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3D 프린팅: 현황과 전망
July 15, 2014
진대제AMP- 길 포럼-
교수 양동열
KAIST, 기계공학과
<SOURCE : sericeo.org, 2013>
Ultra-light Material
Wearable Computer
3D Printing
Context-Awareness
Driverless Car
Gene Therapy
Post Batteries
3D Printed Airbike EADS(European Aerospace and Defense Group)
Made by ALM process (Additive Manufacturing) Material: Nylon+Metal powder
6,000 CFM Leap jet engines sold x 19 nozzles each = 114,000
GE Fuel nozzlesAirbus Wing Brackets
40% weight saving Courtesy: J. Harrop@ IDTechEx
Light weight Innovation
Real car prototyping
First 3D printed Car (Urbee*)Price 50,000 dollars, Fuel Ethanol + Gasoline
All parts are manufacturedby 3D printing
Manufacturing time: 2500 hours
Time consuming
but, It’s beginning
*2011, KOR EcoLogic using Stratasys’s 3D printing service
3D PrintingRapid PrototypingFree Form FabricationAdditive Manufacturing
On Terminologies
3D 프린팅/ 3차원 인쇄술쾌속조형(고속, 급속, 신속)/ 쾌속시작임의형상제조부가적층제조(공정)
What is 3D Printing/ Rapid Prototyping?Technology that can manufacture 3D prototypes through layer-by-layer deposition of materials from CAD data or measurement data
Layer by layer
FlexibleMetalColored material
3D Printing vs. Rapid Prototyping vs. Free Form Fabrication vs. Additive Manufacturing
Diverse needs of customers& Shortening of Product Life Cycle
Complexity and Low Volume of products
Increasing Competition
Rapid Product Development
• Fast & Cost Effective
manufacturing technology
• Minimization of Trial-and-errors
• Concept of Concurrent Engineering
• Fast & Cost Effective
manufacturing technology
• Minimization of Trial-and-errors
• Concept of Concurrent Engineering
3D Printing taking a central role of RPDRPD : Rapid Product Development
ProductsProducts
Subtractive Manufacturing
Rapid Prototyping
Virtual Prototyping
Reverse EngineeringReverse Engineering
3D CAD Modeling3D CAD Modeling
SolidEdge SolidWorks
I-DEAS CATIA
3D Laser Scanner
WB4(CyberWare) SNX(Solutionix)
How Rapid Product Development works?R
apid product Developm
ent
CAD Modeling for manufacturing new productsHow can we realize imaginary products? CAD modeling
1. Imaginary product : Manufacturing fish
2. CAD Modeling: Using software to model
3. Rapid Prototyping machine: Putting SLA file to RP machine
4. Real products
Manufacturing productsby 3D CAD Modeling
Manufacturing productsby 3D CAD Modeling
Transferring CAD file to SLA file
CAD Modeling to make Virtual Prototypes
SolidWorks (Solid Modeler)
Pro-Engineer
CAD modeling data are transformed to STL file format.
