hands-on workshop: basics of 3d printing · advantages of 3d printing –freedom of design...

Hands-on Workshop:

Basics of 3D PrintingIntroduction

Ville Kukko-Liedes IdeaSquare 3.-4.11.2018

Ville Kukko-Liedes

ville.kukko-liedes@aalto.fi

• MA student of Product Development and Machine Design• 3D PrintShop manager in Aalto Design Factory

• Hobbyist 3D printing, 2012• Rapid Prototyping and model making services, 2013• Product development consulting services, 2014• Design Factory PrintShop, 2014

Own DIY machines:

• Mendel Max 1.5, 2012 - 2014

• RepRap Industrial Mini ‘PaPa’, 2014 -->

• RepRap Industrial 2014 --> SOLD

• RepRap Industrial DF ‘NuNu’, 2014 -->

• CoCo, 2017 -->

+ other smaller projects

Saturday

• What is 3D printing and where it can be used?

• Understanding 3D Printing methods

• FDM & SLA technologies

• Getting started with 3D printing

• Hands-On 3D Modeling & printing

• Understanding 3D Printing methods

• Advanced methods

• Hands-On 3D Modeling & printing continues

Sunday

What is 3D Printing?

What is 3D Printing?

Additive Manufacturing (AM):

Construction of physical

objects directly from 3D CAD

data – usually layer upon layer

(CAD = Computer Aided Design)

What is 3D Printing?

Additive Manufacturing (AM):

Construction of physical

objects directly from 3D CAD

data – usually layer upon layer

(CAD = Computer Aided Design)

What is 3D Printing?

As opposed to e.g.

subtractive manufacturing

(milling, turning etc.)

Additive Manufacturing (AM):

Construction of physical

objects directly from 3D CAD

data – usually layer upon layer

(CAD = Computer Aided Design)

What is 3D Printing?

As opposed to e.g.

subtractive manufacturing

(milling, turning etc.)

Additive Manufacturing (AM):

Construction of physical

objects directly from 3D CAD

data – usually layer upon layer

(CAD = Computer Aided Design)

Principle- Stacking two-dimensional layers to form three-

dimensional objects

- Producing 2D layers is relatively simple

- Parts usually need to be supported from below

Principle

STL file – From CAD,

3D-scan, etc.

“Slicing” to multiple layers,

toolpath

calculated for each

Part production

using calculated

paths

Advantages of 3D Printing– Freedom of design – complexity is free

Form optimization, pre-assembly, easy customization..

– No need for toolingNo cost from design changes & cheap small volume prod.

– No need for inventory

On-demand manufacturing, minimal investment,

– Fast lead times & responsivenessQuick alteration in design to respond to customer needs

– Localized manufacturingManufacturing where needed, savings in logistics

– Wide material range – seamless transitions

Innovation potential with new opportunities

– Affordable low volume productionPrice per piece constant regardless of production size

Uses: Rapid Prototyping

- The original and still much used application

of 3D printing

- Commercialized in the 80s

(SLA by 3D Systems)

- Extremely popular in product development:

- Fast testing of form, fit, function,

ergonomics..

- Accurate representation of intended

material properties and function possible

- Affordable and quick to produce

prototypes provide early feedback

- Fail faster to succeed earlier!

Uses: Rapid Prototyping - Concept wireless

charging station for a

plush toy / nightlight

Uses: Rapid Manufacturing

- Use of AM to produce end-use parts and

products

- Expansion during the last 13 years

- From 4% (2003) to 35% (2014)

- Result of process and material

development & media hype

- Notable in medical and aerospace industries

- Medical: Personalized solutions

- Aerospace: Weight optimization

- Potential in multiple fields, but still restricted

to low volume or customized production of

high-end products

- Lacking standards & false assumptions hinder

adoption

3D printed metal parts in BMW i8 convertible

Customized parts in MINI cars

Uses: Rapid Tooling

- Use of AM for indirect production:

- Masters for sand & silicon casting

- Lost wax casting

- Printing sand, metal & plastic molds

- Fixtures for drilling

- Jigs

- Endless number of uses..

