could be hard to remove it from a very
narrow and long channel.
With metal powder or liquid photosensitive polymer, supports are
required. They are built in the same time than the part and act as an
anchorage. They will keep the part in place. They have to be removed
after the process and damage a bit the surface quality in the contact zone
=> small post-machining often required.
- But how does it work ? What means layer-by-layer ?

Everything starts from the CAD file of the part (.iges, .stp) which is
converted in the .stl format, proper to AM technologies. This file is
virtually placed in the building chamber of the process :
The layers of the job (all the virtual parts into the building chamber) are
then automatically generated vertically and the resulting slices of the
part are stored in another file proper to each technology manufacturer.
Now the goal is to convert this virtual slices in a stack of real slices into solid
material and to combine them together to have the desired part :
Virtual world Real world
AM machine
To convert a virtual slice to a real one, the machine simply spreads a thin
layer of raw material (lets say in powder form) over all the bottom of the
working chamber. Then the machine analyze the first slice to
materialize and reproduce it on the layer spread in 2D. It agglomerates
the raw material in the area described on the virtual slice.
Top view of the

virtual slice, areas
to agglomerate
Agglomeration of
the specified
areas
Fresh new layer
of powder
Completed slice
10
LBM process description :
Laser beam
Main tank
Melted
zones
Spread powder
Argon
Recoater
Previous layers
Initial plate
11
Lets begin with the simplest one, the 3D printing of plaster powder with
color functionalities.
1.
The powder is spread over the workplate by a roller
roller
powder
Work plate
2.
The printing head deposit a binder on the areas specified by the slices,
and color on contours
Printing head
Printing head
Binder droplets
layer
Zone without binder
Zone with binder
Powder grain
12
These are the kind of parts produced with 3D printer from Z Corporation :
13
It is possible to print metal (e.g. stainless steel) in 3D with a binder but the
parts have to be post processed to replace the binder by a low melting
temperature metal, such as bronze.
The processed green parts are placed in a oven and, by increasing the
temperature, the bronze melt and the binder is degraded, leaving
porosity in part which filled by the bronze by capillarity.
green part
As built
Curing
brown part
Debinding
Infiltration
Structure of
the final part
14
Some part produce by Prometal 3D printing process (60% stainless steel,

40% bronze) :
= > Can you make such parts with traditional

technologies in one or two week maximum ?
15
The small problem with the previous technology is the multi-material

characteristic of the final part (glue or other metal). How can we have a
part made of only one material ? So they replace the printing head by a
laser driven by a set of lens and mirrors which melt the powder, exactly
like welding. This is the LBM process :
16
When the raw material in a polymer (ABS, polyamide, PVC,) this is quite
easy and you can but part wherever you want in the volume of the work
chamber, the powder itself is enough to support the part.
Magics software from Materialise

17
Here are some parts made of polymer with LBM technology :
18
With metal powder in LBM, there are more barriers to produce parts :
Due to stronger thermal stresses that occurs during welding, the parts
tend to be deformed.
The higher laser power induce higher heat input and the powder doesnt
take it away as efficiently as bulk material
For those reasons, supports have to be added to the CAD file of the part to
prevent deformation and drive the heat away. To ensure this anchorage,
supports of the part are directly welded on the thick removable working
plate :
19
Supports are a necessary evil in LBM but :

If there are in hard-to-reach zone, its very complicated to remove them after the
process.
If they support a very thin structure, this latter can be distorted during removing.
The surface contact between supports and part has a worse surface quality which will
required post machining.
They consume the silicone wiper of the recoater quicker than part area. So more
supports you have, worse is the flatness of the last layers.
This is an additional material cost.
Some design and positioning rules can reduce the amount of supports
needed.
20
Some parts made of metal with LBM technology :
21
Another technology use the same principle but with an electron beam. So it
works under vacuum conditions and the work plate is heated at high
temperature (~600C) which reduce the thermal stresses and, so,
supports are less (not) needed :
22
In every previous technologies, a recoater is needed to spread the powder