STL(“STereoLithography”) file:
Example
STL file
3D CAD Model
STL file
3D Scan data
The surface of a 3D object is approximatedby facet mesh of a number of triangles
Each facet consists of 3 pointsand unit normal vector of a triangle
3D scannersEquipment to acquire 3D shape data of objects
Geometry data (X, Y, Z) & Color data (Texture)
3D scanner (H/W) + Software (S/W)
Equipment to acquire 3D shape data of objects
Geometry data (X, Y, Z) & Color data (Texture)
3D scanner (H/W) + Software (S/W)
3D CMM(Coordinate Measuring Machine)
3D Scanner
3D CMM(Coordinate Measuring Machine)
3D Scanner
Contact type3D coordinate measuring machine
Encoding type with Touch Probe
High accuracy
Laser scannerNon Contact type
Laser beam
White light projectorNon Contact type
Optical interference
Stabilizing, flexible attachment
High accuracyAdvantage
DisadvantageSlow to measure, Objects should be solid
Decreased accuracy
Advantage
Disadvantage Weak to outside interference
Advantage
Disadvantage
Digitizing 3D shape with 3D scanner
CT/MRI Scanner
CT/MRI Image
DICOM format
cf. DICOM (Digital Imaging & COMmunications in medicine) : International medical imaging standard
STL
Mimics
BioBuild
Medical RP
Siemens
Philips
GE DAT
GE Advantage
GE YMS
Picker
Toshiba
Elscint
IMPORT
Objet
Skull
FDM
Spine
3D scanning Procedure of Medical Rapid PrototypingMRI, CT 기술을 이용한 신체 내부의 형상데이터 획득
CT 촬영
체내 횡단면 데이터 획득
데이터 획득데이터들여오기 STL 파일 변환 의료용 RP장비 제작
Introduction toRapid Prototyping
SLA(Stereo lithography)Patented in 1986By Charles Hull
1993 : “3D Printing” by Prof. E. Sachs (MIT)First mentioned “3D Printing”Now “3D Printing” is widely mentioned as the original meaning of Rapid Prototyping
1988 Product release
Rapid prototyping
(AdditiveManufacturing)
SLA(Stereo lithography)Patented in 1986By Charles Hull
Rapid Prototyping & 3D Printing1984 : The Birth of Rapid Prototyping
SLA-250(1988, 250ⅹ250ⅹ250)
Rapid Prototyping includes 3D Printing.“3D Printing” in wide sense Rapid Prototyping
3D Printing
Rapid Prototyping
Cf. High Speed machining
Cf. Additive Manufacturing
Trend of Rapid Prototyping(RP) Market(Source: Wohlers Report 2012 & KT)
0
2
4
6
8
10
12
14
2001 2011 2019E
RP printer market
Secondary servicerelated to RP
Value of productsmanufactured by RPExpansion of application fields includes Education, Leisure, Manufacturing, and etc
CAD design and additional service related RP
Supplying Personal 3D printer
(Unit : One billion dollars)1412
1086420
13.3
3.7
1.12001 2011 2019
(Expected)
7.2
3.3
2.8
Scale of the world market
20%
20%
15%12%
11%
8%
6%3% 5% Automotive
Goods
Medical app.
Aerospace
Industry
Education
Military(Source: Wohlers Report 2012)
Application fields It’s expected that RP market has potential to grow.
By expanding application fields, there are more value of products
manufactured by RP
Regional usage
0
10
20
30
40
(Source: Wohlers Report 2012)
Perc
ent (
%)
Accumulated data on 1968~2011
Rapid Prototyping machine marketTrend of Rapid Prototyping(RP) Market
53%
22%
8%
2%
4%
11%
Stratasys
3D systems
Envision Tec.
EOS
Beijing Tiertime
Etc
(Source: Wohlers Report 2012)
Market share
U.S. leads the RP market.
RP companies from U.S. dominate the RP market
(U.S.)
(U.S.)
(Germany)
(Germany)
(China)
Courtesy: J. Harrop@ IDTechEx
Pink Zone: Red Ocean !
Size-dependent Material-dependentPrecision-dependent
Subtractive manufacturing
Subtractive manufacturing
According to the method to manufacture:
Rapid Prototyping TechnologyRapid Prototyping Technology
Additive manufacturing
Additive manufacturing
Classification of Rapid Prototyping process
High speed Machining
or 3D Printing
Chemical Bonding SinteringSintering GluingGluing
Deposition
Photocuring
Cf. Metal Deposition by Melting
Principle
SLA-7000 (500*500*580)Part & Supports
Post-processing
SLA StereoLithography Apparatus (3D Systems, U.S.)
Apparatus & Part
Laser scanning system + Liquid photopolymer resin
1 Layer thickness [mm] : 0.025 ~ 0.125
Products
High resolutionExpensive
SLA-250(1988, 250ⅹ250ⅹ250)
SLA-7000(1999, 500ⅹ500ⅹ580)
Commercial machines [Unit : mm]
iPro™ 9000(2008, Max.1500 x 750 x 550)
SLA StereoLithography Apparatus (3D Systems, U.S.)
