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1 STRATASYS DIRECT MANUFACTURING
ADDITIVE METALS
ERIC MUTCHLER13 SEPTEMBER
IDENTIFYING APPLICATIONS FOR 3D PRINTINGS MOST COVETED MATERIAL
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AGENDA
Section One – Identifying ApplicationsSection Two – Where's The BenefitSection Three – Designing For Additive MetalsSection Four – Build Set-UpSection Five – Controlling The ProcessSection Six – Summary
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Stratasys is a global leader in 3D printing and additive manufacturing solutions.• Inventors of additive processes
Fused Deposition Modeling (FDM) and PolyJet
• 3,000+ employees across the globe
• Over 25 years of market leadership
• More than 110,000 systems sold (2014)
• $750M combined revenue (2014)
ABOUT STRATASYS
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Stratasys Direct Manufacturing is one of the largest providers of additive and conventional manufacturing services.
• 7 U.S. manufacturing facilities
• 9 Manufacturing technologies
• 600+ employees
• Certifications: ISO 9001, AS9100
• ITAR registered
ABOUT STRATASYS DIRECT MANUFACTURING
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Eurostar‐E3000‐Copyright‐Airbus‐Defence‐and‐Space‐Ltd
WEIGHT REDUCTION
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• Extreme example of “burn”
“BURN”
• Supported area does not have “burn”
1.5in
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• Horizontal up to 30 degrees• 30 degree to 45 degree• 45 degree to 60 degree• 60 degree
SELF-SUPPORTING ANGLES
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• Horizontal to 30 degrees always are supported• Aluminum can build at 30 degrees• All other materials require supports at 0-45 degrees
30 DEGREE
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• 45-60 will have burn or roughness above typical• 60-Vertical will have typical overall appearance
45 and 60 DEGREE
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• Arched tops can eliminate the need for supports
DESIGN FOR THE PROCESS
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1‐5mm
0.05in ‐ 0.19in6‐9mm
0.20in ‐ 0.35in Over 9mm
0.36in
1-5 mm 6-9 mm Over 9 mm
0.05-0.19 in 0.20-0.35
in
HORIZONTAL HOLES
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• Maximum round is 9.7 inches• Maximum square is 8.5 inches
START HERE…
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• Max height is about eight inches• Layout optimized for best performance
PART POPULATION
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• Orientate part• Attach solid supports• Fill with lattice support
TYPICAL BUILD SETUP
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Customer-Manufacturer mutual understanding of application and the component demandsIdentify the anticipated AM benefit
• Part consolidation• lead time savings• cost or design integration tool
APPLICATION EVALUATION
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• Identify risk regions including small features, thin walls, hover hangings, trapped volumes
• Redesign for the process or accept the known risk • Adjust part file in Solidworks/Magics to add solid support and encasements• Position part on build scene in Magics• Support file with various strategies of hatch supports
GEOMETRY EVALUATION
Supports Recommended
Supports Likely
Supports Required
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Two Facilities: Austin TX and Belton TXSixteen Laser Based Metal Powder Bed Machines
• 9 (Austin)• 7 (Belton)
Eight Different Materials
MACHINE FLEET AND STRUCTURE
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• Disseminate identical parameter sets across machines. • Any changes undergo a document process change request.• The parameters are rev controlled to ensure parts built today can be
built identically in the future.
COMMANDING THE FLEET
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To prevent power disturbances, both DMLS sites have back-up power systems.
This helps maintain efficiencies and mitigate the risk of interrupted builds.
MAINTAINING POWER
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Workbench - BuildIt / Powder Report
Digitally capture and mine powder composition
MATERIAL TRACEABILITY
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• Serial numbers designate machine, build, and location
• Allows for complete traceability all the way back to the raw material used/mixed
PART SERIALIZATION
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Part Cutups
• Monitors quality from all machines
• Part specific quality check coupon cutups
• Geometry representative samples
• Metallographic reports
DESTRUCTIVE TESTING
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Stress Relief
Plate‐Part Separation
Part Serialization
In‐process Inspection
HIP
SHT, PHT
Dimensional Inspection
RadiographicInspection
Performance Inspection
Stratasys Direct, In‐house
Powder Removal
This is the only Additive Step
Dimensional InspectionCMM, Faro, Surface Roughness
Radiographic InspectionX‐ray, CT scan
Performance InspectionHydrostatic Pressure, Air Effective Area
Heat Treating Vendor Radiographic Testing Vendor
Post Machining
Outsourced operations are executed by vetted strategic partners.
Cutup MetallographyDMLS
DMLS Delivered Parts are mostly Conventional
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• Seek complex geometries• Consolidate parts• Modify existing geometries• Design for the process • Control the process• Document the process• Test to verify
SUMMARY
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THANK YOU
Eric MutchlerProduct Manager LSStratasys Direct ManufacturingAustin [email protected]