3d printing technologies and materials - gpca … · gcc polymer value chain: creating future...

3D Printing Technologies and Materials

Klaus Gargitter

• 3D Printing Technologies and

Materials• 3D printing technologies

• SLA /DLP

• CLIP/CDLP

• Material Jetting

• SLS

• FDM

• Near Future

Agenda

GCC Polymer Value Chain: Creating Future Leverage

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



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)

We can divide the 3D printing by the

type of material and process that is

used

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


SLA - Stereolithography (laser)

DLP - Digital Light Processing (U.V. projector)


Image Courtesy of 3D Hubs

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.


- 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


- 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


- Epoxi based photopolymers

- Methacrylic acid esters

(Metacrylated monomers / Metacrylated oligomers)

- Acrylic acid esters

(Acrylated monomers / Acrylated oligomers)

- urethane acrylate



Materials (Thermosets)




- Continuous process

- Two stage process: secondary curing by

heat. Improve mechanical properties

- Faster than SLA or DLP

Continuous Liquid Interface Production (CLIP) or

Continuous Digital Light Processing (CDLP)


Image Courtesy of Carbon



- Continuous process:

Isotropic properties






- 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.







- Applications: Small, high detail models,

Jewelry, art, Investment casting, rapid

prototypes, molds, dental, Medical and

health care

- Limitations

Large models


The resin viscosity can increase over time






- Materials:

- Rigid, flexible and elastomeric Polyurethane,

- Cyanate Ester,

- Epoxy and Urethane Methacrylate




Image Courtesy of Adidas : Futurecraft 4D


- 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.

Material Jetting (MJ)


Image Courtesy of Stratasys - Polyjet




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.




- 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.






- 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






- Materials:

- Acrylic monomer + Acrylate olygomer

- acrylic compounds

- PP like, ABS like, flexible,




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



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.



- 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




- 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




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



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



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 3D HubsImage Courtesy of 3Devo




- 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



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,



- 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

Near Future

Image Courtesy of Geeetech Rostock


Thank youwww.gpca.org.ae

www.gargitterap.com.br

[email protected]

3d printing technologies and materials - gpca … · gcc polymer value chain: creating future...

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