Applications
Jaw nerve partArtificial product
Fashion Shoes
Micro StereolithographyMicroStereolithography: Two photon lithography Pattern mask light beam
+ Liquid photopolymer resin
Part
Multi Microstructures can be fabricated.
Ref.) Nicholas Fang’ group at UIUC
Layer-by-layer accumulation method for 3D nano/microfabrication
Coverglass
ImmersionOil
PhotocurableResin
Voxel(90 nm)
at focal point
x
z
Femtosecond laser
Nano Stereolithography
Nano resolution laser+ Liquid photopolymer resin
Nano scaled thinker(D.Y. Yang et al., KAIST, Korea)
10㎛z
yxceramic precursorbefore pyrolysis
5㎛
5㎛
yx
x yz
4.6㎛
fabricated usingSCR500 polymer resin
Electric device
Optics Express, 2010. Advanced Materials, 2011.
Optical device
10 ㎛
Ormocer toroid
CLEO Int. conference, 2011.Applications
nRP
(nano Replication Printing)
1 Layer thickness [mm] : 0.178 ~ 0.356
The cost of the machineand the material is economical.
FDM : Fused Deposition Modeling (Stratasys, U.S.)
PartPart supports
BasePlatform
Support material
Build material
Extrusion headWheel
HeaterNozzle
Apparatus & Part
FDM Maxum-Stratasys(600mm by 500mm by 600mm)
Extrusion head
Principle
ABS Models
Heated extrusion nozzles + Thermoplastic filament
rocess
SLS : Selective Laser Sintering
Working Principle
Audio : front panel Mold by RapidSteel 2.0
Applications
After secondary processes
Electronics HousingDuraForm Flex Ductwork
Functional Materials
DuraForm ® Flex Plastic : Rubber-like materialDuraForm ® EX Natural Plastic : Impact resistanceDuraForm ® HST Composite : Fiber-reinforced plastic
(sProTM140)
• Plastic powders + CO2 laser
• Layer’s thickness : 0.1-0.15 mm
• Functional materials
Characteristics
Sintering powder by laser
Finished 3D PartZ810 (1800 jets)(600mm by 500mm by 400mm)
Engine Block(460mm by 480mm by 330mm)
Architectural Model(360mm by 410mm by 230mm)
3DP: Three-Dimensional Printing(Z Corp., U.S.)
Apparatus & PartPowder + Water-based liquid binder
Dyes added to the liquid binder
Spraying liquid binderwith dye by inkjet
1 hours
20 minutes
Toy
FEA Model (180*350*250 mm)
Phone Sneakers
Ship Tire
Sample parts 3DP: Three-Dimensional Printing (3D systems, U.S.)
How It Works : Dual-jet process
Two UV lamps
Inkjet head 1
Inkjet head 2Inkjet head for Support material
Products
Material 1Material 2
Multi-nozzle stereolithography (Objet)
(Objet Geometries, Israel)
Inkjet Deposition of Photopolymers with UV lamp
Characteristics
Dual-jet process to combine two materials
Functional materials can be mixed
Materials
Vero family(Rigid materials)
Tango family(Flexible materials)
FullCure 720(Transparent materials)
High accuracy Min. 16μm resolution
Polyjet
Sample parts Multi-nozzle Inkjet Deposition of Photopolymers (Objet Geometries, Israel)
Objet Connex500TM
(2007, 500ⅹ400ⅹ200)
Objet Connex350TM
(2009, 350ⅹ350ⅹ200)
Equipment Sample parts
Objet500 Connex3(2014, 490ⅹ390ⅹ200)
Equipment
Sample parts Multi-nozzle Inkjet Deposition of Photopolymers (Stratasys, U.S.)
