advances in desktop 3d printing robert zollo avante technology, llc
TRANSCRIPT
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Advances in Desktop 3D
Printing
Robert Zollo
Avante Technology, LLC
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Workshop Goals
• Help commercial enterprises assess the viability of desktop 3D printing for their business
• Where to go for additional relevant information
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Workshop Topics
“State of the Industry” 3D printing
Compare industrial vs desktop 3D printing
Applications and economics
Things to consider when using 3D printing
Where to go for additional relevant information
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What We Do
• Custom Materials for 3D Printing
• STL Repair/Validation Software
• Architected 3D printers
• Custom Development
• Consulting
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Commercial 3D Printing
State of the Industry
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$2 Billion+35%per year growth!
• Conceptual Prototypes
• Functional Prototypes
• Production Parts (new)
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Why 3D PrintingFor the past 30 years
Rapid Prototyping• Saves time• Efficient revisions• Reduces tooling
errors
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Why 3D Printing
For the past 5 years:
Rapid Prototyping
Specialized, Short Run Production
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Why 3D Printing Now
2013-2014 & beyond: Rapid Prototyping,specialized, Short Run Production andhigh value productionand fixtures, jigs & molds
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Pros & ConsIndustrial 3D Printers
More Material Options
Larger Scale Parts
Faster Printing (maybe?)
More Precise Parts (maybe?)
More Expensive (it depends..)
Service Bureau Option
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EconomicsIndustrial 3D Printers• $25,000 - $1Million
• Metal: $100k-$1mil.
• Metal mat.: $1k+ /lb
• Plastic: $25k -$125k
• Plastic: $100 - $500/lb
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PlasticsIndustrial 3D Printers
• SLA (stereo-lithography $$$
• DLP (digital laser processing) $$
• FDM (fused deposition modeling) $ - $$$
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Industrial 3D Printer Economics
Why So Expensive?
• Too few vendors
• Patent protection
• Customer’s lack of knowledge
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Pros & ConsDesktop 3D Printers
Personal Control
Security
Valuable Feedback
Fast Results (maybe)
Lower Costs (probably)
Faster Revisions (usually)
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Issues withDesktop 3D Printers
Lack of precision
Un-reliable
Limited capabilities
Limited materials
Few reliable vendors
Lack of customer support
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2014:Desktop 3D Printers
New Printers
More accurate
More reliable
New materials
Few reliable vendors
Lack of customer support
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EconomicsNew FDMDesktop Printers:
• Printers: $1,500 - $3,500
• Plastic Filaments: $20 - $100/lb
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Why Not Desktop 3D Printing Now2013-2014 & beyond:
Rapid prototyping,specialized, short run production andhigh value productionand fixtures, jigs and molds
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Correct Materials Make the DifferenceUsing the right plastic materials enables desktop 3D printers to become highly useful machines for
1. Conceptual prototyping
2. Functional prototyping
3. Production of some parts
4. Production of jigs, fixtures and mold components
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State of the Art 2014Industrial vs. Desktop
Materials• ABS (various grades)
• Nylon(various grades)
• Polycarbonate & alloys
• Polysulphone
• Ultem
• etc. etc.
• PLA
• ABS
• Nylon
• PET/G
• Synthetic Rubber
• New Composites
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Physical Attributes
PlasticStiffnes
sImpact Tensile
Melt Temp
PLA high low low low
ABS moderate
moderate
moderate
moderate
Nylon moderate
high high high
PET/G moderate
high high moderate
Synthetic Rubber
lowmoderat
ehigh moderate
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Aesthetic Attributes
Plastic Surface ColorsReflectan
cy“Feel”
PLA smooth bright moderate hard
ABS moderate
moderate
moderate cheap
Nylon smooth bright high slick
PET/G smooth clear highglass-like
Synthetic Rubber
moderate
bright moderate cushy
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Material Cost Guidelines
PlasticPrice/
lbDensity
Cost percubic inch
Cost @50% fill
rate
PLA $10- $15
1.24 $0.56 $0.28
ABS $15-$35 1.04 $0.94 $0.47
Nylon $30-$50 1.07 $1.35 $0.68
PET/G $30-$40 1.3-1.4 $1.70 $0.85
Synthetic Rubber
$30-$50 .93-1.05 $1.42 $0.71
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3D Printing Applications
FDM Materials by Application:
1. Conceptual prototyping: PLA, ABS, Nylon
2. Functional prototyping: ABS, Nylon, Rubber, PETG
3. Production of some parts: Nylon, Rubber, New Composites*
4. Production of jigs, fixtures and mold components:
ABS, Nylon, New Composites*
* proprietary engineering grade materials
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Desktop FDM Materials
“80/20” Rule:
Appropriate use of the right materials enables new generation desktop printers to handle many of the same “state of the art” applications promoted by the industrial printer suppliers (at 10% of the cost!)
