3d printing opportunities for ssl components and fixtures€¦ · global 3d printing forecast min....
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Narendran & Perera, SIL 2018 1
3D Printing Opportunities for SSL Components and Fixtures
Nadarajah Narendran and Indika U. Perera
Lighting Research CenterRensselaer Polytechnic Institute
Troy, NY 12180
Session Number: T2 S1 P1
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What is 3D printing?
3D printing process:• Objects are fabricated by depositing material using print heads, nozzles, or other material deposition or solidification processes using a layer by layer approach with digital information from a computer‐aided design (CAD) model.
• Also known as additive manufacturing (AM)
• Several types of AM processes
http://edition.cnn.com/TECH/specials/make‐create‐innovate/3d‐printing/ Example of vat photopolymerization
https://3dprinting.com/what‐is‐3d‐printing/
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3D printing processes and material
Polymer Metal
Ceramic
Material jettingDirect energy deposition
Vat photopolymerizationMaterial extrusionBinder jetting
Powder bed fusionSheet lamination
Source: Adopted from IDTechEx 2018, Masterclass 7 handoutshttp://www.3ders.org/articles/20170524‐sculpteos‐newly‐released‐state‐of‐3d‐printing‐2017‐report‐shows‐a‐maturing‐market.html
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3D printer and material manufacturers
• 3D Printers• Thermoplastic extrusion
• Stratasys, Ultimaker, RepRap • Selective laser sintering
• 3DSystems, EOS • Vat photopolymerization
• Formlabs, 3DSystems, Carbon 3D• Direct metal laser sintering/Electron beam melting
• EOS, GE (Concept Laser, Arcam)• Binder/Material jetting
• 3DSystems, hp, Stratasys
• Materials• Thermoplastic
• BASF, ARKEMA, COVESTRO
• Vat photopolymerization: • DSM, Dow Corning, Henkel
• Metal powder• SANDVIK Osprey, Renishaw, Advance laser Materials (EOS)
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Expanding market for 3D printing
• Industries who have embraced 3D printing for manufacturing parts and systems
• Automotive
• Aerospace
• Medical
• Consumer products
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Source: ARK investment Management LLC | ark‐investment.com, 2016Source: ARK Investment Management LLC , 2016 |ark‐investment.com
Successful implementation of 3D printing
CFM International’s 3D‐printed fuel nozzle reduces part count from 18 to just 1. (Image source: ge.com)/
3D‐printed parts for the Rolls‐Royce Phantom. (Image source: bmw.com)
Customizable 3D‐printed electric shavers from partnership between Philips, Shapeways and Twikit(Image source: 3dprint.com)
3D‐printed shoes from Adidas and Carbon (Image source: 3dprint.com)
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0
10
20
30
40
2012 2014 2016 2018 2020 2022
Glo
bal r
even
ue ($
Bill
ions
)
Year
Forecast Max.Global 3D printing
Forecast Min. 3Dprinting
Global 3D Printing(estimated)
Global SSL market
Global 3D printing market projections• Global 3D printing market
• $3.1B in revenue in 2013• $12.8B by 2018• $21.0B by 2020.
• 2017 AM service providers• 29% Metal and polymer• 20% Metal• 51% Polymer
Source: Adopted from data obtained including Wohlers , Allied Market Research, Canalys, CCS Insight, Freedonia, Gartner, IBISWorld, Business Wire, IDC, Statista market research reports
[ Source: Wohlers Report 2014 ]
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Reasons for pursuing 3D printing
• Prototyping • Product development • Customization• Cost reduction• Weight reduction• Increased efficiency• Innovation
Source: 3D printing: The next revolution in industrial manufacturing, UPS and Consumer technology Association, 2016
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Can SSL Benefit from 3D Printing?
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Vision for SSL and 3D Printing
Building design Construction Interior finishing
Custom lighting fixture design
On‐demand, On‐site custom fixtures
Interior lighting with custom fixtures
Change Architectural Lighting Practice
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Why 3D print of SSL fixtures?
• Custom fixtures• Improved visual appeal and functions
• Faster new product introductions• Rapid prototyping
• Lower cost SSL fixtures• Reduce cost with composite heat sinks with tailored thermal properties• Reduced carbon footprint: Lower cost manufacturing on‐site (3D printing)• One‐step process: Print/integration of components• Reduce stored inventory of systems and parts
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Components of an LED lighting fixture
[LRC 2017]
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Recent studies
• Goal: To investigate if functional mechanical, electrical, and optical components can be fabricated using current 3D printing technologies and materials to manufacture SSL lighting fixtures
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Mechanical Components
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Objective
• LED systems ‐ Metal heat sinks • To keep LED junction temperatures low • Drawbacks:
• Heavy, Expensive, Overdesigned thermal management
• Study objective: • To investigate if custom heat sinks of suitable thermal properties can be printed using fused filament fabrication (FFF) method
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Estimated Tj with 3D printed heat sinks
Parameter ValueThermal power of LED package ( ) 1 ,2, 5, and 10 WLED package thermal resistance ( ) 10°C/WDiameter of LED package ( 12.7 mmHeat sink length ( ) 10.0 cmHeat sink width ( ) 10.0 cmHeat sink thickness ( ) 2.5 mmHeat sink surface emissivity ( ) 0.9Ambient temperature ( 20°C
LED heat sink
LED package
Thermal conductivity of aluminum ~200 W m-1 K-1
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Thermal performance of 3D printed heat sinks
• In this study we investigated how composite polylactic acid or polylactide(PLA) filaments with thermally conductive fillers affect thermal conductivity of printed heat sinks to manage the junction temperature, Tj, of the LED
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Estimated Tj with different heat sinks
4045505560657075808590
0.1 1 10 100 1000
LE
D c
hip
junc
tion
tem
pera
ture
(°
C)
Heat sink thermal conductivity (W/(m·K))
Generic PLACopper infused PLA variant ACopper infused PLA variant BCarbon fiber PLABronze infused PLAGraphene infused PLAAluminum
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Heat sink temperature profile
• Thermal properties of 3D printed heatsink with different materials
19
Aluminum heat sink
100%
Graphene composite PLA
70%
Copper composite PLA
60%
Generic PLA
50%
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Heat sink geometry effects
20
Tc=64 °C Tc=66 °C Tc=70 °C
8 mm
28 mm
5 mm
5 mm
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Predicting composite thermal conductivity
• To identify and verify a model that can accurately predict the composite material thermal conductivity
21
• Model predictions• Epoxy (κ=0.4 W m‐1 K‐1)• Copper (κ=400 W m‐1 K‐1)• Copper particle size=100 μm
• Experiment• Copper average particle sizes 5 and 150 μm in epoxy host material
Terentyeva et al., 2017.