Photopolymer withblended colors & translucent colors
Hybrid colored materials: Functionality & Visualization
Sample parts
Multi-nozzle stereolithography (Recent Innovation)Connex3
Rapid Prototyping of Metals
Direct metal fabrication processSubtractive manufacturing High Speed Machining
Direct Fabrication tooling
Mold with RP:Secondary process
Direct Fabrication
Characteristics
Reduced number of steps
Minimized dimensional inaccuracy
RP processes that produce metallic parts or molds
directly from CAD solid models.
Metal
Prototypes,
Molds
RapidPrototyping
SecondaryProcesses
Direct FabricationProcesses
Time (days)REDUCED
TIME-to-MARKET
CAD
Modeling
Direct metal fabrication processes
Melt Pool
PowderDeliveryNozzles
PowderInjection
Substrate
Nd:YAG
............................. ........................... ..
LaserCladding
LENS : Laser Engineered Net shapingHow It Works:
Sintering metal powder by laserwith delivery nozzles
Characteristics
Material: Stainless Steels, Titanium Alloy, NickelLayer Thickness: 125 µm (H13)
Metal molds repair and modification
Applications
Injection Mold Housing
Complex innershape part
Mold Repair & Modify
before
after
Different material adapted die
Scanner system
Loose powder
Build plate
Build station piston
Mold
Powder coater
Powder delivery system
Laser
How It Works:
DMLS : Direct Metal Laser Sintering : a kind of SLS
Powders: Mixtures of differentmetallic components
Material : Steel or Bronze basedLayer Thickness: 20 µm
Characteristics
Sintering metal powder by laser
Parts : Dashboard & support
High quality functional component in a short time
Applications
Y stent forartery branches
Injection mold
Tire TreadPattern Mold
(High precision using two sizes of metal powders)
Most expensive: Sciaky
Up to $6M for a single printer
8.4m3 build volume
Combination of 3D Printing with CNC Machining
Sciaky's Electron Beam Additive Manufacturing Solution
Titanium part(Airplane)
Prints in titanium, tantalum, Inconel, …
Ideal for the aerospace market
www.sciaky.com
Subtractive manufacturing as Rapid Prototyping Raw material is carved into a desired final shape
Raw material
Product
Subtractive process
FinishingRough carvingRaw material
High-speed machiningSubtractive Manufacturing
Offering practical advantages precision and versatility
Machining of the impeller
HisRP(KIMM & KAIST) (High-speed Rapid Prototyping)
High speed machining with automatic fixturing
B. S. Shin & D. Y. Yang et al., 2003
0˚ 180˚
automatic fixturing for holding
5-axis Machining
Reduced manufacturing timeLower manufacturing cost
Wide variety of available materialsIncreased product accuracy
Large scale Rapid Prototyping: Thick-layered RP Systems
Large scale RP : Thick-layered RP Systems
Thin Layer with Square Edges
Thick Layer with Sloping Edges
Boundary of CAD Model
t=1 mm
Sloping surface
(first approximation)
t < 1 mm
Stair-stepped surface
• High build speed
• Removal of stair-stepped effect
How It Works:
Thickness of raw material is thick Sloping surface
Dolphin (1,692 mm x 660 mm x 1,274 mm)
Cutting Principle
Surface contours
Surface normal
Cutting vectorSurface tangent
Waterjet cutter Sloping surface thick layersStyrofoam
(10,20,30mm)
Trusurf
Large scale RP : Thick-layered RP Systems
Finished & Painted Dolphin
Experimental Setup
CAM-LEM
Laser
Characteristics
Thick Tangent-cut layers
5-axis laser cutter
Ceramic, Stainless steel
, Foam (6 mm thick)
Sample Parts
Styrofoam Spheres
84 mm-tall)
Laser cutter Thick materialsCAM-LEM
Hotwire Cutter
USL GenerationUSL Generation Cutter Path
USL
Pilot Pin
Stacking & BondingStacking & Bonding
Reference shape
VLM process, DY Yang et al., KAIST
Large scale RP : Thick-layered RP Systems
How It Works : Hotwire cutting styrofoam
Mount Rushmore Memorial
Apparatus • VLM; Variable Lamination Manufacturing• U.S. Patent No. 6,702,918, March 9, 2004
Advanced ApplicationsHigh functionality Bio applicationVisual aids Personal Manufacturing
The State of the Art of
Rapid Prototyping Applications
High functionality & Bio Appl.