- For both prototypes & end-use parts

- Takes advantage of low investment cost, fast

process, and AM introduced benefits such as

contouring cooling channels in injection molds

Masters for silicone casting

DIY petrol motor for a surf board

3D Print

Finished

3D print

Cast

Finished

cast

Sandcasting

Printed wax masters for precision casting

Cores for Glass/Carbon-fiber parts

Vacuum forming cores

Injection molds printed with plastic

Freedom of design

– No need to Design for Manufacturing & Assembly:

Instead Design for Functionality, Weight, Strength etc

– Minimize part count while optimizing topology

– Pre-built assemblies – minimize labor time & QC

– Customization without additional cost – Every part

can be different from the others, even in same batch

Design for AM – Case: bottle opener

Design for AM –

Case: Buckle

68 grams

Case: Boeing / F-18 air duct system re-design

Case: F-18 cooling air system

– Complete re-design for functionality & weight

– This unit: part reduction from 16 to 1

– Improved air flow

– No assembly required

– No tooling required

– Future improvements with minimal cost

– Spare parts on demand and on location

Case: Align / Invisialign tooth retainers

Case: Invisialign tooth retainers

– Digital pre-planning of each unit, “digital inventory”

– Example of mass customization – 40,000 a day

– AM produced individual molds for thermal forming

– Innovative example of utilizing customizability

– RP machines & processes modified for excessive use

Other medical uses

Inert implants Hearing aids

- Surgical planning, prosthesis, tooth crowns & bridges, tissue growth…

AM as innovation enabler

AM as innovation enabler

– Easy and affordable access to AM

technology encourages innovation

– Multiple new companies forming

around 3D printing

– 3D Printing is bringing young people

back to making physical things

Role of 3D printing in the future

– Disruptive potential in manufacturing – happening already3DP can change product design and manufacturing approaches drastically. Materials and processes are developed more for end-use

production.

– Supply chain renewal – future possibilityAway from traditional towards more centralized, on-demand, rapid manufacturing.

– Flourishing innovation around AMNew applications, AM techniques, & businesses emerge on daily basis

– Will every home have a 3D Printer and traditional manufacturing will end?No – Perhaps for occasional use in hobbies or garage-tinkering

Hands-on Workshop:

Basics of 3D Printing

Break

Principle- Stacked two-dimensional layers form three-

dimensional objects

- Producing 2D layers is relatively simple

- Parts usually need to be supported from below

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

FDM – Fused Deposition Modeling

FDM – Fused Deposition Modeling

www.youtube.com/watch?v=oeJLLC2NJQs

FDM – Fused Deposition Modeling

•Thermoplastic is extruded to ‘draw’ a layer at a time

• Build platform lowers with the part and process

repeats

•Dissolvable support material from second nozzle; not

commonly used in lower end printers

•Materials:

•ABS

•PLA

•Polycarbonate

•Nylon

• + Many Others! (PEEK, PETG, composites)

•Manufacturers:

•Stratasys, Tiertime, +multiple lower end

Extrusion lines visible

RepRap Project and its effects

Open Source, community driven, self REPlicating RAPid prototyper

- Founded 2005 by Andrew Bowyer, University of Bath, UK

- First RepRap 3D printer to print parts for itself, 2006

- Reprap inspires Makerbot, first commercial hobby printer, 2009

- Stratasys and 3DSystems both hit consumer market also

- 2016: hundreds of different “consumer 3D printers” available

- Most still hobbyist and DIY maker targeted

as they fail to meet user’s expectations

Not all 3D printers are the same

~200€ ~900,000€

Not all 3D printers are the same

General perception of all levels of 3D printing

Reality

E-Nable prosthetics – Community based project

3D files to print

1. CAD software – Create models yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Free and commercial sites available

3D files to print

1. CAD software – Create models yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Free and commercial sites available

“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape“Designer”: Rhino, Maya, Zbrush“Easy-to-use”: TinkerCAD, Google SketchUp

