Smart Integration of JT in Additive Manufacturing - A Use Case for 3D Printing

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1 Smart Integration of JT in Additive Manufacturing - A Use Case for 3D Printing ProSTEP ivip Symposium 2015 May 6 th, 2015 Marco Grimm, Alexander Christ, Reiner Anderl 1

2 Outline 1 Motivation 2 Additive Manufacturing 3 JT Use Case 3D Printing 4 Conclusion 2

Motivation Additive Manufacturing is gaining relevance due to decreasing machine cost technology improvements 10 Billion US-$ market potential in 2021 Shortcomings of current formats STL (wide spread

3 Motivation Additive Manufacturing is gaining relevance due to decreasing machine cost technology improvements 10 Billion US-$ market potential in 2021 Shortcomings of current formats STL (wide spread but no meta data) AMF (meta data but not wide spread) Deployment of JT as process format for additive manufacturing Different geometry representations Integration of meta data Harmonization with other standardized formats, e.g. STEP Prevalent in Industry 3

4 Outline 1 Motivation 2 Additive Manufacturing 3 JT Use Case 3D Printing 4 Conclusion 4

5 Classification of Additive Manufacturing Processes Additive Manufacturing Processes Initial state Wire Solid Powder/Granulate Foil Liquid Liquid bath Technology Melting and solidification Heating nozzle/ Extruder Melting and solidification Laser beam Bonding with binders Binder nozzle Cutting out and joining Laser beam or blade Photopolymerisation Laser beam Procedure Fused Layer Modeling (FLM) Selective Laser Sintering (SLS) Selective Laser Melting (SLM) 3D - Printing (3DP) Layer Laminated Manufacturing (LLM) Stereolithography (SL) Anderl (2014): ViP A - CAD-Systeme und CAx-Prozessketten 5

6 FLM Process Principle Heated nozzle Design principle CAD model Material supply Slicing process Support structure Component (solidified thermoplastic) Building process VDI 3404 Anderl (2014): ViP A - CAD-Systeme und CAx-Prozessketten 6

7 FLM Process Principle Youtube: morphers21-3d Printed Yoda Wood Grain 7

Comparison of Additive Manufacturing Methods Fused

Layer Laminated Manufacturing (LLM) Selective

Stereolithography (SL) Ultimaker 3DSystems EOS

1 0 0,32 /cm³ (300 /kg) 1,09 /cm³ 0,75 /cm³ (155

(15 /kg) 0,23 /cm³ (200 /kg) Accuracy 0,4 ±mm 0,2

mm 0 Minimal wall thickness 4 mm 2 0 0,2 mm 0,45

8 Comparison of Additive Manufacturing Methods Fused Layer Modeling (FLM) Selective Laser Melting (SLM) Layer Laminated Manufacturing (LLM) Selective Laser Sintering (SLS) 3D - Printing (3DP) Stereolithography (SL) Ultimaker 3DSystems EOS Helisys 3DSystems 3DSystems Material costs 2 /cm³ 1 0 0,32 /cm³ (300 /kg) 1,09 /cm³ 0,75 /cm³ (155 /kg) (75 /kg) 0,20 /cm³ (70 /kg) k. A. (15 /kg) 0,23 /cm³ (200 /kg) Accuracy 0,4 ±mm 0,2 ±0,15 mm ±0,1 mm ±0,05 mm ±0,1 mm ±0,25 mm ±0,15 mm 0 Minimal wall thickness 4 mm 2 0 0,2 mm 0,45 mm 0,05 mm 0,1 mm 2 mm 0,1 mm Anderl (2014): ViP A - CAD-Systeme und CAx-Prozessketten 8

9 Additive Manufacturing Process Chain Creation of 3D CAD model Triangulation of 3D model Slicing and tool path generation 3D printing of physical model Cleaning and finishing CAD native, STEP, IGES Tolerance values STL, AMF Layer thickness G-Code Tool size, accuracy Anderl (2014): ViP A - CAD-Systeme und CAx-Prozessketten 9

Current Data Formats in Additive Manufacturing Surface Tessellation Language (STL) De

facets ASCII or binary data representation Supported by most systems 3D CAD model

capabilities for multi-material generative manufacturing Support of color, materials