over the flat workplate. But it is also possible to add features (coating,
local repair, additional geometry, ) on a non-flat surface with another
principle : replace the drill of a CNC machine with a material deposition
nozzle. Powder is blown through a laser beam thanks to that nozzle and
this allow 5-axis welding. The superposition of tracks can make 3D shapes
Laser +
central gaz
(coaxial)
Shape Gas
Carrier gas
+ powder
Motion direction
Meltpool
Track
Heat Affected Zone
Substrate
23
This process is called Laser Metal Deposition. Thank to multiple axis, it is

possible to bring the material wherever on a surface and locally increase
mechanical properties, repair a damage area or reload a wearing part :
Fraunhofer center
for surface and
laser processing
ICE Pototyping (LENS)
IWS fraunhofer
IRIS
24
The oldest system is working from liquid a photosensitive raw material. The
principle is the same as LBM. The drilled workplate is gradually plunged
in a tank of resin. The liquid surface is leveled by a wiper between each
downward movement and a UV laser polymerize the resin in the
specified areas. This process need a UV curing to finish polymerization
part
supports
wiper
Liquid
displacements
workplate
Liquid polymer
25
Here are some examples made in Stereolithography :
26
3D Objet printing : mix between 3D printing and stereolithography. The

printing head deposits photosensitive resin in specified areas. The
deposition is directly followed by a polymerization with a UV laser
mounted on the same support than the printing head.
27
It is also possible to build in ceramics parts. This is a combination of SLM

and stereolithography technologies. There isnt a spreading of powder
but a paste made of ceramic powder and a photosensitive polymer, like
in SLM, but the laser doesnt melt any material, it polymerizes the resine,
like in stereolithography. After processing the parts, they are removed
from the paste, cleaned and placed in a oven for sintering the ceramic
and remove the polymer. Here are some examples :
Recoater
Parts
Laser processing
Slurry
28
Fused Deposition Modeling : A wire of solid polymer is push through a 3axis heated nozzle which cause slightly melting. The solidification occurs
by air cooling just after extrusion/deposition.
29
Small summary of technologies :

3DP Z-Corp
3DP Objet
3DP Prometal
3DP Optoform
LBM EOS
Stereolithography
LBM SLM Solution
EBM Arcam
FDM Makerbot
LMD
30
Metal technologies :
LBM
EBM
LMD
3DP
Size (mm)
250 x 250 x 350
210 x 210 x 350
900 x 980 x 500
1000 x 500 x 250
Layer thickness (m)
30 - 60
50
130 - 600
70 - 170
Min wall thickness (mm)
0.2
0.3
0.6
0.75
Accuracy (mm)
+/- 0.2 or 0.1%
+/- 0.13 0.2
N.A.
0.2 - 0.3
Build rate (cm/h)
5 - 20
10 40 (lattices 80)
2 - 30
Up to 120
Surface roughness (m)
5 - 15
15 - 35
15 - 20
20 - 30
Geometry limitations
Supports needed
everywhere (thermal,
anchorage)
Very few supports but

rest of the powder no
more fluid but presintered as a cake
No powder bed. Same

limitations as 5 axes
milling.
No support. Almost no
limitation.
materials
Stainless steel, tool

steel, titanium,
aluminum,
Only conductive
materials (Ti6Al4V,
CrCo,)
Every powdered
materials.
SS 316L or 420 + bronze

(standard)
31
size (mm)
10
8
Best surface roughness (m)
layer thickness (m)
4
2
SLM
EBM
LMD
3DP
Build rate (cm/h)
min wall thickness (mm)
Best accuracy (mm)
32
33
34
35
Polymer technologies :
LBM (EOS)
3DP (Z-corp)
Size (mm)
350 x 350 x 630

(P390)
250 x 350 x 200
250 x 250 x 250
500 x 400 x 200
225 x 145 x 150

(Makerbot)
Layer thickness (m)
100 - 150
100
25 - 150
16 - 30
100 - 300
Min wall thickness