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Summary
• Thermal conductivity of 3D printed PLA components depends on build orientation and filler material properties
• In‐plane thermal conductivity better compared to cross‐plane ; greater than 30%
• Infill percentage increase increased the thermal conductivity of 3D printed components
• Need improved performance filaments to meet thermal conductivity needs of heat sinks for LED systems
In‐plane Cross‐plane
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Electrical Components
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Electrical properties of printed conductive traces • Study objective:
• To investigate if electrical traces can be printed with suitable electrical properties
• In this study we investigated electrical resistivity of the 3‐D printed conductive traces with three types of materials and print orientations:
• Graphene infused PLA• Carbon nanotube based PLA• Conductive carbon black based PLA
• Results:• Graphene infused PLA showed the lowest resistivity
(6.1 x10‐3 Ωm) of tested materials• Copper used PCB traces (1.7 x10‐8 Ωm)
• In‐plane build orientation showed the lowest resistivity (70‐80% lower compared to cross‐plane)
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Voltage channel
Current channel
3‐D printed trace
V
A
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Summary
• There are commercial inks with resistivity values similar to copper.
• But they cannot be processed using unmodified FFF‐type 3‐D printers.
• Requires paste extruder attachments to benefit from these highly conductive materials
• For example, Yu et al., recently reported a method where 3D printed hollow channels within elastomer structures were filled with injected liquid metal to form electrical traces
https://support.voxel8.co/hc/en‐us/articles/208004096‐Working‐with‐the‐Conductive‐Silver‐Ink‐Solvent
Yong‐Ze Yu, Jin‐Rong Lu, Jing Liua; 3D printing for functional electronics by injection and package of liquid metals into channels of mechanical structures, Materials and Design 122 (2017).
Yu et al. 2017
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Optical Components
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Optical properties of printed components• Study objective:
• To investigate if SLA printing technology and commercially available materials are suitable for printing lenses of appropriate quality for lighting applications.
• Techniques for manufacturing optical components
• Vat photopolymerization, material jetting, and extrusion (glass material)
• In this study we investigated light transmission and scattering distribution as a function of print resolution and print orientation
• Optical samples were prepared at 50 m and 250 m print resolution
• Samples were evaluated for light transmission and scattering
• in‐plane and cross‐plane
Before polishing After polishing
50 m
250 m
laser
In‐plane
laser
Cross‐plane
GE Energy Smart LED Replacement Lamp ‐MR16Secondary lens and holder for LED lighting systems
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Summary• Study results showed that both print resolution and print orientation affect light transmission and scattering distribution
• Polishing the 3‐D printed optical elements improved performance• Increased print resolution 250 μm to 50 μm increased light transmission and decreased light scattering
• In‐plane print orientation had greater light transmission (~ 3 times) compared to cross‐plane print orientation
• Cross‐plane print orientation had greater light scattering compared to in‐plane print orientation
• Requires post‐processing (polishing, heat treating, or coating) to refine and improve optical performance.
• Chien‐Yao Huang et al., in 2017, showed that precise diamond turning and polishing can improve surface roughness of printed components to below 0.05 μm and light transmittance to above 80%.
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Final Remarks
Narendran & Perera, SIL 2018 30
Final remarks• Opportunities
• Architectural lighting practices• Mass customization
• Custom fixtures (especially for complex geometry design and smaller production runs with unique design changes)• Rapid prototyping and faster new product introductions• Reduce fixture cost
• On‐site manufacturing• Reduce manufacturing cost with manufacturing processes such as 3‐D printing
• Reduce stored inventory
• Challenges• 3‐D printed mechanical, electrical, and optical components
• Component performances need improvement• Components have to be printed separately and integrated separately
• New materials are needed for mechanical, electrical, and optical components to meet performance needs of SSL
• Need strategy for integration of different components• Faster printing speed needed to meet application demand
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Acknowledgments
• Strategies in Light 2018• LRC Faculty, Staff and Students• LRC internal funding• Alliance for Solid State Illumination Systems and Technologies (ASSIST)
• The Federal Aviation Administration (FAA) Cooperative Agreement Number 16‐G‐019
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Thank you
www.lrc.rpi.edu/programs/solidstateEmail: [email protected] (Narendran)
[email protected] (Perera)