Wider variety of available materials
High Performance
Precision, High-speed, Low cost
Visual Aid: Colored Object Personal manufacturing
Application of 3D printingEntertainment
Contents
Fashion
Toy
Functional productAerospace &
Automotive products
Die & Mold
Medical application
Visual productArchitecture
Medical application
Prototype
Mercedez-Benz GL class
Aluminum Engine Support Replaced by Engineering Plastic
Engine Weight Support
Shock AbsorberCrash-worthiness
30% Weight Reduction
Engine Noise Reduction
Use of Engineering Plastics
Use of Engineering Plastics
PA Compound -3kg
(RVR, Mitsubishi) Fender(Civic, Honda) Rear Glass
PC Compound -2kg
(A8, Audi) Tire Carrier
PA Compound -4kg
(Fofour, Smart) Sun Roof
PC Compound-3kg
Indirect 3D Printing Opportunity
The world's first Carbon Fiber 3D Printer https://markforged.com/
Cutaway of aeromotions race car wing support
가격 : 4,999$ (약 530만원)
Anatomy of a continuous filament fabrication part
(1) Nylon base + 3 carbon fiber layers
(2) Nylon honeycomb structure
(3) Final carbon fiber CFF + nylon case
사용 가능 재료
Carbon fiber filamentFiberglass filamentNylon filamentPLA filament
Building Construction by 3D Printing
Conventional Contour Crafting including Curved 3D Shapes
On-site Building Whole Houses On-site Reinforced Wall Construction
Building Innovation by 3D Printing to build Custom-tailored Houses
3D Printing in Fashion as Visual Aids
3D printed dresses at Paris Fashion Week (2013)Iris van Herpen’s Haute Couture show, ‘VOLTAGE’
3D printing does what no other form of clothing manufacture can do when complex shapes need to be created quickly and as one piece
Interview with Iris van Herpen
3D Printed glass
3D Printed footwear
Visual Aids for EntertainmentImagination into reality
User customized guitar 3D printed figures
Kids Drawings Into 3D Printed Figures Mobile RP/ 4D RP
3D Printing Pen as Free Rapid Prototyping
Materials : Plastic(ABS, PLA)
3D Printing Pen: 3Doodler
Without Computer Modeling3D Printing by yourself
Melted plastic Extrusion (99$)
(WobleWorks LLC)
4D Printing and Self transformationConcept of 4D printing : Self transformation of products
with programmable material printed by 3D printer
Inspirations from Nature
DNA
Protein
Self transformed strand Self assembled cube
Skylar Tibbits, MIT
TED talks, (2013. 4.4)
Prospective applications of 4D Printing
Extreme Environments(Aero space constructions)
ManufacturingConstruction
Infrastructure
Aerospace
Eliminating human error and the confusion of complex instructions
Industrial infrastructure
MIT & Geosyntec.(2012)
Current Application: Underground adaptive piping
Expand and contract to regulate water flow
Visual aids : Scientific and Architectural Models
Architecture
Complex geometries can be easily generated.Complex mathematical surface*
*Minimal surface
Growth of nautilus
Shapeways
(Producing, Delivering products with 3D-Printing)Market place to make, buy and sell products by individuals
Possible to Personal Rapid Product Manufacturing
What is shapeways? iPhone 5 case Interior
Lamp
Personal manufacturing
Price : 2,199 $
Personal RP machine Personal Rapid Manufacturing
1 layer: 0.27mm~0.32mm
RP process : FDMMaterials: ABS, PLA
