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3D Printing –

Applications in Industry and Home

Jukka Tuomi

Aalto University

Finnish Rapid Prototyping Association FIRPA

FRC+ Project

Riihimäki April 15, 2014

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3D Printing - Hype

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Stock Market

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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 additive processes

1988 - -

Material removal processes

Stone age (40 000 eaa)*- - - - - - -

Material forming processes

- - - - - Copper age (5 000 eaa)** -- -

*) Aurignasin kulttuuri

**) Sulatettu kupari, taottu aiemmin

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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)

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3D Printing – Process1/2

3D-CAD - Ideas

- Pro/E

- Catia

- SolidWorks

- …

.stl file

.stl file RP&M - SLA

- SLS

- DMLS

- LOM

- FDM

- …

Physical part

Layer-by-layer manufacturing

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3D Model 3D Printing Physical part

3D Printing – Process 2/2

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Examples 1/2

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Examples 2/2

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High-End Products

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Why?

Rapid Prototypig

Rapid Tooling

Rapid Manufacturing

1990 -

1995 -

2000 -

Time to market

Faster Ramp-up

Agile manufacturing and customization

2000

High-end products, production and logistics

”SuperMachines” 2010 -

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Prototypes

Tools

Components

Application Oriented Classification

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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

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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

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ASTM-Approved AM Process Terms

• Vat Photopolymerization

• Powder Bed Fusion

• Material Extrusion

• Material Jetting

• Binder Jetting

• Sheet Lamination

• Directed Energy Deposition

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Laser Sintering (Powder Bed Fusion)

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DMLS Equipment

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One Layer

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Laser Melting Powder

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The Process

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220 Parts Ready for Post Processing

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Design for function

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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

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Weight Optimization

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AM Unique Capabilities 2/2

3 Functional complexity

- kinematic joints

- inserts

4 Material complexity

- different material properties in different regions

- LENS and DMD

- Objet

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Fashion

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Furniture

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Additive Manufacturing Networks

Customers

What means customisation

in here?

How do the customers behave?

How do we express the products

for the customers?

Company networks - Design

- Manufacturing

- Logistics

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Trends 1/2

Component manufacturing

Technical prototypes

3D Printing

Now Future

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Trends 2/2

DIY – Do It Yourself

Metals

End product manufacturing

AM Standards

New design systems

- Tinkercad

- 3DVIA

- 123D

-

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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.

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Thank you!

Jukka Tuomi

jukka.tuomi@aalto.fi

0500-713420