Ed Tackett

3D Printing & Additive Manufacturing Proof-of-Concept Services Calit2 @ the University of California Irvine

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HISTORY 3D printing has been in existence for almost three decades, yet has only recently spread to mass markets. The primary 3DPrinting techniques were established in the eighties (StereoLithography, fused deposition modeling, and laser sintering). These innovations were theoretically groundbreaking, but most practical applications remained prohibitively expensive.

Market Landscape 3D printing is approximately a $600 million-dollar industry. The industry goliath, 3D Systems Corporation, by itself reported a 2011 net income of $41 Million. The 3D printing industry is comprised of different segments. The primary 3DPrinting users include hobbyists, artists, educational institutions, engineering firms, and industrial manufacturers. These segments can be further broken down into three end-uses.

Segment 1 First, there are consumers (designers, inventors) who want their own 3Ddesigns printed, but can’t afford or don’t need to own their own printer. They will seek out a 3D-Printing service like Shapeways, Imaterialise, or Sculpteo to get their object printed. The consumer simply uploads his/her 3D file, chooses the material and build size, and within weeks, the service will print and deliver their 3d model.

Segment 2 The second category consists of hobbyists or diyers, seeking their own personal printers; these printers, provided by companies like BotMill, MakerBot, and BitsFromBytes, range from $800 to $5000. Initially, most hobbyists were most interested in assembling and constructing the printer itself –less interested in the final product. Now, as more printers come preassemble (ready-to-print), greater attention is given to the 3d models themselves.

Segment 3 Third, there is the high-end educational/industrial segment. Lastly, educational institutions, engineering firms, and other large corporations that want to possess their own heavy-duty printers can invest anywhere from $10,000 to $80,000 per printer.

Fused Deposition Modeling (FDM) 1. A spool of themoplastic wire (typically acrylonitrile butadiene styrene (ABS)) with a 0.012 in (300 μm) diameter is continuously supplied to a nozzle

5. The sacrificial support material (if available) is dissolved in a heated sodium hydroxide (NaOH) solution with the assistance of ultrasonic agitation.

2. The nozzle heats up the wire and extrudes a hot, viscos strand (like squeezing toothpaste of of a tube). 3. A computer controls the nozzle movement along the x- and y-axes, and each crosssection of the prototype is produced by melting the plastic wire that solidifies on cooling. 4. In the newest models, a second nozzle carries a support wax that can easily be removed afterward, allowing construction of more complex parts. The most common support material is marketed by Stratasys under the name WaterWorks) 13

3D Printing (3DP) 1. A layer of powder (plaster, ceramic) is spread across the build area 2. Inkjet-like printing of binder over the top layer densifies and compacts the powder locally 3. The platform is lowered and the next layer of dry powder is spread on top of the previous layer 4. Upon extraction from the machine, the dry powder is brushed off and recycled

Selective Laser Sintering (SLS) 1. A continuous layer of powder is deposited on the fabrication platform 2. A focused laser beam is used to fuse/sinter powder particles in a small volume within the layer 3. The laser beam is scanned to define a 2D slice of the object within the layer 4. The fabrication piston is lowered, the powder delivery piston is raised and a new layer is deposited 5. After removal from the machine, the unsintered dry powder is brushed off and recycled

PolyJet/Multijet Modeling (MJM) • Both systems use piezoelectric print heads with thousands of nozzles to jet 16 micron droplets of photopolymer that are immediately cured by UV light. The model material for the part and the support material that fills the voids come from different nozzles. •

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The Objet system uses a photopolymer as support material; the support material is designed to crosslink less than the model material and is washed away with pressurized water. The 3D Systems InVision uses wax as support material, which can be melted away. Because of its 600x600 dpi resolution, MJM is a relatively fast process. The resolution is not as good as for SLA.

Stereo-lithography (SLA)

• The liquid resin is kept either in the fixed surface mode or in the free surface mode. – In the case of free surface, solidification occurs at the resin/air interface, and care needs to be taken to avoid waves or a slant of the liquid surface. – In the fixed surface mode, the resin is stored in a container with a transparent window plate for exposure. The solidification happens at the stable window/resin interface. An elevator is pulled up over the thickness of one additional layer above the window for each new exposure.

Stereo-lithography (SLA) • The two major types of stereolithography stereolithography and projection stereolithography.

are

scanning

– The scanning stereolithography parts are constructed in a point-by-point and line-byline fashion, with the sliced shapes written directly from a computerized design of the cross-sectional shapes by a beam in the liquid. – Projection stereolithography is a parallel fabrication process that enables sets of truly 3D solid structures made of a UV polymer by exposing the polymer with a set of 2D cross-sectional shapes (masks) of the final structures. These 2D shapes are either a set of real photomasks used to subsequently expose the work, or they involve a dynamic mask projection system instead of a physical mask.

Stereo-lithography (SLA) TWO-PHOTON LITHOGRAPHY Two-photon lithography provides a further enhancement of the SLA resolution. If an entangled photon pair comes out from a point of the object plane, it undergoes twophoton diffraction, resulting in a very narrow point spread function on the image plane. The result is extremely local polymerization, with resolutions in the tens of nanometers range.

2 Photon Lithography






Bio-Printing

Drop on demand cell Printer

Bio-Printing

Heart Valve Printer

Bio-Printing

Cartilage Tissue Printer

Bio-Printing

Captive Shell Cell Tissue Printer

Bio-Printing

Muscle Tissue Printer

Bio-Printing

Cell Scaffold Printer

Bio-Printing

Cartilage Tissue Printer

Bio-Printing

3D Printed Ear with Electronics

Bio-Printing

3D Printed Droplet Network of Cells

Bio-Printing

3D Printed Hearing Aid Shell 10,000,000 3D printed hearing aids in circulation worldwide

CandyFab 4000

Sugar drop on demand 3D Printer

Large Format 3D Concrete Printer



Tennessee Ball Clay


Large Format FDM

Micro-StereoLithography



Free form 3D Printer

Free form 3D Printer

Prototype Delta 3D Printer

3D Food Printer

Food Printer

Burritob0t

3D Solar Powered Sand Printer

Ceramic Printing Orbital Re-entry 3D printed alumina/silica architected sandwich panel after bisque firing and sintering. (a) Isometric view; (b) Front view. The external vertical columns were printed to support the face sheet during sintering and preserve the shape of the part. They were removed prior to infiltration and testing

Ceramic Printing Orbital Re-entry

(a) Sintered ceramic cylinder embedded in epoxy resin. Notice that the resin partially wicks through the cylinder (coloring was added to emphasize the gradient in composition). (b) Optical micrograph of a crosssection of the cylinder in (a), showing a gradient in resin volume fraction; (c) Digital thresholding of the image in (b), clearly showing a gradient in porosity. Notice that the infiltrated (hybrid) regions are nearly fully dense, whereas ~50% porosity remains in the ceramic regions.

Material Properties as they exist now

Randal Schubert, HRL Laboratories @ 2013

Thank You ! Ed Tackett, Director [email protected] www.rapidtech.org Facebook ~ RapidTech