MakerBot(USA) NP-MENDEL(Korea)
RP process : FDMMaterials: ABS, PLA
Price : About 1,200 $1 layer: 0.1mm~0.35mm
by personal RM “Liberator” Gun
Personal manufacturing
www.printrbot.com
Printrbot: the Cheapest
Prices start at $3508000 Printrbots sold since 2011Education market worth $260M
CARIMA : DLP(Digital Light Processing) typeProduct : Master +plusMaterial : Photopolymer, visible light lampMax. resolution thickness : 40μm~100μm
ROKIT : FDM typeProduct : EDISON (About 1,500$)Material : PLA (plastic)Max. resolution thickness : 50 μm
SOLISYS : DLP typeProduct : SRP Material : Photopolymer, visible light lampMax. resolution thickness : 50-100 µm
NP-Mendel : FDM typeProduct : NP-Mendel (About 1,200$)Material : ABS, PLA (plastic)Max. resolution thickness : 35μm~100μm
Personal RP machine in Korea
Menix(With KAIST) : Thick–layered RPProduct : VLM seriesMaterial : StyrofoamMax. resolution thickness : 1~4mm
Personal manufacturing
Metal RP machine in Korea
InssTeK : Laser cladding typeProduct : MX seriesMaterial : Cu, Al, Ni, Stainless powder (Metal)Max. resolution thickness : 100μm~2000μm
(Metal-based deposition)
Aerospace applications
World’s First 3D Printed airplane (2011)
Rocket part by 3D printing
Functional component
Airbus A380 component
SLS(Selective laser sintering) with titanium
Rapid Tooling Process for functional dies &molds and Mass production
3D printing을 이용한 쾌속 금형제작과 대량생산
Die and mold manufacturing
Conventional die and mold manufacturing
Subtractive process such as machining
3D printing can produce the die and mold directly and indirectly !
Disadvantage of subtractive processReproducing sharp corners is difficultModification of the die geometry is difficult
DMLS : Direct Metal Laser SinteringSDM : Shape Deposition Manufacturing
Direct 3D printing of Metals for Die & Mold Making
DMT(Direct Metal Tooling) process (InssTek INC, Korea) LENS (Laser Engineered Net shaping)
High performance multi-material dieDirect mold fabrication
Copper interior
Steel exterior
Conformal cooling channels
Die with conformal cooling channels
cooling channels
Modification and restoration
Damaged part Restoration
Modification of the die geometry
3D printing changes the die and mold manufacturing trend
Die and mold manufacturing
Visualization, Verification of Design,
Check of Manufacturability, …
Functional Prototypes and
Manufacturing of small lot size
Manufacturing of Parts using Rapid Tooling
RT Parts (functional material)RP Parts (non-functional material)
Indirect Rapid Tooling (Single reverse, Double reverseand Triple reverse process)
Direct Rapid Tooling
Rapid Tooling Technologies
Direct Tooling Construction
• Use RP Method to Create Inserts for Injection Mold Tooling
• Mold Made from RP Material
• Method : SLS Rapid Tool
2 Green Part: Steel particles with polymer binder
4 Full dense metal mold: steel + copper
3 Brown Part: binder burned out, infiltrate with copper
1. Inserts designed in CAD
• SLS process used to sinter cavity and
core inserts from Rapid Steel material
- carbon steel powder coated with
polymer
• Inserts infiltrated with polymer solution
for
strength during processing
• Inserts processed in furnace to burn off
polymer and sinter steel.
