3D Printing Technologies and Materials Klaus Gargitter
Agenda 3D Printing Technologies and Materials 3D printing technologies SLA /DLP CLIP/CDLP Material Jetting SLS FDM Near Future
3D Printing technologies and Materials There are different 3D printing technologies and materials you can print with, but all are based on the same principle: a digital model is turned into a solid three-dimensional physical object by adding material layer by layer. Image Courtesy of Ultimaker
3D Printing technologies and Materials We can divide the 3D printing by the type of material and process that is used Liquid Materials - Vat Photopolymerization (plastics) - Material jetting (plastics, metals and waxes) - Binder Jetting (ceramics and metals) Solid Materials - Material Extrusion (plastics and composites) - Powder Bad Fusion (plastic and metals) - Direct Energy Deposition (metals) - Sheet Lamination (composites and paper) Image Courtesy of Stratasys - Polyjet
3D Printing Liquid Materials Vat Photopolymerization: Photopolymerization occurs when a photopolymer resin is exposed to light of a specific wavelength and undergoes a chemical reaction to become solid. In general, photopolymers may contain several components including binders, photoinitiators, additives, chemical agents, plasticizers and colorants. However, the three main components which build the photopolymers are binders (oligomers), monomers and photoinitiators. Image Courtesy of Formlabs
3D Printing Liquid Materials SLA - Stereolithography (laser) DLP - Digital Light Processing (U.V. projector) To create a 3D printed object, a build platform is submerged into a translucent tank filled with liquid resin. Once the build platform is submerged, a light located inside the machine maps each layer of the object through the bottom of the tank, thus solidifying the material. After the layer has been mapped and solidified by the light source, the platform lifts up and lets a new layer of resin flow beneath the object once again. This process is repeated layer by layer until the desired object has been completed. Image Courtesy of 3D Hubs
3D Printing Liquid Materials SLA - Stereolithography (laser) DLP - Digital Light Processing (U.V. projector) - produce highly accurate parts with smooth surface finishes and are commonly used for highly detailed objects - Low costs - Desktop printers are available - Print layer by layer - Needs post production (washing to remove not cured resin) - lower shrinkage Image Courtesy of Stratasys
3D Printing Liquid Materials SLA - Stereolithography (laser) DLP - Digital Light Processing (U.V. projector) - Applications: Small, high detail models, Jewelry, art, Investment casting, rapid prototypes, molds, dental, Medical and health care - Limitations Large models Extensive exposure to UV-light The resin viscosity can increase over time Lower HDT Image Courtesy of 3D Systems
3D Printing Liquid Materials SLA - Stereolithography (laser) DLP - Digital Light Processing (U.V. projector) Materials (Thermosets) - Epoxi based photopolymers - Methacrylic acid esters (Metacrylated monomers / Metacrylated oligomers) - Acrylic acid esters (Acrylated monomers / Acrylated oligomers) - urethane acrylate Image Courtesy of Stratasys
3D Printing Liquid Materials Continuous Liquid Interface Production (CLIP) or Continuous Digital Light Processing (CDLP) - Continuous process - Two stage process: secondary curing by heat. Improve mechanical properties - Faster than SLA or DLP Image Courtesy of Carbon Image Courtesy of Carbon
3D Printing Liquid Materials Continuous Liquid Interface Production (CLIP) or Continuous Digital Light Processing (CDLP) - Continuous process: Isotropic properties Image Courtesy of Carbon
3D Printing Liquid Materials Continuous Liquid Interface Production (CLIP) or Continuous Digital Light Processing (CDLP) - Produce highly accurate parts with smooth surface finishes and are commonly used for highly detailed objects - Low costs ($$) - Continuous Print - Two stage, Needs post thermal curing to achieve mechanical good properties. Image Courtesy of Carbon
3D Printing Liquid Materials Continuous Liquid Interface Production (CLIP) or Continuous Digital Light Processing (CDLP) - Applications: Small, high detail models, Jewelry, art, Investment casting, rapid prototypes, molds, dental, Medical and health care - Limitations Large models Extensive exposure to UV-light The resin viscosity can increase over time Image Courtesy of Carbon
3D Printing Liquid Materials Continuous Liquid Interface Production (CLIP) or Continuous Digital Light Processing (CDLP) - Materials: - Rigid, flexible and elastomeric Polyurethane, - Cyanate Ester, - Epoxy and Urethane Methacrylate Image Courtesy of Carbon Image Courtesy of Adidas : Futurecraft 4D
3D Printing Liquid Materials Material Jetting (MJ) - PolyJet works by jetting photopolymer materials in ultra-thin layers onto a build platform. Each photopolymer layer is cured by UV light immediately after it is jetted. Image Courtesy of Stratasys - Polyjet
