Ko-15.

4126 Production Technology Special Topics (2016): 3D-Printing

History and AM Process Chain

Prof. Jouni Partanen
Aalto University

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
Ko-15.4126 Prod Tech Special Topics (2016): 3D-Printing
Tentative Schedule for Lectures

• Jan 7: Course Introduction

• Jan 14: History and AM Process Chain
• Jan 21: Powder Bed Fusion
• Jan 28: Design for AM and Digital Manufacturing
• Feb 4: Inigo Flores Ituarte: Software for 3D-Printing
• Feb 11: Material Extrusion and Directed Energy Deposition
• Feb 18: no lecture
• Feb 25: Pekka Lehtinen: Vat Photopolymerization
• Mar 3: Printing Processes and Sheet Lamination
• Mar 10: Mika Salmi: Medical Applications of AM
• Mar 17: Business Aspects
• Mar 24: Ashish Mohite: 3D-Printing in Architectural and Industrial Design
• Mar 31: Post Processing and Secondary Processes
• Apr 7: Final Exam

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
Ko-15.4126 Prod Tech Special Topics (2016): 3D-Printing

• Lectures on Thursdays 14.15 – 16.00, Lecture hall K1-213

• Jan 7 – Feb 11
• Feb 25 – Mar 31

• Course assignment:
• Hands-on-Training
• Groups of 4 students?
• Exercises will be done in ADDLAB
• 3D-design and 3D-printing
• 3D object and final report
• Course Assistant: Meng Wang
• Jan 23 – Mar 15

• Final Exam on Thursday April 7 at 13.00 – 16.00, Lecture hall K1-216

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Stereolithography Invention

• 3D Systems was founded 1987

• First commercial product

SLA-1 (1988)

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Stereolithography

• The mirror steers the

laser beam to image
one slice of the object

• Photocurable polymer

• Part moves down

• New layer is recoated

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 3D-Printing – objects are made out of slices

• Stacking up 2D
images you can
make 3D objects

• Conceptually
simple process –
great for automation

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
Stereolithography Early Customers - Rapid Prototyping

• Automotive industry
• Aerospace
• Consumer Products

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Stereolithography early business

• 3D Systems was public company from

the beginning

• Large companies got into the business:

• Sony, Du Pont, Mitsubishi, EOS,
others

• 3D Systems had aggressive patent

strategy
• successful

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 FormLabs
• Low cost, stereolithography system, ~ 3000€
• The object is cured from below
• ADDLab

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Powder Bed Fusion Technology

• Commercial at about 1990

• DTM (acquired by 3D
Systems in 2001)
• EOS

• Plastics and metal materials

• Sintering
• Melting (early 2000)

http://www.custompartnet.com/wu/images/rapid-prototyping/sls.png

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Material Extrusion

• Commercial at about 1990

• Stratasys

• Key patents expired at about

2005
• Many low cost products
available today
• Largest number of
machines in world today

http://www.custompartnet.com/wu/fused-deposition-modeling

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Binder Jetting

• Originally developed and patented

by MIT in late 1980s

• Licenced to many companies in

early 1990s
• Z-corp (now part of 3D Systems)
• Voxeljet
• ExOne

http://blog.nus.edu.sg/u0804594/common-rp-techniques/d-3dp/

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Sheet Lamination

• Commercial at about 1990

• Helisys
• went out of business in
about 10 years

• Laser replaced by knife

• Mcor Technologies

http://www.custompartnet.com/wu/laminated-object-manufacturing

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Material Jetting

• Commercial at about 1995

• 3D Systems
• Objet (now part of
Stratasys

http://www.makeuseof.com/tag/what-is-3d-printing-and-how-exactly-does-it-work/

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Different names for 3D-Printing

• Rapid Prototyping (& Manufacturing)

• Automated Fabrication (Autofab)
• (Solid) Free Form Fabrication
• Layer-based Manufacturing
• Rapid Manufacturing
• Additive Manufacturing

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
ASTM-approved AM process terms

• Vat Photopolymerization
• Powder Bed Fusion
• Material Extrusion
• Material Jetting
• Binder Jetting
• Sheet Lamination
• Directed Energy Deposition

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
FIRPA (Finnish Rapid Prototypin Association)

http://firpa.fi

AM Product Matrix
• Collection of all suppliers of AM equipment (about 50
supplier) in matrix form
• All product currently under sale
• Updated regularly by Mika Salmi, Aalto University

http://firpa.fi/AM_konematriisi2013_viimeisin.pdf

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
AM Process Chain

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 AM Process Chain, Step 1: CAD

• 3D CAD, Solid CAD

• More than 2D CAD

• The 3D-describtion must be complete,

visualization softwares not suffieient

• CNC machining, CAD/CAM

• Scanning, reverse engineering

• CT (computer tomography),
MRI (magnetic resonance imaging)

http://fivetechsoftware.com/3d-cad-software-works-with-partmaker-and-other-cadcam-systems.html

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 AM Process Chain, Step 2: STL

• Stereolithography file format

Standard tessalated file format

• 3D objects are described as surface

models

• Surfaces are made of triangles

• Practically all 3D CAD programs

support STL file format

• File repair, DeskArtes

http://tetgen.berlios.de/fformats.stl.html

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
AM Process Chain, Step 3: File Transfer to Machine

• File verification (repair)

• Part orientation

• Support generation

• Scaling, shrinkage compensation

http://1prototype.com/freeform_parts.html

• Multiple copies

• Multiple parts, parts nesting

• Large part segmenting

• Build simulation

• Built time estimator

http://www.stratasys.com/3d-printers/production-series/fortus-900mc

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
AM Process Chain, Step 4: Machine Setup

• Machine setting parameters

• Layer thickness

• Chamber temperature
depends on material etc.

• Laser power

www.3dsystems.com

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
AM Process Chain, Step 5: Build

All automatic process

www.3dsystems.com

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 AM Process Chain, Step 6: Removal and
Cleanup

• Typically many
manual steps:
• Post-cure
• De-cube
• Separate from platform
• Remove supports

www.3dsystems.com
Kon-15.4126 Production Technology Special Topics (2016)
3D-Printing
Prof Jouni Partanen
AM Process Chain, Step 7: Post-processing
• Primary processes:
• Sanding
• Polishing
• Machining critical surfaces
• Infiltrating materials
• Painting

• Secondary processes:
• Vacuum casting
• Investment casting

http://www.laserrepro.com/prototype-model-development/

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 AM Process Chain, Step 8: Application

Application Usage

• Functional parts
• Fit and assembly
• Patterns for prototype tooling
• Patterns for metal castings http://www.rmbproducts.com/aerospace-aircraft-ducting

• Visual aids
• Presentation models
• Education/research
• Tooling components
Wohlers Report 2013: Wohlers Associates, Colorado

http://www.met-l-flo.com/gallery.htm

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
Ko-15.4126 Prod Tech Special Topics (2014): 3D-Printing

Text Book for the Course

Gibson, Rosen, Stucker:

Additive Manufacturing Technologies -
Rapid Prototyping to Direct Digital Manufacturing

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen
 Thank you!
Jouni Partanen
Aalto University
Dept of Engineering Research and Production
jouni.partanen@aalto.fi

Kon-15.4126 Production Technology Special Topics (2016)

3D-Printing
Prof Jouni Partanen