3D files to print

1. CAD software – Create models yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Free and commercial sites available

“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape“Designer”: Rhino, Maya, Zbrush“Easy-to-use”: TinkerCAD, Google SketchUp

3D files to print

1. CAD software – Model yourself

2. 3D scan an existing object – Modify or replicate as is

3. Download existing files – Free and commercial sites available

3D files to print

1. CAD software – Model yourself

2. 3D scan an existing object– Modify or replicate as is

3. Download existing files – Thingiverse, Youmagine, GrabCADmodifiable with Meshmixer

STL file format – triangulated mesh approximation

Remember to set good tolerance!

More triangles = Better results

STL file format – triangulated mesh approximation

Remember to set good tolerance!

More triangles = Better results

Orientation and support material

Complicated support structuresare difficult remove

Avoid overhangs Consider overhang angles whendesigning and orienting

Orientation and support material

Orientation and support material

Orientation and support material

Parts are weakest between layers

Design for FDM Example

Objective: Design and print an object

designed for FDM, which doesn’t need

supports and showcases possibilities of FDM

Features:•Overhangs

•Bridges

•Interlocking parts

•Inserts

•Customizability

•Internal features

Considerations:•Tolerances

•Overhang angles

•Minimized warping

•Orientation

Warping – Due to poor attachment to bed

Happens to PLA and ABS in open printers

Insert

Design for FDM printing

Slicers – Software that link 3D file with printers movement

- Software depends on the printer or user prefence- Makerbot Makerbot Print

- Ultimaker Cura

- Other printers Slic3r, Cura, Simplify3D…

- Many are free and even open source

Settings Checklist for Slicer software

- Material

- Temp (ABS ~230’C, PLA ~190’C)

- Diameter (Usually 1,75mm or 3mm)

- Orientation of model - before “slicing”

- Layer height

- 0,1- 0,3mm usually

- Perimeter thickness (‘shell’ of the part)

- Infill percentage (how dense/hollow the part is)

- Supports (if needed)

Before starting print

- Check Printers build platform

- Is it clean?

- Does it have proper adhesion applied?

- PLA: gluestick, (hairspray, blue tape)

- ABS: Kapton tape, BuildTak

- Check Printers material & nozzle

- Is there plastic? Does it need to changed?

- Always observe first layers of printing – They are most crucial!

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

SL – Stereolithography

SLA printers are more accurate than

FDM, but have their drawbacks.

Strong parts: SLA < FDM

Big parts: SLA < FDM

Need supports: SLA < FDM

Post-processing: SLA < FDM

Harmful chemicals: SLA < FDM

Complex parts: SLA > FDM

Small parts: SLA > FDM

Precise parts: SLA > FDM

https://formlabs.com/support/printer

s/form-2/quick-start-guide/

SL – Stereolithography

SL – Stereolithography

•UV laser cures resin

•Build platform lowers with the part into the resin

vat (or rises from it in some cases)

•New layer of resin is cured and process

repeated

•Materials:

•UV curable resins

•Waxes

•Ceramic

•Manufacturers:

•3D Systems, DWS, Lithoz,

+few hobbyist oriented

For Software: Preform (formlabs.com)

Next – Consider:

•Would you like to learn 3D modeling?

•Which software would be most suitable for you?

•Should you use and modify existing files instead?

•How could you use 3D printing?

•In your work? Hobby? As a new skill?

•Which technology would be better for your application?

•What requirements do your prints have?

•SLA or FDM?