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Workshop Topics
“State of the Industry” 3D printing
Compare Industrial vs desktop 3D printing
Applications & Economics
Things to consider when using 3D printing
Where to Go for more Relevant Information
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Time for a BreakQ&A
Question:
1. How does your company design & make new parts?
2. How long does it take?
3. What does it typically cost?
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Making Printable Parts
“Garbage In….
Garbage Out….”
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Making a Printable Design File
STL FormatFile Sources:
• CAD• Scanner• Other
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Making 3D CAD Files Printable
Files Must be:
1. “Water-tight” STL2. Must consider overhangs3. Must fit on print bed
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3D Scanning
“Reverse Engineering” a part without the blueprints
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The “Seven Deadly Sins” of Desktop 3D Printing
1. Flawed CAD Design
2. Defective STL File
3. Poor Calibration
4. Flawed/Wrong Filament
5. Improper Printer Settings
6. Variable Ambient Conditions
7. Ineffective print bed adhesion
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Guidelines for SuccessfulDesktop 3D Printing
1. Buy a sturdy printer
2. Calibrate, Calibrate, Calibrate
3. Select the right filament
4. Print height, print speed
5. Print temperature(s)
6. Use of cooling fans
7. In-fill strategy
8. Optimal print adhesion method
9. Use of support material
10. Control the environment
11. Safe pemoval Techniquest
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Making Functional Protoypes
Adapt the CAD File to meet the Material Specs.
Be Careful Scaling Up Part Size:
• Warping
• Shrinkage
• Moisture absorption
Physical criteria first
Aesthetics second
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Making Production PartsBalance Physical and Aesthetic Characterisitcs:
• Design Multiple Parts
• Use Multiple Materials
• Use Support Material
• Integrate via 3D Printing
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The Economicsof 3D Printing
Total Cost of Parts
• Design• Prototypes• Pooling• Production cost• Revision cost• Tooling maintenance
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Economics of Desktop 3D Printing
“Rule of Thumb” Number One
Part Simple Medium ComplexCombinatio
n
one unit Yes Yes Likely Likely
2 - 10 Yes Yes Likely Likely
11 - 100 Maybe Maybe Maybe Maybe
101- 1,000
Unlikely Unlikely Maybe Maybe
1,000+ No No Maybe Maybe
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Economics of Desktop 3D Printing
“Rule of Thumb” Number Two
Size Low Load Medium
High Load
Hybrid Load
< 3”x3”x3
”Yes Maybe Maybe Maybe
< 6”x6”x6
”Yes Maybe Unlikely Maybe
< 1’x1’x1’
Maybe Unlikely No Maybe
> 1’x1’x1’
Unlikely No No Unlikely
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Economics of Desktop 3D Printing
“Rule of Thumb” Number Three
Finish Low Load Medium
High Load
Hybrid Load
High Gloss
Yes Unlikely No Unlikely
Smooth Yes Maybe Unlikely Maybe
Matte Yes Likley Maybe Maybe
Not Importa
ntYes Yes Yes Yes
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Many New MaterialsAvailable This Year
Stratasys “simulated PP”*
Natureworks: “PLA co-polymers”
Avante Technology: New “Engineering Grade" materials beyond nylon
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Parts for Wearable Technology12 Important Issues:
• Toxicity (prolonged skin contact)• Staining (color dye leaching)• Skin irritation (chafing)• Uncomfortable (bad “feel”; causes sweating)• Uncomfortable (poor conformity to body)• Uncomfortable (in-sufficient flexibility)• Recovery from repeated flexing• Swelling due to moisture absorption• Shatter-proof• Sweat-proof• Electromagnetic properties• “Drop Test Compliant”
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Key Points:1. There are Sufficient Materials Available Today for modern
Desktop 3D Printers to create:
• conceptual prototypes (PLA, ABS)
• functional prototypes (Nylon, PET, Rubber, ABS)
• simple, small production parts (Nylon, PET, Rubber, other new)
• fixtures, jigs and molds for compression molding, sand casting
2. There is a productivity and cost reduction role for industrial and desktop 3D printing in many businesses right now
3. New materials available this year will enable far greater capability
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Try Desktop 3D Printing Today…(your competitors already are)
For More Information:
Avante Technology, LLC.
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Resources for More Information
• Avante Technology [email protected]
• Software Architects, Inc. [email protected]
• 3DTransform.com Matt [email protected]
• Proforma3DPrinting.com
• RepRap.org
• namii.org
• 3DPrinting.com
• wohlerassociates.com
• 3D Print Show Bellevue August 2014