(mm)
0.6 0.7
2-3
0.2 0.3
0.5 0.6
Accuracy (mm)
0.2 - 0.2% > 100 mm
1-2
+-0.1
+-0.1 -
Positioning : 11 m
Geometry limitations
Almost non
Almost non
Removing
supports in
closed volume
Removing supports
in closed volume
materials
PA, PA+Al, PA+C
Plaster powder
Acrylate-based
resins
Acrylate-based
resins
STL
3DP
(Viper Si2) (Connex 500)
FDM
(Makerbot)
ABS, PLA
36
Best accuracy (mm)
size (mm)
10
9
8
7
6
5
4
3
2
1
0
LBM EOS P390

3DP Z-Corp
layer thickness (m)
STL Viper Si2

3DP Connex 500
FDM Makerbot
min wall thickness (mm)
37
38
39
Summary :
Z-corp : attractive demonstrators, cheap prototype, architecture, trendy
reasons. (color, powder, no support)
3DP Prometal : Stainless steel part with complex internal geometry and
foundry surface quality. (No heat input, powder, no support)
3DP Objet : Mutli-material polymer parts with high resolution and bending
functionalities. (multi-material nozzle, resin, supports needed)
3DP Optoform : Ceramic parts (HA, TCP, Zr,) for bone implants mainly
(paste, supports needed, high shrinkage)
LBM EOS : Polyamide parts for every applications (Powder, no support)
Stereolithography : Transparent resins for every applications (Resin, supports
needed)
FDM : Cheapest technology, medium quality (wire, supports needed)
LBM SLM Solution : Most effective with thin metal parts. (powder, supports
needed)
EBM Arcam : high build rate, well suited for massive parts (Powder, ~no
support)
LMD : repair, local coating, graded material on non flat surface (powder,
limited 3D complexity)
40
Design simplification :
From 12 components to only one with better efficiency :
Sirris
41
Medical prothesis :
Every patient is unique and needs, of course, a specific shape. Material

properties have to be adapted to the bone to preserve it :
42
Complex piping :
Sirris compolight project
43
Articulated parts without assembly :

Objet 3D
EOS
Oak Ridge National Laboratory
Barosens (Morris technology)

Materialise
Objet 3D
44
Lightweight parts :
EADS
Within Technology
EOS
Sirris compolight project
Laser Cusing
45
Jewelry:
Shapeways
46
Customization :
Materialise
Sirris (YAMM)
Sirris (Driessen & Verstappen)
Olaf Diegel
47
Conformal cooling :
Before AM
Part to produce by
injection
With AM
Conventional cycle time: 38s

CCC cycle time: 32s
Reducing cycle time: 16%
Profit for the 1st year: 222.000
(6.000.000 units/year)
48
You can have a part within a week.

A lot of different materials are available.
AM let you make quickly a first prototype to validate a concept and avoid
future mistake.
A lot of functionalities can be added to your part (hinges, spring,
lightweight, conformal cooling, local coating, multi-material,)
The complexity doesnt increase the price.
Highest degree of customization.
Dont forget that supports are sometimes required.
Parts are surrounded by powder /resin/paste which has to be removed.
Post machining or polishing is often required after the process.
=> Thank you for you attention !

Magnien Julien
49

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Masterclass:

Part 03 : Technical aspects

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

The traditional ways to manufacture parts are :

Injection/molding : build a mold and place a melted material inside

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Very high precision

Masterclass: Biomedical applications of Additive Manufacturing

High production rate

Organized by SIRRIS the 12th of March 2013

AM try to solution these problems since 1990 :

Only the required material is used.

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

- Is it just perfect ? Almost :

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

- But how does it work ? What means layer-by-layer ?

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Top view of the

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

LBM process description :

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Zone with binder

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Some part produce by Prometal 3D printing process (60% stainless steel,

= > Can you make such parts with traditional

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

The small problem with the previous technology is the multi-material

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Magics software from Materialise

Organized by SIRRIS the 12th of March 2013

Here are some parts made of polymer with LBM technology :

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Supports are a necessary evil in LBM but :

Organized by SIRRIS the 12th of March 2013

Some parts made of metal with LBM technology :

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

Masterclass: Biomedical applications of Additive Manufacturing

Organized by SIRRIS the 12th of March 2013

In every previous technologies, a recoater is needed to spread the powder

Masterclass: Biomedical applications of Additive Manufacturing