advances in desktop 3d printing robert zollo avante technology, llc

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Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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Page 1: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Advances in Desktop 3D

Printing

Robert Zollo

Avante Technology, LLC

Page 2: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Workshop Goals

• Help commercial enterprises assess the viability of desktop 3D printing for their business

• Where to go for additional relevant information

Page 3: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 4: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

What We Do

• Custom Materials for 3D Printing

• STL Repair/Validation Software

• Architected 3D printers

• Custom Development

• Consulting

Page 5: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Commercial 3D Printing

State of the Industry

Page 6: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

$2 Billion+35%per year growth!

• Conceptual Prototypes

• Functional Prototypes

• Production Parts (new)

Page 7: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Why 3D PrintingFor the past 30 years

Rapid Prototyping• Saves time• Efficient revisions• Reduces tooling

errors

Page 8: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Why 3D Printing

For the past 5 years:

Rapid Prototyping

Specialized, Short Run Production

Page 9: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Why 3D Printing Now

2013-2014 & beyond: Rapid Prototyping,specialized, Short Run Production andhigh value productionand fixtures, jigs & molds

Page 10: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Pros & ConsIndustrial 3D Printers

More Material Options

Larger Scale Parts

Faster Printing (maybe?)

More Precise Parts (maybe?)

More Expensive (it depends..)

Service Bureau Option

Page 11: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

EconomicsIndustrial 3D Printers• $25,000 - $1Million

• Metal: $100k-$1mil.

• Metal mat.: $1k+ /lb

• Plastic: $25k -$125k

• Plastic: $100 - $500/lb

Page 12: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

PlasticsIndustrial 3D Printers

• SLA (stereo-lithography $$$

• DLP (digital laser processing) $$

• FDM (fused deposition modeling) $ - $$$

Page 13: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Industrial 3D Printer Economics

Why So Expensive?

• Too few vendors

• Patent protection

• Customer’s lack of knowledge

Page 14: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Pros & ConsDesktop 3D Printers

Personal Control

Security

Valuable Feedback

Fast Results (maybe)

Lower Costs (probably)

Faster Revisions (usually)

Page 15: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Issues withDesktop 3D Printers

Lack of precision

Un-reliable

Limited capabilities

Limited materials

Few reliable vendors

Lack of customer support

Page 16: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

2014:Desktop 3D Printers

New Printers

More accurate

More reliable

New materials

Few reliable vendors

Lack of customer support

Page 17: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

EconomicsNew FDMDesktop Printers:

• Printers: $1,500 - $3,500

• Plastic Filaments: $20 - $100/lb

Page 18: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Why Not Desktop 3D Printing Now2013-2014 & beyond:

Rapid prototyping,specialized, short run production andhigh value productionand fixtures, jigs and molds

Page 19: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 20: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 21: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 22: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 23: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 24: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 25: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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!)

Page 26: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 27: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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?

Page 28: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Making Printable Parts

“Garbage In….

Garbage Out….”

Page 29: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Making a Printable Design File

STL FormatFile Sources:

• CAD• Scanner• Other

Page 30: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

e

3DTransform.com

Matt Nutsch

Founder

Page 31: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Making 3D CAD Files Printable

Files Must be:

1. “Water-tight” STL2. Must consider overhangs3. Must fit on print bed

Page 32: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

3D Scanning

“Reverse Engineering” a part without the blueprints

Page 33: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 34: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 35: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 36: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Making Production PartsBalance Physical and Aesthetic Characterisitcs:

• Design Multiple Parts

• Use Multiple Materials

• Use Support Material

• Integrate via 3D Printing

Page 37: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

The Economicsof 3D Printing

Total Cost of Parts

• Design• Prototypes• Pooling• Production cost• Revision cost• Tooling maintenance

Page 38: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 39: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 40: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 41: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Many New MaterialsAvailable This Year

Stratasys “simulated PP”*

Natureworks: “PLA co-polymers”

Avante Technology: New “Engineering Grade" materials beyond nylon

Page 42: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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”

Page 43: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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

Page 44: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

Try Desktop 3D Printing Today…(your competitors already are)

For More Information:

[email protected]

Avante Technology, LLC.

Page 45: Advances in Desktop 3D Printing Robert Zollo Avante Technology, LLC

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