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    BPM 29 PDF

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    BPM 29 PDF

    Uploaded by

    nandhinidish
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    bpm-29.pdf

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    146 views67 pages

    BPM 29 PDF

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    nandhinidish

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    Introduction to

    Additive Manufacturing
    aka Additive Layer Manufacturing
    aka Rapid Prototyping
    Julyaka
    2012
    Everett,
    Renton and
    - Cloning
    Designs
    Portland
    aka SteroLithography
    aka 3D Printing
    aka
    BOEING is a trademark of Boeing Management Company.
    Copyright 2009 Boeing. All rights reserved.

    EOT_RT_Sub_Template.ppt | 1/6/2009 | 1

    Class Outline - Agenda

    1.Technology Overview
    2.Hardware and Material
    3.Applications
    4.STL Creation/Processing
    5.Use Cases
    6.Out of the Box

    Technology Overview - Definitions


    Additive Manufacturing consists of a class of
    technologies that can automatically construct
    physical models from Computer-Aided Design
    files.

    Improve communication
    Improve collaboration
    Shorten design cycles
    Stretch R&D dollars
    Improve accuracy
    Eliminate mistakes
    Trigger innovation
    Accelerate Production

    Save your Life?

    Technology Overview - Importance


    Additive manufacturing was named number
    one in Aviation Week & Space Technology
    magazine's May list of "Top Technologies to
    Watch," is a rapidly growing manufacturing
    technology being touted for its cost savings and
    waste reduction. By 2015, the sale of additive
    manufacturing products and services worldwide
    is expected to grow to $3.7 billion from $1.71
    billion in 2011, according to independent
    consultants Wohlers Associates.

    Objective Insight into being able to recognize use cases that


    would benefit from the use of Additive Manufacturing
    (ADDM)

    Insight into how to effectively initiate and integrate the


    use ADDM into a standard engineering process.
    Insight into the benefits and limitations found in each
    of the component disciplines found in the overall the use
    of ADDM.
    A perspective on future directions the use of ADDM
    might go

    General Theory -

    History In the 60s Herbert Voelcker had thoughts of the


    possibilities of using computer aided machine control
    to run machines that build parts from CAD geometry.
    In the 70s he developed the mathematics to describe
    3D aspects that resulted in the first algorithms for
    solid modeling
    in the 80s Carl Deckard came up with the idea of
    layer based manufacturing
    And while there are several people that have
    pioneered the Rapid Prototyping technology, the
    industry generally gives credit to Charles Hull -

    History The term "stereolithography" was coined by


    Charles W. Hull, in his US Patent 4,575,330,
    entitled "Apparatus for Production of ThreeDimensional Objects by Stereolithography" issued
    in 1986.

    History -

    Stereolithography was originally


    defined as a method and apparatus for
    making solid objects by successively
    "printing" thin layers of the curable
    material, e.g., a UV-curable material,
    one on top of the other.
    (Video)

    Processes - Stereolithography

    Processes - Laser Sintering

    Processes Fused Deposition

    Processes - Direct Metal Laser Sintering

    Applications Production

    Technology Overview 3D Printing

    Applications Prototypes
    Physical and Digital Prototyping
    belong TOGETHER
    By L. Stephen Wolfe, P.E.

    Technology Overview Layer Object Manufacturing


    A manufacturing process that uses a carbon-dioxide laser to
    create successive cross-sections of a three-dimensional object
    from layers of paper with a polyethylene coating on the backside.

    A sheet of paper is fed


    through with the aid of small
    rollers. As the paper is fed
    through, a heated roller is
    used to melt the coating on
    the paper so that each new
    layer will adhere to the
    previous layer.

    SOLIDO

    Processes Ballistic Particle Manufacturing


    Ballistic Particle Manufacturing utilizes ink jet or droplet based manufacturing
    techniques, where it builds the models by firing micro-droplets of molten wax
    material from a moving nozzle or jet onto a stationary platform, the platform then
    lowers and the process is repeated for each layer of the model.
    Bill Masters (the BPM
    inventor) first described
    BPM as a spit wad.
    When you shoot a lot
    of wads, he said, they
    begin to take shape,
    and if you can control
    the direction of the
    wads and the motion of
    the device that's
    shooting them, you can
    produce any desired
    shape.

    Processes Ballistic Particle Manufacturing or ???

    Processes Ballistic Particle Sterolithography (kind of)?

    3D printing with ultra-clear materials


    can be used to make highly
    accurate medical models
    that show detailed bone structures.
    Source: Objet

    Almost spooky - ?

    Really spooky - ?

    STL Creation - CATIA

    Create a
    CATIA solid of
    part to be
    generated
    using ADDM

    STL Creation - Tessellation

    STL Creation - Tessellation

    Technology Overview - Considerations


    Speed

    Surface Finish

    Office Environment

    Color

    Pre-Processing

    Waste

    Setup

    Accuracy

    Flight Certified

    Build Envelope

    Material Properties
    Post Build Processes

    Support

    Capital Cost

    Material Cost
    And on and on

    Envelope Utilization
    L. Stephen Wolfe, P.E. Whitepaper Z-Corp

    Technology Overview - Considerations

    But Not Complexity


    That is Free

    Sample - CATIA/Dimension CatalystEX Session

    Sample - CATIA/Dimension CatalystEX Session

    Applications Large Scale?


    Engineering, Operations & Technology | Boeing Research & Technology

    BOEING is a trademark of Boeing Management Company.


    Copyright 2009 Boeing. All rights reserved.

    BOEING PROPRIETARY Distribution Limited to Boeing Personnel

    Support Technologies

    EOT_RT_Sub_Template.ppt
    EOT_RT_Sub_Template.ppt
    | 1/6/2009 | 50

    Applications - Production

    Applications Sales and Marketing

    Applications Clothing?

    Applications Clothing?
    3D Printed Bikini by Continuum & Shapeways

    http://www.shapeways.com/blog/archives/875-N12-3D-Printed-Bikini-Technical-Update.html

    Selective Laser Sintered Nylon - SLS

    $150.00
    http://www.shapeways.com/n12_bikini

    Applications Medical
    3D Printed Jaw Used in Transplant
    2/27/2012
    A team of doctors in The Netherlands performed
    successful jaw transplant surgery recently that
    showcases just how far the power and potential of
    3D printing has come as key asset in medical
    applications, particularly the design and
    development of custom prosthesis.
    An 83-year-old woman suffering from a chronic
    bone infection received a lower jaw transplant of a
    3D-printed jaw made out of titanium powder as
    opposed to undergoing reconstructive surgery,
    which the medical team deemed too risky because
    of her age. Using a 3D model of the patient's lower
    mandible, the medical team, in partnership with
    metal additive manufacturing provider LayerWise,
    constructed and 3D-printed a metal jaw implant
    structure that incorporates articulated joints and
    dedicated features, becoming one of the first
    complete patient-specific implants, according to
    officials.

    Applications Medical

    Applications Medical

    Applications Medical

    Applications Medical

    The EOS direct laser sintering process can be


    used to produce a wide variety of objects,
    such as this customizable titanium necklace.
    Source: Future Factories

    The titanium heel of this


    high-fashion sandal was
    made with DLS.
    Source: Kerrie Luft

    Applications FOOD??

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