Hands-on Workshop:

Basics of 3D PrintingDay 2

Ville Kukko-Liedes IdeaSquare 3.-4.11.2018

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

SLS – Selective Laser Sintering

SLS – Selective Laser Sintering

•Powder stock is joined by partial laser melting

•The powder bed lowers with the part

•New layer of powder is added and process

repeated

•Materials:

•PA (6, 11, 12) (Nylon)

•PA GF, CF (fibre composites)

•PA-Al (30% Aluminium)

•Manufacturers:

•EOS, 3D Systems…

(patents expiring now, low cost machines coming)

Method Material For Tolerance

(mm)

Layer

Thickness (mm)

SLS

PA Functionality

+/- 0,15

(+/- 0,15%)0,1PA CF/GC Hi durability

Wax Casting

SL

ClearAppearance,

Casting+/- 0,05-0,1 0,05-0,2

FlexibleDurability,

Appearance

FDM

ABSFunctionality,

prototyping+/- 0,15-0,3 0,1-0,4

PC

Accuracy

- 3D prints are usually always

comparatively inaccurate

dimensionally as well as

geometrically

- FDM for cheap parts,

printers everywhere. SLA for

small & precise. SLS for

ordering durable & precise

parts

All specs vary depending on machine used

Manufacturing in motion: first survey on the 3D printing community, Statistical Studies of Peer Production.

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion – still..

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

SLM – Selective Laser Melting

SLM – Selective Laser Melting

& Binder coated powder SLS

•Powder stock is joined by laser melting

•The powder bed lowers with the part

•New layer of powder is added and process

repeated

•A lot of supports needed in direct melting!

•Materials:

•Two component (binder coated base)

•Single component:

•Ti6Al4V, 17-4 / 15-5 Stainless, Cobalt

chromium, maraging

•Uses: Molds, small series, prototyping in metal

Additive Industries – Metal 3D printing station

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

3DP – Binder Jetting

3DP – Binder Jetting

•Powder stock is joined by deposited binder

•The powder bed lowers with the part

•New layer of powder is added and process

repeated

•Materials:

•Ceramic, composite, Glass, Metal, Plastic..

•Color printers available

•Usually fragile before post processing

•Uses: Visuals, cores & molds, casting patterns

Full color sandstone + binder - Shapeways

Digital Metal – Höganäs, Sweden

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

LOM – Laminated Object Manufacturing

LOM – Laminated Object Manufacturing

•Sheet is joined to the previous part

•Layer shape is cut into sheet

•Platform lowers and process repeats

•Materials:

•Paper, plastic, metal

•Color printers available

•Not accurate with paper or metal

•Laborious manual support removal

•Uses: Visual aids, metal structures with internal

sensors

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

•Sheet is joined to the previous part

•Layer shape is cut into sheet

•Platform lowers and process repeats

•Materials:

•Paper, plastic, metal

•Color printers available

•Not accurate with paper or metal

•Laborious manual support removal

•Uses: Visual aids, metal structures with internal

sensors

DED – Directed Energy Deposition

•Inert shielding gas jet deposits pwder that is

molten to the part with laser

•Platform moves, while nozzle is usually

stationary

•Materials:

•Metal

•Not very accurate ”net shaping”

•Features machined

•Combined DED + CNC exists!

•Uses: Repairs

DED – Directed Energy Deposition

also LENS – Laser Engineered Net Shaping

Categories of 3D printing

•Vat Photopolymerization

•Powder Bed Fusion

•Material Extrusion

•Material Jetting

•Binder Jetting

•Sheet Lamination

•Directed Energy Deposition

Material jetting

•Printhead (just like in inkjets) deposits droplets

of resin that is cured instantly with UV

•Platform moves down, process repeats

•Materials:

•Resins, various simulated plastic & rubber

•Highly accurate

•Multiple material properties, even smoothly

changing

•Uses: High end visual aids & function test

Material jetting

Dragonfly – PCB Prototyping

MicroTec – 3D Chip Sized Packaging

Kalevala – Jewelry

with wax investment casting

Links to videos

•Kinematics Dress by Nervous System

•SLS Selective Laser Sintering

•SLA Stereolithography

•Binder Jetting metals

•LOM - Mcor Paper Printer

•MORI Hybrid 3DP-CNC

•Material Jetting – Stratasys J750

Ville Kukko-Liedes

ville.kukko-liedes@aalto.fi

Thank you

Printers:

Ordbot: ideasquare-3dprinter-1.cern.ch

X400: ideasquare-3dprinter-2.cern.ch

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Password: 3dprint