Single Reverse Tooling Methods
• Requires RP Master Pattern of Shape to be Molded
• Parting Line Block Required
• First Side of Tool Cast against Pattern Imbedded in Parting Line Block
• Second Side of Tool Cast against First Side
Create Pattern Create Parting Line Block
Cast First Side of Tool
Invert and Remove Parting Line Block
Cast Second Side of Tool
Remove Pattern
Double Reverse Tooling Construction
• Requires Master Pattern of Cavity and Core Inserts
• Cast Reverses
• Cast Mold Insert Against Reverse
• Double Reveres tooling Method: Quickcast Tooling
Create Insert Pattern
Cast Reverse Remove Pattern Cast Tool Remove Reverse
Double Reverse Construction Process
Create Pattern Create Parting Line Block
Cast First Side of Dummy Mold
Invert and Remove Parting Line Block
Cast Second Sideof Dummy Mold
Remove Pattern
< Single Reverse to Create Dummy Molds >
DummyMold
Cast Reverse
Remove Pattern
Cast Tool Remove Reverse
< Double Reverse to Create Tooling >
Triple Reverse Tooling Construction
Cast Epoxy Tooling Complex Mold with Insets and Cooling
Cast Epoxy Tooling
• Rigid, Low Shrink Epoxy
– Two Part Materials
– Cures Over Time (Hours)
• Straight Epoxy Face Coat
• Epoxy/Aluminum Backing
Mold FrameParting Line Block
Pattern
Aluminum Chips mixed with epoxy for strength and conductivity
Completed Mold
Mixture poured to cast mold
Spray Metal Tooling
• Depositing a thin layer of metal using an arc spray process to create the surface of the mold
• Materials : Kirksite, zinc-based alloy, steel• Approx. 0.1” (2.54 mm) Layer Deposited• Backed with Epoxy or a Low Melting Point Metal alloy• Advantages :
- Good for large parts- Little or no additional shrink at the process of mold-making
• Disadvantages : - limited mold life- adding metal inserts, increasing cost and lead time for complex shapes
• Applications : parts of significant size with low-to-medium complexity
Completed MoldArc Spray Process
cf. Kirksite - Composite of Al and Zn
Electroformed Tooling
• Metal (Usually Nickel) deposited on Pattern in Parting Line Block
• Layer Built Up Over Period of Time
• Backed with Epoxy, Metal, or Ceramic
Electroformed Tool Backed with Chemically Bonded Ceramic
Cast Kirksite/Aluminum Tooling
• Rubber, Urethane, or Epoxy Dummy Molds
• Plaster Reverses
• Kirksite/Aluminum Cast Against Plaster
< Rubber Dummy Mold > < Plaster Reverse > < Aluminum Cast >
Spray forming (Ford)
• Depositing the metal onto the pattern to produce the metal shell by wire spray guns• Licensed by Ford• Shell thickness : up to 19 mm (0.75 inch)• Deposition rate : about 6.8 kg (15 lbs) of wire material per hour• Work cell : 760 x 1015 x 250 mm (30 x 40 x 10 inches)• Accuracy : ±0.15 mm (0.006 inch)• Significant cost reductions (about 10-15% less than conventional CNC machining processes)• Much less time than CNC components• Embedded conformal cooling channels on the backside of the tool• Applications : primarily to produce production dies for sheet metal stampings
One million Turbine blades
SampleTools & Parts
60,000 production
Latch covers
Aluminum trim die
Ceramic Shell Casting
SampleTools & Parts
A Ceramic shell casting process that uses an ceramic slurry with an EPS pattern or Wax pattern placed inside of the mold
Definition
Thin thickness possible ( layer thickness 5 – 6 mm )
Good tolerance (0.003-0.005”) : Mold does not shrink
Better surface finish
Higher productivity ( automation possible)
Less disposal cost
Advantage
Ceramic shell casting process (lost wax)Ceramic shell casting process (lost wax)
1. Making the slurry 2. dipping the wax into the slurry 3. Drying process 4. Dewaxing
5. Pour molten metal 6. Solidification 7. Removing shell using hammer
Complete Parts
1. Design CAD model 2. Fabricate foam model 3. Coated with ceramic slurry
4. Coated with sand5. Pouring molten metal into mold
6. Final part after the ceramic shell is broken
EPC(Evaporable Pattern Casting) Proc. for Part ManufacturingEPC(Evaporable Pattern Casting) Proc. for Part Manufacturing
Lost-Foam Process
Signal Transmitter Housing for Wireless Communications Network System
Oil Filter Adapter
Aluminum Transmission Housing L61 Engine Block and Head (General Motors)
ApplicationsApplications
Prostheses and Dental implants
Tissues Engineering and BiotechnologyOperation Aids
Bio-Medical Applications
Bio application: Prostheses and Dental implants
First 3D printed jaw transplant (2012)
Material : Titanium
3D printed skull implant
Prosthetic legs Optimized to customer
Direct 3D printing of human parts
: Hearing AidCustomized by
3D printing
Building Process of a Cranial Prosthesis(1/2) (두개골 인공 삽입물)
Ref) http://www.phidias.org, Phidias Rapid Prototyping in Medicine, No. 2, pp. 4, June, 1999.