3D Printing Liquid Materials Material Jetting (MJ) Material Jetting 3D Printing works similarly to inkjet printing, but instead of jetting drops of ink onto paper, Material Jetting jet layers of curable liquid photopolymer onto a build tray. The most precise technologies for a realistic prototypes with fine details and smooth surfaces. Image Courtesy of Stratasys Image Courtesy of 3D Hubs
3D Printing Liquid Materials Material Jetting (MJ) - Produce highly accurate parts with smooth surface finishes and are commonly used for highly detailed objects - Hight costs ($$$$) - Layer by Layer - producing fully cured models that can be handled and used immediately, without post-curing. Image Courtesy of Stratasys
3D Printing Liquid Materials Material Jetting (MJ) - Applications: Presentation models Master patterns Form and fit models Flexible, rubber-like models Realistic anatomical models Prototypes for fittings, valves, and parts with complex interior features - Limitations Large models Extensive exposure to UV-light Image Courtesy of Stratasys
3D Printing Liquid Materials Material Jetting (MJ) - Materials: - Acrylic monomer + Acrylate olygomer - acrylic compounds - PP like, ABS like, flexible, Image Courtesy of Stratasys
3D Printing Solid Materials Powder bed fusion Powder bed fusion (PBF) technologies utilize a thermal source to induce fusion between powder particles to a prescribed region of a build area, one layer at a time, to produce a solid part. For plastics the SLS process is used Image Courtesy of 3DSystems
3D Printing Solid Materials Selective Laser Sintering (SLS) A laser maps the first layer of the object in the powder, which selectively melts or sinters the material. Once a layer has been solidified, the print bed moves down slightly as the other bed containing the powder moves up; and a roller spreads a new layer of powder atop the object. This process is repeated, and the laser melts successive layers one by one until the desired object has been completed. Image Courtesy of 3D Hubs
3D Printing Solid Materials Selective Laser Sintering (SLS) - produce highly accurate parts with smooth surface finishes and are commonly used for highly detailed objects - Medium costs ($$$) - Desktop printers are not available - Print layer by layer - Needs post production (remove unmelted powder) Image Courtesy of 3DSystems
3D Printing Solid Materials Selective Laser Sintering (SLS) - Applications: Functional prototyping, Parts with complex design with intricate details, Moving and assembled parts - Limitations Cavities within design (unless making use of escape holes) Image Courtesy of Stratasys
3D Printing Solid Materials Selective Laser Sintering (SLS) Materials: For SLS materials must be in powder form - Nylon 12, Nylon 11 - Mineral fiber-filled Nylon - polystyrenes - thermoplastic elastomers, - PEEK. Image Courtesy of S. Berretta, O. Ghita, K. E. Evans, A. Anderson, C. Newman
3D Printing Solid Materials Fusion Deposition Modeling - FDM The most common technology for desktop 3D printing. Great for quick and low-cost prototyping. Cheaper and simple than other technologies Image Courtesy of MakerBot
3D Printing Solid Materials Fusion Deposition Modeling - FDM The FDM printing process starts with a string of solid material called the filament. This line of filament is guided from a reel attached to the 3D printer to a heated nozzle inside of the 3D printer that melts the material. Once in a melted state, the material can be extruded on a specific and predetermined path created by the software on the computer. Image Courtesy of 3Devo Image Courtesy of 3D Hubs
3D Printing Solid Materials Fusion Deposition Modeling - FDM - Applications: low-cost prototyping, functional prototypes, parts, Manufacturing aids Functional prototypes Low volume production parts Education, Architecture, Jewelry, automotive - Limitations non isotropic properties, part quality limitations (strength, aesthetics, resolution). Image Courtesy of All3dp
3D Printing Solid Materials Fusion Deposition Material - FDM Materials (Thermoplastics): Due to the simplicity of the process and the use of thermoplastics as printing materials, It is possible to use a wide range of materials, such as: - PLA (Polylact Acid), ABS, PC, PC+ABS alloy, Nylon, PP, PET, PETG, TPU, HIPS, PVA, ASA (Acrylonitrile Styrene Acrylate), POM (Polyacetal), PMMA, TPC (Thermoplastic copolyester), PEI (Polyetherimide) - It s possible to use composites materials: carbon fiber, wood, metal (bronze, brass, copper, aluminum and stainless steel), Fibre reinforces (kevlar or fibreglass), conductive (carbon black, graphite), magnect, ceramic, Image Courtesy of Stratasys
3D Printing technologies and Materials Near Future - SLA : filled materials. Formlabs announced that it is launching a composite SLA resin with ceramic - FDM: commodities: PE and PP. Amorphous x Crystalline Challenge stick materials on table and warping due crystallization - Ionomers for FDM filament Image Courtesy of Geeetech Rostock
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