10 Current Data Formats in Additive Manufacturing Surface Tessellation Language (STL) De facto standard in additive manufacturing 3D surface approximation through triangular facets ASCII or binary data representation Supported by most systems 3D CAD model Additive Manufacturing File Format (AMF) ISO/ASTM 52915:2013 XML structure Extends STL capabilities for multi-material generative manufacturing Support of color, materials and constellations STL model Tolerance: 0,01 mm File size: 156 kb Triangles: Schützer 10

11 Outline 1 Motivation 2 Additive Manufacturing 3 JT Use Case 3D Printing 4 Conclusion 11

12 Integration of JT in 3D Printing JT Creation of 3D CAD model Triangulated Model Slicing and tool path generation 3D printing of physical model Cleaning and finishing 12

13 Implementation Batch Process 2. Conversion JAVA jar archives (Johannes Raida) 4. Slicing (Slic3r) Creation of 3D CAD model JT(s) STL(s) AMF G-Code 3D printing of physical model Cleaning and finishing 1. Input JT Files 3. Merging (Python Script) 5. Output G-Code Arnold, Flade, Gieringer, Herzog, Philippus, Tsoukas (2014): Integration of JT in the Rapid Prototyping process chain, DiK 13

14 JT based 3D Printing Process Creation of 3D CAD model Creation of JT model JT to STL conversion Slicing and tool path generation 3D printing of physical model Cleaning and finishing 14

15 JT based 3D Printing Process Creation of 3D CAD model Creation of JT model JT to STL conversion Slicing and tool path generation 3D printing of physical model Cleaning and finishing 15

16 JT based 3D Printing Process Creation of 3D CAD model Creation of JT model JT to STL conversion Slicing and tool path generation 3D printing of physical model Cleaning and finishing 16

17 JT based 3D Printing Process Creation of 3D CAD model Creation of JT model JT to STL conversion Slicing and tool path generation 3D printing of physical model Cleaning and finishing 17

18 JT based 3D Printing Process Creation of 3D CAD model Creation of JT model JT to STL conversion Slicing and tool path generation 3D printing of physical model Cleaning and finishing 18

19 JT based 3D Printing Process Creation of 3D CAD model Creation of JT model JT to STL conversion Slicing and tool path generation 3D printing of physical model Cleaning and finishing 19

20 Implementation Hardware and Software Desktop 3D printer (FLM) based on RepRap project (fully Open Hardware) Open-Source Slicers (Slic3r and Cura) JNetCAD JAVA Package for JT Conversion STLmerge Python script Repetier-Host for toolpath visualization 20

Slicing is done on the machine) Usage of web services to control and

21 Use Case 3D Printing Current phase of development Full automation of the JT-based process chain directly on the machine controller (Conversion and Slicing is done on the machine) Usage of web services to control and monitor the machine via the Internet Integration of mobile devices and apps via REST 21

22 Outline 1 Motivation 2 Additive Manufacturing 3 JT Use Case 3D Printing 4 Conclusion 22

Conclusion and Outlook Conclusion Additive

individualized products at the cost of mass

as proof-of-concept was made and validated

Integration of mobile devices Integration of

manufacturing based on JT backbone Anderl

23 Conclusion and Outlook Conclusion Additive Manufacturing enables the production of individualized products at the cost of mass production Integration of JT prevents shortcomings of current additive manufacturing formats First implementation as proof-of-concept was made and validated Future Research Integration with PDM/PLM Integration of mobile devices Integration of web services Distributed additive manufacturing based on JT backbone Anderl (2014): Industrie Advanced Engineering of Smart Products and Smart Production 23

24 Contact Marco Grimm, M.Sc. Research Assistant Alexander Christ, M.Sc. Research Assistant Prof. Dr.-Ing. Reiner Anderl Head of Department Department of Computer Integrated Design (DiK) Technische Universität Darmstadt Otto-Bernd-Str Darmstadt {grimm, christ, anderl}@dik.tu-darmstadt.de Tel:

Sharif University of Technology. Session # Rapid Prototyping

Advanced Manufacturing Laboratory Department of Industrial Engineering Sharif University of Technology Session # Rapid Prototyping Contents: Rapid prototyping and manufacturing RP primitives Application