Prototyping(Solidscape)
Clinical case
두개골 함몰 인공 삽입물 필요
3D Reconstruction(Mimics)
Prosthesis Modelling(SolidWorks)
MRI 측정 인공 삽입물 설계
Custom-made Cranial Prosthesis필수빠른제작, 정확한 삽입물 형상제작
SLASkull
인공 삽입물 형상과 두골형상 비교
Bio application : Surgical planningMinimally invasive surgery with Surgical Planning
Case 2 : Siamese twins
Case 1 : Orthopedic Fracture
Bio application : Operation Aids
Siamese twins
CT scan data 3D Printing 3D Print : Replica of twins
UCLA(U.S.) 2002Ref. cavendishimaging.com
Successful! Operation time : 97hours 22 hours
(Surgical Planning)
Advanced Tissue Sciences,Bio applications in Tissue Engineering
RP기술을 접목한 조직공학 피부, 장기 조직, 장기 제작에 응용
Cell isolation
Cell proliferation
Cell seeding into scaffold
In-vitro cell culture/Tissue regeneration Tissue transplantation
General procedure for application of 3D scaffold
Bio application : 2D/3D bio scaffolds by RP
Bio application : 3D printing of Human Organs
Direct 3D printing of human ear
3D printed artificial ear on a mice
Vacanti mouse Artist Stelios Arcadious20072002
Conventional methodCow cartilage cell
to human earshaped-mold
2013
Lawrence Bonassar,(Cornell University)
Bio application :
Organovo Holdings Inc.Human Organs (Bio paper + Bio ink)
Bio paper
Bio ink
3D printed artificial blood vessel
(FraunhoferInstitute, 2011)
Direct 3D printing of human organs3D printed Bionic ear
Princeton Univ. (2013)
Future prospects of Rapid Prototyping
LimitationsFuture prospects
Current Trend of
Visual aids: extended appl. Personal manufacturing
High functionality
Wide variety of available materials More industrial applications
Bio/Medical Application
Customized shape, Bio compatibilityMedical
Operation Aid
Rapid Prototyping Applications
Future prospects of RP & 3D Printing
Volumetric manufacture of RP Animation-enabled(Mobile) RPAdvance of secondary processes Specialized RP service bureausEnhanced surface quality, e.g. quasi-real lifeUser-friendly Data Connection
RP Enhancement & Visual aidsRP Enhancement & Visual aids
Increased Speed of RP/ Massproduction: Rapid manufacture Increased Precision of RP More variety of materials satisfying required properties, i.e. functionally gradient property and foam-like materialMulti-material, metals
Higher and Diverse FunctionalitiesHigher and Diverse Functionalities
Enhancement of customized RPLow cost 3D printers and low operation cost Simplified Data handling for RPLow cost scanner and data connection, i.e. camera-based scanning method (Smart phone assisted data scanning)
Personal RP machinePersonal RP machine
RP of human skins and hairs RP of various human organsRP of bone structuresSimplified handling/ connection of CT dataRP of stem cellsRP of blood vessels
Diversified Bio/ Medical applicationDiversified Bio/ Medical application
Expected Future Technologies
Courtesy: J. Harrop@ IDTechEx
Facilitated data acquisition ( cf. Mobile Phone) .- New 3D Scanning solutions
Courtesy: J. Harrop@ IDTechEx
Courtesy: J. Harrop@ IDTechEx
Expected Applications in Positive Prospect
Thank you for your attention!
Questions and Discussions
