Additive Manufacturing Turning Mind into Matter Neal de Beer (Ph.D) - PowerPoint PPT Presentation

Additive Manufacturing Turning Mind into Matter Neal de Beer (Ph.D)

Overview � Introduction to Additive Manufacturing � Applications for AM � Current trends � Conclusions and future trends

Introduction to Additive Manufacturing

Basics of Additive Manufacturing 3D Solid Model STL Format Slicing Algorithm Various Additive Manufacturing options Physical Part

Tremendous growth – Worldwide revenues ~ $1.7 bn 30.7 % growth 28 % growth Services Systems & materials Source: Wohlers Associates, Inc.

Tremendous growth – Industrial unit sales + 5% growth

Tremendous growth – Personal 3D Printers + 290% growth! Source: Wohlers Associates, Inc.

Market Forecast Source: Wohlers Associates, Inc.

Different AM Technologies � Stereolithography (SL) � Fused Deposition Modeling (FDM) � Selective Laser Sintering (SLS) � 3D (inkjet) Printing (3DP) � Selective Laser Melting (SLM) � Electron Beam Melting (EBM)

Stereolithography (SL)

Fused Deposition Modeling (FDM)

Selective Laser Sintering (SLS)

3D (inkjet) Printing (3DP)

Applications for Additive Manufacturing

Industries Served Consumer Architectural Other products/ 3.0% Government/ 5.3% electronics military 6.0% 20.3% Academic institutions 8.0% Industrial/ business Motor vehicles machines 19.5% 10.8% Aerospace Medical/dental 12.0% 15.1% Source: Wohlers Associates, Inc.

Range of Applications T ooling Patterns for components metal castings 2.7% 8.9% Direct part Patterns for production prototype 19.2% tooling 12.2% Education/ research 7.0% Fit and assembly Other 12.1% 1.8% Visual aids 10.1% Presentation Functional models models 7.8% 18.4% Source: Wohlers Associates, Inc.

Visual Aids & Concept Models

Visual Aids & Concept Models

Visual Aids & Concept Models

Medical Models

Fashion and Art Industry

Fashion and Art Industry

Fashion and Art Industry

Fashion and Art Industry

Music Instruments

Music Instruments

Current Trends

Current Trends � Serious Manufacturing ◦ Boeing: 200 different parts on 10 aircraft ◦ Est. 40,000 acetabular hip cups made with EBM ◦ 10,000+ metal copings made for dental crowns � New Industry Standards ◦ ASTM International F42 Committee on Additive Manufacturing Technologies ◦ 5 New standards � New Design T ools

New Design Tools � Need a 3D (CAD) model before using AM � Traditional CAD software licenses expensive � Growing informal user community � Examples of new low-end free CAD software: ◦ Google Sketchup (combined with Meshlab) ◦ TinkerCAD (browser-based) ◦ 3DTin (browser-based) ◦ 3DVIA Shape ◦ 123D Beta (Autodesk) ◦ Blender ◦ Spore Creature Creator

Google Sketchup

TinkerCAD

3DTin

3DVIA Shape

123D Beta

Blender

Spore Creature Creator

Current Trends � Growth of DIY Maker Community & Personal 3D printers � Explosion of New Businesses

Explosion of New Businesses � Shapeways � 3D System’s Cubify � MakerBot’s Thingiverse � Materialise’s i.Materialise � Ponoko � Kraftwurx � 3D System’s Freedom of Creation � The 3D Printer Experience � MakeXYZ � Makershop

Current Trends � Labs with 3D Printers and Expansion into Schools and Libraries � Expiration of Key Patents ◦ Last of SLS patents to expire by June 2014 � New types of machines ◦ High Speed Sinter (Loughborough Univ.) ◦ Printoptical technology (LUXeXcel Group B.V)

Current Trends � T ooling for AM ◦ Use of metal AM for tooling ◦ Conformal Cooling � Mainstream press � U.S. Government ◦ $1 bn announced in March 2012 for NNMI ◦ Pilot NAMII project. Total of 15 institutes envisaged

Conclusions and Future Trends

Future Trends � Far more demanding applications � Printed batteries & electronics � Legal issues � Workflow management � 3D Printers for children

Conclusions – Where are we now

Conclusions � Tremendous growth and market opportunities � New AM processes with new materials � New applications � 3D Printing for the masses � Conventional business models are being challenged

Thank you for your attention